端子压接尺寸计算方法

4 0 Correct Application 4 2 Stripping the Wire Prior to crimping all wires must be stripped to the correct length The correct strip length has been obtained when the crimped terminal shows bare wire in the brush and wire witness as shown in the diagram below With acknowledgements to AMP Incorporated Harrisburg PA Care must be taken when stripping wires to achieve a good strip Examples of four bad wire strips and one good one are shown below With acknowledgements to AMP Incorporated Harrisburg PA Internal Appliance Wiring Designer Pack Document No DPIAWD Revision No 02 Page 2 of 6 Copyright 2004 4 0 Correct Application 4 3 Calculating the Crimp Height The first step is to calculate the overall CSA of the wire conductor and also the cross sectional area of the terminal wire barrel To determine the CSA of the wire conductor identify its construction and use the look up table in Section 2 1 Alternatively if the construction is non standard use the following formula CSA mm2 Strand Dia mm 2 x No of Strands x 0 7854 To determine the CSA of the wire barrel first flatten the wire barrel into its developed shape and measure this flattened length mm Multiply this by the thickness of the material to get the cross sectional area See the diagram below With acknowledgements to EDM Crimp Technology London E4 9UA Ensure that both figures are calculated to be in mm2 and add them together to get an overall CSA If more than one wire is to be crimped in a terminal add the CSA of this wire to the overall calculated CSA Using the table on the next page look up the NEAREST overall CSA figure to the one you have just calculated Read across to determine the standard crimp width W mm required and its Standard Tooling Code STC This determines the width of crimp tooling that will be required to perform a good crimp Internal Appliance Wiring Designer Pack Document No DPIAWD Revision No 02 Page 3 of 6 Copyright 2004 4 0 Correct Application 4 3 Calculating the Crimp Height continued Table C Original CSA Crimp Width and Crimp Height Standard tooling crimp dimensions based on a crimp height to width ratio of 65 and a compaction factor of 85 With acknowledgements to EDM Crimp Technology London E4 9UA Once the crimp width W has been determined divide the Original Total CSA by W to obtain the crimp height H This figure has a tolerance of 3 Finally ensure that the crimp height calculated H is between 50 and 80 of the crimp width W See the diagram below Total Original CSA mm2 Standard Crimp Width W mm STC Nominal Crimp Height H mm 0 163 0 50 020 0 33 3 0 234 0 60 024 0 39 3 0 319 0 70 027 0 46 3 0 416 0 80 031 0 52 3 0 527 0 90 035 0 59 3 0 650 1 00 039 0 65 3 0 787 1 10 043 0 71 3 1 016 1 25 049 0 81 3 1 274 1 40 055 0 91 3 1 562 1 55 061 1 01 3 1 979 1 70 067 1 10 3 2 225 1 85 073 1 20 3 2 600 2 00 079 1 30 3 3 005 2 15 085 1 40 3 3 438 2 30 090 1 49 3 3 902 2 45 096 1 59 3 4 394 2 60 102 1 69 3 4 916 2 75 108 1 79 3 5 850 3 00 118 1 95 3 6 866 3 25 128 2 11 3 7 963 3 50 138 2 27 3 9 141 3 75 148 2 44 3 10 400 4 00 157 2 60 3 W H Internal Appliance Wiring Designer Pack Document No DPIAWD Revision No 02 Page 4 of 6 Copyright 2004 4 0 Correct Application 4 3 Calculating the Crimp Height continued Below is a worked example Two stranded wires required to be crimped in a standard F Crimp Terminal One wire Wire 1 has a construction of 30 0 25 used for carrying system current while the second Wire 2 has a construction of 1 0 60 used for carrying neon current CSA of Wire 1 from Table A on page 3 1 473mm2 CSA of Wire 2 from Table A on page 3 0 283mm2 Wire barrel developed length 7 5mm material thickness 0 3mm CSA of Terminal Wire Barrel 7 5 x 0 3 2 25mm2 Total Original CSA 1 473 0 283 2 25 4 006mm2 Looking up nearest Total Original CSA from Table C gives 3 902mm2 This gives a Standard Crimp Width W of 2 45mm Divide the Total Original CSA by the Standard Crimp Width W to determine the crimp height H 4 006 2 45 1 63mm 3 This gives a Standard Crimp Height H of 1 58 1 68mm To check the aspect ratio of height to width at extremes of tolerance is between 50 80 1 58 2 45 64 1 68 2 45 68 The final wire barrel crimp should look as below 2 45mm 1 58 1 68mm Internal Appliance Wiring Designer Pack Document No DPIAWD Revision No 02 Page 5 of 6 Copyright 2004 4 0 Correct Application 4 4 Crimp Inspection The quality of the crimps should be visually inspected to ensure that a good connection is being made As well as checking for crimp width and height other features should be checked as detailed below With acknowledgements to AMP Incorporated Harrisburg PA In addition when developing the crimp process and settings cross sections of the wire barrel and the insulation barrel should be obtained to ensure that visually it conforms to the inspection criteria overleaf Safety standards require that t