Schleuniger - Crimp Micrograph Analysis

Overview

The ESU 6 ElectrolyteStaining Unit is a component of the MicroGraph System for the creation of high quality cross-sectional images of crimp connections and others.

• Very simple handling
• Efficient and quick cleaning
• Cleaning directly under the optics possible
• No waiting time
• Environmentally-friendly

Application Range

With the MicroGraph System (MGS), crimp cross-sectional images can be created in a fraction of the time compared to conventional methods. The system includes modular components that can be combined according to individual needs. The ElectrolyteStaining Unit (ESU) allows the user to quickly and safely stain a pre-cut cross section sample for further analysis.

The sample is stained using an innovative electrolytic staining process using a solution with a Ph level the same as water. Therefore, it is very safe to handle without any of the special equipment or training required with acids. A built-in staining indicator glows depending on the strength of the staining process, thereby giving the operator instant feedback on the effectiveness of the process. Multiple staining pen sizes are available depending on the sample size.

The ESU 6 can be used on a range of applications from crimp cross sections to welded samples.

Overview

Microscope for visual analysis of cross-sectional images of crimped connections.

• Precise results in real-time
• Simple connection and installation with standard PC
• Clear illumination with LED ring light
• Analysis according to international standards
• Quality software for measuring and analysis

Application Range

With the MicroGraph System (MGS), crimp cross-sectional images can be created in a fraction of the time compared to conventional methods. The system includes modular components that can be combined according to individual needs. The MacroZoom Unit (MZU) 1.3 allows the user to quickly and accurately analyze a pre-cut cross-section sample using precision optics and powerful software. The 1.3 megapixel optic unit includes 9 incremental zoom positions that can be calibrated for repeatable and accurate measurements. An optional auxiliary lens can be added to expand the field of vision for larger samples. Sample illumination can be adjusted as necessary with the LED light ring for best picture clarity.

The CrimpLab software included with the MZU is specifically designed for crimp cross-section analysis. It is a powerful yet simple software for capturing all of the critical measurements. Basic functions for measuring height, width, area and radius values are included as well as others, such as strand counter and a crimp area reduction calculator. Images can be stored in multiple formats either with or without measurements and measurement masks can be created for comparison between sample sets. Once all measurements are captured, the information can be easily transferred to a PDF report. Although the CrimpLab software was created specifically for crimp cross-sectional analysis, it is extremely useful for many other quality analysis applications as well.

Overview

Schleuniger’s MicroGraph System allows the creation of high-quality crimp cross-sectional images in a fraction of the time needed with “conventional” methods. The system is comprised of modular components that can be combined according to your individual needs.

Application Range

Crimp cross-sectional analysis has quickly become an integral part of the crimp quality process. With the MicroGraph System (MGS), crimp cross-sectional images can be created in a fraction of the time compared to conventional methods.

The combined sawing-polishing process, innovative electrolyte staining process, and high precision optics result in high quality images for thorough analysis of the connection. Electrical connections (e.g. crimped, welded, soldered or spliced) can be cut (sawed), polished, stained (cleaned), and visually analyzed.

The system includes modular components that can be combined according to individual needs. Ergonomically designed work tables are also available to optimize workflow when combining the components in one area. The complete system can also be integrated into mobile carts to create a mobile quality station.

Overview

The SawInspect System 6 (SIS 6) is an innovative new product that provides crimp quality assurance and quality control to the wire processing industry. This extremely compact sawing and inspection system is used to quickly create and analyze crimp cross-sections by combining three individual Schleuniger quality products into one complete system:

• The precision cutting of the SawPolish Unit (SPU 6)
• The high quality microscope of the MacroZoom Unit (MZU 1.3)
• The electrolyte staining of the ElectrolyteStaining Unit (ESU 6)

Application Range

The SIS 6 can be used as a stand-alone system or mounted on a CrimpCenter automatic cut, strip, terminate machine. A variety of sample holders and the optional 0.2 mm VHM cutting blade make it possible to process many different crimp contacts.

• Compact design with minimized processing movements and steps for fastest results
• Complete cross-section analysis and job management with CrimpLab 2 software
• Full analysis in seconds after just a few clicks with CrimpLab 2 Automatic software

The SIS 6 allows users to create cross-sectioned samples in just a few quick steps. The individual sample is placed in the holder and aligned with the saw blade. The unique blade is designed to provide a very clean cut that does not require polishing. After cutting, the sample holder is quickly moved from the blade to the microscope with the use of guide rails. The sample holder rotates 90º allowing for a perfect view of the cross-sectioned sample. All necessary parameters of the cross-sectioned contacts can be measured and analyzed with the equipped CrimpLab 2 Standard software.

With the new SIS 6, all processing steps and motions have been minimized to increase efficiency and provide the fastest results. The SIS 6 can be used as a stand-alone system or mounted on a CrimpCenter automatic cut, strip, terminate machine. A variety of sample holders and the optional 0.2 mm VHM cutting blade make it possible to process many different crimp contacts on the SIS 6.

Overview

The SawPolish Unit is a component of the MicroGraph System for the creation of high quality cross-sectional images of crimp connections.

• Three models for sawing and polishing a wide range of crimp connections
• Polishing disc is in line with the saw blade for fast and simple processing
• Compatible with ElectrolyteStaining Unit and MacroZoom Unit 1.3 for a complete crimp cross-section analysis
• Numerous sample holders are available for a variety of applications, such as welding, potting and connector inspection

Application Range

The SawPolish Unit enables users to saw and polish samples quickly and cleanly using the combined sawing-polishing process. The SawPolish Unit can process crimp contacts for cross-sections up to 60 mm² (1/0 AWG) or a maximum sample height up to 20 mm (0.79”). The saw blades will cleanly cut most common materials, such as copper, aluminum, steel, alloy steel, stainless steel, titanium, bronze, brass, cast iron, gold, silver, inconel, nimonic, hastelloy, magnesium alloys and plastic. Other materials may be possible and can be evaluated during sample processing.

The sample is placed in an interchangeable sample holder and inserted into the sample slide. The cutting blade and polishing disc are aligned so that the sample can be cut and polished in one motion to minimize processing time. The carbide blades cut so cleanly that polishing is frequently not even required thereby reducing overall process time. The sample holder can then be removed and installed into other components of the system for further analysis.

Cutting blades are available in various widths to accommodate a range of sample sizes. Similarly, numerous sample holders are available for a variety of applications, such as welding, potting and connector inspection.