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Quality Crimp Handbook
SECTION 2
PURPOSE
This handbook provides general guidelines and procedures for understanding and achieving acceptable crimp
terminations. A glossary in Section 4 lists common terms and definitions. Section 5 lists the tools that are
necessary to take accurate measurements and evaluate the crimp's acceptability.
The tooling setup is critical in determining the quality of the finished crimp. The attributes that need to be
considered include crimp height, conductor brush, bell mouth, and cut-off tab and strip length and insulation
position. Variability in one or more of these attributes can reduce the measured pull force. It can be difficult to
establish acceptable variability limits because the attributes all interact with one another.
For example, a track adjustment for bell mouth also will change the cut-off tab length and the insulation wire
position while strip length and wire locations affect the conductor brush and insulation position. Adjusting the
insulation crimp height may result in a slight change to the conductor crimp height measurement. It may be
necessary for the setup person to make multiple adjustments before establishing an optimal setup.
The order the setup is done may help reduce the number of repetitions required for an optimum setup.
Section 6 has a flowchart for a process setup while Section 9 is a troubleshooting guide for common problems.
Using Statistical Process Control (SPC) during the crimping process can help minimize the amount of defects.
Section 8 provides a general explanation of the benefits of using SPC.
This handbook is structured so that parts, or all, of its contents can be used as a procedural guide for ISO
requirements.
Order No: TM-638000029
Revision: D
Release Date: 09-04-03
Revision Date: 12-23-09
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Page 4 of 24
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