Crimping terminals is a common wire assembly process dating back to several decades. Throughout the years processing methods and operations 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 most popular crimp types, crimp methods used to supply a quality wire to terminal connection and migration path from manual processing to automation of your 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 by using a seam where the two sides get together and form a circle and solid machines connector where crimp barrel is seamless, normally produced on terminal crimping machine. Closed barrel terminals come insulated or non-insulated and so are in loose form or on the reel. Instances of closed barrel terminals include rings, quick connects, ferrules and solid pins employed in aerospace applications.
Open Barrel: Open barrel terminals are generally U shaped just before crimping and therefore are crimped across the terminal within a B shape or overlapped. Open barrel terminals are often available mounted on a reel but in some instances can be purchased in loose form for lower volume processing. Together with a barrel for that wire, some open barrel terminals feature an insulation support for applications for extra 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 over the terminal in the crimp process.
Wezag Crimp Tool 1Hand Tools: A hand tool is commonly used in low volume or prototype crimp applications. Tooling in the hand tool might be fixed and non-removable from your hand tool frame or could be removable. Crimp dies are around for open barrel and closed barrel terminals A trusted means of crimping wire to terminals with good repeatability. As volumes increase, repeated processing of terminals with hand tools may 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 as well as 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 in the crimp anvil. The operator presses a foot pedal and the crimp press cycles, forming the terminal across the wire and advancing another terminal for further processing. A wide range of applications can be processed with bench top crimping equipment through the consumption of different press tonnages and applicators/die sets (fixed and quick change).
Automated Crimp Processing: Automated processing adds a wire cut and strip element on the crimp process. The most basic form is the stripper-crimper which adds a wire stripping unit to your bench crimp press to strip the final of the wire and presenting the wire towards the crimp nest for crimping.
Automated crimp centers process the wire looking at the source in a barrel or reel, cut and strip the wire to length and present it into a crimp press for crimping. Reel fed applicators are similar as the bench top type. When it comes to loose piece terminals, a vibratory bowl is utilized to orient the terminals and offer on the crimp press for wire cutters.
As volumes increase, the requirement to automated also increases. On occasion, the increase is dramatic, requiring a greater step through the automation migration path. But normally the rise is controlled and slower so migration can take a multi step approach over time.
Hand Tool to Bench Top Migration: Migrating from the hand tool to power assisted bench top crimping needs a bench top crimping platform like the Accu-Crimp 62 or electric powered CS200 from Wezag Tools (both pictured above).
Heavy-duty Applications use higher tonnage to provide the strength needed toprocess large terminals. The Wezag UP60 is pneumatic powered and offers over 7 tons of crimp force.
Non-Fixed hand tool die sets may be removed and compatible with bench top crimping units. This reduces the total cost of 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 such as the Primo XLT or Uno multi-station machines is straightforward and simple. Mini style applicators utilized in a bench press application as pictured above may be mounted from a bench top press on the press on the automation system. Some applications need a different feed cam to give the terminal about the press downstroke to permit to the robotic arm to dexopky08 into position without having interference through the terminal.
However, with regards to loose piece terminals, separate presses with integrated vibratory bowl fed systems may be required since 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 needs a crimp press and applicator as described above. The initial step is determining the compatible terminal on reel equivalent. If your quick change mini applicator works extremely well, then your coax stripper might be quickly changed from a terminal type to another by just switching the terminal applicator.