We must be not familiar with insulation terminal, which is actually a seal inside the insulation plastic metal, with a hole at both ends can be inserted into conductor. Initially, since the insulated terminals are welding up or intertwined, it sometimes be very inconvenient and messy. Therefore, we cam connect them by using the insulated terminal at the moment, and you can disconnect at any time with the head orderly wiring. However, most of may do not know how to crimp insulated terminals and these article is aimed to handle your worries towards it.
List:
1. Choosing the wire of insulated terminals
2. Tools of crimping insulated terminals
3. How to crimp insulated terminals?
4. Further information
Choosing the wire of insulated terminals
Do not use solid cored wire.
Next determine the wire size. The most common size are AWG (American Wire Gauge), Cross sectional area in square mm and strand and diameter count. There are plenty of sizes around to help you convert between common sizes.
However, as long as you use standard wires, then this should not give you a significant issue.
Tools of crimping insulated terminals
Ratchet crimp tool
There exists a built-in ratchet in the best crimper. It will avoid the jaws opening back up when the handles are being squeezed together.When applying enough pressure, the ratchet will disengage and release the crimped part.
Manual crimp tool
The result of using manual crimping tools is nearly the same as that of ratchet crimp tool except more vigilant users should be. This style of crimper is generally less sturdy. In order to ensure that the jaws are lined up properly on the connector, enough attention must be given into crimping.
Notice:
All kinds of pliers like needle nose pliers, vises, hammers or flat rocks are not crimper. Therefore, the result of using those tools will lead to a bad crimping which will then leave air pockets between the wire and connector. In the end, the air pockets may collect moisture and lead to corrosion and even breakage.
How to crimp insulated terminals?
1.Before carrying out a lot of crimps, it is worthy to do a test crimp on representative wire and terminals to ensure you have settings correct.
2.The wire insulation layer must be stripped off before pressing. The stripping length must be as required to ensure that the conductor and the insulation layer are in the correct position when the terminals are pressed together. The insulation layer must be cut neatly and evenly.
3.The wire should then be inserted until the insulation on the wire touches the end of the barrel.
4.The wire and terminal are then inserted into the crimper. The color of the terminal’s insulation needs to be matched with the same color on the crimping tool.
5.The conductor must be placed horizontally in the terminal pressure wire frame, and the conductor end must exceed the pressure wire frame and the maximum exceed cannot exceed 1mm. Conductor brush can not interfere with the plug and lock function of the terminal, can not affect the sealing and safety after installation. What’s more, the conductor brush should not extend to the terminal area.
6.After the crimp is completed, the wire and connector should still hold together after trying to pull them apart with great force.
Notice:
If the wire does not fit in the barrel, or is excessively loose, the wrong size of either wire or connector was chosen. If necessary, add a solder joint between the wire and connector.
Further Information
The end of the insulation sheath must extend out of the insulation sheath pressing frame, but the insulation sheath is not allowed to extend into the core wire pressing frame.
After crimping, the edge of the crimping frame of the core wire must have a bell mouth. The size of the bell mouth varies according to the wire diameter. The front horn of the core wire pressing frame is not required, but the maximum size requirement must refer to the requirements of the rear horn.
The tail shall be clearly cut and shall not exceed 1.0 to 1.5 times the thickness of the terminal material at the longest and the incised burr shall not exceed 0.03mm. Additionally, tail cutting and burr shall not interfere with the installation and connection of terminals, shall not damage the insulation skin of electric wires, shall not exceed the installation shell and thereby affect the sealing and safety of the whole connector.
Choose wrong size terminal for the wire or wrong size wire for the terminal.
Be cautious not to strip too much insulation off.
Therefore, as we mentioned before in this short essay, crimping the insulated terminals is not an easy task to finish. Either preparation or specific operation should be ignored if you want to ensure quality when crimping. Hoping that we could help you to crimp the insulated terminals in a proper way.
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