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Crimping Inspection

DOC NO: QP180 REV:


WRITTEN BY: M. James DATE: 10/12/01
APPROVED BY: DATE:
DEPARTMENT: Quality Assurance

1.0 INTRODUCTION
1.1 This procedure instructs the inspector in the inspection methods and testing
requirements, in order to facilitate a reliable crimp connection. The tools and
equipment shall meet the requirements of this procedure.
2.0 REQUIRED MATERIALS
2.1 (TOOLS, SPACE, CERTIFICATIONS, ETC.)

3.0 REFERENCES
3.1 (DRAWINGS, SPECIFICATIONS, ETC.)

4.0 INSTRUCTIONS
4.1.1 Records. The manufacturing department shall develop and maintain records of
tool calibration and maintenance. The manufacturing department shall develop
and the quality control department shall maintain records of crimp testing Records
shall be kept to identify the operator, the finished product and the tools used.
They shall be identified as:
4.1.2 Crimper Calibration and Maintenance Schedule: This document provides
the type of maintenance procedures, calibration procedures, and the intervals
based on specifications provided by the manufacturers.
4.1.3 Crimper Maintenance Log CM-001: This log shall be used to record all
scheduled maintenance performed as per the Crimper Calibration and
Maintenance Schedule.
4.1.4 Crimper Calibration Log CC-001: This log shall be used to record all
scheduled calibrations performed as per the Crimper Calibration and
Maintenance Schedule.
4.1.5 Crimp Test Log CT-001: This log shall be kept to identify the operator, job
number, crimp/die set/crimper combination, any set up characteristics and the
running quantity of crimps made.
4.2 Verification. The quality department shall verify all requirements and
specifications of this procedure.
4.3 Wire. Solid wire shall not be used for crimping. Stranded wire shall be used.

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Crimping Inspection

DOC NO: QP180 REV:


WRITTEN BY: M. James DATE: 10/12/01
APPROVED BY: DATE:
DEPARTMENT: Quality Assurance

4.3.1 Wire Damage: Any evidence of conductor damage such as nicks, cuts, or
compression of the material to the point where the cross sectional area has
been reduced past normal shall be rejected.

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Crimping Inspection

DOC NO: QP180 REV:


WRITTEN BY: M. James DATE: 10/12/01
APPROVED BY: DATE:
DEPARTMENT: Quality Assurance

4.4 TOOLING.
4.4.1 Full Cycle Ratcheting: All hand crimp tools shall be of the full cycle
ratcheting type, which shall prevent the indentors from releasing before the
crimp cycle has been completed. All other crimpers shall be approved by the
production manager and meet UL compliance for their application.
4.4.2 Un-Calibrated Crimp Tools. Out of calibration or uncalibrated tools shall
not be used.
4.4.3 Non-Adjustable Tools. If the tools are damaged or broken it shall be removed
from service.
4.4.4 Tool Identification. Each crimp tool shall be identified and marked. As a
minimum the marking shall include the following
4.4.4.1 Serial number.
4.4.4.2 Date of calibration.
4.4.4.3 Date calibration expires.
4.1 Tool Control. Gaging tests and tensile testing of samples will be used to verify
compatibility and maintain reliability of crimping tools. Reference calibration
procedure for gauge testing.

4.4.5 Factory calibration: When required the manufacturer of the tool or a


calibration laboratory shall make calibration adjustments.
4.4.6 Sealing Of Adjustable Tools. All adjustable crimp tools and retention tester
shall be calibrated, set and sealed prior to their application. If the seal is
broken or damaged the tool shall be removed from service
4.4.7 Calibration Method. The initial calibration and the re-calibration of the
crimp tool shall be in accordance with the manufacturers specifications
4.4.8 Calibration Period. Tools shall be re-calibrated according to the “Crimper
Calibration and Maintenance Schedule”.

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Crimping Inspection

DOC NO: QP180 REV:


WRITTEN BY: M. James DATE: 10/12/01
APPROVED BY: DATE:
DEPARTMENT: Quality Assurance

4.2 Crimp Inspection:


4.4.9 Conductor Insertion:
4.4.9.1 On open barrel crimps the conductors shall be flush or greater (Ref. Gproc-
004) than the end of the barrel.
4.4.9.2 On closed barrel crimps the conductors shall be visible in the inspection hole.
4.4.10 Insulation Clearance: Insulation clearance shall meet the following
dimensions
4.4.10.1 .01 to .03 for no. 20 awg and smaller
4.4.10.2 .01 to .05 for no. 18 awg and larger.

4.4.11 Insulation Grip: Where applicable crimps with insulation grips shall be
properly formed as to grip and support the wire.
4.4.12 Examination Of Crimp Contact. Inspection of crimp contact will
depend on the type of contact being used. Check for the following:
4.4.12.1 Cracks in the plating or base metal.
4.4.12.2 Plating removal or flaking.
4.4.12.3 Out of round of the wire well entrance.
4.4.12.4 Exposed base metal.
4.4.12.5 Bent of deformed contact.
4.4.12.6 Proper Bell-mouth
4.4.12.7 Properly placed crimp mark.
4.4.12.8 Damage to crimp insulator.
4.4.12.9 Stray wire strands.
4.4.12.10 Wire in contact area.
4.4.12.11 Over crimped
4.4.12.12 Under crimped.

4.5 Process Controls.


4.5.1 Verification Method. Using the Crimping Guidelines Table 1.1 in the M.O.P
verify the tool, setup, and any other pertinent information pertaining to the
crimp contact being used. In addition all applicable criteria from Gproc-005
Inspection shall be used.
4.5.2 Test Method. The crimp contacts shall be placed in a tensile testing device
with appropriate fixtures, and sufficient force applied to pull the wire out of the
assembly or to break the wire or crimped item. The head travel speed of the
tensile device shall be xxx per minute.

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Crimping Inspection

DOC NO: QP180 REV:


WRITTEN BY: M. James DATE: 10/12/01
APPROVED BY: DATE:
DEPARTMENT: Quality Assurance

4.5.2.1 Test Interval. Shall be performed according to the “Crimper Calibration and
Maintenance Schedule”.
4.5.2.2 Number Of Test Samples. A minimum of three test samples shall be prepared
for each crimp combination.
4.5.2.3 Examination Of Test Sample. Each individual test sample shall be inspected
to the requirements of this procedure and the observations recorded and
maintained.
4.5.2.4 Required Crimp Strength. The tensile strength of the crimp test sample
connections shall be in accordance with Table 1. For those contact conductor
crimp connections not contained in table 1, the tensile strength of the crimp
connection shall be no less than 60% of the tensile strength of the wire. See
Table 2 for wire tensile strength.

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Crimping Inspection

DOC NO: QP180 REV:


WRITTEN BY: M. James DATE: 10/12/01
APPROVED BY: DATE:
DEPARTMENT: Quality Assurance

4.5.3 TABLE 1.
CRIMP TENSILE STRENGTH
WIRE BARREL SIZE CONDUCTOR SIZE BASE CONDUCTOR TENSILE
AWG MATERIAL STRENGTH LBS
22M, 24 28 COPPER 3.1
26 COPPER 5.2
24 COPPER 8.0
22 26 COPPER 5.2
24 COPPER 8.0
22 COPPER 12.8
22D 28 COPPER 3.1
26 COPPER 5.2
24 COPPER 8.0
22 COPPER 12.8
20 24 COPPER 8.0
22 COPPER 12.8
20 COPPER 20.6
16 20 COPPER 20.6
18 COPPER 32.0
16 COPPER 41.2
12 14 COPPER 65.1
12 COPPER 103.2
10 10 COPPER 159.0
8 8 COPPER 288.8

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Crimping Inspection

DOC NO: QP180 REV:


WRITTEN BY: M. James DATE: 10/12/01
APPROVED BY: DATE:
DEPARTMENT: Quality Assurance

4.5.4 TABLE 2
WIRE TENSILE STRENGTH
WIRE SIZE TENSILE STRENGTH TENSILE STRENGTH TENSILE STRENGTH
LBS UL LBS UL QUICK LBS MIL-T-7928
DISCONNECT
26 3 - 7
24 5 - 10
22 8 8 15
20 13 13 19
18 20 20 38
16 30 30 50
14 50 50 70
12 70 70 110
10 80 80 150
8 90 - 225
6 100 - 300
4 140 - 400
2 180 - 550
1 200 - 650
1/0 250 - 700
2/0 300 - 750
3/0 350 - 825
4/0 450 - 875
250 MCM 500 - 1000
300 MCM 550 - 1120
350 MCM 660 - 1125

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Crimping Inspection

DOC NO: QP180 REV:


WRITTEN BY: M. James DATE: 10/12/01
APPROVED BY: DATE:
DEPARTMENT: Quality Assurance

This is a controlled document. No changes can be made to this document without


consulting with the approving and written signatory listed above before implementation.
This document shall be reviewed annually.

REVISION HISTORY
Effective
Rev Description Of Change Author
Date

Next Review due 2001 2002 2003 2004


Reviewed By

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