Crimping is a process where a cable is stripped and the stands of wire are then placed into a metal terminal. The terminal is after that squeezed around the wire stands to ensure :

  • the wire is securely help by the terminal
  • there is good electrical contact between the terminal and the wire

Crimping is the process in which a wire is permanently fixed to the contact of a connector. This is done using mechanical force.  Generally one can find crimps in many forms and sizes but the principle behind them all is the same.  The goal of terminating wires is to obtain the strongest mechanical connection with the highest electrical conductivity. Poor mechanical terminations may result in broken wires or even intermittent connections.  They can also cause failed or erratic circuit operation, undesirable heat build-up and even fire.

 

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Wire Size

Wires can have varying sizes or gauges that can carry different amounts of electrical current with each wire that is used for a separate purpose. The size (in AWG) is called out with a number, like 8 or 10, followed by the letters AWG, which stand for American Wire Gauge.

BIS can crimp on wire configurations 0,35-10 mm2 (AWG7-AWG22), depending on customer requirements regarding the final product.

Terminal Type

Terminals vary depending upon the type of cable, and need different crimping tools as well as associated dies. Not only will dies vary based on the type of terminal connection which is being made, but also by the gauge of the wire, even if it is based upon American wire gauge or Imperial standard wire gauge. Some of the most common terminal types are: BNC, RF connectors, D-sub, Military, Telephone, Fiber optic, DIN, Modular/RJ.

BIS can crimp wires on various terminal configurations, based on the customer's specifications.

Crimp Quality

When a terminal is crimped to a wire, there are created micro connections which allow current to flow through the connection. Even though it might seem that a tighter crimp is better, the wire cross section is reduced by the over-tightened terminals. Crimping errors, such as loose crimp or even wrong ratio of wire to terminal, might result in hotspots or even burnout.

Respecting the standards in force (ISO 9001:2015 but with the rigor of IATF 16949:2016) and being dedicated to quality principles, BIS assures customers a high level of product quality.

Operation

A wire crimper is an primordial part of the crimping process, the other parts being the terminal and wire. Terminal size is widely universal and can accept many sizes of gauged wire, which can also fluctuate widely within the same nominative value. As such, the crimp tool is a means of compressing the terminal to both the wire's insulation (for positioning) and the wire's brush (for conduction).

Crimp Testing

The most cost-effective method of ensuring that the specifications stay with tolerances is crimp-force analyzing. Crimp-force monitoring can be done during production. In most cases, crimp-force monitors can detect changes in crimp quality, alert the operator, and then shut down the machine to prevent repeating defects.

There are several destructive tests that we are using to ensure the crimp quality:

  • Bend test: a quality connection will be able to accommodate 90° bends in different directions without misplacing the insulation or wire crimps.
  • Crimp height testing: This is measured from the top surface of the formed crimp to the bottom radial surface and it provides a metric for the mechanical and electrical reliability connection. For this test is used a caliper or crimp micrometer which provides process control and a good measure of terminal compression.
  • Pull test: The test is made by attaching hanging weights to the wire for one minute, or using a mechanical pull tester.

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