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Deutsch Heavy Duty Contact System

Common Contact System

Fundamental to the Deutsch connector series is the principle that all wires are terminated by a

O.E.M. or their supplier need stock in volume. The Deutsch contact is a solid, closed barrel, crimp

type terminal, manufactured by a cold heading process using solid copper alloys for sizes 20,16

and 12. The contact is interchangeable within the complete Deutsch connector families and are

selected based upon the user , s application. Stocking costs, engineering cost and termination

costs are slashed, because the number of evaluations, test procedures, test reports, process

standards, drawing notes, etc., is reduced if not eliminated.

COMMON TOOLING

By selecting the common Deutsch contact system, the only one style of tool is needed to remove

wires. In designs like the DT Series connectors even this tool is eliminated. One or two types of

hand crimp tools are used to crimp the five different sizes of contacts to the wire end. For

COMMON TERMINATIONS

The selection of Deutsch connectors means that the contact termination system will be the

same, thus reducing the chance of errors in the harness assembly. Performance, reliability and

maintainability are critical to any electrical system. The use of a common contact system

eliminates many of the failures reported in harness where hundreds of different types of

terminations are used. The end result of selecting Deutsch is increased profits and long term

The Crimp Concept

CRIMPING

Crimping may be defined as the art of joining a conductor to a pin or socket contact by

precision crimp joints in preference to solder.

CRIMPED TERMINATIONS

Crimping has become an increasingly important jointing method in multi contact connectors and

junction devices. It is now the dominant termination method, for some very good reasons:

additives are used.

over - are reliability of a crimped connection are controlled by the crimping tool, not the

operator. The tool releases the contact only after the full crimping cycle is completed. No

special training is required. The tools are relatively inexpensive.

Terminations are required or modified in the field exactly as in the shop, using the same

tools and the same techniques and with the same ease of operation and same certainty

of results.

CRIMPING CONFIGURATIONS

There are many different types of crimps employed today. These range

from the terminal fold -over tab type of crimp to the single indent

crimp , hex crimps and finally the standard four indenter crimp. The

Connectors utilizing crimped contacts usually permit the

removal of these contacts several times so that modification,

circuit changes or replacement of contacts may be made with

the little difficulty and with the same quality assurance as in

production line assembly. Crimping may be accomplished either with hand tools, power tools or

automated power tools. Repeatability of the crimp operation is characteristic provided precision

crimping tools are employed. These tools must be capable of being gagged to insure that proper

crimp depth are maintained. Inspection holes in each contact permit quality control personnel to

view the wire strand ends thereby assuring that the conductor is properly positioned in the

crimp barrel.

Crimp Inspection

TENSILE TEST

The following information is provided as an aid to manufacturing facilities which terminate

results. A axial load of 1.0 in./min. should be applied starting from zero pounds until there is

wire/contact separation or wire breaking. Care should be taken not to clamp holding jaws on

the crimp barrel.

CRIMP INSPECTION

Crimping tools are, in some cases, more expensive than soldering tools, bit this is more than off -

set by the lower total installation and maintenance costs resulting from the simplicity and

rapidity of the crimping operation. However, controls are required to make sure first, that the

operator uses the proper crimping tools designed for the type and size contact being

crimped ,and then, that the pin or socket is properly inserted into the contact. The usual

procedure is to insert the wire into the open end of the contact, then close the crimping tool,

When the correct tool is used for crimping, a good termination is

assured. However if there is question as to the tool , s condition, the

distance across the indent bottoms can be measured. This is called the

„ T“ dimension (T for terminal). There is a corresponding „ Go - No - Go“

gauge for measuring the positioning of the tool indentors, the

„ G“ ( gauge) dimension.

Don , ts