A critical element of any wire termination is the connection
between the wire and the contact. Crimping of terminal contacts
is one method of achieving this connection.
A good termination both ensures mechanical integrity and
meets electrical requirements for the application.
In addition to the basic requirements outlined in this section,
there should also be no damage to plating or finish, no contact
deformation that would cause friction or increase force to
insert or load the contact into the connector body, and no
contact deformation that does not allow all contact locking
tabs or wings to fully engage and lock into the connector body
Conductors should not be cut or modified in any manner in
order to fit into the contact. Conductors should not be tinned
prior to termination, unless otherwise specified.
All crimping needs to comply with the manufacturers' published
requirements, i.e., crimp height, pull test, etc., without
regard to the specific tooling used. For complete understanding,
refer to applicable connector or terminal manufacturer's
requirements and instructions. All crimped terminations need
to meet industry requirements, such as EIA, IEC, NEMA, UL or
other as designated.
The following topics are addressed in this section:
5.1 Stamped and Formed Contacts
5.1.1 Insulation Support Crimp
5.1.2 Insulation Inspection Window
5.1.3 Conductor Crimp
5.1.4 Crimp Bellmouth
5.1.5 Conductor Brush
5.1.6 Carrier Cutoff Tab
5.2 Machined Crimp Contacts
5.2.1 Insulation Clearance
5.2.2 Insulation Support (Insulation Support Style Contacts)
5.2.3 Conductor Location
5.2.4 Crimping
5.2.5 Under Size Conductor - CMA Buildup Crimps
(5-1)
(5-2)
1. Insulation inspection window
2. Bellmouth
3. Brush inspection window
4. Locking tab/tang
5. Insulation crimp area
6. Conductor crimp area
7. Terminal mating area
8. Cut off tab (may be at either end of terminal)
9. Terminal stop ear
Target - Class 1,2,3
• Insulation fully enters and extends past the insulation crimp
tabs.
• If multiple wires are used insulation from all wires extend
past the insulation crimp tabs.
• Insulation crimp does not cut or break insulation.
• Insulation crimp tabs fully wrap and support insulation.
• For insulated lugs, the insulation crimp is evenly formed and
contacts the wire insulation providing support without damaging
the insulation
Acceptable - Class 1
Process Indicator - Class 2
Defect - Class 3
• Puncturing of the insulation surface by the insulation crimp
tabs, provided that the tabs do not penetrate down to the
conductor.
Acceptable - Class 2,3
• Minor deformation of the insulation surface as long as the
insulation crimp tabs do not cut, break, penetrate or puncture
the surface of the wire insulation.
• Insulation crimp tabs provide a minimum side support of
180° to the wire insulation and both tabs contact the top of
the wire insulation.
• Insulation crimp tabs do not meet at the top, but encircle the
wire leaving an opening of 45° or less at the top.
• The outer insulation sleeve on insulated terminals shall
remain secured to the terminal after crimping..
Defect - Class 1,2,3
• The insulation crimp tabs pierce the insulation penetrating
down to the conductor.
• The insulation crimp tabs do not provide support at least
180° around the insulation.
• Crimp tabs that encircle the wire but leave an opening of
more than 45° at the top .
• Both insulation crimp tabs are not in contact with the top of
the insulation.
• Conductors are in insulation crimp area of the contact.
Below show some pictures of the defects.
