Crimping wires with sleeves

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2018-03-20 01:39:19

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Now there are a huge number of technologies allowing fast and reliable splicing electrical wires and cables. Each of the methods has both pluses and minuses. Wires and cables are joined by welding or soldering. You can use twist or bonding conductors terminal blocks, Sisami. All these methods are good and effective. But when you want to get really good compound will help crimping there.

The Result of this method – a good contact is protected from oxidative processes and a particularly strong connection. The only negative – nereshennost. Disconnect the two cables will not work. Would have only cut. Crimping the wires is performed with the use of special ferrules-liners. They can be purchased at any hardware store or market. The cost of these items is about $ 1 per unit.

crimping wire

They are inserted into veins. And the sleeve then use a hand press to deform, and thereby create a reliable electrical connection.

Why crimping-is it reliable?

Connecting wire crimping – the most strong way of connection. Such reliability cannot be achieved by any one of the existing mounting. To get a quality connection, there should be adequate contact area and strength. Popular with home craftsmen stranding two conductors does not give neither one nor the other. Twisting of the conductors are often oxidized (even with tape). And it's not very good for electrical contact. The use of nuts or PPE allows to improve some characteristics of durability for easy twisting.

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wiring crimping

However, an absolute guarantee of the reliability of this connection here either. Terminals – is an ideal solution, but in the case of high amperages, they do not fit. Good contact batter with the help of soldering. Here and strength, and excellent contact. But there are disadvantages of such connection. The solder can be warmed if using conductors of large current flows. Also brazing wire is not always convenient and secure.

Perfect contact can be achieved by welding. However, the tools for establishing such a connection is quite expensive and is not available to everyone. Also work with these devices requires certain skills. Crimping of wires allows to obtain a perfect electrical contact, and the communication will be most reliable from the point of view of strength. To break such a fastener is very difficult.

Connections

The Technology includes two options for crimping. This way, local indentation and solid compression. To work apply copper or aluminum wire. The sleeve should also be of these materials. There are elements of the copper-aluminum alloy.

crimping wire lugs

Since aluminum cables are prone to increased oxidation of the films, the casing must be trimmed and treated with special lubricants. Copper wire is also pre-processed. The use of lubricants reduces the risk of possible damage to the veins. Also significantly decreases the friction force. Crimping is performed in manual or hydraulic tool. In the latter case-shaped press. It is commonly used in major industries.

How it works? The two ends of the cable to compress them to make round shape. To continue living is inserted into the sleeve until it stops. You can connect not exactly butt. But in this case, the cross section of all wires does not exceed the stub. In the case of local pressure, the contact depends on the depth of the holes. The latter can be measured with a Vernier caliper. If you are using solid compression, then check the cross-sectional area. Then when crimping the wires is successful, you must treat the outer layer with tape or locating. Further, the wire and cable neatly stacked in the junction box.

Required tool

To connect wire or cable core thus need a special tool. A mechanical tongs. They allow quite tightly clamping the ends of the sleeve on its entire length.

ferrules for the wires under the crimping

Hand tool allows you to compress the tip section which is less than 120 mm2. The larger sleeve is compressed by means of a hydraulic tool. If the task is to connect several cores of different sizes, then it is better to use the tool for crimping the wires of another type. These pliers are equipped with interchangeable punches and matrices under different section.

The Casings for the wires under the crimp and their varieties

To obtain an ideal connection, you will need to pick up a sleeve or ferrule. In the technical documents of the sleeve for crimping the wires have certain designations. So, there are the following tips:

  • Copper.
  • Aluminium.
  • Composite.
  • Insulated connectors.

The GM and GML

Brass fittings used to work purely with copper cables and conductors. They are divided into two types – the GM and GML. The first isordinary copper connecting sleeve. They are not protected, do not have protective coatings, not pre-processed. Appearance resembles nothing like an ordinary tube. GML – this is also a copper jacket but it is tinned.

sleeve for crimping wires

The surface of the tip is covered with a special layer of tin-bismuth alloy. This protective layer prevents oxidation and corrosion processes. Copper oxidizes rapidly, and the protective alloy allows to avoid this. After connecting using GML wires made of copper do not enter into oxidation reactions. Some professionals use a tinned copper sleeve for the wires by crimping with aluminum conductors. According to masters, the tin layer does not direct contact between the conductor and a copper sleeve. But it is not recommended. In the deformation process violated the integrity of the protective layer, and corrosion-it's only a matter of time.

Aluminum shells

In technical documents, they are referred to as “HA” and fit only to work with aluminum. It is not necessary to use them for wires of other materials.

Combined shell

This is the aluminium-copper lugs. They are referred to in documents as DIN.

sleeve for the wires under the crimping

With their help it is crimping copper wires with aluminum butt. These devices are ideal in cases where it is necessary to build a new cable with the old wiring. On the one hand you put a copper wire on the other – aluminum. Two parts of the cartridge are connected by a friction weld.

Casings ICG

This insulated connectors for the wires under the molding. This casing is a conventional tip with the tin alloy. Top part covered with insulation of PVC. With the help of such a device is well-connected multi-core cables with copper components. ICG nice and easy to work with – no need to remove her isolation before the process.

Tip Sizes, design features

Minimum available cross-section for GML – 1.5 mm2. Further, the size of grow – 2, 4, 6, 10 mm2 and above. From these values we can say that the cross-section of the sleeves equal to those available wires and cables. Encryption bits is quite simple. For example, HML-6 – copper ferrule, tin plated. The cross section is 6 mm2. In the case of the combined casings the label indicates two sizes – for aluminum wires and for copper. For example, the DIN 16/10 – 16 for aluminum, and 10 – for copper.

By design, the sleeve can be through in the form of a hollow tube or partition. Second apply if you are crimping wire ferrules butt. These dividers are in the middle of the sleeve. With their help, you can control the depth of entry of the cable. If you want to increase it, both ends will go to the tip to the same length.

Errors to test

Often beginners, professionals working with the electrician can make mistakes. Especially their make a handyman in the process of renovating a house or apartment. Consider the most typical of them are allowed in the process of connection method crimping. The cross section of the sleeve is smaller than the wire. Never if link is not worth trying to reduce the cable and adjust it to the size of the tip.

a tool for crimping wires

This can lead to increased electrical resistance and decreased throughput. In places such lived connections will get very hot and eventually just collapse. The second popular mistake – liner, the diameter of which is more than you need. In this case, you will not be able to obtain the necessary mechanical strength of the connection. Even bent mine a few times, good connections still do not get it.

Cutting the liner

When you are crimping copper wires or any other the shortage of shells, many are trying to cut the tip into several parts. This is due to saving money. But such an action will only lead to increased resistance and heating. Also a wire would be bad to make out. The connection is only designed for this tool. Do not try to perform the task of crimping and crimping hammers, pliers or any other tool. The element will take shape and will not clip the wire. So, you can harm the casing and cable.

Summary

Crimping – is a reliable way to connect two wires or conductors and to obtain a good contact. But you should only use intended for this device. As a result, you will get high quality permanent connection that will not oxidize.


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Alin Trodden - author of the article, editor
"Hi, I'm Alin Trodden. I write texts, read books, and look for impressions. And I'm not bad at telling you about it. I am always happy to participate in interesting projects."

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