We usually are uncertain about the reliability of an electronic device. We are unsure about its life span or longevity. Even for the manufacturers, this is real stress and a technical part for the manufacturing of an electronic device. They need to make sure that the device is fully functioning without any kind of major or minor halts. Especially when the device is made for the consumers to be purchased for their daily use, this needs to be made sure that the electronic device completes its longevity successfully and makes the customers happy. That is why there is a very important element to be taken care of while manufacturing any electronic device.
What is Crimping?
Crimping is a very important aspect in wiring. It is a necessary process to increase the reliability of electronic devices. That is why there are numerous different sizes and shapes of crimping tools so that they can perfectly crimp the wires of each size in the device. The Terminate Standard is one of the major and common tools for crimping wire. This is one of the easy tasks for manufacturers. They know well know how to crimp wires and use the special crimping tools to perfectly crimp them. There are male and female crimp pins as well through which crimping can efficiently work. For this reason, 22 to 26 gauge wires are required which fit the crimping tools accurately.
Process for Crimping Wires
There is one common step for crimping the wires which are important for all the following processes. This step is to make sure that all the connections of the wires are connected and plugged in properly. This is because the entire crimping process depends on the connections that all the connectors are accurately placed. One single mistake would result in delaying the crimping process. Secondly, it is crucial to know about the quality of the connections, because if the quality is good the crimping will lead to making the electronic device more reliable. Below mentioned are the steps for crimping wires.
1. Selecting an Appropriate Crimper
· Buying Ratchet Crimpers:
The ratchet crimpers ensure the durability of the electronics and make them simpler to use. It is the first part of the crimping process that an appropriate crimper is purchased for the best results. So there is a built-in ratchet in the ratchet crimpers which has made the task more convenient. You simply have to apply little pressure on the handles and the rest of the work is performed automatically. The wider and spacious jaws of this crimper enable to cover more area of the connector surface. You can easily buy Ratchet Crimpers from online stores.
You can also go for a manual crimper. It is similar to a Ratchet Crimper but a little effort is required for the results. You need to make sure that the jaws of the crimper are perfectly aligned and in an accurate position so that you can apply pressure on the handles to make it work. Manual crimpers can wear and tear quicker if the jaws are not properly aligned. This also leads to improper crimping.
· Crimping Die:
All the crimpers come with a die which is a top part of the crimper. This part does the entire crimping. Due to this reason you need to be particular about the size of the die and the gauge wire you have chosen to use. So it's the best way that you choose that die which is appropriate for your gauge wire. The different colored wires indicate the gauge which is the best fit for that wire.
2. Perfectly Strip the Wire:
The second process is to strip the wire for the crimping die. For this, you need to place 0.64 cm of the wire into the die. Make sure the hole is located in the crimping die for the gauge wire to be inserted. For this purpose, the crimping dies have colored hole to make it convenient for locating the specific colored wire gauge in the correct place.
· Remove the Insulation:
After this, remove the insulation from the wire so that you can take the bare wire out. This can be done by using the crimping tools to rip the insulation form the wires. Just a little pressure on the handles is required and pulls off the insulation to rip it. The bare wire is supposed to be of the same length of the barrel connector.
If you have a manual crimping tool, you need to pull the insulator perpendicularly making sure that the wire is steadily placed.
· Twist the Wire Completely:
Now you need to twist the wire completely to make it dense. You need to press the bare wire with your thumb and forefinger and then keep twisting it until it becomes firm and stiff. Make sure that you always twist the tip to make it more compressed. The intense twisting would result in building a strong connection for the process.
3. Connecting the Wires with the Connector
· Inserting the Bare Wire in the Barrel:
You have to be cautious while inserting the bare, exposed wire in the barrel connector. Keep the process continued until and unless the barrel is touched with the insulation. The wire should not be extending the barrel more than 0.64 cm.
· Accurately Place the Barrel in the Crimper:
Place the terminal in a horizontal position in which the barrel side faces upwards and the flat side of the terminal faces downwards. Match its tools from the colors markings of the insulator and pull it perpendicularly with the gauge.
· Press the Crimper with Force:
For manual crimpers, you need to squeeze the crimper with a force so that the insulation is ripped off. This can be done by placing the terminal perpendicularly over the barrel connector.
· Make Sure that the Connection is Not Lose:
The connection might get loose if a wire of the wrong size is inserted. It does not give accurate results and the crimping does not work.
· Properly Seal the Terminal:
Make sure you properly seal the electrical terminal with an electric tape by wrapping it over the bare or exposed wire.
