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Crimping terminals is a type of wire assembly process dating back several decades. Over time processing methods and procedures were established and improved to make sure optimum crimp quality and electrical conductivity in the wire to terminal connection. This short article will cover the normal crimp types, crimp methods used to supply a quality wire to terminal connection and migration path from manual processing to automation in the crimp process.

Closed Barrel: Closed barrel terminals possess a round crimp barrel that surrounds the wire being crimped. There are 2 typical open barrel configurations, formed by progressive stamping process with a seam where the two sides get together and form a circle and solid machines connector where the crimp barrel is seamless, normally produced on terminal crimping machine. Closed barrel terminals come insulated or non-insulated and are in loose form or on the reel. Samples of closed barrel terminals include rings, quick connects, ferrules and solid pins used in aerospace applications.

Open Barrel: Open barrel terminals are often U shaped just before crimping and therefore are crimped around the terminal in the B shape or overlapped. Open barrel terminals are typically available mounted on a reel but occasionally can be found in loose form for lower volume processing. As well as a barrel for your wire, some open barrel terminals include an insulation support for applications for extra strain relief (from vibration or wire movement). Open barrel terminals normally are un-insulated but in some cases use a partially loaded insulator pod which can be inserted within the terminal in the crimp process.

Wezag Crimp Tool 1Hand Tools: A hand tool is used in low volume or prototype crimp applications. Tooling within a hand tool could be fixed and non-removable through the hand tool frame or might be removable. Crimp dies are for sale to open barrel and closed barrel terminals A trusted approach to crimping wire to terminals with good repeatability. As volumes increase, repeated processing of terminals with hand tools might cause force on an operator.

Bench Top Crimping: Crimping terminals with bench top crimping equipment provides moderate volume processing of loose piece and reel mounted terminals.

Wezag CS 200With loose piece terminals, the terminal and wire are hand loaded to a crimp nest as well as the operator cycles the press by using a foot pedal or palm button.

applicators2Reel mounted terminals are processed by using a crimp press and applicator. The applicator has a mechanical or pneumatic feed which positions the terminal around the crimp anvil. The operator presses a foot pedal and the crimp press cycles, forming the terminal over the wire and advancing the subsequent terminal for further processing. A wide array of applications could be processed with bench top crimping equipment from the utilization of different press tonnages and applicators/die sets (fixed and quick change).

Automated Crimp Processing: Automated processing adds a wire cut and strip element for the crimp process. The standard form is definitely the stripper-crimper which adds a wire stripping unit to a bench crimp press to strip the end of your wire and presenting the wire on the crimp nest for crimping.

Automated crimp centers process the wire from the source within a barrel or reel, cut and strip the wire to length and offer it to a crimp press for crimping. Reel fed applicators are identical as being the bench top type. With regards to loose piece terminals, a vibratory bowl is used to orient the terminals and provide towards the crimp press for large wire strippers.

As volumes increase, the need to automated also increases. On occasion, the increase is dramatic, requiring a greater step with the automation migration path. But normally the rise is controlled and slower so migration can take a multi step approach with time.

Hand Tool to Bench Top Migration: Migrating coming from a hand tool to power assisted bench top crimping requires a bench top crimping platform like the Accu-Crimp 62 or electric powered CS200 from Wezag Tools (both pictured above).

High Quality Applications use higher tonnage to supply the ability needed toprocess large terminals. The Wezag UP60 is pneumatic powered and supplies over 7 plenty of crimp force.

Non-Fixed hand tool die sets can be removed and appropriate for bench top crimping units. This reduces the total cost in the migration from hand tools to powered bench top equipment.

Bench Top to Automated Process Migration: Migrating coming from a bench top to automated processing machine like the Primo XLT or Uno multi-station machines is straightforward and straightforward. Mini style applicators used in a bench press application as pictured above might be mounted directly from a bench top press on the press about the automation system. Some applications demand a different feed cam to feed the terminal about the press downstroke allowing for that robotic arm to dexopky08 into position with no interference from the terminal.

However, in the case of loose piece terminals, separate presses with integrated vibratory bowl fed systems may be required because they are not much of a standard setup by using an automated machine.

Loose Piece to Reel Mounted terminal Migration: Converting from loose piece processing to reel fed terminals demands a crimp press and applicator as described above. The first task is determining the compatible terminal on reel equivalent. If a quick change mini applicator can be used, then the coax stripper might be quickly changed from a terminal type to another one just by switching out your terminal applicator.

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