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Connectors as crimp contacts

The crimp connections have proven themselves millions of times over in all areas of industry, automotive technology, aviation, the transport industry, and in medical equipment.

Connectors are also known as crimp contacts. They are available in a wide range of versions and designs. They are divided into two main groups: the solid/turned connectors or contacts are referred to as being “closed”, while the punched/rolled connectors or contacts are “open”. In electrical installation, these crimp connections fall under the heading of “solder-free electrical connections”.

The scope of performance as well as test specifications are described in European standard DIN EN 60352-2. “Crimping” is a joining process to permanently connect one or more conductors with a contact. A stripped conductor is inserted into the crimp zone of the contact and connected by means of a defined crimping process. This results in a permanent, reliable connection that cannot be detached.

The following main groups define the various connector types, with a broad spectrum of dimensions and conductor cross section ranges: punched-rolled contacts, turned contacts, hard-soldered crimping cable lugs, tubular and compression cable lugs, butt connectors, insulated crimping cable lugs, pin cable lugs, uninsulated and insulated ring cable lugs, uninsulated and insulated fork-type cable lugs, uninsulated and insulated slip-on sleeves, and coaxial CATV connectors.

Crimp profiles

The B crimp profile is mainly used for punched-rolled contacts. Solid turned connectors/contacts mainly exhibit profiles in four-mandrel crimping (4/8 indent), square, oval, mandrel crimping, twin mandrel crimping, WM crimping, hexagonal (hex) + mandrel crimping, and B crimp.

Mechanical crimping pliers with a ratchet system or hydraulically operated tools with different die sizes and crimp profiles process cross sections larger than 10 mm². Depending on the machine type, square and four-mandrel profiles up to 10 mm² are installed in electrical, pneumatic, and electropneumatic crimping machines. For larger cross sections, such as for a charging connector, the B crimp profile is also used.


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