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APPLICATORS PREMIUM QUALITY MANUFACTURING OF CRIMP CONNECTIONS TE APPLICATION TOOLING /// APPLICATORS PREMIUM QUALITY MANUFACTURING OF CRIMP CONNECTIONS Selecting the Applicator for Your Requirements SELECTION GUIDE OCEAN Applicator 2.0 - Mechanical • Wire range: 0.13 - 10.0 mm2 • Applicable for 90% of standard terminals • Available in Atlantic (w/male adapter) and Pacific (w/ female adapter) style formats to handle multiple press styles Flexibility • Designed to handle the smallest terminals • Robust crimp height adjustment ring Value • Optimized crimper and anvil geometry Pneumatic Power OCEAN Applicator 2.0 - Pneumatic Cycle Counts • Wire range: 0.13 - 10.0 mm2 • Compact air feed design for easier fit into most bench presses • Applicable for 90% of standard terminals • Available in Atlantic (w/male adapter) and Pacific (w/ female adapter) style formats to handle multiple press styles Safety • Designed to handle the smallest terminals • Robust crimp height adjustment ring • Optimized crimper and anvil geometry • Intuitive adjustments on the airfeed Large Wire Splice Mid Size • Wire range: 25.0 – 50.0 mm2 • Wire range: 0.5 – 25 mm2 • Wire range: > 10.0 – 25.0 mm2 • Fine adjustment • Press stroke: 40.0 mm • Press stroke: 40.0 mm • Shut height: 135.78 mm Center Line & Applicator Alignment Gauges CQM II • Ideal instrument to assure correct Feed Adjustment Savings positioning of all TE applicators • Compatible with TE & commercially available crimping presses, using quick changes style applicators PAGE 2 • Fine adjustment • Can fit on presses that accept traditional applicators • Shut height: 135.78 mm • Side feed splice terminals up to 45.0 mm CrimpData App • Robust casting frames EYE Check • Provides compatibility verification between terminals and tooling • Scans and looks up applicator and terminal information • Enables you to record cycles on the applicator spare parts • Scan this QR code to download from the APP store Collars • Designed to protect applicators from unwanted motion and damage during transport • Available in three colors to help differentiate between active and inactive applicators TE APPLICATION TOOLING /// APPLICATORS OCEAN 2.0 Applicator Facts and Features Chrome plated ram for improved lubricity, corrosion resistance, Robust fine adjust wire crimp height with range and wear of 1.5 mm in increments of 0.01 mm Black nitriding for corrosion resistance, Large insulation crimp height strength and durability adjustment range State-of-the-art crimper manufacturing for even tighter tolerances Precision machined strip Adjustable strip guide for precise guide customized for placement each terminal Crimp Features application – bell-mouth – cut-off – bend up / down Spring loaded terminal drag designed for easy loading/unloading DID YOU KNOW... Spare Tooling: Chrome plating, specialized materials, precision tolerances, and mirrored surface finishes yield up to a 30 % customer reported increase in tooling life • Most lead makers are only producing leads 60 % of the time • Applicators are a decisive criterion for machine efficiency • Terminal feeding issues are the most common adjustment • OCEAN applicators provide – 60 % improved ram/housing alignment – 50 % faster set-up and adjustment times – 30 % customer reported tooling life increase Easy, predictable and precise adjustments TE APPLICATION TOOLING /// APPLICATORS PAGE 3 PREMIUM QUALITY MANUFACTURING OF CRIMP CONNECTIONS Choosing an Applicator OCEAN 2.0 Applicator Series The new OCEAN 2.0 applicator series was designed With the knowledge and experience of over a half specifically to exceed the requirements of today and century designing and manufacturing applicators and meet the demands of tomorrow. tooling, TE Connectivity (TE) has taken terminal crimping to a new level. Using the proven OCEAN applicator platform as a base, TE has developed the latest wave in applicator technology...the OCEAN 2.0 Applicator. TE has listened to customer input and market demands to innovate and improve the popular OCEAN applicator to be more robust, faster to install/ adjust and even more accurate. By consolidating our applicator offering to this latest OCEAN 2.0 applicator platform, TE can provide design consistency and tooling standardization to the market. One of the major benefits to the customer is offering the ultimate in flexibility with a choice of feeding options; new and improved mechanical and pneumatic feed options. The lead and harness industry of today is more price and quality competitive than ever before. Crimping standards continue to be raised to higher levels of quality and repeatability. The industry continues to expect more from application tooling. One Applicator Platform – Modular Family Design - 2 feed options – Mechanical & Pneumatic - Same feed units can be used on Side-Feed and E nd-Feed style applicators - All units can be easily removed and i nterchanged for upgrades if desired - 2 ram interface styles (“Atlantic” or “Pacific” style) - Same wire crimper, insulation crimper, and anvil u sed on both applicator styles Atlantic-Style Mechanical Feed Pneumatic Feed Pacific-Style Mechanical Feed PAGE 4 Pneumatic Feed TE APPLICATION TOOLING /// APPLICATORS Choosing an Applicator Standard Features on all OCEAN 2.0 Applicators One of the major design goals of the OCEAN 2.0 applicator series was increased flexibility. By giving the applicator the ability to flex between different terminator configurations it allows customers to quickly adapt their applicators to whatever configuration is needed. All parts to reconfigure the applicator are included and attachable to the unit for safe storage and quick access. As standard equipment the latest applicator will have all the accessories needed to switch between 30 and 40 mm stroke terminators, pre-feed and post-feed cam configurations and cut and no-cut carrier options. The wire stop / wire stripper can also be easily adjusted for the desired application, and a mechanical counter is included for tracking cycle counts. The applicator comes with all parts needed to configure it to any terminating method that is acceptable to the application. • Pre-feed and post-feed cams • Cut and no-cut carrier options • Adjustable terminal stripper • Adjustable spring-loaded terminal hold down • Mechanical counter • Fine adjust crimp height mechanisms OCEAN Applicator Part Number System Because so many features have been added to the applicator the part numbering system used to identify the applicators can be simplified significantly. Now, when ordering an applicator the customer will only need to identify what style and feed type they require. OCEAN Applicator Style Atlantic Style Pacific Style Description Part Number Scheme Mechanical Feed xxxxxxx-1 Air Feed xxxxxxx-2 Atlantic Air Feed with sensors & no valve assembly 3-xxxxxxx-2 Atlantic Mechanical feed for Bench Strip-seal terminators 5-xxxxxxx-1 Atlantic Air feed for Bench Strip-seal terminators 5-xxxxxxx-2 Atlantic Mechanical feed (-1) with spare part kit (7--7) 7-xxxxxxx-1 & 7-xxxxxxx-7 Atlantic Air feed (-2) with spare part kit (7--7) 7-xxxxxxx-2 & 7-xxxxxxx-7 Spare Parts Kit 7-xxxxxxx-7 Mechanical Feed 2-xxxxxxx-1 Air Feed 2-xxxxxxx-2 Spare Parts Kit 7-xxxxxxx-7 * N on-crimp height adjust applicator is designed to run in a terminator with system Iii crimp height adjust technology. TE APPLICATION TOOLING /// APPLICATORS *** Part number example. Spare Part Kits have been designed to be used on all styles of OCEAN applicators with pneumatic feed. PAGE 5 PREMIUM QUALITY MANUFACTURING OF CRIMP CONNECTIONS OCEAN Applicator Facts and Features Two Terminal Feed Options Mechanical Feed The cam/follower design produces repeatable feed in the industry. Independent forward/backward adjustment. Standard Features • Significantly improved repeatability • Same feed module for side feed and end feed • Single tool adjustments • Infinite micro feed adjustment increments 1 revolution = 0.7 mm Advantages • Precise and repeatable terminal position over the anvil • Independent forward and back stroke adjustment • 50% faster adjustments compared to HDI/HDM Cam follower Feed cam This design gradually starts the terminal into the feeding process. Pneumatic Feed Independent forward/backward adjustments, independent flow controls, repeatable feed. Standard Features • Single tool or tool-less adjustments • Same feed module for side feed and end feed • Independent forward & back adjustments • Micro feed adjusted incrementally with steps 0.04 mm forward terminal position • Maximum feed length: 48.25 mm Advantages • Independent forward and back stroke adjustment • Adjustable speed actuation • Self actuating • Single or tool-less adjustment • Single piece piston and rod assembly • Internal exhaust valves Smaller air feed design on the OCEAN 2.0 Applicator fits into more terminators PAGE 6 TE APPLICATION TOOLING /// APPLICATORS OCEAN 2.0 Applicator – Redesigned from the Bottom Up The OCEAN 2.0 applicator series includes several new features to aid in reliability and repeatable performance. To help prevent misalignment and during installation, the OCEAN 2.0 design includes a pinned baseplate. Standardization of adjustment and mounting screws reduces the number of tools needed to install and/or adjust an applicator. The OCEAN 2.0 line has been designed to reduce the number of unique tools needed to service, thereby shortening downtime and improving upon TE’s already impressive quick install rate. Standard Socket – Head cap screw anvil mounting Pinned baseplate design helps prevent misalignment TE APPLICATION TOOLING /// APPLICATORS PAGE 7 PREMIUM QUALITY MANUFACTURING OF CRIMP CONNECTIONS OCEAN 2.0 Applicator – Small Wire Crimping 0.22 mm2 / 24 AWG Applicators for small wire sizes the specification requirements for bell-mouth and Today’s miniaturized terminals demand a high quality cutoff tabs, which are commonly controlled with very applicator in order to meet the requirements of crimp small tolerances. specifications with very small tolerances. The TE Miniaturization of the connectors places higher OCEAN 2.0 applicator, with its improved ram align- demands on the processing machines. ment, fine adjust crimp height control and other enhancements is well suited to meet these requirements. We have even more features for those applications running small wire sizes (terminals for wire sizes below 0.35 mm2 (22 AWG). These features focus on the location control of the crimper and anvil along the axis of the terminal wire barrel. Especially the crimp applicator has to fulfill high requirements: • High mechanical precision • Repetition accuracy of the terminal feeding system • Low friction of the ram Wire Size 0,13 mm2 with miniaturized terminal We were able to better control this location by changing the method in which we mount the anvil to the base plate in the applicator. This increased control allows the crimped terminal to more consistently meet OCEAN applicator for small terminal is designed to improve the repeatability of the anvil location relative to the ram. This is accomplished by tighter tolerances on several components, special anvil, modified base-plate and a customize shoulder screw to accurately locate the anvil. All other components (including ram and housing) are normal ocean parts. Terminal hold-down designed Insulation crimp adjustment specific to terminal body increments to match that of Pneumatic feed reduced cable insulation range Touch Tooling: – Crimper and ram reduced clearance (closer fitting) – No crimper spacer minimize tooling stack tolerance build-up – Shear depressor mount on underside of ram (constant Terminal strip guide assembly remount height) requiring 75 % less set-up and adjustment Closer fitting terminal drag Terminal strip guide assembly: – – – – Closer fitting relative to applicator base plate Finer bell-mouth / cut-off tab adjustment Increased strip guide assembly to applicator base plate engagement Reduced clearance between terminal stock t hickness and guide plate Anvil: – Location by close tolerance shoulder screw – Reducing need to adjust terminal strip guide – Repeat position - Frontal bell-mouth lock and adjustment PAGE 8 TE APPLICATION TOOLING /// APPLICATORS OCEAN Applicator – LITEALUM Wire Crimping Executive summary • We have developed a series of applicators that • In parallel with LITEALUM terminal development, TE application tooling has been developing crimp tooling crimp all of the terminals released to date • We have met a number of challenges and have solutions to each • Primary goal: Keep the crimping process the same • We continue to work on future improvements for crimping aluminum. TE is a terminal manufacturer with this goal, giving to our customers a major competitive advantage Unique applicator features of LITEALUM wire crimping • Wire crimper with 3-d blend • Anvil (slightly different has tapered angle) • Wire depressor Tooling – crimper & anvil Insulation crimper Wire crimper Front cover crimp Wire crimp (uses special spring-loaded depressor) • Housing (has cut to mount left side style stripper) • Modified drag to reduce lateral movement • Fine adjust insulation adjuster Value for the customer OCEAN applicator design, global standard OCEAN applicator for MQS terminals OCEAN applicator for LITEALUM terminals Special wire crimp profile 3 dimension blend TE APPLICATION TOOLING /// APPLICATORS PAGE 9 PREMIUM QUALITY MANUFACTURING OF CRIMP CONNECTIONS TE CrimpData App Our OCEAN applicator offering just got a whole lot more flexible thanks to TE CrimpData. With this mobile app you can manage applicator and spare parts inventory, and quickly verify that you have the right applicator for your terminal without having to run back to your desk. And it’s completely free to download from your smart phone or tablet’s app store! • Get part numbers of spare parts • Set individual cycle count of spare parts • Coming soon (order spare parts) What can it do? • Reads the new data matrix bar-code on applicator tags to provide the latest crimp information. • Provides compatibility verification between terminals and tooling • Scans and looks up applicator and terminal information • Enables you to record cycles on the applicator and spare parts 2D data-matrix bar-code ID tag PAGE 10 TE APPLICATION TOOLING /// APPLICATORS TE CrimpData App Manual Search Functionality Don’t have a QR code? No problem. Manually enter the serial or part number and search the database for applicator and terminal specs. Bar-code Scanner Click, scan and search with the touch of a button. The Right Tool for the Job TE CrimpData can help you quickly cross reference the applicator to your terminal and verify if it’s the right match. Order Parts Ready to check out? TE CrimpData allows you to find and order compatible spare tooling. (Coming soon) Sharing Tool Quickly launch your email to send order details to yourself or someone else. Stay on Track Track and edit applicator and individual cycle counts for spare tooling. Power of the Cloud The TE CrimpData app is available on both the iPhone and Android platforms. TE CrimpData connects to TE.com and provides a wealth of information like wire size charts, and application specifications. Search for “TE CrimpData” to locate and download the App. Manage inventory and stay productive all with the power of the TE CrimpData app. TE APPLICATION TOOLING /// APPLICATORS PAGE 11 PREMIUM QUALITY MANUFACTURING OF CRIMP CONNECTIONS Effective Crimp Performance Detachable Lubricator Assembly It is easy to overlook, but routine greasing can be a factor in reducing production downtime. Checking tooling – inspecting crimpers and anvils – before they break also will support production continuity. Just as with any machinery, lubrication of the applicator reduces wear and even protects against corrosion. Specific use of contact lubricant on terminals prevents the friction that can lead to sticking in the crimper, bent terminals, and premature crimper wear. • Assembly for side feed and end feed versions are available • Simple attachment • Broad wick and variable adjustments for complete terminal coverage • Clear composite shell for easy viewing of lubricant levels Description Part Number Side feed assembly 2119955-1 End feed assembly 2119955-2 Transporting Applicators Safely Although applicators are manufactured to withstand the impact of crimping, crimpers and anvils must not contact each other. Such contact can scrape the plating or the crimping surface, causing a friction point. Friction points can form metal buildup, ultimately causing reject crimps and even tool breakage. This problem is easily avoided. Always leave a terminal in the crimp tooling when moving the applicator from one location to another. This allows the terminal to receive any possible contact and protects the tooling. The collar protects the applicator from unwanted motions and damages. Description Part Number Collar orange – standard TE color delivered with the applicator 2119783-1 Collar red – order separately 2119783-2 Collar green – order separately 2119783-3 PAGE 12 TE APPLICATION TOOLING /// APPLICATORS Effective Crimp Performance OCEAN applicators are dedicated to providing high Side Feed Applicator End Feed Applicator quality crimp connections to meet corresponding with Gauge built in with Gauge built in specifications. OCEAN applicator gauges ensure the correct applicator alignment to produce high quality crimp connections. Description Part Number OCEAN Applicator Gauge, Side Feed 2161422-2 OCEAN Applicator Gauge, End Feed 2161422-3 Side Feed Applicator Gauge End Feed Applicator Gauge Gauges Compatible with TE Connectivity and commercially available crimping presses, using quick changes style applicators. Applicator Gauge Ideal instrument to assure correct positioning of all TE applicators • Connectivity applicators • Simple installation and use Description Part Number Applicator Gauge Kit, Crimp Machines 528440-5 TE APPLICATION TOOLING /// APPLICATORS PAGE 13 PREMIUM QUALITY MANUFACTURING OF CRIMP CONNECTIONS Selecting an Applicator Online A convenient lookup function on the TE website will If you do not find an applicator to meet your requirements, guide you through applicator selection and provide please refer to www.te.com/support-center access to all necessary documents and drawings. www.te.com/usa-en/products/application-tooling/mini-applicator-parts-search.html 928999-1 Enter a terminal PN. 2151493 2151493-1 Enter a complete applicator PN as listed below. Click on an applicator PN. Click on a pdf and open customer drawing with crimp data or further documentation. PAGE 14 TE APPLICATION TOOLING /// APPLICATORS Selecting Replaceable Tooling Online Only by the use of genuine TE Connectivity tooling Enter the applicator part number, and click on Search can you be assured of a long-lasting tool life and very Parts. The part numbers of replaceable tooling will be reliable production. The design, materials, and manu- displayed. facturing quality of TE tooling translate directly into fewer rejects, fewer breakdowns and interruptions. To determine the tooling part number for a specific The same lookup allows you to enter the part number of a crimper and find out what applicators is suitable for it. applicator, simply set your web browser to www.te.com/global-en/products/application-tooling/applicator-spare-parts-search.html 1 2151493 Enter an applicator PN without dash numbers. 2 A list of all applicator PNs where the spare part used will be shown. 3 1-1338690-2 Enter your spare part PN and click on the button Search Parts. Select a spare part PN and return to the previous screen. 4 A complete applicator overview using this PN is shown. www.te.com/commerce/DocumentDelivery/DDEController 2151493-2 Enter a TE part number and click on the search button. A list with documents and drawings relating to this PN is shown. 114-18022 Enter a document number and click on the search button. The relevant document is shown. TE APPLICATION TOOLING /// APPLICATORS PAGE 15 Let’s Connect To learn more about the right TE tooling for your needs, visit tooling.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 Contact us today to learn more E-mail (Americas): fieldservicesnorthamerica@te.com tooling.te.com © 2019 TE Connectivity Ltd. family of companies. All Rights Reserved. AMP, EYE Check, LITEALUM, OCEAN, RAYCHEM, SOLARLOK, TE Connectivity and TE connectivity (logo) are trademarks. Crimpmatic is a trademark. MOST is a trademark. Other product and/or crimping names herein might be trademarks of their respective owners. 1-1773864-9 4-19 Rev B TE APPLICATION TOOLING /// APPLICATORS Phone (Americas): 800-722-1111 or 717-986-3434 E-mail (EMEA): TEFE1@te.com Phone (EMEA): +49-6151-607-1518 For additional information download catalog from tooling.te.com. www.te.com