Crimp Connection Technique / Crimping

The crimp connection technique was developed for the use of screwed connections with stranded cable. Stranded cable is cable which has its conductor made from a large number of thin wires which have been twisted together rather than cable with one single thick wire. These thin wires can easily break-off with a screw connection. In addition, they can evade the screw. A reliable and stable connection is therefore not possible. During crimping, a cable end sleeve is inserted over the end of the stripped stranded cable. The sleeve is then pressed together with crimping pliers. The material then ‘flows’ together as a result of the forming pressure of the pliers creating a homogenous copper rod. This connection can now be either screwed in to a crimp plug with a grub screw or fixed in a terminal. In addition to standard cable end sleeves, WBT also offers sleeves with injection moulded plastic collars. When using this version, the sleeve is pushed further over the stripped area so that the collar reaches over the cable insulation. This way, the kink sensitive area between the cable sleeve and cable insulation is protected during bending. This is particularly important if the cable is to be frequently moved. Crimping is a far superior connection technique for stranded cable in comparison to soldering when cable with a thick cross-section should be soldered, since the possibility of a so called ‘cold’ soldered joint exists. In such a case, an air bubble can form under the cold solder which keeps the joint chemically active and susceptible to surface corrosion. The deciding advantage of crimping is also that neither soldering material (flux and solder), nor heat are required. Solder is a mixture from, among others, tin, flux (mostly aggressive) and a small part of silver. The solder joint is therefore always seen as the weak point of conductor contact. Heat affects not only the conductor and insulation material but it is also capable of releasing gases from the PVC of the cable sheath which can form on the contact point and remain chemically active. Crimping on the other hand has none of these disturbing characteristics. The cable end sleeves from WBT are available in pure copper (Cu) or fine silver (Ag) and have no negative effects on the conductivity of the cable. In addition, the fixing by means of the grub screw, provides an excellent mechanical stability and keeps the transition resistances to a minimum. Crimp connectors usually require more fabrication complexity. At WBT all crimp connectors possess Torx screws with a special fine thread. This guarantees that a one time applied pressure will be perfectly held. Crimp connectors are re-useable.

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