BEST PRACTICESFOR IDC MAGNETWIRE TERMINATIONA QUICK GUIDE TO ECONOMICTOOLING SOLUTIONSAPPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONEARLY COLLABORATION
We provide custom tooling solutions that directly interface with your product. Early and consistentcommunication is key for the most reliable and economical solutions.
For additional information, please go to tooling.te.com and visit our “Magnet Wire Equipment” page.

Please Contact Us:
Americas
Asia / Pacific
Application Tooling
P.O. Box 3608
Harrisburg, PA 17105-3608, USA
ToolingSales@te.com
717.810.2082

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 2OUR DESIGN PROCESS
Once you have spoken with a TE Terminal Application Specialists at TE Connectivity (TE), we gathersome information about your product and a quote can be made.

We will work with you to create the appropriate application tooling specifically for your product. The
following guidelines describe various areas that can create design challenges for your product. A
solution can always be found, but it will be more efficient and economical to stay within the “suitable”
concepts, rather than risking extra time and expense on the “challenging” options.

Clear communication is key to confirm that your expectations are met with the correct applicationtooling.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 3

THE MAG-MATE TERMINALINTERCONNECTION SYSTEM
The MAG-MATE, Mini MAG-MATE, and SIAMEZE terminal products can be used on a variety ofapplications. Common examples include: small motors, relays, transformers, bobbin coils, shadedpole-motors, solenoids, and motor protectors with a thermal cutout.

This reliable system provides insulation displacement termination for unstripped copper and aluminummagnet wires. TE Connectivity is capable of producing creative solutions for all aspects of magnet wire
termination for a variety of wires and production levels.

Stators and bobbins are common products (topleft, bottom left) but more creative solutions that
include diode insertion (right) can be produced
through our system that allows for multiple
terminals to be inserted while still connected(bussed/commoned).

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 4HOW OUR SYSTEM WORKS
A cavity within customer product will house the inserted terminal, and should contain features for wire
and terminal support, as described in TE Connectivity application specifications.

MAG-MATE Terminal:
Unstripped wire is inserted
in the cavity through theslot, and makes contact
with the bottom of the slot
and top 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 is fully inserted into thecavity.

Mini MAG-MATE Terminal:
A smaller interconnection system is design for
extremely small wire
diameters. This terminal
uses a unique cam action
to provide the IDC contact
without applying tension tothe magnet wire.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 5Standard MAG-MATE Terminals

Standard SIAMEZE Terminals

The standard process forFor SIAMEZE terminals, theMAG-MATE terminals

insertion process is quite

has specialized tooling tosimilar to the MAG-MATE

create an excellent connection

terminal process, except withand efficient removal of scrap

different specialized tooling.

wire.

Please review the application
specifications for SIAMEZE
terminal insertion for theappropriate cavity geometry.

SIAMEZE Terminals With Lead Lok Terminals
One of the advantages of the SIAMEZE terminal is the ability to terminate both themagnet wire and lead wire in the same process. The SIAMEZE terminal is insertedwith the standard process, and a secondary insertion with the appropriate toolingapplies the Lead Lok terminal.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 6ADVANTAGESTO THE SYSTEM
Because terminals and tooling for this system are all through TE Connectivity, we provide an experience
encompassing all of your needs for magnet wire termination through our collaboration and knowledge
gained through years of experience.

With the MAG-MATE, Mini MAG-MATE, and SIAMEZE
terminal applications, there is no use of solder, increasing
productivity, reducing environmental impact, increasing
quality of the finished product, and improving employee
safety.

This system can be used for various wire sizes andproduction levels, with Mini MAG-MATE terminals
applying to wire sizes 52-30 AWG (0.02 to 0.250mm), MAG-MATE terminals connecting to wires
sizes 34-12 AWG (0.16 to 2.05mm), and SIAMEZE
terminals for wires of 36-12 AWG (0.127 To 2.05Mm). Our tooling options range from low volume or repair and prototyping to automated andsemi-automated solutions for processing millionsof parts a year.

Our tooling solutions provide the option of “On-the-flyInsertion,” which allows for an automatic change fromsingle to multiple (bussed/commoned) terminals to beinserted in a single stroke.
Left: Arbor press for low volume; Right: Vertical
Machine-Single Terminal for larger volumes; Bottom:
Module for integration into high volume productionlines.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 7

RECOMMENDATIONSThis information is to aid early involvement for a customer design. It is not comprehensive, and best
results will occur by contacting our team. Following the guidelines outlined in this document will
provide the most reliable and economical tooling solution possible for your product. These are notcomprehensive, and an Application Tooling specialist at TE Connectivity should always be consulted
prior to designing your product around these guidelines.

If any of these guidelines cannot be met, please contact us.
We always confirm a solution is found.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 8

TRIMMING
The wire trimming portion of the insertion process requires several considerations. During terminal
insertion, the post trim blade will simultaneously cut the wire support block. The following guidelines
will confirm that trimming will be efficient. It is not required to trim the excess wire, which may allow forsome additional flexibility in your design. However, wire retention for all parts is necessary for proper
termination. Please contact us for more information on options for wire trimming and retention, as there
are various solutions that can be tailored to suit your needs.

Ideal
The suitable design for good trimming includes
a support block with a cavity slot for the wireaccording the application specifications for yourselected terminal.

UnacceptableA support block for trim must be included for aclean cut. If a support block cannot be provided,the wire can be left uncut. Tie off posts, often used
for bobbins, can serve as the support block aswell.

Challenging
Clearance below and around the support block
should allow for the blade to travel past the product to allow for the cleanest cut.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 9

Keeping wire ends short will reduce handling and scrap wire problems. Gravity is typically used for theremoval of scrap wire and the wire support. If this is not adequate or possible, it is recommended that itis removed by vacuum or other means provided by the customer. Please note, the scrap from terminal
cut-off is collected by a module.

Acceptable

Challenging

The wire slot in the cavity cannot be obstructed by the coil windings, and the wire must be able to beplaced in the bottom of the wire slot for both entry and exit of the cavity. This will confirm a clean cut
and is required for proper termination.

Acceptable

Unacceptable

For most terminals, it is suitable for the trim of the wire to occur away from the carrier strip of the terminal (top trim). It is challenging to have the carrier strip adjacent to the trim (bottom trim), because of
the required spacing needed for the various cutting components to process the terminal.

Acceptable

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATION

Challenging

PAGE 10

TOOL CLEARANCE
Cavities should be the highest portion (plane) of the product, leaving adequate clearance for the tooling.
This will confirm that there is clearance for the tooling before, during, and after terminal insertion. Otherwise, some geometries may completely prevent terminal insertion, such as the example below. Consider
the volume of wound wire on the product as well.

Unacceptable

Acceptable
The insertion area should be kept clear for thetooling footprint. The tooling needs to be able tomake even contact with the top, flat surface of thecavity in order to properly apply the forces to thecavity and terminal for good insertion.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 11CAVITIESCavities should generally be kept as shallow as allowed by the application specification for the terminal
selected with help from our terminal application specialists.

Acceptable

Challenging

Design of the product should refrain from any locking features on the insertion or cut surfaces of thecavity to confirm that wire can be properly cut without any damage to the product. Protrusions above
the cavity will also cause issues with terminal insertion.

Acceptable

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATION

Challenging

PAGE 12MULTIPLE INSERTIONS
If your product requires multiple terminals to be inserted into cavities at the same time, it is requiredthat the cavities are spaced center-to-center to match the terminal spacing listed as the “die feed” on
the terminal drawing.

Acceptable

UnacceptableIf multiple terminals will be inserted, but will not need to be pressed at once, the cavities can be spaced
differently, as they will be separate from the carrier strip prior to insertion (bussed v. single). However,these cavities cannot be brought closer together than the spacing of the terminals on the reel, as thiswill cause collisions.

Single Insertions
It is often possible to insert combinations ofbussed (commoned) and single terminals with thesame machine, saving cost and time. These types
of applications will need close review by TE Con-Both Single and Multiple Insertions

nectivity Application Tooling specialists to confirm
that there is no tooling interference.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 13

CAVITY LOCATION
If the cavities are placed around the circumference of the product, all cavities should have the same
distance to the center of the product (radius). Cavity placement should consider fixture movement
during the insertion process. It is ideal if cavities are related in location through either rotation ortranslation, allowing for one type of motion for the positioning of the cavities. This will prevent
secondary operations, keeping cost lower and reliability higher

Ideal

Challenging

Translate Only

Rotate Only

Cavities should be placed close together to prevent the need for excessive fixture movements, also reducing complexity and cycle time.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 14

DISTORTION AND
APPLICATION FORCES
Winding forces may distort the molded part. Dimensions for the application should be inspected after
winding the wire. Any variation due to winding must be within tolerance.

The plastic molding must be able to resist the force of insertion which can be as much as 1112 Newtons.
For clarification of material choices and design, please reference the appropriate application specification. Cavity design must allow for support in line with the insertion. The bottom of the cavities must beflat to allow for support during the insertion process.

Suitable

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATION

Challenging

PAGE 15WIRE TENSION AND
SELECTION
Mini MAG-MATE Terminals
It is important that the wire that is in the cavity is not put under high tension. Due to the nature of thin
wire, if it is under tension during terminal insertion, breaking and failure of the connection can occur.

Acceptable

Unacceptable

SIAMEZE Terminals
When using the SIAMEZE with Lead Lok solution,
it is imperative that the proper lead wire type isselected according to the appropriate application
specification. Damage to the terminal and yourproduct can occur if the proper wire type is notselected.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 16

WE WORK WITH YOU
With so many things to keep in mind, confirming that your product will efficiently and cost effectively
interface with TE Connectivity tooling might be daunting. However, our solutions are customized to yourneeds, and innovative design is at the core of what we do. Do not hesitate to ask us questions, as we arealways happy to help.
Whether you need low volumes of prototype partsor require automation to integrate into a cell, wewill utilize our resources and experience to create
exactly what you need.

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 17

Engineering Notes

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 18

Engineering Notes

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATIONPAGE 19

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

Time is Money.

Waste Not. Want Not.

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

MAG-MATE, Mini MAG-MATE, SIAMEZE, TE Connectivity, and the TE connectivity(logo) are trademarks.
© 2018TE Connectivity Ltd. family of companies

2338149-1

08/18

All Rights Reserved.

Original

APPLICATION TOOLING /// BEST PRACTICES FOR IDC MAGNET WIRE TERMINATION