CQM-Crimp Quality Monitor

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CQM Crimp Quality Monitor
Crimp Height as a Production Quality Tool
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To Meet the Need for Effective Testing

• Testing Requirements
• Driven by 6-Sigma, other international standards
• Non-destructive evaluation of every crimp
• Need to test crimp performance to the intent of
  the terminal designer
• Tyco Crimp Quality Monitor (CQM)
• Effective tool to meet these requirements
• The only monitor on the market that uses sensors
  to measure both
• Crimp force
• Displacement
• Determines crimp heightthe most effective crimp
  quality metric

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Terminal/Crimp Design Considerations

• Designer Seeks Balance of Performance
  Requirements
• Mechanical performance
• Tensile strength
• Pull-out resistance
• Electrical performance
• Contact resistance
• Capacity
• Determines Optimum Crimp Profile
• Crimp height and range
• Desired area reduction

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Concepts in Terminal Design

• CMA (Circular Mil Area)
• A Circular Mil is the Area of a Circle 0.001"
  or 0.0254 mm in Diameter

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Concepts in Terminal DesignArea Index

• Reducing circular mil area

gtgt
WIRE 4100 CMA
CRIMPED TERMINATION 8800 CMA
WIRE BARREL 6900 CMA

• TOTAL UNCRIMPED 11,000 CMA

• TOTAL CRIMPED AREA gt UNCRIMPED WIRE ALONE

(Total Crimped Area / Total Un-Crimped Area) x
100 Area Index
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Achieving Area Index Reduction

• Application Crimp Tooling
• Determines final crimp form
• Crimp geometry including width, lead-in, etc.
• Area Index
• Final Area Index Determined by Height of Crimp

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Area ReductionKey to Performance

• Undercrimp
• Low electrical conductivity
• Low retention

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Area ReductionKey to Performance

• Overcrimp
• High extrusion
• Damaged strands
• Damaged terminal
• Reduced total area

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Achieving Mechanical Strength
Increasing Mechanical Strength
Mechanical Strength
Crimp Design Range
Increasing Crimping Force Decreasing Crimp Height
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Achieving Good Electrical Performance
Electrical Performance (Decreasing Millivolt
Drop Resistance)
Increasing Crimping Force Decreasing Crimp Height
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The Optimum Design Point
Electrical Performance
Increasing Mechanical Strength Electrical Perfor
mance
Mechanical Strength
Crimp Design Range
Decreasing Crimp Height
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Conventional Measurement Techniques

• Pull-out Force
• Concerns
• Potential damage to termination
• Add to cycle time
• Analysis of Force Profile
• Concerns
• Correct point of measurement
• Detection of termination anomalies

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CQMPractical Measurement of Crimp Height

• Patented Methodology
• Easy-to-use Calculation of Crimp Height, Force
  Profile
• Best Measurement to Check Compliance With Crimp
  Design
• Real Time Measurement During Crimp CycleNo
  Overhead
• Inspects 100 of Terminations

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CQMMethodology

• Position Sensor in Terminator

• Force Sensor in Ram or Base Plate

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CQMMethodology

• Algorithm in Microcomputer
• Analyzes force signature
• Identifies crimp height from zero-force point on
  retreating ram
• Determines deformation energy

GOOD Crimp Curve
Spring-back area of curve used to determine
crimp height
Crimp Height
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CQMMethodology

• Force Signature Identifies Common Crimp Errors
• Insulation
• Short brush

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CQMA Convenient Tool

• Compact, User-friendly Monitor
• Full screen display
• Touch screen operation
• Multiple language support
• Network data communication capability

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CQMAccurate Measurement

• Calibration Run First
• Measure reference crimp
• Short calibration run to determine statistical
  limits
• All calibration parameters entered on screen
• Achieves High Production Accuracy
• 0.013 mm 0.0006 in for base plate mount
• 0.005 mm 0.0002 in for ram mount
• Calibration data stored with all parameters for
  auditability

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Data Displays to Track Process

• Crimp curves
• Force vs. Position
• Real time display of crimp profile
• Monitor crimp cycle as it happens

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Data Displays to Track Process

• Crimp curves
• Force vs. Time
• Position vs. Time
• Both provide useful diagnostic information

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Data Displays to Track Process

• Operator Feedback
• Go/No-go
• Statistics of Run

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Operator Interface

• Touch Screen
• Full Alphanumeric Keypad
• Language SupportEnglish, Spanish, Italian,
  German, Chinese, French

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Automatic Terminator Adjustment

• Crimp height measurement provides feedback
• Self-adjusting mechanism on press changes shut
  height
• Compensates for different crimps

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AMP CQM Crimp Quality Monitor

• Convenient
• Versatile
• Effective tool to comply with contemporary
  quality standards
• Improve harness production quality and yields