Crimping uninsulated ring terminals securely connects a wire end to a terminal, providing a reliable electrical connection. The process involves preparing the wire, inserting it into the terminal, positioning both in the correct crimping tool, and applying pressure.
Here is a breakdown of how to crimp uninsulated ring terminals:
Step 1: Gather Your Tools and Materials
Before you begin, ensure you have the necessary items. Having everything ready makes the process efficient and helps achieve a proper crimp.
- Uninsulated Ring Terminals: Make sure these match the wire gauge you are using and the bolt size for the connection point.
- Wire: The wire you intend to terminate.
- Wire Strippers: To remove the insulation from the wire end.
- Crimping Tool: Crucially, use a crimping tool designed specifically for uninsulated terminals. These tools typically have shaped dies that form a robust crimp (often a B-crimp or similar) onto the metal barrel of the terminal.
- Heat Shrink Tubing (Optional): For adding insulation and strain relief after crimping.
- Heat Gun (Optional): To apply heat shrink tubing.
Step 2: Strip the Copper Wire
Prepare the wire by removing the correct amount of insulation.
- Determine the required strip length by holding the uninsulated ring terminal against the wire. The stripped portion should be just long enough to insert fully into the terminal's crimp barrel, reaching but not extending past the end of the barrel.
- Using the correct gauge slot on your wire strippers, carefully strip the insulation from the end of the wire. Avoid nicking or cutting any of the wire strands.
Step 3: Insert the Wire into the Terminal
Twist the stripped wire strands together lightly to keep them tidy.
- Insert the stripped wire end fully into the crimp barrel of the uninsulated ring terminal. The wire insulation should butt up against the end of the terminal barrel, with no exposed copper visible outside the barrel.
Step 4: Position the Terminal in the Crimping Tool
Selecting the correct die on your crimping tool is vital for a successful crimp.
- Identify the appropriate crimping die size on your tool that matches the wire gauge you are crimping.
- Open the crimping tool jaws and carefully place the uninsulated terminal barrel into the correct die cavity. Ensure the seam of the terminal barrel (if it has one) is positioned correctly according to the tool's instructions, often facing away from the main crimping indenter. The wire should extend straight out from the terminal.
Step 5: Crimp the Terminal
Apply pressure to create the secure electrical and mechanical connection.
- Close the handles of the crimping tool firmly and completely. The tool will deform the terminal barrel around the wire, creating the crimp. Most quality crimping tools designed for uninsulated terminals have a ratcheting mechanism that prevents the handles from opening until the crimp is fully formed.
- Once the tool releases, open the jaws and remove the crimped terminal.
Inspect the crimp to ensure it is tight and secure. The wire should be firmly held within the terminal barrel. A good crimp will typically show a distinct indentation from the tool's die.
Step 6: Apply Heat Shrink (Optional)
Adding heat shrink tubing provides insulation, protects the connection from environmental factors, and adds strain relief.
- Before inserting the wire in Step 3, slide a piece of appropriately sized heat shrink tubing over the wire.
- After completing the crimp in Step 5, slide the heat shrink tubing over the crimped barrel and a small portion of the wire insulation.
- Apply heat with a heat gun until the tubing shrinks snugly around the terminal and wire.
By following these steps, you can create reliable crimped connections using uninsulated ring terminals.
