Crimping solutions are essential for several industries, and the processes and procedures involved are often complex and unique. The key to producing a high-quality crimp is consistently and accurately carrying out the technique. You can take several steps to accomplish this goal, including guaranteeing the crimping procedure is used by your industry’s safety requirements. These include ensuring the crimping tool is in good working order, maintaining the crimping force, and checking the crimping height.
Ensure crimp quality checks take place systematically
Using a crimp tester and conducting a crimp quality review is a surefire way to avoid product failure. However, although it may sound like a no-brainer, the results may vary from assembly to assembly. As a result, a rigorous and well-thought-out crimp test plan is required to avoid a product disaster.
Thankfully, harness manufacturers have standardized a crimp quality review program to ensure every crimp is quality. Moreover, the latest tools in the crimping solutions Florence SC arsenal can provide a high degree of automation. While these technologies do not cover every assembly, the resulting efficiencies are worth the investment.
For example, the latest crimp test tools can perform manual and automated pull testing. Manual pull testers are a cost-effective alternative to motorized models. They can also handle multiple assemblies at once, reducing operator fatigue.
Crimp force monitoring
Crimp force monitoring is crucial to the quality of a wire terminal crimp. It provides real-time pass/fails feedback. A faulty wire connection cannot be used for further production.
Crimp force monitors compare the subsequent crimps to a reference crimp. These monitoring systems improve productivity, reduce scrap and help keep your customers happy.
Crimp force monitoring helps you produce more of the right and less of the wrong products. This technology combines a piezoelectric sensor and an electronic control unit to generate a force-angle curve. The curve is then compared to a known “good” reference. When the curve doesn’t match, an error message is sent.
Crimp force monitors are typically used in fully automated wire assembly systems. However, they can be used in a variety of crimping applications.
Crimping of fuel gas/oxygen/compressed gas hoses
Air and gas hoses transfer compressed air, fuel gas, and oxygen. They should be carefully selected. A faulty hose can cause injury or damage to property. The materials used to make the hoses vary according to their use.
Rubber is one of the common materials for air hoses. It is inexpensive and practical for outdoor use. Moreover, it is flexible. However, it can degrade over time.
Polytetrafluoroethylene (PTFE) is another alternative. This material can also undergo a process called “post-sintering,” which increases the strength of the hose.
Acetylene, propane, and natural gas are the most commonly used fuel gases for welding. While they are low-pressure, these cylinders should be stored safely.
Crimp height testing
Crimp height testing is critical to ensuring your crimps’ quality. This nondestructive measurement helps detect defects that can cause poor terminations and can also be used to strip sheaths.
A combination of compaction of the wire and terminal and proper crimp tool profile determines optimal crimp height. The compaction ratio should be between 17 and 24 percent for optimum crimp height. A pull force of at least 50 to 250 millimeters per minute is recommended.
Various methods of measurement have been suggested to measure crimp height. However, the most commonly employed way is a handheld micrometer. While it can be effective, it must be more accurate and convenient.
Carrying hazardous/toxic/flammable materials
Crimping of hoses carrying hazardous/toxic/flammable materials is not recommended for safety reasons. On the contrary, it is due to the possibility of contamination or damage. Instead, proper selection and maintenance is a safer option.
The correct selection of hoses will minimize the chances of failure. In addition, a good quality crimper will help to prevent out-of-spec crimps. Ideally, a crimper should be used in clean environments. It is also a good idea to remove and clean the grease from the crimper regularly.
If the hose you’re using has a crimping device, check for chips in the die or cracks in the collets. These should be addressed before re-crimping.
Hoses are commonly made from a variety of materials. These include polymer, plastic, or metal. As a result, they are available in a wide range of sizes, shapes, and designs. Therefore, choosing the proper hose is essential for industrial facility maintenance.