Group standard VW 60334

Issue 2016-07
Class. No.: 69606

Descriptors: connector, contact, crimp, crimped connection, electrical connection, solderless connection

Crimped Connection on Aluminum Cables

Solderless Electrical Connections

Contents
Page
1 Scope ......................................................................................................................... 2
2 Terms and definitions ................................................................................................. 2
2.1 Open crimp barrels ..................................................................................................... 4
2.2 Self-covering crimp barrels ........................................................................................ 5
2.3 Front cover crimp ....................................................................................................... 5
2.4 Conductor crimp ......................................................................................................... 5
2.5 Insulation crimp .......................................................................................................... 5
2.6 Additives ..................................................................................................................... 5
2.7 Single-wire seal crimp ................................................................................................ 5
3 Requirements ............................................................................................................. 5
3.1 General requirements ................................................................................................ 5
3.2 Requirements for the cable ........................................................................................ 6
3.2.1 Cable .......................................................................................................................... 6
3.2.2 Stripping ..................................................................................................................... 6
3.2.3 Conductor end ............................................................................................................ 7
3.3 Requirements for the crimped contact element ......................................................... 8
3.3.1 Contact elements ....................................................................................................... 8
3.3.2 Damage ...................................................................................................................... 8
3.3.3 Compatibility with ultrasonic welding .......................................................................... 8
3.3.4 Bending and twisting .................................................................................................. 8
3.3.5 Cable bending ............................................................................................................ 9
3.3.6 Material removal and chip formation .......................................................................... 9
3.3.7 Severing of strands in single-wire seal contacts ........................................................ 9
3.3.8 Section planes ............................................................................................................ 9
3.3.9 Requirements for the front cover crimp microsection image .................................... 10
3.3.10 Conductor crimp dimensions .................................................................................... 10
3.3.10.1 Crimp height ............................................................................................................. 11
3.3.10.2 Crimp width .............................................................................................................. 12
3.3.10.3 Supporting angle ...................................................................................................... 12
3.3.10.4 Supporting length ..................................................................................................... 13
3.3.10.5 Flank end clearance ................................................................................................. 13
3.3.10.6 Distance between crimp flank ends ......................................................................... 14
3.3.10.7 Flash height .............................................................................................................. 14

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3.3.10.8 Flash width ............................................................................................................... 14

3.3.10.9 Base thickness ......................................................................................................... 15
3.3.11 Conductor crimp design ........................................................................................... 15
3.3.11.1 Crimp length ............................................................................................................. 15
3.3.11.2 Cracks and notches ................................................................................................. 16
3.3.11.3 Bellmouth on single-wire seal contact ...................................................................... 17
3.3.12 Insulation crimp ........................................................................................................ 17
3.3.12.1 Bend test for self-covering contacts ......................................................................... 17
3.3.12.2 Insulation crimp, type A (F-crimp) ............................................................................ 19
3.3.13 Single-wire seal crimp .............................................................................................. 19
3.3.13.1 Single-wire seal position .......................................................................................... 19
3.3.13.2 Symmetrical O-shaped single-wire seal crimp (O-crimp) ......................................... 20
3.3.13.3 Asymmetrical O-shaped single-wire seal crimp (wrap crimp) .................................. 20
3.4 Cut-off tab requirements .......................................................................................... 20
4 Making the crimped connection ............................................................................... 21
4.1 General requirements .............................................................................................. 21
4.2 Tools ......................................................................................................................... 21
4.3 Crimping devices ...................................................................................................... 22
4.3.1 Crimp height ............................................................................................................. 22
4.3.2 Conductor pull-out strength ...................................................................................... 22
4.4 Setup process .......................................................................................................... 22
4.4.1 Cable position .......................................................................................................... 22
4.4.2 Microsection image .................................................................................................. 23
4.5 Check during production .......................................................................................... 23
4.5.1 Crimp force monitoring ............................................................................................. 23
4.5.2 Stripping quality monitoring ...................................................................................... 23
4.5.3 Position monitoring ................................................................................................... 24
4.6 Non-destructive testing ............................................................................................ 24
4.7 Destructive testing .................................................................................................... 24
4.7.1 Conductor pull-out force ........................................................................................... 24
4.7.2 Microsection image .................................................................................................. 24
4.7.3 Bend test .................................................................................................................. 25
5 Applicable documents .............................................................................................. 25
Appendix A Tests ......................................................................................................................... 26

1 Scope
This standard specifies the definitions, requirements, and test criteria for evaluating solderless
electrical crimped connections that are produced using open crimp barrels and multi-stranded, fine-
stranded, and ultra-fine stranded conductors made of aluminum.
This standard also specifies the requirements for producing, testing, and evaluating crimped con-
nections.

2 Terms and definitions

The terms and definitions are defined in IEC 60050-581.
For designations, see figure 1 to figure 4
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Legend
1 Contact area
2 Connection A – transition area between mating section and conductor crimp
3 Front cover crimp
4 Conductor crimp
5 Crimped connection
6 Insulation crimp
7 Connection B – transition area between conductor crimp and insulation crimp
8 Cut-off tab
Figure 1 – Self-covering contact example 1

Legend
1 Contact element
2 Possible filler protrusion
3 Closed seam
4 Insulation
Figure 2 – Self-covering contact example 2
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Legend
1 Contact area
2 Connection A – transition area between mating section and conductor crimp
3 Conductor crimp
4 Connection B – transition area between conductor crimp and insulation crimp
5 Single-wire seal crimp
6 Cut-off tab
Figure 3 – Single-wire seal contact example 1

Legend
1 Contact element
2 Conductor end
3 Conductor
4 Single-wire seal
5 Insulation
6 Protruding insulation
Figure 4 – Single-wire seal contact example 2

2.1 Open crimp barrels

Open crimp barrels are conductor or insulation crimps with a U-shaped, V-shaped, or pre-shaped
opening. Open crimp barrels are common with stamped contact elements.
The crimping operation simultaneously closes the open crimp barrel and separates the contact ele-
ment from the support strip.
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2.2 Self-covering crimp barrels

Self-covering crimp barrels are crimps in which corrosion protection is achieved with the use of a
special crimp geometry and the use of additives. Connection A and connection B in particular must
be covered by the corrosion protection.

2.3 Front cover crimp

Covering the front end of the crimp in order to protect from corrosive media ingress is referred to
as the "front cover crimp." The covering action is supported by additives. Any functional limitations
in the contact area are impermissible. The contact part manufacturer must specify the design in a
binding manner.

2.4 Conductor crimp

The connection between the contact element and the stranded conductor is referred to as the
"conductor crimp." The conductor crimp must ensure the permanent electrical connection between
the contact element and the stranded conductor. After the crimping operation is completed, it is im-
permissible for the crimp to expand so that it is not as tight anymore.

2.5 Insulation crimp

The connection between the contact element and the cable at the outer diameter of the insulation
is referred to as the "insulation crimp." The insulation crimp is intended to absorb mechanical loads
and vibrations in order to prevent them from affecting the conductor crimp. When crimped, the in-
sulation crimp envelops the circumferential insulation, holds it in place, and protects against corro-
sive media ingress on the cable side.
For the insulation crimp design type, see section 3.3.10.

2.6 Additives
Additives are used in order improve transverse conductivity and resistance against corrosive me-
dia. 100% process control regarding the application surface, weight, and positioning is required.
The measures must be agreed upon with the appropriate department. The additives must be used
as per the contact part manufacturer's specifications. The use of additives always requires the ap-
proval of the appropriate department. The contact part manufacturer must specify, in a binding
manner, the additives to be used, as well as their application and storage.

2.7 Single-wire seal crimp

A single-wire seal crimp is a connection between the contact element and the single-wire seal es-
tablished by means of compression deformation. The single-wire seal crimp must ensure the per-
manent fit of the single-wire seal on the contact element.
For the single-wire seal crimp design types, see section 3.3.13.

3 Requirements

3.1 General requirements

Crimped connections must be implemented as per the drawing specifications in the version cur-
rently in effect. The contact part manufacturer must specify the part-specific crimp dimensions
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(crimp height, crimp width, etc.) in a binding manner and document them in the standard part draw-
ing. The specified crimp dimensions must be adhered to. There must not be any mechanical dam-
age or twisting or bending of the support strip or contact elements before processing.
Overall requirements for the performance of component development contracts as per Volkswagen
standard VW 99000

3.2 Requirements for the cable

3.2.1 Cable
Only cables with bright strands released by Volkswagen may be used (see VW 60306-2). The
drawing specifications are binding. This standard is not applicable to solid cables or flat cables.
The electrical conductor must not be hot-dip-galvanized or soldered.
The manufacturer specifications regarding shelf life must be adhered to. Processing after the shelf
life has expired is impermissible. Cable material with properties that have been adversely affected
within the permissible processing time must not be used. An issued build sample approval (BMG)
becomes valid only after process capability verification agreed upon with the appropriate depart-
ment has been provided.

3.2.2 Stripping
Stripping must be done with suitable tools using a process that is verifiably reliable. Strands in the
conductor must not be cut off, torn off, or pulled out during the process. Notches on the strands
resulting from cutting with the wire stripper are impermissible. Signs of scraping on strands result-
ing, e.g., from the axial movement of the wire stripper when pulling off the insulation are permissi-
ble. Corresponding monitoring must be installed. The contact part manufacturer must specify the
strip lengths in a binding manner. A maximum of 0,25 mm is permissible for the diagonal cut at the
end of the cable. The insulation must be cut smoothly and perpendicular to the conductor and then
pulled off.
Protruding strands are impermissible (see figure 5).

Figure 5 – Protruding strands

If the stripped cable will not be processed immediately, the stripped ends must be protected from
fraying with, e.g., insulating sleeves. Possible reasons for delayed processing include, e.g., a num-
ber of immediate connections in series on one side or splices.
After pulling off the insulation, the conductor strands must not fan out by more than 25% (relative to
the conductor diameter at the edge of the stripped area) (see figure 6).
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Figure 6 – Stranded conductor fanning out

Unclean cutting of the insulation, damage to the insulation, and the presence of insulation remains
on the stripped portion of the conductor during and after stripping are impermissible (see figure 7).

Figure 7 – Faulty insulation

Strands must not be twisted too tightly in order to prevent strands from being damaged or severed
during the crimping operation or ultrasonic welding (see figure 8).

Figure 8 – Conductor end twisted too tightly

3.2.3 Conductor end

The conductor end (see figure 9) projects beyond the end of the conductor crimp.
Cable cross section: (2,5 – 6,0) mm2
Conductor protrusion: (0,2 – 1,0) mm
The plugging and locking functions of the contact element must not be negatively affected by the
projecting end of the conductor. In general, projecting strands (see figure 10) must not negatively
affect the system properties or the housing's function.

Figure 9 – Maximum protrusion of the conductor end

Figure 10 – Projecting strands

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For self-covering crimps, the part-specific insertion position or the position of the conductor end in
the setup process must be documented and verified with release samples (longitudinal section).
The contact part manufacturer must define the section planes in a binding manner and specify
them in a corresponding processing specification. It must be reliably verified that specifications are
adhered to during cable manufacture.

3.3 Requirements for the crimped contact element

3.3.1 Contact elements

The contact elements used must conform to the requirements and specifications of the standard
part drawing. Contact material with properties that have been adversely affected must not be used.
The contact part manufacturer must specify the maximum shelf life of the contacts before process-
ing in a binding manner. It must be ensured that adherence to the maximum shelf life can be
checked. The contact material must conform to VW 75174 and the corresponding standard part
drawing.

3.3.2 Damage
The contact area (see figure 1) and the locking lances must not be damaged or deformed after the
crimping operation. Deformation of the contact element as a result of crimping in its contact area is
impermissible.

3.3.3 Compatibility with ultrasonic welding

Since ultrasonic welding can be required in order to process the contact parts and cables or for
cable manufacture, the contact part manufacturer must confirm compatibility with ultrasonic weld-
ing or specify a corresponding minimum distance.

3.3.4 Bending and twisting

Unless otherwise specified in the standard part drawing, the following requirements apply: The lat-
eral bending of the longitudinal axis must not be greater than 3° to each side in the crimp area (see
figure 11).

Figure 11 – Lateral bending

The bending of the longitudinal axis in the crimp area must not be greater than 5° upward or down-
ward. Twisting of the crimp area relative to the contact body must not exceed 5° (see figure 12).
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Figure 12 – Bending of the longitudinal axis of the contact element

3.3.5 Cable bending

Directly after crimping, the cable can have an offset in any direction. This offset is unavoidable due
to the crimp design, the high degree of compression, and the associated extreme elongation of the
cable inside the crimp. Suitable measures must be taken in order to reduce the offset. The permis-
sible extent of the offset must be agreed upon with the appropriate department.

3.3.6 Material removal and chip formation

For the self-covering contacts, an insulation material that is defined by the system and is crimped
onto the crimp barrel from outside, as well as an insulation material that is bearing against the
crimp barrel or sticking out from it, is permissible.

3.3.7 Severing of strands in single-wire seal contacts

It is permissible for there to be visible deformed strands in connection area B. It is impermissible
for strands to be severed in connection area B.

3.3.8 Section planes

For self-covering crimp barrels, sections through all areas of the contact are required (see
figure 13). These sections must be prepared as per the specifications from the appropriate manu-
facturer or the contact part manufacturer. The contact part manufacturer must define the evaluation
and acceptance criteria in a binding manner.
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Legend
1 Cross section (opposite the crimp opening): Front cover crimp
2 Cross section (opposite the crimp opening): Conductor crimp
3 Cross section (opposite the crimp opening): Insulation crimp
4 Longitudinal section (approximately parallel to the crimp base)
Figure 13 – Section planes for self-covering crimp

3.3.9 Requirements for the front cover crimp microsection image

The front cover ears must be curled (see figure 14). Cracking on the crimp base is impermissible.

Figure 14 – Sample microsection image for front cover crimp

3.3.10 Conductor crimp dimensions

See figure 15.
The corresponding dimensional specifications must be taken from the part drawings for the con-
tacts.
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Legend
1 Crimp height Ch
2 Crimp width Cw
3 Measurable crimp width Cwm
4 Supporting angle αs
5 Supporting length Ls
6 Flank end clearance Fc
7 Distance between crimp flank ends (CFE)
8 Flash height Fh
9 Flash width Fw
10 Base thickness tb
Figure 15 – Conductor crimp dimensions

The thickness of the contact material in the crimp area (S) must be taken from the standard part
drawing. Limits are specified for the indicated crimp dimensions. Any deviating values specified in
standard part drawings are binding.
Uneven curling of the two crimp flanks is permissible, provided that the requirements for the sup-
porting length, supporting angle, and distance between crimp flank ends are adhered to.
The specified crimp dimensions must be tested as per the specifications in table A.1 and documen-
ted by the wiring harness manufacturer.

3.3.10.1 Crimp height

The crimp height must be measurable using a nondestructive method.
The crimp height is a crimped connection dimension that is not defined by the tool, i.e., it is adjust-
able (conductor and insulation crimps).
The crimp height is specified by the contact element manufacturer and must be documented in the
standard part drawing for the corresponding contact element.

Conductor crimp:
The crimp height is a dimension that can primarily be influenced with the crimping process and is
crucial for the crimp resistance values and the stability of these values.
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The crimp height measurement is taken in the center of the conductor crimp with suitable measur-
ing equipment.
Example: crimp height dial gage (see figure 16)

Figure 16 – Crimp height measurement using a special dial gage

Insulation crimp:
The crimp height is a dimension that can primarily be influenced with the crimping process and is
crucial for cable-side crimp protection against corrosive media ingress. The insulation crimp height
is measured perpendicular to the anvil impression, as close as possible to the cut-off tab.
The crimp must be positioned in such a way as to have 3-point support. The crimp must be preven-
ted from tilting.

3.3.10.2 Crimp width

The crimp width is a crimped connection dimension that is defined by the tool, i.e., it is not adjusta-
ble (conductor and insulation crimps).
The crimp width is specified by the contact element manufacturer and is documented on the stand-
ard part drawing of the corresponding contact element. The width of the crimp at the crimp base
can be determined with a dial gage, for example.

3.3.10.3 Supporting angle

The supporting angle can only be determined with a microsection image (cross section in conduc-
tor crimp). The supporting angle must not deviate by more than 30° from the vertical (αs ≤ 30°); see
figure 17.
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Figure 17 – Supporting angle

3.3.10.4 Supporting length

The supporting length can only be determined with a microsection image (cross section in conduc-
tor crimp).
As a minimum requirement, the supporting length for the crimp flank ends must correspond to the
following portion of the contact material thickness as a function of the cable cross section (see
figure 18):
Cable cross sections 2,5 mm2, 4,0 mm2, 6,0 mm2: Ls ≥ 0,1 mm
The specifications of the release drawing are always binding (see section 4.1).

Figure 18 – Supporting length

3.3.10.5 Flank end clearance

The flank end clearance can only be determined with a microsection image (cross section in con-
ductor crimp). None of the crimp flank ends must abut the inner wall of the crimp barrel (see
figure 19).
Fc ≥ 0,1 S
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Figure 19 – Symmetry and curling depth

3.3.10.6 Distance between crimp flank ends

The distance between crimp flank ends can only be determined with a microsection image (cross
section in conductor crimp).
Distance between crimp flank ends curled on opposite sides (see figure 20).
CFE = Ix1 – x2I
CFE ≤ S

Figure 20 – Crimp flank ends

3.3.10.7 Flash height

The height of the flash is affected by the degree of wear of the crimping tool and the feed settings
(see figure 21).
Fh ≤ 1 × S

3.3.10.8 Flash width

Fw ≤ 0,5 × S, (see figure 21)
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Legend
1 Flash height Fh
2 Flash width Fw
3 Crack
Figure 21 – Flash at crimp base

3.3.10.9 Base thickness

The base thickness can only be determined with a microsection image (see figure 22).
tb ≥ 0,75 S

Legend
1 Base thickness tb
Figure 22 – Base thickness

3.3.11 Conductor crimp design

3.3.11.1 Crimp length

On self-covering crimps, the crimp barrel is closed across its entire length and tapers in a funnel
shape in the transition area between the conductor and insulation crimps after processing. There
must not be any visible open points or conductor material. Insulation material that prevents the
seam from closing must not project from the seam, and the crimp flanks must not be unevenly
curled (flaw caused by excessive force). It is permissible for there to be insulation chips resting out-
side.
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Due to the contact geometry, aluminum may become visible in the conductor crimp area in the
case of single-wire seal contacts (see figure 23). This material deposition is permissible from con-
nection area B (see figure 3) to, at most, the center of the conductor crimp area. The curled flanks
support each other.

Legend
1 Crimp length
2 Front bellmouth
3 Rear bellmouth
Figure 23 – Crimp length and bellmouth on single-wire seal contact

The crimp flank seam on self-covering contacts must be closed (see figure 2). There must not be
any open points, and no insulation or conductor material must project from the seam. The crimp
barrel is closed across its entire length and tapers in a funnel shape in the transition area between
the conductor and insulation crimps after processing.

3.3.11.2 Cracks and notches

Cracks and notches can result from, e.g., poor crimping tool condition or the stamping quality at
the crimp base in particular. This does not apply to:
– Wrinkles that can occur on the inside of the curls
– Impressions required for the crimped connection's function
Cracks and notches are impermissible (see figure 24).

Legend
1 Crack
Figure 24 – Crack in the crimp base
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3.3.11.3 Bellmouth on single-wire seal contact

A bell-shaped runout (bellmouth) is required at the rear edge of the conductor crimp towards the
cable (see figure 18). This bellmouth must prevent the strands from being notched or severed.
Strand deformation that is not relevant to function and that occurs as a result of the high compres-
sion is permissible.
No bellmouth is absolutely required at the front edge of the conductor crimp towards the contact. A
front bellmouth of equal or lesser size as the rear bellmouth is permissible.

3.3.12 Insulation crimp

The insulation crimp of the contact element must be designed as per the standard part drawing for
a cable as per VW 60306-2. The insulation end is crimped in the transition between the conductor
and insulation crimps and is not visible after processing. The crimp claws must dip into the insula-
tion. The insulation may be punctured by the crimp claws, but this must not result in the strands
being severed. The insulation end must not be crimped in the conductor crimp. A correct position
must be ensured. The insulation must not be cut through at the inlet to the crimp barrel.

3.3.12.1 Bend test for self-covering contacts

The bend test (see figure 25) is a destructive test. The test objects must not continue to be used.
A bend test must be used to verify that the insulation is being held correctly in the insulation crimp.

Legend
1 Bend 90° up
2 Bend 180° down
3 Bend 90° up
Figure 25 – Bend test

The bend test must be carried out on 5 test objects as per figure 25.
The contact elements must be crimped with aluminum cables as per VW 60306-2.
The minimum cable length is 150 mm. For cable lengths under 300 m, both sides must be crimped.
One bend test cycle contains 3 bends in the up, down, right, and left directions each. The contact
must be held in a suitable housing or in a comparable retainer as per the specifications in the in-
stallation guideline for the contact part or as per the housing manufacturer's specifications. The
housing that must be used must be agreed upon with the appropriate department.
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It is impermissible for the housing to have a positive influence (e.g., a smaller bend radius or deep-
er dipping into the housing). After the bend test, the insulation must not have slipped out of the
insulation crimp or been severed.
There must not be any visible conductor material (visual inspection with microscope or magnifying
glass with 5x magnification).
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3.3.12.2 Insulation crimp, type A (F-crimp)

See figure 2 and figure 26.

Legend
CW2 Insulation crimp width
CW2m Measurable insulation crimp width
CH2 Insulation crimp height
Figure 26 – Dimensions for type A insulation crimp

The crimp width and crimp height dimensions specified in the standard part drawing must be ad-
hered to.
The insulation crimp ears must curl in and the flanks must touch each other. The flank ends are
allowed to penetrate the insulation or pierce it and touch the conductor, but must not sever any
strands. The insulation is gripped along its entire perimeter without any gaps. The grips penetrate
the insulation. They are allowed to pierce it and touch the conductor. On the cable-side end of the
insulation crimp, the insulation must be crimped along its entire perimeter. A visible conductor at
the cable-side end of the insulation crimp, e.g., due to an incorrect insulation end position or sev-
ered insulation, is impermissible.
The bend test as per section 3.3.12.1 must be fulfilled.

3.3.13 Single-wire seal crimp

The crimp flanks must be curled to the extent that the single-wire seal is maintained reliably when
the contact is fitted into the pin housing.

3.3.13.1 Single-wire seal position

The insulation crimp ears must rest against the single-wire seal along the entire length. The single-
wire seal must not be damaged or punctured by the crimp flanks.
The single-wire seal is positioned as per figure 27.
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Figure 27 – Position of single-wire seal in the crimp pattern from the standard part drawing

3.3.13.2 Symmetrical O-shaped single-wire seal crimp (O-crimp)

The insulation crimp ears wrap around the single-wire seal by a maximum of 360°. Overlapping of
the crimp claws is impermissible (see figure 28).

Figure 28 – Symmetrical O-shaped single-wire seal crimp

3.3.13.3 Asymmetrical O-shaped single-wire seal crimp (wrap crimp)

The insulation crimp ears wrap around the single-wire seal by more than 360° (see figure 29).

Figure 29 – Asymmetrical O-shaped single-wire seal crimp

3.4 Cut-off tab requirements

The cut-off tab (see figure 30) must be visible at least at the shoulder and must not project beyond
the measuring edge by more than 0,3 mm for self-covering crimps or 0,5 mm for single-wire seal
crimps (see figure 31).
Flash is allowed at the measuring edge.

Figure 30 – Cut-off tab

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Figure 31 – Measuring edge on the cut-off tab

Independently of the design type (insulation crimp or single-wire seal crimp), the cut-off tab and
flash must not negatively affect the contact's plugging function or its installation in the housing.
The cut-off tab and flash must not damage the single-wire seal.
These requirements also apply to later removal and reinstallation of the contact element, e.g., for
rework.

4 Making the crimped connection

4.1 General requirements

The quality of a crimped connection can only be measured to a limited extent without destruction.
Consequently, the required quality of the crimped connection and, thus, its functional capability,
can only be achieved if the following are used and adhered to respectively:
– Genuine manufacturer tools, wear parts, and consumables
– Suitable machines with verified repeat accuracy
– Preventive maintenance for the specified machines, tools, and wear parts
– Proper and qualified operation
– Effectively and reliably applied 100% process assurance with suitable tools (e.g., fixture, cut
monitoring, position monitoring, crimp force monitoring, pull-out force measurement)

The assurance measures to be used must be agreed upon with the contact part manufacturer and
the department responsible for the release.

4.2 Tools
The use of genuine crimping tools and inserts (wear parts) is required because the contact part
manufacturer is responsible for the system. The respective standard part drawings of the contact
part manufacturer, which are made available to the cable manufacturer via Audi BusinessNet, form
the basis for this.
The contact part manufacturer has system responsibility for the contact part.
The cable manufacturer is responsible for the entire crimping process.
Justified deviations from these specifications require the approval of the appropriate Contact
Development and Quality Assurance departments of the vehicle manufacturer.
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Genuine crimping tools and genuine wear parts are crimping tools and wear parts which have been
confirmed by the crimping manufacturer for use in the relevant contact. The crimp dimension
specifications of the contact drawing and this standard must always be adhered to.

4.3 Crimping devices

The only permissible crimping devices are fully automatic cable processing machines that have a
conductor gripper position repeat accuracy ≤ ±0,1 mm. In addition, the crimping device must en-
sure a defined applicator position that remains constant during the setup operation and the running
process. Equipment for the continuous automatic 100% monitoring of the crimp force is required.
The following characteristics must be adhered to during the running process and must be ensured
with capability verifications for the crimping device:
– Axial positional tolerances are adhered to
– No severed strands during or after stripping by the wire stripper
– The strip length and stripping quality are adhered to

Crimping devices must be equipped in such a way that a consistently high crimping quality is en-
sured and faulty parts can be sorted out reliably.
The processing quality and repeat accuracy must be verified and documented with the Q matrix
(see table A.1 and table A.2).
The Q matrix defines the scopes that must be tested for release tests and checks during produc-
tion depending on the type of release.

4.3.1 Crimp height

50 crimped connections are crimped with the nominal crimp height as per the release drawing (all
cross section variants) and the crimp heights are measured.
Crimp height requirement: Cmk ≥ 2,0

4.3.2 Conductor pull-out strength

20 crimped connections are crimped with every possible cross section, each with the minimum and
maximum crimp heights, respectively, as per the release drawing in all cross section variants.
Requirement for minimum conductor pull-out force Fmin: (xˉarithm. - 3σ) > Fmin

4.4 Setup process

4.4.1 Cable position

The cable position in the setup process is crucial for adherence to the process tolerances. The tip
of the cable (front edge) must be positioned flush with the reference line. The contact part manu-
facturer must specify the position of the reference line in a binding manner. In the setup process,
the cable is parallel to and resting on the knife. The contact is resting over the anvil without any
external force influences. If the contact is patently inclined at the time of setup, the next contact on
the support strip must be used or the current contact must be aligned relative to the anvil during
setup. The set position must be documented.
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VW 60334: 2016-07

4.4.2 Microsection image

The conductor and insulation positioning in the closed crimp barrel must be verified and documen-
ted with the longitudinal section in the conductor axis in the direction of the conductor end. The
conductor end is lined up at the front cover ears. A gap relative to the front cover ears is permissi-
ble as long as all serrations are covered by conductor material during the setup process.
On both sides, the insulation is a maximum of one contact material thickness in front of the insula-
tion-crimp-side start of the taper or projects all the way to the center of the taper. Insulation materi-
al must not extend all the way to the serrations in the conductor crimp (see figure 32).

Figure 32 – Longitudinal microsection image

4.5 Check during production

4.5.1 Crimp force monitoring

The crimp force monitoring is a load-displacement measurement during the crimping tool's work
stroke. The load-displacement curve for an OK crimp moves within the target curve. This target
curve is determined by a calibration process after:
– Every change in the tool settings
– Every tool clamping, tool change
– Every change of the contact roll

When processing aluminum, the crimp force monitoring can only be used as a complementary as-
surance tool for the insertion position. Missing and damaged contact parts or tools continue to be
monitored.

4.5.2 Stripping quality monitoring

Only properly stripped cables are allowed to be used in the crimping process. A reliable process
must be used to verify that:
– incorrect strip lengths
– strand fraying
– pulled-out strands
– insulation remains on the stranded conductor
are detected and faulty parts are automatically disposed of.
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VW 60334: 2016-07

4.5.3 Position monitoring

During contact processing, it must be ensured, during the process, that the cable position is being
adhered to. The axial positional tolerances of the conductor tip in the cable gripper arm (machine
fixing point ±0,25 mm) must be monitored during the process.

4.6 Non-destructive testing

For the crimp dimensions, see section 3.3.10

4.7 Destructive testing

4.7.1 Conductor pull-out force

The conductor pull-out force from the conductor crimp is measured as an accompanying produc-
tion check (see table 1). It is carried out for self-covering crimp barrels with effective insulation grip-
ping. The following minimum conductor pull-out force values are required:

Table 1 – Required minimum values for the conductor pull-out force

Cable cross sec- Contact size

tion in mm2 1,2/1,5 2,8 4,8 9,5
2,5 70 N (105 N) 70 N (105 N) 70 N (105 N) -
4,0 - 110 N (125 N) 110 N (125 N) 110 N (125 N)
6,0 - - 160 N (175 N) 160 N (175 N)
NOTE 1: If, due to system-relevant reasons, the conductor pull-out strength is measured with an
insulation crimp/single-wire seal, the values in parentheses apply.

4.7.2 Microsection image

Microsection images must be prepared for evaluating the crimp quality achieved with the crimping
tool.
It must be ensured that the machining direction is opposite to the crimp opening so that no forces
that could open the crimp occur during sectioning.
For tests that are not conducted during production, the part must be cast in synthetic resin in order
to prevent changes to the crimp when the microsection is prepared.
In order to make sure that microsections can be evaluated properly, the surface can be polished or
etched after the crimp is sectioned. The quality of the specimen surface must make it possible to
clearly evaluate the characteristics.

Microsection preparation
When monitoring the conformity of production, the synthetic resin casting step for specimens can
be omitted. Microsection images are prepared with suitable fixtures while meeting the correspond-
ing requirements.
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VW 60334: 2016-07

Unless otherwise required, the Q matrix applies (see table A.1 and table A.2).
The following specifications must be documented:
– Contact part number
– Contact part supplier
– Part number and manufacturer of the cable yard good
– Microsection images and measured values for crimp heights and widths for the front cover,
conductor, and insulation crimps
– Longitudinal microsection image
– Image magnification factor
– Identification of cutting batch, incl. cutting order (number of production batch)

4.7.3 Bend test

For requirements, see section 3.3.12.1

5 Applicable documents
The following documents cited in the standard are required for the application of this standard:
Some of the cited documents are translations from the German original. The translations of Ger-
man terms in such documents may differ from those used in this standard, resulting in terminologi-
cal inconsistency.
Standards whose titles are given in German may be available only in German. Editions in other
languages may be available from the institution issuing the standard.

VW 60306-2 Electrical Cables for Motor Vehicles; Aluminum Cables; Single-Core, Un-
shielded
VW 75147 Wiring Harnesses in Motor Vehicles; Quality Requirements for Products
and Processes
VW 75174 Motor Vehicle Connectors; Tests
VW 99000 Overall Requirements for the Performance of Component Development
Contracts; updated translation: 2022-02
IEC 60050-581 International Electrotechnical Vocabulary – Part 581: Electromechanical
Components for Electronic Equipment
Page 26
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Appendix A (normative) Tests

Table A.1 – Q-Matrix: Release tests

Process ca-
Dimension/ Cable manu- Machine ca- pability (pro-
Contact
Section characteristic/ facture re- pability (tool duction re-
BMG
attribute lease release, Cmk) lease,
Cpk, Ppk)
Volks-
wagen/Au-
Cable manu- Cable manu- Cable manu-
di/contact
facturer facturer facturer
part manu-
facturer
Section 2 Connection A e e e e
Section 2 Connection B e e e e
Additive in
Section 2.6 e/m e/m e/m e/m
contacta)
Section 3.2.2 Stripping e e e e
Conductor pro-
Section 3.2.3 e/m e/m e/m e/m
trusiona)
Damage to con-
Section 3.3.2 tact area/locking e e e e
lances
Compatibility
Section 3.3.3 with ultrasonic e e - -
welding
Contact bend-
Section 3.3.4 ing/ e e e e
twisting
Section 3.3.5 Cable bending m m m m
Material remov-
Section 3.3.6 al Chip forma- e e e e
tion
Severing of
Section 3.3.7 e e e e
strands
Section 3.3.10.1 Crimp heightb) m m m m
Measurable
Section 3.3.10.2 m m m m
crimp width
Supporting an-
Section 3.3.10.3 m m m m
gle
Supporting
Section 3.3.10.4 m m m m
length
Flank end clear-
Section 3.3.10.5 m m m m
ance
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Table A.1 (continued)

Process ca-
Dimension/ Cable manu- Machine ca- pability (pro-
Contact
Section characteristic/ facture re- pability (tool duction re-
BMG
attribute lease release, Cmk) lease,
Cpk, Ppk)
Volks-
wagen/Au-
Cable manu- Cable manu- Cable manu-
di/contact
facturer facturer facturer
part manu-
facturer
Distance be-
Section 3.3.10.6 tween crimp m m m m
flank ends
Section 3.3.10.7 Flash height m m m m
Section 3.3.10.8 Flash width m m m m
Section 3.3.10.9 Base thickness m m m m
Compression
Section 4.4.2 e e e e
(microsection)
Section 3.3.11.1 Crimp length e e e e
Cracks/
Section 3.3.11.2 e e e e
notchesc)
Crimp inlet/
Section 3.3.11.3 e e e e
bellmouth
Insulation crimp
Section 3.3.12 e e e e
design
Insulation
Section 3.3.12.2 m m m m
crimp height
Insulation
Section 3.3.12.2 m m m m
crimp width
Positional devia-
tion of
Section 3.3.12.2 e e e e
insulation
crimp flanks
Section 3.3.12.1 Bend test e e e e
Single-wire
Section 3.3.13 e e e e
seal
Single-wire seal
Section 3.3.13.1 e e e e
position
Cut-off
Section 3.4 tab/stamping m m m m
flash
Microsection im-
Section 4.4.2 10 units 10 units 10 units 10 units
aged)
Section 4.7.1 Pull-out force mb) me) mb)e) me)
Page 28
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Table A.1 (continued)

Process ca-
Dimension/ Cable manu- Machine ca- pability (pro-
Contact
Section characteristic/ facture re- pability (tool duction re-
BMG
attribute lease release, Cmk) lease,
Cpk, Ppk)
Volks-
wagen/Au-
Cable manu- Cable manu- Cable manu-
di/contact
facturer facturer facturer
part manu-
facturer
Additional char-
acteristics as
- per manufactur- e/m e/m e/m e/m
er
specification
Section 4.4 Setup processf) e e e e
a) Depends on the contact system used
b) Statistical analysis for process reliability verification
c) With magnifying glass (5x), contact and insulation
d) Measure and evaluate every relevant axis and position.
e) For the quantity, see section 4.3.1.
f) The result must be photographically documented.

NOTE A.1: Abbreviations: e = evaluate; m = measure

Table A.2 – Q matrix: Tests during production

Initial sample in- Tool configura- Start of produc-
Dimension/
spection report tion intervention tion batch,
Section characteristic/
(ISIR) (e.g., wear part changes to
attribute
(VW 75147) change) equipmenta)
Cable manufac- Cable manufac- Cable manufac-
turer turer turer
Section 2 Connection A e e e
Section 2 Connection B e e e
Additive in
Section 2.6 e/m e/m -
contactb)
Section 3.2.2 Stripping e e e
Conductor protru-
Section 3.2.3 e/m e/m e
sion
Damage to con-
Section 3.3.2 tact area/locking e e e
lances
Compatibility with
Section 3.3.3 - - -
ultrasonic welding
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Table A.2 (continued)

Initial sample in- Tool configura- Start of produc-
Dimension/
spection report tion intervention tion batch,
Section characteristic/
(ISIR) (e.g., wear part changes to
attribute
(VW 75147) change) equipmenta)
Cable manufac- Cable manufac- Cable manufac-
turer turer turer
Contact
Section 3.3.4 bending/ e e e
twisting
Section 3.3.5 Cable bending m m e
Material removal
Section 3.3.6 e e e
Chip formation
Severing of
Section 3.3.7 e e e
strands
Section 3.3.10.1 Crimp height mc) m m
Measurable
Section 3.3.10.2 m m -
crimp width
Section 3.3.10.3 Supporting angle m m -
Section 3.3.10.4 Supporting length m m -
Distance between
Section 3.3.10.5 m m -
crimp flank ends
Distance between
Section 3.3.10.6 m m -
crimp flank ends
Section 3.3.10.7 Flash height m m e
Section 3.3.10.8 Flash width m m e
Section 3.3.10.9 Base thickness m m -
Section 4.4.2 Compression e e -
Section 3.3.11.1 Crimp length e e e
Cracks/
Section 3.3.11.2 ed) ed) e
notches
Crimp inlet/
Section 3.3.11.3 e e e
bellmouth
Insulation crimp
Section 3.3.12 e e e
design
Insulation
Section 3.3.12.2 m m m
crimp height
Insulation
Section 3.3.12.2 m m
crimp width
Positional devia-
Section 3.3.12.2 tion of insulation e e e
crimp flanks
Section 3.3.12.1 Bend test e e e
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Table A.2 (continued)

Initial sample in- Tool configura- Start of produc-
Dimension/
spection report tion intervention tion batch,
Section characteristic/
(ISIR) (e.g., wear part changes to
attribute
(VW 75147) change) equipmenta)
Cable manufac- Cable manufac- Cable manufac-
turer turer turer
Single-wire
Section 3.3.13 e e e
seal
Single-wire seal
Section 3.3.13.1 e e e
position
Cut-off tab/
Section 3.4 e/m e/m e
stamping flash
Longitudinal mi-
Section 4.4.2 e e ee)
crosection image
Section 4.7.1 Pull-out force mf) m m
Additional
characteristics as
- per e/m e/m -
manufacturer
specification
Section 4.4 Setup processg) e e e
a) Tool change, cable change, contact part change, change in tool settings
b) Depends on the additive used
c) Statistical analysis for process reliability verification
d) With magnifying glass (5x), contact and insulation
e) Additionally at the end of each production batch
f) For the quantity, see section 4.3.1.
g) The result must be photographically documented.

NOTE A.2: Abbreviations: e = evaluate; m = measure