New Ocean Applicators from TE
Exceeding the Requirements of Today
to Meet the Demands of Tomorrow
New Ocean Applicator Series from TE Connectivity
New Ocean Applicator Series
With the knowledge and experience of over a half century designing and manufacturing world leading
applicators and tooling, TE is taking terminal crimping to a new level. Using the time proven HDM and HDI
applicator platforms as a base and the innovation and improvements from the System
III
Applicator, TE is taking
a large step forward. TE has listened to customer input and market demands to innovate and improve the
combined strength of these industry leading designs to create the new Ocean Applicator Series.
The lead and harness industry of today is more price and quality competitive than ever before. Crimping
standards continue to be raised to higher levels of quality and repeatability. The industry continues to expect
more from application tooling. The Ocean Applicator Series was designed specifically to exceed the
requirements of today and meet the demands of tomorrow.
By consolidating our applicator offering to this new applicator, TE can provide design consistency and tooling
standardization to the market. One of the major benefits to the customer is offering the ultimate flexibility with a
choice of feeding options: New and improved Mechanical and Pneumatic feeds combined with the innovative
and precise Servo Feed option. The Ocean Applicator design makes it possible for customers to perform field
upgrades to System
III
technology. It will provide an upgrade path for
terminal intelligence
that allows the
machine to obtain set-up features as the applicator is upgraded.
One Applicator Platform — Modular Family Design
• 2 ram interface styles (“Atlantic” or “Pacific” style ram collar)
• Same wire crimper, insulation crimper, and anvil used on both applicator styles
• 3 feed options
• Mechanical
• Pneumatic
• Servo
• Same feed units can be used on Side-Feed and End-Feed style applicators. All units can be
easily removed and interchanged for upgrades if desired.
Atlantic-Style SF Servo
Atlantic-Style SF Pneumatic
Atlantic-Style SF Mechanical
Pacific-Style SF Servo
Pacific-Style SF Pneumatic
Pacific-Style SF Mechanical
Need More Information?
For information about tooling, call 888-777-5917 or 717-810-2080
or e-mail toolingsales@te.com.
For drawings or technical data, contact your TE Connectivity sales engineer or call the Technical Support
Center: 1-800-522-6752. Dimensions are in millimeters unless specified otherwise. Values in brackets
are English equivalents unless specified otherwise. Specifications subject to change. Consult TE
Connectivity for latest specifications.
2
New Applicator Series from TE Connectivity
Terminal Feed Types
Mechanical Feed
The industry standard TE mechanical feed design has been completely revamped to
address the needs of today and the future. Mechanical designs of the past could be
difficult for operators to adjust, particularly small applications that require the terminal
to be located very precisely in the crimp area. Easily accessible micro adjustments for
the forward and back stroke have been created. This allows for precise and repeatable
terminal location in the crimp area.
During the development of this new feed mechanism several different designs from the
industry were evaluated, along with the HDM mechanical feed mechanism. During this
analysis it was discovered that all of the designs had an existing condition. This existing
condition presented a major concern in the performance of mechanical feed designs.
The roller (cam follower) that tracks the cam for the feed cycle to start and finish
actually leaves the cam surface at the end of the cycle. It does not fully track the
gradual slope of the cam. The result is an “instantaneous terminal acceleration” in the
next feed cycle, produced by the sudden contact of the cam follower with the cam. This
causes the terminal to be thrown forward instantly and not brought up to speed
gradually as is preferred. This violent acceleration can lead to feed inaccuracy.
The TE mechanical feed design keeps the roller and cam in constant contact for a
smooth transition through each feed cycle to offer superior feeding performance.
Feed Cam
Cam Follower
Industry Standard
New Applicator
Back Stroke
Adjustment
Forward
Adjustment
Need More Information?
For information about tooling, call 888-777-5917 or 717-810-2080
or e-mail toolingsales@te.com.
For drawings or technical data, contact your TE Connectivity sales engineer or call the Technical Support
Center: 1-800-522-6752. Dimensions are in millimeters unless specified otherwise. Values in brackets
are English equivalents unless specified otherwise. Specifications subject to change. Consult TE
Connectivity for latest specifications.
3
New Ocean Applicator Series from TE Connectivity
Terminal Feed Types
Pneumatic Feed
The pneumatic feed unit was designed to be self actuated by the applicator and
only needs constant air supplied to the pneumatic feed unit. No terminator air
valve is required. This allows the Pneumatic-Feed applicator to be compatible
with many terminators including the TE AMP 3K/40, AMP 5K/40, Model G,
Model T, DT3000 and DT5000 Terminators as well as many other competitive
brands.
Improvements in the pneumatic feed provide flexibility and fine adjustment
increments for a higher level of crimp precision. Quick and simple adjustments
can be made since the forward terminal positioning and back stroke adjustment
are independent of one another. The forward terminal location can be adjusted
in very fine 0.04mm increments for precise terminal
positioning in the crimp area. The back stroke is also
Removable
incremental at 0.08mm steps.
The pneumatic cylinder was specially designed to be double
acting with constant air pressure. This provides the ability to
adjust the speed of actuation. The terminal positioning speed
can be reduced to improve the repeatability of terminal
placement.
All of the new applicators are completely metric to provide the
convenience of a single set of tooling to adjust and perform
maintenance. The pneumatic-feed can handle terminal feed
lengths from the very small to the very large with a maximum
of 48.25mm.
Servo Feed
The Servo Feed Applicator must be used with AMPOMATOR System
III
Lead-
Maker or a Precision Controller unit attached to a terminator or lead-maker
machine.
In the Servo Feed Applicator, the feed function is completely independent of the
ram stroke. The limitations of the mechanical linkage are gone. Also gone are
manual adjustment every time terminal spacing varies or feed errors arise, as well
as the errors that rob machine uptime and reduce productivity. With a servo
motor and ball screw drive system, the feed is controlled by commands from the
terminator. The feed detaches from the crimp mechanism with a simple, tool-less
latch. When the job changes, you only change the applicator; the servo feeder
remains. The servo feed is so versatile and precise, with the push of a button the
terminal is advanced or retracted by 0.03mm. The changes are then saved in the
iButton data module.
The data module built into the Servo Feed Applicator stores the personality of the
applicator, its identity, and the terminals it can crimp. It also contains all crimping
parameters for system confirmation, including saving data on the previous run for
easy access the next time the applicator is used. Data is transmitted through a
simple contact for processing in the terminator and the system computer. There’s
no separate cable or connector, just the contact that completes the circuit when
the applicator is snapped into place.
For information about tooling, call 888-777-5917 or 717-810-2080
or e-mail toolingsales@te.com.
For drawings or technical data, contact your TE Connectivity sales engineer or call the Technical Support
Center: 1-800-522-6752. Dimensions are in millimeters unless specified otherwise. Values in brackets
are English equivalents unless specified otherwise. Specifications subject to change. Consult TE
Connectivity for latest specifications.
Protective
Cover
Back Stroke
Adjustment
Forward
Terminal
Position
Need More Information?
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New Applicator Series from TE Connectivity
A Stronger, Smarter, More Reliable Applicator
It takes more than a better feed to make a better applicator. Along with the robust, reliable construction you
expect from TE. The crimping section of the new Ocean Applicator incorporates redesigned components and
optimized operation, without feed concerns or constraints. TE places emphasis on engineering products for the
highest performance and longest life is reflected in some of the
details of the design.
Terminal Hold Down
Terminal positioning is critical. As a result, the terminal depressor
has been redesigned in the new Applicator. The terminal
depressor is spring-loaded, which requires no adjustment
between terminal crimp height changes, and is a solid steel piece
for long life and positive terminal bend control.
Fine Adjust Wire and Insulation Crimp Adjustments
The tool-less adjustment features have been developed to
provide fine increments for improved precision and simple
adjustments to help reduced setup times.
Wire crimp height adjustment
• Positive detent positioning
• Range = 0 - 1.5mm, Steps = 0.01mm
Terminal Positioner
Insulation Adjustment
Range (mm)
3.30
1.70
0.85
Step Size (mm)
0.19
0.10
0.05
• Insulation step sizes are selected based on terminal
application requirements
Insulation
Crimp Height
Adjustment Dial
Wire Crimp Height
Adjustment
Position Indicator
for Wire &
Insulation Crimp
Settings
Need More Information?
For information about tooling, call 888-777-5917 or 717-810-2080
or e-mail toolingsales@te.com.
For drawings or technical data, contact your TE Connectivity sales engineer or call the Technical Support
Center: 1-800-522-6752. Dimensions are in millimeters unless specified otherwise. Values in brackets
are English equivalents unless specified otherwise. Specifications subject to change. Consult TE
Connectivity for latest specifications.
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Microcontroller MCU
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