application specification · figure 4 conductor crimp this is the metallurgical compression of a...

APPLICATION SPECIFICATION

REVISION: ECR/ECN INFORMATION: TITLE: MX150 Female Receptacle 0.30mm Thick

Application Specification

SHEET No.

A EC No: UAU2011-0628

1 of 18 DATE: 1/29/2011

DOCUMENT NUMBER: CREATED / REVISED BY: CHECKED BY: APPROVED BY:

AS-33012-002 Kate Ferguson Ajay Dhir Brian Moser

TEMPLATE FILENAME: CRIMP_SPEC[SIZE_A](V.1).DOC

MX150™ RECEPTACLE CRIMP TERMINAL

1.0 SCOPE This specification details the crimping information and common practices for general crimps for the Molex MX150 receptacle terminal per sales drawing SD-33012-002. Please refer to the sales drawing for additional part information. The information in this document is for reference and benchmark purposes only. Based on the guidelines of USCAR-21 the user is responsible for validating crimp performance based on tooling, equipment and wire that is being used. All measurements are noted in millimeters unless otherwise specified.

2.0 PRODUCT DESCRIPTION

DEFINITION OF TERMS

Figure 1




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DEFINITION OF TERMS (CONT.):

The terminal drawing is a generic terminal representation. It is not an image of any terminal listed in the scope.

Figure 2

INSULATION CRIMP WIDTH

(ICW)

INSULATION CRIMP HEIGHT

(ICH)

13

12

CONDUCTOR CRIMP WIDTH

(CCW)

CONDUCTOR CRIMP HEIGHT

(CCH)

11

10

CONDUCTOR

ANVIL FLASH

14




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EXCESSIVE CONDUCTOR BRUSH, CUT SEALS

BELLMOUTH (FLARE) The flare that is formed on the edge of the conductor crimp acts as a funnel for the wire strands. This funnel reduces the possibility that a sharp edge on the conductor crimp will cut or nick the wire strands.

Figure 3

CONDUCTOR BRUSH The conductor brush is made up of the wire strands that extend past the conductor crimp on the contact side of the terminal. This helps ensure that mechanical compression occurs over the full length of the conductor crimp. The conductor brush should not extend into the contact area or above the conductor crimp height. CAUTION: Excessive conductor brush extended above the transition/crimp can cause connector water leak by compromising the glands of the matte seal.

Bad Crimp Good Crimp Figure 4

CONDUCTOR CRIMP This is the metallurgical compression of a terminal around the wire's conductor. This connection creates a common electrical path with low resistance and high current carrying capabilities.

CONDUCTOR CRIMP HEIGHT The conductor crimp height is measured from the top surface of the formed crimp to the bottom most radial surface. Do not include the extrusion points in this measurement. Measuring crimp height is a quick, non-destructive way to help ensure the correct metallurgical compression of a terminal around the wire's conductor and is an excellent attribute for process control. The crimp height specification is typically set as a balance between electrical and mechanical performance over the complete range of wire stranding and coatings, and terminal materials and plating. Although it is possible to optimize a crimp height to individual wire strandings and terminal plating, one crimp height specification is normally created.

5 6

8

10

CONDUCTOR BRUSH FLUSH OR BELOW CRIMP




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CUT-OFF TAB LENGTH This is the material that protrudes outside the insulation crimp after the terminal is separated from the carrier strip. A cut-off tab that is too long may expose a terminal outside the housing, it may fail electrical spacing requirements or could lead to excessive seal tears in matte sealed connectors. In most situations, a tool is setup to provide a cut-off tab that shall not exceed 0.50mm, no burrs. CAUTION: Excessive length or burrs can cause connector water leak by compromising the glands of the matte seal. EXTRUSIONS (ANVIL FLASH) These are the small flares that form on the bottom of the conductor crimp resulting from the clearance between the punch and anvil tooling. If the anvil is worn or the terminal is over-crimped, excessive extrusion can result. An uneven extrusion may also result if the punch and anvil are misaligned, if the feed is misadjusted and if there is insufficient or excessive terminal drag. CAUTION: Excessive length or burrs can cause connector water leak by compromising the glands of the matte seal.

Figure 5

INSULATION CRIMP HEIGHT Insulation crimp heights are specified in section 3.0, table 2. MX150 receptacle terminals are designed to accommodate multiple wire sizes. Although within the terminal range, an insulation grip may not completely surround the wire, an acceptable insulation crimp will still be provided. Evaluate the insulation section by cutting the wire flush with the back of the terminal. Once the optimum setting for the application is determined it is important to document the insulation crimp height. Then, as part of the setup procedure the operator can check the crimp height.

END-OF-INSULATION POSITION This is the location of the insulation in relation to the transition area between the conductor and insulation crimps. Equal amounts of the conductor strands and insulation needs to be visible in the transition area. The end-of-insulation position ensures that the insulation is crimped along the full length of the insulation crimp and that no insulation gets crimped under the conductor crimp. The end-of-insulation position is set by the wire stop and strip length for bench applications. For automatic wire processing applications the end-of-insulation position is set by the in/out press adjustment.

STRIP LENGTH The strip length is determined by measuring the exposed conductor strands after the insulation is removed. The strip length determines the conductor brush length when the insulation position is centered between conductor and insulation crimps. CAUTION: Care must be taken not to leave indentations on the wire surface during the strip and cut operation as this can affect the integrity of grommet to wire seal performance and can cause wire leaks.

0.1 mm max.

LOWEST POSITION

12

7

9

14

14

19




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CRIMP BULGE Caution needs to be taken with the crimp tooling to prevent a bulge exceeding the overall width of the terminal. Bulge must not exceed 2.65 mm, the maximum width of terminal as it will impact the terminal to cavity function on the MX150 sealed plastic.

Figure 6

GRIP INSULATION STEP The designed offset between the conductor grip and the insulation grip. Not to be altered by crimp process on all grip sizes except 22 AWG.

Figure 7

GRIP STEPS – For M3 Grip Terminals only (P/n: 33012-2004/3004 & 33001-4005/5005) The designed offset between the conductor grip and the insulation grip. The grip step should not be altered during the crimping operation. See Section 3.0, Table 3 for grip step specification. Caution: Steps are designed to ensure seal performance in MX150 connection systems

Figure 8

15

EXCESSIVE BULGE

16a 16b




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3.0 PRODUCT SPECIFICATIONS

Table 1

Terminal Order No. Grip Code

Wire Size Insulation Diameter Range

Strip Length Right Payoff “B” Wind

Left Payoff “D” Wind

33012-2001 33001-2003 33001-4001 33012-2021 33001-2021 33001-4021

33012-3001 33001-3003 33001-5001 33012-3021 33001-3021 33001-5021

14 14/16 AWG & 2.00/1.50mm

2

2.18-2.70 4.70-5.60

33012-2002 33001-2004 33001-4002 33012-2022 33001-2022 33001-4022

33012-3002 33001-3004 33001-5002 33012-3022 33001-3022 33001-5022

18 18/20 AWG & 1.00/0.75mm

2

1.70-2.54 4.70-5.60

33012-2003 33001-2005 33001-4003 33012-2023 33001-2023 33001-4023

33012-3003 33001-3005 33001-5003 33012-3023 33001-3023 33001-5023

22 22 AWG &

0.50/0.35mm2

1.20-1.70 4.70-5.60

33012-2004 33001-4005

33012-3004 33001-5005

M3 0.50/0.35mm

2

Note: Preferred terminals for use in sealed applications

1.20-1.70 4.70-5.60

9




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Table 2

Terminals were validated per USCAR-21 using the following wire specifications: M1L-123A (TXL), M1L-126A1 (metric), a M1L-135A1 (UTX), b SAE J1128 (GXL), c JASO D 611 (AVSS), d WSK-1A348-A2 ,e HIFLON (core wire: stainless steel Φ0.16. 7 strands and surrounding wire: Ni Plated Copper, 30 strands) and f T3ZHID wire. Customers are required to complete validation testing if tooling purchased outside Molex Inc. and/or wire specifications are different than above. Note1: Preferred terminal for use is sealed application with 0.35m² and 0.50mm² wires.

Terminal Order No.

Wire Size Insulation Diameter

Range

Conductor Barrel Insulation Barrel

Right Payoff “B” Wind


CCH ±0.05

CCW ±0.10

ICH ±0.10

ICW ±0.10

33012-2001 33001-2003 33001-4001 33012-2021 33001-2021 33001-4021

33012-3001 33001-3003 33001-5001 33012-3021 33001-3021 33001-5021

14 AWG 2.54-2.69 1.65 2.45 2.90 2.75

14 AWG a 2.34-2.49 1.65 2.45 2.70 2.60

16 AWG 2.18-2.34 1.35 2.45 2.40 2.60

2.00mm2 c 2.60-2.70 1.60 2.45 2.90 2.75

1.50mm2 2.20-2.40 1.40 2.45 2.60 2.60

33012-2002 33001-2004 33001-4002 33012-2022 33001-2022 33001-4022

33012-3002 33001-3004 33001-5002 33012-3022 33001-3022 33001-5022

18 AWG 1.91-2.06 1.25 2.15 2.00 2.30

18 AWG b 2.18-2.54 1.25 2.15 2.40 2.60

20 AWG & HIFLON WIRE e

1.70-1.85 1.15 2.15 1.90 2.10

20 AWG b 2.05-2.41 1.15 2.15 2.00 2.30

1.00mm2 1.90-2.10 1.30 2.15 2.00 2.30

0.75mm2 1.70-1.90 1.25 2.15 1.95 2.10

33012-2003 33001-2005 33001-4003 33012-2023 33001-2023 33001-4023

33012-3003 33001-3005 33001-5003 33012-3023 33001-3023 33001-5023

22 AWG 1.50-1.65 1.00 1.60 1.85 1.90

0.50mm2 1.40-1.60 1.10 1.60 1.80 1.90

0.50mm2 c 1.60-1.70 1.10 1.60 1.85 1.90

0.35mm2 d 1.20-1.40 0.95 1.60 1.70 1.90

33012-2004 33001-4005 See note 1

33012-3004 33001-5005 See note 1

0.35mm² f 1.20 – 1.40 1.05 ± 0.03 1.60 1.75 2.00

0.50mm² f 1.40- 1.70 1.10 1.60 1.90 2.00

10 11 12 13




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Table 3

Specifications

Balloon # Feature Requirement

1 Bend Up 3° MAX

2 Bend Down 3° MAX

3 Twisting 3° MAX

4 Rolling 3° MAX

5 Front Bell Mouth Not Required

6 Rear Bell Mouth 0.30 - 0.70

7 Cut-off tab length 0.50 MAX

8 Conductor length/

Wire brush 0.40 MAX

Not to extend above conductor crimp height

9 Wire strip length 4.70 ~ 5.60

10 Conductor Crimp Height See Table 2

11 Conductor Crimp Width See Table 2

12 Insulation Crimp Height See Table 2

13 Insulation Crimp Width See Table 2

14 Conductor Anvil Flash 0.1mm MAX

15 Grip Insulation Step 0.30 ± 0.10 All terminals except 22ga

0.00±0.10 22ga / 0.50mm2 / 0.35mm

2

16a For M3 grip terminals only

Conductor Grip Step 0.30 ± 0.10

16b For M3 grip terminals only

Insulation Grip Step 0.15 ± 0.30

17 For M3 grip terminals only

Bend Up 1.5° REF

18 For M3 grip terminals only

Bend Down 1.5° REF

20 Crimp Seam Seam shall not open and no wire is allowed out of the crimping area




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BEND UP & DOWN – ALL TERMINALS EXCEPT FOR M3 GRIP

Figure 9

M3 INUSLATION GRIP STEP

Figure 10

16b

1 2




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4.0 REFERENCE DOCUMENTS Reference documentation for general practices are located on the website per the below links:

1. Molex Quality Crimping Handbook http://www.molex.com/images/products/apptool/qual_crimp.pdf 2. Molex-Recognizing Good Crimps http://www.molex.com, search for Application Tooling 3. SAE/USCAR-21 Performance Specification for Cable-to-Terminal Electrical Crimps

http://www.sae.org/servlets/productDetail?PROD_TYP=STD&PROD_CD=USCAR21-1

5.0 PROCEDURE 5.1 GENERAL MEASUREMENT AND EVALUATION REQUIREMENTS Crimp Height Measurement (Extrusion Evaluation)

1. Complete tool set-up procedure. 2. Crimp a minimum of 5 samples. 3. Place the flat blade of the crimp micrometer (Figure 11) across the center of the dual radii of the conductor

crimp. Do not take the measurement near the conductor bellmouth. 4. Rotate the micrometer dial until the point contacts the bottom most radial surface. If using a caliper, be

certain not to measure the extrusion points (anvil flash) of the crimp. 5. To check for extrusion (anvil flash) use the caliper (Figure 12) to measure the crimp height. If the caliper

measurement is greater than the crimp micrometer measurement the extrusion is not acceptable. CAUTION: Excessive extrusion can cause connector water leak.

Figure 11 Figure 12




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MOLEX APPLICATION TOOLING

Table 4

SMALL POLARIZATION RIB

Terminal order number




PLATING

GRIP SIZE AWG

METRIC (mm

2)

OEM Ratchet Hand Crimper For use with

SAE TXL & ISO FLRY Wire

Molex Applicator* For use with


MX150 0.30

FEMALE

33012-2001 33012-3001 Tin 14 63811-5900 63900-0700

33012-2001 33012-3001 Tin 16

33012-2002 33012-3002 Tin 18

63811-6000

63900-0800

33012-2002 33012-3002 Tin 20 63900-0900

33012-2003 33012-3003 Tin 22 63900-1000

33012-2001 33012-3001 Tin 1.50 63811-6100

63900-0700

33012-2002 33012-3002 Tin 1.00 63900-0800

33012-2002 33012-3002 Tin 0.75 63811-6200

63900-0900

33012-2003 33012-3003 Tin 0.50 63900-1000

33012-2003 33012-3003 Tin 0.35 N/A N/A

33012-2004 33012-3004 Tin 0.35 - 0.50 N/A 63901-8700

33001-2003 33001-3003 Gold 14 63811-5900 63900-0700

33001-2003 33001-3003 Gold 16

33001-2004 33001-3004 Gold 18

63811-6000

63900-0800

33001-2004 33001-3004 Gold 20 63900-0900

33001-2005 33001-3005 Gold 22 63900-1000

33001-2003 33001-3003 Gold 1.50 63811-6100

63900-0700

33001-2004 33001-3004 Gold 1.00 63900-0800

33001-2004 33001-3004 Gold 0.75 63811-6200

63900-0900

33001-2005 33001-3005 Gold 0.50 63900-1000

33001-2005 33001-3005 Gold 0.35 N/A N/A

33001-4001 33001-5001 Silver 14 63811-5900 63900-0700

33001-4001 33001-5001 Silver 16

33001-4002 33001-5002 Silver 18

63811-6000

63900-0800

33001-4002 33001-5002 Silver 20 63900-0900

33001-4003 33001-5003 Silver 22 63900-1000

33001-4001 33001-5001 Silver 1.50 63811-6100

63900-0700

33001-4002 33001-5002 Silver 1.00 63900-0800

33001-4002 33001-5002 Silver 0.75 63811-6200

63900-0900

33001-4003 33001-5003 Silver 0.50 63900-1000

33001-4003 33001-5003 Silver 0.35 N/A N/A

33001-4005 33001-5005 Silver 0.35 - 0.50 N/A 63901-8700

*Using Molex application tooling requires that reels be used with left payoff or “D” Wind direction




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Table 4 continued

LARGE POLARIZATION RIB





PLATING

GRIP SIZE AWG

METRIC (mm

2)

OEM Ratchet Hand Crimper For use with


Molex Applicator* For use with


MX150 0.30

FEMALE

33012-2021 33012-3021 Tin 14 63811-5900 63900-0700

33012-2021 33012-3021 Tin 16

33012-2022 33012-3022 Tin 18

63811-6000

63900-0800

33012-2022 33012-3022 Tin 20 63900-0900

33012-2023 33012-3023 Tin 22 63900-1000

33012-2021 33012-3021 Tin 1.50 63811-6100

63900-0700

33012-2022 33012-3022 Tin 1.00 63900-0800

33012-2022 33012-3022 Tin 0.75 63811-6200

63900-0900

33012-2023 33012-3023 Tin 0.50 63900-1000

33012-2023 33012-3023 Tin 0.35 N/A N/A

33001-2021 33001-3021 Gold 14 63811-5900 63900-0700

33001-2021 33001-3021 Gold 16

33001-2022 33001-3022 Gold 18

63811-6000

63900-0800

33001-2022 33001-3022 Gold 20 63900-0900

33001-2023 33001-3023 Gold 22 63900-1000

33001-2021 33001-3021 Gold 1.50 63811-6100

63900-0700

33001-2022 33001-3022 Gold 1.00 63900-0800

33001-2022 33001-3022 Gold 0.75 63811-6200

63900-0900

33001-2023 33001-3023 Gold 0.50 63900-1000

33001-2023 33001-3023 Gold 0.35 N/A N/A

33001-4021 33001-5021 Silver 14 63811-5900 63900-0700

33001-4021 33001-5021 Silver 16

33001-4022 33001-5022 Silver 18

63811-6000

63900-0800

33001-4022 33001-5022 Silver 20 63900-0900

33001-4023 33001-5023 Silver 22 63900-1000

33001-4021 33001-5021 Silver 1.50 63811-6100

63900-0700

33001-4022 33001-5022 Silver 1.00 63900-0800

33001-4022 33001-5022 Silver 0.75 63811-6200

63900-0900

33001-4023 33001-5023 Silver 0.50 63900-1000

33001-4023 33001-5023 Silver 0.35 N/A N/A

* Using Molex application tooling requires that reels be used with left payoff or “D” Wind direction




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Crimp Tooling Geometry - All terminals except M3 grip terminals (see page. 15)

The crimp tooling information shown below is based on the tooling that Molex used to perform USCAR-21 (Crimp performance) and to establish recommended crimp height and widths. Based on the guidelines of USCAR-21 the user is responsible for validating crimp performance based on tooling, equipment and wire that is being used.

Figure 13

CRIMP STRAIGHTNESS

A method for maintaining crimp straightness is shown in figure 14 below.

Figure 14

APPLICATION S

PECIFICATION

REVISIO

N:

ECR/ECN IN

FORMATIO

N:

TITLE:

MX150 Female Receptacle

0.30mm Thick

Application Specific

atio

n

SHEET No.

A

EC N

o:UAU2011-0628

14 of 18

DATE:1/29/2011

DOCUMENT N

UMBER:

CREATED / R

EVISED BY:

CHECKED BY:

APPROVED BY:

AS-33012-002

Kate Ferguson

Ajay Dhir

Brian Moser


Table 5 (see Figure 13 fo

r Geometry

)

V

±0.05

1.40

1.40

1.30

1.30

1.30

1.15

1.15

1.30

1.05

1.05

1.15

0.95

0.95

0.95

0.95

1HIFLON WIRE: CORE WIRE: STAINLESS STEEL, SUS DIA 0.14, 7 STRANDS

SURROUNDING WIRE: NICKEL (Ni) PLATED COPPER (Cu) DIA. 0.14, 30 STRANDS INSULATOR: PTFE

U +0

-0.03

2.72

2.72

2.52

2.52

2.52

2.23

2.23

2.52

2.04

2.04

2.23

1.84

1.84

1.84

1.84

R

±0.005

6.11

6.11

6.11

6.11

6.11

1.93

1.93

1.93

1.93

1.93

1.93

1.44

1.44

1.44

1.44

P

±0.005

2.44

2.44

2.44

2.44

2.44

2.14

2.14

2.14

2.14

2.14

2.14

1.60

1.60

1.60

1.60

N

±0.03

6.91

6.91

6.51

6.51

6.51

6.46

6.46

6.51

6.36

6.36

6.46

6.31

6.31

6.31

6.31

M + 0.0 3

-0.00

1.35

1.35

1.28

1.28

1.28

1.13

1.13

1.28

1.03

1.03

1.13

0.93

0.93

0.93

0.93

K

±0.005

13.12

13.12

12.96

12.96

12.96

12.65

12.65

12.96

12.42

12.42

12.65

12.28

12.68

12.68

12.68

J ±0.005

7.05

7.05

7.05

7.05

7.05

6.52

6.52

6.52

6.52

6.52

6.52

6.57

6.57

6.57

6.57

G

±0.005

1.19

1.19

1.19

1.19

1.19

0.99

0.99

0.99

0.99

0.99

0.99

0.72

0.72

0.72

0.72

F ±0.005

0.6

0.6

0.6

0.6

0.6

0.57

0.57

0.57

0.57

0.57

0.57

0.42

0.42

0.42

0.42

E

±0.005

12.82

12.82

12.82

12.82

12.82

12.46

12.46

12.46

12.46

12.46

12.46

11.98

11.98

11.98

11.98

WIRE SPECIFICATION

M1L-123A

JASO D 611

M1L-135A1

M1L-123A

M1L-126A1

M1L-123A

M1L-126A1

SAE J1128 (GXL)

M1L-123A & HIFLON WIRE

1

M1L-126A1

SAE J1128 (GXL)

M1L-123A

M1L-126A1

JASO D 611

WSK-1A348-A2

WIRE APPLICATION

METRIC

-

2.0

-

-

1.5

-

1.0

-

-

0.75

-

-

0.5

0.5

0.35

SAE

14

-

14

16

-

18

-

18

20

-

20

22

-

-

-

LEFT PAYOFF “D” WIND

33012-3001 33001-3003 33001-5001 33012-3021 33001-3021

33001-5021

33012-3002 33001-3004 33001-4002 33012-3022 33001-3022 33001-5022

330012-3003 33001-3005 33001-5003

33012-3023 33001-3023 33001-5023

RIGHT PAYOFF “B” WIND

33012-2001 33001-2003 33001-4001 33012-2021 33001-2021

33001-4021

33012-2002 33001-2004 33001-4002 33012-2022 33001-2022 33001-4022

33012-2003 33001-2005 33001-4003

33012-2023 33001-2023 33001-4023




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CRIMP TOOLING GEOMETRY – M3 GRIP TERMINALS

The crimp tooling information shown below is based on the tooling that Molex used to perform validation testing to establish recommended crimp height and widths. The user is responsible for validating crimp performance based on tooling, equipment and wire that is being used.

Figure 15: CONDUCTOR PUNCH

Terminal Order No. A +0.005/-0.00 B ±0.005 C ± 0.005 D ±0.005 33012-2004/3004 33001-4005/5005

1.56 0.72 0.42 6.57




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Figure 16: INSULATION PUNCH

Terminal Order No. E ±0.005 F ±0.03 G ±0.005 33012-2004/3004 33001-4005/5005

2.00 6.31 1.00




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Figure 17: CONDUCTOR ANVIL

Terminal Order No. H +0/-0.005 I ±0.005 J ±0.005 33012-2004/3004 33001-4005/5005

1.61 0.08 1.44

Figure 18: INSULATION ANVIL

Terminal Order No. K ±0.005 L ±0.005 M ±0.005 33012-2004/3004 33001-4005/5005

1.98 0.95 0.33




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Figure 19: TERMINAL POSITIONING WITH WIRE PRESS AND BOX SUPPORT TOOLING

The box support helps to control straightness of crimped lead during crimping.

application specification · figure 4 conductor crimp this is the metallurgical compression of a...

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