Connector Tooling Guide - AeroElectric Connection

More documents

Recommendations

Info

PREFACE &TABLE OF CONTENTS®DANIELSMANUFACTURINGCORPORATIONDaniels tools have been utilized in militaryaircraft and aerospace programs for over50 years.By continuously planning and addingto our product lines, we are now fulfilling thedemands of other high technology fields suchas computers, lasers, communications, andmany other areas of electronic packaging.The people behind the DMC name arepleased to present our Connector AssemblyTools and Accessories on the pages thatfollow. We believe the application data whichaccompanies each section will answer yourspecific questions concerning tooling;however, we encourage you to contact us bytelephone or fax for the personal services ofour knowledgeable staff of applicationexperts.NOTICEANY PRICES WE QUOTE VERBALLY OR ANYPRICES APPEARING IN OUR PRINTED PRICE LISTSARE SUBJECT TO CHANGE WITHOUT PRIOR NOTICE.IF YOU NEED FIRM PRICES FOR FUTUREDELIVERIES YOU SHOULD REQUEST A WRITTENQUOTATION FROM OUR SALES OFFICE.WE ARE NOT LIABLE FOR CONSEQUENTIAL ORSPECIAL DAMAGES OF ANY NATURE OR KIND, RESULT-ING FROM THE USE OF ANY OF OUR PRODUCTS.DANIELS MANUFACTURING CORP.526 THORPE RD. • ORLANDO, FL 32824 U.S.A.PHONE 407/855-6161 • FAX 407-855-6884E-MAIL: DMC@DMCTOOLS.COM • WWW.DMCTOOLS.COMCONTENTSPreface & Table of Contents . . . . . . . . . . . . . . . . . . 2Important Facts About Crimping . . . . . . . . . . . . . . . 3Standard Adjustable Crimp Tool . . . . . . . . . . . . . . . 4M22520/1-01 (AF8)Miniature Adjustable Crimp Tools . . . . . . . . . . . . . . 6M22520/2-01 (AFM8)M22520/7-01 (MH860)M22520/39-01 (39-000)Ultra Precision (MH800)Pneumatic Crimp Tools . . . . . . . . . . . . . . . . . . . . . . 8(WA22)(WA22P)(WA27F)Miniature Hand-Held Pneumatic Crimp Tool. . . . . . 9Large Gage Pneumatic Crimp Tool . . . . . . . . . . . . 10M22520/23-01 (WA23)Technical Application Guide. . . . . . . . . . . . . . . . . . 12Connector IllustrationContact Color Code (BIN)Wire StrippingM39029 Contact GuideConnector/Assembly Tool GuideVibra-Feed Automatic Crimp Station. . . . . . . . . . . 43Circular Indent Crimp Tools . . . . . . . . . . . . . . . . . . 44(MH801) (MH802) (MH803) (MH804)M22520/4-01 (GS100-1)M22520/31-01 (GS200-1)Coaxial Contact Tool Selection Guide . . . . . . . . . . 45Open Frame Crimp Tools . . . . . . . . . . . . . . . . . . . . 47M22520/5-01 (HX4)M22520/10-01 (HX3)Pneumatic Open Frame Tool . . . . . . . . . . . . . . . . . 49(HX23) Bench PressRF Connectors Tool Selection Guide. . . . . . . . . . . 51Pneumatic/Hydraulic Crimp Tool Systems . . . . . . 63Hydrac Hydraulic Crimping Tools . . . . . . . . . . . . . 66Universal Power Feeder Crimp System. . . . . . . . . 67Custom Application and. . . . . . . . . . . . . . . . . . . . . 69Contact Retention Test ToolsInstalling and Removal Tools . . . . . . . . . . . . . . . . . 70MIL-I-81969MIL-I-81969 Tool P/N Guide . . . . . . . . . . . . . . . . . . 71Hand-Held Pneumatic Wire Stripper . . . . . . . . . . . 73(WSP 1630)Wire Cutting, Stripping Preparation Equipment . . 74EMI/RFI Band Application System. . . . . . . . . . . . . 76Fiber Optic Cleaving Tool . . . . . . . . . . . . . . . . . . . . 80Video Training System . . . . . . . . . . . . . . . . . . . . . . 82Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . 83Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 85FOR WARRANTY & LIMITATION OF LIABILITY INFORMATION SEE PAGE 85© COPYRIGHT 2003 DANIELS MANUFACTURING CORPORATION – 2126/01/REV 8
IMPORTANT FACTSABOUT CRIMPING®DANIELSMANUFACTURINGCORPORATIONCRIMPING: THEN AND NOWThe first multi-pin connectors wereterminated by soldering the conductorto non-removable contacts. However,high temperature applications andthe need for simple and reliable fieldservice led to the introduction ofconnectors with removable contacts.These were crimped onto the conductorrather than being soldered.The first standard crimp tooldeveloped to crimp these new contactswas introduced in the earlysixties. MS3191-1, a military drawing,defined this tool and its accessories.The MS3191-1 utilized a four indentcrimp pattern together with a positivestop locator which controlled the travelof the indenters (crimp depth).The MS3191-1 design was acompromise between simplicity ofoperation and crimp performancesince the crimp depth for any givencontact was not adjustable to accommodatethe differing diameters of theconductors to which it would becrimped. It was, however, suitable forthe crimp connectors of that era.An improved tool design featuringindependently adjustable crimp depthswas soon introduced as MS3191-4.The MS3191-4 had an internal adjustment,totally independent of the locator,which permitted the selection ofseven separate crimp depths, allowingoptimal crimping of conductors rangingfrom AWG 12 to 26 regardless ofthe wire barrel size of the contact.MS3191-4 also introduced theuse of the double tipped indenter toproduce an eight indent crimp patternwhich has consistently achievedsuperior tensile pull off values.MS3191-4 introduced the conceptof a turret head containing three locatorswhich could be used withoutseparating any of them from the basiccrimp tool.In 1969 two military specificationsfor crimp tools were developed toreplace the existing military drawings.They were MIL-T-22520C (Navy) andMIL-T-83724 (USAF) which defined astandard size crimp tool similar to theMS3191-4, but with an expandedeight step crimp depth range. Thesespecifications also defined a miniaturecrimp tool to crimp conductors assmall as AWG 32.Both documents were combinedin 1971 into MIL-C-22520D. Allprevious military standards for crimptools were then cancelled includingthe MS3191.MIL-C-22520 has since replacedmany other crimp tool documentsincluding: MS3198, MS22910,MS17776, MS28731, MS90388,MS14037, MS27437, MS27828,MS27832, MS55619, MS27426 andothers. This list includes specificationsfor indent crimp tools, terminal lugcrimp tools, pneumatic tools, coaxialcable crimp tools and connectorsservice kits.The establishment of MIL-C22520was a milestone on the road to crimptool standardization. Its developmenthas eliminated the waste and confusionwhich accompanied the overlappingapplications of many different“standard” crimp tools called out by adeluge of unrelated military drawings.MIL-C-22520D for the first timeestablished a single specification whichset forth performance requirements forall crimp tools to be used on militarystandard electrical connectors.THE CRIMPING CONCEPTCrimping is a method of firmlyattaching a terminal or contact end toan electrical conductor by pressureforming or reshaping a metal barreltogether with the conductor. Theforming of a satisfactory crimpdepends on the correct combinationof conductor, crimp barrel and tool.When applied with a properlymatched tool a union would beestablished which has both goodelectrical and mechanical characteristics.The tool will provide theserequirements consistently and reliablywith repeatability assured by qualitycycle controlled tooling. There areseveral common configurations ofcrimped joint; several examples areshown below.The electrical resistance of aproperly designed and controlledcrimped joint should be equal to, orless than, the resistance of an equalsection of wire. Specifications statethe requirements in terms of millivoltdrop at a designated current.The mechanical strength of acrimped joint and hence its pull-outforce (tensile strength), varies with thedeformation applied. Therefore, byproperly shaping the deformation ahigh pull-out force can be achieved,i.e. the crimp die of the tool determinesthe crimp configuration anddeformation.The dies in the tool determine thecompleted crimp configuration whichis generally an element of contactand/or connector design. Some of thedesign considerations are: a) The typeof contact, its size, shape material andfunction, b) The type and size of wiresto be accommodated, c) The type oftooling into which the configurationmust be built.EIGHT INDENTFOUR INDENTTWO INDENTHEXAGONAL CRIMPCIRCULAR CRIMPB CRIMPNEST & INDENT CRIMPCAPTIVE CRIMPINSULATION DISPLACEMENT© COPYRIGHT 2003 DANIELS MANUFACTURING CORPORATIONPAGE 3
Page 1: ConnectorToolingGuide®DANIELSMANUF
Page 5 and 6: ®DANIELSMANUFACTURINGCORPORATIONOt
Page 7 and 8: ®DANIELSMANUFACTURINGCORPORATIONUL
Page 9 and 10: © COPYRIGHT 2003 DANIELS MANUFACTU
Page 11 and 12: LARGE GAGE CONTACTAPPLICATION INFOR
Page 13 and 14: TECHNICAL APPLICATION GUIDEM39029 C
Page 15 and 16: MIL-C-24308MINIATURE RECTANGULARRAC
Page 17 and 18: MIL-C-26482SERIES 2CIRCULARBAYONET
Page 19 and 20: MIL-C-26518CLASS RMINIATURE RECTANG
Page 21 and 22: MIL-C-38300CIRCULARTHREADED OR BAYO
Page 23 and 24: MIL-C-38999SERIES 1SCOOP PROOF - CI
Page 25 and 26: MIL-C-38999SERIES 3TRI-START COUPLI
Page 27 and 28: MIL-C-5015SERIES 3400CIRCULARTHREAD
Page 33 and 34: MIL-C-81659SERIES 1RECTANGULARFRONT
Page 35 and 36: MIL-C-81703SERIES 2CIRCULARRACK & P
Page 37 and 38: MIL-C-83723SERIES 2CIRCULARTHREADED
Page 39 and 40: MIL-C-83733RECTANGULAR MINIATURERAC
Page 41 and 42: MIL-T-81714TERMINAL JUNCTIONSCONNEC
Page 43 and 44: PAGE 43© COPYRIGHT 2003 DANIELS MA
Page 45 and 46: COAXIAL CONTACTTOOL SELECTION GUIDE
Page 47 and 48: OPEN FRAMECRIMP TOOLS®DANIELSMANUF
Page 49 and 50: PNEUMATIC OPENFRAME TOOL®DANIELSMA
Page 51 and 52: R.F. CONNECTORSTOOL SELECTION GUIDE
Page 53 and 54:
R.F. CONNECTORSTOOL SELECTION GUIDE
Page 55 and 56:
Page 57 and 58:
Page 59 and 60:
Page 61 and 62:
Page 63 and 64:
PAGE 63© COPYRIGHT 2003 DANIELS MA
Page 65 and 66:
Page 67 and 68:
Page 69 and 70:
CUSTOM APPLICATION &CONTACT RETENTI
Page 71 and 72:
MIL-I-81969 TOOLPART NUMBER GUIDE®
Page 73 and 74:
HAND HELD PNEUMATICWIRE STRIPPING T
Page 75 and 76:
Page 77 and 78:
Page 79 and 80:
Page 81 and 82:
Page 83 and 84:
GLOSSARYOF TERMS*®DANIELSMANUFACTU
Page 85 and 86:
GLOSSARYOF TERMS*®DANIELSMANUFACTU
show all

Connector Tooling Guide - AeroElectric Connection

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?