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Crimping of machined D-sub pins with 4-Way Indent Pin C

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rjquillin

Joined: 13 May 2007
Posts: 123
Location: KSEE

Posted: Wed Dec 10, 2008 7:18 pm Post subject: Crimping of machined D-sub pins with 4-Way Indent Pin C

At 09:33 12/10/2008, you wrote:

  	  Quote: 	
		  I think I have several problems and oversights that need to be addressed. 	


 Having been to this training required for my employment, I find the gold standard to be NASA 8739.4

 CRIMPING, INTERCONNECTING CABLES, HARNESSES, AND WIRING



   http://workmanship.nasa.gov/ws_8739_4.jsp

 There is a radio button on page "Click Here to view NASA-STD-8739.4" that downloads a 2.1MB pdf.



 This document is worth a read by anyone wiring flight hardware.  It deals with not only crimp connections, but also stripping, soldered splices, harnessing, lacing and most anything else you could want to know about making and inspecting reliable connections, both shielded and unshielded.



 Regarding crimpers, frequently on eBay you can find AFM-8 adjustable (for differing gage wire) crimpers, Daniels or other, with positioners to get the pin where it belongs for under $100.



 Bob has some great stuff published to make our lives easier and I'm not quibbling with it, but this really is worth the read.  Appendix A beginning on page 103 details what is and is not acceptable in pictures.



 Ron Q.

 

 Ronald Quillin

 Principal Electronic Technician 

 Center for Astrophysics and Space Sciences

 University of California, San Diego 

 9500 Gilman Drive 

 La Jolla CA 92093-0424

 +1.858.534.4489 V

 +1.858.534.2294 F 

     [quote][b]

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rjquillin

Joined: 13 May 2007
Posts: 123
Location: KSEE

Posted: Wed Dec 10, 2008 7:24 pm Post subject: Crimping of machined D-sub pins with 4-Way Indent Pin C

At 09:33 12/10/2008, you wrote:

  	  Quote: 	
		  I think I have several problems and oversights that need to be addressed. 	


 Having been to this training required for my employment, I find the gold standard to be NASA 8739.4

 CRIMPING, INTERCONNECTING CABLES, HARNESSES, AND WIRING



  http://workmanship.nasa.gov/ws_8739_4.jsp

 There is a radio button on page "Click Here to view NASA-STD-8739.4" that downloads a 2.1MB pdf.



 I also intended to include the link to this visual guide

  http://workmanship.nasa.gov/insp.jsp

 Excellent color pics and drawings.



 Ron Q.

     [quote][b]

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nuckolls.bob(at)aeroelect
Guest

Posted: Thu Dec 11, 2008 8:07 am Post subject: Crimping of machined D-sub pins with 4-Way Indent Pin C

At 11:33 AM 12/10/2008, you wrote:

 	  Quote: 	
		  I think I have several problems and oversights that need to be addressed.



I'm using a tool that looks like this:

http://aeroelectric.com/Pictures/Tools/Crimp_Tools/rct-3.jpg

As you said, it is setup for one size of wire and one type of 

pin/socket.   I've been using it on 20AWG and probably 22 AWG which 

would immediately indicate some inconsistency.  But in this case, I 

was using it on 24AWG wires that was part of a pre-made harness pig tail.



In addition, I was trying to strip the wire just far enough to 

barely clear or be flush with the pin.  Given that this crimper 

seems to crimp concentrically at the the very tip of the pin, 

allowing any of the insulation into the pin could further compromise 

the crimp.  (I'm attaching 2 pics of the pin that failed).

I first need to determine what size wire the crimper is setup for 

and limit its use to that wire.  And re-confirm I'm using the right 

pins (non-high density).



For this particular connection involving the 24AWG wires, I'm going 

to follow your guidance on using a 9 pin D-sum with solder terminals 

along with shrink tubing, clear adhesive and more shrink 

tubing.  It's a good solution for this particular connection.



I'll have to take a closer look at the adjustable Daniels crimper if 

I want to get serious... but it may be too expensive to justify.



What do you think?


	


   Thanks for the great pictures. I've added those to my

   reference library. It seems that Eclipse is back to their

   old habits.



   When I started stocking that tool many moons ago, I

   discovered that the pin-positioner was cut wrong

   allowing the pin to set too deep in the tool. This

   causes the crimp to happen too far back on the wire

   grip as shown here . . .



http://aeroelectric.com/Pictures/Tools/Crimp_Tools/4-Quad/Positioner_Mod_0.jpg



   I used to check every tool and modify as shown

   here . . .



http://aeroelectric.com/Pictures/Tools/Crimp_Tools/4-Quad/Positioner_Mod_1.jpg



   I put every positioner in the lathe and cut it back

   on the pin-entry end to achieve the dimension shown.

   This moved the pin up in the too such that the

   wire-grip was just flush to slightly under-flush

   with the face of the tool.



   B&C checked the tools too after I turned that

   activity over to them. Tim reported to me some

   months later that the pin-positioners were coming

   in okay. I figured that it was the result of a

   letter I wrote to Eclipse citing the problem.



   The other part of your problem is putting 24AWG wires

   into a 20/22 AWG pin. The tool is designed to have a slightly

   over-crimp on 20AWG and slightly under-crimp on 22AWG.

   This means it's way under-crimped for 24AWG. You fix this

   by striping 24AWG wire 2X length for exposed strands and

   fold the strands back to double the amount of copper

   in the finished joint.



   Alternatively, your idea of a fixed "plug" in the

   bottom of the pin-positioner works too but you

   have to be VERY careful about too much plug . . .

   it can be hard to get out. You can use a small

   twist drill to clear the hole.



   Bob . . .

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