CRIMPING TERMINALS The importance of using the right tool INDUSTRIAL SYSTEMS /// CRIMPING TERMINALS: THE IMPORTANCE OF USING THE RIGHT TOOL

Crimping Terminals: The importance of using the right tool There are few things in the world of electrical assembly that appear more straightforward than crimping wires to terminals. Stripped wire is inserted into a short metal tube called a wire barrel. A crimping tool then compresses the wire barrel tightly around the strands of the stripped wire, forming one homogeneous metal. No solder, heat, or flux is needed, and the job is done in moments. Its simplicity is why the solderless terminal remains one of the most popular connectors on the market for more than seventy years. Solderless terminals...

Crimping Terminals: The importance of using the right tool Optimizing Crimp Performance ELECTRICAL PERFORMANCE Increasing Mechanical Strength & Electrical Performance Tool and terminal are carefully engineered to act in tandem, creating crimps that optimize electrical and mechanical performance. A connector engineer configures the crimp profile (crimp height and crimp width) to achieve the desired form of the wire and wire barrel when formed into one homogeneous metal. Too loose a crimp will result in poor mechanical performance and electrical conductivity. Too tight a crimp may improve electrical...

Crimping Terminals: The importance of using the right tool Crimp Tensile Strength Testing A crimped terminal or splice is mounted on a test system by securing the terminal in a clamping fixture attached to a tensile testing machine. The system applies a linear pull on the test specimen at constant applied force until the crimp fails. The wire must not pull out, break, or separate from the crimp before the minimum crimp tensile strength requirement is met. Figure 5 – Crimp Tensile Strength Test Results SOLISTRAND Tensile (lbs.) 250 Figure 4 – Crimp Tensile Strength Test – Diamond Grip Butt Splice...

The Misinterpretation of Industry Certifications Unfortunately, companies that use solderless terminals routinely misunderstand agency certification criteria, and unknowingly put their own products at risk. According to the certification criteria for solderless terminals, all crimps must be created using tools and terminals from the approved source. If a terminal is not terminated with the tooling as noted in the associated report, it is not considered approved since all testing and evaluation of the terminal by the certification agency was done in conjunction with the specified tools. From the...

Crimping Terminals: The importance of using the right tool Save on Applied Costs with TE Tooling TE’s team of Field Engineering Service Specialists work with customers to provide expert guidance in creating custom wire crimping solutions that maximize throughput and optimize Applied Cost. Most manufacturing companies have fewer productive machine hours than they realize. In many cases it is possible to gain an additional 20 - 60% of productive time each day by selecting the right tooling and making basic changes in process, training, and/or equipment. The Field Engineering Service team is available...

Crimping Terminals: The importance of using the right tool Conclusion Crimping wires to terminals is not a “one size fits all” process; it is a carefully engineered solution – terminal to tooling. In fact, solderless terminals are designed to perform as specified only when crimped by tools from the same manufacturer. If the tool and terminal are not from the same manufacturer, the crimp will not meet industry certifications because the quality of the connection cannot be guaranteed. Defects may not even be visible to the naked eye. Taking the time to select the proper tool and terminal ensures...

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