We were contacted by Pektron to quote for the 2 different assemblies in the photo.
These assemblies require 30awg wire (0.05mm sq.) and a Molex Pico-Clasp series crimp terminal.
Our machines regularly run 28awg wire (0.08mm sq.) with this crimp terminal, and are designed to work with wire sizes down to 36awg (0.0123mm sq.)
As we hadn’t run wire this small we set-up a trial validation to ensure we could process this combination of wire and terminal reliably, and to check the in-process crimp force monitors would work consistently.
Once we had validated the wire processing we looked at product assembly.
The drawings we were provided required the wires to be twisted into pairs, however no consideration to banding restrictions had been made.
Due to the small size of the terminals, if twisted incorrectly they might not be securely latched into the connector.
Again we carried out trials to ensure we could provide the required twist, without affecting physical performance, by leaving a section un-twisted near the connector.