In the process of crimping, there are several common mistakes that need to be avoided to ensure a secure and reliable connection:
1. Using the Wrong Crimping Tool or Die: Selecting the incorrect crimping tool or die that doesn't match the terminal or wire specification can lead to improper crimps. Always use the correct tool and die as recommended by the manufacturer .
2. Incorrect Crimping Pressure: Applying too much or too little pressure can result in over-crimping or under-crimping, respectively. Both can compromise the connection. Use a calibrated crimping tool with a pressure gauge to ensure the correct amount of pressure is applied .
3. Poor Wire Preparation: Stripping the wire incorrectly, leaving too much or too little insulation, or not aligning the wire properly before crimping can lead to poor connections. Always prepare the wire correctly and ensure it's the right length for the terminal .
4. Not Using the Correct Termina: Using a terminal that is not designed for the wire gauge or type can result in a weak connection. Always use terminals that are compatible with the wire you are using .
5. Improper Crimp Height: The height of the crimp should be within the specified range. Abrasion or looseness in the crimping tool can lead to discrepancies in crimp height .
6. Gap Between Barrel and Insulation: A gap can result from abrasion of the crimping tool or using an incorrect wire, leading to an improperly crimped wire .
7.Partial Insertion of Conductor: If the conductor is not fully inserted into the barrel, or if the insulated cover of the wire is inserted, it can result in a faulty crimp .
8. Damaged Insulation: The crimping process should not damage the cable insulation. Look for pressure marks or other signs of damage after crimping .
9. Bent Crimp Flanks: The crimp flanks must properly enclose the cable without bending, otherwise the crimping or insulation fixing will be defective .
10. Torn Individual Wires: During crimping, individual wires should not break off or be cut or torn at the exit from the insulation .
11. Twist Angle Too Large: The crimp area should not be twisted excessively relative to the contact body of the plug connector; the maximum permissible angle is typically no more than 10° .
12. Resoldering the Crimping Point: Soldering a crimp connection afterward is a common mistake. The heat can damage the cable insulation and affect the contact material, potentially leading to corrosion and electrical insulation issues .
To avoid these errors, always follow the manufacturer's guidelines, use the correct tools and dies, prepare wires properly, and inspect crimps visually and with the appropriate measurement tools after crimping. Regular maintenance and calibration of crimping tools are also essential to ensure consistent, high-quality crimps .
