PROPER CRIMPING METHODS

Crimping is the widely used descriptor for applying an electrical/electronic terminal or pin contact to a wire. It can also be called "terminating". There are many (probably millions) of different types of contacts from a large number of companies available. Almost every contact requires a different die to form it onto the gage of wire it is designed for. Dies come in various forms. The simple handtool is the cheapest way but also the slowest (200/hr) and lease accurate way to crimp a contact onto a wire. Handtools by their vary nature require a person to manipulate a plier type tool, plus loading a contact and placing a wire into correctly and holding the placement all while squeezing the plier handles to form the contact onto the wire. Repeatability is an issue with this method and only gets worst as operator fatigue sets in with time. This method should only be used for field repair services. It is not recommended for medium or large production numbers. Even small runs that repeat if quality is taken seriously should not be performed with a handtool method.

The next best method for crimping would be to obtain a crimping press with the correct die and process the wires to be crimped by the operator placing one wire at a time into a die stop and pressing a foot pedal to activate the press, thus forming the contact. This method is a real step up in accuracy and quality along with speed of operation. Typical rates of production up to 1200 and higher crimps per hour can be achieved by an experienced operator. Repeatability is much better than a hand tool set up. The press and die can also be combined with a crimp quality monitor (see crimp quality monitor article) to achieve a real quality crimp. The cost of the press (typically 5G's) and the die (2G's-7G's) is a significant outlay of capitol. This is one reason handtools are still used.

The best method for crimping would be to obtain a fully automatic wire processor. This type of machine cuts, strips, and places the wire robotically and crimps the contact also. The repeatability is even better than the press and die set up and as for the handtool, well let's not go there! These automatic machines can also incorporate the crimp quality monitor to form a superb system. Sigma six capabilities are acheiveable. The only drawback to the these machines is obviously the capitol outlay. Be sitting down when you hear the price if you go out for a quote to pick up a system like this. Typical good machinery names are KOMAX, SCHLEUNIGER, TYCO, and there are many others too numerous to mention.

At C-T Wire Prep we have chosen to use Tyco brand automatic processors to cut, strip and crimp wires automatically for our customers.

The only way for a Wire Harness Manufacturer to operate in todays world is obviously to have automatic machines along with a real time quality management system. If you can't or won't spend the money on this type of machinery then let us at C-T build your wire harnesses, custom cables or even just the wire lead assemblies and free your time up, so you can concentrate on your main business focus!