To create mechanical connections of wires with lugs and cables, special devices are used. Depending on the material and its cross section, tools are used for crimping tips, which come in several types. They allow you to provide maximum area contact and uniform pressing of the cable core and shank.
general information
In the process of connecting various types of technical devices and electronics, you have to work with wires. For such a procedure, a special tool is most often used - crimping pliers for tips. They are selected depending on the type of wire. Now appeared various types new cables. They differ from each other:
- power parameters;
- conductivity.
To prepare the contact of the leading wires it is necessary to correctly crimp the connecting ends. For this purpose, press tongs are usually used as crimps for lugs. electric cable. Most often with this special tool electricians, radio amateurs and auto mechanics work.
This type of tool can be used for simple cables. It is also used in the processing of unusual non-standard connectors, for example, a network cable for a computer.
Due to its characteristics, ferrule crimping pliers have become a very popular tool. It's inexpensive and effective remedy for work.
The simple design of the equipment makes it possible to easily and quickly perform the pressing of the tips. The principle of the press tongs device allows you to quickly and efficiently crimp the cable. This helps to carry out the highest quality connection between the connecting structure and the rest of the conductors. The price of an electrical installation tool will depend on the manufacturer, quality, material used and type of device.
Tool types
Now many manufacturers produce crimping equipment. The finished tool must have a narrow pressing direction. a certain kind wires. They also produce pliers of a universal type, designed for production and domestic needs.
At home, the crimping tool should be as suitable as possible for operations with stranded wires in the mains. It is used with:
- switches;
- sockets;
- energy saving meters;
- various lighting fixtures.
A high-quality, reliable and safe connection of an electrical and mechanical nature can be provided by properly selected electrical installation tools for crimping wire lugs. This type of tool is a pressing type of equipment. Most often, crimping pliers for crimping wire lugs are used when it is necessary to secure a contact in low current systems. Depending on the purpose, such equipment is divided into several types:
- press tongs;
- hydraulic hand press;
- mechanical press;
- electromechanical press.
Crimping can be done mechanically or hand tools. It is made by indentation, solid or combined compression. In the inner part of the press, on one side, there is a working piston with a cuff. With the help of a built-in spring, it returns to its previous position. On the other side there is a plunger and a pressure cylinder.
Excess pressure is built up in the cylinder itself, after which oil enters it. It moves the working piston and it acts on the matrix, creating required pressure in the tip area. This design is equipped with a two-way plunger.
The working cylinder will be open when, at idle, the circuit quickly creates fluid injection in it. Another circuit opens slightly, developing maximum effort at the very end idle move. When the support valve is closed, the return spring connected by the oil bottle and the working cavity brings the piston to its previous position.
The crimping press is also equipped safety valve. At elevated level pressure in the system, excess oil is returned back to the oil bottle.
Principle of operation
Pressing tongs allow you to accurately and quickly remove the desired length of insulation on the wiring without damaging the core itself. They are adjusted to the required diameter manually or automatically.
During manual tuning there is a possibility of damage to the wiring. If you do it in automatic mode, then when removing the braid, the cross section of the cord does not touch. This type of equipment is most often used in working with lighting and distribution boxes.
To cut in one step, the cutting edge must always be sharp. This will allow you to qualitatively remove the outer insulation of the wire.
First you need to remove the outer insulation at the ends of the connected wires. In a cleaned form, they are threaded into a sleeve. Its diameter can be different, it depends on the sum of the sections. The sleeve itself must be suitable metal. After that, press tongs are used for crimping.
The sleeve must be insulated insulating material or heat shrink tubing. This procedure is quite simple if you use the right tool correctly. hand model it is necessary to compress with sufficient force so that the crimping is of high quality.
Criterias of choice
There are several important features which must be taken into account when choosing equipment of this type. The crimping range is of great importance. It indicates the minimum and maximum cross-section of the cable, which can be compressed with manual press tongs.
For cables with a small cross section, a tool with a range of 0.5-6 mm2 is quite suitable. For thicker cables, it is better to choose equipment with parameters of 10-20 mm2.
Pay attention to the insulation of the tool handles. Usually they are made of plastic, however, some models of crimpers began to be covered with special rubberized inserts. Such a material does not conduct electricity, which is always important when handmade with cables. If the wire is energized, then it is not dangerous for a working person.
Hello, dear readers of the Electrician's Notes website.
In today's article, I will share with you information about the crimping tool insulated tips- These are manual press tongs EGI-60 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 at, RCD, sockets, switches, chandeliers, lamps, counters 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 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 multi-wire (flexible) copper wires. For single-wire (rigid) wires, bare lugs must be used.
As an example, consider the crimping of 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.
After pressing in without fail checking mechanical strength the resulting connection and the integrity of the insulating cuff.
On the surface of the insulated cuff, an imprinted brand in the form of the letter "G" is visible.
Here's what happened.
And this is the view from the back.
P.S. Now you can imagine how to crimp insulated ferrules using EGI-60 pressing tongs and their analogues. Thank you for your attention.
Various household and not only appliances require connection to the electrical wiring available in the building. And often for this you have to carry out special preparation of wires. To make this task easier, experts often use such handy tool like crimping pliers. Not all home craftsmen are aware of this, so it will be useful for them to find out what this type of press is, what types it is, and how to handle it during repair and installation work.
general information
As man created new types of technology, new types of cable connections for various purposes, power and conductivity appeared. In order to connect the equipment in accordance with the current requirements and regulations, it is necessary to prepare the contacts of the leading cores in a special way. To do this, you need to properly crimp their tips.. This is exactly what special crimping pliers were created for.
This is one of the indispensable tools that many radio amateurs, auto mechanics and electricians must have in their arsenal. With the help of such pliers, it is possible to crimp the contacts not only of ordinary cables, but also of specific connectors for non-standard connectors. Despite the fact that for last years range of tools for electrical work has significantly expanded, pliers for crimping tips are still one of the most popular tools for performing such an operation. This is largely facilitated by the low cost of their production, availability and high efficiency.
Such ticks have quite simple design, thanks to which it is possible, even without special electrical knowledge, to crimp the tips. Such a press is a very reliable device with which you can crimp cables quite well. This guarantees a strong connection between all the conductor mi and directly connecting structure.
To date, there are enough a large number of crimping tool models, which may differ not only functionality but also cost. The latter may depend on several factors:
- press manufacturer;
- construction type;
- quality and material of the final product.
Tip Description
Most cable lugs are marked with four letters - NShVI. In the deciphered version, this abbreviation will sound like "insulated pin sleeve tip." To put it in a more understandable language, this is a common sleeve for a flexible stranded wire. Its main purpose- protection of the end of the cable, which is used for fastening in a screw clamp terminal. After removing the insulation, a lug is put on the end of the cable, and then it is crimped with a special device. Most often, press pliers are used for this.
The metal part of the tip is most often made of electrolytic copper. It has insulation only on the back side. The thickness of the insulator is noticeable larger diameter metal part of the tip. It looks like a cuff. The tip is attached to insulating coating wires. Crimped it metal part , which fixes inside the cable core. When creating a connection between the handpiece and the screw clamp, the entire metal part is hidden in the socket of the device. Only the safe dielectric part of the cable is visible from the outside.
Tool types
If you go to any store that sells electrical products, you can be amazed great variety the crimping pliers offered there. Such a wide range due, among other things, to the fact that each manufacturer uses its own standard in the manufacture. This explains why such tools can have different functionality.
For example, in stores you can find highly specialized pliers designed for crimping wires of only a certain type, and a wider-purpose tool with which you can crimp cables when connecting and repairing not only household appliances, but also production equipment. Every consumer should know about this and take this moment into account when he goes to buy a press for crimping tips.
With the help of crimping pliers, you can create a high-quality and safe connection of an electrical and mechanical nature. It is this feature that is one of the main features of the classification of the instrument in question. It should be said what is the crimping pliers represent a class of pressing equipment. In most cases, they are used when working with low current systems to ensure reliable fixation of contacts.
Crimping pliers can be classified into several types depending on the purpose.
For stripping the sheath and insulation of the cable
Via this type pliers can quickly and fairly accurately cut off a certain section of the insulation on the wire, while maintaining the integrity of the core itself. Modern crimping pliers often have the ability to adjust to a certain diameter so that you can easily remove the insulation from the core without risk of damaging it. This setting can be done in two ways:
- manually;
- automatically.
When trying to manually select suitable diameter there is a risk of error and damage to the wire. Therefore, it is best to make such a setting automatically. Then you can be sure that the removal of the braid will be done without negative consequences to cut the cord. It is this type of preparation for crimping that is used when working with distribution and junction boxes. Special attention must be drawn to the cutting edge, which must be sharp. Then the outer insulation will be removed in one step without the risk of "chewing" the wire into the tool.
For end sleeve press
For this type of operation, several types of hydraulic presses are offered for sale, which may differ in the shape of their sockets and the shape of the tool. There are models in which the sockets are made with plastic flanges, but some can be made without them. They can have a trapezoidal shape or be designed for crimping cores. square shape.
Pliers whose sockets are equipped with plastic flanges should be selected when stranded wire lugs are to be crimped. With this task, they will perfectly cope thanks to square shape, which can ensure a secure fixation of all cores. Pliers of this type are ideal for mounting, as well as centering cables of any type of section. If you need to perform a more accurate and reliable crimping of contacts, it is necessary to choose pliers with an emphasis on the diameter of the cable.
For insulated cable lugs
If the wiring has insulated contacts, then a hydraulic crimping press should be selected. cable lugs oval shape. According to the standard, their matrix has three forms for the press, each of which corresponds to specific color: red, blue and yellow. And for each of these colors, there is a tip, sleeves and other connectors for sale that are designed to be used with it.
About to crimp insulated wiring using a terminal press of this type, care must be taken to ensure that the joint edge is correctly positioned. It should be strictly in the middle of the upper profile of the pincers. Compliance with this condition is great importance, since when placing the edge on the side, the reliability and tightness of fixing the electric core will suffer.
Such pliers are designed to work with a cable without insulation, as well as open-type conductors made of brass. In the design of such a tool, a special rod is provided. Crimping is carried out strictly in the center, while the rod must be planted directly on the separation seam. A slightly different design has pliers for crimping open lugs made of brass.
They have two types of clamps, among which one is for wire, and the second is for insulation. To perform the most reliable crimping of open contacts, it is recommended to attach a locator to them . This is very convenient fixture , with which you can ensure the exact position of the contacts. If the task is to crimp the terminals, then it is best to do this with special tongs for pressing plugs.
Principle of use
Understanding the principle of operation of pliers for crimping insulated lugs in wiring is not so difficult. To do this, it is enough to know the nuances of the workflow itself, during which it may be necessary to use them. In addition to the wire whose contacts need to be crimped, you will need a crimping tool and a connecting element that is attached to the end of the contacts.
During the installation and repair of various home appliances often have to work with wires. And for their quality performance, often reliable and secure connections are required. solve this problem without specialized tool impossible. Most often, crimping pliers are used for this. Today, such a tool is on sale in a wide range, which makes it possible to choose the most suitable option taking into account the task facing the specialist.
However, the choice of pliers for crimping cable lugs is not simple task as it might seem at first. Even though in stores you can find universal pliers to perform such work, it is still recommended to choose a highly specialized tool that can guarantee the highest quality crimping of contacts. Accordingly, the crimping of the tips itself should be performed by a specialist, since for the quality of such work, it is necessary to have experience and knowledge.
The key to any quality electrical connection is the area of \u200b\u200bcontact of the wires - the larger it is, the more reliable the contact. Of course, all this is selected relative to the cross section of the connected wires, so the main thing here is to do without fanaticism. If the first connections of this type were long twists crimped with pliers, now they are straight wires that crimp pliers fasten together inside a special crimping sleeve. The disadvantage of this connection method is the need to have a crimping tool and consumables in the form of bushings or lugs, but this is fully offset by an increase in the speed of work and an improvement in its quality.
Where are crimping pliers used?
Regardless of the size of the crimper, it has only two main uses - the preparation of current-carrying conductors for fixing them to the terminals of sockets, switches and other electrical appliances, as well as the connection of several wires to each other.
In the first case, crimping is justified if stranded wires are used. If they are clamped into the contact terminals without preparation, then over time, under the influence of an electric current (it creates microvibration), the veins will “shrink”, free space will appear between them and the contact will generally weaken.
This is one of the reasons why the use of solid wires is recommended for laying power wiring, but with the spread of crimping devices for wire lugs, this recommendation has lost its meaning.
Crimping is also used when working with cables. large section- it was used even long before the advent of "household" devices. True, a high-quality connection can only be obtained using a special press for crimping cable lugs, which even now is far from being pocket-sized. To create the necessary force, such devices use the principle of a jack or a separate hydraulic drive - human force, even applied through a conventional lever, is not enough to compress a thick cable with high quality. An example of such a device in the video:
It will be useful to crimp and, if necessary, connect two or more wires. In this case, they are assembled together, a sleeve is put on them and crimped. In this case, the wires can be inserted into the sleeve both from one side and from both sides: in the first case, a kind of twist is obtained, and in the second - a coupling.
The advantage of this type of fastening is that after crimping, air does not penetrate into the sleeve - in fact, a tight connection is obtained. This allows you to connect in this way even copper and aluminum wires, the contact between which, under normal conditions, oxidizes over time.
Varieties of crimping pliers
Structurally, crimping pliers are divided into two main types - operating on the principle of pliers or diaphragm.
The first of them are more common - they perform squeezing only from two sides, but unlike pasatages, they have cutouts in the jaws. special form that act as guides. This allows you to perform high-quality fastening on the wire core of the lugs, the base of which in the cross section has a "P"-shaped shape.
On video different kinds wire crimping tools:
The advantage of such devices that crimp wire cores is their relative versatility - they can “get close” to the tips from any side. The main drawback lies in the need to have several such pliers “on hand”, since cutouts for 3-4 cartridge sizes are usually placed on the jaws. As an option, you can purchase a universal crimping crimper with interchangeable dies, which are mounted on a special cassette. If you need to work with other types of tips, the old ones snap into place in the cassette and suitable ones are selected in their place.
Diaphragm devices can crimp sleeves from four or six sides - depending on the diaphragm mechanism. Due to the full girth of them, a better and tighter crimping of the end of the cable is performed, and the device automatically adjusts to any thickness of the sleeve.
Before choosing such a tool, one must take into account its main drawback - you can only crimp a sleeve into which the wires are inserted on one side - otherwise the pliers will remain on the wire, since their head is closed.
A somewhat separate category are crimpers that crimp a computer cable such as "twisted pair" and the like. The principle of operation of such a tool is the same as that of two-jaw pliers, but instead of iron or copper bushings, their matrices are "sharpened" to work with plugs for computers or telephones. Here, it is not crimping as such, but the displacement of contacts that cut through the insulation of the wires and tightly pressed against their cores.
How to work with crimping pliers - important nuances
The process of crimping wires is intuitive - the sleeve or tip is put on the wire(s), a matrix of tongs is supplied to it, the tool handles are closed and the contact is ready. In practice, most often the “first pancake”, or even several, turn out to be “lumpy”, and practically in literally– Connections may be far from ideal. There have also been cases when, in a seemingly well-compressed wire, contact deteriorated over time.
If the shape of the terminals is not maintained
In the first case, the squeezing force settings of the matrix parts are to blame, which can be different for both individual wires and the tips themselves. Because of this, professionals prefer to have at least two tools to avoid having to reconfigure the spring to work with different wires or sleeves.
The quality of work is also affected by the material from which the sleeves are made and their thickness. Tight terminals are always much easier to crimp and hold their shape better than those made of soft materials.
The correct orientation of tips with a “P”-shaped section is, although lying on the surface, but often ignored requirement, and after all, the misalignment of parts in any mechanism does not always fall into the zone of permissible error.
Twisting stranded conductors before crimping
For every experienced electrician who started with twisting and soldering wires, this movement is most likely already a reflex, but when crimping is performed for stranded lugs, then you have to get rid of it. The validity of this assertion can be verified simple experience- take a pair of single-core single-wire wires, place them crosswise and squeeze with pliers. In some cases, both wires are deformed, and sometimes only one, but at the same time it will be almost completely broken and will hang out on a thin isthmus. Of course, the conductivity of this vein will decrease significantly.
If the wires do not twist, then when the tip is crimped, they will be located parallel to each other and, when deformed, they will simply fill all the voids without crushing each other.
The nuances of wire sleeves on the video:
Color marking of sleeves and matrices
Different sizes of sleeves some manufacturers mark individual flowers and the same labels are applied to matrices of ticks.
It must be remembered that unified system it has not yet been developed for this, so if you purchase sleeves focusing only on color, you can get consumables that are not quite suitable.
As a result - what to choose
Crimping pliers are very subject to the rule that each job needs its own tool, only here everything is a little more complicated, since a separate device is by and large needed for each type of wire used, if you do not want to mess with adjusting the spring force. Therefore, what specific tool is needed and in what quantity can only be decided on the basis of everyday work tasks.
Modern electrical engineering is constantly being improved, including in the field of connecting wires and cables for various purposes, power and conductivity. The quality of the wiring largely depends on how well the leading wires and their contacts are prepared. They must be crimped in a certain way, and this task is completely solved by special pliers for crimping wire lugs. They are widely used among electricians. Using the tool, not only ordinary cables are crimped, but also various connectors used in non-standard connectors.
Application of crimping pliers
All pressing tongs, regardless of their size, are designed to perform two main tasks. In the first case, several wires are securely fixed to each other, and in the second case, current-carrying wires are prepared for their subsequent fastening in the terminals of various electrical devices.
First of all, crimping is required when connecting stranded wires. If they are inserted into the contact terminals unprepared, then gradually under the influence of microvibrations created electric shock, individual cores will be compacted. A free space is formed between them, and therefore the contact will become much weaker. For this reason, power wiring was previously always laid with single-core wires. However, after press tongs appeared, this recommendation has lost its relevance.
The connection of cables of large cross-section by crimping has been used since ancient times, when household tools was not there yet. The quality of such operations was ensured by the use of special powerful presses capable of creating the necessary force. These devices operate on the principle of a jack, and many of them have a separate hydraulic drive. With the help of such presses, even the thickest cables are reliably connected.
The crimping method has proven itself well when connecting two or more wires. For this purpose, crimping pliers and wires are used. A special sleeve is put on their ends, assembled together, after which they are crimped. Depending on the type of connection, the wires are inserted from one or both sides of the sleeve. The first option allows you to get reliable twisting, and the second - high-quality.
The main types and varieties of ticks
Structurally, all crimping pliers - crimpers can be of two types. The former work as, and the latter are diaphragmatic. The first option is the most widely used. In this case, compression is performed only from two sides. The main difference from pliers are special-shaped cutouts located in the jaws. They act as guides and provide high-quality fastening of the tips on the wire core.
Such crimping pliers are considered universal to a certain extent, since they can grip the tips from all sides. The main disadvantage of such pliers is the presence on the sponges of only 3-4 cutouts under different sizes sleeves Therefore, during the work you have to use several tools. Most the best option the use of a universal crimper is considered, which includes interchangeable dies fixed on a special cassette. In order to crimp the wire, the most suitable tip is selected, and the unnecessary one is inserted into the cassette in its place and fixed.
Diaphragm pliers can be used to crimp four or six sides, depending on the design of the operating mechanism. Full wrapping on all sides allows for the tightest crimping of cable ends. During operation, the pliers are automatically adjusted to a specific sleeve diameter. The main disadvantage of such a tool is the possibility of crimping sleeves only on one side due to the closed head.
AT separate category it is possible to include crimpers designed for crimping computer cables. They work in the same way as double-jaw pliers, with the exception of the matrices themselves, which have a specific configuration for computer and telephone plugs. In this case, the essence of crimping is to shift the contacts that cut through the insulation of the wire and are tightly pressed against its cores.
Depending on the purpose, the entire crimping tool is divided into the following categories:
- Removal of insulation and sheath from wires and cables. With these pliers, a section of insulation is cut off without damaging the cores. They can be customized to desired diameter manually or automatically. It is essential to keep the cutting edge sharp so that the outer insulation can be cut in one stroke.
- Crimping end sleeves. The crimping tool has trapezoidal or square sockets. They can be with or without flanges. In order for the clamping of contacts to be reliable and accurate, the pliers must be selected according to color coding, which corresponds to a certain diameter.
- Crimping pliers for insulated ferrules. The tool has an oval shape, and in the matrix there are nests for the press in the amount of three. They are marked in red, blue and yellow. Sleeves, tips and other types of connectors with a similar color indication correspond to these colors. This marking performs the connection of insulated tips, placing them in the desired socket.
- Crimping bare lugs. The main working element is a special rod located along the separation seam and compressing the sleeve in the center.
Crimping with hydraulic tool
High-quality crimping significantly improves the current conductivity at the joints, prevents overheating and emergency situations due to poor contact. At home, for these purposes, ordinary household tongs are used, designed to work with wires with a cross section of up to 4 mm2.
For continuous or combined crimping of a cable with a cross section of 4-400 mm2, it is necessary to use more powerful tools that provide high operating pressure. This category includes hydraulic pliers or hydraulic presses.
The design uses cylinders of various diameters, interconnected and representing a system of communicating vessels. Each of them has a piston. The internal cavity of the cylinders is filled with water, oil or other suitable liquid, therefore such a tool is hydraulic.
In accordance with Pascal's law, the force acting on any point of a fluid at rest is evenly distributed throughout the volume. Thus, if a certain force is applied to a piston of a smaller diameter, then when transferred to a large piston, it will increase. The greater the difference between the areas of the pistons, the stronger will be the force that occurs on the large piston.
Each hydraulic tool of this type has a single, double or triple action. Equipment simple action equipped with one working body - a movable partition. In double or triple action presses, there are respectively two or three working bodies. Their work processes are coordinated with each other, and general management carried out with the help of special distribution equipment.
Structurally, the hydraulic press can be vertical or horizontal, closed or open type. With this tool, you can crimp not only metal, but also other materials.
When choosing a hydraulic tool, the presence of a pressure limiting valve must be taken into account. This element provides additional reliability, eliminating overloads due to pressure. You should pay attention to the types of pressing heads, which are open or closed, as well as the diameters of the working sections. All hydraulic tools consist of sub-groups, each of which performs operations with cables up to 70, 120-300 and 400 mm2.
How to work with crimping pliers
Each pliers are used in accordance with their intended use. However, there are general principles relating to any instrument. When performing each operation, you will need a wire or cable of a certain section, the pliers themselves, as well as sleeve tubes or other connecting elements.
For example, you can take the Internet wires.
- The ends of the wires are cleaned of external insulation. This operation will require pliers with a semicircular recess at the bottom and cutting edge above. A wire is placed in the recess, after which its upper side is pressed with a blade. 1-2 turns are made around the cable, the insulation becomes notched and removed without any effort. For normal crimping, you will need a cleaned area, 3-5 cm long.
- The cores of cable conductors are aligned and placed in desired sequence by connector type. They are closely pressed against each other and cut so that 1-1.5 cm remains for connection.
- The wires are brought into the connecting device with the preservation of the sequence. At the same time, the lower notch of the connector must reach the cable insulation so as not to cause damage when crimping actions are performed.
- The whole device is placed in the seat of the pincers. After re-checking correct location flowers are pressed.
- Upon completion, the integrity of the connector and the strength of the connection are checked.
