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www.us-tech.com Best Practices in Crimp Applicator Maintenance By Rob Boyd, Senior Product Manager, Schleuniger, Inc.
the implementation of crimp force monitors contin- uing to rise, applicator maintenance is key to any crimp process. However, many companies neglect this task or simply do not know what is necessary.
O
Basic Cleaning The most important factor in applicator
maintenance is probably the simplest — keeping the applicator clean and free from excessive dirt and terminal scraps. Applicators should be cleaned using a soft bristle brush and never with com- pressed air. Compressed air tends to blow particles into cracks and crevices where it should not be. Applicators should get a basic cleaning daily,
or after every shift. They should get a thorough cleaning at least once a week or every 25,000 cycles. A thorough cleaning consists of completely disassembling the applicator so that dirt and metal scraps can be removed from the tooling, the slides and the feed track. This is also a good time to check the condition of the crimping dies and anvils to ensure that they are not damaged.
Lubrication Applicators should be lubricated once per day.
Synthetic lubricants and greases such as Permatex (with PTFE), Superlube and Chevron Ultra Duty are recommended. Synthetic motor oil, such as SAE 20 or 30, is also recommended because it is relative- ly inexpensive and easy to obtain. A simple three-in- one oil is also commonly used. A light coating of lubricant is all that is need- ed on any component that might see friction.
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ne of the most significant factors in crimp quality is the condition of the applicator. With quality standards getting tighter and
Ensure the slides and tooling are thoroughly coat- ed, but do not put on too much. Too much grease tends to attract and hold dirt and debris. Finally, a terminal oiler is recommended for
gold-plated terminals. Because gold is so soft, it will rub off and start to coat the crimp tooling. Eventually, the buildup causes the terminals to
simple method to ensure that the upper tooling is centered is as follows:
l l l l
Gently install the applicator ram, ensuring that the upper tooling does not contact the lower tooling.
Lay a thin strip of paper over the lower crimp anvil.
Install the lower and upper tooling and hardware but do not completely tighten the screws.
Gently but firmly push the upper tooling down over the anvil. While keeping downward pressure on the ram, tighten the screws to secure the upper and lower tooling.
Once the tooling is installed properly, ensure
To prevent premature wear, tooling should be inspected regularly.
stick excessively in the crimp tooling. A terminal oiler minimizes this buildup.
Tooling Setup To prevent excess wear, tooling must be
mounted properly. When tooling must be replaced, take extra precautions to ensure that mounting surfaces are clean and in good condition. Crimp tooling must sit flush with the base plate and applicator ram. The upper tooling, or crimp die, must be centered over the lower crimp anvil. A
that the terminal feed adjustment provides accu- rate terminal placement. This applies for pneu- matic, mechanical or motorized feeds. However, when working with a mechanical feed applicator, consider the press it will go into. Depending on the quality of the terminal brake, the feed adjustment might differ between a slower press, such as an older bench press, or faster presses, which are common on automatic machines.
Prevent Tooling Crashes Most applicators are shipped with ram col-
lars. Ram collars prevent collisions between the upper and lower tooling when the applicator is not installed in a press. Such collisions may damage the tooling prematurely. Signs of tooling damage may be scarring or marking inside the upper crimp die. Damage might appear as consistent marking on the crimped terminal or rounded edges on the
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