Precisetool Terminal Tension Testing Service

 Precisetool provides professional terminal tensile testing services.

1. Terminal mapping and document creation

After receiving customer's terminals (jack/pin) and wire samples, first of all, the technical staff performs terminal mapping. The mapping process must be meticulous and rigorous to ensure the accuracy of the data. Then, the technical staff performs the terminal sorting and information screening to ensure the integrity of technical information and to provide customers with the most economical and reasonable selection of tools.

Terminal Platting(Example)

2. Preliminary selection

Secondly, model selection of terminal crimping tool, crimping tool selector position, as well as positioners. Selector position determined by a professional formula. This formula comes out after numerous attempts and tests and has high applicability and accuracy. But the result is still a theoretical selector position, taking into account the actual rebound of material and other factors, the tensile test is needed to determine the ultimate reliability.

Formula of crimping tool theoretical selector position

3. Terminal crimping

Use the selected crimping tool for terminal crimping. Position #6 of pneumatic crimping tool YJQ-W3Q is suitable for the terminal above. Use the YJQ-W3Q to crimp the wires and terminals according to the correct operating procedure.

Pneumatic crimping tool YJQ-W3Q

4. Image collection

Take pictures. Including the terminals before and after crimping.

Crimping sample

5. Terminal tensile testing

As the selector position calculated by the formula is theoretical, it can not fully ensure the reliability of the terminal tension value. So a terminal tensile test is necessary.

Tensile Test Example

6. Experimental analysis and summary

The results of the tensile test are made into a tensile test record table. The recommend  model and related data, such as terminal name, wire size, positioner, crimp outer diameter, crimp inner diameter, crimp position parameters, test tension value, and diagonal value etc., should be clearly presented in the test record table. Draw tensile test chart which makes the test results more intuitive. The results show that the position #6 achieve the standard tension. Of course, customers need to perform other related performance testing.

Terminal information table

Tensile test record table

After packaging crimped terminal, stick the label: number, customer name, time, selection of tools, suitable positioner and other information. Finally, send the terminal information table and tensile test record table to customers. Crimped samples send back to customers for reference, and do other performance testing and then make the final tool selection.

Brief Introduction of Hand Crimp Tool Kit —— KIT1024

KIT1024 Products List: YJQ-W2A (AF8 M22520/1-01) Hand Crimping Tool + TH1A Turret Head (M22520/1-02) +TH163 Turret Crimper Positioner (M22520/1-04) +UH2-5 Adjustable Crimper Positioner (M22520/1-05) + G125 Go-no-go Gage (M22520/3-01) + 9/64 Hex Wrench + 8-32UNC×1 Screw + 8-32UNC×5/16 Screw

KIT1024

Product List of KIT1024

Datasheet/Specification of KIT1024

1. Precisetool YJQ-W2A Aviation Hand Crimping Tool for Military Connectors Aerospace Wiring Harness

· Qualified to M22520/1-01

· Equivalent to DMC AF8 Crimping Tool

· Has limitless application within the specified wire range of 12—16 AWG

· Gives a Mil-Standard 8 impression crimp, which assures maximum tensile strength

· Crimp depth can be adjusted by an 8 position selector knob conveniently located on the tool frame

· The precision ratchet controls cycling of the tool in both directions of handle movement which assures the same accurate crimp every time

· The carefully engineered design achieves the absolute maximum mechanical advantage and it is light-weighted to help minimize operator fatigue

· Suitable for military institutions, aviation companies and electronic connectors/military connectors/heavy duty connectors companies, wiring harness or cable assembly manufacturer

2. Precisetool TH163 (M22520/1-04) Adjustable Turret Head for AF8 Wire Crimper

· Weight: 0.25 lb

· Equivalent to M22520/1-04

· Adjustable turret crimper positioner

· Gives a standardized and accurate crimp every time

· Can be adjusted to match the diameter of the connectors and the wires desired

· A dataplate affixed to turret head lists specific contact part numbers, the corresponding position color code, and suggested selector depth settings for the wire size being used

3. Precisetool TH1A (M22520/1-02) Adjustable Turret Positioner For AF8 Aerospace Hand Crimping Tool Cable Crimper

· Weight: 0.25 lb

· Equivalent to M22520/1-02

· Adjustable turret crimper positioner

· Gives a standardized and accurate crimp every time

· A dataplate affixed to turret head lists specific contact part numbers, the corresponding position color code, and suggested selector depth settings for the wire size being used.

4. Precisetool UH2-5 (M22520/1-05) Postioner Head for Aviation Pneumatic/Hand Tools Wire Cable Crimping Tool

· Weight: 0.15 lb

· Equivalent to M22520/1-05

· Can be easily mated to the crimping tool frame

· Adjustable for a wide range of wire and connector sizes

· Adapt the tool frame to specific military or proprietary contact combination

· The screw can be secured with the locknut provided

· The selected contact is inserted through the entry hole on the opposite side of the tool frame from the head

· The height adjusting screw is rotated until the contact is in the proper position for crimping

· Can be used on commercial installations, home maintenance, laboratory work, and heavy duty military or aerospace applications

5. Precisetool G125 (M22520/3-1) Go-no-go Gauge for AFM8/AF8 Cable Crimping Tool

· GO: 0.039 inch

· NO-GO: 0.044 inch

· Equivalent to M22520/3-1

· Periodic gaging is recommended to insure accurate calibration

· Set the tool selector knob to position 4, and check indenter closure with the gage

Installation and Removal Instruction of M22520 Crimper Positioners

M22520 series manual and pneumatic crimping tools are widely used in crimping wires and terminals in electrical connectors. The crimping pliers, if not used with the positioner, the operator will have to determine the position of each crimping by eyes which will not only take unnecessary time and effort, but also reduce the overall efficiency. Thus, the positioner plays a very important role in the manual or pneumatic crimping process. 

Among all kinds of positioners, fixed positioners, screw-adjustable positioners, turret positioners are the three main types. Screw-adjustable positioner and turret positioner are more welcomed by the majority of customers because of its wide range of application.

Proper installation and removal of the positioner are of vital significance. Here we briefly introduce the installation and removal steps of turret positioners.

Positioner: TH163 (M22520 / 1-04) Turret Positioner

Adaptation Tools: YJQ-W2A (M22520 / 1-01) Four-indent Crimping Pliers

Installation of Positioner

1. With tool in open position, press positioner trigger latch to release turret to indexing position

2. Place positioner onto retaining ring with alignment pin in alignment hole

3. After positioner is seated against retainer ring, tighten socket head screws with 9/64" hex

4. Press turret to check if it is installed correctly or work proporly

5. With tool in open position, press positioner trigger latch to release turret to indexing position again

6. Refer to dataplate on positioner. From color code column, select the positioner color that corresponds with the appropriate part number and size of contact to be crimped. Rotate until color coded insert is in line with the index mark. Press turret until it snaps in latched position

Then, the installation process has been completed. Refer to dataplate. From wire size column, determine the selector setting that corresponds with the contact being used. Remove spring clip from selector knob and rotate until correct setting is in line with selector mark. Next, the crimping operation can be performed.

Removal of Positioner

With tool in open position, release turret. Loosen screws until threads are disengaged from retainer ring and remove with a straight lifting motion.

Caution: Tool must be in open position whenever positioner is being installed, removed or released. Damage to turret head and crimp tool may result if this procedure is not followed.

In addition, there are some other positioner installation pictures for your reference.

Is the installation and removal process very simple?

Tips on the Use and Maintenance of Hand Crimping Pliers

The cold crimping technology is widely used in the fields of wire harness manufacturing, aerospace, new energy vehicles, rail transportation, connector manufacturing, because of its characteristics of high reliability, simple operation, cost saving and no pollution. This makes manual crimping tools more widely used in related manufacturing industries. Then, do you know how to better use crimping tools to extend tool life? Here I will take M22520 series hand crimping pliers for example to tell you a few about the use and maintenance of crimping pliers.

Tip 1 Crimping pliers are precision tools which can not be transferred to other uses and can not operate the tool indiscriminately. Please crimp with the appropriate force.

YJQ-W1A (M22520/2-01) Hand Crimping Pliers + SK2-2 Crimper Positioner

YJQ-W7A (M22520/7-01) Hand Crimp Pliers + 86-37 Adjustable Crimper Positioner

Tip 2 The right crimping tool should be chose to crimp the terminals and wires. When the size of the terminal does not match that of the crimping pliers, there may be insufficient crimp or excessive crimp. Do not insert rigid steel contacts or solid cylindrical contacts into the crimp hole, otherwise it may cause damage to the crimping pliers.

Different Crimping Tools for Different Terminals

 

Step1 Put the terminal into the crimp hole.

Step2 Insert the wire into the terminal.

                                                  Step3 Press the crimping pliers handle properly to complete crimping.

                                         Simple Instruction of Terminal Crimping Step（YJQ-W2D）

Tip 3 Use with suitable positioners. Install and remove the crimper positioners with the correct method. When you install or remove the positioner, the tool must be in fully open position. After crimping, remove the positioner carefully and store it securely.

Installation of Screw-adjustable Positioner UH2-5(M22520/1-05) 

Installation of TH163 Turret Head

Tip 4 Do not twist the wire to be crimped. Otherwise it will affect the terminal and wire crimping effect, affecting the tension value.

Do not twist the wires to be crimped

Wire Crimping Cross-section after twisting the wire

Tip 5 Keep the indenter tips clean and carefully remove any remaining deposits, but do not immerse the tool directly in cleaning solution.

Indenters tips of YJQ-W2A (M22520/1-01) Manual Crimping Tool

Indenters tips of YJQ-W1A (M22520/2-01) Manual Crimping Tool

  

Tip 6 Crimping pliers should be cleaned and stored in a clean, dry place to prevent dust and impurities from entering the crimp frame, or it will affect the performance of pliers.

The manual crimping tool YJQ-W1A（M22520/2-01）placed in the cleaning box.

Be sure to store it carefully and keep it safe.

Tip 7 Crimping pliers must be regularly inspected and maintained. After being used for a certain period of time, it is necessary to check the accuracy of the crimping pliers with a Go-NOGO gauge. As shown in the picture, operate the tool to the fully closed position. If the “GO” gage end can pass freely, but the NO-GO end can not pass completely, it means the tool is still qualified.

Operation Instruction of Go-NOGO Gauge G125 (M22520/3-01)

            Choose the right one to detect.

Tip 8 If the crimping pliers are broken, parts are scattered or any abnormality is found, stop using them. Do not transform the crimping tool. Do not attempt to disassemble tool or make repairs. Please contact the factory's technical service personnel for repair.

All these use and maintenance knowledge of crimping tools, have you gotten it?