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APPLICATION TOOLING FOR MAGNET WIRE PROCESSING FROM TE Connectivity (TE) TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY APPLICATION TOOLING FOR MAGNET WIRE PROCESSING Inserter for MAG-MATE and SIAMEZE Terminals AMPLIVAR Product Terminator (APT) AMP 5/K-40 Thru Splice Terminator TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 2 BY USE OF THESE TOOLS TE MAGNET WIRE TERMINALS ARE APPLIED, SEE THE FOLLOWING EXAMPLES: MAG-MATE Terminals Standard .187 and .300 MAG-MATE Terminals (Product Specification 108-2012) Standard .500 Box MAG-MATE Terminals (Product Specification 108-2053) Slim Line MAG-MATE Terminals (Product Specification 108-1484) Mini MAG-MATE Terminals (Product Specification 108-2016) See also Catalog 82221 (Magnet Wire Terminals and Termination Systems) SIAMEZE Terminals Standard Range SIAMEZE (Product Specification 108-2085 ) High Temperature Standard Range SIAMEZE (Product Specification 108-2293 ) Fine Range SIAMEZE (Product Specification 108-2244 ) Medium Range SIAMEZE (Product Specification 108-2239 Heavy Range SIAMEZE (Product Specification 108-2316 ) See also Catalog 82221 AMPLIVAR Splices 9 Serrations - Pigtail Type 7 Serrations - Pigtail Type 5 Serrations - Pigtail Type 5 Serrations - Pigtail Type Miniature Splice - Pigtail Type See also Catalog 82221 TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 3 APPLICATION TOOLING FOR MAGNET WIRE PROCESSING MAG-MATE Insertion Equipment Spare Parts MAG-MATE Insertion Equipment • Semi-automatic machine for integration into a manual workstation or production line Calipper • The insertion machine can be installed horizontally or vertically according to the requirements • Separate control cabinet • Separate touch panel • Pneumatically operated, compressed air 6 bars • Insertion tools driven by compressed air cylinders Technical Data: • Weight: app. 17 kg • Weight with Z axis movement: app. 22 kg • Dimensions of inserter (D x W x H): 600 mm x 220 mm x 165 mm (200 with Z axis movement) • Diameter of contact reel: app. 630 mm • Dimensions of control cabinet (D x W x H): Options/Functions: • Moving table • Adapter plate • Suction system for waste disposal • Limitation of mechanical Insertion force • Insertion force monitoring system 210 mm x 380 mm x 480 mm (app) • Separate wire cutting function • Power supply: 230 V, 50Hz, 6 A • Bridge function for 2 / 3 / 4 contacts • Sound level: < 70 db(A) • Touch screen • Compressed air supply : 6 bars • Bridge function on/off • Compressed air connection: 1/8 “ • Special function for Multispring contact application • Air consumption (l/cycle): app. 2.8 • Fine-adjust of contact insertion depth • Contacting force: max 1000 N • Language module for user interface • Cycle time: 0.9 – 1.3 sec (depending on operator) • Electrical interface • Temperature: 10°C – 45 °C • Humidity: 30 % – 85 %, preferably 55 % (without Overview on our full MAG-MATE modules portfolio, condensation) see Appendix A, page15. • Dusty environment to be avoided Please contact our specialists for details. TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 4 MPT-5 Specifications (All Versions) Technical Data: Air Requirements (Do NOT use lubricated air) • Min Machine Working Pressure: 552 kPa [80 psi] • Max (Preferred) Machine Working Pressure: 621 kPa [90 psi] • Max Supply Line pressure: 1034 kPa [150 psi] Electrical Requirements • Voltage: 100-220 Vac • Frequency: 50/60 Hz • Circuit: Single Phase • Current: 1.0 A • Noise: 83dBA_ With Scrap Vacuum Tube Located Away From Operator and in Scrap Container Options/Functions • Moving Tube • Customized fixtures • Integrated scrap suction • Independent wire cutting function • Bridge function Note that the dimensions shown below are for the module only and do not include the electronic and pneumatic subassemblies, which must be mounted separately. • Right/Left feed capability (two different terminals) The MPT-5 product terminator machine Horizontal Bench Machine consists of a module, a horizontal adaptor kit, an electronic assembly and a pneumatic assembly. • Selective bridge function (On-The-Fly Operations) • Feed position fine adjust The MPT-5 product terminator Vertical Bench Machine consists of a module, a “C“ frame or “L“ arm, an electronic assembly, and a pneumatic assembly. • Depth position fine adjust DIMENSIONAL DATA* Horizontal Module Only Bench Machine Vertical Bench Machine Depth Height Width 711.2 mm [28 in.] 711.2 mm [28 in.] 737 mm [29 in.] 304.8 mm [12 in.] 914.4 mm [36 in.] 1168 mm [46 in.] 381 mm [15 in.] 812.8 mm [32 in.] 838 mm [33 in.] Weight (Approx.) 22.7 kg [50 lbs] 43.1 kg [95 lbs] 113.4 kg [250 lbs] *Dimensions may vary depending on options and specific applications. TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 5 APPLICATION TOOLING FOR MAGNET WIRE PROCESSING Insertion Process for MAG-MATE Terminals (Standard & Slim Line) MAG-MATE: Unstripped wire is inserted in the cavity through the slot, and makes contact with the bottom of the slot and top of the anvil. The terminal is pushed through the inserter “tube” and positioned in the cavity by the insertion finger. As the terminal is inserted into the cavity, the insulation film on the wire is stripped by the IDC slot and stripping shoulders, while the locking barbs on the terminal secure the terminal within the cavity. The post trim blade cuts the wire support block and scrap wire as the terminal is fully inserted into the cavity. Terminal Examples Insertion Process for Mini MAG-MATE Terminals 1 Mini MAG-MATE: A smaller, Mini MAGMATE Interconnection 2 3 system is design for extremely small wire diameters. This terminal uses a unique cam action to provide the IDC contact without applying tension to the magnet wire. Terminal Examples TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 6 Insertion Process for SIAMEZE Terminals Standard SIAMEZE: For Siameze Terminals, the insertion process is quite similar to the MAG-MATE process, except with different specialized tooling. Please review the application specifications for Siameze insertion for the appropriate cavity geometry. Terminal Examples Insertion Process for Leadlok/ SIAMEZE Terminals SIAMEZE with Leadlok: One of the advantages of the Siameze terminal is the ability to terminate both the magnet wire and lead wire in the same process. The Siameze terminal is inserted with the standard Siameze process, and a secondary insertion with the appropriate tooling applies the Leadlok terminal. TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 7 APPLICATION TOOLING FOR MAGNET WIRE PROCESSING Combination with manually operated tools MAG-MATE insertion combined with crimping After MAG-MATE terminal insertion is done, the magnet wire coil has to be connected to the outside world: An example is the poke-in of a bare wire end or a crimped terminal into the MAG-MATE Terminal: Poke-in of a stripped solid wire end For these terminals you need a crimp tool, e.g. a CERTI-LOK hand tool or an SDE hand tool or a PRO-CRIMPER hand tool. Poke-in of crimped terminal For these terminals you need a crimp tool, e.g. a CERTI-LOK hand tool or an SDE hand tool or a PRO-CRIMPER hand tool. Crimp Terminal Examples MAG-MATE terminal Directly crimped Inserted Terminals also can be crimped directly onto a stranded wire. Example: Mini MAG-MATE terminal with crimp con­ nection. TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 8 Manually operated tools for repair and service Manual SIAMEZE Leadlok Terminal Application For repair & service , but also for prototyping it can be useful to work with manually operated tools. Here you find some examples. For further manually operated tools don’t hesitate to contact our specialists. Manual MAG-MATE Terminal Application TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 9 APPLICATION TOOLING FOR MAGNET WIRE PROCESSING Work Center for semi automatic insertion of MAG-MATE or SIAMEZE terminals We offer standardized or customized work centers, which are in line with the EU Machinery Directive 2006/42/EG. They are designed to automatically insert the terminals into the cavities of coil bodies. Correct positioning of the coil in front of the inserter is done either manually or automatically. The work center consists of our inserter for MAGMATE and SIAMEZE contacts being integrated into a complete work environment. After the coil is positioned,the terminals supplied on reels are cut off from the carrier strip and inserted into the contact chambers. At this time the excess magnet wire is cut off and the other side terminated in the terminal cavity using insulation displacement technique. Light grids assure protection of the worker during operation of the machine. Easy operation of the work place is possible by a touch Manual positioning of coil by use of a manually operated locater unit screen. Insertion process is started by pedal switch. Locater for manual positioning Locater for automatic positioning Semi automatic positioning of coil by use of a motor-driven locater unit TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 10 Workstation Application: MAG-MATE terminal with Multispring contact Case: An electrical drive stator has to be combined with a PCB. The cavities of the stators are designed for MAG-MATE terminals. The thru holes of the PCB can be contacted by Multispring. Needed: A combination of MAG-MATE IDC and press-fit contacting method. Solution: MAG-MATE terminal with Multispring contact. After insertion of the terminals the PCB is pressed onto the housing by means of a connector seating device. Automatic Workstation For rough work environment we also can offer robust designs for work places according to the specific needs of our customers. Components and Controls (Examples) • Inserter Machine • Electrical Power Supply Unit • Compressed Air Supply Unit • Touch Screen • Emergency Stop Button • Light Grid • Malfunction Light • Safeguard • On Button/Off Button Please contact our specialists for full specification of the work center Bench-top Custom Solutions Customized fixtures can be designed for specific applications. Processing two different terminals in the same machine provides our customers with the most economical solution, reducing processing and handling times. TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 11 APPLICATION TOOLING FOR MAGNET WIRE PROCESSING Splicing Equipment AMP 5/K-40 CE thru splice terminator stand-alone semiautomatic bench machine for end feed and for side feed AMPLIVAR terminals. Technical Data: • Deflection: 0.13 mm [.0046 in.] Maximum per 4,448 Newtons [1,000 lb] Crimp Force • Noise: Less than 82 dBa Typical at operator position with standard mechanical feed applicator • Weight: 77.3 Kilograms [170.4 lb] — Height: 585 mm [23 in.] without reel supports • Electrical: 100 – 240 Vac, 50/60 Hz, Single-Phase Current. Operating current is 3 amp • Air: 620 – 760 kPa [90 – 100 psi], 2.83 liters/sec (6 scfm) When required for use with air feed End-Feed and Side-Feed applicators used with applicators AMP 5/K-40 CE through-splice terminators are two- • Physical Environment: Temperature: piece applicators consisting of a tool holder and 4.45 – 40° C [40.5 – 104° F] • Relative Humidity: Less than 95 % (non-condensing) applicator base. The tool holder is secured to the ram of the AMP 5/K-40 CE through-splice. All AMP 5/K-40 CE through-splice terminators are equipped with a “precision adjust” feature. Splicing Equipment The wire ends being spliced together have to be inserted into a slot in the protection guard. AMPLIVAR Side feed ­­ terminal AMPLIVAR End feed terminal A sight window allows correct positioning of the wire ends over the open crimp terminal barrel. The AMPLIVAR crimp terminals are either side feed or Side feed applicator with ­protection guard End feed applicator with ­protection guard end feed terminals. Accordingly a side feed or end feed applicator has to be installed into the thru splice terminator. Additional hand protection guard TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 12 Splicing Equipment Pigtail Splices AMPLIVAR product terminator (APT) For pigtail-type splices (up to 3 wires in 1 splice) and direct connect contacts Technical Data: • Weight: approx. 68 kg with CQM • Width: 965 mm with CQM and • Product Reel • Depth: 890 mm • Height: 356 mm • Electrical: 240 VAC, 50 Hz, .5 A, 1 f For operations with multiple wire sizes, the APT 5A provides programmable sequencing of different crimp-height settings, and it can store up to 2,000 • Air: 5,5-7,5 bar different programs of 7 different settings each. • Crimp Height Adjust in .0005 “ [0.013 mm] The maximum time to auto-adjust between pro- increments over .064” range grammed crimp heights is 2 seconds. Splicing Equipment Pigtail Splices Termination process: • Magnet wire and lead wire are placed in the terminal barrel being in the crimping position • Operator depresses the foot switch • Terminator automatically – shears terminal from its strip – crimps the terminal onto the wire – shears off the excess wire – advances the next terminal into the crimping position Remarks: • If customer CMA is less than the minimum published • Two or three wires may be joined in one splices CMA for the AMPLIVAR product, we offer our wire • Terminator designed for combinations of magnet wire and lead wire (stranded, solid or fused stranded) • Large number of wire combinations requires some tooling changes stuffer assembly 2161635-1 as an option. This option provides additional magnet wire CMA to the terminated CMA to meet the specified CMA range for a given AMPLIVAR product. • For the correct tooling selection, please contact our specialists TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 13 TE CONNECTIVITY APPLICATION TOOLING: IDC MACHINE QUOTATION QUESTIONNAIRE Please provide the following information so we can create an accurate quote for your production needs. Contact Information: Company Name: Contact Name: Product Information: Company Address: Contact Email: Contact Phone: Has your application been reviewed by a TE Connectivity Terminal Application Specialist? If so, who did you work with? Please list all terminals to be inserted in this application: What products are you interested in? Complete bench machine and fixture If a fixture is requested, what level of automation is Manual Semi-Automatic needed? Automated Line Integration Will the machine be robotically loaded? Yes No What timeframe do you expect for the start of production? Please submit this form to: magnetwireus@te.com Mailstop 140-50 P.O. Box 3608 Harrisburg, PA 17105-3608, USA Specifications and Testing: *Are you able to provide 5-10 samples of product for initial review? Yes No **Do you require a run off of the machine? Yes No Module only What is your expected yearly terminal usage? If you are replacing an existing machine, what is the machine part number? Do you have any testing/acceptance requirements? Yes No No If the machine is integrated into a line, is host control required? Yes No Will the machine be replacing an exisiting AMP or TE Yes No Connectivity machine? Do you have any machine specifications or Yes No requirements? Yes For best results, please review “Best Practices for IDC Magnet Wire Termination,” which can be found with other useful information at tooling.te.com If you answered “Yes” to any of the questions regarding specifications and testing, please attach all appropriate documentation. Attachments: In order to produce a complete quote, all of the following items must be attached. If not all documentation is currently available, a budgetary quote can be provided. -Detailed, fully dimensioned and tolereanced drawings of bare bobbin/stator including material (e.g. 15% GF nylon) -Drawings of Completed Assembly [Including: TE terminal(s) part number(s), terminal orientation in cavity, magnet wire type (e.g. AL, CU), magnet wire gage, wrap-off trim (required or not required)] -3D Models of the bobbin/stator assembly (CREO or .STP format) if available -All information on the wire that will be used for this application including, but not limited to: gage, number of strands, material, insulation type. Please Note: *Customers are required to provide terminals adn bobbins/stators for all machine conditioning and qualification. **Additional charges may apply. TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY PAGE 14 APPENDIX A: Overview on our full MAG-MATE MODULE portfolio MAG-MATE pneumatic No Options 1 Moving Table 2 Moving Tube 3 Adapter Plate X 4 Suction system for waste disposal X 5 Insertion force limitation, mechanical 6 Insertion force monitoring 7 Separate wire cutting unit 8 Bridge function, 2 contacts 9 Bridge function, 3 contacts 10 MPT-5 X MAG-MATE MK I MAG-MATE MK II X X X X X X X X X X X X X X X X X X X X Bridge function, 4 contacts X X 11 Touch screen X X 12 Bridge On/Off function X X X 13 Processing function for Multispring X X 14 Fine adjust insertion depth X X 15 Language module for user interface 16 Electrical interface for base machine TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY X X X X X PAGE 15 Let’s Connect To learn more about the right TE tooling for your needs, call us a 717-810-2082 or email ToolingSales@te.com TE Technical Support Center USA: 1.800.522.6752 UK: Canada: 1.800.522.6752 France: +33.1.34.20.8686 Mexico: +52.55.11.06.0800 Netherlands: +31.73.624.6999 Latin/S. America +54.11.4733.2200 +44.0800.267666 China: +86.400.820.6015 Germany: +49.6151.607.1999 Waste Not. Want Not. Time is Money. In manufacturing downtime can be expensive. That’s why TE is constantly working to improve product availability and delivery rates. With a strong global footprint, short lead times and a strong distribution channel, TE has the equipment and the accessories to keep production online. To check distributor stock and availability for your tooling needs go to: www.te.com/commerce/sck/cdi.do Whether its time or scrap, in manufacturing everyone knows that waste costs money. With our on-site certification and consultation services, we can help you: • • • • Reduce downtime Reduce scrap Maintain crimp quality Improve manufacturing efficiency Connect with us today to learn more. • • • E-mail: fieldservicesnorthamerica@te.com Phone: 800-722-1111 or 717-986-3434 For additional information download catalog #1-1307619-0 from tooling.te.com. Catalog 1-1773899-1/ 11-18 / Application Tooling TE connectivity (logo) and TE Connectivity are trademarks. TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY