Wiring Harness News WHN Sep-Oct 2013

INDUSTRIAL INFO-TAINMENT • Refrigerator Art s i : • Reps or Direct Salespersons? e h s T su re • Automatic Coax & Cable Company Is tu • Inside TE Connectivity’s Aluminum Crimp a • Crimp Force Monitoring - The Recipe for Success e F • Grow Your Control Panel Manufacturing Business • Wire Wisdom - Hype About Discontinuing Hypalon Wiring Harness News NOVEMBER/DECEMBER 2012 1 SEPTEMBER OCTOBER 2013 Automatic Coax & Cable Fred Noer ____________________________ G lenda and Gary Martinet have cause for celebration: This year is their 25th anniversary of founding, owning and operating their business, Automatic Coax & Cable (ACC) in Sanford, Fla. The milestone is a significant achieve- ment in a challenging industry and an unsettling U.S. economy. Why have the Martinets, each 63 years old, been able to mark this special occasion? One word – passion. They have it in abundance. Passion enabled the Martinets to take an initial $1,400 investment in equip- ment (including a Eubanks cut-and-strip machine they still have) and build a company expected to hit $2.5 million in sales this year. The 2014 forecast is $3 million plus. Another major business element – Inside TE Connectivity's Aluminum Crimp Joe Tito Wiring Harness News ____________________________ A t the EWPT Expo in Milwau- kee this past May, I was once again afforded the opportuni- ty to attend a presentation from USCAR on aluminum wiring for automotive. Quite honestly, I almost skipped the presentation this year. Not that the USCAR folks haven’t been great presen- ters. Quite the contrary. It just seemed like it might be a rehashing of previous information. But I’m so glad I resisted the urge to grab that extra danish, and attended Don Price’s presentation. In it, he revealed a glimpse of TE Connectivi- ty’s approach to some of the major issues surrounding crimping aluminum wire. It seems the industry is finally get- ting some traction with high volume, reliable aluminum crimp crimping. I wrote an article for Wiring Harness News back in 2012, on the pressures from auto manufacturers to replace cop- per with aluminum wherever possible. At that time, Randy Sumner of Delphi advised that designing new aluminum terminals would defeat any cost savings. He further stated that whoever could come up with the most innovative solu- tion for sealing these junctions, without a secondary process like epoxy shields or heat shrink, would have a competi- tive advantage. The answer had to come in the crimp itself. It seems TE has come a long way towards that goal. Eager to see if I could dig even deeper into the new TE technology, I scheduled an inter- view with Dave Fleak, Automotive Prod- uct Manager for TE Transportation Solu- tions, in Winston-Salem, NC. TE Connectivity has been in the alu- minum crimping market in some fash- ion for some 30 years, according to Fleak. “Even today, we’re heavily in the appliance, and military/aerospace industries,” for which, surprisingly, TE actually makes aluminum wire, he noted. “Now the dynamics of crimping wires for an aircraft, versus the economies of crimping for 15 to 20 mil- lion vehicles, are quite different,” he said, ________________Continued on page 28 Gary (left) and Glenda Martinet (right) with the Automatic Coax & Cable (ACC) team. people – led Gary Martinet to buy the equipment in the first place. While working as a rep selling screw-machine parts and custom molded plastics, he learned that a customer needed cable assemblies. When Martinet came across the equipment stashed in the back of the garage of a woman holding a rum- mage sale, he made a connection. Despite the equipment purchase depleting the Martinets’ personal sav- ings account to only $100 and Gary hav- ing no background in cable assembly, Glenda embraced what he had done. “He’s always been an entrepreneur,” she said. ________________Continued on page 52 Crimp Force Monitoring “The Recipe for Success” By Gustavo Garcia-Cota, Crimping Product Manager, Schleuniger, Inc. __________________________________ I n my line of work, I have the priv- ilege of visiting many wiring har- ness shops that produce wiring harnesses for many different industries. One of the common issues I’ve noticed when visiting shops that use crimp force monitors (CFMs) is that the CFMs are usually turned off, regardless of the brand, because engineers and operators are not using them properly. While I hope this does not apply to your specif- ic situation, it may be worth paying an unexpected visit to your crimping work areas to look for indications of whether the CFMs are being used regularly. Chances are they are not. Unless of course it’s audit time, then you can be sure all the CFMs will be on! Why, with all of their benefits, are CFMs not being used regularly by employees? One of the biggest problems is the lack of understanding of the vari- ables affecting the CFM’s ability to detect variations. Crimp quality detec- tion is similar to baking a cake. There are a lot of ingredients and if one ingredient is missing or of bad quality, you likely are not going to achieve your desired result. This article will go back through the basics of a crimp quality detection sys- tem and discuss what ingredients or variables you need to consider before switching off that CFM. What can CFMs actually detect? One very basic and important con- cept that needs to be understood in order to achieve successful crimp force monitoring is “what a CFM can actually detect.” There is a general assumption within the industry that crimp force monitoring will provide reliable detec- tion of all general crimping errors dur- ing processing, including: • Wrong strip length • Missing strands • Wrong wire cross section • Wrong terminal • Inconsistent terminal material • Insulation in wire crimp • Wrong insertion depth • Wrong crimp height Is this assumption correct? It depends! While this is not a very scien- tific answer, it is the correct one. What many people fail to realize is that simply plugging in a CFM will not solve all their ________________Continued on page 22