HINTS AND TIPS: MAKING CRIMPING SAFE AND SECURE

With the rapid increase in electric drives and the necessary control electronics, the need for fast and secure connections is increasing. Plug types such as Scotchlok connectors, Western plugs, module plugs, Cannon plugs and many more are suitable for crimping – the joining process in which the connection is made via plastic deformation using a compression tool. Here are five things to consider when crimping cable:

• Consider the crimping die shape: When selecting a crimping tool, make sure that the die shape matches the shape of the connector being used. The die shape should be designed to evenly distribute force around the entire connector barrel during the crimping process. Choosing the wrong die shape can lead to an uneven crimp that can result in high resistance or even arcing.

• Use the right crimping technique: There are several techniques for crimping, such as indent crimping, hexagonal crimping, and insulated crimping. Each technique has its advantages and disadvantages and is suitable for different types of connectors and cables. Make sure to select the appropriate technique for the job.

• Choose the right connector material: Connectors come in a variety of materials, including copper, brass and aluminium. The material selected should be compatible with the cable and the environment in which it will be used. For example, copper connectors are more conductive than aluminium, but aluminium is lighter and more corrosion-resistant.

• Use proper stripping techniques: To prepare the cable for crimping, it is essential to strip the insulation from the wire correctly. When stripping, avoid nicking or damaging the wire strands, as this can cause a weak or unreliable connection. Use a high-quality stripping tool designed for the cable’s size and insulation material.

• Test and inspect the connection: After crimping the connector onto the cable, it is critical to test and inspect the connection for integrity. Use a high-quality digital multimeter to check the resistance of the connection, and ensure that it falls within the manufacturer’s specifications. Inspect the crimped connection for any signs of damage or weakness, and replace or repair it as needed.

The complexity of possible crimp connections is continuously increasing. In addition to flexible and solid wires, fibre optic cables, antenna cables, telephone and LAN cables and many other types of cable can now also be processed with crimping tools.

Some of the tools even have innovative support features, for example, universally adjustable positioning aids or electronic displays for wear and the necessary calibration for crimping pliers for very sensitive crimp connections.

Due to the large number of different plug connections, crimping pliers in many different versions are required. As a rule, these pliers are operated with one hand – but there are also models for particularly large conductor cross-sections that facilitate two-hand operation thanks to their favourable design.

Crimping pliers for wire ferrules exert pressure on both ferrule and wire from all sides via four crimping parts. In this way, when choosing the right crimping profile or using an automatic crimping tool due to plastic deformation, a mechanically firm and electrically secure connection is achieved.

Crimping pliers, which are able to automatically adjust to the cross-section of the sleeves to be machined, were developed especially for the professional sector. The use of the right pressing jaws is guaranteed at all times – which makes crimping quicker and more convenient.

KNIPEX has a range of assortment boxes, such as the 97 99 906, with insulated wire ferrules which are a convenient and practical solution for storing and dispensing these essential components. These boxes feature a handy, transparent dispenser box with a rotating lid that allows for easy access to the individual wire ferrules inside. The lid has an opening that makes it simple to remove a single wire ferrule, without having to take the entire box apart. The wire ferrules are also color-coded according to DIN standards, making it easy to identify the correct size and type of ferrule needed for a specific project. The boxes are stackable and re-closable, which makes them easy to store and organise.

KNIPEX, knipex.com

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