Issue link: https://te.mouser.com/i/1349209
Automotive Connector Strategies and Solutions for Space Saving Page 9 TE AUTOMOTIVE /// White Paper | Automotive Connector Strategies and Solutions for Space Savings Dimensions and performance of the NanoMQS and MCON 0.50 platforms Dimensions Performance Pin-to-pin pitch 1.8 mm Current Capacity 3A (90° C) Wire Size 0.13 mm to 0.35 mm 2 Maximum Temperature 170° C (Ag) Blade Size 0.5 x 0.4 mm Vibration Resistance SG4 (Ag) LV214-Compliant Yes Position Assurance Primary and secondary locking 11 | THE ROLE OF TOOLING IN AUTOMATIC HANDLING The challenge of miniaturizing automotive-grade components extends to the wire termination and crimp- ing process. Application tooling plays a vital role in ensuring high-performance connectivity and true automotive vibration resistance with the termination of smaller wires. WHY ARE SMALLER WIRES HARDER TO CRIMP? Intrinsically, miniaturized terminals are constructed from thinner material, which means that they are eas- ier to deform or mangle during the crimping process. It also means that the presence of flash, or crimp deformation in the form of protrusions, becomes more significant as it can form a larger percentage of the overall terminal profile. This is problematic because flash can hinder insertion into, or damage to, a connector housing, particularly its sealing components. Small-wire applications typically require smaller tooling gaps to avoid producing significant flash. Tooling gap refers to the flash escapement space between a crimper and anvil when the two are at crimp height. For reference, a tooling gap as small as 0.05 mm can produce significant flash for a terminal with a crimp width of 1.00 mm. The smaller size also makes it much more challenging to accurately position the wire within the terminal during the crimping process. Small-gauge wires are less rigid which makes them susceptible to drooping or bending, hindering insertion into the terminal. Similarly, it is more difficult to align the terminal to the anvil within the crimp applicator tool. Crimp asymmetry is another characteristic of lower-quality crimping that can cause reduced electrical and mechanical performance. Inaccurate placement of terminals over the anvil is a leading cause of asymmetry and flash. This inaccuracy can be caused by improper setup or by a substandard terminal feed mechanism. Typically, high-quality pneumatic feed applicators produce more accu- rate results than mechanical or lower-quality pneumatic feed applicators. APPLICATION TOOLING FOR SMALL WIRES AND MINIATURIZED TERMINALS TE applicators for small-wire crimping use highly accurate pneumatic or servo feed mechanisms. These mechanisms enable users to set the initial terminal alignment easily and maintain consistent alignment while the applicator is in use. TE collaborates with partners early in the development stage to develop complete component and tooling solutions that meet unique application needs. TE pre-tests these component and tooling solu- tions against automotive standards so that end-users obtain a holistic and certified solution they can completely rely on. Figure 10. TE's OCEAN 2.0 Applicator