English ? esky P?????? Polski Connectors Components DVI - Automotive Spare parts Search News Address Deutsch Heavy Duty Contact System DT DTM Series DTP Series Common Contact System One way DTHD HDP20 - plastic Introduction: HD30 - metal Fundamental to the Deutsch connector series is the principle that all wires are terminated HD10 single contact system. The only variation in contacts is HD10 - CAN J1939 common " describes the DRB complete Deutsch connector family and applies to a DRC SRK - STRIKE by a that dictated by wire gauge. The world Deutsch contact system well. A solid contact can be assembled with the common system of contacts, tooling, processes and terminations. COMMON CONTACTS SM - DIN72585 Battery Connectors Indux multipole The basic system uses five contact sizes: 4,8,12,16 and 20. These are the only contacts that an O.E.M. or their supplier need stock in volume. The Deutsch type terminal, contact is a solid, closed barrel, crimp manufactured by a cold heading process using solid copper alloys for sizes 20,16 Contacts and 12. The contact is interchangeable within the AS - Autosport 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 MIL - military standards, complete Deutsch connector families and are drawing notes, etc., is reduced if not eliminated. Sensorics For PCB and ECu Adaptors COMMON TOOLING By selecting the common Deutsch contact system, the only one style of tool is needed to remove Tools wires. In designs like the DT Series connectors even this tool is Harness hand crimp tools are used to eliminated. One or two types of crimp the five different sizes of contacts to the wire end. For automation, semi and full automatic crimping equipment is Glossary of wire termination per available that will process thousands hour. COMMON PROCESSING Using the Deutsch contact means terminus that the way an O.E.M. supplier attaches a wire to this never varies. This procedural standard allows harness assemblers to become highly proficient in terminating Deutsch connectors. 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. maintainability are critical to any eliminates Performance, reliability and electrical system. The use of a common contact system many of the failures reported in harness where hundreds of terminations are used. The end result of different types of selecting Deutsch is increased profits and long term performance. The Crimp Concept CRIMPING Crimping may be defined as the art controlled of joining a conductor to a pin or socket contact by compression and displacement of metal. It has been used for many In a good crimp joint there is a years. mutual metal flow causing symmetrical distortion of wire standards and contact material. The mil cross are practically eliminated. Such a -section area is but slightly reduced and all voids joint is similar to a cold weld. Mechanical strength and good electrical continuity are established. Because of the new connectors are subjected there environments to which electrical has been a drastic change in thinking relative to the use of precision crimp joints in preference to solder. CRIMPED TERMINATIONS Crimping has become an increasingly important jointing method in multi contact junction devices. It is now the dominant Since no wet process is ? connectors and termination method, for some very good reasons: involved, corrosion is not a problem. No adhesives, fluxes or additives are used. The human element is ? virtually eliminated in making the joint. Strength, over - are reliability of a crimped connection are controlled by the crimping tool, not the operator. The tool releases the contact only after the special training is full crimping cycle is completed. No required. The tools are relatively inexpensive. ? With smaller gauge wire, the ? The joint can be inspected crimp is as strong as the wire itself. visually. Viewing the wire through an inspection hole in contacts makes inspection quick, easy and sure, both ? The crimping tool is ? Plating thickness on contacts the by the operator and the inspector. universal, it accepts both pins and sockets of many types. is not restricted, as in solder joints, so better resistance and contact reliability are Crimping can be done ? accuracy and corrosion achievable. anywhere, even in the field, without special preparation. Terminations are required or modified in the field tools and the same exactly as in the shop, using the same techniques and with the same ease of operation and same certainty of results. ? Surface cleanliness is not ? Total installed and critical. maintenance costs are lower since joining is quick and easy. CRIMPING CONFIGURATIONS There are many different types of from the terminal fold crimps employed today. These range -over tab type of crimp to the single indent crimp , hex crimps and finally the standard four indenter crimp. The four indenter crimp and contact 4 -intender crimp, Cross-section Across Axis provides the most uniform displacement of wire material. The wire strands and the contact material are formed together in a solid mass with little or no reduction of the mil area of the wire strands. A minimum of voids exists and very little extrusion of the wire strands has taken place. CRIMPING CHARACTERISTICS Connectors utilizing crimped contacts usually permit the removal of these contacts several times so 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 automated Octatadent - Horizontal Cross-section that modification, accomplished either with hand tools, power tools or power tools. Repeatability of the crimp operation is crimping tools are employed. characteristic provided precision These tools must be capable of being gagged to insure that proper crimp depth are maintained. Inspection holes in each contact view the wire strand ends permit quality control personnel to thereby assuring that the conductor is properly positioned in the crimp barrel. Contact Specification Pins Materials: Solid copper Termination alloy Crimp Method: Manufacturing Cold -headed Method: Finish -Standard: Nickel plated Finish Options: Gold, Tin FEATURES ? Solid shoulder for high tensile strength pin retention. ? Nickel plated as standard for corrosion resistance. ? Inspection hole for conductor stand visibility. ? Insulation cup not required due to integral wiring sealing connector grommet design. Sockets Material: Solid copper alloy with stainless steel sleeve. Termination Method: Crimp. Manufacturing Method: Cold -headed. Finish -Standard: Nickel plated. Finish Options: Gold FEATURES ? Solder is not recommended, ? Wire lead -in chamfer for 4, ? No retention tangs required, eliminating flux corrosion and reducing assembly costs. 8, 12, 16 and 20 AWG wire entry. eliminating contact damage and the need for secondary locks. Crimp Inspection TENSILE TEST The following information is provided as an aid to manufacturing facilities which terminate Deutsch crimp type contacts. The term results when crimp tooling typical " is used to is in good working order and properly calibrated. The term used to illustrate appoint at which tooling is pressure, illustrate expected tensile strength minimum is suspected of having excessive wear, insufficient air bad calibration , etc. Minimum does not imply that the crimp is unacceptable, only that an adjustment should be made. The manner in which the tensile test is performed is important in oder to attain valid test results. A axial load of 1.0 in./min. should be applied starting wire/contact separation or wire from zero pounds until there is 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 set by the lower total installation and maintenance costs rapidity of the crimping resulting from the simplicity and operation. However, controls are required to make sure first, operator uses the proper crimping tools designed for the crimped ,and then, that the pin or procedure off that the type and size contact being socket is properly inserted into the contact. The usual is to insert the wire into the open end of the contact, then thus crimping the wall of the contact close the crimping tool, into the wire at several points around the circumference. When completed, correct assembly can be checked visually. The removed insulation should expose a conductor length that will pass beyond the inspection hole in the contact and still reveal 1/32 3/32 " of conductor between the contact Damaged wire strands. ? Missing wire strands. ? Wire strands not entering the ? Wire not inserted to the " to and the insulation on the wire. The operator and inspector can ? Acceptable Crimp thus check for: contact barrel. proper depth in the contact. When the correct tool is used for crimping, a good termination is , s condition, the assured. However if there is question as to the tool distance across the indent bottoms can be measured. This is called the T" dimension (T for terminal). There is a corresponding gauge for measuring the positioning of the Go - No - Go" tool indentors, the G" ( gauge) dimension. TENSILE TEST Minimum Tensile Contact Wire Size & Type Gauge 4 PIN 6 300 lbs. 500 4SOC 6 300 lbs. 500 8 PIN 8 125 lbs. 250 8 SOC 8 125 lbs. 250 8 PIN 10 90 lbs. 200 8 SOC 10 90 lbs. 200 12 PIN 12 75 lbs. 120 12 SOC 12 75 lbs. 120 12 PIN 14 70 lbs. 95 12 SOC 14 70 lbs. 95 16 PIN 16 25 lbs. 45 16 SOC 16 25 lbs. 45 16 PIN 18 25 lbs. 35 16 SOC 18 25 lbs. 35 20 PIN 20 20 lbs. 25 20 SOC 20 20 lbs. 25 Strength 1 in/min Contact Part 0460 -204 -0490 6 0462 -203 - 4 SOC TOOLING CROSS REFERENCE AWG Range Number 4 PIN Strength Pull CONTACT - PART NUMBER / CRIMP Size & Type Typical Tensile 6 04141 DIA Over Insl. Recommended Crimp Tool Min / Max Strip Length .280 .292 .461 .031 HDP-400 .190 .240 .461 .031 HDP-400 .134 .170 .253 .031 HDT 48 -00 .100 .134 .250 .312 HDT 48 -00 .100 .134 .250 .312 HDT 48 -00 .040 .095 .156 .218 HDT 48 -00 0460 -204 8 PIN 08141 8 -10 8 SOC 0462 -203 - 8 -10 08141 0460 -204 12 PIN 12141 12 -14 12 SOC 0462 -203 - 12 -14 12141 0460 -215 14 PIN 16141 16 -18 14 SOC 0462 -209 - 16 -18 16141 0460 -202 16 PIN 16141 16 -18 16 SOC 0462 -201 - 16 -18 16141 0460 -202 20 PIN 20141 20 -24 20 SOC 0462 -201 - 20 -24 20141 CRIMPING PROCEDURE HDT 48 1. Strip (see - 00 recommended strip lengths ) insulation from wire. 2. Raise selector knob and rotate until arrow is aligned with wire size to be crimped. 3. Loosen lock nut, turn adjusting screw in until it stops. 4. Insert contact, turn adjusting screw counter clockwise out until contact is flush with indentor cover. Tighten lock nut. 5. Insert wire in contact, contact must be centered between indicators, close handles until handle contacts 6. the stop. Release handles and remove crimped contact 7. Insert terminal to insure that all strands are in crimp barrel. NOTE: Tool must be WIRE TERMNATION readjusted for each type/size of contact. - Do , s and Don 'ts Do , s ? Check strip lengths. ? Protect wire strands. ? Gauge the crimp ? Check crimp selector for ? Tensile pull test. ? Specify Deutsch ? Check crimp locations. indenters. correct wire size settings. manufactured terminals. Don , ts ? Add solder. ? Apply heat. ? Leave exposed conductor ? Overcrimp. ? Rely on T -Dim measurements only. ? Use Field maintenance ? Buy bogus terminals. wire strands. " crimp tools for volume production. (c) 2008 Imcon, spol. s. r. o. Exclusive representative of compagnie DEUTSCH GmbH. Marianske nam. 1, 61700 Brno; Czech Republic tel. +420 545 234 440; fax. +420 545 233 169; e - mail: