汽车线束端子接插件应用介绍

OUTLINEIntroductionofCrimpConnectionTechnology端子压接技术介绍IntroductionofWaterProofTestforaSealedConnector密封接插件防水测试介绍IntroductionofConnector/Contact/SealApplicationSpec.接插件/端子/密封件应用规范介绍Introductionofcabledesign&layout导线设计和线束布置走向要求WHATISCRIMPING?什么是压接？page2Crimpingistheprocessofattachingaterminalontoawireundermechanicalpressure.压接是在导线和端子接触区域施加压力使其成型，实现紧密连接的工艺ThesolderlessconnectionstartedfromAMPin1941.无焊连接技术最早源于AMP1941年提出REQUIREMENTSONACRIMPCONNECTION压接要求Inseparable,longtimereliableelectricalandmechanicalconnectionofoneorseveralconductorsandthecrimpterminal.在压接端子与导线之间提供不可分离的,长时间可靠的电气和机械连接Easeofmanufacturingoftheconnection压接应便于生产加工CRIMPTYPES端子压接类型page4Advantages优势:•OptimumdesignofCrimpBarrelfordesiredwiresizerangeandmaterialthicknessbycalculation.通过计算即可得出适合特定线径范围和料厚的压接结构•FitsforseveralwiresizesonlybyadjustingCrimpHeight.仅调整压接高度即可用于不同线径压接•Terminalmanufacturingatlowcostbysequentialstampingdies通过连续冲压生产实现低成本•Easeoftermination,fullyautomatedpossible压接自动化•Stableelectricalconnection,evenunderhazardousEnvironment.苛刻环境下性能稳定QualifiedCrimpedConnectionRequirement合格压接的要求：Wire导线:1.选用线径符合压接端子适用性要求2.剥线符合要求（长度适合，不损镀层，末端不开裂分叉）Terminal端子1.按形式不同，分为开筒式和闭筒式2.按镀层不同，分为镀锡，镀银，镀金，镀镍等3.按是否含绝缘压接或密封部分进行区分CrimpingTool压接工具CrimpComponents压接三要素压接准备：端子选用CrimpComponents压接三要素合格的剥线不合格的剥线压接准备：剥线要求CrimpComponents压接三要素剥线长度参考端子114使用规范CRIMPINGMACHINEANDHANDTOOLKITS压接设备和工具page8Alpha356Multi-FunctionalFully-AutomaticCrimpingMachine多功能全自动端子压接机Alpha477LeadMakerDoubleCrimpConnectionswithtwodifferentwiresAlpha477可同时压接两种不同线径Thiskindofmachineissuitableforsamplemaking常用于样品制作HandToolKits手工压接工具CRIMPAPPLICATOR压接模具和刀片page9COMMONCRIMPTERMINALS常用压接端子page10AMPMCPContactFamilyMCONContactFamilyDIA1,5/2,5mmMQSFamilyTimersContactFamilySensorFlatContactCOMMONCRIMPTERMINALS常用压接端子page11DeutschCommonContactsCONTACTCURRENTCARRYINGCAPACITY端子载流能力page12MQSAMPMCP1.5AMPMCP6.3AMPMCP2.8StandardPowerTimerMicroTimerJuniorPowerTimerFASTINFASTONMultilockPositivLockRoundcontactsDIA1,5mmupto7,5ASignalcurrentsupto50Aupto15Aupto40ASensorFlatcontactRoundcontactsDIA2,5mmMaxiPowerTimerAMPMCP9.5upto90AMCON1.2MQSAMPSeal„size16“contactpage12WIREDEFINITION导线page13Core:Material/Plating/Gaugesize/StrandquantityInsulation:Material/ODDESIGNATIONOFWIRESIZEFORCONDUCTORS导线尺寸定义Wiresectionsizecanbedefinedas:-mm²CommonforEuropeanmarket-AWGAmericanWireGaugetableofwiresizes,orderedinoppositedirectione.g.AWG240,205mm²AWG161,3mm²noeasyconversiontomm²possiblecommonformagnetwireconversion:1mm²=1973,51CMA-CMACircularMilAreaTEMPERATURECLASSOFTERAYCHEMAUTOMOTIVEWIREpage15CRIMPINGPRODUCTS压接产品page16Single-wireCrimp单线压接Double-wireCrimp双线压接Multi-wireCrimp多线压接CONDUCTOR/INSULATIONCRIMPING芯线压接与绝缘皮压接page17•Thereisadifferentiationtobemadebetweenaconductorcrimpandacrimpforaninsulationsupport.芯线压接与绝缘皮压接有一定的区别：•Theconductorcrimpinsuresagoodconnectionbetweenthewireandtheterminal.芯线压接保证了端子与电线的良好连接•Theinsulationcrimpsupportsthewiretoreducetheaffectsofvibrationsandmovementontheconductorcrimp.绝缘皮压接是为了减少震动以及移动对芯线压接的影响PROCESSOFF-CRIMP压接过程page18压接刀具打开，端子放置在下刀上，导线由手或机械设备送至合适的位置。上刀向下移动，把导线压入包筒。包筒随上刀折弯，压接成型。设定的压接高度保证了压接质量。Theapplicationtoolisopened.Acontactispositionedontheanvil.Theleadisinsertedbyhandormechanically.Thecrimpermovesdownandpressestheleadintothecrimpbarrelandmakescontactwiththecrimpedges.Inthenextprocessingstagethecrimpedgesarerolled-round,theconductoriscompressedatthesametime,andthecrimpisformed.Thefinalpositionatagivencrimpingheightguaranteesthenecessarycompressionofthecon-ductortoformatightlycompressedcrimp.压接过程中，导体受到套管的挤压，在经度和纬度两个方向上均发生形变，形成冷焊：导体与套管表面的原氧化膜变形破裂导体与端子套管的纯净金属表面充分紧密接触挤压变形过程中的微运动显微镜下，可观察到金属表面互相交融粘连BasicPhilosophyofCrimp压接原理WIREPOSITIONING放线位置（后送料）page20前切料刀后切料刀下模WIREPOSITIONING放线位置（侧送料）page21下模端子支撑page22Thequalitativeassessmentofaconductorcrimp(usingtheexampleofanF-crimp)isdeterminedby.端子压接质量判断有以下几个方面：•Visualinspection外观检测•Measurementofthecrimpheight压接高度测量•Analysisofcrosssection压接剖面分析•Measurementofpulloutforce压接保持力测量EvaluationofaCrimpTermination端子压接质量判断page23•Visualinspection外观检测•Measurementofthecrimpheight压接高度测量•Analysisofcrosssection压接剖面分析•Measurementofpulloutforce压接保持力测量EvaluationofaCrimpTermination端子压接质量判断端子压接典型位置和术语•Bellmouth：钟形口（喇叭口）•Front：前部（钟形口）•Rear：后部（钟形口）•ContactBody：触点本体•CutoffTab：切断突起•LockingLance：锁定针•WireCrimp：导体压接区•InsulationCrimp：绝缘压接区•ConductorEnd：导体端部•InsulationEnd：绝缘体端部•Cable：线缆FeaturesofCrimpedTerminal端子压接区域特征端子压接质量判断方法：外观检查导体端部要求：a.导体端部应与导体压接区域顶端平齐，最多不超过压接区域顶端1mm（图中a区域）b.超过导体压接区域端的导体部分不能阻碍端子的对配功能和锁扣功能c.若端子对配的连接器采用的是familyseal,则导体压接区域顶端的导体部分长度建议不大于0.5mm绝缘层顶端要求：绝缘层顶端需在wirecrimp和insulationcrimp之间区域（图中b区域）可见。abVisualInspection外观检查导线截面积喇叭口长度端子压接质量判断方法：外观检查压接两端喇叭口要求：a.导体压接区域后端需有喇叭口结构，喇叭口长度尺寸根据线径决定。b.导体压接区域前端喇叭口可允许的最大值与后端一致。VisualInspection外观检查page27端子压接质量判断方法：外观检查端部切断突起（料头）要求：a.料头必须可见，以保证端子没有损伤。b.料头不应影响端子正常插入塑壳和对配。c.料头最大长度不应超过0.5mm，对于使用familyseal的连接器，料头最大长度不应超过0.3mm，料头不能损伤密封圈。VisualInspection外观检查page28•Visualinspection外观检测•Measurementofthecrimpheight压接高度测量•Analysisofcrosssection压接剖面分析•Measurementofpulloutforce压接保持力测量EvaluationofaCrimpTermination端子压接质量判断端子压接质量判断方法：高度测量导体部分