Applitek Technologies Corporation - Products and Services

1. Which feed cam should I be using in my terminal applicator?

With regards to mechanical feed type terminal applicators: The feed cam is a mechanical component generally mounted to the vertically moving applicator ram (or sometimes called “plunger”). It is specifically profiled to produce a horizontal feeding motion to index continuous strip terminals into position.

There are two times in a press cycle to mechanically feed the terminals. One is during the upward motion of the crimp tooling and the other is during the downward motion of the crimp tooling.

In a “bench” type application wherein an operator will hand present the wire end to the terminal applicator, it is important for the terminal to already be positioned in place over the crimp anvil awaiting the presentation of the wire end. In other words, the terminal is stationary and provides a target for operator wire positioning. Therefore, the terminals must feed on the upstroke after crimping the previous terminal. “Bench” applications require an “upstroke” cam.

In an “automatic” type application, the wire processing machine automatically positions the wire into the terminal applicator and then must remove the crimped terminal out of the applicator. In this case, it is desirable to provide both an unobstructed area over the anvil and sufficient time to swing the wire in and out of the crimping area. “Automatic” applications use a “downstroke” cam.

One other point about feed cams: The specific profile machined into the cam is designed to facilitate a specific throw (horizontal distance traveled) of a cam follower (roller) within a specific vertical travel of the applicator ram (or plunger). Given this, the applicator cam profile must be matched to the terminal press stroke.

Since standard available terminal presses use strokes of 1.63 inches and 1.13 inches, APPLITEK offers three standard cams:

UPSTROKE for 1.13 inch press stroke (for “bench” operation).
UPSTROKE for 1.63 inch press stroke (for “bench” operation).
DOWNSTROKE for 1.63 inch press stroke (for “automatic” operation).

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2. Do I need a “left-to-right” or a “right-to-left” applicator?

There are three possible directions that continuous strip terminals can enter standard terminating presses. One direction is from the left press side, another direction is from the right press side, and the last is from the rear of the press. The first two directions require “side feed” terminal applicators, the third requires a “rear feed” terminal applicator (for “end-to-end” type continuous strip terminals).

The point of reference with regards to defining “left”, “right”, or “rear” involves viewing the terminating press from the front whereby the “front” is the face of the terminating press in which the wire end will be presented for crimping. In other words, the direction in which the operator would normally sit and face the press.

Once viewing the press from this viewpoint, terminals feeding into the “left” terminating press side require a “left-to-right” applicator. Terminals feeding into the “right” terminating press side require a “right-to-left” applicator.

“Left-to-right” feed applicators are by far the most common. “Right-to-left” feed applicators are relatively rare. It is important that the terminal designer be aware as to which direction the stamping die should be designed in conjunction to reeling the terminals out of the stamping die in the correct direction as to facilitate the final unreeling direction into the terminal applicator.

To determine which way reeled terminals will feed. First unwind a short length of terminals. Turn the reel such that the crimp wing tips point upward and are closest to the operator. This will indicate which direction the terminals will feed into the terminal applicator.

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3. How many cycles should my crimping tooling and applicator last?

Crimp tooling life is highly dependent on the particular application. It is impossible to predict the exact life of a tool. Obviously, one would like to have a perishable tool wear out before it breaks. Some applications such as very small terminals with very short pitch dimensions on a continuous strip require very small tooling cross-sections to fit between the adjacent terminals. In this case, weakness of tooling is inherent in the design by necessity. In other cases, terminals designed with “center” type carriers require small pieces of the carrier to be cut off within the die area. This also may result in small tooling cross-sections but it also creates small pieces of scrap that can cause tooling jam ups and potentially pre-mature tooling breakage.

Thicker terminal stock materials that are generally used on larger size wires require higher crimping forces and therefore more stresses on the tooling and less life.

APPLITEK uses several different tooling steels, heat treating processes, and platings/coatings to optimize life for a given application.

As far as the “terminal applicator” life: This is also impossible to predict since it is highly dependent on the type of application, degree of usage, lubrication, routine maintenance, number of jam-ups, etc. We have customers who have reported 20+ million cycles but this is by no means any kind of controlled study.

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4. Can I let the carrier strip run out of the applicator instead of chopping it up in the applicator?

Absolutely, but specify this requirement at the time of ordering.

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5. Will an APPLITEK applicator work with my “Stripper Crimper”?

It is important to specify the make and model at the time of inquiry. APPLITEK applicators are compatible with certain "Stripper Crimpers" but sometimes require modifications.

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6. Will an APPLITEK applicator work with my “Seal Applicator” press?

It is important to specify the make and model at the time of inquiry. Specially modified APPLITEK applicators are compatible with certain major "Seal Applicator" presses.

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7. I received my applicator but the crimped terminal doesn't fit into the housing block?

We specifically ask that any requirements for "seals" or "housing blocks" be stated at the outset. In fact, we generally require samples to avoid problems. This information is crucial to determining proper crimp specifications.

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8. I don't have crimp specifications, can APPLITEK determine these?

APPLITEK has a unique expertise at determining proper crimp specifications with "state-of-the-art" methods for verification and would prefer to always determine the appropriate crimp specifications. However, we are sensitive to the fact that many terminal manufacturers and users require their own crimp specifications to be held. We will build to your specifications providing that your specifications result in a crimp quality that falls within APPLITEK acceptable limits.

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9. I am designing a terminal, can APPLITEK help?

We routinely get involved in terminal design consultation. Specifically the crimp barrel end of the terminal or connector. We can specify the crimp wing size and pre-form shape, provide carrier design recommendations, and specify the final crimp shape and crimp specifications. In fact, we have saved our customers thousands of dollars by reducing or eliminating stamping die changes due to design flaws by those less experienced in the crimping process.

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