Crimp Pull Force and Crimp Height Test Log Worksheet
Crimp quality is verified by two quick measurements that every harness shop already makes: crimp height with a micrometer and pull force with a force gauge. This log records both against your limits, flags failures and tracks first pass yield by day.
| Date | Harness / part | Terminal PN | Wire | Applicator / press ID | Operator | Pull force (lbf) | Minimum pull (lbf) | Crimp height (mm) | Height min (mm) | Height max (mm) | Pull margin over minimum (lbf) | Pass (1) / Fail (0) | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
6.2 | 1 | ||||||||||||
5.5 | 1 | ||||||||||||
7.9 | 1 | ||||||||||||
-1.2 | 0 | ||||||||||||
10.4 | 1 | ||||||||||||
9.1 | 1 |
Minimum pull force and crimp height limits in the example rows are illustrative. Take the limits from your terminal manufacturer's application specification and your customer or IPC/WHMA-A-620 requirements. A sample passes only when pull force is at or above the minimum and crimp height is within the min and max limits. Record the applicator ID so a failing sample can be traced to a tool.
Trend crimp data across lines and shifts
Optional: discuss collecting crimp and pull data into a system that flags drift by applicator.
Optional. The tool and every export work without this. No spam.
How to use the log
At setup, after an applicator change, and at the sampling interval defined in your control plan, crimp a sample, measure height, then pull test it and enter the readings. Enter the limits from the terminal supplier application specification. The sheet calculates the margin of pull over the minimum and a pass or fail flag. The summary shows first pass yield and the number of failures so a trend is visible at a glance.
- Log the applicator or press ID on every row
- Record every setup and changeover sample, not only passing ones
- Enter limits from the terminal application specification
- Hold material from a failing sample until the cause is understood
What the checks tell you
Crimp height reflects how well the crimp barrel was compressed, and a height outside the supplier window signals wrong applicator setup, wrong wire gauge or wear. Pull force tests the mechanical strength of the connection, and a value near the minimum, even if passing, warns that the process may be drifting. Neither check replaces cross-section analysis when it is required for a qualification, but together they catch most day-to-day process drift.
Reading the summary
First pass yield equals passing samples divided by samples taken. A single failure out of six is a 17 percent drop, so look at the failure rows rather than the percentage. Watch the lowest pull margin: a shrinking margin over several samples often precedes failures, for example from worn crimp dies or wire strand damage during stripping. Sort or filter by applicator ID in Excel to separate tool problems from operator or material problems.
Common mistakes
Using one minimum pull value for all gauges instead of the value for that wire and terminal combination. Measuring crimp height at the wrong location or with a micrometer without crimp anvils. Pulling too fast, which changes the reading. Recording only the passing samples. Not recalibrating the force gauge and micrometer on schedule, which makes the whole log unreliable.
Frequently Asked Questions
Where do I get the minimum pull force?
Use the terminal manufacturer's application specification for that terminal and wire combination, and any stricter requirement from your customer or the workmanship standard. Do not use a single value for every gauge.
How often should I pull test crimps?
Follow your control plan. Common practice is at setup, after applicator or wire changes, at shift start, and at intervals during a run. Higher classes and critical circuits justify more frequent sampling.
What if the height passes but the pull fails?
Treat it as a failure. Check wire strand damage, wire gauge, insulation position and terminal lot. Height alone does not prove the strands are properly captured, so investigate before continuing production.
Can I export this log for audits?
Yes. Export to Excel or PDF and store it with the work order or lot record. Keep calibration records for the gauges used with the log.
If crimp and pull data are captured on paper or in standalone files, we can talk through bringing them into your MES or quality system so process drift shows up automatically.
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