Manufacturing, Testing & Quality
Crimp Height, Pull Force, and Cross-Section Review
Crimp height, pull force, and cross-section review answer different control questions. Use the exact terminal, wire, applicator or tool, setup data, measurement method, sample frequency, acceptance source, and record format so the results apply to the actual crimp combination.
Prepared by MTTJPublished: Updated:
Decision summary
What to carry into the decision
- Treat each terminal, wire construction, and applicator combination as a defined setup.
- Use crimp height for a controlled dimension, pull force for destructive mechanical evidence, and cross-section review when the program needs internal crimp evidence.
- Keep conductor and insulation support criteria distinct.
- Record method, units, sample selection, frequency, limits, and disposition with every result.
Define the crimp combination
Record terminal manufacturer and full part number, plating or variant, wire manufacturer or controlled construction, conductor size and stranding, insulation material and diameter, seal if present, strip length, applicator or tool identity, and setup data.
Do not combine results from visually similar terminals or nominally equal wire sizes unless the controlled criteria support the combination.
Crimp evidence table
State the source and method for every limit.
| Crimp height | Measurement location and orientation, instrument, units, target or range, sample frequency, setup condition, and reaction to drift. |
|---|---|
| Pull force | Sample preparation, insulation support treatment, grip, pull direction and rate, peak or failure criterion, units, frequency, and disposition. |
| Cross section | Sample cut and preparation, section location, image or measurement method, features reviewed, limits, frequency, and record. |
| Visual and assembly | Bellmouth, conductor brush, strand condition, insulation support, terminal damage, seal and cavity fit, seating, and lock. |
Use crimp height as a process control
Measure at the specified conductor-crimp location with the method and units tied to the terminal and wire data. Record the setup and sample frequency needed for the program, including what happens when a value is outside the limit.
Insulation support is evaluated separately where applicable; it should not be confused with the conductor-crimp measurement.
Define pull testing completely
A result cannot be compared unless the method is consistent.
- State whether insulation support is active, removed, or otherwise treated for the method.
- Define the grip, pull direction, rate, sample length or preparation, and result to record.
- Name the acceptance source, limit, units, and sample frequency.
- Record failure mode or observation when the method requires more than the peak value.
Plan cross-section review
Identify why the section is being reviewed: setup confirmation, qualification, periodic evidence, change validation, or investigation. Define the section plane, preparation, magnification or image method, measurements or visual features, acceptance, and record.
Apply the conclusion only to the represented terminal, wire, tool, setup, and process condition.
Common crimp-review mistakes
Avoid quoting a pull result without test rate or insulation-support condition, measuring crimp height at an undefined point, applying one limit across terminal variants, and treating a single cross-section image as ongoing process evidence. Keep instrument and fixture status with the recorded method where required.