Tyco Electronics 2031940-2 Reference guide

409-10092
Customer Manual
Crimp Quality Monitor 2031940-2 (For Use
1 of 86
LOC B
E 2008 Tyco Electronics Corporation, Harrisburg, PA
All International Rights Reserved
TE logo and Tyco Electronics are trademarks.
*Trademark. Other products, logos, and company names used are the property of their respective owners.
TOOLING ASSISTANCE CENTER 1-800-722-1111 This controlled document is subject to change.
For latest revision and Regional Customer Service,
visit our website at www.tycoelectronics.com
08 SEP 08 Rev A
with AMPLIVA * Product Terminator IIIA
Assembly 679453-[ ] and 679457-[ ])
EAD THIS FI ST ! 2..........................
SAFETY PRECAUTIONS
1. INT ODUCTION 3...................................................
1.1. The Crimp uality Monitor 3........................................
1.2. The Manual 4...................................................
1.3. Specifications 4.................................................
2. ECEIVING, INSPECTION AND INSTALLATION 4............................
2.1. Receiving 4....................................................
2.2. Inspection 4....................................................
2.3. Installation 5....................................................
3. OPE ATION 5......................................................
3.1. Basic Outline of Operation 5........................................
3.2. Crimp Analysis Results 8...........................................
4. C IMP QUALITY MONITO MENUS AND SC EENS 10.......................
4.1. Production 11..................................................
4.2. Crimp Height Calibration 29.........................................
4.3. Job Setup 36...................................................
4.4. Kits 44........................................................
4.5. Parts 50.......................................................
4.6. System Settings Menu 61..........................................
4.7. Statistics 77...................................................
4.8. Diagnostics Menu 78.............................................
4.9. Power Down 84.................................................
4.10. Version Screen 84...............................................
4.11. Enter Passsword Screen 85........................................
5. C IMP QUALITY MONITO MAINTENANCE 86.............................
5.1. Touch Screen Cleaning 86.........................................
5.2. Daily Maintenance 86.............................................
5.3. uality Control Maintenance 86......................................
5.4. Evaluation and Repair 86..........................................
6. EVISION SUMMA Y 86..............................................

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Crimp Quality Monitor 2031940-2
Rev A2 of 86 Tyco Electronics Corporation
SAFETY PRECAUTIONS AVOID INJURY
Safeguards are designed into this application equipment to protect operators and maintenance personnel from
most hazards during equipment operation. However, certain safety precautions must be taken by the operator
and repair personnel to avoid personal injury, as well as damage to the equipment. For best results, application
equipment must be operated in a dry, dust–free environment. Do not operate equipment in a gaseous or
hazardous environment.
Carefully observe the following safety precautions before and during operation of the equipment:
D ALWAYS wear appropriate ear protection.
D ALWAYS wear approved eye protection when operating powered equipment.
D ALWAYS keep guard(s) in place during normal operation.
D ALWAYS insert power plug into a properly grounded receptacle to avoid electrical shock.
D ALWAYS turn off the main power switch and disconnect electrical cord from the power source when
performing maintenance on the equipment.
D NEVER wear loose clothing or jewelry that may catch in moving parts of the application equipment.
D NEVER insert hands into installed application equipment.
D NEVER alter, modify, or misuse the application equipment.
TOOLING ASSISTANCE CENTER
CALL TOLL FREE 1-800-722-1111 (CONTINENTAL UNITED STATES AND PUERTO RICO ONLY)
The Tooling Assistance Center offers a means of providing technical assistance when required.
In addition, Field Service Specialists are available to provide assistance in the adjustment or repair of the
application equipment when problems arise which your maintenance personnel are unable to correct.
INFORMATION REQUIRED WHEN CONTACTING THE TOOLING ASSISTANCE CENTER
When calling the Tooling Assistance Center regarding service to equipment, it is suggested that a person
familiar with the device be present with a copy of the manual (and drawings) to receive instructions. Many
difficulties can be avoided in this manner.
When calling the Tooling Assistance Center, be ready with the following information:
01. Customer name
02. Customer address
03. Person to contact (name, title, telephone number, and extension)
04. Person calling
05. Equipment number (and serial number if applicable)
06. Product part number (and serial number if applicable)
07. Urgency of request
08. Nature of problem
09. Description of inoperative component(s)
10. Additional information/comments that may be helpful
DANGER

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Crimp Q ality Monitor 2031940-2
Rev A 3 of 86
Tyco Elect onics Co po ation
Figure 1
Front Panel
Back Panel
Display/Touchsc een
Powe On"
Indicato
Senso Po t
Cooling Vents
Powe Switch
I/O Po t
USB Po ts
Compact Flash Ca d
1. INTRODUCTION
1.1. The Crimp Q ality Monitor
Crimp Quality Monitor (CQM) 2031940–2 provides immediate inspection of the crimp height and the work
curve of a crimped part (wire/terminal combination) by analysis of data provided by force and position sensors.
The sensors are built into the AMPLIVAR Product Terminator (APT) IIIA. The Crimp Quality Monitor notifies the
operator with visual cues when faulty crimps occur. See Figure 1 for front and back panel views of the CQM.

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The Crimp Quality Monitor also adjusts the tooling sequentially to obtain the crimp height associated with each
part to be crimped.
Crimp Quality Monitor 2031940–2 is used specifically with the APT IIIA Assembly 674453–[ ] or 679457–[ ].
These instructions are to be used in conjunction with any documents co ering the APT IIIA machine. Pay particular
attention to safety precautions found in this document.
1.2. The Manual
The CQM’s operation, functions, screens, and touch screen inputs are detailed in this document. Refer to
customer manuals and instructions shipped with the APT IIIA machine for further information.
1.3. Spe ifi ations
Below is a list of the specifications for the Crimp Quality Monitor.
DIMENSIONS
L ngth 246 mm [9.7 in.]
H ight 119 mm [4.7 in.]
Width 224 mm [8.8 in.]
WEIGHT
W ight 4.55 Kg [10 lbs]
ELECTRICAL REQUIREMENTS
Voltag 100-240 Vac
Fr qu ncy 50/60
AMBIENT OPERATING ENVIROMENT
T mp ratur 5-40 ° C [41-104 ° F]
R lativ Humidity 20-95 p rc nt (non-cond nsing)
2. RECEIVING, INSPECTION AND INSTALLATION
2.1. Re eiving
Crimp Quality Monitor (CQM) 2031940–2 is thoroughly inspected during and after assembly. A final series of
inspections is made to insure the proper functioning of the Crimp Quality Monitor before packaging and
shipping.
However, damage may occur during shipment. Remove the outer bands from the box and carefully remove the
CQM from the box. Inspect the CQM for damage. If damage is evident, file a claim against the carrier and
notify Tyco Electronics immediately.
Sa e the shipping carton/box and the entire documentation package shipped with the CQM.
2.2. Inspe tion
1. After inspecting for damage, install the power cord, plug the CQM into an appropriate supply, and turn
the power on. The power indicator light on the front of the CQM should be lit. On the back panel, the 5
volt and 24 volt indicator lights should be lit.
NOTE
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NOTE
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Tyco Electronics Corporation
2. After a couple minutes the Main Menu screen, the Kit Information screen, or the Shutdown Error
screen should appear on the CQM and the heart beat light on the back panel should be flashing. Touch
the button on the screen to clear the Kit Information screen or the Shutdown Error screen to
display the Main Menu screen.
3. If the power indicator light is not lit, the heart beat light is not flashing, the 5 volt light is not lit, the 24
volt light is not lit, or the Main Menu screen cannot be viewed, turn the power off and notify Tyco
Electronics immediately.
Otherwise, touch the button on the Main Menu screen to display the Power Down screen. Touch
the “Shutdown” button on the Power Down screen. When the message “It is now safe to turn off power”
is displayed, turn the power off, unplug the power cord, and continue with Paragrap 2.3, Installation .
2.3. Installation
T ese instructions apply to AMPLIVAR Product Terminator IIIA (APT IIIA) Assembly 679453-[ ] and 679457-[ ].
1. Be sure the APT IIIA is properly installed and set up as described in the APT IIIA customer manual.
2. Secure the bottom plate of the CQM to the mounting bracket with the four supplied screws.
3. Mount the remote status (light indicator) box using the supplied fastener strips. The remote status box
should be placed at a location visible to the operator.
4. Attach the I/O Cable to the I/O Port of the Crimp Quality Monitor.
5. Attach the Sensor Cable to the Sensors Port of the Crimp Quality Monitor.
6. Connect the power cord to the back of the Crimp Quality Monitor.
7. Power up the CQM and use the CQM diagnostics screens (refer to Paragraph 4.8) ) to verify the
proper operation of the following:
S Sensors
S Inputs and Outputs (i.e., red and green lights, machine interface)
S Crimp Height Adjustment Motor
3. OPERATION
The following example outlines the basic steps to operate the Crimp Quality Monitor. Refer to Section 4,
CRIMP QUALITY MONITOR MENUS AND SCREENS, for a description of the various screens and menus
used by the monitor.
3.1. Basic Outline of Operation (Sample Setup)
W en t e CQM option is enabled on t e APT IIIA, t e mac ine can only be cycled w en t e Crimp Quality Monitor is
displaying a calibration or production screen.
In the following example, four magnet wires on a motor winding are to be crimped to four stranded wires. The
motor is named MOTOR.344678. A kit is created containing four parts (wire/terminal combinations) that are to
be crimped in sequence. The part names are 18–X1.18STR–BLUE, 18–X2.18STR–BROWN,
20–X3.20STR–BLACK and 20–X4.20STR–RED. The job name is ACME–MOTORS.344678. The nominal
crimp height for the 18–X1.18STR–BLUE part is 0.078 inches and the estimated crimp height adjustment offset
is 0.009 inches.The operator’s name is Jordo. To complete the job, 4000 good motors must be made in
batches of 25.
1. From the Main Menu screen, touch the “Job Setup” button to enter the Job Setup screen and
establish the job settings.
NOTE
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NOTE
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Rev A6 of 86 Tyco Electronics Corporation
a. Touch the “Job Name” button on the Job Setup screen to display the Enter Job Name screen.
b. Enter the job name ACME–MOTORS.344678.
c. Touch the “Operator” button on Job Setup screen to display the Operator screen.
d. Touch the button on the Operator screen to display the Enter New Operator Name screen.
e. Enter the operator name (JORDO).
f. Touch the operator name (JORDO) on the Operator screen to highlight it, then touch the
button to select JORDO as the current operator.
g. Touch the “Kit Name” button on the Job Setup screen to display the Kits (Select for Job) screen.
h. Touch the button to display the Enter New Kit Name screen.
i. Enter the kit name MOTOR.344678. After the kit name is entered the Kit Editor screen is
displayed.
j. Touch the button to display the Parts (Select for Kit) screen.
k. Touch the button to display the Enter New Part Name screen. Enter the part name
(18–X1.18STR–BLUE). After the part name is entered, the Part Editor screen is displayed.
l. Touch the “Crimp Height” button on the Part Editor screen to display the Enter Crimp Height
screen. Enter a crimp height of 0.078 inches.
m.Touch the “Offset” button to display the Enter Adjust Offset screen. Enter a crimp height
adjustment offset value of 0.009 inches. This is a starting value and may be changed by the CQM
during the crimp height calibration process or while running production.
n. Touch the “Calculate Control Limit” button to turn on the feature that tells the monitor to
automatically calculate the control limit tolerance for the part during production.
All other settings for the part are left at the default settings.
o. Touch the button to save the changes and return to the Parts (Select for Kit) screen.
p. Touch the part name (18–X1.18STR–BLUE) to highlight it.
q. Touch the button to select the part for the kit and return to the Kit Editor screen.
The steps to create, edit and select a part for the kit are repeated for the other three parts.
r. After the other three parts have been added to the kit on the Kit Editor screen, touch the
button to save the changes and return to the Kits (Select for Job) screen.
s. Touch the kit name (MOTOR.344678) to highlight it.
t. Touch the button to select the kit for the job and return to the Job Setup screen.
u. Touch the “Job Size” button on the Job Setup screen to display the Enter Job Size screen. Enter
a job size of 4,000.
v. Touch the “Batch Size” button on the Job Setup screen to display the Enter Batch Size screen.
Enter a batch size of 25.
w. Touch the button on the Job Setup screen to save the job settings and return to the Main
Menu screen.
2. From the Main Menu screen, touch the“System Settings” button to enter the System Settings Menu
screen, in order to change the system settings.
a. Touch the “Position Sensor” button on the System Settings Menu screen to display the Position
Sensor screen.
b. Verify that the position sensor values are correct for the machine. The numbers are engraved on a
plate attached to the ram cover and are included in the machine documentation. If the values are
incorrect or have not been entered, touch the order number (0–5) buttons to display the screens to
enter the position sensor values.

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Rev A 7 of 86
Tyco Electronics Corporation
c. Touch the button to save the changes to the position sensor values and return to the System
Settings Menu screen.
d. Touch the button to return to the Main Menu screen.
3. From the Main Menu screen, touch the “Calibration” button to enter the Calibrate Crimp Height
screen. For each part in the kit, the crimp height calibration process sets the adjust offset and
establishes a reference position value that the CQM uses to calculate crimp height. All parts in the kit
must be calibrated before entering the Production screen.
a. Touch the part name (18–1.18STR–BLUE) to highlight it.
b. Touch the “Calibrate Part” button to display the Calibrate Part screen.
c. Make a crimp using the same wire/terminal combination that will be used in production. The CQM
will detect the beginning of the crimp and collect force and position data. When the end of the crimp is
detected the CQM will try to analyze the data. If analysis is successful, the Crimp Detected screen is
displayed.
d. Visually inspect the crimp and measure the crimp height. Initially the crimp height may be out of
tolerance. This crimp height may still be used for calibration because the CQM will change crimp
height offset to a value that should result in a crimp closer to the nominal crimp height value.
e. If the crimp is suitable for calibration, touch the “YES” button to display the Enter Hand Measured
Crimp Height screen. Otherwise, press the “NO” button to return to the Calibrate Part screen, and
then repeat the crimp and inspection steps.
f. Enter the hand measured crimp height.
g. After the crimp height is entered, the Calibrate Part screen is displayed. If the crimp height
entered was within 0.0005 inches of the nominal crimp height for the part, the message “Part has
been calibrated” is displayed. Otherwise the message “Make a crimp” is displayed and the crimp,
inspection, and enter crimp height process is repeated.
h. After the message “Part has been calibrated” is displayed, touch the button to save the
calibration values and return to the Crimp Height Calibration screen. A checked box beside
the part name indicates that the part has been calibrated. The calibration process is repeated for the
other three parts in the kit. The parts can also be calculated as a group by touching the Calibrate Kit
button. In this case, crimps are made in sequence, inspected, and the crimp height for each part is
entered.
i. After all parts have been calibrated, touch the button to return to the Main Menu screen.
4. From the Main Menu screen, touch the “Production” button to enter the Production screens. Begin
crimping the parts (wire/terminal combinations) in their proper sequence. The CQM displays the current
part to be crimped. Every crimp is analyzed for a valid crimp height.
a. Initially crimps that are evaluated as having a crimp height within the specified tolerance are
identified as “Learn” crimps and the Learn Crimp screen is displayed. The “Learn” crimps are visually
inspected. If the crimp is acceptable, touch the “Accept as Good” button to return to the Production
screen. After the specified number of “Learn” crimps have been accepted for a part, the CQM will
perform the work index and peak force analysis along with the crimp height analysis for that part.
b. If the “Learn” crimp is not acceptable, touch the “Repeat Crimp,” “Next Part,” or the “Reset Kit”
button to continue production. The button touched determines how the monitor will proceed in the kit
sequence.
c. After a crimp is evaluated as “Good”, the CQM will adjust to the offset for the next part in the
sequence and production can continue.
d. After a crimp is evaluated as “Inspect,” “Bad,” or ”Invalid,” the corresponding error screen is
displayed. Touch the ”Accept as Good,” “Repeat Crimp,” “Next Part,” or the “Reset Kit” button to
continue production.
e. The Batch/Job Complete screen will be displayed each time the batch count reaches 25 and
when the job count equals 4000. Touch the button on this screen to continue production.

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Rev A8 of 86 Tyco Electronics Corporation
f. Touch the button on the Production screen to return to the Main Menu screen.
5. Statistics for the job can be viewed on the Statistics screen by touching the “Statistics” button on the
Main Menu screen.
3.2. Crim Analysis Results
The results of the crimp analysis are displayed on the Production/CQM and Manual Operation screens. The
crimp height, work index value and peak force value are displayed on these screens. In the “Status” box,
crimps are reported as “Learn,” “Good,” “Inspect,” or “Bad.” If the CQM is unable to analyze the data collected,
the message “Invalid” is displayed in the status box. Two additional messages, “Control Limit” and “Control
Count” may be added to the “Good” message.
A. Learn Crim
The “Learn Crimp” message is displayed when the CQM calculates a crimp height within tolerance, but the
limits for the work index and peak force analysis have not been established.
The green light and red light are turned on. See the third NOTE 3 (below).
The Learn Crimp screen is displayed. Refer to Paragraph 4.1,L.
The operator must visually inspect the crimp. If it satisfies the inspection criteria, the operator should touch
the “Accept as Good” button on the Learn Crimp screen. The work index and the peak force values for
the crimp will be used to establish the limits for the work index and peak force analysis. See the NOTE 1
(below).
B. Good Crim
The “Good” message is displayed when the calculated crimp height is within tolerance and the work index
and peak force values are within the acceptable limits.
The green light is turned on and the CQM will advance to the next part in the kit. See NOTE 3 (below).
The batch and job counts are incremented if a kit is completed containing all good crimps or crimps that
were accepted as good. See NOTE 2 (below)
C. Good / Control Limit
The “Good/Control Limit” message is displayed when a “Good” crimp completes a sample of all good
crimps and the average crimp height of the sample exceeds the control limit for a sample. Refer to
Paragraph 4.5,E.
The crimp height adjustment offset for the part is changed to adjust the crimp height closer to the nominal
value.
D. Good / Control Count
The “Good/Control Count” message is displayed when the number of consecutive samples, containing all
“Good” crimps, whose average crimp height exceeds the crimp height control limit tolerance for a sample,
equals the control count. Refer to Paragraph 4.6,D.
The Control Count Error screen is displayed. Refer to Paragraph 4.1,O.
The green light and the red light are turned on. See NOTE 3 (below)
A “Control Count” result overrides a “Control Limit” result.
E. Ins ect Crim
The “Inspect” message is displayed when the CQM calculates a crimp height within tolerance but the work
index value or the peak force value is outside the acceptable limits. Refer to Paragraphs 4.5,G and 4.5,H.
The Inspect Crimp screen is displayed. Refer to Paragraph 4.1,M.
The green light and the red light are turned on. See NOTE 3 (below)
The operator must visually inspect the crimp. If it satisfies the inspection criteria, the operator should touch
the “Accept as Good” button on the Inspect Crimp screen. See NOTE 1 (below).

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Crimp Q ality Monitor 2031940-2
Rev A 9 of 86
Tyco Electronics Corporation
F. Bad Crimp
The “Bad” message is displayed when the CQM calculates a crimp height out of the specified tolerance.
Refer to Paragraph 4.5,D.
When there is a bad crimp, the Bad Crimp Height screen is displayed. Refer to Paragraph 4.1,N.
The red light is turned on. See NOTE 3 (below).
G. Invalid Crimp
The “Invalid” message is displayed when the CQM is unable to analyze the data collected.
The Invalid Crimp Data screen is displayed. Refer to Paragraph 4.1,P.
The green light and the red light are turned on. See NOTE 3 (below).
The operator must visually inspect the crimp and measure the crimp height. If it satisfies the inspection
criteria, the operator should touch the “Accept as Good” button on the Invalid Crimp Data screen.
An attempt should be made to determine the cause when the crimp is determined to be “Invalid.” For
possible causes, touch the button on the Invalid Crimp Data screen to display the Invalid Crimp
Help screen.
When a cri p is accepted as good as a result of the operator touching the Accept as Good" button on Learn Crimp ,
Inspect Crimp ,OR Invalid Crimp screens, the CQM will advance to the next part in the kit. The batch and job counts
are incre ented when the kit is co pleted containing all good cri ps or cri ps that were accepted as good. See
NOTE 2.
If, as a result of the batch and job count being incre ented, the batch count equals the batch size or the job count
equals the job size, the Batch/Job Complete screen is displayed and the red and green lights will be turned on.
The red and green cri p status lights are connected by a cable to the I/O port on the back of the CQM. The lights
should be located in a position that allows ease of observation while the achine is operating.
NOTE 1
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NOTE 2
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NOTE 3
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Crim Quality Monitor 2031940-2
Rev A10 of 86 Tyco Electronics Corporation
4. CRIMP QUALITY MONITOR MENUS AND SCREENS
Most of the main functions of the Crimp Quality Monitor are accessed through the Main Menu screen.
The Main Menu screen is displayed when the CQM is turned on. The Main Menu screen displays the kit
name that has been selected for the job and displays the buttons that the operator touches to access other
screens.
Touch the “Production” button to display the Production screen. Refer to Paragraph 4.1.
Touch the “Calibration” button to display the Crimp Height Calibration screen. Refer to Paragraph 4.2
Touch the “Job Setup” button to display the Job Setup screen. Refer to Paragraph 4.3.
Touch the “Statistics” button to display the Statistics screen. Refer to Paragraph 4.7.
Touch the “Kits” button to display the Kits screen. Refer to Paragraph 4.4.
Touch the “Parts” button to display the Parts screen. Refer to Paragraph 4.5.
Touch the “System Settings” button to display the System Settings Menu screen. Refer to Paragraph 4.6.
If a system pass ord has been created, the pass ord must be entered on the Enter Pass ord screen (see Paragraph
4.11) before the System Settings Menu screen is displayed.
Touch the “Diagnostics” button to display the Diagnostics Menu screen. Refer to Paragraph 4.8.
If a system pass ord has been created, the pass ord must be entered on the Enter Pass ord screen (see Paragraph
4.11) before the Diagnostics Menu screen is displayed.
Touch the button to display the Power Down screen. Refer to Paragraph 4.9.
NOTE
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NOTE
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