For any wiring repair or electrical wiring repairer, knowing the exact terminology is a basic requirement of professionalism. When a beginner asks what the wire clip is called, the experienced electrician will answer that the correct term is: crimper or clamp-tick. It is these tools that provide a reliable connection of the vein to the tip, ensuring that there is no heating and sparking in the future.
However, in a professional environment, you can hear other names, depending on the type of work performed and the design of the mechanism itself. A hydraulic press, mechanical clamp or simply “cracking” are all variations of the same device adapted for different cable sections. Understanding the difference between them will allow you not only to communicate competently with suppliers, but also to choose a really effective tool for a specific task.
In this article we will discuss in detail the classification of equipment, the technical features of various models and the criteria by which the tool for working with copper and aluminum is chosen. You'll find out why European standards We need a matrix, and for American It is completely different, and how to avoid a fatal mistake when buying.
Main types of tools: from crimpers to hydraulics
The main representative of the family of crimping tools is a handheld crimper. This is a compact device resembling a passage, but having a special shape of sponges (matrixes) to form a tight contact. Hand-held models are ideal for working with wires up to 10 mm2 and are often used in automotive electricians or assembling shield equipment.
For more serious tasks, where a force of several tons is required, hydraulic presses. They can be manual (with a pump) or battery, which greatly facilitates the work of the installer. Hydraulics provide uniform compression on all sides, creating a monolithic connection that cannot be achieved by conventional mites.
- 🔧 Mechanical ticks - the simplest option for one-time work, often without a rattling mechanism.
- ⚡ Crimpers with ratchet - equipped with a locking of the press until the complete completion of the cycle, which guarantees quality.
- 🚜 Hydraulic tool It is used for large-sized cables (16 mm2 and above) in the industrial sector.
- 🔋 Battery presses – Mobile solutions for large installation volumes at height or in hard-to-reach places.
The choice of a specific type depends on the frequency of use and the scope of work. If you need to occasionally squeeze a couple of wires in the garage, a high-quality hand-held crimper is enough. For daily professional operation in facilities, it is better to invest in a battery model or reliable hydraulics.
Design and operation of crimping ticks
Regardless of what the crimping for wires in the store catalog is called, the principle of its operation is based on the deformation of the metal sleeve or tip around the conductive vein. The key element of the design is matrix (or sponges) that have a profile corresponding to the shape of the connector. They are the ones that give the right form to the contact.
The most important component of modern hand-held crimper is ratchet (claps) It prevents the sponges from being pressed until maximum compression force is achieved. This eliminates the human factor: the wizard will not be able to unclutch the tool prematurely, which guarantees the perfect crimping geometry.
⚠️ Warning: Attempting to break down quality ticks with a rattle before the cycle is completed can lead to breakdown of the mechanism. If you made a mistake with the size of the tip, press the handle until the characteristic click of unlock.
Professional models are often equipped with regulator Or replaceable heads. This allows you to adapt the same tool to different types of insulation and metals. For example, soft copper requires less effort than hard aluminum or steel.
When buying a crimper, be sure to check the presence of a clamping pen in the closed position. This makes it easier to store the tool and prevents accidental injury in the bag.
Types of matrices and compatibility with tips
One of the most common problems when choosing a tool is the incompatibility of matrices with the tips used. There are two main profiling standards: hexagonal (hexagonal) and bladed (indent) The hexagonal matrix compresses the sleeve from all sides, ensuring a uniform pressure distribution, which is critical for large cross sections.
The blade matrices form characteristic dents (blades) on two or four sides. This method is more commonly used for type tips Nshwi (for multi-core wires) or car terminals. Using an inappropriate matrix can cause the wire to be pulled out of contact even under a slight strain.
| Type of matrix | Application | Advantages | Limitations |
|---|---|---|---|
| Hexagonal | GML shells, TMM tips | Uniform cleavage, high reliability | It requires precise size selection. |
| The bladed (Indent) | Clemma, NSHVI, connectors | Universality, compactness | Less contact area |
| Oval. | Scrolling (casing) connection | Keeps the round section of the beam | Less reliable for tyre lines |
| Tortoral | Ending of multi-lives | Comfort of shielding | Only for specific types |
When working with aluminum-headed It is necessary to use matrices specifically designed for this metal, since aluminum has a high fluidity and requires a specific compression profile to prevent weakening of contact with time.
Specificity of automotive and industrial crimping
In automotive electricians, the connection requirements are much higher due to constant vibration, temperature changes and humidity. Specialized services are most often used here. car-crimpers plug-in DJ, AMP, Molex. They have a complex sponge shape that simultaneously clamps the contact and bends the “ears” to fix the insulation.
The industrial sector dictates its own rules, where speed and large cross-sections are the priority. Here, manual labor is replaced by manual labor. hydraulic heads electric-powered. They allow you to perform hundreds of cycles of crimping per shift without operator fatigue, which is critical when laying cable tracks.
☑️ Checking crimping readiness
It is important to note that car terminals often require interchangeable matrices, as each connector manufacturer (whether or not they are a part of the car) Bosch, Denso or Yazaki) may use its standards for contact form. Universal mites here work worse than specialized ones.
Technology of correct crimping: step-by-step algorithm
The quality of the connection depends not only on the tool, but also on the adherence to the technology. The first step should always be to clean the wire. The length of the insulation removal shall correspond exactly to the length of the tip tail. If you clean too little, the contact will be bad; if too much, the bare part will stick out, creating the risk of short circuit.
Then there is the step of inserting the wire into the tip. The veins should be straightened and tightly inserted to the point. Pressure is made by moving the handles of the tool until the rattle is triggered. In the case of hydraulics, it is necessary to monitor the pressure and not exceed the recommended standards, so as not to deform the tip itself.
⚠️ Attention: It is strictly forbidden to use conventional pliers or hammer for squeezing power tips. Such a compound will have a high transient resistance, which will lead to heating and possible fire.
After the cycle is completed, it is recommended to conduct a visual inspection and, if possible, a test for pulling force (for critical joints). A properly compressed wire should not be turned inside the sleeve.
What to do if the cleavage is weak?
If you used a tool without a rattle and realized that the force was insufficient, in no case do not try to press the connection again in the same place - this will violate the structure of the metal. The only right solution is to cut the tip and use a new one. Repeated crimping is unacceptable for lines of force.
Frequent errors in selection and operation
One of the biggest mistakes is to buy a cheap tool made of “silumin” or soft steel. Such crimpers quickly lose the geometry of sponges, begin to luft and eventually spoil expensive materials. Savings on the tool in electrical installation is unacceptable.
The second common mistake is ignoring the wire material. Attempt to squeeze a polycore wire with a matrix for a monovela (or vice versa) will lead to damage to the veins or poor-quality contact. Always pay attention to the marking of the tool: it indicates the ranges of sections and types of wires.
- ❌ The use of rusty or dirty matrices leaves burrs in contact.
- ❌ Crushing over the insulation - unless it is provided by the design of the terminal.
- ❌ The use of WD-40 to lubricate the mechanism - washes out the factory lubricant and collects dust.
- ❌ Storing the tool in the open form - leads to loosening of the axes.
Regular tool maintenance, oxide matrices cleaning and dry storage will extend the life of your equipment for years. Remember that a good crimp is the key to the security of the entire electrical network.
Investing in a quality branded Crimper (e.g. Knipex, Weidmüller, IEK Professional) pays off with no emergencies and no complaints from customers in the future.
Can you squeeze the tips with ordinary passages?
Technically, you can insert and compress, but the reliability of such a connection will be extremely low. Passengers do not create uniform pressure on all sides, which leads to the appearance of voids inside the sleeve. Over time, contact will weaken, start to warm up and can cause a fire. For temporary repairs on the knee - perhaps, but not for permanent use.
What is the difference between a crimper and a clamping tick?
They're synonymous. However, the term “crimper” is more often applied to a professional instrument with precise matrices and a ratchet mechanism. “Crushing mites” is a more general household name, which can imply simple mechanical clamps without calibrating the force.
Do I need a special tool for aluminum wires?
Yes, preferably. Aluminum is a soft and fluid metal. There are special matrices with a high compression ratio for it and the use of quartz-vaseline paste is often required to prevent oxidation. It is possible to squeeze aluminum tips with copper matrices, but with caution, controlling the force.
How do you know if the matrices are worn out?
Signs of wear: the appearance of burrs on the clamped shells, loose fit of the sponges in a closed state, the appearance of backlash in the hinge, the need to apply excessive force to trigger the rattle. If the working surface of the matrices shows deep workings from the tips, it is time to change the tool.