Crimp press for cable. Crimpers for crimping insulated and non-insulated terminals and lugs. For insulated cable lugs

Every house, apartment or garage has an electrical connection, where it often becomes necessary to repair old wiring or install new ones. When laying electrical wiring is required, and doing it reliably, this is the key to correct operation electrical appliances and security. The best way to do this is with electrical cable crimps.

If the wires are loosely connected, for example, by twisting or soldering, the junction heats up, which most often leads to a fire. Such an unreliable connection does not provide proper throughput and causes instability electrical network, which leads to the failure of electrical equipment.

These shortcomings are deprived of the connection method using crimping (crimping) of wire lugs. To do this, use a special tool - crimpers (crimps), which provide tight and high-quality contact.

Strictly speaking, wire crimping is about the same as in other areas of activity.
Creating the tightest possible connection by applying mechanical force.
Creating (if possible) an inextricable connection that can withstand significant physical exercise to break.
The ability to ensure the continuity of the flow (we have current) at the most difficult conditions operation.
Installation speed without loss of connection quality.

We will proceed from this, because we often need the crimping of cable lugs, although we do not know anything about this. Although it seems simple:

Here we put the cable into such a little thing with a handle, we will properly squeeze the sides of the entrance, and it will be possible to screw this thing anywhere. By the way, such sleeves for crimping wires are sold anywhere, so you can buy them very inexpensively. Like a tool, because the lugs for wires for crimping with your own hands and pliers cannot be crimped.

So, for a one-time job, this will not be the most budget solution. Especially if you do not understand how crimping wires compares favorably with other cable methods.

First of all, wire crimping only applies to multicore cables. This should be borne in mind, since a reliable connection of one core, even with the most powerful mechanical loads, cannot be obtained.

The second is very important point. The number of cores matters, but the diameter of the cable does not. That is why the thinnest cables are crimped, the crimping forces of which are minimal.

And third. Crimping cable lugs is not possible without a special tool that is designed to perform this procedure.

And most importantly. What do we get as a result of pressing? We actually get cold welding» with the help of mechanical force of all cores of a crimped cable with a lug, without the use of soldering or other temperature effects.

This is the meaning of crimping wires - creating a strong connection quickly and without using the reliable switching method familiar to an electrician.

We just press the cable into the ferrule so hard that the connection becomes permanent. Well, the speed of installation, of course, is a significant factor for connections in electrical wiring. Even in crimping, there are limits to the applied force, so do not push the cable and lug too hard. Everything needs a measure.

Soldering a stranded wire is not the easiest operation, because you need to expose all the wires, make sure they are clean in terms of contact, and only then start soldering. Any core in a stranded wire has insulation, and this often creates difficulties in establishing reliable contact.

Just crimping the cable lugs solves all these problems, because with the help of mechanical force (compression), not only the insulation of individual cores is destroyed, but also a strong connection of the entire cable is created for better contact.

The problem is that the size of these sleeves is small, and the markings are incomprehensible to those who are not specialists. But before that, let's define the difference between a sleeve and a cable crimping lug.

These are typical sleeves:

With its help, you can "lengthen" the cable, both the same section and different.

And this is a typical tip:

And just in both photos it is clearly seen that there is practically no place for full marking, unlike such sleeves and tips:

Therefore, there can be only one recommendation - well-marked products will cost more, while unmarked ones are no worse. You just need to consult with the seller, as a rule, they are well versed in this issue.

different types

ring tips (NKI);
fork tips (NVI);
pin round tips (NShKI);
flat (plug) connectors (RPI-P, RPI-M, RSHI-P, RSHI-M, etc.);
piercing type couplers (OV).

Here it is necessary to return to the tool that provides crimping of wires, because each tool shows the dimensions for the standard shape of the jaws, and the force itself is accurately measured by diameters. So, if you didn’t make a mistake with the diameter, you won’t be able to apply excessive force.

And, despite the fact that the lugs for wires for crimping are different, with the same diameter and force, and the standard of the tool will be the same. It is a pity that this parameter is not reflected in the marking. Apparently because usually such work is done by professionals, not home electricians.

But it is precisely the standards that allow home electricians to stock up on universal crimping pliers and, without any problems, crimp cable lugs for their own purposes. It is quite simple to master this procedure, and technologically it is the same for crimping an RG-45 connector and a tip for a three-phase machine.

When crimping a multi-core cable, special lubricants are indispensable. Therefore, use sleeves and tips that already have this lubricant inside. In any case, this is a one-time operation. It will not work to remove the sleeve or tip in order to rearrange it to another place.

As a result, having mastered the installation of sleeves and tips, you will be able to quickly restore the desired connection, carry out repairs without problems, as well as a connection that, in fact, will not need repair for many years.

For every inhabitant, a striking example of incorrect wiring is the stair switchboard, many apartment owners have melted wires in the switchboard, there are twists.

Ferrules for wires for crimping can save citizens from the possibility of heating and ignition electrical wiring as a result of poor-quality wire contact, the absence of cable lugs.

Sleeves and tips are intended to remove or minimize the contact resistance, in other words, to exclude poor-quality contact, for a bolt or screw.

High-quality contact in the connection, contact resistance:

For crimping (crimping for lugs) of wires and cables, special products are used - lugs and sleeves. Tips can be stranded wires and single-core wire, they are subdivided according to the purpose and type of wire for which they are used (copper or aluminum).

copper tube

With different diameters under the wire and the mounting hole, which does not have a protective coating;
for crimping electrolytic tinned with different holes for fastening.

uncoated, TM - X - Y, where X is the cross section of the wire, Y is the size of the hole for fastening;
coated, TML-X-U.

This type of product is marked as TML (o), it is noteworthy that they can be installed on the ends of cables using solder and soldering, which almost completely removes the value contact resistance.

Quite often in electrical engineering there is a connection of an aluminum wire with a copper cable, in this case it is recommended to use aluminum-copper lugs for high-quality connection of an aluminum wire and a shield copper bus.

With a decrease in the overall dimensions of devices and devices, pin products have become popular tips for ending. They are used in electrical equipment and circuit breakers in protection devices. With the reduction of clamping fasteners, the pin is the most optimal solution for good contact. This species is marked as NSHP.

Wire crimp - types

cylindrical shape;
forklifts;
loop;
connecting;
knife.

In addition, the crimping range is important, which shows the maximum and minimum cable cross-section. When working with wires with a diameter of 0.25 to 16 mm, use manual press tongs. They are suitable for laying and repairing computer networks, telephone lines and other low current systems.

The crimping of car battery wires, cable lugs with a diameter of not more than 120 mm and the installation of substations are performed using a hydraulically driven tool.

For large volumes, it is advisable to use electric pliers, which can operate in automatic or semi-automatic mode.

Additional insulation. Usually, plastic is used to make tick handles, but some models also have rubber inserts. It does not conduct electricity and reduces the risk of electric shock.
Blade on the working part of the tool. It allows you to cut the cable and do without additional equipment.
If it is necessary to crimp sleeves of different sizes in large quantities, then it is better to choose pliers with rotary dies or an adjustable punch.
Due to the design features, they can be used to work with wires. different section. No crimping large diameter carried out with the help of pliers with curly sponges.

For crimping insulated and not insulated tips, in order to fix them at the ends of wires of various sections, apply manual press tongs called crimpers. Crimpers are professional tools for electrical installation, and are produced by many manufacturers of hand tools.

With the help of pressing tongs, you can crimp the tips various types: ring, fork, pin, plug, sleeve and flat connectors, connector sleeves and other types of lugs.

The jaws of the mites are called the matrix, there are recesses on it special form for different diameters of crimped wires, flexible stranded and solid single-wire, and, accordingly, for various lugs.

Insulated lugs are suitable for stranded wires, bare lugs are suitable for single-wire rigid ones.

Tips as such are a convenient means of reliably connecting sockets, circuit breakers, UZO, lamps, switches, chandeliers, counters and many other devices.

For crimping conductors of a significant cross section, more than 16 square millimeters, hydraulic presses are used, but for the needs of professional electrical installation, manual press tongs and crimpers are also suitable.

Press tongs (crimpers) are different. There are specialized crimpers, for example, for crimping only 4P4C and 4P2C telephone jacks, as well as multifunctional ones, combining, for example, a stripper - a stripping tool. There are crimpers for fiber optic connectors, for D-sub connectors, etc.

A typical crimping crimper has comfortable plastic handles and a steel body and jaws. Such a device allows you to crimp the tip with one hand.

Particularly convenient are crimpers with a ratchet mechanism that blocks the opening until the end of the crimping of the tip is completed, so that undercrimping does not occur. If the crimping needs to be interrupted due to, for example, an error in the wire or ferrule diameter, the ratchet can be released manually.

Crimps often located on the jaws are marked different colors, for example, a crimp for a wire with a cross section of 0.25 to 1.5 sq. mm is marked in red, from 1.5 to 2.5 sq. mm in blue, from 4 to 6 sq. mm in yellow.

This is necessary so as not to get confused and not make a mistake with the diameter of the wire and with the tip. By the way, the insulated tips themselves also have colored cuffs of the corresponding colors.

The pressing process is quite simple. For example, you need to crimp the wire PuGV 1x4.0 sq. mm. To do this, take the necessary tip, for example, we need an annular one, and we chose NKI 6.0-4, which is suitable for wires with a cross section of 4 to 6 sq. mm.

First, the insulation is removed from the wire for the length of the tubular part of the tip to get the contact part, the wire strands are twisted a little, the tip is put on so that the wire protrudes slightly (about 1 mm) beyond the cuff, and the insulation rests against the metal.

The tip is installed in a matrix of press tongs, in our case - in yellow, and the crimp is carried out, holding the wire. There is an indentation along the profile of the tip into the wire. Then check the strength of the obtained crimping.

With the help of press tongs, you can crimp various connectors, crimp a variety of wires, and select any necessary lugs.

Among the extensive range of crimpers on the market today, every professional installer will easily select a tool for his profile. It can be a simple crimper or crimper stripper, multifunctional, or for only one type of connector, such as RJ45.

Crimping pliers for automotive terminals

Crimping pliers for auto wire terminals are an auto tool, thanks to which the wires inside the sleeve are well spliced and the cable is connected to the lug. The use of this tool in a car workshop significantly increases the speed and quality of work on repairing the electrical wiring of your car or your client.

Moreover, this tool is not limited to professional equipment, and therefore can be used for private car repairs in the garage.

Crimping pliers automotive terminals are divided into 2 varieties: diaphragmatic or functioning like ordinary pliers. The latter squeeze parts from 2 sides.

They have special holes on the jaws that allow you to correctly guide and adjust the repaired parts. These tools are considered universal, since they can be used to get to problem areas with different parties and projections.

Diaphragm crimping pliers adjust elements on 4 or 6 sides. More precise instrumentation properties depend on aperture functions. This mechanism provides a very tight cable crimp.

In addition, due to the features of the equipment, it can adapt to the sleeves different sizes which ensures its versatility.

But diaphragm crimping pliers have a certain disadvantage. They can only be used if the wires are inserted into the sleeve from one side. Otherwise, the pliers will be on the wire due to the structural features of their head.

The hydraulic manual press is designed for crimping cable lugs and sleeves with a hexagon, with a cross section of up to 70 mm². Copper lugs and sleeves must not exceed a cross-sectional area of 50 mm².

Does the design have a pressure relief valve. Such products are more reliable, they prevent overloading the press from pressure.
Type of pressing head, which can be open or closed.

pre-open the stopper;
pull out the matrix;
put the wires and tip;
close the device.

And only after that you can start crimping the cable. For wires of small cross sections, the process is much simpler. If the press has an open type C-head, the wires can be pressed quickly anywhere.

Up to 70 mm².
Up to 120 mm².
Up to 300 mm².
Up to 400 mm².

With an increase in the power of the press, its mass increases. Some manufacturers reduce weight by using light aluminum alloys for the housing. All hydraulic presses are designed for crimping copper and aluminum wires.

Complete with a press there are replaceable dies for crimping. Most modern models, are equipped with rotating heads and fast travel device.

Inside the device, on the one hand, there is a working piston with a cuff - a spring is mounted to return it to its original position. On the other side, a pressure cylinder and a plunger are installed.

The main components of a manual handpiece press

Pos. 1 - axis.
Pos. 2 - head.
Pos. 3 - matrix half-forms.
Pos. 4 - screw.
Pos. 5 and 6 - handles.

The pump plunger reciprocates.
The cylinder is pressurized.
Oil under pressure begins to flow into the working cylinder, moving the working piston.
The piston, acting on the matrix, creates the right pressure on the tip.
The design has a two-way plunger.
At idle, the circuit that provides rapid injection of fluid into the working cylinder is open. In the end idle move the second circuit begins to open, developing maximum effort.
The return spring, with the shut-off valve open, which connects the working cavity of the cylinder and the oil cylinder through the channels, returns the piston to its original position.
The crimping press for cable lugs is equipped with safety valve, which, when the pressure in the system is exceeded, begins to bypass a certain amount of oil back into the oil bottle.

Handpiece manufacturing

What to do if you don’t have special crimping tools at hand or just don’t want to buy them if you only need to crimp one or two tips?

Many faced with this problem resort to wrong ways, which further only worsen the contact, not providing a reliable connection.

They begin to flatten the tip with hammers, simply squeeze it in a bench vise, crush it with pliers, and press it in with a chisel. All these methods are not correct and do not bring the desired result. After such amateur performance, poor contact is obtained with its further heating during operation.

True, some manage to compress the tip with a hydraulic press so that the wire quietly crawls out of it, it is worth pulling with a little effort.

There are other ways to crimp power wires with tips using improvised tools that can be found in almost everyone in a garage or at home.

The easiest and fastest way is to press in with a center punch.

ordinary hammer;
the tip itself, no matter what type and manufacturer;
vice or sledgehammer;
a center punch or, in extreme cases, a 200mm nail can be used once.

insert the tip into the wire;
put it on a hard surface - an anvil, vise, wide side of a sledgehammer;
and with uniform blows of the hammer on the center punch make point dents on the tip. First on one side, then on the other.

In this case, it is not necessary, as many do, to pre-flatten the tip with a hammer. In the process of strikes, this will happen anyway.
The number of cores, that is, holes from impact on the metal, depends on the length of the tip.

At the same time, on the reverse side of the tip, the crimping points should not be symmetrical with those on the front, but shifted by a couple of millimeters.

The most important thing is not to make a hole through the tip and control the impact force. Therefore, if you use a 200mm nail for this, you should first of all blunt it.

As a result, you will get sufficient contact, which, of course, cannot be compared with crimping with a professional PGR-70 tool, but in the absence of super-rated loads, it will last a long time. The most important thing in this method is to choose the right wires and tips. The declared cross section is very often less than the actual one.

For reliable contact, the wire must fit snugly inside the sleeve without any slack. That's why this moment always checked manually, do not blindly trust the numbers on the cable sheath and on the tip blade.

There are other simple ways to connect ferrules to wires without using a press. For radio amateurs who do not have problems with solders and other devices, ordinary soldering is suitable.

This is not exactly a crimp, but it is still a connection method without the use of a special crimping tool.

The wire is tinned, the tip inside too. At the same time, in its upper part, where the blade is, a small hole must be drilled in the sleeve.
The stripped end of the cable is brought in, after which the entire structure (cable + tip) is wrapped with fiberglass tape.
Heated gas burner and molten tin begins to pour into the hole from above.
With constant heating with a burner, it will easily penetrate between the wire strands and the walls of the sleeve. The fiberglass will prevent the tin from flowing out.

Some do it even easier. They put tin inside the tip, heat the whole thing with a burner or even on gas stove and then insert the tinned cable there.

In order not to damage the insulation at the end of the wire, you can use a building hair dryer to warm up:

If you do not have soldering accessories, and you consider crimping with a dot using a center punch not reliable enough, then the third method remains.

Pick up a long enough threaded screw so that it overlaps the pressed part of the sleeve. The diameter of the screw should not be large, so as not to push through and crush the tip itself.

Position this screw along the tip. Then you compress the entire structure in a vice. As a result, you should get something like this form of pressing.

If one screw is not enough, a second one is superimposed over the depressed one and compressed again. You can initially use 2 screws, only installed on different sides of the sleeve. The main thing is not to overdo it and not break the sleeve.

To prevent the screw from moving, it can be fixed with electrical tape. In general, summing up, we can say that these three methods have the right to life, and many only connect the power cable wires and lugs in this way.

Content:

For high-quality connection of contacts of devices, equipment, crimping of the ends of the cable and wires that are connected to them is used in electrical engineering - this method gives an excellent connection of conductive surfaces. In order to use crimping, you need lugs or sleeves that have different kind and appointment. The crimping method requires a special tool. Consider what tips are and how they are crimped.

Types of tips for crimping

For every inhabitant, a striking example of incorrect wiring is the stair switchboard, many apartment owners have melted wires in the switchboard, there are twists. Crimping wire lugs can save citizens from the possibility of heating and igniting electrical wiring as a result of poor-quality wire contact, lack of cable lugs.

When there is good contact between the cable or wire being connected and the connection device, the transition resistance is minimized, and with an increase in current load on the contact group, they can heat up in case of poor contact. Sleeves and tips are intended to remove or minimize the contact resistance, in other words, to exclude poor-quality contact, for a bolt or screw.

For crimping (crimping for lugs) of wires and cables, special products are used - lugs and sleeves. Tips can be for stranded wires and solid wire, they are divided according to the purpose and type of wire for which they are used (copper or aluminum).

For crimping the copper conductors of the cable, lugs are used, made of a solid-drawn copper tube, which is flattened on one side and has a hole for a screw connection. This type of tips happens:

with different diameters for a wire and a mounting hole that does not have a protective coating;
for crimping electrolytic tinned with different holes for fastening.

The marking of this type of tips is as follows:

uncoated, TM - X - Y, where X is the cross section of the wire, Y is the size of the hole for fastening;
coated, TML-X-U.

There is another type of lugs with a control window, these are tinned copper products for terminating cable and wire cores. A feature of this type is the ability of the termination performer to control the correctness of crimping through the control window. This type of product is marked as TML (o), it is noteworthy that they can be installed on the ends of cables using solder and soldering, which almost completely removes the value of the transition resistance.

Tips NShVI

Cable lugs for crimping NShVI are a pin sleeve product with insulation. Electrolytic copper is the material from which it is made, insulation is installed on the back side, which is thicker than the metal part. When the terminated wire is inserted into the socket with this lug, only its insulated part remains under the clamp. In industry and in everyday life, this type of lugs is used for cables up to 35 sq. mm in cross section, they are pressed with a special tool.

There are several modifications of this tip, which differ in the number of wires connected in one tip. For two cables, the marking has the form NShVI2, there are no structural differences in this lug, the same metal part and PVC cuff, but the diameter of the sleeve (skirt) is larger, designed for two wires.

Features of working with NSHVI

Cable lugs of this type are intended only for multi-core cables, they cannot be used in the termination of wires with one core. For rigid (single-core) wires, crimping is used with bushings (sleeves) without insulation. Crimping of stranded wire is carried out as follows:

the cross section of the wire is selected, the brand of the tip is selected, into which the cores must enter freely and tightly from the side of the skirt;
in practice, the type of tip is selected with some margin. Example: PV-3 wire with a cross section of 1.25 sq. mm can be terminated with a tip from 1.5 sq. mm. Skirt section - up to 2.5 sq. mm.

Tool

Crimping of cable lugs is carried out with a special tool that is designed and manufactured for this purpose. A tool is necessary for crimping the lugs, since a person with a simple effort cannot create the necessary force for high-quality termination of the cable core. Which crimping tool to choose depends on the cross-section of the wire or cable that is being worked on. We list the most used tool:

Press tongs brand PK2 or PK2M are hand tool, which is used in the termination of conductors of wires and cables with a cross section of up to 10 sq. Mm.
Press tongs of the PK1 or PK1M brand are a reinforced version of manual tongs with long handles, they can make the end of lived up to 50 sq. mm.
Tongs are hydraulic, manual, which without much effort can terminate the core up to 10 sq. mm.
Hand press, which is used in industrial production for a wire with a section up to 240 sq. mm.
Hydraulic press with electric drive or foot pedal, cable ends up to 300 sq.mm.

Crimping sleeves

Not in every device or device, switching an external circuit uses cable lug, there is also a sleeve ending, its choice is made according to the type of connected wire (copper, aluminum). For cables with copper conductors - marking of sleeves GML, where:

G - product name, sleeve;
M - the material from which it is made, copper;
L - the product has a coating, tinned.

For aluminum wires, the GAO brand is selected: an aluminum sleeve of a closed type. When it is necessary to make a connection with the transition of aluminum to copper, a product made of an alloy is selected. It is not allowed to use products for copper wires on aluminum conductors, this is a heat couple that will heat up due to an electrochemical reaction that takes place in the material of these conductors when connected.

Preparing for pressing

You can’t just put a cable tip on a core, you need to perform a number of preparatory steps:

clean the desired length of the end of the wire or cable from insulation - you can use a special tool, a stripper;
we twist the cores by hand and insert them from the side of the skirt into the tip;
first, the tip is selected according to the cross section of the core, observing the conditions for free and tight entry into the tip sleeve.

Crimping of wires with tips is carried out with a special tool. On each press there is a marking of matrices and the main part according to the type of tip or the cross section of the core. Now the color standard is observed, for this reason it is easy to combine the section and the matrix in the desired position.

How to crimp a wire

In the event that you have not previously crimped cable cores, you need to practice on unnecessary pieces of wire or cable. To obtain a high-quality connection, you must adhere to the developed rules:

The cable inserted into the sleeve (sleeve with a flare) of the tip must be held by hand in the socket.
After making sure that the matrix matches the selected tip, you can begin to squeeze the handles of the press until the ratchet mechanism is activated and an audible click.
The ratchet mechanism of the press simplifies the pressing process. The mechanism does not allow the press to unclench, and when the wire is crimped unsuccessfully, it must be unlocked.
Double-circuit crimping compresses the insulated part of the ferrule and the metal contact. Such a matrix has two sockets, they are different in size, so you need to carefully look so that the cuff fits into its socket, and the metal contact of the tip into its own.

Conclusion

Each tip must correspond to the wire, most common mistake in crimping cable cores, it consists in a mismatch between the selected tip and the material of the wire; you should not put on a too loose sleeve on the wire. Do not allow the use of products of large diameter for terminating conductors of a smaller cross section, this can lead to an increase in contact resistance and heating of the contact. You can not cut the sleeve into two parts in order to save products, do not use homemade tips.

For high-quality crimping of cable cores, it is necessary to use a special tool, a chisel and a hammer will not be able to make the necessary compression, to give high-quality contact.

What to do if you don’t have special crimping tools at hand or just don’t want to buy them if you only need to crimp one or two tips?

Many, faced with this problem, resort to the wrong methods, which in the future only worsen the contact, not providing a reliable connection.

After such amateur performance, poor contact is obtained with its further heating during operation.

True, some manage to compress the tip with a hydraulic press so that the wire quietly crawls out of it, it is worth pulling with a little effort.

There are other ways to crimp power wires with tips using improvised tools that can be found in almost everyone in a garage or at home.

Pressing with a center punch

The easiest and fastest way is to press in with a center punch. For this you will need:

The process is very simple and uncomplicated:

At the same time, on the reverse side of the tip, the crimping points should not be symmetrical with those on the front, but shifted by a couple of millimeters.

The most important thing is not to make a hole through the tip and control the impact force. Therefore, if you use a 200mm nail for this, you should first of all blunt it.

As a result, you will get sufficient contact, which, of course, cannot be compared with crimping with a professional PGR-70 tool, but in the absence of super-rated loads, it will last a long time.

The most important thing in this method is to correctly select the cross section of the wire and tip. The declared cross section is very often less than the actual one.

For reliable contact, the wire must fit snugly inside the sleeve without any slack. Therefore, this moment is always checked manually, you should not blindly trust the numbers on the cable sheath and on the tip blade.

Connecting the wire and the tip by soldering

There are other simple ways to connect ferrules to wires without using a press. For radio amateurs who do not have problems with solders and other devices, ordinary soldering is suitable.

This is not exactly a crimp, but it is still a connection method without the use of a special crimping tool.

The wire is tinned, the tip inside too. At the same time, in its upper part, where the blade is, a small hole must be drilled in the sleeve.

The stripped end of the cable is brought in, after which the entire structure (cable + tip) is wrapped with fiberglass tape.

It is heated by a gas burner and molten tin begins to be poured into the hole from above.

With constant heating with a burner, it will easily penetrate between the wire strands and the walls of the sleeve. The fiberglass will prevent the tin from flowing out.

Some do it even easier. They put tin inside the tip, heat the whole thing with a burner or even on a gas stove, and then insert a tinned cable there.

In order not to damage the insulation at the end of the wire, you can use a building hair dryer to warm up:

Pressing with screw and vise

If you do not have soldering accessories, and you consider crimping with a dot using a center punch not reliable enough, then the third method remains.

Pick up a long enough threaded screw so that it overlaps the pressed part of the sleeve. The diameter of the screw should not be large, so as not to push through and crush the tip itself.

Position this screw along the tip. Then you compress the entire structure in a vice. As a result, you should get something like this form of pressing.

If one screw is not enough, a second one is superimposed over the depressed one and compressed again.
You can initially use 2 screws, only installed on different sides of the sleeve. The main thing is not to overdo it and not break the sleeve.

To prevent the screw from moving, it can be fixed with electrical tape.

In general, summing up, we can say that these three methods have the right to life, and many only connect the power cable wires and lugs in this way.

However, only factory specialized tool you can create a reliable and durable contact, which you will forget about immediately after crimping and it will not disturb you during the entire period of work.

Crimping pliers for automotive and similar configuration terminals are indispensable when working with a car to perform electrical connections using connectors or such terminals. In the material, we will consider the features of the use of crimping pliers, their varieties and scope.

In the process of working with various cables there is a need to connect them to electronic and household appliances. For this purpose, crimping pliers for crimping various configurations and sizes are used for crimping wire lugs.

Since in the course of the development of technology, new types of connecting wires for various purposes were developed, with varying degrees power and conductivity, the design of the cable connection was also subject to change. To prepare the contacts of the leading wires, their lugs must be suitably crimped with tongs.

Application of crimping pliers

Crimping pliers are widely used by radio amateurs, auto mechanics and electricians in the process. The use of pliers is indispensable for crimping the contacts of standard cables and specific connectors of a non-standard connector (for example, a network cable for a PC). Press tongs today standard size for crimping contacts are the best option to complete this task.

The design of the crimpers makes it possible to perform crimping easily and quickly, and the principle of operation ensures reliable and tight crimping. This ensures a strong connection between the conductors and the connecting element. The price of wire end pliers is determined by the manufacturer, type of construction, quality and material used.

Crimping pliers are designed for crimping insulated wires:

NCI tips of ring type;
tips NVI fork type;
pin round tips NShKI;
flat and plug connectors RPI-P, RPI-M, RSHI-P, RSHI-M;
piercing couplers OV
connecting sleeves GSI.

Sleeve crimping pliers are widely used for flexible wire strands in the process of connecting circuit breakers, sockets, chandeliers and lamps.

Compression of connecting sleeves in the industry is carried out using hydraulic crimping tongs, which are designed for cable cores with a cross section of 16 to 240 sq. mm.

Later in the article we will tell you how to use crimping pliers manual and hydraulic type, we will give the principles of their work and application features. The pliers should be selected based on the cross section of the cable core.

The main types and varieties of ticks

Today, many manufacturers produce crimping pliers based on various standards. Buyers are offered pliers with a narrow scope (pressing a specific type of cable) or a wide purpose (universal production pliers). Therefore, before buying, you need to decide on the type of tool you need.

When used in everyday life, the tool can have a multi-profile purpose for crimping stranded wires of sockets, switches, chandeliers.

Pressing tongs create a strong and safe electrical and mechanical connection. Crimping pliers are classified as a type of crimping equipment, they are often required for fixing contacts in low current systems. Tools are divided into several varieties.

To strip wire insulation

With this tool, you can remove a section of insulation without damaging the core. Manual and automatic installation the required diameter to be removed from the core. In the case of manual diameter setting, there is a risk of damage to the wire, and automatic allows you to clearly remove the entire insulation layer. In most cases, this type is used for distribution and branch boxes. And you should pay attention to the sharpness of the cutting edge so that it does not chew the wire.

For press sleeves

Crimping pliers end sleeves differ in nests and their shape. The sockets may or may not be equipped with plastic flanges. The plastic ferrules provide maximum crimping efficiency, and the square configuration ensures that all strands are firmly in contact. This type device allows you to easily cope with mounting or centering for any type of cable cross-section. For extremely tight fixation of the contacts, the pliers are selected according to the diameter in accordance with the color marks.

For insulated wire lugs

Crimping pliers for insulated ferrules are characterized by an oval configuration. According to the standard, the matrix provides three standard forms for the press, which differ in colors - red, blue and yellow. Accordingly, tips, sleeves and other connectors with similar colors are provided for them. When working with the tool, you must follow correct location joint edges, it should be in the middle of the upper edge of the pliers. This design is provided in such a way that when it is located on the side, the edge violates the tightness of the cable or wire.

For crimping non-insulated cable lugs

Such press tongs for crimping are used on bare wire, and on brass wires. For the press, a special rod is provided in the tool, which must be placed on the separation seam. Crimping tools open cable from brass can be provided for separate clamps - one for the core, and the second for the winding. To strengthen the press, it is recommended to use a locator that will provide a clear positioning.

Twisted pair crimping pliers

Twisted pair crimping pliers are provided for 8 or 4 cores, used to insert wires into the connector. For example, twisted pair is used when connecting a cable for a high-speed Internet connection.

Crimping with hydraulic tool

Crimping pliers with a hydraulic mechanism are designed for crimping cables with large diameter over 120 sq. mm for industrial purposes. Hydraulic crimping tongs are similar to wire cutters or pliers, where lever-like handles actuate the crimping jaws to shape the plastic connector. The result is a tight, secure connection.

Due to the presence of a hydraulic mechanism, the force to actuate the tool is significantly reduced. It becomes possible to clamp the connector in several approaches, gradually increasing the force. Most professional tools are equipped with a hydraulic mechanism.

How to work with crimping pliers

Crimping pliers for ferrules and sleeves suggest that the principle of their use for pressing contacts in a cable can be easily understood from the workflow in practice. To complete the task, you will need a specific wire, clamps and a connecting component that needs to be placed at the end of the contacts. Let's bring step by step instructions and the rules for using press tongs to perform crimping:

remove the outer winding from the cable using pliers, on which there is a semicircular cavity on top, and a cutting edge on top;
put the cable in the recess and press the upper edge with the cutting side;
after several rotations around the wire, the insulation is cut along the entire circumference and can be easily removed;
for a correct connection with a reliable contact, a stripping of 4 cm is allowed;
align and arrange all the cores in the required sequence in accordance with the type of connector and the indicated color markings;
when all the wires are straightened, clamp them and cut them, leaving 1.5 cm of contacts for further connection;
put the pins in the connector, keeping their location. Twisting stranded conductors carried out strictly on the basis of the indicated colors according to the scheme. Insert the wires so that the lower notch of the connector touches the cable winding. This measure is necessary to minimize the risk of damage to the wire during the crimping process;
place the device in the pliers, after checking the correctness of the colors. After checking, perform pressing;
on the last stage check the security and reliability of fixation, as well as the integrity of the connector.

Press pliers are an indispensable tool for crimping twisted pair, crimping insulated lugs and cables without insulation. The tools are available in various sizes, with manual or hydraulic crimping for industrial applications and large wire diameter.

Hello, dear readers of the Electrician's Notes website.

In today's article, I will share with you information about the tool for crimping insulated lugs - these are EGI-60 manual crimping pliers made in Italy. They are also called "crimpers". At the end of the article I will show specific example how to work with them.

A bit of history. The Italian company EGI began its activity back in 1973 and to this day is engaged in the production and production of professional tool for electrical installation. To be honest, I have no doubts about the quality of this tool. Maybe someone will refute my thoughts.

Here is the packaging.

Appearance.

EGI-60 are designed for crimping insulated:

ring tips NKI
fork lugs NVI
pin round tips NShKI
flat and plug connectors RPI-P, RPI-M, RSHI-P, RSHI-M (mother and father)
piercing couplers OV
connecting sleeves GSI

The matrix (sponges) of the EGI-60 pliers allows you to crimp the cores with a cross section from 0.25 to 6 (sq. mm). These pliers are just right for domestic use, for example, for crimping flexible stranded conductors of wires and cables with, RCD, sockets, switches, chandeliers, lamps, meters electrical energy etc.

For production purposes, we have a hydraulic press that can be used to crimp conductors of wires and cables with a cross section of 16 to 240 (sq. mm). I will talk about it in more detail in my next articles. Subscribe to the newsletter.

The device and parameters of the press tongs EGI-60

Pincers have the strengthened three-hinged lever mechanism.

The handles are made of high-quality plastic, and the body material is made of steel.

The length of the handles is 15 (cm), which allows crimping with two hands. Although it is not difficult to cope with one hand.

The handles are connected to the jaws using pins with retaining rings.

The EGI-60 has a ratchet mechanism that mechanically blocks the opening of the handles until the crimping cycle is completed.

Thus, the risk of “underpressure” due to human error is reduced.

If, suddenly, you have chosen a tip or a core of an inappropriate section and have already begun crimping, then the ratchet mechanism can be unlocked at any time using the “dog”.

This model does not have a matrix pressure regulator.

The weight of these ticks is about 500-600 (g).

The pliers are equipped with a non-removable cast three-position matrix (or in simple words"sponges").

There are three standard crimps in the die. Each crimp for clarity is painted in the appropriate color:

red - 0.25 - 1.5 (sq. mm)
blue - 1.5 - 2.5 (sq.mm)
yellow - 4 - 6 (sq.mm)

Manufacturers of insulated lugs, sleeves, connectors and taps specially produce them in accordance with these colors (insulating collars are painted), because it is very convenient for installation and speeds up the crimping process.

During crimping, each crimp puts a stamp on the body of the tip or sleeve with the following letter:

red - I (1)
blue - G (2)
yellow - E (6)

These letters are so small that I could hardly see them. And even the camera could not clearly focus on them. So do not judge strictly by the photo.

How to use press tongs when crimping insulated ferrules

Crimping is one of the most reliable ways contact connections. I spoke in detail about the advantages of this method in an article about - follow the link and read.

Now let's move on to an example.

Remember the most basic rules of crimping!!!

1. How to choose the brand of wire?

Crimping of insulated lugs and sleeves is possible ONLY on stranded (flexible) copper wires. For single-wire (rigid) wires, bare lugs must be used.

As an example, consider compression copper wire PV-3 1x2.5 sq. mm (the new designation for this wire is PuGV).

2. What type and section of the tip should I choose?

The tips are not designed for one specific wire section, but for several ranges at once. Agree, very convenient.

Thus, for the considered wire PV-3 1x2.5 sq. mm, I chose the ring lug NKI 2-6, designed for a wire cross section from 1.5 to 2.5 (sq. mm).

The tip could be chosen not only as an annular NKI, but fork - NVI or pin - NShKI. It all depends on the operating conditions and connection method.

3. Stripping

We remove the insulation from the wire core to a length equal to the tubular part of the tip. To strip the insulation recent times I use .

It is the tubular part that is the point of contact of the wire with the tip - it can also be called the contact part.

The tubular (contact) part of the tip can be determined visually. Its diameter is somewhat smaller than the diameter of the insulating cuff.

After removing the insulation, the core of the wire must be twisted a little to avoid the occurrence of bends and plexuses of its individual conductors.

4. We put the tip on the wire

The stripped wire should protrude beyond the insulating collar by no more than 1 (mm), and it is better to be flush with its edge.

The insulation of the PV-3 wire must go inside the insulating collar until it stops with the tubular part.

We select the appropriate crimp on the matrix (in my example it is blue) and start the wire with the tip like this.

Because crimping is double-circuit (I talked about this at the beginning of the article), then make sure that one circuit compresses the tubular (contact) part of the tip, and the second - the insulated cuff over the wire insulation.

6. Tip crimping

We hold the wire from falling out of the tip and begin to squeeze the handles of the tongs until the ratchet mechanism is unlocked.

Crimping occurs by pressing to a certain depth the copper tip of the NCI into the copper flexible stranded wire PV-3 along the selected crimping profile.