In this final part of the introduction to Crimp Quality Solutions, we are focusing on the tools used to validate and monitor crimp quality. Part one was an Overview of Crimp Quality Solutions. Part Two covered Training and Support Services
It is simply not enough to know what needs to be done, you must apply the knowledge and translate it to action. In today’s production environment, there is little room for error. Wth razor thin margins, quality issues can be costly to an organization. Not only in hard currency (returns, rework etc..), but also in reputation. Avoiding quality issues is critical to a company’s future. Cutting corners is not a solid business strategy.
To assure your terminal crimps are the best quality from part one to the end of a production run, the right tools must be used. It should be noted that there is a convergence in the use of Quality measurement tools between pre and in-process monitoring.
Here are the essential tools used to validate and monitor crimp quality.
If you have calibrated your crimp press to the standard shut, your press has demonstrated capability for shut height alone…. for that one piece. In order to determine the press is statistically capable, shut height and press force need to be evaluated. And that requires more than one press cycle. The PAL4000 Press Analyzer accomplishes a full capability study of the press. And it stores the data for comparing with past press studies. Maintenance will benefit by prioritizing press service.
Crimp Height Micrometer
A Crimp Height micrometer is critical to measure the wire crimp height during validation and process monitoring. The flat anvil rests on the top of the crimp while the pointed spindle rests in the underside (center) of the crimp.
Other measurements like wire crimp width, insulation (height and width) as well as strand diameter. Digital Calipers can also work, but resolution (two decimals) is lower than blade micrometers (three decimals).
As a secondary crimp test, pull testers measure the secureness of the crimp. Motorized pull testers pull the wire at a constant rate and takes out the operator (or operator to operator) variation. Automatic data logging reduces time and potential for entry error.
Crimp Cross Section
What was once a dedicated crimp development tool in large wire harness and terminal stamping companies can now be found in quality departments and and the production floors of a wide range of companies. Quick sample preparation and imaging are standard features. X-Scan is a powerful software analysis tool with automatic crimp profile tracing and a full list of crimp attributes.
Crimp Force Monitors
Crimp Force Monitors are a standard quality tool in wire harness production. Crimp Monitors use force sensors mounted to the press and convert force to a crimp curve which when compared with pre-production validation samples, can detect typical defects such as strands missing and insulation in the crimp. Crimp Monitors are mounted to both automatic processing machines and bench top presses.
Processing inputs for crimping include the operator and process tools (crimp applicator), materials (wire, terminals). Crimp tests include crimp height, pull test, cross section and Crimp Monitor teach in. Verifying this information prior to production is possible but prone to human error. Automating using a client/server system takes error out of the process by comparing processing inputs with established standards stored on a server computer.
Our Global Technology Partners Crimping and Stamping Technologies are highly specialized in the crimp testing process. An authority in a crimp validation and process monitoring, C&S supplies all of the above technologies and are constantly adjusting their processing solutions to meet new demands of the wire processing industry. That and the global support provided by their experienced technicians make C&S a valuable partner in crimp quality.
No matter where you company is in it’s wire harness journey, WPS and C&S have you covered. We are there to support your requirements from end to end. Visit CrimpQuality.Solutions and click the Let’s Get Started Link.