Using a wire terminal crimping tool involves a precise process of connecting a wire to an electrical terminal, creating a secure and reliable connection. The fundamental steps include preparing the wire, positioning the terminal and wire correctly within the tool, and then applying pressure to form the crimp.
Understanding the Crimping Process
Crimping is a method of joining a wire to a connector by deforming one or both to hold the other, without the use of solder. This mechanical connection offers excellent electrical conductivity and mechanical strength when done correctly.
Step-by-Step Guide to Crimping a Wire Terminal
Successfully crimping a wire terminal requires careful preparation and execution. Follow these steps for a strong, lasting connection:
1. Prepare Your Wire
Before you begin, ensure your wire is ready for crimping.
- Select the Right Wire: Choose a wire of the appropriate gauge (AWG) for your terminal and application.
- Strip the Insulation: Using a wire stripper, carefully remove the insulation from the end of your wire. The exposed wire length should match the barrel length of your terminal. Avoid cutting or nicking the wire strands.
2. Choose the Correct Terminal and Tool Die
- Terminal Selection: Select a terminal that matches your wire gauge and application (e.g., ring, spade, butt connector). Ensure it's the correct type for your crimping tool (insulated or non-insulated).
- Die Selection: Most crimping tools have multiple crimping slots or interchangeable dies. Match the correct crimping slot/die to the size and type of your terminal. Using the wrong size can lead to a weak crimp or damage the terminal.
3. Position the Terminal in the Tool
- Open the crimping tool's jaws.
- Place the terminal into the correct crimping slot. For insulated terminals, ensure the insulation crimp barrel is in the larger die section and the conductor crimp barrel is in the smaller die section. The terminal should rest securely in the tool, often held in place by friction.
4. Insert the Wire into the Terminal
This is a critical step for a proper crimp.
- Insert the Wire: As referenced, "You would next take your wire. And insert it you'll see how it's sticking through just like we're supposed to." This means pushing the stripped end of the wire fully into the terminal's barrel until the insulation butts up against the start of the conductor crimp section. For insulated terminals, the wire insulation should be positioned within the insulation crimp barrel. A small amount of conductor might slightly protrude from the other end of the terminal, indicating full insertion.
5. Crimp the Terminal
With the wire and terminal correctly positioned, it's time to make the connection.
- Squeeze the Crimper: "And then squeeze your crimper. All the way to the end. Until it releases." Apply firm and steady pressure to the crimping tool handles. Many quality crimping tools have a ratcheting mechanism that prevents the jaws from opening until a full crimp cycle is completed, ensuring consistent pressure. Continue squeezing until the tool automatically releases or the handles meet.
6. Inspect the Crimp
After crimping, always inspect your work to ensure a secure connection.
- Visual Check:
- Conductor Crimp: The wire strands should be tightly compressed within the terminal barrel.
- Insulation Crimp (if applicable): The insulation should be securely gripped, providing strain relief without crushing the insulation or cutting through it.
- No Loose Strands: Ensure no wire strands are straying outside the crimp.
- Pull Test: Gently tug on the wire to verify it's securely held within the terminal. If it pulls out, the crimp was insufficient, and you'll need to cut and re-crimp.
Types of Wire Crimping Tools
Different applications and terminal types require specific crimping tools.
| Tool Type | Description | Common Usage |
|---|---|---|
| Ratcheting Crimpers | Feature a mechanism that ensures a full crimp cycle, preventing under-crimping. | Professional and high-volume work |
| Non-Ratcheting Crimpers | Rely on manual pressure, requiring more skill to achieve consistent crimps. | Occasional or light-duty use |
| Open Barrel Crimpers | Designed for uninsulated, open-barrel terminals (e.g., automotive, D-Sub pins). | Automotive, electronics |
| Insulated Terminal Crimpers | Have specific dies for insulated terminals (red, blue, yellow typically correspond to wire gauges). | General electrical, automotive |
| Coaxial Crimpers | Used for crimping coaxial cable connectors (e.g., BNC, F-type). | A/V, network installations |
| Modular Plug Crimpers | Specifically for crimping RJ-style connectors (RJ11, RJ45) for networking and telephony. | Networking, telecommunications |
Tips for Successful Crimping
- Cleanliness: Ensure terminals and wires are clean and free of grease or corrosion.
- Consistency: Aim for consistent stripped lengths and crimping pressure.
- Practice: If new to crimping, practice on scrap wire and terminals to get a feel for the tool and proper technique.
- Safety First: Always wear appropriate personal protective equipment, such as safety glasses, when working with tools.
By following these steps and understanding the nuances of your crimping tool, you can create reliable and durable electrical connections.
