Compendium - A Preview

To give you an impression of the structure and content of the e-book, we have
created this preview for you. For this preview we have selected some pages from
different topics.

Principles

W
of
Crimping Technology
IE
Compendium
(unabridged version)
EV
www.crimp-academy.com
PR

© KabelForum.com - Volker Kratt | Translation: Andrea Weyh | Version: 2022-11-22

 1. PREFACE

Crimp and press connections are an essential component in connection technology.

Millions of such connections are made every day. They have largely replaced soldered
connections and proven themselves over the years as state-of-the-art connections.

The use of crimp connections can be found wherever electronics or electrics find their
application. That is to say, pretty much everywhere.

Particular attention is paid to crimp connections that are integrated into

EW
systems that directly serve to protect and ensure the safety of people
(like ABS anti-lock braking system, airbag, emergency call systems,
aviation, medical equipment, etc.).

However, crimp and press connections are only adequate if they com-
ply with the required standards and can only function if they are well
executed.
Burned closed end connector

The challenge in wire processing is the handling of dimensionally un-

stable materials*. An essential prerequisite for the production of high-
quality wire harnesses is first and foremost the experience of the person
responsible for adjusting the production equipment as well as the
knowledge of the production personnel on what to pay attention to.
I
This documentation covers the principles of crimp and press connec-
tions.
EV
It was created based on current standards and the latest research, al-
ways with regard to their relevance in the “real world” of cable harness Burned crimp connection
manufacturing.

This documentation and the seminar film "Principles of crimp and press
connections" are intended to give you the opportunity to train and fur-
ther educate employees within the framework of in-house training
courses, or simply to serve as a reference book.
PR

Continuous developments in the field of wire processing mean that this

documentation is revised and complemented at irregular intervals. In-
formation on updates or new versions can be found on our websites.

Faulty crimp

© KabelForum.com – Principles of Crimping Technology 25

 2.4 PROCESSING OF STRANDED COPPER CONDUCTORS

Important: When processing copper strands, good contacting and the low-
est possible contact resistance is directly dependent on an optimal crimping
process.

Right after the stripping procedure, the process of oxidation begins on the surface
of the copper wires. And this affects all individual wires within a stranded wire con-
ductor. Within a very short period of time, a firmly adhering and durable oxide layer
of about 2 to 4µm is formed. Depending on the humidity and temperature, this in-
sulating oxide layer is formed more or less quickly.

The color changes from a shiny orange-reddish shade to a matt dark brown surface, depending on the degree of oxidation

EW
(also called: passivating effect). This surface serves as a protective layer and prevents the penetration of oxygen or oxygen
compounds such as water, thus stopping further corrosion and making copper very resistant to weathering.

In crimping connection technology, this oxidized surface is undesirable because it has

an electrically insulating effect and is responsible for increased transition resistances
in a crimp connection. Due to the irregular pressing of the stranded conductor during
the crimping process, this oxide layer is broken up. Together with the crimp contact, a
friction-locked and keyed permanent connection with good electrical properties is cre-
ated.

Conversely, this means that the more cavities and undeformed individual strands are
visible in the micrograph, the worse the electrical and, of course, the mechanical prop-
erties of the crimp connection. Moisture can penetrate into existing cavities, which in-
I
itially, in a normal environment, does not cause any further deterioration in the prop-
erties of the crimp connection. However, if the ambient conditions change, copper may
also be attacked and destroyed ("pitting corrosion").
EV
Of course, it is important that a created crimp also maintains its form. It’s generally not
a problem with the closed crimp barrel. But for the open crimp barrel the crimp form is key. When sheet metal is deformed,
the material tends to spring back into its original shape after the bending process. This effect also occurs after the crimp
flanks have been rolled in. To counteract this, the crimp flanks must touch and support each other (picture below: position
A).
PR

open crimp barrel: closed crimp barrel

The crimp flanks support each other (A)

© KabelForum.com – Principles of Crimping Technology 31

 2.9 THE OBJECTIVE OF CRIMPING TECHNOLOGY

EW
The assessment of the results of the individual work steps required for an ideal crimp connection is the bread and butter
of wire processing. What is good, what is tolerable and what is bad? What consequences can faulty crimp connection
have for the function of the wire harness? How can these faults be detected or avoided to begin with?

These are the questions that need to be answered. This documentation is intended to help with the search for answers.
I
EV
PR

(1) Critical error: Missing rear bellmouth (flare). Crimp connection is bad and must
not be used!

(2) Tolerable error: Insulation crimp overcrimped.

© KabelForum.com – Principles of Crimping Technology 36

 3. THE CONDUCTOR

3.1 BASIC CONDUCTOR STRUCTURE

Solid wire

EW
(Main use: electrical installations in buildings)

Stranded wire
The more individual wire strands there are in a cable, the more flexible
I
the cable. The sum of the cross sections of all individual wire strands
equals the cross section of the cable.
EV
PR

Sheathed cables (Jacketed cables)

Multiple conductors made of single wires are referred to as multi-con-
ductor or multi-conductor sheathed cables.

Shielded cables
(Coax - Triax)

© KabelForum.com – Principles of Crimping Technology 53

 3.12 WIRE STRIPPING

3.12.1 BASIC RULES OF WIRE STRIPPING

Making a good, working crimp connection starts with properly stripping the wire. During the stripping
process, the stripping blades cut the insulation, but must not damage or cut the strands in the process.

Important: According to the official standards, all individual wire strands must be undamaged and complete!

In the field, there are wires that have a large number of individual wires in relation to the nominal cross-section (finest-
stranded wires). These conductors can often NOT be stripped without loss. Then, in deviation from the standard, the
values defined in the customer's processing instructions or delivery specifications apply.

Example: Specification in % depending on the cross-section whereby the result is rounded down:
Up to 0.5 mm² = 5%; up to 0.75 mm² = 8%; above 0.75 mm² = 8%.

EW
Effective control in manufacturing:
When you find single, cut-off wire strands on the workstation or in the
bin!

I
EV
If the cutting edge of the stripping blade hits the insulation
(1), the cable is deformed (2). I.e. the insulation is
compressed. Then the insulation "flows" around the cutting
edge (3) and is cut (4).

This means that depending on how hard or soft an insulation

is, the pressure of the blade must act on the insulation for a
certain time until it is cut. The softer the insulation material,
PR

the longer this dwell time of the knife. If the dwell time is too
short, the insulation is only partially cut.

Of course, the sharpness of the blade also plays an important

role. If a knife wears out and becomes increasingly dull, the cutting properties deteriorate and as a result the dwell times
become longer.

Important: Optimizing the dwell times increases the production speed. Regular controls of the stripping results
give conclusions about the sharpness of the stripping blades.

© KabelForum.com – Principles of Crimping Technology 79

 3.12.14 ERROR DESCRIPTIONS DURING STRIPPING

3.12.14.1 OVERVIEW

Good stripping vs. Bad stripping

Stripping OK
All single wires are present and undamaged
Insulation is cleanly cut

Indicated in % depending on the cross-section and the result is rounded down.

Up to 0.5 mm² = 5%* | up to 0.75 mm² = 8%* | over 0.75 mm² = 8%*
From a conductor cross-section of 25 mm², no more than 30 individual strands* may be cut off (finest stranded conduc-
tors).

EW
*Attention: The specifications may change, depending on customer specs & requirements!

Individual wires damaged and / Single wire pulled Surface of single conductor strands
or cut off scratched on one side

Insulation improperly cut Insulation threads Insulation damaged

I
EV
Insulation residues on Twisting of the individual strands Broom shaped
the single strands lifted conductor

Kinked wire strand Conductor overtwisted

Variations in stripping length
PR

Wire strands strongly oxidized Protruding Insulation

(„hollow“ cable)

© KabelForum.com – Principles of Crimping Technology 108

 4. CRIMPING: OPEN BARREL CRIMP CONNECTORS
4.1 THE BASICS

4.1.1 TERMS & DEFINITIONS

W
1 Contact area
IE 8 Bellmouth (rear)
EV
2 Wire crimp (conductor crimp) 9 Cutoff tab at the front
3 Insulation crimp 10 Cutoff tab at rear
4 Transition to contact area 11 Stripping length
5 Transition to insulation crimp 12 Conductor end
6 Conductor protrusion 13 Conductor
7 Bellmouth (front) 14 Seal

4.1.2 OPEN CRIMP BARRELS

PR

Cross-sections of up to approx. 50 mm² can be processed in open barrel crimp

sleeves. The stripped conductor can be inserted from "above" into the open
crimping area.

The areas of application for this contact variant include cable harnesses for the
automotive, household appliance and aircraft industries. This contact variant is
suitable for processing in large quantities. Wherever crimp connections have to
be produced in large quantities, this contact variant is used. Processing is car-
ried out on special production equipment which ensures almost 100% repro-
ducibility of the processing quality, while at the same time producing large
quantities.

© KabelForum.com - Principles of Crimping Technology 130

 4.1.10 OVERVIEW OF CRIMP SHAPES

B/F-Crimp up to approx. 50 mm²

A standard crimp shape for open crimp sleeves.

O-Crimp up to 6 mm²

Wire end ferrule in open claw form for fixing the individual
wires of a stripped cable.

W
OV-Crimp (for insulation crimps)

„OV“ stands for „overlap“

Insulation crimp form for open crimp sleeves. Often used for
wires with reduced insulation thickness.

O-Crimp, asymmetric (for insulation crimps)

Asymmetrically wrapped around wire insulation.

Insulation crimp shape for open crimp barrels.

Application:
IE
EV
1. fixation of single wire seals
2. for wires with reduced insulation thickness

O-Crimp, symmetric (for insulation crimps)

Symmetrically wrapped around wire insulation.

Insulation crimp shape for open crimp barrels.

PR

Application:
1. fixation of single wire seals

Roll crimp
Used for uninsulated flag terminals

© KabelForum.com - Principles of Crimping Technology 142

 4.1.11 ASSIGNMENT

4.1.11.1 ASSIGNMENT CRIMP CONTACT – NOMINAL CROSS SECTION – T OOLING

For an optimal crimp connection, the following factors must match:

+ Crimp contact
+ wire (structure and cross section)
Good
+ Crimp tool = Crimp connection
+ Crimp tool setting

W
IE
Crimp contacts can be designed for several cross sections or cross section ranges ("Ranges"). This occasionally leads to
poor crimp connections, even if the official data and crimp specifications from the product description (catalog) are adhered
EV
to.

The following example is intended to illustrate this problem:

Explicit notice: This problem can principally occur with all crimp contact manufacturers. The following example
has nothing to do with the qualification of a certain manufacturer.

Approved according to data sheet for nominal cross section(s):

Wire Range (mm [AWG]) = 0.50-1.40² [20-16], (2) 0.50² [20]
PR

(1) cross section 0,75 mm² (2) cross section 0,5 mm²

If the crimp flanks roll in unevenly, the permissible tolerances are quickly exceeded despite approval for this cross-section
and the crimp connection is judged to be poor!

Important: Even official data sheets do not automatically guarantee good crimp connections.
Always check crimp connections via micrographs!

© KabelForum.com - Principles of Crimping Technology 143

 4.10 THE CUT-OFF TAB – CONNECTION TO THE CARRIER STRIP

Crimp terminals are provided on reels, bound to carrier strips. This connection is
separated shortly before the crimp flanks are rolled in during the crimping process.
The remnants of these cut connections are referred to as cut-off tabs, which are
of particular importance in the visual inspection of crimp connections.

Neither the insulation crimp flanks nor the functional area of a crimp contact may
be deformed or damaged! A visible cut-off tab means that the insulation crimp flanks or the functional area of the crimp
contact did not come into contact with the cutter during the separation process. Consequently, damage or deformation of
both areas can be excluded.

Undetectable cut-off tabs do not automatically mean that damage or deformation must be present. However, in such cases

W
it is very time-consuming to check for these possible defects. It is easier if the tab can be recognized during the visual
inspection. For this reason, it is important that tabs are visible or at least 0.1 mm long.

4.10.1 CUT-OFF TAB LENGTH

The cut-off tabs must be recognizable (at least 0.1 mm)

and may be no longer than the thickness of the contact

IE material. The length must not exceed 0.5 mm. The tabs
must not be bent or deformed.

The cut-off tabs (10 + 12) and the burr (11 + 13) on these tabs must neither hinder nor
influence the assembly of the contact in the connector housing or in corresponding mat-
ing contacts.
EV
4.10.2 CUT-OFF TAB LENGTH IN SEALED CONTACTS

When processing single-wire seals, the cut-off tab

(12) must not exceed a maximum length of 0.3
mm and must not damage the seals.

4.10.3 SETTING THE CUT-OFF TAB LENGTH IN AN ENDFEED APPLICATOR

(1) Cutting unit

(2) Crimp contact
PR

(3) Cutter thickness

The thickness of the cutting blade depends on the

length of the connection (6) of the crimp contacts.

An example of calculation:

1.50 mm connection (6)

- 0.25 mm front cut-off tab (4)
- 0.25 mm rear cut-off tab (5)
=1.00 mm thickness cutting blade (3)

© KabelForum.com - Principles of Crimping Technology 212

 5. TEST METHOD AND APPLICATION

Important: The basic test procedures in crimping technology are described in this chapter using the example of the open
crimp barrel. In principle, the sequence of these test procedures is the same for all crimp contact variants. The require-
ments for the different contact variants of the closed crimp barrel (ferrule, turned contacts, etc.) can be found in the corre-
sponding chapters.

5.1 FUNDAMENTALS AND GENERAL INFORMATION

Quality standards in crimping and pressing technology are becoming ever more stringent.
Especially in the case of connections that are integrated into systems that directly serve the

W
protection and safety of people (ABS anti-lock braking system, airbag, emergency call sys-
tems, aviation, medical equipment, etc.), the quality requirements are constantly being in-
creased.

If a harness maker wants to be approved as a supplier, he must meet these high standards Micrograph
with his processing equipment and testing methods. And if the prospective electrician wants
to take his skilled worker's examination or obtain the master craftsman's certificate, he must
prove that he can meet the required quality.

tion. IE
The days when crimp and press connections were made with "flat nose pliers" or "hammer
and chisel" are long gone. Today, even in the prototyping phase, care is taken to ensure
that samples are produced with the processing equipment that will later be used in produc-

Everyone is familiar with the reports of recall actions in the automotive industry, house fires
due to short circuits, etc., or control cabinet wiring manufactured in Europe that arrives de-
fective in the Far East and therefore a machine or entire production facilities fail to operate. Crimp height-
EV
Quality control in production costs money! But it is necessary, because the follow-up costs measurement
in case of a failure of e.g. a crimp connection may be many times higher. The buzzword:
"certification" is known today in every modern, quality-oriented company and the certificates
are today a MUST for every expanding company.

A prerequisite for this is, in addition to the high-quality processing equipment, of course also
an optimal, cost-effective quality management. A good quality system not only shows your
prospective customers that your company values quality, but also demonstrates your ex-
pertise and can help you win new contracts.
Pull-out tester
PR

In the world of crimping and pressing technology, there are five basic test methods:

1. visual inspection
2. measurement of crimp dimensions
3. pull-out test
4. micrograph + micrograph evaluation
5. crimp force monitoring (only in crimping technology)
Piezo position
for crimp force
monitoring
Important: These test methods complement each other and are the backbone of any qual-
ity assurance in crimping technology. Each test method on its own is NOT sufficient! Only
the combination of these test methods enables a production of consistently high and repro-
ducible quality of crimp connections!

Crimp force monitoring

control unit

© KabelForum.com - Principles of Crimping Technology 225

 5.2 VISUAL INSPECTION

Visual inspection of crimp connections is one of the most important tests in wire processing and crimping technology.
The basic principles for a visual inspection are specified by the customer or the quality guidelines of the production.
Many areas of a crimp connection can only be inspected with considerable technical effort. This in turn depends on
the equipment used for production and, of course, on the quantities produced.

The requirements for a crimp connection and the corresponding background are described in detail in the topics
"Crimping - Open Crimp Sleeve" and "The Closed Crimp Sleeve".

The most important aids for the employees in the production are appropriate visual boards, posters and, of course,
instruction and training. Because only if the inspecting person knows where to look and how to look correctly, there
will be a correct result of the inspection.

W
5.2.1 THE VISUAL INSPECTION PROTOCOL

Of course, this result can also be recorded in a corresponding protocol. The visual inspection record can also be
helpful for practicing and learning, especially for new examiners. Until a corresponding qualification is achieved, the
visual inspection protocol ensures that nothing is forgotten.

Visual inspection of the connection:

IE
The following is an example of a visual inspection protocol for the open crimp sleeve:

OK NOK
EV
(1) Rear bellmouth present / bellmouth correctly executed
(2) Front bellmouth present / bellmouth correctly executed
(3) Strands and insulation/seal visible
(3) Stripping clean and good / all strands present
(4) Strand protrusion visible (max.0.5 mm)
(5) Contact area undamaged and straight
(6) Wire crimp symmetrical and closed
(7) Burr formation
PR

(8) Insulation crimp correctly executed. Position and design of the crimp flanks
(9) Cut-off tabs present and visible (max. 0.5 mm)
(10) No damage to the insulation (pressure marks allowed)
(11) Seal correctly positioned and undamaged
(12) Crimp contact overall straight and not bent
(13) Uneven breakage of strands after pull-out test
Comments:

Date: _____________ Signature: _________________________

© KabelForum.com - Principles of Crimping Technology 233

 5.3 MEASURING CRIMP DIMENSIONS

5.3.1 WIRE CRIMP HEIGHT – OPEN CRIMP BARREL

The crimp height (2) is an adjustable dimension in the processing tool. The
crimp height is specified by the contact manufacturer depending on the
conductor/cross section. As a non-destructive test, crimp height
measurement offers reliable quality control during ongoing production.

In the processing guideline (specification) which is defined for each crimp

connection during design, the respective tolerances are usually defined in
addition to the crimp dimensions.

The extent of the tolerance depends on the crimp height range in which the

W
mechanical and electrical properties of a crimp connection are still OK with
certainty. The tolerances specified by the customer are always decisive. These tolerances can also deviate from the
actual specification of the manufacturer. This happens if the crimp connection is to be used for safety-relevant con-
nections, for example.

If no tolerances are defined for the crimp height, the following table provides a means of orientation. The crimp height
tolerance is defined according to the cross-section ranges.

0.03 - 0.20 mm²

0,20 - 0,50 mm²
0.30 - 0.81 mm²
0.50 - 6.00 mm²
IE
Tolerances for the crimp heights without tolerance specifications
Cross-section range
mm² AWG
AWG 32-34
AWG 24-20
AWG 22-18
Tolerance
+/- 0.02 mm
+/- 0.03 mm
+/- 0.04 mm
+/- 0.05 mm
EV
6.00 - 25.00 mm² +/- 0.10 mm
25.00 - 50.00 mm² +/- 0.15 mm

5.3.2 MEASURING TOOLS– OPEN CRIMP BARREL

When measuring the crimp height, the anvil (3) must always be positioned above the
rolled crimp flanks and the measuring tip (4) on the crimp base.
PR

Caliper with special grinding

When measuring with a caliper, the measuring pressure is built up by hand. This means that the measuring result
depends on the sensitivity of the operator. This measuring device may only be used by skilled and trained workers.
Furthermore, this measuring device is unsuitable for small crimp contacts.

© KabelForum.com - Principles of Crimping Technology 234

 The picture on the left shows examples of universal
crimp contact receptacles.

Position 3 shows the receptacle for ring tongues.

The picture on the right shows a special receptacle for wire-end

ferrules: After insertion into the receptacle (1), a cover (2) is
pushed over the wire-end ferrule. The ferrule cannot come out

W
of the receptacle. The geometry of the receptacle prevents
kinking. This means that it is not necessary to fix the ferrule by
hand. An optimum measuring result is achieved.

Important: When inserting the crimp contact into the

receptacle, the crimp connection must not be damaged
or deformed.

IE
The pulling direction (3) must be made along the longitudinal axis of the
contact and conductor! If the conductor would bend in one direction (4)
directly after the wire crimping area, this would inevitably have an effect
on the measuring result!

In order that the crimp contact and the wire can align themselves ac-
EV
cordingly, the holder is mounted movably. When the pull-out test is
started, the fixture rotates so that the crimp contact forms a line with
the wire.

5.4.2.3 CLAMPING DEVICE FOR THE W IRE

Clamping devices that close in a self-ten-

sioning manner are ideal. This means that
the greater the tensile force or load, the
greater the clamping force. During use, it is
normal for the wire to slip a little through the
PR

clamping jaws at the start of the test.

Mechanical clamping devices are used for larger cross sections.

The forces that occur during the pull-out test are correspondingly high and
require a considerably more massive clamping of the wire.

Pictured left: Schleuniger 28, a motor-driven pull-out tester with a measuring

range of up to 10,000 N.

© KabelForum.com - Principles of Crimping Technology 240

 5.5 MICROGRAPH PREPARATION

5.5.1 PRINCIPLES
The micrograph shows the inner structure of the crimp connection in a
cross-section through the crimp connection.

Micrographs help in the development of a crimp connection when deter-

mining the crimp dimensions and when checking the crimp quality of crimp-
ing tools.

When you purchase a new crimping tool, you will receive comprehensive Crimp connection OK
documentation from your supplier. This includes, in addition to sample
crimps, a micrograph of the crimp connection made with this tool.

W
This micrograph documents the crimping result with optimum tool setting
and is your reference for all further micrographs of crimp connections made
with this crimping tool.
The crimping area is overfilled! Wrong
Of course, this micrograph also shows you whether there were any errors
assignment of crimp contact to con-
in the crimp connection beforehand. The most common error is an incorrect
ductor cross-section. The crimp

area of the crimp contact.

IE
assignment of the nominal cross-section of the wire to the wire crimping

The reason: no or as small as possible stock-keeping and narrowing down

of the crimp contact variants cause the crimp contact manufacturers to
combine several conductor cross-sections into cross-section ranges.

For example: You have a crimp contact that is supposed to cover a cross-
contact is too small!
EV
section range in the wire crimp of 0.5 to 1.5 mm². Then the crimping in the
wire crimp is optimal for a conductor cross-section of (e.g.) 1.0 mm².

With a conductor cross-section of 0.5 or 1.5 mm², the crimping in the wire
crimp can still be just within the tolerances. In any case, it will not be opti-
mal. The larger this cross-section range of the crimp contact is designed The crimp flanks are rolled in too far!
(e.g.: 0.75 to 2.5), the greater the risk that the crimping in the wire crimp Wrong assignment of crimp contact to
area will be outside the permissible tolerances. conductor cross-section.
The crimp contact is too large!
PR

Important: Already during the assignment of the nominal cross-section of the wire to the crimp contact, within
the scope of development, the quality of the compression of the conductor in the wire crimp of the crimp
connection should be checked via a micrograph. And this applies in general to all crimp contact types!

If the development is completed and it is found during the production of crimp connections that the crimping is not
optimal, the necessary changes (alternative crimp contacts) are usually no longer carried out. This is often due to the
fact that there are no alternative crimp contacts available for the connector housing used that enable optimum crimping
of the stranded compound. Consequently, suboptimal or poor crimp connections are produced. The tolerances are
adjusted accordingly or the crimp connection is approved via a special approval.

If your customer submits such a combination to you in an order where the crimping result is poor according to the
micrograph, you should point this out to your customer in any case! As a "crimp pro", offer your customer alternatives
with which you can achieve an optimum crimping result. If your customer does not accept your alternatives, have your
customer sign off on this "bad crimp connection" as intentional. This way you show professional competence and if
the crimp connection fails you are exempt from all recourse claims!

© KabelForum.com - Principles of Crimping Technology 248

 5.6 CRIMP FORCE MONITORING AND THE OPEN CRIMP BARREL

5.6.1 THE PHILOSOPHY BEHIND IT

Process monitoring of the crimping process ensures prompt detection of faults in crimp
connections. Already during the production process the decision about good / not good of
each individual crimp connection should be made and these should be immediately sorted
accordingly.

A quality certificate should be available for each batch size, which is necessary as a pre-
caution in the context of product liability and is required by many customers today as part
of the certification process.

W
The following crimping errors should be detected:
• Missing individual strands in the conductor (cross-section changes).
• Insulation crimped in the wire crimp.
• Broken wear parts.

Crimp forces are rapidly changing force variables in the millisecond range with a typical range of a few 100N to about
40kN. Piezoelectric force sensors are used to measure these force characteristics. They are excellently suited for
measuring dynamic and quasi-static loads.

IE
The most common methods in crimp quality monitoring are pure force control or a combination of force/time control
taking into account the working stroke of the crimping machine.

Important when using a crimp force monitoring system: crimping machine and crimping tool must be 100%
OK!
EV
Crimping tools that are rough-running or worn, or have too much play in the guide areas, are not suitable for use with
a crimp force monitoring system. Of course, the same also applies to crimping machines. A check is only meaningful
if the GOOD/BAD tolerance window can be set small enough, for example, to detect missing individual wire strands
via the force measurement.

Conclusion: The use of crimp force monitoring systems is ALWAYS associated with additional maintenance!
PR

Top tool fixture of a RAM crimp force monitoring system (by Komax)

© KabelForum.com - Principles of Crimping Technology 258

 Fully automatic crimping machine
(by Komax)

Cutting to length, stripping and crimping are performed fully au-

tomatically at both ends of the wire.

In addition, a wide variety of options are available for pro-

cessing the end of the wire (tinning, ultrasonic welding, double
crimping, etc.).

Alpha series

EW
Fully automatic crimping machine - transfer lines
(by Komax)

In addition to the individual processing and assembly of the

wire ends, complex cable harnesses can be assembled fully
automatically on transfer lines.

Zeta series
As with all modern fully automatic crimping machines, individual modifications and changes to the wire harness can be
implemented by replacing individual modules. In this way, even wire harnesses with a customer-specific variety of
versions can be manufactured effortlessly.

6.3 STRUCTURE OF A CRIMPING MACHINE

I (1) Receptacle for the contact coil
EV
(2) Drive motor
(3) Eccentric
(4) Guide
(5) Ram (fixture for the crimping tool pressure block)
(6) Bottom tool fixture with quick clamping device for the crimping tool
(7) Guide plate for the crimp contacts

Important: The bottom tool fixture (6) of the crimping machine and the
base plate (C) of the crimping tool must be flat and undamaged. When
inserting the crimping tool into the crimping machine, it is essential to
ensure that there are no residues from cut-off tabs, wires strands or insulation
PR

materials between the surfaces of the bottom tool holder (6) and the tool base
plate (C).

Especially when using crimp force monitoring, damage to the bottom tool fixture
(6) and the tool base plate (C) lead to incorrect measurements. As a result,
higher tolerances must be set, which makes the detection of errors (e.g. missing
individual strands) only possible to a more limited extent.

© KabelForum.com – Principles of Crimping Technology 278

 6.4 THE STRIPPER-CRIMPER (OPEN CRIMP BARREL)
6.4.1 BASICS AND PHILOSOPHY

Stripper-Crimper KM3011
Manufacturer: AAC / KMI
(A) Crimping tool
(B) Stripping unit

With the Stripper-Crimper, the stripping and crimping process is

carried out in one work cycle. The advantage: Optimal positioning
of the stripped wire in the crimp contact. Particularly with smaller
nominal cross-sections, manual insertion and positioning of the
stripped wire is subject to errors. These errors are virtually elimi-

EW
nated by using stripper crimpers. Of course, an optimal adjust-
ment of the individual components of the machine is important for
this purpose.

Stripper-Crimpers are mainly used when the ends of the wire

cannot be processed on fully automatic machines (e.g. multi-core
sheathed cables) or for small quantities.

Stripper crimpers should always be used when the nominal

cross-section is smaller than 0.5 mm². In this cross-section
range, the crimp contacts are small, which makes correct, man-
ual insertion of the stripped wire considerably more difficult. (Po-
I sition of the wire in the crimp contact.)
EV
6.4.1 STRIPPER -CRIMPER : THE FUNCTIONAL UNITS

Stripper-crimpers are available in various designs.

The schematic sequence shown here illustrates and
describes the basic processes, irrespective of the
technical design.

In general, the stripper crimper consists of 3 compo-

nents:

(A) Gripper unit

PR

(B) Stripping unit

(C) Crimping applicator

(1) Gripper (2) Movable stripping blade (3) Fixed

stripping blade (4) Sensor holder with sensor and
spring plate (5) Anvil (6) Wire crimp (7) Insulation
crimp

© KabelForum.com – Principles of Crimping Technology 285

 7.1.2 CRIMP APPLICATOR : DEFINITIONS

Endfeed Crimp Applicator

(A) Tool body

(B) Identification label
(1) Tool base plate
(2) Tool table
I (4) Shear unit
(5) Contact guide
(6) Feed finger EW
(3) Wearing parts kit (7) Contact brake
(8) Ram (top tool fixture)
(9) Adjustment: Feed stroke
(10) Adjustment: Feed position
EV
Sidefeed Crimp Applicator
PR

© KabelForum.com – Principles of Crimping Technology 315

 7.2.1 REFERENCES IN THE SIDEFEED CRIMP APPLICATOR

The ram (1) is guided in the base body (2) of

the crimping tool. It must move easily and
without play.

EW
The surface (A) on the ram (1) is the reference sur-
face for all assemblies in the crimping tool.

If a crimping tool is set up, all parts are positioned

I and fixed in relation to this reference surface.
EV
Step 1
PR

The wearing parts kit (3) with wire crimper, spacer

plate, insulation crimper, spacer ring and the pres-
sure piece.

Step 2

The anvil (4) with the shear unit for separating the
crimp contacts from the carrier strip.

© KabelForum.com – Principles of Crimping Technology 379

 8.4.4 WIRE STRIPPER WITH STRAIGHT BLADES

When stripping with standard hand strippers, mailnly straight

stripping blades are used.

The disadvantage:
A large part of the insulation must be torn off when pulling off
the insulation residue after cutting (red hatched area). This re-
sults in an unclean cut edge of the stripped insulation.

This can lead to the insulation in the wire crimp area being crimped during the subse-
quent crimping process or to the insulation crimp not being able to fully capture the in-
sulation!

I Cutting in the
Insulation

EW Pulling off the insulation residue

Error: (1) No
clean cut due to
straight and worn
EV
straight cutting
blades in a wire
stripper.

Error: Uncleanly cut, frayed insulation

Error: Insulation thread in wire crimp area!

PR

Improperly cut insulation (A), in addition to the visible

damage to individual wire strands, causes the uncut
insulation to be pulled. These "insulation threads" (B)
are crimped to the conductor in the wire crimping
area.

The effects are poorer electrical properties. The con-

tact resistance is increased and, at higher currents,
this also results in higher heat generation.

Important: Convert your hand strippers to V-

stripping blades or use alternative hand strip-
pers adapted to the geometric shape of the
wire!

© KabelForum.com – Principles of Crimping Technology 459

 9.15 WORKING WITH HAND CRIMP TOOLS – OPEN CRIMP BARRELL

The crimping result decides whether your hand crimping pliers are suitable for your application!

Every new hand crimping tool can be verified by checking the crimp connections made with it.

Important: If the crimp connections are OK, then the hand crimping pliers are also OK.
By constantly checking the crimp quality, the quality and condition of the hand crimper are checked at the same
time with each crimp. With a brand product, many thousands of good crimp connections can be made. Of course,
it is important that the tool is handled with care, which should really be a self-evident fact.

9.15.1 POSITIONING CRIMP CONTACTS – INSERTION DEPTH

W
A correctly mounted positioning aid matched to the crimp contact is abso-
lutely essential for creating a good crimp connection with hand crimping
pliers.

Crimp contact position OK!

The rear bellmouth (1) prevents a predeter-

mined breaking point between the solid
IE
EV
crimped stranded conductor and the flexible
area of the wire.

Important: The smaller the crimp

contact, the smaller the runouts, the
more precise the positioning in the crimping
tool must be.

With a cross-section of 0.50 mm², the Cross-section

rear bellmouth (1) must be 0.40 mm mm² AWG Length Tolerance
PR

long. The size of the bellmouth de- 0.03 - 0.56 mm² AWG 32-20 0.25 mm +/- 0.15
pends on how the crimp contact is po- 0.30 - 0.81 mm² AWG 22-18 0.25 mm +/- 0.15
sitioned in the die of the hand crimping 0.50 - 2.50 mm² 0.40 mm +/- 0.20
tool. 2.50 - 6.00 mm² 0.60 mm +/- 0.30

© KabelForum.com – Principles of Crimping Technology 491

 9.21 WORK INSTRUCTIONS: CREATING A CRIMP CONNECTION

9.21.1 DETERMINING THE STRIPPING LENGTH

The stripping length is included in the specification of the crimp contact. If the stripping length is not specified, the correct
stripping length must be determined.

Calculation:

(1) Length of the wire crimping area (e.g.): 5.0 mm 5.0 mm

(2) Distance between wire and insulation crimp: + 1.0 mm
(e.g.) 2.0 mm : 2 = 1 mm.
(3) Conductor protrusion (0.1 to max. 0.5 mm) + 0.2 mm

W
Stripping length: = 6.2 mm

IE
The stripping length (1) is correct if:
(A) Insulation and conductor are visible between the insulation crimp (4) and the
wire crimp (5).
(B) A conductor protrusion is visible behind the wire crimp. (0.1 to max. 0.5 mm)
EV
9.21.2 STANDARD STRIPPING PLIERS

Note: Minimum requirement for hand strippers is the use of V-shaped blades!

Set the stripping length.

(A) Move the stop (a1) until the stripping length (a2) corresponds to the specifications for
the crimp connection.

(B) Insert the wire straight into the stripper.

Push the end of the wire onto the stop (a1) and close the
PR

stripper completely.

(C) Check stripping length

Insert the stripped wire into the crimp contact. Check the po-
sitions according to the crimp contact type. If necessary, correct the stop (a1).

Check:
• Wire crimp completely filled?
• Position end of stripped conductor = ok?
• Position cut edge of insulation = ok?

© KabelForum.com – Principles of Crimping Technology 504

 10. CLOSED CRIMP BARRELS

10.1 TYPES AND CRIMP SHAPES

Indent Crimp 0.75 to 300 mm²

-Tubular cable lugs + connectors (standard version)
-Ring type terminal ends for solderless connections, without insu-
lating sleeve, (acc. to DIN 46234)
-Pin type terminal ends for solderless connections, without insulat-
ing sleeve, (DIN 46230)
-Insulated cable lugs

EW
-Tubular cable lugs + connectors for fine-stranded conductors
-Compression cable lugs + connectors, AL compression cable lug

Double Indent Crimp

0.5 to 16 mm²
Tubular cable lugs + connectors (standard version - VDE 0220)

"WM" Crimp shape

6 to 240 mm²
Tubular cable lugs + connectors
(acc.to VDE 0220, fine stranded conductors IEC 60228)
I
EV
Square crimp shape
0.1 - 25 mm²
Machined contacts

Square crimp shape

Wire-end ferrules + twin wire-end ferrules
0.14 to 16 mm²
PR

Trapezoid crimp shape

Wire-end ferrules + twin wire-end ferrules Insulated ferrule
0.14 to 240 mm²

Trapezoid special crimp shape

10 to 240 mm² Twin Ferrule
Crimping of ferrules with thinned ("compacted") fine stranded con-
ductors (IEC 60228).

Hexagonal crimp shape

Space-saving crimp shape that can produce optimum contact in Uninsulated ferrule
narrow, round terminal blocks with the same cross-section com-
pared to square crimps.

© KabelForum.com – Principles of Crimping Technology 509

 11. WIRE END FERRULES

11.1 BASICS

The standard for the processing of ferrules is IEC 46228 (= DIN 46228).

Wire end ferrules are used as a joining aid when assembling the ends of the wire
(in screw terminals), to protect the individual wire of the conductor and for good
contacting in the spring terminal strip.

Wire end ferrule and clamp connections - Yes or no?

EW
A question that is always an issue in everyday practice.
Standards & clamp connections: As in many areas of crimping technology, you can only find statements for the use of
ferrules that leave some room for interpretation. Standards should essentially be there to provide a clear statement about
the "how to"! Statements around clamping technology like: "The connection must be durable and safe" are not really
helpful. So, connections are made because "it has always been done that way" or according to the principle "hope: it
should work".

Only damage caused by problems of connection variants lea ds to

normative prohibitions. A good example of this is the soldered
stranded compound, which, when fixed in a screw terminal, inevita-
bly leads to the failure of the connection! ( see also: cold flow). This
connection combination, soldering as a substitute for ferrules in
I
screw terminals, is no longer permitted by the VDE 0100 -520 stand-
ard.
EV
When planning and implementing a connection via a terminal block,
Defective mains plug caused by a
it is always important to consult the manufacturer's data sheet. In it,
soldered stranded conductor!
you will find the necessary information about the properties and the
Quelle: https://de.wikipedia.org/wiki/Kabelbrand
correct design of the connection. And in case of doubt? Simply ask
the manufacturer! The prerequisite here is, of course, that you also
find or have a competent contact person.

A rule or even a mandatory use of ferrules is not to be found in the

known standards. The standard EN60999-1 / VDE 0609 defines all
screw connections and also screwless clamp connections (only for
PR

copper conductors). In this standard, one finds the information that

all mechanical clamp connections, regardless of the clamping prin-
ciple, must be designed by the manufacturers in such a way that all
"unprepared" conductors can be safely connected without "pre -treat-
ment". This applies to the entire variety of conductors offered, from
solid one-stranded conductors to flexible fine-stranded wires.
Spring-cage connection from Phoenix
"Unprepared" or "without pretreatment" means: cutting, stripping Contact
and mounting the conductor directly in the clamp connection. If a Left w/o, Right with a ferrule
ferrule is crimped onto the stripped conductor beforehand, it is th en
"prepared" or "pretreated". The standard for terminal blocks (IEC
60947-7-1) states: A manufacturer of a terminal connection must
specify a "pre-treatment" of the conductor if this is relevant and
therefore important for a safe connection in the termina l.

Screw terminal - operating principle

© KabelForum.com – Principles of Crimping Technology 511

 12. TURNED CONTACTS – 4/8-INDENT C RIMP

12.1 GENERAL

Turned (or machined) contacts are used in power and control lines in multi-pole
plug connections. A classic turned contact is found, for example, in mains plugs
via which a toaster or a coffee machine draws its current.

Turned contacts are machined from solid rod and are always the “closed barrel”
type, meaning that the area where the wire will be inserted forms an unbroken,
360 degree cylinder.

EW
Fig.: Turned contacts. Left: socket. Right: contact pin. (Source: Amphenol-Tuchel
Electronics)

They come in different shapes and sizes and are primarily used where quality requirements are very high, such as in the
military, aerospace and medical markets. Applications for the machined contacts range from computer interface connec-
tions to flexible production lines in the automotive industry.

Turned contacts are characterized by special processing criteria:

• Consistent crimp quality guarantees constant contact resistance.
• High corrosion resistance due to quasi cold welding.
• Processing of different conductor cross-sections can be realized with only one contact type.
I
Turned contacts are mostly processed in a closed frame crimp tool with 4 indenters that leave an 8-indent impression (4
or 8 dents) in the crimp area. To make it easier, we will subsequently call it “4-indent crimp”.
EV
When processed in a tool with open frame, it’s generally a square crimp shape, sometimes a square shape with two
additional indents or (much rarer) a B-crimp shape.

12.2 CONTACT SHAPE

(A) The insulation fixation serves as relief for the wire crimp area.
Turned crimp contacts are available with and without insulation fix-
ation.
(B) The heart of the crimp connection, the wire crimping area.
(C) The contact area is designed according to the application. Basi-
cally, in a connection of crimp contacts, one is designed as a (male)
PR

pin contact and the mating connector as a (female) contact socket.

Important for crimp connections without insulation support(A): The

crimp connection must be structurally protected against mechanical
loads via the connector housing and/or the device housing directly after
the connector housing. In the connector housing, this can be done by means of
strain relief, in control cabinets or other component housings by means of
appropriate fixation of the wires, e.g. by means of cable ties.

© KabelForum.com – Principles of Crimping Technology 526

 13. INSULATED CABLE LUGS

13.1 PROCESSING METHODS

(1) Partially insulated crimp cable lug

(2) Fully insulated crimp cable lug
(3) Partially insulated crimp cable lugs on strip (taped)

EW
Crimped partially insulated crimp cable
lug

13.2 HAND CRIMP TOOLS AND DIE SETS

The individual contacts are processed with special hand
crimping pliers.

Picture left: Dies in a hand crimping tool for processing

I partially or fully insulated crimping cable lugs.
EV

Contour of the crimp die in the area of the insulation crimp for
insulated crimp contacts with insulation fixation.
PR

13.3 CRIMP APPLICATORS

Fig. right:
Crimp applicator for taped pre-insulated crimp terminals for use with
standard crimping machines or fully automatic crimping machines.

© KabelForum.com – Principles of Crimping Technology 542

 15. SPLICE TECHNOLOGY
Like many areas in wire processing and crimping technology, splice technol-
ogy (or splicing) is not regulated by standards. Splice technology is based
on the standard (DIN EN 60352) for the processing of open crimp ferrules.
15.1 GENERAL INFORMATION
The splice technology is the name for an alternative special form in crimp
technology.
Important: Splice technology is not defined by standards! The quality
specifications and test methods for splice connections are derived
from the standards and applicable manufacturing standards for the open
crimp barrel and are supplemented by individual, company-specific manu-

W
facturing specifications. Depending on the application and field of use of the splice connection, quality requirements
may change or suboptimal connections may be tolerated via special approvals.
The main differences compared to conventional processing of open crimp barrels:
• The crimp contact is cut out of a material strip without waste, preformed and then crimped.
• A splice connection does not have an insulation crimp.
• The width of the spliceband determines the length of the wire crimp area.
• The cross-section range is typically between 0.05 and 6 mm².
•

15.2
IE
Due to the design of the splice machine, it is possible to process very short connections (wire lengths).

THE SPLICE MACHINE

EV
PR

The design of the splice machine offers a operating range (A) in which very short
connections can be processed. This is the great advantage of the splice technology
with which electrical components can be connected with stranded conductors.
Fig. left: The very short connection of this coil can be optimally connected to the
stripped stranded conductor with a splice machine. With classic crimping applicators
and the use of open crimp barrels, such short connections simply couldn’t be realized.

© KabelForum.com – Principles of Crimping Technology 574

 16. ASSEMBLY – DISASSEMBLY OF CRIMP CONTACTS

16.1 INSTALLING WIRES

Min. bending radius R = 2 X cable diameter

I EW
Important: Do NOT bend wires directly after the crimping area. The rule of thumb for bending radii when laying
wires: 2 X the diameter of the wire = the smallest permissible bending radius.
EV
Important: The wire must NOT be:
1. be bent narrower than the bending radius. The single wires inside (2) are compressed, while the single wires
outside (1) are stretched and break off.

2. be routed around sharp-edged corners (3). In addition to tearing off individual

wires (see 1), there is a risk here that the insulation may be worn through due to
vibration, for example (4). Use cable ducts, corrugated tubes, edge protectors,
etc. to protect the wire when drilling holes!
PR

To avoid damage to the wires, do NOT mechanically clamp them between

fixed structural, body or housing parts during installation!

© KabelForum.com – Principles of Crimping Technology 589

 17. CRIMPING TECHNOLOGY – PROCEDURAL INFORMATION

17.1 FOREWORD & NOTES

The processing of open crimp ferrules is defined by DIN EN 60352-2. However, these specifications are very general and
define only a relatively small part of the current standard in crimping technology. These insufficient definitions in the standard
lead to discussions time and again, especially in the case of crimp connection failures or claims. The fact is: crimp connec-
tions that "only" meet the requirements of DIN EN 60352-2 are very often not up to the actual, real requirements in today's
practice.

Today's standards are defined by the very detailed factory standards of the major industrial sectors. The specifications are

EW
described down to the smallest detail in accordance with the subsequent area of application of the crimp connection. Ad-
vantage: Behind all these additional specifications to the DIN EN standard, there is always a technical justification. Resulting
from experience and failures from the past. The quality and therefore also the durability of the crimp connection is thus
constantly increased and improved many times over in comparison to the "DIN EN standard".

The present processing information forms the basis for the evaluation of crimp connections by Kabelforum and can also be
the basis for an internal company standard or a supplier specification. This processing information can also be used as a
validation procedure for crimping tools.

Please note that the processing specifications of your customer are primarily decisive for your production and testing. In
case of doubt, you should have a discussion with your customer and clarify the corresponding quality specifications.

In addition to the standards, you can expand your quality specifications as you wish within the framework described here.
I
This depends on your company's understanding of quality and, of course, on your willingness to invest. Fully automatic
machines, with the appropriate monitoring modules, deliver the best quality, but also at a considerable price. Ultimately, the
application decides which quality specifications are mandatory.
EV
Important: A factory standard or supplier specification always covers 2 basic areas:
• General quality specifications for cable processing and crimping technology.
This defines the basic specifications around wire processing and crimp connections.
• Application-specific quality specifications.
Depending on the crimp connection, specifications deviating from the standard are defined. In most cases,
this concerns the micrograph evaluation and can lead to a special release in the case of suboptimal crimp
connections.

Important: Depending on the application of the crimp connection, quality specifications may change. This is espe-
PR

cially true if the assignments of the nominal cross-section of the wire to the crimp contact do not fit. In this case, the
possible mechanical and electrical load on the crimp connection in use determines which compromises in quality
are possible.

Important: The procedures and rules of this documentation also apply to the use of hand tools. Even if suboptimal
quality is to be expected as a result of the use of these tools.
If the work steps performed with hand tools do not meet the required quality specifications, they must not
be used!

These processing guidelines are a collection of information from standards (including factory standards), processing
specifications or the result of practical tests and empirical values and do not claim to be complete. All information is
without guarantee and does not relieve the user of his own responsibility and duty of care with regard to his appli-
cations! The technical background for the individual specifications can be found in the corresponding chapters in
the reference book: "Fundamentals of Crimping Technology".

© KabelForum.com – Principles of Crimping Technology 604