Another thought just struck me:
There haven't been any pictures of your failed IDC connections. These connections are basically guaranteed to fail without strain relief. I recall it was pointed out that these are not ribbon cables, but individual wires. If these are not carefully and thoroughly strain-relieved, then any wire movement will grind the strands against the insulation cutting knives can rapidly chew through the 36G strands.
Even if the knives don't wear through the strands, they can cause the wires on the compression side of a bend to kink. Doing a careful inspection of the broken area will reveal which mode.
Wayne Thayer
-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Joyce Koo
Sent: Thursday, March 28, 2013 8:40 AM
To: [log in to unmask]
Subject: Re: [TN] Detecting Cut Wire Strands on Insulation Displacement Cables
That doesn't make sense. If everything is OK, you still got your cable cut, that OK is not so "OK". Used wrong tooling or tooling designed wrong with usage that outside your spec? (but could be well in their spec ;-(
Joyce Koo
Researcher
Materials Interconnect Lab
Office: (519) 888-7465 79945
BlackBerry: (226) 220-4760
-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Paul Black
Sent: Thursday, March 28, 2013 8:22 AM
To: [log in to unmask]
Subject: Re: [TN] Detecting Cut Wire Strands on Insulation Displacement Cables
All of the material has been what the manufacturer has specified for the IDC equipment, which is their own equipment. According to the cable supplier, they are operating and maintaining the equipment to the manufacturer's specifications, although I am going to want to see the records for verification.
Paul Black
Manufacturing Engineer
978 421-9695 phone
978 421-0025 fax
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www.zoll.com
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-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Goodyear, Patrick
Sent: Thursday, March 28, 2013 12:00 AM
To: [log in to unmask]
Subject: Re: [TN] Detecting Cut Wire Strands on Insulation Displacement Cables
Are the connectors correctly sized for the cable and insulation type? Are the cables held ridged during crimping? Would be two questions I ask.
Pat
-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Paul Black
Sent: Tuesday, March 26, 2013 6:21 AM
To: [log in to unmask]
Subject: [TN] Detecting Cut Wire Strands on Insulation Displacement Cables
In trying to track root cause of an intermittent failure, we discovered, by dissection, that some wire strands of an Insulation Displacement Cable had been cut (see atached picture with cover removed). Each wire is 7 strands of 36 gauge wire. The supplier of the cable agrees with the conclusion and is talking with the supplier of the IDC equipment used.
To verify that this is truly the root cause of the problem, we need known good cables, but all of them are currently suspect. The thought was to x-ray the cables to verify all of the strands are intact, but the IDC contacts surrounding the wire strands make it difficult, even at 100x magnification. Does anyone know of a method that might help detect the broken strands or a company that might have the capability?
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