Crimper (wiring tool)

Lugs of different types - straight, "forked", ring, used for cutting the end of the core / wire.

Wire crimping is used in the process of preparing stranded wires for screw or terminal connections, for connecting stranded and single-core wires to each other and for installing a terminal on the wire intended for installation in a connector. The connection of wires by crimping is considered preferable compared to soldering, especially for open electrical circuits ^[1] , and more technologically advanced compared to welding. In order to exclude galvanic pairs , copper terminals and sleeves are used for crimping copper wires, for aluminum - aluminum.

Tips for crimping stranded wires are available in various types:

• Cylindrical tip sleeve (sleeve). The tip is used to prepare the ends of the stranded wire stripped from insulation for installation in a screw terminal block . The ferrule prevents separation of the conductors of the stranded wire and prevents their damage and breakage. The bushings are made of copper or aluminum, they are a segment of a thin-walled tube and are often supplied with a plastic colored insert that facilitates the installation process and allows color marking. For crimping this type of tip, a specialized segmented crimper is used.
• Tip loop type "O". The tip is used to prepare the ends of the stranded wire stripped from insulation for installation in a screw terminal block. The terminal block screw passes through the hole in the lug, and for installation it is necessary to completely unscrew the screw from the terminal block. This type of ferrule prevents the wires from disconnecting even when the fixing screws are loosened. For crimping, specialized or universal pliers are used.
• Tip fork type "U". The tip is used to prepare the ends of the stranded wire stripped from insulation for installation in a screw terminal block. The screw goes into the slot of the tip, and for installation it is necessary to loosen the screw connection, enough for installation in the terminal block. This type of lug simplifies the process of mounting wires to the terminal block. For crimping, specialized or universal pliers are used.
• Knife tip for knife connector. The tip is used to prepare the ends of the stranded wire stripped from insulation for installation in the knife connector. This type of connector is used in automotive electrics and power electronics, wherever an inexpensive reliable connection of individual wires is required. For crimping this type of tip, specialized or universal pliers are used.
• Special tips for installation in the connector. A large number of connectors from various manufacturers imply an assembly sequence consisting of several stages. The first step is stripping the wire and installing a ferrule on it. The second stage is the assembly of wires with lugs in the connector. The tips used in the connectors are unique to each type of connector and require the use of a special type of tool in most cases.
• Connection sleeves for connecting wires to each other. To connect the wires by crimping, copper or aluminum thick-walled tubes (sleeves) are used. Two or more ends of the wire are inserted into the sleeve and crimped with a special crimper or universal pliers. The connecting sleeves are available uninsulated and with an insulating plastic sheath. The strength of the sheath allows crimping the connection without removing the sheath.
• Tips pin, flag, ring, hook-shaped and other forms for crimping on a cable are available for ease of installation in installation products of various electrical distribution fittings.

Due to the variety of pressing tips, there are a large number of universal, specialized, manual, automatic and semi-automatic crimpers for installing tips.

Auto Crimpers

High-performance equipment for wire processing allows you to strip the wire, install the ferrule and crimp in automatic and semi-automatic modes. Such equipment consists of an electric press and crimping tool (applicator). Applicators are available separately for each type of tip. Applicators can only perform crimping or trimming, stripping and crimping the tip in one stroke.

Hand Tool

Hand tools, depending on the size and type of contacts or tips, are available in the form of universal pliers, specialized hand crimpers, electric, pyrotechnic and hydraulic portable presses.

• Manual hydraulic press for crimping handpieces with cross-section from 25 to 300 mm²
•  
•  
•  

• GOST 23981-80 “Cable terminals . General specifications "
• GOST 9581-80 “Tips for cable aluminum and copper-aluminum, fixed by crimping. Design and dimensions "
• GOST 23469.0-81 "Cable sleeves. General specifications "
• GOST 23469.2–79 "Sleeves cable connecting aluminum, fixed by crimping. Design and dimensions "
• GOST 23469.3–79 "Cable connecting copper sleeves, fixed by crimping. Design and dimensions "
• GOST 23598-79 " Pin cable lugs. Design and dimensions "
• GOST 22002.5-76 " Pin cable lugs with a closed shank, fixed on the conductors of wires. Design and dimensions "
• GOST 9688-82 "Ring cable lugs . Design and dimensions "
• GOST 10434-82 “Contact electrical connectors . Classification. General technical requirements "
• GOST 17441-84 "Contact electrical connections. Acceptance and test methods "
• BCH 139-83. Instructions for terminating, connecting and branching aluminum and copper conductors of insulated wires and cables and connecting them to the terminals of electrical devices
• Belotserkovets V.V. Small mechanization of electrical work. - M .: Energoizdat, 1982. - S. 35-44. - 104 p.
• Sibikin Yu.D. Electrical installation manual . - M .: Publishing Center "Academy", 2003. - 336 p. - ISBN 5-7695-1317-9 .

• Crimping conductors of wires and cables