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Professional conductor crimping

Mechanical joining of the contact and conductor

Crimping describes the mechanical joining of the contact and conductor.

In addition to crimping, two further terms are used, based on standards. The type of deformation plays a decisive role here. Based on the type of contact, a distinction is made between:

  • Squeezing, for insulated cable lugs.
  • Pressing, for ferrules, uninsulated cable lugs, turned contacts, and similar closed connectors.

When processing spade connectors, for example, this is called crimping. In order to establish a reliable connection between the contact and conductor, a number of important points must be considered:

  • The conductor must be prepared correctly
  • The conductor and contact must be compatible
  • The conductor must be positioned correctly in the contact
  • The correct crimping tool must be selected
  • The conductor and contact are placed in the designated die nest of the pliers.

Professional crimping pliers are always equipped with a pressure lock that can be unlocked. It unlocks as soon as the required crimping pressure is applied. This prevents operation with insufficient pressure. This guarantees consistent crimping results for the user with maximum possible pull-out values. Automatic or semi-automatic crimping machines are often used when processing large numbers of contacts.

Standards DIN EN 60352‑2 and DIN EN 60999‑1 are among the references used to subsequently assess crimping results. In addition to a variety of electrical and mechanical tests, conductor pull-out tests are the decisive criterion. All tools in the CRIMPFOX series from Phoenix Contact are calibrated and tested in accordance with the applicable standards. These tools ensure long-term stable, gas-tight crimping. We recommend checking the crimp quality every 5000 cycles or once per year, using suitable, calibrated test equipment.

Features of crimping pliers
1Precise: precision-manufactured dies with symmetrical crimping shape guarantee high-quality crimping results.
2Ergonomic: the weight ratio is balanced out appropriately. The plastics used feel particularly pleasant to the touch.
3Safe: the special handle design and use of non-slip plastics prevent the tool from slipping in your hand.
4Effortless: the optimized leverage reduces the actuation force required by up to 30 percent.
5Comfortable: thanks to the particularly small handle width, the tool fits perfectly in your hand.
6Force optimization: a fixed support pad reduces the amount of force that needs to be applied.
7Process reliability: automatic cross section adjustment and the pressure lock which can be unlocked manually ensure reliable crimping.
8Durable: the use of high-quality materials and components minimizes wear.
9Robust: the special design of the head area protects the tool.

PHOENIX CONTACT Ltd

Halesfield 13
Telford
Shropshire
TF7 4PG
0845 881 2222

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