Crimping requires not only a tradesman's skill, but also a suitable crimping tool and the appropriate contacts. The requirements for crimping connections are specified in international standards and guidelines, e.g. DIN EN 60352-2.
An essential quality factor is the tensile strength achieved in the connection, as well as the avoidance of typical crimping errors. However, caution is required: every conductor does not fit every contact and no single tool is suitable for all tasks. After all, the individual production tolerances of conductors and crimping materials do not enable every conductor to be processed with every contact.
“We are now determining an increasingly clear development – that conductors' nominal cross-sections are often not being complied with,” reports Steffen Kallenbach, Product Manager Tools at Weidmüller.
“Over the last few decades, conductor material has been subject to ongoing optimisation, such that the required conductivity is also specified if material is saved. So it's not really an issue per se. However, the problem arises during processing with wire-end ferrules. If the ferrule originally designed for the nominal cross-section no longer fits the conductor, the crimping dies must compensate for this size discrepancy. This certainly isn't an easy task if the conductor in fact only measures 2.8 mm² instead of the stated 4 mm², for instance. To compensate, we advise to use crimping tools with a spring-loaded effect.”In the case of the spring-loaded tools, two forces work together with great precision: as soon as the potential of the omega spring has been exhausted, the shear
spring takes over. In this way, the suspension is sufficiently extended to neatly crimp conductors and wire-end ferrules with one another, despite an insufficiently accurate fit. Essentially, Weidmüller uses metal instead of plastic as the material for the spring-loaded elements in manual tools. As the spring performance is incapable of influencing even extreme external temperatures in this way, we are relying on a neat crimp connection in different industrial sectors and climate regions.
One current example of a product with a spring-loaded effect is the PZ 6 Roto L.
Featuring the rotatable crimp insert, the tool can be used as the available space permits, since conductors and wire-end ferrules can be inserted both from the front and the side of the tool. The lockability of the crimp insert combines the benefits of a fixed and a rotatable tool, so users remain flexible in their applications.
Since conductors and wire-end ferrules can be crimped with a single tool across the entire cross-section range from 0.14 mm² to 6 mm², the time-
One current example of a crimping tool with a spring effect is the
PZ 6 Roto L
consuming process of changing tools is rendered unnecessary – and reliable crimping results are achieved at all times thanks to the spring-loaded effect.
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Expert paper on crimping: Suitable precision tools ensure reliable connections
Need to crimp in hard-to-reach places? Then reach for our PZ 6 Roto L
Published in February 2014
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