Crimping terminals is a kind of wire assembly process going back several decades. Over time processing methods and operations were established and improved to guarantee optimum crimp quality and electrical conductivity from the wire to terminal connection. This information will cover the common crimp types, crimp methods used to provide a quality wire to terminal connection and migration path from manual processing to automation of the crimp process.
Closed Barrel: Closed barrel terminals have a round crimp barrel that surrounds the wire being crimped. The two main typical open barrel configurations, formed by progressive stamping process using a seam in which the two sides come together and form a circle and solid machines connector the location where the crimp barrel is seamless, normally produced on wire strip crimp machine. Closed barrel terminals come insulated or non-insulated and therefore are in loose form or on the reel. Instances of closed barrel terminals include rings, quick connects, ferrules and solid pins found in aerospace applications.
Open Barrel: Open barrel terminals are generally U shaped prior to crimping and they are crimped throughout the terminal inside a B shape or overlapped. Open barrel terminals are generally available placed on a reel but occasionally are available in loose form for lower volume processing. As well as a barrel for that wire, some open barrel terminals feature an insulation support for applications for added strain relief (from vibration or wire movement). Open barrel terminals normally are un-insulated but in some instances use a partially loaded insulator pod which can be inserted across the terminal throughout the crimp process.
Wezag Crimp Tool 1Hand Tools: A hand tool is commonly used in low volume or prototype crimp applications. Tooling in a hand tool could be fixed and non-removable in the hand tool frame or might be removable. Crimp dies are available for open barrel and closed barrel terminals A reliable method of crimping wire to terminals with good repeatability. As volumes increase, repeated processing of terminals with hand tools can cause stress 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 some crimp nest and the operator cycles the press using a foot pedal or palm button.
applicators2Reel mounted terminals are processed utilizing a crimp press and applicator. The applicator has a mechanical or pneumatic feed which positions the terminal about the crimp anvil. The operator presses a foot pedal as well as the crimp press cycles, forming the terminal within the wire and advancing the subsequent terminal for additional processing. A variety of applications can be processed with bench top crimping equipment through the usage of different press tonnages and applicators/die sets (fixed and quick change).
Automated Crimp Processing: Automated processing adds a wire cut and strip element to the crimp process. The most basic form will be the stripper-crimper which adds a wire stripping unit into a bench crimp press to strip the end from the wire and presenting the wire to the crimp nest for crimping.
Automated crimp centers process the wire by reviewing the source within a barrel or reel, cut and strip the wire to length and offer it to your crimp press for crimping. Reel fed applicators are identical as being the bench top type. In the matter of loose piece terminals, a vibratory bowl can be used to orient the terminals and present to the crimp press for pipe cutting machine.
As volumes increase, the need to automated also increases. On occasion, the increase is dramatic, requiring a better step through the automation migration path. But normally the increase is controlled and slower so migration might take a multi step approach as time passes.
Hand Tool to Bench Top Migration: Migrating from your hand tool to power assisted bench top crimping needs a bench top crimping platform such as the Accu-Crimp 62 or electric powered CS200 from Wezag Tools (both pictured above).
Heavy Duty Applications use higher tonnage to deliver the energy needed toprocess large terminals. The Wezag UP60 is pneumatic powered and provides over 7 plenty of crimp force.
Non-Fixed hand tool die sets might be removed and works with bench top crimping units. This reduces the overall cost of your migration from hand tools to powered bench top equipment.
Bench Top to Automated Process Migration: Migrating from your bench top to automated processing machine such as the Primo XLT or Uno multi-station machines is straightforward and straightforward. Mini style applicators employed in a bench press application as pictured above might be mounted straight from a bench top press for the press in the automation system. Some applications need a different feed cam to give the terminal in the press downstroke to permit for the robotic arm to dexopky08 into position with no interference from your terminal.
However, in the case of loose piece terminals, separate presses with integrated vibratory bowl fed systems may be required as they are not a standard setup with an automated machine.
Loose Piece to Reel Mounted terminal Migration: Converting from loose piece processing to reel fed terminals requires a crimp press and applicator as described above. The initial step is determining the compatible terminal on reel equivalent. If a quick change mini applicator may be used, then this coax stripper could be quickly changed from one terminal type to another simply by switching out the terminal applicator.