Archive for July 2012

Processing Heat Shrink with the Judco Focus Lite.

The heat gun has been a standard method of processing heat shrink for decades.  However processing heat shrink tube with a heat gun is generally slow and consumes a significant amount of energy.

The Judco Focus Lite line is a cost effective method of processing heat shrink of various sizes. The energy efficient halogen bulbs operate on demand for fast and efficient shrinking of heat shrink tube. Wire Process Specialties in partnership with Judco Manufacturing has supplied Judco Focus Lite technology to a large number of companies spanning multiple industries to process heat shrink in their assemblies. Faster processing time and lower energy cost are the results of introducing Judco Focus Lite Technology to their assembly processes.

Several models are available to shrink tube from 5/8″ to 1.5″ OD to 15.5″ in length. Connect Your Way to WPS or visit wireproces.com/Judco for more information.

Crimp Quality Process Validation and Monitoring: Part One

Validating and monitoring the process of crimpimg a wire to a terminal is a very critical in today’s wire harness production environment. So critical that some industries have mandated the use of advanced validating and monitoring crimp technology to reduce exposure (and liability) to financial loss if a defective harness is introduced into a a product. in this three part series, we will explore some of the techniques and technology being used in wire harness facilities worldwide. In part one, we will cover pre-production crimp validation.

Crimp Height

Crimp Height is an initial pre-production test to determine if the crimp compression meets the manufacturer’s specifications.  Crimp Height micrometers are used as they have a point on the spindle which rests on the underside of the crimp.  The anvil side has a flat surface which rests on the upper side of the crimp.  Using standard micrometers or verniers can provide false reading as they may pick up the points of the bottom anvil mark and not the center bottom of the crimp.  Using digital micrometers allow the crimp height reading to be downloaded to data collection/analysis software.

 

 

 

Pull Testing

Pull Testing is a destructive test to determine if the wire is properly secured into the wire crimp of the terminal.  Pull test procedures require the insulation support to be peeled back so the pull test reading is based on the wire to terminal crimp only.  A motorized pull tester pulls the wire from the terminal at a steady rate which improves the accuracy and consistency of the crimp.  And a digital output provides the ability to collect and analyze the pull test data.

The model PT100 shown is used as a standalone pull tester, interfaced with a computer for data collection/analysis/capability studies or fully integrated into a plant wide validation and real time crimp monitoring system.

 

Crimp Cross Section

Once you have established your crimp height and pull test, do you assume everything you see outside is the same inside the crimp?  Manufacturers of terminals work hard to ensure the wire to crimp size match properly and there is a science to establishing the proper shape and size of the crimp to fit a specified wire range.  But outside of the manufacturer’s work to determine the proper crimp size to wire, other factors come into play which can affect the crimp:

 

  • wire OD which can vary within a specified wire range.
  • tool wear.
  • wrong tooling used or wire size used which does not meet the terminal specifications.

The effect of these changes can cause the wire to be unevenly distributed inside the crimp.  Something which cannot be determined without doing a cross sectional analysis.  Here is an example:

In this case, the wire crimp looks normal but the wire distribution is not even.

Did you know, this effect is one factor which can cause false readings on in-process monitoring of crimping using crimp force monitoring tools? False readings can be rejecting good parts or accepting bad parts.  The right wire gauge for the terminal, consistent wire distribution within a crimp and the proper crimp forming tools can provide consistent crimp quality.

 

Crimp cross sections are created by cutting the wire from the terminal, grinding/polishing the terminal down to the approximate mid point of the wire crimp and using etching chemicals to prepare the end of the wire.  The crimp is loaded to a microscope and a digial image is produced.  Further analysis include a calculation of the crimp area. A cross section is a pre-production analysis tool used in some critical applications but can be costly on a regular basis.  Having the documentation on a crimp cross section on the introduction of a new wire termination is a good practice (mandated in some industries) as it provides an understanding of what to expect from the crimp monitoring process. Wire Process Specialties can assist in the equipment required for processing cross sections in house or through our Cross Sectioning Service.

Data Collection

Data Collection is a critical part of pre-production and production to ensure your crimp process is meeting your specifications.  Data is used for validation prior to production, capability analysis and to document crimping results for review by your quality and production personnel, customers and external quality auditors to verify compliance with national and international standards.  Data collection can be as simple as using the tools above to manually or automatically recording results, within a local inspection station where all tools are combined to provide a bigger picture of the crimp quality.  For larger operations, client/server systems provide crimp specifications to the inspector, measurements are made and validated before production can commence.  Then in process measurements are taken and stored electronically across all processing machines plant wide.   In part two, I will outline typical tools for in process quality monitoring of wire to terminal crimping.

Wire Process Specialties partners with C&S Technologies, a global leader in the supply of crimp process validation and monitoring systems.  We can supply simple inspection tools or create a complete integrated system for plant wide control of the crimping process.  Connect Your Way to Wire Process Specialties to get a personalized assessment of your requirements.

Processing Options for Transformer Manufacturing.

Wire Process Specialties serves many industries that require assembly processes for electrical and electronics.  One industry that WPS has served for a number of years is in Transformers and Magnetics.  WPS supplies a multiple of solutions for the processing of magnet wire and coil winding from simple wire end processing to complex automation for transformer assembly.

Magnet Wire Stripping

The Carpenter Magnet Wire Stripper series provide cost effective methods to remove the enamel from magnet wire.  Models include the conical wheel 88F shown above for stripping ultra-fine wire down to 48 awg, the 27F with a collet stripping head and available extension wand and the 14B for heavy duty round and rectangular wire.

 Material Cutting

 The Compu-Cut 42B is a heavy duty cutter for a multitude of uses.  Cutting heat shrink, pvc and fibreglass tube as well as wire and irregular shaped material can be processed with the 42B. The 42B is part of the Compu-Cut machine series which includes the 33 and 36A models.

All consumable and spare parts for Carpenter machines are available through WPS.  For more information on the Carpenter Compu-Cut machines and Magnet wire stripping line Connect Your Way to WPS or visit wireprocess.com/carpenter

 Heat Shrink Tube Processing

 

 The heat gun has been a standard method of processing heat shrink for decades.  The Judco Focus Lite line is a cost effective method of processing heat shrink of various sizes. The energy efficient halogen bulbs operate on demand for fast and efficient shrinking of heat shrink tube.   Several models are available to shrink tube from 5/8″ to 1.5″ OD to 15.5″ long.  Connect Your Way to WPS or visit wireproces.com/Judco for more information.

Other Processing Options

Applicators and crimping presses for reel fed terminals, terminals and connectors,  quality validating and monitoring systems for crimping, wire marking, wire cut and strip equipment for stranded and multi-conductor wire.

Connect Your Way to WPS to discuss your assembly processes for your products.  We have over three decades of experience serving our valued customers from coast to coast.

Our Vision Explained – Part Two

In part one,  I outlined some of the basic factors required to achieve the vision “To earn the privilege to be our Customer’s Natural Choice of a supplier of Assembly Solutions.  In part two, I am covering innovation.

Webster’s dictionary defines Innovation as: 1 : the introduction of something new 2 : a new idea, method, or device.

Constant Innovation is one of the core values of Wire Process Specialties.  Innovation at WPS covers our internal processes and product offering. Internally, we are focused on ways we can be more efficient in communicating to our customers, making information easy to access

At WPS we are not standing still, we believe there is always a better way to work, finding new ways to add value to the relationships we build with our customers.

Is this vision a guarantee of suceess in every case? No it does not guarantee success. Not every company values this focus. It is our objective to make each customer exchange mutually beneficial. Demonstrating the value of high trust relationships is very important. When trust is earned, our value as a partner with our customers is enhanced.

Our vision is part of our vision, value and mission statements our commitement to our customers which can be found on the  company profile page of WireProcess.com.

Carpenter Compu-Strip 97A Cut and Strip machine.

The Compu-Strip 97A is a heavy duty cut and strip machine designed to process single conductor stranded and multi-conductor cable.  This high performance wire processing machine is used in many industries including electrical panel manufacturers, wire and cable harness suppliers and companies who process wire for electrical or electronic devices.

 The Compu-Strip 97A is equipped with a precision motorized ball screw cut/strip head to cut and strip wire from 8 to 32 awg, flat cable to 0.520″ wide and multi-conductor wire up to  0.312″ diameter.  The wire feed uses belts for a secure but gentle grip for accurate feeding.   Standard V blades are included with radius V, oval and other profiles for flexible processing.

 The 97A can operate as a standalone processor or with a bench top or floor mount powered pre-feed.  Wire Marking options are available as is wire stackers for long lengths.

Carpenter Manufacturing is a valued Global Technology Partner of Wire Process Specialties and supplies high quality wire processing equipment for a wide range of wire processing applications.

 The Compu-Strip 97A is part of the Carpenter family of wire processing machines.  For more information on Carpenter Mfg, visit WireProcess.com or Connect Your Way to WPS.

Our Vision Explained – Part One.

“To earn the privilege to be our Customer’s Natural Choice of a supplier of Assembly Solutions.”

The words in this vision statement have framed our way of doing business for almost three decades.

To be your customer’s natural choice?  A little lofty given the competitive nature of our business today right?  Not really. Our vision keeps us focused on the job ahead of us.  The real action is in the first phrase “To earn the privilege”.  Far too many companies large and small take their customers for granted, feeling a sense of entitlement in some respects.  When this happens, the original customer/supplier partnership is affected and opens up the opportunity for new competitors to enter and replace your company as a primary supplier – and trusted partner. As the incumbent supplier this erodes market share.

So how do we start to “earn the privilege”?  First remembering that this is an ongoing process with no end date.  In the pursuit to earn the privilege, there are several factors we consider:

  • Trust is the first step.  This is not something you immediately achieve, it takes time.  When starting with a new customer, small steps to gain trust are critical.  Often it is being relegated to a secondary supplier role. Stating our values, mission and code of ethics in writing provides some accountability to our actions.
  • Adding value to the relationship.  We are constantly looking for ways to reduce cost, improve efficiency. Anything that directly or indirectly improves the customer’s bottom line.
  • Be available.  Nothing hurts a business relationship more than taking too long to respond to an inquiry.  Someone else will be ready and able to respond quicker if they are given the opportunity.
  • Understand our customer’s concerns.  Helping to solve even a simple problem with a cost effective solution goes a long way to solidifying a customer relationship.

In part two, I will cover innovation as a key factor in making good business relationships even better.  And taking us one more step towards our vision of being your Natural Choice of a supplier of Assembly Solutions.

Our vision is part of our vision, value and mission statements our commitement to our customers which can be found on the  company profile page of WireProcess.com.