Patent Publication Number: US-2022216662-A1

Title: Programmable memory positioner and calibration system for a crimp tool and related methods

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application Ser. No. 62/661,288 filed on Apr. 23, 2018 the contents of which are herein incorporated by reference in their entirety. 
    
    
     TECHNICAL FIELD 
     The present invention relates to the field of crimping tools, and, more particularly, to a programmable memory positioner and calibration system for a crimp tool and related methods. 
     BACKGROUND 
     Contacts as used herein are defined as the termination points in electrical/electronic interconnect systems. When a complex wire harness is constructed, hundreds, perhaps thousands, of contacts are terminated by individually crimping a prepared wire into the contact wire barrel. 
     A crimp tool for this purpose typically has four crimping elements (indenters or crimping dies) positioned at 90° to each other. The crimping elements advance toward the center of an opening in the tool with a uniform and controlled path when the crimp tool is actuated by closing a handle manually, or actuated using a power source. A typical crimp tool has a built-in stop for single applications, or a multi-step adjustment for multiple wire/contact diameters. 
     Mechanical crimp tools which are used for aerospace and high reliability applications are equipped with an adjustable device that requires the actuation mechanism which drives the crimping elements to close fully, and then to open fully. That device in mechanical crimp tools is typically referred to as the ratchet. When it controls the motion of the crimping elements in both the closing and opening direction, it is referred to as a two way ratchet. If the motion of the crimping elements is controlled only in the closing direction (acceptable) it is referred to as a one way ratchet. 
     The design of the crimp tool includes selecting a defined shape to be formed onto the tip of each indenter. A defined stop location is selected for each wire size (diameter) and contact wire barrel diameter/wall thickness, and this information is documented by the contact and tool designers. 
     In addition, the wire depth/stop settings are usually embossed (labeled) on the crimp tool positioner dataplate. Sometimes the wire material, construction, or plating will change the crimp depth or indenter shape. 
     One type of crimp tool is referred to as a four (4) plane crimp tool. In the industry, it is often referred to as the 4/8 indent crimp configuration, since it usually has two points on each indenter. An example of a contact  100  crimped to a wire  102  is shown in  FIGS. 1 and 2A-2B . The wire barrel  104  is slipped over the prepared wire  102  and the indentors (also referred to herein as crimp dies) form the indentions  106 . A cross section of the wire barrel  104  taken in the direction of line B-B is shown in  FIG. 28  illustrating the indentions  106  crimped to the wire  102  in four planes. 
     The stop location of the crimp tool is referred to as the “crimp depth” or the “die closure.” The crimp tool is typically set with a go-no/go gage  108  as shown in  FIGS. 3 and 4A-48 . The gage  108  has a hardened and durable cylindrical pin  110  on the green end  114  referred to as the “go” gage with a diameter that conforms to the minimum crimp depth/die closure. A hardened and durable cylindrical pin  112  is on the other red end  116  of the gage  108  which conforms to the maximum crimp depth/die closure diameter and is commonly referred to as the “no/go” gage. 
     In order to set the crimp tool to the desired crimp depth, a technician adjusts the crimp tool to a predetermined setting by dialing a selector number, or setting a knob which rotates a screw on the crimp tool. Next, the technician closes the handle of the tool (or actuates a power closing mechanism on pneumatic or electric/hydraulic crimp tools) to the fully closed position. The “go” pin  110  is then inserted between the indenters  118   a,    118   b  as shown in  FIG. 4A . Then the gage  108  is removed and turned around, and the “no/go” pin  112  is inserted into the crimp cavity of the tool as shown in  FIG. 4B  to attempt to slide between the indentors  118   a,    118   b.  If the tool is properly calibrated to the desired crimp depth, the “go” pin  110  will enter the crimp cavity, and the “no/go” pin  112  will not enter between the crimp indenters  118   a,    118   b.    
     This gaging procedure for the crimp tool is used to determine whether the crimp tool is acceptable or unacceptable for use on the production line (or maintenance operations) to terminate contacts or terminals. If the “go” pin  110  does not enter the crimp cavity, which is defined by the indenters  118   a,    118   b,  or the “no/go” pin  112  enters the crimp cavity, the tool is marked not acceptable for production line or maintenance use, and the crimp tool is sent to repair where the crimp tool is examined by trained personnel. A repair may include changing parts and components of the crimp tool, and will typically require adjustment of an internal setting/stop mechanism internal to the crimp tool, which is not accessible without removing sealed covers. 
     Referring now to  FIGS. 5-8 , the crimp tool  130  is typically universal within a wire diameter range (#20 to 12 AWG or 0.5 to 3.0 mm 2  are typical wire diameter ranges for a common four plane crimp tool). A detachable positioner  120  is a component that adapts the universal crimp tool  130  to one specific application such as one contact configuration, and a designated range of wire diameters, for example. A positioner  120  is shown in  FIGS. 5 and 6 . A single application may be a family of contacts with differing part numbers, but with common features. 
     The positioner  120  typically has two functions. The first function is to hold and position the contact in a precise central location (side-to-side, and up/down) in a receiving port  134  to the indenters  118   a,    118   b,    118   c,    118   d,  of the crimp tool  130  as shown in  FIGS. 7 and 8 . The positioner  120  ensures that the resulting crimp is at the correct location on the contact wire barrel. It also positions the contact centrally to assure that the indents are uniform and concentric around the diameter of the contact wire barrel. 
     The second function of the positioner  120  is to have a permanent label (i.e., “dataplate”)  122  affixed to it. The dataplate  122  displays the compatible contact part numbers  127 , and the specified (predetermined) crimp depth settings  126  for each wire size  124  which is allowed to be terminated in that particular contact wire barrel as shown in  FIG. 6 . 
     Referring now to  FIGS. 7 and 8 , when the wire size is selected from the dataplate  122  on the positioner  120 , the crimp tool  130  is required to be manually adjusted by some obvious means. The adjustment can be made by a stepped selector knob  132  with a number scale, or a knob affixed to an adjustment screw. The adjustment sets the crimp depth to the setting that was predetermined by the designer for that wire diameter in that particular contact wire barrel. 
     In view of the foregoing background, it is therefore an object of the present invention to provide a device that is automatic and operates with precision, and is part of a system to further gather information during the manufacture of wire harnesses, and provide traceability for improving quality of manufacture. This and other objects, features, and advantages in accordance with the present invention are provided by a crimp tool for crimping a prepared wire into a corresponding contact wire barrel. The crimp tool includes a handle, and a head having a receiving port therethrough and the head is coupled to the handle. In addition, the crimp tool includes a plurality of crimping dies positioned around a periphery of the receiving port of the head that are configured to advance towards a center of the receiving port, an adjustment knob having a plurality of depth settings to adjust a crimp depth of the plurality of crimping dies, and a positioning head having a memory chip storing positioner data and the positioning head is removably engaged with the receiving port. The crimp tool also includes a positioner interface removably coupled to the head, and includes a reader configured to read the positioner data stored on the memory chip of the positioning head. 
     The positioner interface may have a housing and a retainer arm extending away from the housing and ever the positioning head, and the retaining arm has the reader. The positioner interface may also include a tool memory for storing tool data. The tool data may include a number of crimp operations since a last calibration. The positioner interface may also include a transmitter configured to transmit the positioner data read from the memory chip to a computer having a display and input device. In a particular aspect, the positioner interface may include the computer having the display and the input device. 
     The crimping dies are positioned around the periphery of the receiving port and are actuated when the handle is manually closed. The crimp tool may also include a power closing mechanism to actuate the crimping dies positioned around the. periphery of the receiving port. 
     The computer may be configured to generate a list of a plurality of available contact part numbers and wire sizes corresponding to the positioner data read from the memory chip, and to receive a selected contact part number and a wire. size that was selected from the list by a user using the input device. 
     The computer may also be configured to determine whether the crimping depth of the plurality of crimping dies is currently set to a crimp depth required. by the selected contact part number and the wire size, and to generate an indicator to the user to adjust the crimping dies to the required crimp depth when adjustment is required. 
     The adjustment knob of the crimp tool may be in. electrical communication with the positioner interface to indicate the current crimp depth of the plurality of crimping dies. The positioner interface may be configured to transmit the current crimp depth of the plurality of crimping dies to the computer. 
     In a particular aspect, the crimp tool may include a calibration gage having a gage pin, where the gage pin is configured to slide into the positioner interface for storage and to slide into the receiving port when calibrating the plurality of crimping dies. The gage pin may include a non-conductive core having a plurality of elongated conductive segments thereon and insulated from each other, where each of the plurality of conductive segments are in electrical communication with the positioner interface and configured to transmit a signal when making contact with one of the plurality of crimping dies to determine a position of a respective crimping die. 
     In another particular aspect, a crimp tool calibration system for crimping a prepared wire into a corresponding contact wire barrel includes a computer having a processor and a memory coupled to the processor, a positioner having a memory chip storing positioner data, and a tool frame. The tool frame includes a head having a receiving port therethrough, where the receiving port has a first end and a second end and configured for the positioner to be removably engaged with the first end of the receiving port during a crimping operation. The tool frame also includes a plurality of crimping dies positioned around a periphery of the receiving port, an adjustment device to adjust a crimp depth of the plurality of crimping dies, and a positioner interface coupled to the tool frame and having a tool memory storing tool data, a reader, and a transmitter. The reader is configured to read the positioner data stored on the memory chip of the positioner, and the transmitter is configured to transmit the positioner data and the tool data to the computer. 
     In another particular aspect, a method of using and calibrating a crimp tool is disclosed. The crimp tool includes an adjustment; knob having a plurality of depth settings to adjust a crimp depth, a positioning head having a memory chip storing positioner data, and a positioner interface having a reader configured to read the positioner data stored on the memory chip of the positioning head. The method includes transmitting the positioner data read from the memory chip to a computer having a display and input device, generating a list of a plurality of available contact part; numbers and wire sizes corresponding to the positioner data read from the memory chip, and receiving a selected contact part number and a wire size that was selected from the list by a user using the input device. The method also includes determining whether the crimping depth is currently set to a crimp depth required by the selected contact part number and the wire size, and generating an indicator on the display to adjust the tool to the required crimp depth when adjustment is required. 
     The method may also include sliding a gage pin into a receiving port of the crimp tool, where the gage pin comprises a non-conductive core having a plurality of elongated conductive segments thereon and insulated from each other, and transmitting a signal when making contact with one of the plurality or crimping dies to determine a position of a respective crimping die. The method may include adjusting the crimp depth on the tool to correspond to a calibrated crimp depth. In addition, the method may include transmitting to the computer and storing a contact size and a wire size for each crimping operating, and a number of crimp operations since a last calibration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic of contact crimped to a wire; 
         FIG. 2A  is a schematic of a contact; 
         FIG. 2B  is a schematic of a cross section of the contact taken in the direction of line BB of  FIG. 2A ; 
         FIG. 3  is a schematic of a gage; 
         FIG. 4A  is a detailed view of a first end of the gage of  FIG. 3 ; 
         FIG. 4B  is a detailed view of a second end of the gage of  FIG. 3 ; 
         FIG. 5  is a perspective view of a positioner; 
         FIG. 6  is a schematic of a dataplate of the positioner of  FIG. 5 ; 
         FIG. 7  is a longitudinal cross sectional view of a crimp tool; 
         FIG. 8  is a top view of the crimp tool of  FIG. 7 ; 
         FIG. 9A  is an elevational view of a crimp tool in which various aspects of the disclosure may be implemented; 
         FIG. 9B  is an elevational view of a powered crimp tool in which various aspects of the disclosure may be implemented; 
         FIG. 10 . is a top view of the crimp tool of  FIG. 9A ; 
         FIG. 11  is a view of the positioner and positioner interface of the crimp tool of  FIGS. 9A and 9B ; 
         FIG. 12  is a schematic of a crimp tool calibration system in which various aspects of the disclosure may be implemented; 
         FIG. 13A  is a schematic of a crimp tool calibration system of  FIG. 12  with a wireless aspect; 
         FIG. 13B  is a schematic of a crimp tool calibration system of  FIG. 12  having a QR code; 
         FIG. 14  is a screen shot of a display menu of the crimp tool calibration system of  FIG. 12 ; 
         FIG. 15A  is a screen shot a subsequent display of  FIG. 14 ; 
         FIG. 15B  is a QR code label or display; 
         FIG. 16  is a perspective view o a motorized crimp tool in. accordance with. the invention; 
         FIG. 17  is a top view of the crimp tool of  FIG. 9A  having a calibration gage removed; 
         FIG. 18  is a detailed view of the calibration gage of  FIG. 17  being positioned for use; 
         FIG. 19  is a detailed view of the calibration, gage of  FIG. 17  placed within a receiving port of the crimp tool of  FIGS. 9A or 9B ; 
         FIG. 20  is an exploded view of a gage pin of the gage of  FIG. 17 ; 
         FIG. 21A  is a detailed view of the gage pin of  FIG. 20 ; 
         FIG. 21B  is a cross sectional view of the gage pin of  FIG. 21A  taken in the direction of line B-B; 
         FIG. 21C  is a schematic of the gage pin having an insulator sleeve; 
         FIG. 22  is a block diagram of a crimp tool calibration system in which various aspects of the disclosure may be implemented; 
         FIG. 23  is a schematic of wire caliper in which various aspects of the disclosure may be implemented; 
         FIG. 24  is a general flowchart of a method of using the crimp tool of  FIGS. 9A or 9B ; and 
         FIG. 25  is a general flowchart of calibrating the crimp tool of  FIGS. 9A or 9B . 
     
    
    
     DETAILED DESCRIPTION 
     The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. For example, the invention may be powered manually, electrically, pneumatically, or hydraulically. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout. 
     Currently there is widespread use of mechanical crimp tools and compatible mechanical positioners in wire termination operations. A high level of supervision and manual inspection is required in wire harness production, because incorrect positioners for the contact being used can easily happen. Some common errors include that the crimp tool can inadvertently be adjusted to the incorrect crimp depth setting, the crimp tool calibration can be out of date, and a number of highly manual operator dependent errors can happen. 
     Referring now to  FIGS. 9A-11 , a crimp tool  200  and positioner  208  for crimping a prepared wire into a corresponding contact wire barrel, is described herein that would eliminate most manual operations (past the initial setup and directed periodic internal calibration) which is required by typical mechanical crimp tools and positioners. In particular, the positioner  208  is fitted with a memory chip  209  such as a Programmable Read Only Memory chip (PROM), for example, which has the positioner part number programmed. into the memory. This allows a database to store and used to retrieve contact part numbers, wire type, size, part number, crimp depth settings, and miscellaneous data/photo files and calibration data programmed and saved in the database to be retrieved and displayed on the controlling computer monitor or tool display  205 . The memory chip  209  is readable using a reader  206  of the positioner interface  202  when the positioner  208  is affixed onto the crimp tool  200  as shown in  FIGS. 9A, 9B and 10 . The positioner interface  202  may be coupled to the positioner  208  using an electrical connector or can be wireless, e.g., RFID wireless signals.  FIG. 11  illustrates the positioner  208  being in communication with the positioner interface  202  and without showing the crimp tool  200  for clarity. 
     When the positioner  208  is installed into the receiving port of the crimp tool head  210 , the reader  206  will interface electronically with the memory chip  209  in the positioner  208 . This information is communicated to, and interactive with, a controlling network  220  by wireless or wired connection. For example, a transmitter  223  of the crimp toot  200  is configured to transmit the positioner data and the tool data to the controlling computer  214 , which may be coupled to a network  220  (as shown in  FIGS. 12 and 13A ) via LAN  222  and/or WAN  224 . Transmission from the crimp tool  200  may be wi-fi, Bluetooth, Zigbee, RFID, for example, using a receiver  216 . 
     This is determined and arranged by screen choices made by the technician during setup operations. The reader  206  may also serve as a latch to hold the positioner  208  in place. 
     The crimp tool  200  is selected to meet the contact and wire diameter range of the application, and the particular positioner  208  is selected to be compatible with the one contact configuration, or family of contacts all having common characteristics. 
     When the compatible crimp tool  200  and the positioner  208  are mated and latched, digital communication begins between internal and external databases which retrieve data, monitor, and control the setup of the crimp tool  200  and the positioner  208  as shown in  FIGS. 12 and 13A . The use of the crimp tool  200  and positioner  208  can be logged into a production or maintenance control system, and traceable records are recorded. Communication with the network can be accomplished via wire  212  as shown in in  FIG. 12 , or wireless communications as shown in  FIG. 13A  (selected during setup) as described below. In addition, as shown in  FIG. 13B , a camera  239  or any other image capturing device such as a cell phone/pad device  241  can also read information from a patterned label/stamp  237  such as a QR code to gather data and inform the user of correct usage of the tool and the required accessories for a job such as a wire harness, for example. 
     In a particular aspect, the controlling computer  214  can be external when the crimp tool  200  and positioner  208  are used for production or wire harness manufacturing applications. However, when the crimp tool  200  and positioner  208  are used for maintenance or low volume remote use, a crimp tool  200  with an internal controlling computer with display (monitor)  205  may be preferred for portability, and can be made available by the manufacturer. 
     A display on the controlling computer  214  will indicate the connection when the crimp tool  200  is turned on (by a switch) and a positioner  208  is installed and latched onto the crimp tool  200 . The internal read only data in the memory chip  209  of the positioner  208 , and firmware  229  (see  FIG. 22 ) stored by the crimp tool microprocessor  207  of the compatible crimp tool  200  will communicate and verify the compatibility and condition of the crimp tool  200  and positioner  208 . 
     The total number of crimp operations (or cycles) since the last self-calibration operation is stored in memory  231  of the crimp tool microprocessor  207 , and is registered and displayed. on the controlling computer  214 . The positioner  208  will, identify itself to the controlling computer  214  with its part number, and the database which corresponds to that part number will fill the user screen on the controlling computer  214  with information (based on setup choices made by the user) as shown in  FIG. 14 . This will include all the contact part numbers which are assigned to that positioner  208 , contact manufacturer name, military or standard number reference, wire/cable information, and notes or process references. 
     The crimp tool  208  may be fitted. with three buttons  236 ,  238 ,  240  or touch screen sensors on the controlling computer monitor (depending on equipment used, and setup choices made by the user) as shown in  FIG. 14 . When the top button/sensor  236  is actuated, the display menu  230  will scroll the list of contact part numbers  232  up. When the lower button/sensor  238  is activated, the display menu  230  will scroll the contact information  232  down. When the correct contact part number is aligned with a window or some alignment indicator, the center button/sensor  240  can be activated to select the contact part number which is in position. 
     When the contact part number is selected, the stored digital memory will open the data that pertains to that contact (wire size and crimp depth settings) and display it on the controlling computer  214 . A. wire size/part number menu  234  will open on the display as shown in  FIG. 14 , and the wire can be selected by scrolling up or down with the button/sensor pad (previously used to select the contact part number). 
     The part number  252  and wire size  254  selected will move to a designated minor position on the display  250 , at which time, the display  250  will show a graphic which has a circle  260  in the center with an up-arrow  258  on one side and a down-arrow  256  on the other side as shown in  FIG. 15 . 
     Based on the selection of the contact and wire size/type, the predetermined crimp depth setting for the crimp tool frame, contact, and wire size is determined by the controlling computer  214 , if the actual setting as it is currently adjusted is inappropriate for the selected wire size and contact, it will illuminate the circle  260  in the center of the display red, and it will blink either the up-arrow  258 , or the down-arrow  256  to indicate to the operator/user which direction to turn the adjustment knob  132  on the crimp tool  200 . 
     If the up-arrow  258  is blinking, it indicates the adjustment knob  132  requires turning in a direction that makes the crimp depth larger in diameter. If the down-arrow  256  is blinking, it indicates the adjustment knob  132  should be rotated in the opposite direction to decrease the crimp depth. As the correct position nears, an indication is generated for alerting the user. For example, the indicator may be the circle  260  is red and will begin blinking or changing color, indicating to the operator/user to slow down. When the setting is correct for the wire/contact application, the circle  260  will turn green, and an audible signal is activated, for example. As those of ordinary skill in the art, the indication can be visual, aural, haptic, etc., for example. 
     During crimping operations, the internal electronics will be updating and refreshing the position indicators and other sensors, and if a change in crimp depth selector adjustment occurs (someone intentionally or inadvertently changes the setting), the crimp tool  200  is overstressed, or a shock due to dropping occurs, an alarm is activated in the crimp tool  200 , an indication will appear on the controlling computer  214 , and the number of suspect terminations is recorded into the database. 
     The adjustment knob  132  may include a movement sensor  233  (see  FIG. 9A ) such as a precision potentiometer which will change resistance in very small mechanical increments. As can be appreciated by those of ordinary skill in the art, other sensors to sense mechanical movement may also include optical sensors, capacitive sensors, and/or magnetic, sensors. When the crimp tool power switch is turned on, the movement sensor  233  is read/monitored by the internal microprocessor  207  and firmware  229  in the crimp tool  200 . The microprocessor is configured to refresh frequently, and any change in setting is held in the database, and dealt with in accordance with setup screen choices made by the technician. 
     A battery condition of the crimp tool  200  will also be monitored by the crimp tool microprocessor  207  and firmware  229 , and change is indicated to the technician when it is necessary should the crimp tool  200  be battery powered. 
     A function is programmed into the positioner  208 , the crimp tool  200 , and the controlling computer  214  so that the technician can select and display the gaging dimension in either inch or millimeter, for example. 
     The positioner  208  is also configured to be mounted to a compatible motorized adjustment crimp tool  200 ′ shown in  FIG. 16 . The motorized adjustment crimp tool  200 ′ may be fitted with an automatic adjustment unit  270  that may include a precision actuator or a stepper motor, for example, a control circuit, and specialized software to perform the crimp depth adjustments under the control of the positioner  208 , the crimp tool microprocessor  207 , and the controlling computer  214 . 
     When the positioner  208  is coupled to a motorized crimp tool  200 ′, relevant information and a configuration is stored in the crimp tool memory  231  of the microprocessor  207 ′ that identifies (to the controlling computer  214 ) the type of crimp tool to which the positioner  208  is attached. The database having the internal firmware will reset the software accordingly. 
     When the technician selects tare contact part number and the wire size using the same process described previously for the operation of the positioner  208  and the manual crimp tool  200 , the automated adjustment unit  270  in the motorized crimp tool  200 ′ will actuate the stepper motor to turn the adjustment knob  132  in the needed direction, and stop it precisely at the place where the correct crimp depth will occur. 
     In operation, the crimp tool  200  will identify itself to the controlling computer  214  with the crimp tool part number, type, serial number, and other types of identification data, based on setup screen choices. This identification data is acknowledged and maintained in the master database. The crimp tool  200  is configured with a crimp cycle counter system that may include a permanent magnet in the crimp tool handle or some location in the crimp tool closing mechanism. The magnet will pass a magnet activated sensor (such as a reed switch) each time the crimp tool cycles. As can be appreciated by those of ordinary skill in the art, any sensor that can tally a count could be used such as an optical switch or the contacts of an electrical switch. The total number of crimp duty cycles (one closing and opening of the crimp tool) is counted and retained in the database. 
     The crimp tool  200  may also he equipped with a crimp force sensor(s) which will sense the relative force required to close the crimp tool handle, or powered closure mechanism for a powered crimp tool  201  as shown in  FIG. 9B  via a connection  221  to a power source. When this feature is present in the crimp tool  200 , the force is recorded, and the data is used to indicate whether the cycle was under load or not. It may also be used to indicate if the crimp tool  200  was overstressed (indicating that it was used improperly or used to crimp something other than the intended contact). This closing force sensing feature may also be used to indicate operator imposed defects. 
     General use for the closing force sensing function of the crimp tool  200  such as to detect if the crimp tool crimped a contact or was cycled without a contact, and to sense an overstressed application of the crimp tool can be accomplished with low accuracy strain gages. 
     Setup choices will allow the crimp tool  200  to be managed appropriately. For instance, the technician can decide to gage every desired number of cycles, and the crimp tool will indicate to the technician when that number has been reached. The user  275  can decide to gage older, high cycle tools more frequently, and many other choices are available to the technician, and controlled by setup screen choices made by the technician. 
     When it is determined that the crimp tool  200  is required to be calibrated due to the number of crimp operations or otherwise, an indicator is generated that may be an audible, visual, and/or haptic signal, for example, on the controlling computer  214  or crimp tool  200 , and normal crimping operations will cease until the calibration is complete. 
     The technician is instructed to unlatch a calibration gage  204  as illustrated in  FIG. 17  from its storage holder on the positioner interface  202  of the crimp tool  200 . A gage pin  244  of the calibration gage  204  is inserted and latched into the receiving port  211  on the head  210  of the crimp tool  200 , on the side of the crimp tool opposite to the positioner  208 . The positioner  208  need not be removed. A wire  242  may be attached to the calibration gage  204  and may extend and retract as needed from the positioner interface  202 . The wire  242  also keeps the calibration gage  204  with the crimp tool  200  for which it was designed. The calibration gage  277  may also include a microprocessor that includes memory for storing and reading data and firmware. 
     The technician is instructed to close the crimp tool handle or close the mechanism actuation (powered crimp tools) prior to inserting the gage pin  244  into the receiving port  211 . This will allow the tool indenters to be retracted to a position where gage damage is least likely. 
     Referring now to  FIGS. 17 and 18 , the crimp tool  200  with the calibration gage  204  is ready to insert/latch into the receiving port  211  where it is used for calibration gage verification. 
     When the calibration gage  204  is latched into the receiving port  211  using latch  246 , as illustrated in  FIG. 19 , the gage pin  244  will extend into the center of the indent cavity to a location between the crimping dies. The receiving port  211  is configured so the gate pin  244  is central to the crimp tool crimping dies, and the gage pin  244  is oriented radially to a position where the crimping dies align with conductive segments  248   a,    248   b,    248   c,    248   d  of the gage pin  244  (see  FIGS. 20-21 ). 
     If the indent gap in the crimp tool  200  is set to a diameter smaller than the gage pin  244 , the calibration gage  204  will still latch into place, but the gage pin  244  will compress into the gage handle  215  under light spring pressure, for example, so as not to be damaged, or damage the crimping dies. A switch  213  in the gage handle  215 , as shown in  FIG. 19 , is configured to sense the compressed position of the gage pin  244 , and causes instructions to be generated for the user to slowly adjust the crimp tool  200  using the adjustment knob  132  in the direction that will open the crimping dies, and allow the gage pin  244  to enter the indent cavity. 
     The gage pin  244  of the calibration gage  204  has a precise diameter and length which acts as a reference diameter. When the gage pin  244  is installed into the receiving port  211 , the user is instructed by the controlling computer  214  to adjust the crimp tool using the adjustment knob  132  to a position where each of four indenters, for example, lightly touch the gage pin  244 . They will be acknowledged by electrical continuity between each crimping die and the corresponding elongated conductive segment  248   a,    248   b,    248   c,    248   d.    
     In another aspect, an insulating sleeve  245  can be placed over the conductive areas ( 248   a,    248   b,    248   c,    248   d ), as shown in  FIG. 21C , and these areas can then be sensed individually by a capacitive sensor. Very small variances of distance and dimensions can be used to indicate if the crimping dies  118   a,    118   b,    118   c,    118   d  as a whole group are within calibration, or if any particular one has failed or is damaged. 
     When all four crimping dies  118   a,    118   b,    118   c,    118   d  are lightly touching the respective conductive segments  248   a,    248   b,    248   c,    248   d  (or a different sensing element such as the insulating sleeve  245 ) and the force is monitored by a strain gage, a precise reference diameter is established, and recorded in the crimp tool memory  231  of the microprocessor  207 . This precise diameter setting comprises the datum point, and used as the reference basis for diameters selected by the crimp tool  200  using the adjustment knob  132 , which may be motorized  270  or manual. 
     When the gaging operation is complete, the user is instructed by the controlling computer  214  to unlatch the calibration gage  204  from the receiving port  211 , and reinstall it in the positioner interface  202 , where it is stored until it is needed for additional gaging operations. A switch/sensor  217  on the positioner interface  202  will activate when the calibration gage  204  is properly stored, and the crimp tool  200  returns to normal crimping operations. 
     A reset of the calibration cycle count will take place in the microprocessor  207  of the crimp tool  200 , and the controlling computer  214  will keep a complete record of the calibration, including the date, operator ID, and Job Code, for example. 
     The operator is instructed by the controlling computer  214  to reset crimp depth adjustment to the previous setting, and the positioner operation will resume. The controlling computer  214  will verity the positioner ID (part number), and resume data collection for the crimping operations. 
     The number of crimp duty cycles since the last calibration is kept in active, non-volatile memory  231  of the microprocessor  207  in the crimp tool  200 . The controlling computer  214  will manage the cycle count as it relates to calibration of the crimp tool  200 . 
     The gage pin  244  of the calibration gage  204  is configured in a way that it electrically or optically senses when each of the four indenter tips  118   a,    118   b,    118   c,    118   d  (i.e., crimping dies) touch the gage pin  244 , and therefore will establish a reference setting which resets the basis of the electronic measuring system internal to the crimp: tool/positioner, and the calibration is confirmed. 
     Referring now to  FIGS. 20 and 21A-21B , the gage pin  244  is divided (by casting or machining) into four elongated conductive segments  248   a,    248   b,    248   c,    248   d,  and bonded to a non-conductive core  250  such as a symmetrical four channel plastic form in the center, for example. Each conductive segment  248   a,    248   b,    248   c,    248   d  is insulated from the other segments, but have metal exposed on the outer diameter. Each conductive segment  248   a,    248   b,    248   c,    248   d  is connected to a wire  255   a,    255   b,    255   c,    255   d,  or circuit board having a conductive path to the microprocessor  207  in the crimp tool  200 . 
     The diameter of the gage pin  244  is closely held to a gage dimension/tolerance. When the crimping dies  118   a,    118   b,    118   c,    118   d  touch the outside diameter of the gage pin  244  having the conductive segments  248   a,    248   b,    248   c,    248   d,  an electrical path (to ground) is established, and allow the microprocessor  207  to sense the position of each crimping die  118   a,    118   b,    118   c,    118   d.    
     An alternative configuration for the gage pin  244  comprises a non-conductive core, such as a ceramic rod, with printed segments, and the printing media is conductive and durable to the extent required to support the gaging needs of a production crimp tool. 
     In operation, the gaging pin  204 , and electro-mechanical functions of the crimp tool  200  are measured, tested, and verified on an annual basis, or a schedule that meets the technician experience and environment of the technician. 
     An advantage of using this system includes that the crimp tool  200  can be used in production or maintenance operations with frequent calibration intervals based on the number of cycles under load the crimp tool  200  has experienced, and at other desired intervals (e.g., annually). The crimp tool and gage diameter/operation can be scheduled for inspection in a well-equipped test lab by experienced and authorized technicians. 
     Since the system is intended for broad use across various industries, gaging error management in crimp tools is handled differently by various technicians and managers. A graphical user interface (“GUI”)  225  is displayed on a display  235  of the controlling computer  214  and is configured the user/managers  275  to select options, and control calibration gaging errors in the appropriate way for their needs (see  FIG. 22 ). 
     During the set-up of the management, monitoring, and control of the positioners and calibration gages in a user location or across the enterprise, the GUI  225  presents set-up answers/choices to the user which will configure the system across all compatible positioners, calibration gages, and crimp tools in the location or the enterprise. 
     In a particular aspect, the selections may include the following: 
     The option to “TAKE NO ACTION” or “TAKE ACTION” when out of gaging errors are found: 
     If “TAKE NO ACTION” is the choice, the tools in this system will make adjustments (motorized Tools) . 0 r instruct the operator to rotate the crimp depth selector knob, and manually adjust the tool (non-motorized tools) back into the correct gaging range. 
     If “TAKE ACTIONS” is selected the crimp tool will not be automatically adjusted (motorized tools) or give instructions for the operator to adjust it (non-motorized tools). The user is instructed by a message on the display that the tool is to be sent for repair, and the tool is identified as not being eligible for production line use until the repair is performed, and the authorized administrator restores it to useable status. 
     Whether action is taken or not, a record of the out of gaging condition will become part of the data stored for that crimp tool, and a record of the date and condition(s) is available as a permanent record in the database  227 . 
     When all “tool use” issues are resolved with crimp tool that reported out of gaging, a person with assigned user rights of manager or above can override the gaging error lockout, and restore the crimp tool to normal production use. The crimp tool will self-adjust in the standard way for motorized tools  200 ′, or guide the user through adjustment in the standard way in the case of a manual adjustable crimp tool  200 . The override will become part of the database  227 . 
     A gaging error threshold can be elected of 0%, 2%, 5%, for example, or any number that is entered into a setup screen on the GUI  225  (person must have user rights of administrator or above). The selected gaging error threshold can be configured across all tools in a select group, or across all tools enrolled in the user enterprise. 
     The database  227  which controls the positioner compatible crimp tools is extensive and powerful. It includes assignable lookup functions and access to data beyond the immediate application being used. 
     In addition, the positioner  208  and the calibration gage  204  may be fitted to manually closed crimp tools  200  (tools with moveable handles closed by human strength), or powered crimp tools  201  (tools which move through the crimp cycle by means of electric, pneumatic, or hydraulic power). 
     A block diagram of a system  272  in various aspects of the disclosure may be implemented is illustrated. In particular, the system  272  includes the crimp tool  200  ( 200 ′ for motorized crimp tool) having a microprocessor  207 . The microprocessor  207  includes memory  231  (for storing and reading data) and firmware  229 . In addition, the crimp tool  200  includes a transmitter  223  for communicating with the controlling computer  214  which may he remote, local or part of the crimp tool  200 . As explained above, the crimp tool  200  includes an adjustment knob  132  to adjust the crimp depth. The positioner  208  includes the memory chip  209 , which is configured to be read by the reader  206 . The reader  206  may be included with the positioner interface  202 , which is communication with the microprocessor  207 . 
     The controlling computer  214  is operated by a user  275  using GUI  225 . The controlling computer  214  includes a display  235  for the GUI  225  and a database  227  storing data regarding the crimp tool  200  and positioner  208 , and also the data used for selecting a correct crimp depth as explained above with respect to  FIGS. 14 and 15 . The controlling computer  214  may also be in communication with a network  220  (e.g., a cloud service). 
     Often the technician may not know the wire part number or size by the AWG or Metric designation which is selectable through the positioner/wire data. This is a common issue with maintenance use of crimp tools. Accordingly, an optional (wired or wireless) plug-in wire caliper  300  may be used to, automatically select the wire size, and change the crimp tool settings to the appropriate settings for the wire diameter being measured as shown in  FIG. 23 . In addition, can identify if installed positioner is incorrect for given wire size or selected contacts are incompatible for wire size. 
     A plugin jack  219  may conveniently be positioned on the crimp tool  200  so that the wire caliper  300  can be coupled to it using output plug  302 . In another particular aspect, the crimp tool  200  is wirelessly  301  coupled to the wire caliper  300 . When the contact is selected by the method previously described, the technician is instructed by the GUI  225  to measure the wire  308  by opening the, measuring jaws  306  of the wire caliper  300 , and closing them under spring pressure on the wire  308  (outside diameter of the stripped bare conductor (preferred) or over the wire insulation jacket). The technician is asked by the GUI  225  if the measurement jaws  306  are affixed to the conductor (metal wire strands) or the insulation (outer covering). The technician will select the appropriate answer by moving up or down and selecting the answer. When that question is answered, the controlling computer  214  will compare the readings (measured diameter) with the database  227 , and display the wire size using the, GUI  225 , and send data to the automatic adjustment unit  270  of a motorized crimping tool  200 ′ which will cause the motor to activate, and move to the correct crimp depth for that contact/wire size combination. If a manually adjusted crimp tool  200  is being used, then information on the controlling computer  214  will activate, and using the GUI  225  instruct the operator to rotate the crimp depth adjustment knob  132  accordingly. 
     Referring now to the flowchart  400  in  FIG. 24 , and generally speaking, a method of using the crimp tool illustrated in  FIGS. 9A-22  will be discussed. From the start  402 , the method includes transmitting positioner data read from a memory chip to a computer having a display and input device, at  404 , and, at  406 , generating a list of a plurality of available contact part numbers and wire sizes corresponding to the positioner data read from the memory chip. Moving to  408 , the method includes receiving a selected contact part number and a wire size that was selected from the list by a user using the input device, and at  410 , determining whether the crimping depth is currently set to a crimp depth required by the selected contact part number and the wire size. The method also includes, at  412 , generating an indicator on the display to adjust the tool to the required crimp depth when adjustment is required. If the crimp tool needs to be calibrated, at  414 , then a method of calibration  420  begins as shown in  FIG. 25 , otherwise the method ends at  416 . 
     The calibration of the crimp tool begins, at  422 , with sliding a gage pin into a receiving port of the crimp tool, where the gage pin comprises a non-conductive core having a plurality of elongated conductive segments thereon and insulated from each other, and transmitting, at  424 , a signal when making contact with one of the plurality of crimping dies to determine a position of a respective crimping die. Moving o  426  the method may include adjusting the crimp depth on the tool to correspond to a calibrated crimp depth. In addition, the method may include, at  428 , transmitting to the computer and storing a contact size and a wire size for each crimping operating, and a number of crimp operations since a last calibration. The method ends at  430 . 
     Many modifications and other embodiments of the invention will me to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.