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Crimping terminals is a type of wire assembly process dating back several decades. Throughout the years processing methods and operations were established and improved to assure optimum crimp quality and electrical conductivity of the wire to terminal connection. This post will cover the typical crimp types, crimp methods used to provide a quality wire to terminal connection and migration path from manual processing to automation from the crimp process.

Closed Barrel: Closed barrel terminals possess a round crimp barrel that surrounds the wire being crimped. There are two typical open barrel configurations, formed by progressive stamping process using a seam in which the two sides get together and form a circle and solid machines connector in which the crimp barrel is seamless, normally produced on terminal crimping machine. Closed barrel terminals come insulated or non-insulated and are in loose form or with a reel. Examples 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 prior to crimping and they are crimped around the terminal within a B shape or overlapped. Open barrel terminals are typically available mounted on a reel but in some cases can be bought in loose form for lower volume processing. Along with a barrel for your wire, some open barrel terminals feature an insulation support for applications for additional strain relief (from vibration or wire movement). Open barrel terminals normally are un-insulated but in some cases possess a partially loaded insulator pod that is inserted over the terminal throughout the crimp process.

Wezag Crimp Tool 1Hand Tools: A hand tool is used in low volume or prototype crimp applications. Tooling within a hand tool may be fixed and non-removable through the hand tool frame or might be removable. Crimp dies are accessible for open barrel and closed barrel terminals A trustworthy way of crimping wire to terminals with good repeatability. As volumes increase, repeated processing of terminals with hand tools might cause strain 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 a 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 features a mechanical or pneumatic feed which positions the terminal in the crimp anvil. The operator presses a foot pedal and also the crimp press cycles, forming the terminal across the wire and advancing the next terminal for more processing. A wide array of applications might be processed with bench top crimping equipment from the utilization of different press tonnages and applicators/die sets (fixed and quick change).

Automated Crimp Processing: Automated processing adds a wire cut and strip element for the crimp process. The most basic form is definitely the stripper-crimper which adds a wire stripping unit to a bench crimp press to strip the final from the wire and presenting the wire towards the crimp nest for crimping.

Automated crimp centers process the wire from its source in the barrel or reel, cut and strip the wire to length and present it to your crimp press for crimping. Reel fed applicators are exactly the same because the bench top type. With regards to loose piece terminals, a vibratory bowl is used to orient the terminals and offer on the crimp press for large wire strippers.

As volumes increase, the necessity to automated also increases. On occasion, the rise is dramatic, requiring a better step throughout the automation migration path. But normally the increase is controlled and slower so migration can take a multi step approach as time passes.

Hand Tool to Bench Top Migration: Migrating from the hand tool to power assisted bench top crimping demands a bench top crimping platform just 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 provides over 7 a lot of crimp force.

Non-Fixed hand tool die sets may be removed and compatible with bench top crimping units. This reduces the overall cost in the migration from hand tools to powered bench top equipment.

Bench Top to Automated Process Migration: Migrating from the bench top to automated processing machine such as the Primo XLT or Uno multi-station machines is easy and simple. Mini style applicators used in a bench press application as pictured above could be mounted directly from a bench top press on the press around the automation system. Some applications need a different feed cam to give the terminal in the press downstroke allowing for your robotic arm to dexopky08 into position with no interference through the terminal.

However, with regards to loose piece terminals, separate presses with integrated vibratory bowl fed systems may be needed because they are not much of a standard put in place by using 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 first step is determining the compatible terminal on reel equivalent. If your quick change mini applicator may be used, then this coax stripper might be quickly changed in one terminal type to a different one just by switching out of the terminal applicator.

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