APPLICATIONTOOLINGFOR MAGNET WIRE PROCESSINGFROM TE Connectivity (TE)TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITYAPPLICATION TOOLINGFOR MAGNET WIRE PROCESSING
Inserter for MAG-MATE andSIAMEZE Terminals

AMPLIVAR Product Terminator (APT)AMP 5/K-40 Thru Splice Terminator

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 2BY USE OF THESE TOOLS TE MAGNET WIRE TERMINALS AREAPPLIED, SEE THE FOLLOWING EXAMPLES:
MAG-MATE Terminals
Standard .187 and .300 MAG-MATE Terminals(Product Specification 108-2012)
Standard .500 Box MAG-MATE Terminals(Product Specification 108-2053)
Slim Line MAG-MATE Terminals(Product Specification 108-1484)
Mini MAG-MATE Terminals(Product Specification 108-2016)
See also Catalog 82221(Magnet Wire Terminals and Termination Systems)

SIAMEZE Terminals
Standard Range SIAMEZE(Product Specification 108-2085 )High Temperature Standard Range SIAMEZE(Product Specification 108-2293 )Fine Range SIAMEZE(Product Specification 108-2244 )Medium Range SIAMEZE(Product Specification 108-2239
Heavy Range SIAMEZE(Product Specification 108-2316 )See also Catalog 82221

AMPLIVAR Splices
9 Serrations - Pigtail Type
7 Serrations - Pigtail Type
5 Serrations - Pigtail Type
5 Serrations - Pigtail Type
Miniature Splice - Pigtail TypeSee also Catalog 82221

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 3

APPLICATION TOOLING
FOR MAGNET WIRE PROCESSING
MAG-MATE Insertion Equipment

Spare Parts

MAG-MATE Insertion Equipment• Semi-automatic machine for integration intoa manual workstation or production lineCalipper• The insertion machine can be installed horizontallyor vertically according to the requirements• Separate control cabinet• Separate touch panel• Pneumatically operated, compressed air 6 bars
• Insertion tools driven by compressed air cylinders
Technical Data:• Weight: app. 17 kg• Weight with Z axis movement: app. 22 kg• Dimensions of inserter (D x W x H):
600 mm x 220 mm x 165 mm(200 with Z axis movement)• Diameter of contact reel: app. 630 mm• Dimensions of control cabinet (D x W x H):
210 mm x 380 mm x 480 mm (app)Options/Functions:• Moving table• Adapter plate• Suction system for waste disposal• Limitation of mechanical Insertion force• Insertion force monitoring system• Separate wire cutting function• Power supply: 230 V, 50Hz, 6 A• Bridge function for 2 / 3 / 4 contacts• Sound level: < 70 db(A)• Touch screen• Compressed air supply : 6 bars

• Bridge function on/off• Compressed air connection: 1/8 “• Special function for Multispring contact application• Air consumption (l/cycle): app. 2.8• Fine-adjust of contact insertion depth• Contacting force: max 1000 N• Language module for user interface• Cycle time: 0.9 – 1.3 sec (depending on operator)• Electrical interface• Temperature: 10°C – 45 °C• Humidity: 30 % – 85 %, preferably 55 % (without 		condensation)• Dusty environment to be avoided

Overview on our full MAG-MATE modules portfolio,
see Appendix A, page15.
Please contact our specialists for details.

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 4

MPT-5 Specifications (All Versions)Technical Data:
Air Requirements (Do NOT use lubricated air)• Min Machine Working Pressure: 552 kPa [80 psi]
• Max (Preferred) Machine Working Pressure: 621 kPa[90 psi]
• Max Supply Line pressure: 1034 kPa [150 psi]Electrical Requirements• Voltage: 100-220 Vac• Frequency: 50/60 Hz• Circuit: Single Phase• Current: 1.0 A• Noise: 83dBA_With Scrap Vacuum Tube Located Away From Operator
and in Scrap Container

Options/Functions• Moving Tube
• Customized fixtures• Integrated scrap suction• Independent wire cutting function• Bridge function
Note that the dimensions shown below are for the module only and do not include
the electronic and pneumatic subassemblies, which must be mounted separately.

• Right/Left feed capability (two different terminals)

The MPT-5 product terminator machine Horizontal Bench Machine consists ofa module, a horizontal adaptor kit, an electronic assembly and a pneumatic assembly.

• Selective bridge function (On-The-Fly Operations)• Feed position fine adjust

The MPT-5 product terminator Vertical Bench Machine consists of a module, a “C“frame or “L“ arm, an electronic assembly, and a pneumatic assembly.

• Depth position fine adjust

DIMENSIONAL DATA*HorizontalModule Only
Bench Machine

VerticalBench Machine

DepthHeight
Width711.2 mm [28 in.]

711.2 mm [28 in.]

737 mm [29 in.]

304.8 mm [12 in.]

914.4 mm [36 in.]1168 mm [46 in.]

381 mm [15 in.]

812.8 mm [32 in.]

838 mm [33 in.]

Weight (Approx.)22.7 kg [50 lbs]

43.1 kg [95 lbs]

113.4 kg [250 lbs]

*Dimensions may vary depending on options and specific applications.

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 5APPLICATION TOOLING
FOR MAGNET WIRE PROCESSING
Insertion Process for MAG-MATE
Terminals (Standard & Slim Line)
MAG-MATE:
Unstripped wire is inserted
in the cavity through theslot, and makes contact withthe bottom of the slot andtop of the anvil.
The terminal is pushed
through the inserter “tube”
and positioned in the cavity
by the insertion finger.
As the terminal is inserted into the cavity, the insulation film on the wire is stripped by the IDC
slot and stripping shoulders, while the locking barbs on the terminal secure the terminal within
the cavity. The post trim blade cuts the wire support block and scrap wire as the terminal isfully inserted into the cavity.
Terminal ExamplesInsertion Process for Mini MAG-MATE Terminals
1Mini MAG-MATE:
A smaller, Mini MAGMATE Interconnection

23system is design for extremely small wire diameters. This terminal uses
a unique cam action toprovide the IDC contact
without applying tension
to the magnet wire.

Terminal Examples

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 6Insertion Process for SIAMEZE Terminals

Standard SIAMEZE:For Siameze Terminals, theinsertion process is quite
similar to the MAG-MATE
process, except with different
specialized tooling. Please
review the application
specifications for Siameze
insertion for the appropriate
cavity geometry.

Terminal Examples

Insertion Process for Leadlok/
SIAMEZE Terminals

SIAMEZE with Leadlok:
One of the advantages of theSiameze terminal is the ability to terminate both the magnet wire and lead wire in thesame process. The Siameze
terminal is inserted with thestandard Siameze process,and a secondary insertion
with the appropriate toolingapplies the Leadlok terminal.

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 7APPLICATION TOOLING
FOR MAGNET WIRE PROCESSING
Combination with manuallyoperated tools
MAG-MATE insertion combined with crimping
After MAG-MATE terminal insertion is done, the magnet
wire coil has to be connected to the outside world:
An example is the poke-in of a bare wire end or acrimped terminal into the MAG-MATE Terminal:
Poke-in of a stripped solid wire end
For these terminals you need a crimp tool, e.g. a
CERTI-LOK hand tool or an SDE hand tool or aPRO-CRIMPER hand tool.
Poke-in of crimped terminal
For these terminals you need a crimp tool, e.g. a
CERTI-LOK hand tool or an SDE hand tool or a
PRO-CRIMPER hand tool.

Crimp Terminal Examples

MAG-MATE terminal
Directly crimped
Inserted Terminals also can be crimped directly ontoa stranded wire.
Example: Mini MAG-MATE terminal with crimp con­nection.

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 8Manually operated tools
for repair and service

Manual SIAMEZE Leadlok
Terminal Application

For repair & service , but also for prototyping it can beuseful to work with manually operated tools.
Here you find some examples. For further manuallyoperated tools don’t hesitate to contact our specialists.
Manual MAG-MATE Terminal Application

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 9APPLICATION TOOLING
FOR MAGNET WIRE PROCESSINGWork Center for semi automatic insertion of MAG-MATE or SIAMEZE terminals
We offer standardized or customized work centers,
which are in line with the EU Machinery Directive
2006/42/EG. They are designed to automatically insert
the terminals into the cavities of coil bodies. Correctpositioning of the coil in front of the inserter is done
either manually or automatically.
The work center consists of our inserter for MAGMATEand SIAMEZE contacts being integrated into acomplete work environment.
After the coil is positioned,the terminals supplied onreels are cut off from the carrier strip and inserted into
the contact chambers.
At this time the excess magnet wire is cut off and theother side terminated in the terminal cavity using
insulation displacement technique.
Light grids assure protection of the worker during
operation of the machine.
Easy operation of the work place is possible by a touch

Manual positioning of coil by use of a manually operated locater unit

screen.
Insertion process is started by pedal switch.

Locater for manual positioning

Locater for automatic positioning

Semi automatic positioning of coil by use of a
motor-driven locater unit

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 10

Workstation Application:
MAG-MATE terminal with Multispringcontact
Case:
An electrical drive stator has to be combined with aPCB. The cavities of the stators are designed for
MAG-MATE terminals. The thru holes of the PCB can becontacted by Multispring.
Needed: A combination of MAG-MATE IDC andpress-fit contacting method.
Solution:
MAG-MATE terminal with Multispring contact.
After insertion of the terminals the PCB is pressed onto
the housing by means of a connector seating device.

Automatic Workstation
For rough work environment we also can offer robust
designs for work places according to the specific needsof our customers.
Components and Controls (Examples)• Inserter Machine• Electrical Power Supply Unit
• Compressed Air Supply Unit
• Touch Screen• Emergency Stop Button• Light Grid
• Malfunction Light• Safeguard• On Button/Off Button
Please contact our specialists for full specification ofthe work center

Bench-top Custom Solutions
Customized fixtures can be designed for specificapplications. Processing two different terminals in thesame machine provides our customers with the mosteconomical solution, reducing processing and handlingtimes.

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 11APPLICATION TOOLING
FOR MAGNET WIRE PROCESSING

Splicing Equipment
AMP 5/K-40 CE thru splice terminator stand-alone
semiautomatic bench machine for end feed and forside feed AMPLIVAR terminals.
Technical Data:• Deflection: 0.13 mm [.0046 in.]Maximum per 4,448 Newtons [1,000 lb] Crimp Force• Noise: Less than 82 dBa Typical at operator position 		with standard mechanical feed applicator• Weight: 77.3 Kilograms [170.4 lb] — Height: 585 mm 		
[23 in.] without reel supports• Electrical: 100 – 240 Vac, 50/60 Hz,
Single-Phase Current. Operating current is 3 amp• Air: 620 – 760 kPa [90 – 100 psi], 2.83 liters/sec(6 scfm) When required for use with air feed

End-Feed and Side-Feed applicators used withapplicators

AMP 5/K-40 CE through-splice terminators are two-• Physical Environment: Temperature:
4.45 – 40° C [40.5 – 104° F]• Relative Humidity: Less than 95 % (non-condensing)piece applicators consisting of a tool holder andapplicator base.
The tool holder is secured to the ram of theAMP 5/K-40 CE through-splice. All AMP 5/K-40 CE
through-splice terminators are equipped witha “precision adjust” feature.

Splicing Equipment
The wire ends being spliced together have to beinserted into a slot in the protection guard.

AMPLIVAR
Side feed ­­terminal

AMPLIVAR
End feedterminal

A sight window allows correct positioning of the wireends over the open crimp terminal barrel.
The AMPLIVAR crimp terminals are either side feed orSide feed applicator with­protection guard

End feed applicator with­protection guard

end feed terminals. Accordingly a side feed or end feed
applicator has to be installed into the thru spliceterminator.

Additional hand protection guard

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 12

Splicing Equipment Pigtail Splices
AMPLIVAR product terminator (APT)For pigtail-type splices (up to 3 wires in 1 splice) anddirect connect contacts
Technical Data:• Weight: approx. 68 kg with CQM• Width: 965 mm with CQM and• Product Reel
• Depth: 890 mm• Height: 356 mm• Electrical: 240 VAC, 50 Hz, .5 A, 1 f

For operations with multiple wire sizes, the APT 5A
provides programmable sequencing of different
crimp-height settings, and it can store up to 2,000• Air: 5,5-7,5 bardifferent programs of 7 different settings each.

• Crimp Height Adjust in .0005 “ [0.013 mm]

The maximum time to auto-adjust between pro-increments over .064” range

grammed crimp heights is 2 seconds.

Splicing Equipment Pigtail Splices
Termination process:• Magnet wire and lead wire are placed in the terminal 		barrel being in the crimping position• Operator depresses the foot switch• Terminator automatically– shears terminal from its strip– crimps the terminal onto the wire
– shears off the excess wire– advances the next terminal into the crimping
position
Remarks:• Two or three wires may be joined in one splices• Terminator designed for combinations of magnet 		wire and lead wire (stranded, solid or fused stranded)• Large number of wire combinations requires some 		
tooling changes• If customer CMA is less than the minimum published 		
CMA for the AMPLIVAR product, we offer our wire 		
stuffer assembly 2161635-1 as an option.
This option provides additional magnet wire CMA to 		the terminated CMA to meet the specified CMA range
for a given AMPLIVAR product.

• For the correct tooling selection, please contact our 		specialists

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 13

TE CONNECTIVITY APPLICATION TOOLING:
IDC MACHINE QUOTATION QUESTIONNAIRE
Please provide the following information so we can create an accurate quote for your production needs.

Contact Information:
Company Name:
Contact Name:

Product Information:

Company Address:
Contact Email:Contact Phone:Has your application been reviewed by a TE Connectivity Terminal Application Specialist?
If so, who did you work with?
Please list all terminals to be inserted in this application:
What products are you interested in?
Complete bench machine and fixture
If a fixture is requested, what level of automation isManualSemi-Automaticneeded?
Automated Line Integration
Will the machine be robotically loaded?
Yes
No

What timeframe do you expect for the start ofproduction?

Please submit this form to:magnetwireus@te.com
Mailstop 140-50 P.O. Box 3608
Harrisburg, PA 17105-3608, USA

Specifications and Testing:*Are you able to provide 5-10 samples of product for
initial review?
Yes
No**Do you require a run off of the machine?
Yes
No

Module only

What is your expected yearly terminal usage?

If you are replacing an existing machine, what is themachine part number?

Do you have any testing/acceptance requirements?
Yes
NoNo

If the machine is integrated into a line, is host control
required?
Yes
No

Will the machine be replacing an exisiting AMP or TE
Yes
NoConnectivity machine?

Do you have any machine specifications orYes
Norequirements?

Yes

For best results, please review “Best Practicesfor IDC Magnet Wire Termination,” which canbe found with other useful information attooling.te.com

If you answered “Yes” to any of the questions
regarding specifications and testing, please attach
all appropriate documentation.

Attachments:
In order to produce a complete quote, all of the following items must be attached. If not all documentation
is currently available, a budgetary quote can be provided.
-Detailed, fully dimensioned and tolereanced drawings of bare bobbin/stator including material(e.g. 15% GF nylon)-Drawings of Completed Assembly [Including: TE terminal(s) part number(s), terminal orientationin cavity, magnet wire type (e.g. AL, CU), magnet wire gage, wrap-off trim (required or not required)]-3D Models of the bobbin/stator assembly (CREO or .STP format) if available-All information on the wire that will be used for this application including, but not limited to: gage,
number of strands, material, insulation type.
Please Note: *Customers are required to provide terminals adn bobbins/stators for all machine conditioning
and qualification. **Additional charges may apply.

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

PAGE 14APPENDIX A: Overview on our full MAG-MATE MODULE portfolio
MAG-MATE
pneumatic

NoOptions

1Moving Table

2Moving Tube

3Adapter Plate

X

4Suction system for waste disposal

X

5Insertion force limitation, mechanical6

Insertion force monitoring

7

Separate wire cutting unit

8

Bridge function, 2 contacts

9

Bridge function, 3 contacts

10

MPT-5

X

MAG-MATE
MK I

MAG-MATE
MK II

X

X

X

X

X

X

X

X

X

X

X
X
X

X

X

X

X

X

X

X

Bridge function, 4 contacts

X

X

11Touch screen

X

X

12

Bridge On/Off function

X

X

X

13

Processing function for Multispring

X

X

14

Fine adjust insertion depth

X

X

15

Language module for user interface

16

Electrical interface for base machine

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY

X

X

X

X

X

PAGE 15

Let’s Connect
To learn more about the right TE tooling for your needs, call us a 717-810-2082 or email
ToolingSales@te.com

TE Technical Support Center
USA:

1.800.522.6752

UK:+44.0800.267666

Canada:1.800.522.6752

France:+33.1.34.20.8686

Mexico:+52.55.11.06.0800

Netherlands:+31.73.624.6999

China:+86.400.820.6015

Latin/S. America +54.11.4733.2200
Germany:+49.6151.607.1999

Waste Not. Want Not.

Time is Money.
In manufacturing downtime canbe expensive. That’s why TE isconstantly working to improve
product availability and delivery
rates. With a strong global footprint, short lead times
and a strong distribution channel, TE has the equipment
and the accessories to keep production online.
To check distributor stock and availability for your toolingneeds go to: www.te.com/commerce/sck/cdi.do

Whether its time or scrap, inmanufacturing everyone knowsthat waste costs money. With
our on-site certification andconsultation services, we canhelp you:••••

Reduce downtime
Reduce scrap
Maintain crimp quality
Improve manufacturing efficiency

Connect with us today to learn more.
•••

E-mail: fieldservicesnorthamerica@te.com
Phone: 800-722-1111 or 717-986-3434
For additional information download catalog#1-1307619-0 from tooling.te.com.

Catalog 1-1773899-1/ 11-18 / Application Tooling
TE connectivity (logo) and TE Connectivity are trademarks.

TE APPLICATION TOOLING /// MAGNET WIRE TOOLING SOLUTIONS FROM TE CONNECTIVITY