Electrical wire is that scientific invention which has become a backbone of communities all over the world. There is not a single place where a wire is not playing a significant role in making functional civilizations. Our houses, schools, hospitals and industries depend on wires. A wire conducts electrical flow from one place to another. This takes place by joining numerous wires into various circuits.
What is electrical crimping?
Circuits are made by making wire joints (or electrical terminals) with the help of an electromechanical device, an electrical connector. But to use an electrical connector, a wire is to be linked to it through the process of crimping. Either you’re attaching two pieces of wires or directly connecting a wire to a terminal, the quality of this connection depends on how well the wire has been crimped to the connector. It is a style of fixing stranded wires to metal fittings that are collectively known as crimp connectors. These are then used to connect the wire to other conducting component(s). Wire wrapping and soldering is not as ideal as crimping, especially where the heat from soldering is inappropriate. Also, a well performed crimping technique has many benefits such as:
· A gas-tight electrical connection which prevents air and moisture from damaging the metals and causing corrosion.
· No alloys are used which makes it mechanically stronger.
· Wires of both small and large cross-sections can be connected through crimping whereas only small cross-section wires can be used with wire wrap.
· Crimp connectors take up limited space.
Stranded core wires work best with crimp connectors as solid core wires aren’t malleable or ductile enough to be joined in a strong connection. Therefore the only point that has to be focused on during electrical crimping is to achieve the necessary compressive force which can be accomplished by an efficient crimping tool. A loose connection results in an open circuit which is the most difficult problem to diagnose, specifically in complex electrical systems such as automation and heavy duty appliances, where crimping is the usual method used.
Several
different styles of crimping tools are available in the market. One of the most
popular and cost-effective crimpers are ratchet crimp tools with integral die
sets which make it conveniently simple and durable for users. Others include
Crimp Tool Frames with Interchangeable Die Sets, Manual Crimp Tools and Mill
Spec Crimp Tools. However, there is an advanced apparatus that is proving to be
the most efficient and precise method of crimping.
A crimping applicator, on the other hand, is an advanced device designed to fit
onto a crimper. These are the most efficient and precise way to create wire and
terminal connections. The applicator parts, which are responsible for better
performance as compared to crimping tools, are the reel and 5-5 Ton press. The
way crimp contacts come on a reel which are operated by 5-5 Tin press ensures
the crimp is precisely rigid and delivered with the accurate amount of
compressive force that is required to permanently pinch the wires together. The
applicator is seated in a press which is either electric or pneumatic, more
often a combination of both. The press enables the crimps to be delivered to
the applicator through the reel of crimps called bandoleer.
To operate a crimp press, usually a foot pedal is used. Each time the crimp
cycle is required by the operator, the foot pedal is to be presses. This allows
the operator to have their hands free for easily installing the wires to the
press. The efficiency of an applicator is preferable due to creation of strong
and secure bonds between conductors and contacts. Above mentioned mechanism of
semi-automatic crimping applicator provides good support, which allows many
more crimp connections to be produced in a short time interval as compared to
manual production. Furthermore, this method lowers the rate of faults resulting
in bad connections. It improves quality of the mechanical connection between a
wire and a terminal/contact.
Another variant of crimping applicator is the fully automatic crimp applicator.
It has been exclusively designed to crimp small cross section and short cable
lengths. Whatever your requirements are, this class of applicator can perform
double side crimping, twisting, fluxing or tinning. This allows complying with
international standards and regulations, such as the crimp quality found in the
quality criterion by the PFMEA (Process Failure Mode and Effect Analysis) and
the Crimp Force Monitor.
The
only drawbacks of crimp applicators are the high purchasing cost and the
strictly performed servicing by experienced professionals to maintain
applicator’s adjustment power. Lack of maintenance can make bad connections due
to damaged terminals in any circuit. This is why crimp applicators are usually
possessed by cable assembly specialists or organizations that are set up to
produce their own cable assemblies in house.
Application Tooling companies sell various types of applicators which are
listed below:
1. Applicator Series (Strip Form Terminals)
2. Large Wire Size Applicator (Strip Form Terminals)
3. Mid Wire Size Applicator (Strip Form Terminals)
4. Special Applicators for New Technologies
5. Mini Applicator (Strip Form Terminals)
6. Applicators for Standard Loose Piece Terminals
Successful crimping results from the correct relationship between wire, terminal, and crimping tool. Once the terminal selection is made and crimping criteria defined by the connection designer, the tooling characteristics are fully determined.
A
crimp applicator could cost around 1000 to multiple 1000 pounds which is why
several companies have started to choose to sub contract their cable and wire
harnesses. The sheer investments in tooling required makes more sense to use
qualified sub-contractors who already have the tooling.
It is said that applicators are “the heart of the crimping process”. This is
why quality maintenance is of critical importance.
This guide will help you in looking for applicators that delivers high quality connections which have to meet stringent specifications. It is a complete solution for all your crimping and cable assembling problems.
