Crimp (electrical)

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An electric wrinkle is a type of electrical connection without solder.

The Crimp connector is usually used to terminate the broken wire. The benefits of crimping over soldering and wire wrapping include:

Well-designed and well-designed wrinkles are designed to be gas-resistant, preventing oxygen and moisture reaching metals (which are often different metals) and causing corrosion.
Since no alloy is used (as in solder) the connection is mechanically stronger.
Disconnected connections can be used for cables from small and large sections, whereas only small sectional wires can be used with wire wrap.

In the first step of crimping, the terminal is inserted into the crimp tool. In the second step, the wire is inserted into the terminal.

In the third step, the handle of the crimp tool is squeezed together, compressing and reshaping the terminal until it is welded cold to the wire.

The resulting connection may seem loose on the edge of the terminal, but this is desirable so it does not have a sharp edge that can cut off the outer strands of the wire. If executed correctly, the center of the crimp will be swaged or cold-formed.

More specialized crimp connectors are also used, for example as signal connectors on coaxial cables in applications at high radio frequencies (VHF, UHF).

Video Crimp (electrical)

Histori

According to one manufacturer of crimp tools, the development of standard crimp tools and procedures occurs on this timeline.

1940s All terminations are soldered (Programmed)
1953 AMP introduces Crimp Barrel Terminals
1957 Cannon Brothers experimenting with Contact Machines with Crimp Barrels
1960 Buchanan introduces MS3191-1 4 Indent Crimp Tool with Ratchet
1963 MS3191-1 published as the first Crimp Standard Tool
1965 MS3191-4 was introduced by Daniels Manufacturing Corporation
1969 MIL-T-22520 published and dated to replace all previous specifications
1974 Changed to MIL-C-22520, and many Slash Sheets added
1996 Changed to MIL-DTL-22520
2010 Changed to AS22520

Maps Crimp (electrical)

Wrinkle type

Style

Terminal Insulated vs. Non-Insulated
crimp wire vs. crimp isolation

Shape stiffness

C crimp
D crimp
F crimp (a.k.a B crimp) originally designed and named by AMP Incorporated, is used only on non-isolated connectors, such as Packard 56, Weather Package, and Metri Package
O crimp
W crimp
Overlap/OVL hitch
Closed wrap (limited)
Wrap of Four Mandrel
Mandrel (sick) obstacle
Mandrel crimp-narrow (indentation)
Hexagonal Wrinkles
Mandrel (indent) hitch
Square wrinkles
Trapezoidal crimp
Trapezoidal indent crimp
Front crimp trapezium
Tyco crimp
Western crimp

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Assess quality crimp

Fogged connections will only be reliable if a number of criteria are met:

All strands have changed shape, become trapezoidal forms, into cold streams into the terminal body
The compression style is not too light, or too strong
The body of the connector is not too flawed
Large voids are not left behind in crimp (caused by insufficient wires inside the connector)
The wire must have as many cables as possible, so some of the damaged or unplugged cables will not affect the crimp density, thereby lowering the electrical and mechanical properties of the connection.

Various examples of good and bad wrinkles exist. This typically provides the micrograph of the crimped connection, which is a cut-off assembly connection in the cross section and then polished.

Crimp Gallery ETCO
Cross Separation

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Crimp tools

Various kinds of crimper (a.k.a. crimp pliers) exist, and they are generally designed for specific terminal types and sizes.

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Simple crimp connector

They meet a variety of uses, including allowing cables to be easily stopped to screw terminals, fast-on/quick-disconnect/spade-foot terminals, wire splices, or any of these combinations. A tubular connector with two curls for an in-line splicing cable is called a butt splice connector. The Crimp-on connector is attached by inserting the broken end of the wire to the connector section, which is then mechanically shaped/compacted ( wrinkled ) tightly around the wire. Crimping is done with special crimping pliers. The main idea behind the crimped connector is the finished connection gasproof .

A broken connection fulfills a similar role, and can be considered the same, to the soldered connection. There are delicate considerations for determining the right type - the crimp connection is sometimes preferred for these reasons:

It's easier, cheaper, or faster to reproduce reliable connections in large-scale production.
Fewer harmful, toxic, or harmful processes are involved in reaching the connection (soldered joints require aggressive cleaning, high heat, and possibly toxic flakes).
Mechanical characteristics that may be superior because they eliminate tension and lack of wicking solder.

Two main classes of crinkled terminals exist. The barrel connector has a cylindrical opening for the wire, and the crimp tool damages the circular shape into one of the above mentioned styles. The open-barrel terminals have "ears" of metal shaped like V or U, and crimp terminal curves and folds them over the wire before shifting the wire to the terminal. Open-barrel terminals are claimed to be easier to automate as it avoids the need to drain the wire into a narrow barrel terminal hole.

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Special crimp connector

Crimp connections are used usually to repair connectors, such as BNC connectors, to coaxial cables quickly, as an alternative to soldered connections. Usually male connectors are plugged into cables, and women are installed, often using soldered connections, to the panel on the equipment. Special strength or manual tool is used to attach the connector. Wire cutters that strip off the outer jacket, protective braid, and inside insulation for the correct length in one operation are used to prepare the cable for crimping.