Abstract: A system for mounting an electrical terminal applicator to a cassette containing a plurality of terminals is provided. The system includes a support plate for fixedly attaching to the applicator, and a yoke releasably attached to the support plate. The yoke and support plate define an attachment therebetween providing at least one degree of freedom of motion of the support plate relative to the yoke in an attached state. The yoke is further configured to be movably mounted to the cassette with at least one additional degree of freedom of motion.

Abstract: A system for mounting an electrical terminal applicator to a cassette containing a plurality of terminals is provided. The system includes a support plate for fixedly attaching to the applicator, and a yoke releasably attached to the support plate. The yoke and support plate define an attachment therebetween providing at least one degree of freedom of motion of the support plate relative to the yoke in an attached state. The yoke is further configured to be movably mounted to the cassette with at least one additional degree of freedom of motion.

Abstract: A terminal locator for a hand tool includes a base, a magnet, and a holder attached to the base and rotatable with respect to the base between an open position and a closed position. The holder has a magnet passageway and a resilient latch retaining the magnet in the magnet passageway.

Abstract: A system for mounting an electrical terminal applicator to a cassette containing a plurality of terminals is provided. The system includes a support plate for fixedly attaching to the applicator, and a yoke releasably attached to the support plate. The yoke and support plate define an attachment therebetween providing at least one degree of freedom of motion of the support plate relative to the yoke in an attached state. The yoke is further configured to be movably mounted to the cassette with at least one additional degree of freedom of motion.

Abstract: A terminal locator for a hand tool includes a base, a magnet, and a holder attached to the base and rotatable with respect to the base between an open position and a closed position. The holder has a magnet passageway and a resilient latch retaining the magnet in the magnet passageway.

Abstract: A terminal crimping device includes crimp tooling comprising an anvil and a ram movable toward the anvil with a crimp zone being defined between the anvil and the ram configured to receive a wire and a terminal configured to be crimped to the wire by the crimp tooling. An ultrasonic transmitting transducer is coupled to at least one of the anvil and the ram that transmits acoustic signals through the wire and terminal. A filter is provided on at least one of the anvil and the ram in the path of the acoustic signals that affects the acoustic signals.

Abstract: A terminal crimping device includes crimp tooling comprising an anvil and a ram. A crimp zone is defined between the anvil and the ram. The crimp zone is configured to receive a wire and a terminal. The crimp tooling crimps the terminal to the wire during a crimp stroke. The terminal crimping device also includes an ultrasonic transducer module having at least one ultrasonic transducer held by at least one of the anvil or the ram. The ultrasonic transducer generates a plurality of ultrasonic pulses during the crimp stroke and directs the ultrasonic pluses through the terminal. The ultrasonic transducer receives the ultrasonic pulses and generates ultrasonic data based on the received ultrasonic pulses. The terminal crimp tooling also includes a crimp quality module communicatively coupled to the ultrasonic transducer module. The crimp quality module performs coherent processing of the ultrasonic data to determine a crimp quality.

Abstract: A terminal crimping device includes crimp tooling and a seal depressor fixed to the crimp tooling. The crimp tooling and the seal depressor move with a movable ram along a crimp stroke towards and away from a base that receives a wire assembly and a terminal thereon. The crimp tooling crimps the terminal to both a wire and a compression seal of the wire assembly during the crimp stroke. The seal depressor has a contact tab that engages and at least partially depresses the compression seal of the wire assembly during the crimp stroke to hold the compression seal in place as the crimp tooling crimps the terminal to the wire assembly.

Abstract: A terminal crimping device includes crimp tooling and a seal depressor fixed to the crimp tooling. The crimp tooling and the seal depressor move with a movable ram along a crimp stroke towards and away from a base that receives a wire assembly and a terminal thereon. The crimp tooling crimps the terminal to both a wire and a compression seal of the wire assembly during the crimp stroke. The seal depressor has a contact tab that engages and at least partially depresses the compression seal of the wire assembly during the crimp stroke to hold the compression seal in place as the crimp tooling crimps the terminal to the wire assembly.

Abstract: A terminal crimping device includes crimp tooling including an anvil and a ram movable toward the anvil with a crimp zone being defined between the anvil and the ram configured to receive a wire and a terminal configured to be crimped to the wire by the crimp tooling. An ultrasonic transducer is coupled to at least one of the anvil and the ram that receives acoustic signals sent through the wire and terminal. A crimp quality module receives signals from the ultrasonic transducer. The crimp quality module determines a crimp height of the terminal based on the acoustic signal received by the ultrasonic transducer. Optionally, the crimp height may be determined based upon a transmission time of the acoustic signal from a transmitting transducer to a receiving transducer. The crimp height may be determined based upon a speed of sound transmission coefficient of the terminal and the wire.

Abstract: A terminal crimping device includes crimp tooling defining a crimp zone configured to receive a wire and a terminal. The terminal is configured to be crimped to the wire by the tooling during a crimp stroke of the crimp tooling to form a crimped terminal. The crimp tooling includes an ultrasound module ultrasonically coupled to the crimp tooling and the wire and the crimped terminal when present. The ultrasound module transmits acoustic signals through the crimped terminal and the wire. The ultrasound module also receives echo acoustic signals being reflected back to the ultrasound module. The ultrasound module generates echo signals based on the echo acoustic signals. The terminal crimping device also includes a crimp quality module that receives the echo signals from the ultrasound module and determines a crimp height of the crimped terminal based on the reflected echo acoustic signals received by the ultrasound module.

Abstract: A terminal crimping device includes crimp tooling including an anvil and a ram movable toward the anvil. A crimp zone is defined between the anvil and the ram that receives a wire and a terminal configured to be crimped to the wire by the crimp tooling. An ultrasonic transducer assembly is held by at least one of the anvil and the ram. The ultrasonic transducer assembly is ultrasonically coupled to the terminal and is ultrasonically isolated from the crimp tooling. The ultrasonic transducer assembly may directly engage the terminal. The terminal crimping device may include an isolation member ultrasonically isolating the ultrasonic transducer assembly from the crimp tooling.

Abstract: A terminal crimping device includes crimp tooling comprising an anvil and a ram. A crimp zone is defined between the anvil and the ram. The crimp zone is configured to receive a wire and a terminal. The crimp tooling crimps the terminal to the wire during a crimp stroke. The terminal crimping device also includes an ultrasonic transducer module having at least one ultrasonic transducer held by at least one of the anvil or the ram. The ultrasonic transducer generates a plurality of ultrasonic pulses during the crimp stroke and directs the ultrasonic pluses through the terminal. The ultrasonic transducer receives the ultrasonic pulses and generates ultrasonic data based on the received ultrasonic pulses. The terminal crimp tooling also includes a crimp quality module communicatively coupled to the ultrasonic transducer module. The crimp quality module performs coherent processing of the ultrasonic data to determine a crimp quality.

Abstract: A termination tool includes a frame having a ram cavity and a connector cavity configured to receive an electrical connector therein. A driving handle is coupled to the frame and is movable between an open position and a closed position. A primary ram assembly is received in the ram cavity and is coupled to the driving handle. The primary ram assembly is configured to engage the electrical connector. A secondary ram assembly is received in the ram cavity and coupled to the driving handle. The secondary ram assembly is configured to engage the electrical connector. The primary and secondary ram assemblies are actuated by the driving handle along different primary and secondary strokes as the driving handle is moved from the open position to the closed position.

Abstract: A terminal crimping device includes crimp tooling including an anvil and a ram movable toward the anvil. A crimp zone is defined between the anvil and the ram that receives a wire and a terminal configured to be crimped to the wire by the crimp tooling. An ultrasonic transducer assembly is held by at least one of the anvil and the ram. The ultrasonic transducer assembly is ultrasonically coupled to the terminal and is ultrasonically isolated from the crimp tooling. The ultrasonic transducer assembly may directly engage the terminal. The terminal crimping device may include an isolation member ultrasonically isolating the ultrasonic transducer assembly from the crimp tooling.

Abstract: A terminal crimping device includes crimp tooling comprising an anvil and a ram movable toward the anvil with a crimp zone being defined between the anvil and the ram configured to receive a wire and a terminal configured to be crimped to the wire by the crimp tooling. An ultrasonic transmitting transducer is coupled to at least one of the anvil and the ram that transmits acoustic signals through the wire and terminal.

Abstract: A terminal crimping device includes crimp tooling defining a crimp zone configured to receive a wire and a terminal. The terminal is configured to be crimped to the wire by the tooling during a crimp stroke of the crimp tooling to from a crimped terminal. The crimp tooling includes an ultrasound module ultrasonically coupled to the crimp tooling and the wire and the crimped terminal when present. The ultrasound module transmits acoustic signals through the crimped terminal and the wire. The ultrasound module also receives echo acoustic signals being reflected back to the ultrasound module. The ultrasound module generates echo signals based on the echo acoustic signals. The terminal crimping device also includes a crimp quality module that receives the echo signals from the ultrasound module and determines a crimp height of the crimped terminal based on the reflected echo acoustic signals received by the ultrasound module.

Abstract: A terminal crimping device includes crimp tooling including an anvil and a ram movable toward the anvil with a crimp zone being defined between the anvil and the ram configured to receive a wire and a terminal configured to be crimped to the wire by the crimp tooling. An ultrasonic transducer is coupled to at least one of the anvil and the ram that receives acoustic signals sent through the wire and terminal. A crimp quality module receives signals from the ultrasonic transducer. The crimp quality module determines a crimp height of the terminal based on the acoustic signal received by the ultrasonic transducer. Optionally, the crimp height may be determined based upon a transmission time of the acoustic signal from a transmitting transducer to a receiving transducer. The crimp height may be determined based upon a speed of sound transmission coefficient of the terminal and the wire.

Abstract: A termination tool includes a frame having a ram cavity and a connector cavity configured to receive an electrical connector therein. A driving handle is coupled to the frame and is movable between an open position and a closed position. A primary ram assembly is received in the ram cavity and is coupled to the driving handle. The primary ram assembly is configured to engage the electrical connector. A secondary ram assembly is received in the ram cavity and coupled to the driving handle. The secondary ram assembly is configured to engage the electrical connector. The primary and secondary ram assemblies are actuated by the driving handle along different primary and secondary strokes as the driving handle is moved from the open position to the closed position.

Abstract: A compression tool for terminating wires to a connector includes a frame that has a receiving space configured to receive the connector. A handle is rotatably coupled to the frame. A ram is held by the frame. The ram has an engagement end within the receiving space that is configured to engage the connector. The ram is movable between an initial position and a final position. A link is coupled between the ram and the handle. The link is variably positionable with respect to at least one of the handle or the ram to change the final position of the ram within the receiving space to control a shut height of the compression tool.