High-quality connection of electric circuits is the foundation of safety and reliability of any system, whether it is a complex on-board network of a modern car or stationary wiring. Pressure It is considered one of the most reliable methods for long-lasting contact with low transient resistance, which is critical to prevent overheating and fires.
To perform this operation, a specialized tool is needed that allows you to create a non-separable connection with specified mechanical characteristics. The market offers a wide range of solutions, from simple hand-held models to hydraulic systems, and the choice of the right one. crimper It directly affects the quality of the final result.
Understanding the working principles and technical features of various types of crimping devices avoids common errors such as underweight or damage to the vein. In this article, we will discuss in detail what tools are necessary for professional work with the cable and tips.
Classification of crimping tool
All tools for working with cable products can be divided into several main categories depending on the type of drive and application. The simplest hand-held models, often called ticks, are designed to work with the small-section soft materials, where the operator's effort is sufficient to form a high-quality crimping.
More complex mechanical systems are equipped with a ratchet mechanism that prevents the sponges from being unclutched until the full pressing cycle is complete. This eliminates the human factor and ensures that shell-slip will occur strictly according to the specified profile of the matrix, providing the necessary contact density.
- 🔧 Hand mites for single small diameter tips
- 🔩 Mechanized Crimperes with a ratchet for serial work
- ⚡ Hydraulic presses for thick-walled copper and aluminum veins
- 🛠️ Universal sets with interchangeable matrices
To work with high-voltage Hydraulic presses are often used in the automotive industry in lines or thick power cables. They can be manual (with a pump) or electrified, allowing for the several tons of force required to deform thick-walled surfaces. case copper or aluminum.
Design features of the Crimperes
The key element of any crimping device is the matrix that directly forms the connection profile. Matrixes can be built into the tool body or removable, allowing the use of one mechanism to work with different sizes of tips.
The compression profile is different: to the point, to the hex (hex) or to the rental. For electrician The most common matrices forming local indentations, as they provide a reliable connection without excessive thinning of the sleeve walls. hexagonal Circumcision is more often used for lines of force, where uniformity of pressure from all sides is important.
⚠️ Note: Using an inappropriate profile matrix for a particular type of tip may lead to insulator failure or insufficient contact density, causing sparkling.
Ergonomics of handles also plays an important role, especially with a large amount of work. Modern models are equipped spring-driven return and anti-slip linings, which reduces the fatigue of the hands of the master. The quality of the metal from which the tool is made determines its resource and ability to maintain sponge geometry after thousands of compression cycles.
Why is the snoring mechanism important?
The cranking mechanism (rattle) blocks the reverse movement of the sponges until the complete closure of the matrix is achieved. This prevents the operator from pressing the ticks, unclutching them, leaving the tip in a weak, unreliable state. For beginners and professionals, this is a guarantee of stable quality of each connection without the need for constant visual control of effort.
Matrices and sizes selection
The correct choice of the matrix depends not only on the cross-section of the wire, but also on the type of tip used. Tube-shaped The tips require one type of compression, and the bushings require another. An error in selection can lead to the conductor being pulled from the sleeve with minimal mechanical impact.
The automotive industry is often used bush-up tips (NSHVI), for which special square matrices are designed. They squeeze the sleeve from four sides, tightly pressing the veins against the walls, which is especially important in conditions of constant vibration engine and running gear.
For power connections, for example, when connecting a starter or generator, copper tin tips of the TML type are used. It is critically important to use hexagonal matrices corresponding to the diameter of the tailing to ensure maximum contact area and minimize resistance.
- 📏 Matrixes for bushing tips (square profile)
- 🔌 Matrixes for terminals and connectors (profile to point)
- 🔋 Hexagonal matrices for power shells
- 📐 Adjustable stops for accurate positioning
Some advanced tools have stop-pointThis allows you to position the wire in the matrix. This eliminates the possibility of displacement of the crimping point, which is especially important when working with short tails or in hard-to-reach places of the hood space.
Technology of performing pressing
The process of creating a high-quality connection begins with the preparation of the vein. The insulation shall be removed to a length corresponding to the depth of landing in tipwithout damaging the copper veins themselves. Excessive cleansing can lead to oxidation of the open part of the conductor inside the sleeve.
The next step is to choose the right one. tool and setting up the matrix. The wire is inserted into the sleeve to the point, after which the crimping is made. It is important to observe the compression sequence if a multi-profile matrix is used: first the part closest to the shoulder blade is squeezed, then the remaining segments are squeezed.
☑️ The algorithm of correct repressing
After the mechanical action is completed, it is recommended that a visual inspection and, if possible, a burst force check be carried out. Quality The crimping should not have cracks on the metal of the sleeve, and the wire should not be turned inside it. For additional protection against corrosion, the entry point of the wire into the sleeve is often treated conductive Or shrinkage.
⚠️ Attention: It is strictly forbidden to use conventional pliers or hammer for pressing power tips. This does not provide uniform pressure and leads to microcracks in the metal, which will lead to heating over time.
Comparison of hand and hydraulic tools
The choice between hand tools and hydraulic tools depends on the scope of work and cross-section of the cables being processed. Hand-held crimpers are compact, lightweight and ideal for working with wires up to 10-16 mm2, covering 90% of tasks in the field. electrician.
A hydraulic tool is necessary when working with sections from 25 mm2 and above. It allows you to create an effort that is not available to human muscles, providing a monolithic connection even for the human body. aluminum veins that require a greater degree of deformation for reliable contact.
| Parameter | Hand-held crimper | Hydraulic press | Electrohydraulics |
|---|---|---|---|
| Max. cross-section (copper) | up to 16 mm2 | up to 300 mm2 | up to 400 mm2 |
| Effort. | Depends on the operator. | Up to 6 tons | Up to 10 tons. |
| Speed of operation | High (small sections) | Medium | Tall. |
| Weight. | Light (300-500g) | Heavy (3-5 kg) | Medium (with battery) |
For stationary workshops specializing in the repair of freight transport or special equipment, the availability of hydraulic The press is mandatory. At the same time, for mobile car electricians compact mechanically Crimper will be the optimal solution, taking up a minimum of space in the case.
When working with aluminum wires, be sure to use quartz vaseline paste to remove the oxide film before pressing, even if the tip is tinted.
Tool care and maintenance
The pressing tool requires regular maintenance to maintain accuracy. Periodic cleaning of sponges from metal dust and lubrication hinged The joints prevent jamming and wear. The cranking mechanism also needs to be cleaned of contaminants that can disrupt its operation.
Store the crimper should be in a dry place, preferably in the factory case, to avoid corrosion and mechanical damage to the matrices. Tempered steel The sponge is hard but fragile, so falling the tool on a hard surface can lead to chipping, which will spoil the crimping profile.
Regular calibration checks are an important part of professional equipment maintenance. If you notice that the tool requires excessive effort or, conversely, does not press the sleeve to the end, it may be necessary to regulation Or replace worn-out parts. In the conditions of intensive operation in the car service, the tool may need to be replaced every few years.
- 🧼 Regularly clean the working surfaces from shavings
- 🛢️ Lubricate the moving parts with light engine oil
- 📦 Keep it in a protective case in the hut.