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This electronically generated standard is authentic and valid without signature. The English translation is believed to be accurate.
In case of discrepancies the German version shall govern. Numerical notation acc. Hans Bauer Tel. All rights reserved. No part of this document may be transmitted or reproduced without prior permission of a Standards Department of the Volkswagen Group.
Parties to a contract can only obtain this standard via the B2B supplier platform www. The specifications in this standard apply only to single cable crimps. In individual cases, the standard part drawings of the contacts and cable lugs provide detailed crimp specifications.
In addition to this, the contact manufacturers supply processing specifications containing additional information that must also be taken into consideration. Specifications in the respective standard part drawing take precedence. Definitions The terms and definitions in this standard are specified in the IEV Designations see Figure 1 and Figure 2.
Open crimp barrels are customary in punched contact 2. The crimping operation simultaneously closes the open crimp barrel while separating the contact element from the transport strip. Closed crimp barrel Conductor crimps, insulation crimps, or single-wire seal crimps with closed contour have closed crimp barrels.
They are customary in tubular cable lugs. Closed crimp barrels are usually conductor crimps. Single-wire seal crimps or insulation crimps in the form of closed crimp barrels require significant effort and, thus, are seldom implemented.
Conductor crimp Connection between the contact element and the stranded conductor. The conductor crimp must ensure the permanent electrical connection between the contact element and the stranded conductor. Insulation crimp Connection between the contact element and the cable at the outer diameter of the insulation.
The insulation crimp is designed to absorb mechanical loads and vibrations to prevent them from affecting the conductor crimp. For the design types of the insulation crimp, refer to Section 3. The single-wire seal crimp must ensure permanent fit of the single-wire seal on the contact element. For the design types of the single conductor sealing crimp, refer to Section 3.
Connection A Transition area between the contact area and the conductor crimp. Connection B Transition area between the conductor crimp and the insulation crimp. These specified crimp dimensions must be adhered to exactly. Depending on the wire cross-sections and contact elements to be processed, the wear part profiles or crimpers and the anvil profiles must be properly matched. Cable Only copper cables with bare or surface-treated strands that have been released by Volkswagen must be used; VW applies.
This crimp standard is strictly not applicable to solid cables, aluminum conductors, or flat ribbon cables. The electrical conductor must not be dip-tinned or soldered. Cable material whose properties have been adversely affected must not be used. After 2 years of storage at the latest, proof must be provided that the cable material can still be used. The cable material must continue to comply with the requirements in VW and the relevant standard part drawing. Stripping Special tools must be used for stripping.
The length of insulation to be stripped must be defined by the cable manufacturer, taking into consideration the applicable specifications.
The strands must not be scored or otherwise damaged when insulation is stripped. The calculated number is always truncated to the next integer value. No strands must be cut off. No more than 2 strands must be cut off. It is not permissible for strands to protrude; see Figure 3. Fanning out of the strands is not permissible; see Figure 4.
Figure 4 — Fanned out stranded wire Unclean cutting of the insulation, damage to the insulation, or the presence of insulation residues on the stripped portion of the conductor is not permitted; see Figure 5. Figure 5 — Defective insulation Strands must not be overtwisted in order to prevent severing or damaging of the strands during the crimping operation; see Figure 6.
Figure 6 — Overtwisted conductor end Conductor end The conductor end see Figure 7 terminates at a point not before the conductor crimp end but no more than 1 mm beyond it. The plugging, latching, or bolting function of the contact element must not be impaired by the projecting end of the conductor.
For cable lugs, the conductor end also must not extend into the bolt-on surface. Figure 8 — Protruding strands The insulation end must be visible in the window between the wire crimp barrel and insulation crimp barrel.
No cable insulation must be caught in the conductor crimp. Requirements for the crimped contact element Contact elements The contact elements used must conform to the requirements and specifications of the standard part drawing. Contact material whose properties have been adversely affected must not be used. After 2 years of storage at the latest, proof must be provided that the contact material can still be used. The contact material must still comply with the requirements in VW and the relevant standard part drawing.
Damage The contact range see Figure 1 and the locking pins must not be damaged or deformed after the crimping operation. Deformations of the contact range of the contact element as a result of crimping are not permitted. Figure 10 — Bending of the longitudinal axis of the contact element Dimensions of conductor crimp See Figure Limits are specified for the indicated crimp dimensions. Any deviating values specified in standard part drawings are binding.
The specified crimp dimensions must be adhered to according to the quality assurance matrix and documented by the harness manufacturer. Crimp height Measurable in a non-destructive manner. Not tool-dependent, i. The crimp height is specified by the contact element manufacturer and is documented on the standard part drawing of the relevant contact element.
They have been developed and are widely applied in many industries, particularly in the automotive. For example, manufacturers of automotive components simply do not order a connection from a company that does not comply with corresponding standards. The standards are based on mechanical and accelerated environmental tests duplicating potential operating conditions which a connection can experience through the expected automobile life cycle. They make demands to components and their dimensions, compacting compression rate and contact resistance.
Comprehensive Software for Crimp Cross Section Analysis Overview The CrimpLab 2 software is designed specifically for the analysis of cross sectioned terminals and replaces the previous software version, CrimpLab 1. Two different versions of the updated software are available, CrimpLab 2 Standard and CrimpLab 2 Automatic, both with many enhancements that make cross section analysis easier than ever. With the CrimpLab 2 Standard software users can measure all critical crimp dimensions using simple measurement tools. The CrimpLab 2 Automatic software features an automatic contour recognition function allowing users to measure all cross section dimensions of standard B-crimps automatically with just a few clicks.