How to crimp wires

Wire crimping sleeves: what they are, types and selection criteria

To ensure an uninterrupted supply of electricity, it is important to take care of the reliable connection of the wires with sleeves. A common phenomenon is twisted connections in electrical wiring sections.

At both ends, the twist points oxidize over time and become very hot under heavy loads, which can lead to short circuits and spontaneous combustion. It is also important to consider that due to the electrochemical properties of aluminum and copper, they cannot be connected directly.

Special crimp sleeves for connecting wires can provide the most reliable crimping.

What is crimping wires with sleeves?

Crimping with sleeves - permanent connection of wires

Crimping is a common procedure in electrical engineering; its peculiarity lies in the connection of electrical wiring with special sleeves.

The connecting mechanism is a connecting tube made of metal. To crimp the wires, their cores are inserted into a sleeve. By crimping the tube with the wires inside, it is possible to achieve a reliable connection.

At home, crimping is done using pliers, but it is preferable to use a special tool - press pliers.

The sleeve is compressed in two or three places, and the pressed area is insulated using insulating PVC tape or heat shrink tubing. Sometimes insulated connecting sleeves are used to connect elements; in this case, there is no need to re-process the electrical wiring section.

Connecting wires with sleeves must be carried out in the following cases:

• It is necessary to connect wires with a large cross-sectional area.
• There is no possibility of using alternative methods of connecting the wire. For example, wiring inside a distribution box where visibility is poor at high altitudes or where it is impossible to place the terminal block.
• It is necessary to connect wires in lines with high load.

Crimping sleeves for wires have their advantages and disadvantages. The first ones predominate:

• The crimping tool is equipped with a comfortable working area. This principle of operation allows you to perform assigned tasks in a limited space, for example, in distribution boxes or a socket box. Inside the socket box, crimping the wiring contacts allows you to shorten the wires to an absolute minimum.
• To compress the tube used, crimping pliers are used. Unlike analogues, this tool does not require a connection to electricity to operate and belongs to the group of manual ones. If the power is not yet connected, crimping is the only reliable way to connect the wires.
• To carry out soldering or welding, you must have certain knowledge and skills. Any person can cope with crimping after the first trial time. It is important to have press pliers and consumables; in extreme cases, you must have pliers.

Crimping allows you to connect wires made of different materials, for example, aluminum and copper. Soldering and welding do not provide such opportunities.

The disadvantages include the following:

• The need to constantly have in stock and regularly replenish stocks of cartridges of different sizes.
• The connection is characterized by considerable dimensions, which sometimes complicates the implementation of certain tasks.

It is also worth mentioning the significant costs of consumables.

Operating principle of a wire crimper

Crimping is carried out in two ways: continuous compression and local indentation.

Aluminum or copper wire is used for crimping. For this reason, a sleeve made of aluminum or copper should be used. There is also a copper-aluminum or connecting tube for conductors made of different materials.

Aluminum cable forms an oxidizing film over time; for this reason, the sleeve must be carefully cleaned and treated with a special compound. To protect the material from oxidation, quartz vaseline paste is most often used. Copper wire also needs to be treated with special compounds. Thanks to them, the likelihood of damage to the wire core during crimping is reduced, and the friction force is also reduced.

Stranded strands are aligned and folded so that they easily fit into the sleeve. The cable is inserted into the cartridge until it stops. The elements need to be connected not at the junction, but with a small plant.

Sleeves must be used that are designed and designed for the total cross-section of the cores being crimped. If a press with local (point) indentation is used, 2-3 veins are made evenly along the entire length, this is necessary for reliable and high-quality electrical contact, as well as ensuring mechanical strength at the junction. When using square or hexagonal matrices, you should follow the same rules.

It is important to ensure that the sleeve does not crack during crimping, and also to ensure that there are no compressed cavities. After the crimping has been carried out, the connection point is isolated using elbow cloth or electrical tape. The final step is to carefully fold the cable into the junction box.

Differences in wire crimping tubes by material

Connecting sleeves are divided into several types depending on the material of manufacture. The use of different types is due to the fact that, due to the electrochemical properties of metals, some react actively with each other, which leads to oxidation of the wires and their overheating under load.

Copper sleeves

The abbreviation GM indicates that the sleeve is made of high-quality copper. Used exclusively for connecting copper wiring. The surface of the GM is not covered with a protective shell, so it can only be used in non-aggressive environmental conditions.

Tinned sleeves

Tinned sleeves are used to connect copper wires intended for use in aggressive environments. These are the same copper sleeves, only their surface is coated with a special compound that forms a white protective shell. The abbreviation is as follows - GML.

The advantage of tinning is to protect the material from electrochemical corrosion, however, it is prohibited to use GML for aluminum wiring. This is due to the fact that during the compression process the protective layer is partially destroyed, which will result in direct contact between aluminum and copper.

Connecting tubes for cores made of different materials

The installation of electrical lines, as a rule, is not complete without the use and connection of cores made of different materials. For such purposes, special sleeves are used, which are considered combined and are called GAM.

The design is simple, but its peculiarity lies in the use of different materials. Two parts of the tube are welded into one, one is made of aluminum and the other of copper. The middle, the junction is equipped with a special limiter.

Thanks to it, equal input of the cores is ensured on both sides.

This variety differs in shape. This can be explained by the fact that the aluminum part of the tube has a larger diameter due to the need for a larger cross-section of the conductor.

The algorithm for crimping GAM is similar to the previous methods.

There is another type of sleeves designed for crimping wires. Its difference lies in the coating of the surface with insulation. Their operation does not require the additional use of connecting heat-shrinkable tubes or PVC tape. The surface of the sleeves is covered with a material that has plastic characteristics. During crimping, the PVC layer is also compressed, but there will be no direct contact between the sleeve and the wire.

Crimping tools

In any hardware store, the electrical goods department offers a large assortment of sleeves. A crimping device is also purchased to complete the task. The most budget and popular:

• Double-jaw equipment has the appearance of pliers, but is additionally equipped with a compression reinforcement with two jaws. There are also different types of crimping jaws, such as round tips or fork jaws. The average cost on the Russian market is 800 – 1000 rubles.
• An analogue of the previous device is four-jaw crimpers. They are intended exclusively for sleeves. The cost is several times higher and already starts from 2000 rubles.
• Wire stripping device. There are several types and modifications depending on the material from which the wiring is made.

A cutter can also be useful for making precise cuts. The price is more than acceptable, about 150 rubles.

Press pliers

Press pliers for crimping sleeves and wires

The most common crimping tool for sleeves is press pliers. They are even used for domestic purposes, since they can be used to crimp various terminals and non-standard connectors.

There are several types of press jaws depending on their purpose:

• for crimping sleeves;
• to remove the insulating layer from the core.

The crimp design is divided into several varieties, their main difference being the size and shape of the sockets. The nest may have a trapezoidal or square shape. Also, nests are divided according to additional equipment or the absence of plastic flanges. With their help, a reliable crimping of a multi-core cable is carried out.

To obtain a reliable connection, the tool size must match the diameter.

Modifications of crimping pliers:

• A tool designed for non-insulated parts. Equipped with one rod, which is located at the dividing joint during the crimping process. The pipe itself must be crimped in the very center.
• Equipment designed for insulated parts. Equipped with three oval die press shapes. Each of them has blue, red and yellow colors. Insulated tubes are painted in similar colors to make it easier to select the required press.

Wire crimping sleeves are a type of permanent connection. To avoid installation errors, you need to have a wiring diagram in front of your eyes.

Source: https://StrojDvor.ru/elektrosnabzhenie/gilzy-dla-obzima-provodov/

Wire crimping

Crimping of wires is one of the most effective ways to connect them in places with increased vibration and the possibility of mechanical pressure, as well as in cases where the length of the connected wires is not sufficient for soldering or welding.

This procedure can be carried out in two ways, using tips or sleeves, but one thing remains the same - it can be performed efficiently only using a special tool - press jaws or more complex hydraulic pressing equipment.

But first things first.

Crimping wires with sleeves: detailed instructions

To connect wires using sleeves, first of all, you need to study the technical tables and select, in accordance with the given cross-section of the wires, the required size of the sleeve, matrix (curly bracket/plier groove) and punch (the movable element of the crimping tool, which applies direct pressure to the sleeve). And then it’s a matter of technology

1. Place the wires in the box and remove the outer insulation by 3 cm if you plan to use sleeves with a cross-section of 4-16 mm. sq., or 2 cm, in the case of using sleeves of a smaller cross-section.
2. Sort the wires into groups. Insert each of the groups into a sleeve of the required cross-section. In our example, the wires have a cross-section of 2.5 mm. sq., they are divided into groups of 4 wires, therefore, the ideal option is to use a sleeve with a cross-section of 10 mm. sq.

1. For such sleeves, in accordance with the technical tables, press pliers HD-16L can be used; with their help, double crimp each of the sleeves - at their inlet and outlet.
2. All that remains is to isolate the resulting connections. This can be done by putting on a piece of heat-shrinkable tubing with an adhesive layer and blowing it with hot air, or simply wrapping the required areas with insulating tape.

At this point, crimping the wires with sleeves can be considered complete.

Useful tips and tricks

1. Using sleeves to extend the chain, make the joint of the wires exactly in the center of the sleeve.
2. Very carefully select the section of the sleeve for the wires to be connected: the more correctly they are selected, the fewer voids that increase the risk of poor contact will remain inside the sleeve, the better.

   If this was not possible, fill the empty space in the sleeve with pieces of bare wire. Their length, naturally, should be less than the length of the metal tube used.

3. The insulation of wires crimped with sleeves must extend beyond the sleeve cuts by at least 1 cm.

4. In the case of splicing a different number of wires on both sides or at least one multi-core cable, insulated lugs (NSHVI) should be used for crimping, not sleeves.

Crimping wires with lugs: instructions

1. Crimping wires with lugs is essentially a procedure similar to that described above.
2. First, determine the size of the tips.
3. Then the connected wires are exposed. In this case, it is better to do this with the help of a special tool - a stripper.
4. A tip of the required diameter is placed on the cleaned conductive part of the wire. Moreover, the wire must be stripped exactly to the length of the tip sleeve - no more and no less.
5. The wire with the sleeve on it is placed in the appropriately sized groove of the press pliers and crimped by squeezing the handles of the tool.
6. The crimping is completed, all that remains is to remove the crimped wire from the groove of the pliers and use it for its intended purpose.

What kind of tool can be used for crimping wires?

As is obvious from the above text, the most common tool for crimping wires are press pliers of the PC type - 1,2, 1M, 2M, 4, however, other options are also possible (they are used less frequently due to their bulkiness and high cost):

• manual hydraulic press;
• hydraulic press with electric drive;
• manual mechanical press.

Source: http://podmasterij.ru/elektrichestvo/opressovka-provodov.html

Crimping and termination of wire and cable cores

In this article we will talk about the technology of crimping wires and cables. The meaning of this process is to connect the cores using a connecting sleeve. The connection is made by deforming the sleeve-core pair. This method ensures high quality and good mechanical strength of contact connections. The shape and degree of deformation is determined by the tool used.

Connection of cores with sleeves

When connecting distribution boxes, crimping of wires is carried out quite rarely. Typically, in such cases, self-clamping terminal blocks are used or soldering or welding is performed. Crimping in boxes can still be found in old Khrushchev buildings with aluminum wiring.

Crimping of wires is carried out by inserting wires into a tubular sleeve and squeezing it with a press with a certain level of deformation.

Wire crimping can be done using the following methods:

• local indentation;
• volumetric compression;
• combined compression.

Local compression is produced by the teeth of the punch, which create increased pressure on one or more places, which allows for electrical contact. Continuous compression, accordingly, is produced by pressure along the entire length of compression.

The combined method involves continuous compression with additional compression of the punch with teeth in certain places.

Each of the described methods can ensure reliable connection of contacts only in cases where the surface was prepared before crimping and the sleeve and working tool were correctly selected.

Connection of current-carrying conductors up to 10 mm/sq.

To organize branches and connections of aluminum and copper conductors, press jaws and standard sleeves are used. Connections in such cases can be one-sided, when the wire is inserted from one side of the sleeve, or two-sided. The material of the sleeves is selected in accordance with the material of the cores

Cable crimping algorithm:

1. At the ends of the cores, the insulation is removed by 2-3 centimeters. They must be cleaned to a metallic shine. If the conductors are aluminum, then they must first be lubricated with quartz vaseline paste. Copper wires, in turn, can be left clean.

2. In accordance with the technical table, punches, dies and sleeves are selected. If the sleeves are too large, then the free space can be sealed using additional cores. When using stranded conductors, removing the conductor wire to adjust the cross-section is not allowed.

3. The cores must not be twisted. They are laid parallel to each other, after which the connecting sleeve is put on. If copper wires are used, then before putting on the sleeve, they must be wrapped in two layers of copper or brass foil. The thickness of the foil is 0.2 millimeters and the width is 20-22 millimeters.

4. The connections are crimped using press pliers using the local indentation method. The degree of crimping is determined by the technical table.

5.After crimping, the connections are wiped with a rag soaked in gasoline and insulated.

Connection of current-carrying conductors from 16 to 240 mm/sq.

The principle of crimping such cores is almost the same as described above. The exception is the use of a more powerful tool and a two-way connection type.

Before crimping, you again need to prepare the cores. To do this, you need to remove 3.5-6.5 centimeters of insulation.

Before crimping, you need to prepare the wires. Then you need to round off their ends:

• stranded wires are rounded off with pliers;

• single-wire - with a special tool, which is usually sold in a crimping kit.

Before crimping, copper wires are treated with technical petroleum jelly, and aluminum wires, respectively, with quartz-vaseline paste. Typically, the sleeves are lubricated from the inside at the factory. There is no need to be afraid that the lubricant will increase the resistance - if the technology is followed, it will be forced out of the contact area into the voids.

The cores are inserted into the sleeve from both sides. It is important that the joint occurs right in the middle of the sleeve. With local indentation, the degree of deformation is checked with a special probe or caliper at the place where the pits form. If the compression is continuous, then the cross-sectional dimensions must be checked according to the table.

Basic mistakes when crimping connections

a mistake during crimping is the wrong choice of sleeve. If it is significantly less, then the conductor will be strongly pressed by the edge of the sleeve. This may cause the flattened wire to break.

On the other hand, if it is too large, then the contact will not be very reliable. In such a situation, the wires may wobble inside the core. Over time, such connections will heat up and burn, which will ultimately lead to loss of contact.

The second mistake is incorrectly selected punches and dies. This can lead to a similar effect, resulting in over or under crimping of the sleeve. This problem is complicated by the fact that the working elements of the tool wear out over time and lose their primary characteristics.

IMPORTANT! Do not shorten the factory sleeve - this will reduce the reliability of the contact.

The third mistake is using a chisel and hammer to crimp cable lugs and sleeves. From the point of view of officially accepted methods, this is a terrible crime, but in life there are various situations and, in extreme cases, their use takes place. If it is possible to purchase good tools, then there should be no alternative.

In the end, we present the recommended combination of cross-sections of cores and cable sleeves:

1. The total cross-section of the cores in the press sleeve is 7.5 mm/sq. Cable press sleeve – 4-1. Press jaws – PK-3.

2. The total cross-section of the cores in the press sleeve is 13 mm/sq. Cable press sleeve – 5-1. Press jaws – PK-3.

3. The total cross-section of the cores in the press sleeve is 15 mm/sq. Cable press sleeve – 4-2. Press jaws – PK-3.

4. The total cross-section of the cores in the press sleeve is 20 mm/sq. Cable press sleeve – 6-1. Press jaws – PK-3.

5. The total cross-section of the cores in the press sleeve is 26 mm/sq. Cable press sleeve – 5-2. Press jaws – PK-3.

6. The total cross-section of the cores in the press sleeve is 41 mm/sq. Cable press sleeve – 6-2. Press jaws – PK-3.

crimping of tips

Source: https://electrikagid.ru/montaj-electroprovodki/opressovka-i-okoncevanie-zhil-provodo.html

How to properly crimp wire lugs - 5 crimping rules

How to properly crimp a cable lug or sleeve using a hydraulic press? Are there any rules or regulations that may affect the quality of crimping? Of course, they exist, and buying a high-quality press does not guarantee you reliable contact on a particular tip. Let's look at the main points of high-quality crimping or crimping of thick-walled tips.

Which tip to choose

Before you begin crimping, you must select the correct tip. It is worth remembering that tips come in different types - different sleeve thicknesses, different inlet diameters. Moreover, this happens with tips of the same section, but from different manufacturers.  

Therefore, it is not always the same matrix; you can crimp 2 different lugs for a wire of the same cross-section.
In addition, the number of sleeve crimps may also differ. If you want to achieve a high-quality connection that will reliably serve you for years, use the following recommendations.

The core, stripped of insulation, must clearly correspond to the diameter of the tail part of the tip.

Backlash may be acceptable, but it should be minimal.

If the tip material is aluminum, then the choice is simpler. Select a tip of the same cross-section as the cross-section of the wire. You can navigate by the inscriptions on the blade of the contact part.

But if the material of the product is copper, then certain difficulties arise. But there are several solutions here too.

• ⚡There are GOST tables that can be used to select the desired type. But this is not entirely convenient, because... you need to clearly know and distinguish between core flexibility classes, and you won’t have these tables at hand.
• ⚡measure the diameter of the core with an ordinary caliper. Then compare it with the diameter of the inner part of the tip shank. This can be done with the same caliper, or using the inscriptions on the blade.

The third number in the abbreviation TM-35-8-9 will be exactly the required diameter. That is, if the diameter of the core that you measured turned out to be 8.5 mm, then the most suitable tip would be the one marked TM-35-8-9. Please note that the diameter of the core should be slightly smaller, but not larger than the diameter of the shank .

The material of manufacture of the tip and sleeves must be the same as the material of manufacture of the wire or cable core. Connect aluminum wires using aluminum sleeves and lugs. Copper with copper. Otherwise, corrosion processes cannot be avoided.

If you need to connect an aluminum lug to a copper contact (on a switch or switch), use an aluminum-copper lug or use aluminum-copper washers. There are special aluminum-copper sleeves for joining copper and aluminum cable cores.

Preparatory work with the cable

Strip the insulation from the cable cores to the required length. What is this length?

It should be equal to the depth of the tip, plus 5mm margin.

A reserve is required because the tip will be stretched and deformed during crimping (especially aluminum).
Try to make the cut of the insulation even, strictly at an angle of 90 degrees to the axis of the cable itself.

If the cable cores are triangular in shape, they must be ground off with a rounding file. Otherwise, you will never achieve this density during crimping:  

After removing the insulation, the bare core must be cleaned and degreased. To do this, use special contact pastes.  

The procedure for crimping tips and sleeves

For crimping thick-walled tips and sleeves, it is best to use a hydraulic press. The press set initially includes universal dies for any tips and wires. Under no circumstances use a tool not intended for crimping (hammer, chisel, etc.).

A contact pressed in this way will not last long, especially if it constantly experiences heavy loads.

The next question that arises for an ignorant user is how many times should I press the tip with a press? Once, twice or three times? This depends on 2 parameters:

• ⚡from tip length
• ⚡and matrix width

In the operating instructions for the press that comes with the tool, there is a plate indicating the required number of crimps. Please note one thing: this table is intended for tips and sleeves made in accordance with GOST. How they differ from other brands can be found in the article Cable lugs, markings and types.

Insert the tip into the press so that the matrix cross-section markings (35-50-70, etc.) are imprinted on the front side of the tip, and not on the side or bottom. 

• ⚡The first crimping of the tip should be done closer to the blade (where the bolt is inserted)
• ⚡Perform the following crimps in order, moving from the blade to the tail of the tip
• ⚡the same rules apply for sleeves

This must be done in this sequence, because with each press the tip tends to lengthen (sometimes up to ten percent!). And if you start pressing from the end (not from the blade), during the last crimp, there is a high probability that you will have a void at the end of the sleeve. And you will not achieve the contact that was necessary.

First of all, this applies to all aluminum products. For copper this is not yet so critical.

When crimping from the side of the blade, the tip will seem to fit onto the core, tightening the connection more and more. The insulated tips even have special digital markings indicating the pressing order.  

The crimping ends at the moment when the matrices close together. If you need to perform two or three crimps, step back 2-3mm from the previous crimping point and continue crimping.

When crimping, the formation of a small flash is acceptable.
It can be removed or filed off. A very common mistake is the formation of large “ears” on the tip. This results from an incorrect choice of matrix.

If such “ears” do appear, you should not cut them down to the base of the sleeve . Otherwise, a gap may form in the tip and the crimp contact will become loose.

After the tip is crimped, it is advisable to insulate the area between where the shank ends and the remaining uninsulated part of the core. It is best to use heat-shrinkable tubing for this.  

5 rules for crimping

To summarize the above, if you want to get high-quality and durable crimping, you need to adhere to five rules:

1. choose the right tip
2. properly clean the vein
3. use a specialized tool
4. select the required matrix
5. follow the crimping sequence

Source: https://domikelectrica.ru/kak-pravilno-obzhimat-nakonechniki-dlya-provodov-5-pravil-opressovki/

Insulated pin sleeve lug for wires and its crimping

Single wire type cables are very well suited for distributing 220V power throughout the house. They are rigid, so you can bend them however you want, and because the wire inside is a single rod, without additional tools, using ordinary electrical connectors, it quickly connects to other wires and blocks (for example, in an electrical panel).

Power cords are a completely different story. They are flexible, and inside one wire consists of a dozen or even several dozen thin copper wires. The vast majority of power cords supplied with household appliances and all kinds of extension cords are made using wired multi-core cables.

Using such cables, you can connect two or more wires to one point without using external electrical connectors. For this purpose, cable end sleeves (pin lug) are used and today’s article will be about them. An important advantage of this solution is that the switch has a very good contact surface with the cable or wires.

In addition, the terminals of such a sleeve can be used wherever it is necessary to connect cables such as a network line. Connecting a cable to an electrical connector of a product (module) without a clamped bushing may result in the connector screw pressing only on part of the cable wires, which will weaken reliability and conductivity.

Insulated pin bushings

The insulated pin sleeve lug for attaching to wires consists of two parts:

1. the conductor is a tube several tens of millimeters long. This is the part that will be compressed.
2. insulation - a plastic element in different colors and thicknesses, depending on the size of the cable for which the tip is intended.

Of course, they can be purchased in various sizes to perfectly match the cross-section of the cable being crimped. Here is a table of the main characteristics:

It is worth explaining how the different sizes of insulated tips are described. The example of marks in the figure shows:

• HI - Product type as a symbol.
• 2,5 — a terminal designed for clamping a single wire with a maximum cross-section of 2.5 mm2.
• 2 X 2.5 - the terminal is designed to tighten two wires, each of which has a maximum cross-section of 2.5 mm2.
• / 8 — length of the conductive element in millimeters.

So if you see the symbol “HI 2 X 1.5 / 8” in the store, this means that the package contains insulated lugs designed to tighten two wires, each with a maximum cross-section of 1.5 mm2 and a conductive element length of 8 mm.

Please note: on the insulation side, the hole of the single lug is round, and the hole of the double lug is rectangular, so that the two wires can be placed next to each other.

Crimper for pin bushings

The pin lug crimp consists of a series of indentations and tabs, each of a different size. Each hole is used to clamp bushings of a different size.

Each hole has a number that determines what cable section the hole is intended for. For example, this crimp can clamp wires with a cross section from 0.5 mm to 16 mm square.

Other types of crimping tools

Crimping tools from different manufacturers have their own shape, but when it comes to the most convenient option, let's note the automatic crimper.

Such a device does not require searching for the hole that best fits a given tip. There is one hole and during clamping it automatically adjusts to the inserted end of the coupling and the clamps.

On various websites and online stores, this type of crimping machine is called universal, but the range of conductor cross-sections it supports is usually limited, for example from a cross-section of 0.25 to 6 mm2 or from 6 to 16 mm2. More versatile, in terms of the range of wire cross-sections, are hand crimpers like the one shown above.

How to crimp a pin lug

This is a simple operation. Just do it once and you can consider yourself an expert on this topic. It may take two or three tries, but let's start from the beginning. Let's look at two examples:

1. We will compress a wire with a cross section of 2.5 mm2 using a 2.5 / 8 sleeve
2. Let's fasten two conductors at one end: one 2.5 mm, the second section 1.5 mm2 using a 2 x 2.5 / 10 sleeve

Crimping a single bushing with a wire

First of all, we remove the insulation from the test 3-core cable with a cross section of 2.5 mm. It is better to use an insulation stripper, but you can do it the classic way - using a knife.

After removing the overall outer insulation, strip the insulation from the end of each wire separately. It is worth stripping the insulation to the same length as the length of the sleeve, which in this case is 8 mm.

Now all you need to do is put the sleeve (tube) on the end of the wire. Ideally, the sleeve insulation will match the wire insulation.

It is not acceptable to place the ferrule so that the copper wires between the wire insulation and the ferrule insulation are visible. Such a connection is both unreliable and unsafe!

Now you need to insert the sleeve into the hole of the tool of the required size and compress it. We find 2.5 on the crimping device and insert it to the end of the tube with the wire, then press the handle and everything is done.

You can check whether the lug is securely seated on the wire by holding the cord with one hand and pulling the cable with the other. You may have to apply more pressure if the tip moves.

Double Pin Lug Crimping

Clamping two wires at one end requires the use of a double terminal for the given cable cross-section.

The first step is identical. Remove the insulation from the ends of both wires. The double lug we'll be putting on has a sleeve length of 10mm, so will require a little more insulation than before. Holding both wires parallel to each other, insert them into the end of the sleeve. There is no need to pre-twist the cables together. Slowly (so as not to become disheveled) we put the tip on the wires.

After inserting the tube, it is enough to insert the tip with the wires into the corresponding hole in the crimping device. The tip is 2 X 2.5, so a 2.5 hole will be too small. A 4 mm2 hole fits here.

Press the tip while squeezing the handle of the device. Ready!

Twisting wires before crimping

Now about twisting the wires. Some people do this every time because once it's done, it's easier to push the wires into the end pin (tube).

Of course you can do this, the effect is ultimately identical.

But when twisting wires, it is a mistake to screw them in one at a time and then try to twist them together. Cables with this twist have a larger cross-section and may not fit into the grommet hole.

Options for crimping bushings

You can use wires with other cross-sections of lugs. You don't always have all types of bushing terminals on hand. For example, to clamp one 1.5 mm² wire, you can use a 2 x 0.75 ferrule. Of course it's not professional because the tip insulation doesn't fit perfectly, but in most cases it gets the job done just fine.

When it is necessary to clamp, for example, three wires, it is worth using one terminal with a correspondingly large cross-section. The single lug has a round insulation shape which will be better for three conductors than square insulation. For example, we want to connect three wires with cross sections: 2.5 mm2 - 2 pcs. and 1.5 mm2 - 1 pc. It's worth trying to use one terminal for 6mm2 wires. It should fit perfectly.

Pin sleeve lug - price

Pin sleeve lugs can be bought in Russian stores from 1 ruble per piece. Larger and more expensive products can cost up to 30 rubles. They are usually sold in packs or universal sets of several dozen pieces.

Conclusions and wishes

We are confident that this useful instruction will allow you to successfully crimp wires with pin ferrules. In any case, you have already perceived another interesting idea by reading this article. And if you have any questions, ask in the comments.

Source: https://2shemi.ru/nakonechnik-shtyrevoj-vtulochnyj-izolirovannyj-dlya-provodov-i-ego-opressovka/

Connecting wires and cables with sleeves

There are many ways to connect electrical cables, which have their own advantages and disadvantages. They can not only be combined by welding or soldering, but also twisted, secured in terminal blocks, and secured with PPE. One of the most reliable and optimal connections is crimping wires with sleeves.

Thanks to this method, good electrical contact and high mechanical strength can be obtained. Crimping is a permanent connection and after it the wire cannot be disconnected, it can only be cut.

It is done as follows: the sleeve and the cores that are inserted into it are deformed under the action of the press and a reliable electrical contact is formed that satisfies the rules of the Electrical Installation Code described in Chapter 2.1, paragraph 2.1.21.

What tools are used

In order to make this type of connection, special tools for crimping wires, such as mechanical and manual crimping pliers, are most often used. With their help, you can tightly clamp the contacts along the entire length. Hand pliers can compress a sleeve with a cross-section of less than 120 mm2. A sleeve with a large cross-section is connected without pliers, but using a hydraulically driven tool.

If it is necessary to crimp several wires of different sizes, then you should use pliers that have a matrix for different sections and adjustable punches. The advantage of such a tool is that there is no need to constantly reinstall something; you just need to turn the matrix or punch screw to the required section.

Never crimp sleeves or ferrules with pliers or in a vice - this will clamp the core, but will not provide good mechanical strength and contact. At the slightest load the core will come out of the sleeve. The point of crimping is to apply pressure on the sleeve or tip from different sides and form a certain shape that firmly holds the conductive core!

Connecting wires by crimping is the most optimal method in terms of mechanical strength, but it is considered non-separable. To disconnect the cable, you need to cut a certain section. And to connect them, any conductor of any cross-section (both copper and aluminum) will do.

Crimping technology

There are two methods by which crimping is carried out:

• local indentation;
• complete compression.

The wire for crimping is copper or aluminum. Therefore, the sleeve can be either copper or aluminum. There is also copper-aluminium.

Since an aluminum cable is prone to the formation of an oxidizing film, the aluminum sleeve must be cleanable and treated with a special lubricant. To protect aluminum from oxides, quartz vaseline paste is used.

Copper wire is also subject to lubricant treatment. With its help, the likelihood of damage to the core during crimping is reduced and friction is reduced.

If the cores are multi-wire, they are aligned and folded so that they easily fit into the sleeve; you can twist the wires a little. Then the cable is inserted into the cartridge until it stops. The connection can be made not end-to-end, but, for example, with a factory. Then the total cross-section of all wires should not exceed the cross-section of the bushing.

In any case, sleeves are used that are designed for the total cross-section of the cores being crimped.

If a press with point (local) indentation is used, make 2-3 pressings evenly distributed along the length of the sleeve to ensure mechanical strength of the connection and good electrical contact.

For continuous crimping using hexagonal or square dies, the recommendations are essentially the same. In both cases, it is important that the sleeve does not crack during crimping (if it is too small) and that there are no uncompressed areas or cavities (if it is too large).

After the crimping has been carried out, it is necessary to create an outer insulating layer at the junction using electrical tape or elbow cloth. After insulation, you should carefully fold the wires and the cable itself in the junction box.

Source: https://samelectrik.ru/soedinenie-provodov-i-kabelej-gilzami.html

Crimping pliers for crimping wire lugs

For high-quality connections of various wires and cables with sources and consumers of electricity, metal crimp lugs and sleeves are used. Their fastening to the ends of wire products is carried out using press pliers for crimping the tips.

Features of crimping pliers

The principle of operation of the tool is similar to the operation of pliers. The difference between crimping pliers for ferrules is the complex profile of the pressing jaws. Crimping pliers or crimpers have different sizes and shapes of the planting bed. Each type of tool is designed for crimping wires and cables with a certain cross-section and number of cores.

Tools for crimping wire lugs and cable cores allow you to quickly and efficiently make switching connections between power units. The crimping process for cable lugs is quite simple. A sleeve is placed on the bare end of the wire or stranded wire. She is led into the opening of the ticks. Using the force of the fingers, the hands squeeze the levers of the tool, and the crimper compresses the sleeve with the wire.

Main types of ticks

Installation of SIP cable from pole to house

Crimping pliers are divided into two types. The most common type is a design that works like pliers. That is, the sleeve is compressed on both sides. Other pliers are diaphragm crimpers.

Passatizhny

The tip is crimped in the same way as pliers grip a part. The working surface of the dies has cutouts into which the tip shank is threaded. This design is suitable for those fastenings that do not require special reliability.

To increase crimping force, hydraulic ferrule crimping tools were invented. Thanks to this improvement, the pliers became more efficient. The design uses cylinders with pistons filled with oil, which creates a large pressure of the matrices on the tip sleeve.

Pliers with removable dies

Important! Some crimpers are equipped with several types of removable matrices. The versatility of the tool eliminates the need for pliers for each conductor cross-sectional size.

Diaphragm pliers

The originality of the design of diaphragm crimpers lies in the comprehensive coverage of the tip shank. The principle of operation is similar to the movement of the aperture blades of photographic lenses. The only drawback of such devices is the impossibility of inserting pliers into the connection of the two ends of the wires.

Note! The diaphragm tool is used as a press for pin or flat metal tips. The all-round clamp is much more effective than the plier type for covering the end switches of wire products.

Application area

High-voltage wires - device and application

Pliers for crimping wire lugs of certain designs are used depending on the cross-sectional composition of the cable product. The main areas of use of crimpers can be represented by the following list:

• stranded wires and thin-walled lugs;
• stranded wires and thick-walled lugs;
• lugs and large-section electrical cable;
• sequential crimping of wires;
• crimping computer cables.

Stranded wires and thin-walled ferrules

Thin-walled lugs are used for small-section wires - from 0.5 to 3.5 mm2. The elements are marked NSHVI. The abbreviation stands for as follows:

• N – tip;
• Ш – pin;
• B – bushing;
• And - isolated.

NSHVI lugs are used for crimping stranded copper wires with subsequent insertion into sockets of various electronic devices. The crimper handles are compressed until the spring mechanism of the device is activated.

Note! Multi-stage clamp matrices allow you to work simultaneously with wires with a cross-section in the range indicated above. This eliminates the need for a large number of hand crimping tools.

Press pliers create a strong and reliable compression of the tips. Without them, one would have to twist stranded cores or solder the terminals of switchgear devices. The use of pressed end switches completely eliminates problems associated with breakage of thin wires, wire breakage, and the risk of short circuit.

Stranded wires and thick-walled ferrules

Thick-walled shanks are used for crimping multi-core power cables. Their maximum cross-section reaches 16 mm2. Press pliers PK-16 are used only for multi-core wires. The tool can compress the sleeve so tightly that it can easily break a single core.

The cable crimping process occurs in several stages:

1. At the end of the wire, mark the length of the sleeve.
2. Using special nippers, remove the insulation from the marked area.
3. Place a piece of heat-shrinkable tubing so that it does not touch the exposed wire.
4. The cleaned end of the cable is inserted into the sleeve. The insertion of the wire should be tight, but without force.
5. The tip is crimped using pliers.
6. The protruding veins are bitten off.
7. Use a hair dryer to heat the heat shrink tube until it tightly grips the cable.

If the letter “U” is indicated in the marking of the tool, this means that the ratchet mechanism is located inside the handles, which creates a large force on the jaws of the crimper. The PK-16-U pliers compress more easily during cable crimping.

Large cross-section lugs and electrical cable

Crimping for large cross-section electrical cable lugs is done using a manual hydraulic press. Initially, the valve of the device is slightly open, and the rod slowly moves to its original position. At the beginning of the piston stroke, the valve opens completely, which ensures compression of the dies with great force.

Large cross-section cables are rarely found in indoor equipment. Hydraulic pliers are mainly used for installing lugs on high-voltage cables for fastening them in switchboards of industrial facilities. Hydraulic crimping pliers for dimensional lugs are also used for laying and switching power cables in power panels at the entrances of residential buildings, administrative buildings and civil buildings.

The hydraulic press is equipped with cassettes with replaceable dies. The upper lever is equipped with a magnet, which, after compression, returns the handle to its original position. The levers are equipped with rubberized shells, which ensure electrical safety of the device. Crimping of two cables with a double-sided sleeve is carried out when moving the electrical panel. These pliers for simultaneous crimping of two wires are also used when extending copper conductors with a diameter of 6-12 mm2.

Consistent wire crimping

This method is used when connecting sections of wires into a single whole. This is especially important for sequential crimping of conductors with cores made of different metals. For example, when you need to make a connection between aluminum and copper wires, use a crimp sleeve.

The fact is that twisting metals of different names will cause destructive processes from their direct contact with each other. The connecting sleeve becomes a kind of bridge between aluminum and copper.

The bare wires are inserted into the sleeve on both sides. After this, the sleeve is compressed with pliers. The compressed sleeve prevents air from entering the connection, which prevents the occurrence of oxidation processes in the metal of the wires.

Computer cable crimping

Often the question arises of crimping an Internet cable to connect it to a computer or connecting several PCs with a local network. For this purpose, a twisted pair cable is used. The wires are unraveled and distributed parallel to each other. At the same time, the strict color arrangement of the wires is observed.

Plastic RJ-45 connectors are used as tips. Polymer tips are intended for insertion into the sockets of hubs and network adapters. A twisted pair consists of eight wires. Insulated conductors twisted in pairs minimize interference when electric currents pass through them.

Plastic cable lug

Special crimpers are used to crimp cable ends. The RJ-45 connector is a plastic box with an opening for the cable on one side and contact terminals on the other side.

Power cable crimping pliers

The process of installing connectors on network cables is as follows:

• remove one centimeter of insulation, for this there is a special connector on the pliers;
• twisted pairs are unraveled and aligned in a certain order;
• Using wire cutters, cut the wires evenly so that the bare ends of the cores are formed;
• the wires are inserted into the RJ-45 connector, the cut wires with their cores should be tightly adjacent to the back of the terminals;
• The plastic connector is inserted into the opening of the pliers, then the tool handles are squeezed.

The twisted pair wires should be arranged from left to right in the following order (looked from above from the entrance to the connector):

1. White-orange.
2. Orange.
3. Green-white.
4. Blue.
5. Blue and white.
6. Green.
7. White-brown.
8. Brown.

How to use crimping pliers correctly

Welding electrical wiring

Self-mastery of crimping pliers may initially be accompanied by the creation of a poor-quality connection between the sleeve or tip and the wire. It often happens that what appears to be a reliably performed crimp hides a bad contact. This can happen for two reasons.

If the shape of the terminals is not maintained

A discrepancy between the size of the tip or sleeve and the opening between the matrix jaws can cause distortion of the compressed element. Before you start crimping, you should try on the tip to the opening in the pliers. It is also important that the bare end of the wire fits tightly into the holes of the shank or sleeve.

A bundle of wires or a single core should fit into the connecting element with light tension. If you have any doubts about the reliability of the fastening, you should practice on separate sections of the cable. After crimping by hand, you need to check the strength of the connection. If there is the slightest play, the crimp should be rejected and crimping should be resumed with a different end cap.

Excessive clamping may damage the conductors inside the sleeve. The accompanying documentation for crimping pliers usually indicates the cross-sectional dimensions of the tips directly for each opening of the pliers. The use of connectors made of soft metal alloys should be avoided. Over time, the tip may lose strength and contact will become unreliable.

Twisting stranded wires before crimping

A mistake can be made due to the habit of twisting the wires, which is done before insulating or soldering manual connections. This is absolutely impossible to do.

You can check the harmfulness of twisting in a simple way. It is worth squeezing the twisted multi-core cables with pliers to make sure that there is deformation and damage to the integrity of the wiring.

If, when removing insulation from the cable installation section, twisted conductors are found, they must be straightened. Only after this the conductors are inserted into the opening of the tip or sleeve.

Color coding of tips

Color marking is used for NShVI tips. The color of the connector skirt corresponds to a specific wire cross-section:

• black – 1.5 mm2;
• blue – 2.5 mm2;
• gray – 4 mm2;
• yellow – 6 mm2;
• red – 10 mm2.

Color marking table for NShVI tips

Crimping wires using pliers cannot compare with hand twisting or soldering in terms of quality and speed of connections. For any connections you can always choose the right crimper model.

Source: https://amperof.ru/instrument/obzhimnye-kleshhi-opressovki-nakonechnikov-provodov.html

Cable crimping, wire lugs, crimping without tools

Crimping a wire cable is a very responsible task, especially if this connection is a power connection. In this article we will look at how to correctly terminate connections of low-current wires (up to 15–20 amperes).

Remember! The use of power cables and lugs made of the wrong material and cross-section can lead to serious consequences, such as fire of the wiring, for example.

So, how to properly crimp wires with lugs

In addition to selecting the necessary wires and tips, to perform this task you will need a special tool called a “crimper” or press pliers.

Externally, the tool is very similar to pliers, at the ends of which a special matrix is ​​installed, into which the tips and the non-insulated part of the cable are inserted.

This tool is designed to provide uniform ferrule force around the wire, eliminating poor contact when crimping the cable. In addition, there are universal tools that allow you not only to crimp, but also to cut the cable, remove the insulation from it and twist the core.

Particular attention should be paid to the type of cable; in domestic conditions, the power cable can be of two types:

• with a monolithic core;
• stranded

When crimping a wire with a monolithic core, it is enough to remove the insulation layer with a small margin (up to 0.3–0.5 cm), (using a tool or using an insulation stripping knife), then straighten and degrease the area to be worked with, after which you should put it on a thermal insulating tube onto the cord.

Then, we select on the tool (by a jumper in the matrix) a certain section and type of tip. After carrying out the above manipulations, you need to insert the prepared end of the wire into the tip, after making sure that there are no cracks in it.

Install the ratchet lock lever. Failure to comply with this point may result in poor-quality crimping of the tip and, accordingly, poor quality of the connection.

The final part of crimping a wire with a monolithic core with a tool:

• make sure the connection is correct;
• insert the tip all the way into the device so that the numbers with the matrix markings are knocked out on the front or back sides of the tip;
• completely recess the exposed section of the wire into the tip;
• applying force, press the crimper handles;
• as soon as the operation is completed, the handles will automatically begin to return to their original position (to do this, it is necessary to move the ratchet locking lever to the “locked” state);
• The cord has been terminated; the final step is to put the heat-shrinkable braid on the connection point and warm it up with a special hairdryer or lighter.

If the handles do not return to their original position, then this problem may be caused due to the following problems:

• too weak compression of the tool handles;
• malfunction of the ratchet mechanism;
• “weak” spring in the ratchet;
• The ratchet locking lever is not fully installed.

If you have to terminate multi-core wires, then the above method should not be used, as it has many nuances.

Therefore, wires with a large number of cores are crimped according to the following instructions:

• remove part of the insulation from the wire (with a small margin of up to 0.3–0.5 cm); when removing the insulation, it is highly advisable to use a special tool that allows you to remove the braid and not damage the cable cores, but if such a tool is not available, you can use a sharp knife (when removing the insulation, you should make sure that the wire cores were not affected);
• put a small piece of thermal insulating braid on the cord;
• after which the bare area must be degreased with alcohol and a special electrically conductive paste applied (the most common options are compositions such as “KVT” and “EPS”).

After the above manipulations, cable processing can be considered complete.

• set the required cross-section and type of tip in the device matrix;
• install the tip completely into the device so that the numbers with the matrix markings are on the front or back sides of the tip;
• we insert the straightened cable cores into the lug until it stops ( Attention! Twisting the cable cores is prohibited );
• applying force, press the crimper handles;
• The crimping of the stranded wire is completed, now we return the heat shrink that was previously placed on the cord to the connection point and warm it up with a hair dryer, soldering iron or turbo lighter;
• After completing the operation, the handles should return to the standard (unclamped) position; if this does not happen, then the reason for this may be the problems described above.

How to crimp wire lugs without tools

From the point of view of construction technology, crimping wires without the appropriate tool is prohibited, the only exception being rough installation to check the work performed.
However, for any household work with low-current consumers, work without a crimping tool is allowed.

There are several methods for ending cords without tools:

• soldering using refractory high-temperature solders;
• “non-standard” crimping using cores, hammers, and notching the tip

Soldering tip

For soldering, you, of course, do not need serious and expensive press pliers/crimpers, but the following “household” repair tools should be present in your arsenal:

1. Soldering iron (from 80 W)/blowtorch/gas burner.
2. Soldering kit (fluxes/rosin, various types of solders).
3. Heat shrink tubing and/or electrical tape.
4. Basic knowledge and skills of working with a soldering iron.

The algorithm of actions is as follows:

• if you have a soldering iron/blowtorch, heat it up to operating temperature, if you don’t have one, turn on the burner on the kitchen stove;
• While the tool is heating up, we perform operations to remove the insulation from our cord (remove with a margin of 0.3–0.5 cm), making sure not to damage the cores;
• we put the thermal insulating braid on the cord and move it to a safe distance until we need it;
• degrease the cleaned area;
• degrease the tip;
• apply flux to the inside of the tip;
• Pre-cut the solder into small pieces so that it covers the inside of the tip by about half to a third;
• apply flux with a soldering iron to the stripped part of the cord, tin it (if there is no soldering iron, then skip this step);
• carefully, holding the tip with pliers so that the solder particles do not fall out of it, place it on the kitchen tile (if you don’t have a soldering iron) or heat it with a soldering iron/lamp/burner for several minutes until the solder inside becomes plastic and liquid;
• as soon as the solder is ready, quickly and carefully take the cord by the insulation and install it into the tip, while continuing to heat the tip, holding it with pliers, if there is an empty space between the tip and the solder does not come out, then add solder to these places until it will not begin to “crawl out”;
• then turn off the soldering iron/burner and give it a few minutes for the solder to completely harden;
• After hardening, we wrap 2-3 layers of electrical tape around the connection between the cable and the tip, move the thermal braiding, securing it at the edges with electrical tape.

Crimping using a core/hammer

This method has many disadvantages, the main one being insufficient pressure, which can lead to heating of such a connection. However, it is often practiced, especially in cases where the connection will not work with high-current devices.

This method requires a minimum of tools:

1. Hammer.
2. Kern (optional, but recommended).
3. A small file for metal.
4. Vise (optional, but recommended).
5. Conductive paste (highly desirable).
6. Insulation tape and/or heat shrink.

To finish with these tools, we do this:

• remove the insulation from the cord (margin 0.3–0.5 cm);
• make sure that the wires are not damaged;
• straighten all the wire strands, twist them slightly (half a turn, no more!);
• take the tip and make a small cut with a file (about 1/5 of the entire length of the tip) on the wire side;
• put on the heat shrink, move it 10–20 centimeters so that it does not interfere; degrease the cord;
• evenly apply conductive paste;
• we clamp the tip in a vice or place it so that it can be comfortably held with one hand;
• after which we completely install the wire into the tip;
• we take a core and a hammer and begin to strike the central part of the tip, which should be “compressed” (if there is no core, then you can use the thin part of the hammer);
• make 4–5 fixation points;
• turn the tip over and repeat the operation;
• check the connection for strength;
• We put heat shrink on the connection, heat it;
• ready, the connection is pressed!

Source: https://ProFazu.ru/provodka/montazh/obzhim-kabelya.html

Sleeves for crimping wires - types, tools, errors

It is necessary to use sleeves for crimping wires if uninterrupted power supply and long-term safe operation of electrical appliances really matter. The reluctance or impossibility of crimping in this way will invariably lead to premature failure of the devices, primarily due to deformation of the connections under the influence of load.

Crimping should be understood as a simple operation of connecting wires using special sleeves - tubes made of different types of metal. In this case, the sleeves play an important role as a connecting mechanism. The wires are placed into the body of the sleeve, after which the tube is crimped using a special tool. The result is a reliable and secure connection.

Compress the connecting sleeves in several places using heat shrink tubing or PVC tape for insulation. In some cases, it becomes appropriate to use insulated sleeves, which are discussed in more detail below.

Crimping of wires using metal tubes is advisable in cases where:

1. It is necessary to connect the wires in areas with high load levels.
2. If wires with a large cross-section need to be connected.
3. It is impossible to use alternative connection options (at a height, in the absence of the required visibility, inside a junction box, etc.).

The crimping process has several positive aspects:

1. The connection can be made without connecting to the mains using press jaws.
2. The work does not require special skills or experience; anyone can handle it with their own hands, provided they have even the most primitive set of tools.
3. You can work with a crimping tool in confined spaces with the ability to shorten wires to a minimum to increase installation density.

In addition, it is worth noting that crimping does not impose restrictions on the types of wires that must be connected, unlike welding.

Types of connecting tubes

Crimping of wires can be carried out using connecting sleeves in several designs. The choice of connecting tube will depend on the electrochemical properties of the metal from which it is made and its interaction with the material of the wire.

There are several options for materials for the manufacture of sleeves:

• copper;
• tinned;
• combined universal;
• isolated.

Copper tubes (CM) are used for copper wires, the crimping of which cannot damage the protective layer due to its absence. The tubes cannot be used in aggressive environments.

Tinned sleeves (GML) are suitable for copper type cables used in aggressive conditions. The white protective layer covering the surface of the product fully copes with the main functions. The tubes are not suitable for working with aluminum wires due to possible contact of the protective layer, which is partially destroyed during compression, with aluminum.

Combined tubes (GAM) are necessary for crimping mixed-type wires. There is a limiter in the central part of the connection between the aluminum and copper tube structure. It allows you to insert wires on both sides as smoothly and delicately as possible.

Combined wire sleeves have a distinctive feature - their shape. The aluminum part is larger than the copper part. This is due to the resistance of aluminum, which exceeds the resistance of copper. During the crimping process using such tubes, wires are inserted on each side, taking into account the type of metal.

The last option for sleeves is insulated (GSI). They replace additional insulation with PVC tapes due to the presence of heat-shrinkable tubing. Their structure is similar to the structure of GML tubes, with the exception of a PVC layer that does not transmit electricity. The protective layer is quite plastic and reliable, indestructible even during the crimping process, taking the shape of a metal.

What you need to know about the sizes and design features of tubes

Sleeves for connecting wires are divided not only by the type of material from which they are made, but also by size and range of sections. The minimum cross-section is 1.5 m. This applies to GML type tubes. Further indicators are growing. It is worth remembering that the tubes are produced with a cross-section similar to the cross-section of the wires.

A separate point is the design of the products. The tubes can be through and with a partition located in the center. Partitions are needed to control the depth of the wire entry when extending from two sides, joint to joint.

Principle of wire crimping

You can perform crimping of wires using sleeves in several ways. It will not be possible to single out the best of them, since comparison is inappropriate here. The choice of crimping method directly depends on the conditions for electrical installation work, cross-sectional parameters and other important points. Let's consider the features of the main method of crimping using sleeves.

Work begins by introducing the previously stripped ends of the wires into the cavity of the sleeve. The next step is crimping - squeezing using a special tool. The metal surface of the cores and sleeve is compressed, resulting in a reliable adhesion of the parts. It is necessary to connect at several points, followed by insulation of the connection points. An exception is working with insulated sleeves for crimping, which do not require additional insulation.

When choosing this method of connecting wires, you need to remember that the contact will not be disconnected in the future. Taking this into account, work will need to be carried out carefully and prudently.

The main mistakes in the core crimping process

Independent installation of sleeves on wires, even with repeated operations, can become unsuccessful due to mistakes made. The most common ones are below:

1. Cutting connecting tubes. During the crimping process, it may seem that the length of the sleeve is too long and that cutting will not spoil the result. Wanting to get four or even six cartridges out of two, inexperienced craftsmen do not notice how they are worsening the result. Reducing the length of the section for fastening the cores leads to a decrease in the contact strength.
2. Selecting a tube of the wrong diameter. A sleeve that is too large will complicate the electrical installation process and will only be appropriate when working with copper conductors that can be bent at the end and inserted in this form into the hole. Aluminum wires cannot be bent, they will simply break. A sleeve that is too narrow may lead to the idea of ​​grinding the wires to fit into the cavity. It is highly not recommended to do this, since it is precisely such manipulations that, as a result of reducing the cross-section in the area, can subsequently cause ignition.

Any unintended manipulations with the sleeves during the crimping process will compromise the integrity and reliability of the contact - this must be remembered.

Recommendations for crimp testing

If difficulties arise in selecting a sleeve that is ideally suited for the wires in size, it is better to opt for a tube slightly larger than required. In this case, the void can be filled by cutting bare wire with a slightly shorter length than the sleeve. Compaction in this way will improve the quality of the crimp.

Extending the wire using crimping should imply that the connection joint is located exactly in the center of the tube.

When isolating the joint, the connecting tape must extend beyond the edges of the sleeve by at least 10 mm. If multi-core wires are connected to each other or it is necessary to splice different numbers of them on both sides, then the correct solution would be insulated type connecting sleeves.

In conclusion, we note that crimping as a process is not difficult if you act consistently, use a special tool and suitable sleeves. One way or another, you need to remember that we are talking about a permanent connection, so you will need a wiring diagram. Having a plan at hand will help you avoid mistakes during the work.

Sleeves for crimping wires - types, tools, errors

Source: https://220.guru/electroprovodka/provoda-kabeli/gilzy-dlya-opressovki.html