Crimping

It is the connector manufacturer who designs the lugs and sleeves, and validates his products by defining the method of installation and, consequently, the choice of crimping. For this purpose, there are several standards that define either the performance of the solution (intensity, aging, etc.) or the description of the solution (dimensions, shapes, etc.). Here are a few examples : - NF C20-130 : Bare tubular crimping lugs, in copper or copper alloy, for copper conductors - NF C33-090 : Connection of aluminum cores by closed-die stepped deep punching for aluminum conductors - NF C33-021 : Insulated cables and their accessories for energy networks - Pre-insulated connection materials for swaging - NF C63-061 : Connection fittings for conductors of which at least one is insulated and made of aluminum or aluminum alloy - NF EN 60352-2 : Solderless connections - Part 2 : crimp connections - General requirements, test methods and practical guide - DIN 46235 : Terminals for crimp connections - DIN 46267 : Junction connectors, non-tensile - DIN46329 : Crimp connection terminals - circular form for aluminum conductors - DIN 48083 : Press inserts for pressed connections - size of hexagon press form

There are no regulatory requirements for checking such equipment. Most users require annual inspection of tools and dies. Penta recommends an annual inspection, for the following reasons : - Hydraulic presses or cable cutters are tools that develop very high forces (we're talking several tons here). They also generate high hydraulic pressures inside the mechanisms. A check will validate your tool's safety (risk of leakage under high pressure, high forces at the end of the tool), reliability (no loss of output or pressure, no drop in output which could lead to future failure...), and performance (ensuring the right force, the right cycle time...). - A controlled die set will ensure both correct positioning of the dies in the tool, and certainty as to the application of the right swaging form on the connector/sleeve, with the aim of ensuring the right connection to the conductor.

This is a vast subject. Technically, hydraulics is a means of transforming energy to obtain what we want - in this case, to apply a very (very) high force to cut or crimp/punch. All other means of transforming energy (pneumatics, gears, chains, cam systems, etc.) also have their advantages, but hydraulics is the one that provides the greatest reduction in effort, in the smallest space. For example, a manual tool, with the force of 2 arms, can exert a force of around 30daN, whereas a hydraulic press can generate a crimping force of 125kN, or 12500daN. We're talking about a gear ratio more than 400 times greater than that of a manual tool, all combined in a mini-hydraulic power unit weighing just 3kg. In all our tools, hydraulic pressure will technically reach between 500 and 700 bar (daN/cm²).

If we take the operations in order, here are the prerequisites for a good connection : 1. Make sure that the components to be connected are compatible (sleeves/lugs and conductor/cable). 2. Determine the correct set of dies to apply the hexagonal swaging. 3. Choose the right tool to apply the force The result is consistent when the die set is flush with the parting line. This indicates that the swaging has been applied to specification. If the dies do not touch and the press has completed the swaging, then there is a malfunction that needs to be identified.