After stripping, appropriate contacts or wire end ferrules can be crimped to the cable end. Crimping produces a reliable connection between conductor and contact, and has more or less completely replaced soldering.
Crimping describes the production of a uniform, non-detachable connection between conductor and connecting element. This should be achieved exclusively by the use of a high- quality precision tool. The result is a safe, reliable connection in both electrical and mechanical terms.
Weidmüller offers a wide range of mechanical crimping tools. An integral ratchet mechanism with disengage option guarantees optimum processing quality. Crimp connections produced with Weidmüller tools comply with international standards and specifications.
The DIN EN 60352-2 standard recommends that tools and contacts should come from the same manufacturer, since this is the only way to ensure consistently high quality. Otherwise, it is the user who is responsible for the quality. Weidmüller tools are designed to fit with Weidmüller contacts and thus are in full compliance with the DIN EN standard.
Crimping of wire end ferrule: an example of an optimum crimp of different cross-sections:
A crimp connection using manual and automatic Weidmüller tools can be seen below. The conductor insulation must be pushed into the plastic collar and the ferrule sleeve must be completely filled by the conductor. Depending on the cross-section, the conductor should protrude approx. 0 … 0.5 mm from the ferrule sleeve.
Note: The AWG cross-section specifications can be compared with the equivalent metric specifications.
Faulty crimping connections due to an incorrect combination of cable and wire end ferrule:
It is not possible for a tool to function reliably with every combination of conductor and crimping material. It is possible that the standard requirements for the crimped product can’t be achieved, although taken on their own, both conductor and crimping material comply with the corresponding standard. The individual production tolerances of conductor and crimping material do not allow every conductor to be combined with every contact.
The combination of conductors, crimping material and crimping tool must be coordinated: this procedure is all the more difficult given the large number of products on the market.
This means that the material must be defined and the crimping result tested, ensuring that the test, and later on the tool, satisfy the same conditions.
Faults which can occur during crimping:
• Cracks along the sides and die impressions
• Splitting of the ferrules
• Asymmetrical crimping shape
• Extreme burrs formed along the sides
• Ferrule not filled by the conductor
• Single conductors pushed back protruding from the collar
• Single conductors squeezed off
• Plastic collar damaged by the crimping jaw
• Conductor insulation not pushed into the plastic collar
• Ferrule bent longitudinally after crimping
The ferrule must not split open after it has been connected once in any Weidmüller terminal corresponding to the conductor cross-section (with a torque according to IEC 60947-1).