Before we get into details regarding connection technology, we would like to give you some tips for the compression process, so that your terminal lugs connection are secured and can withstand for long.
Once the conductors and connectors have been made, the actual pressing can start. Cable lugs can be cleanly and professionally processed without under or over-pressing, if you use efficient tools. Therefore, the choice of the crimping tool and cable lug should be within the system: the same manufacturer for a connector, the cable lug and device. Expert pressing and compatible tool components prevent increased contact resistance which results in an increase in temperature that can cause a fire in the worst case.
Crimping in the cable lug always commences on the connection side and functions towards the cable side. On a connector, however, the first crimp is in the middle. Otherwise, material can’t lengthen, and it can lead to the production of cracks.
For instance, the number of pressings needed for crimped bimetallic lugs as per DIN 46235 is identified by markings on the connector and cable lug. For tubular cable lugs, the frequency of pressings can be found in the catalogue.
Ensure that the pressing technique is entirely completed. The full pressing process is crucial because the required compression regarding pressed material is only accomplished at the end of the pressing phase. This is the only way the right pressing can be achieved.
Before actual pressing, ensure the cleanliness of the components. This suggests that the conductors are clean metallically by brushing and aluminum cables are checked for the visible oxidation layer, which needs to be removed. In general, you must make sure that no metallic traces remain on the conductor, otherwise contact abrasion may occur.
By using an efficient wire stripper, you can clean the cables. Make sure not to destroy the conductor and length of the stripped component should be approximately 10 per cent longer than the connector or cable lug’s insertion size. The reason is the connection, or cable lug extends by nearly ten per cent during the pressing. So, do not skimp on the stripping!
Besides, make sure the press inserts are not soiled or damaged. Their profile must depict a metallic sheen.
Electro-hydraulic or mechanical press depends upon how you plan to use. Mechanical crimping devices are better for small and medium cross-sections.
For larger cross-sections, a hydraulic tool with changeable inserts is typically better. Also, the number of pressing must be considered.
While you apply sufficient pressure to small and straightforward pressings through mechanical pliers, the pressing of extensive conductors with electro-hydraulic presses is now a customary practice.