In an other life, I've seen people believing that "stronger" was better 
so they over crimped everything. Then, to satisfy our requirements, the 
made a pull test on everything... I mean everything! They took a 30lbs 
weight and made sure every lug was tested before shipping. Then, when I 
told them to use a bit of flux on the soldered connection, the when to 
the hardware store to buy plumbing paste.

The elongated ring terminals convince me to audit them... you can guess 
the rest of the story.

On the good side, it made my boss a believer of "audit before we hire".

Never thought I would go through such a nightmare over crimping...

Thanks All!

On 12/6/2012 11:58 AM, Inge Hernefjord wrote:
> We have spent hours and hours on crimping. People did not take the quality
> requirements seriously. Just 'simple' crimping. A monkey can do it, as said
> one boss. Series of tests gave an image that shocked the involved, and we
> dedicated two MSE guys to work 100% for one year with crimping. Resulted in
> a bunch of updated assembly directives. Among many background papers we
> used Hans Danielsson's inches thick report from the car industry. He
> demonstrated how connections and contact joints were the far most common
> source in car electronics..
>
> Inge
>
> On 6 December 2012 16:23, Gerald Bogert
> <[log in to unmask]>wrote:
>
>> December 6, 2012
>>
>> One important crimping consideration in addition to verifying tensile
>> strength is to confirm that the crimp tool used was used in a manner to
>> ensure full ratchet action of the tool was achieved as required by the
>> IPC workmanship standards.  Some air operated crimp tools can be set to
>> different pressure settings.  Normally, for air operated crimp tools, to
>> achieve full ratchet action the tool is set to a specific pressure
>> depending on the tool used (e.g., 90 PSI).  However, if the tool is set
>> at a lower pressure (e.g., 60 PSI) you will get a crimp that is not
>> fully formed but it may or may not still pass tensile testing, depending
>> on the type of wire and lug used.  The lower pressure setting would
>> violate the IPC standards since less than full tool ratchet action would
>> occur.
>>
>> -----Original Message-----
>> From: TechNet [mailto:[log in to unmask]] On Behalf Of Bob Landman
>> Sent: Thursday, December 06, 2012 9:59 AM
>> To: [log in to unmask]
>> Subject: Re: [TN] Crimp tensile strength
>>
>> Molex crimping tool instructions include information on measuring crimp
>> tensile strength.  I haven't checked but would expect Tyco/Amp also to
>> have the information.  It's the only way to verify a "good" crimp has
>> been made.
>>
>> One item of interest: we recently had a problem with consistent crimps
>> of a Molex terminal.  The documentation was of no help.  The technician
>> noticed that the "V" grove that the terminal is placed into prior to
>> closing the handles of the tool seemed worn.  There are two such groves
>> in the tool and the other one (for smaller gauge wire)  had never been
>> used so that made it obvious there was a problem.  The terminals would
>> roll a bit to one side or the other before the tool closed.
>>
>> The documentation says nothing about the groves but clearly they are a
>> significant feature of the tool.
>>
>> A few minutes with a triangle file restored the grove.  The tool again
>> yielded 100% good crimps.
>>
>> Bob Landman
>>
>> On Dec 6, 2012, at 1:48 AM, Inge Hernefjord <[log in to unmask]>
>> wrote:
>>
>>> JF, je vais vouz envoyer offline " The Crimping Handbook". /Inge
>>>
>>> On 30 November 2012 14:03, JF <[log in to unmask]> wrote:
>>>
>>>> Hi all,
>>>>
>>>> I'm trying to find a chart to evaluate crimp quality. This chart was
>>>> about "Crimp tensile strength". Can't remember what it was.
>>>>
>>>> Thanks for any help!
>>>>
>>>> JF
>>>>
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