1. Connections 23
by Jean-Marc Myette
E
veryone who designs, builds or
services electrical equipment is
familiar with a crimp style connec-
tor. It is a basic component that is used to
either connect or terminate wires. Crimp-
ing is a method of firmly attaching a ter-
minal or contact end to an electrical con-
ductor by pressure, forming or reshaping a
metal barrel, together with the conductor.
Forming a satisfactory crimp depends on
the correct combination of conductor,
crimp barrel and tool.
Hand crimp tools for electrical related
purposes have been used since the early
1900’s. This is well before the develop-
ment of either semi or fully automated equip-
ment. Hand crimping tools still are available
in various shapes and configurations, and
vary widely in quality, performance, and
cost. Hundreds of patents have been awarded
for hand crimping tool innovations.
The technology of crimping was devel-
oped to provide a high quality connection
between a terminal and a wire at a rela-
tively low cost and as a substitute to sol-
dering and the problems associated with
that procedure. The end result of a bad
crimp could be a fire or shock hazard
being introduced into an end product
application and use.
The Crimping Concept
Hand crimping tools are widely used in
many industries and for various uses
including in-field service tools, small pro-
duction requirements, prototyping terminal
or connector designs, developing crimp
specifications, repair tools for the wire har-
ness production environment, and for use
in environments that present restrictions to
crimp equipment size, weight, and maneu-
verability such as those presented with wire
harness assembly boards. The tools can be
either manually driven or power driven.
When evaluating manual tools, it becomes
obvious that some individuals will have
WHAT TO LOOK FOR INYOUR NEXT CRIMPING TOOL.
2. 24 Connections
difficulty using these tools simply because
of the strength and leverage needed to pro-
vide enough force to operate the tool.
Manual tools sometimes require awk-
ward postures of the back, shoulders,
elbows, and wrists. The combination of
force and these postural requirements for
use places workers at risk of injury. Conse-
quently, performing crimping tasks with
manual or manual hydraulic assisted tools
places very high stresses on these areas.
Maintaining and calibrating tools is also
important. Although maintaining the tools
can improve worker satisfaction and safety,
the incentive for doing such could be at
risk. Many of the manual tools are easier to
use while crimping or cutting when they
are out of calibration, and workers may be
prone to using them this way. This could
lead to poor connector integrity and failure.
Manual tools, although well designed
for meeting the crimping requirements of
connectors, have limitations and can cause
problems - problems that can affect the
integrity of the connection and the safety
of the person making the connection. Tool
manufacturers have been working for
many years to develop more efficient,
user-friendly tools. One alternative is bat-
tery-operated tools that reduce both the
high forces and awkward postures associ-
ated with the manual tool designs.
Basic Crimping Tool
Features
There are several features that a crimp-
ing tool should incorporate. It should guar-
antee that a specific crimp height has been
achieved. It should provide for precision
alignment of the opposed crimping forms.
Where applicable, the tool itself should
provide for a means of accurately locating,
supporting, and holding the terminal or
connector in place during crimping as
opposed to the operator holding the com-
ponents.
The tool should be designed so that the
manual force required falls within accept-
able human factor guidelines. The shape,
weight and required human intervention of
the tool should conform to good ergonom-
ic practice.
There are numerous intangible benefits
that result from choosing the best available
tools. But these benefits are sometimes dif-
ficult to quantify in terms of savings. Cer-
tainly the improvements
in productivity and safety
are real and ultimately
provide good electrical
connections.
Worker satisfaction is
improved when crimping
tools are easy to operate
and eliminate the tedious
burden of manually hav-
ing to crimp with a hand
tool. The reduced physical
stress required for operat-
ing recently developed
crimping tool technology
and the improved posture
achieved by the user cuts worked-related
injuries and claims. Crimping tools that are
lightweight and incorporate an ergonomic
design minimize the risk of repetitive
motion injuries that can occur with tradition-
al hand crimping tools.
Ultimately, crimping tools that improve
performance; provide a uniform, consis-
tent crimp by skilled or unskilled employ-
ees; and offer savings in labor and job-
related time reductions provide payback in
a short timeframe.
Battery-Powered
Crimping Tools
If you need to make only a few crimps
on smaller cable sizes, manual tools are
satisfactory. But for larger cable sizes, you
need hydraulic tools for the force needed
to get a 6-ton, 12-ton or
even 15-ton crimp. A
remote hydraulic pump
can power these
hydraulic tools. There are
also hand-powered units
and those using a battery-
powered motor. All are
available in a variety of
interchangeable die- and
dieless-types.
Users want faster,
lighter weight, more
compact, and easier-to-
use tools. Today’s
hydraulic, pneumatic,
and battery-powered tools deliver just that.
In the last few years, manufacturers have
made several advancements to make these
tools more operator-friendly. These
include making the tools lighter and small-
Jean-Marc Myette, Product/Market Manager,
Industrial Division with old and new crimping
tools and accessories.
This 12-ton compression tool combines the cost-savings
of a dieless tool with the superior performance of an
hexagonal crimp.
Crimping tools
that are lightweight
and incorporate and
ergonimic design
minimize the risk
of repetitive
motion injuries.
4. 26 Connections
Battery-powered tools are growing in
popularity for cable installation and termi-
nation operations. Electrical contractors,
plant maintenance electricians, and electri-
cal and telecommunications utilities per-
sonnel or workers use battery-powered
knockout punch drivers, cable cutters, and
crimping tools. Battery-powered tools
have taken a lot of the work out of crimp-
ing, but they are more expensive than other
tools. These tools come in 6-ton, 12-ton
and 15-ton interchangeable die type and in
a variety of dieless styles. The main bene-
fit of battery-powered tools is their fast
cycle times - 5 to 20 seconds for most
operations. Users also like the consistency
that these tools provide. These tools are
also relatively compact making it easy to
get into tight work areas and they reduce
fatigue from repetitive operations.
The Benefits of
Battery-Powered Tools
Manual tools obviously continue to be
the least expensive type for cutting and
crimping, but they can’t generate enough
force needed on larger cable sizes. For
repetitive situations, they can be tiring
and even lead to repetitive motion
er. There are two recent innovations in cut-
ting and crimping tool product develop-
ment that are helping users to achieve
these goals faster and easier - battery-pow-
ered tools and combination tools that per-
form more than one function.
Klein Tools Ad
4C
injuries. Battery-powered tools are more
expensive than manual tools, but you can
use them on a wide range of cable sizes.
They are more productive than other
types of tools, and they put the least
amount of stress on the operator.
The advent of battery-powered tools
makes them much more attractive to
installers. With their increased power, the
newer crimping tools allow users to work
more efficiently and accurately. This
means more work gets done in the same
time at lower cost. But just as importantly
are the benefits to the user. These newer
tools reduce strain that comes from the
effort required to grip and manipulate tools
with sufficient force to do the job. Using
tools that reduce this effort means less
fatigue and injury and higher productivity.
Evaluate your present tool inventory in
comparison to the type of work being com-
pleted to ensure successful job completion
and worker satisfaction. Also, determine
where you can improve your tool invento-
ry to save time and money.
For more information on crimping tools,
circle reader information no. ??? s
Lighttweight and efficient, battery-operated tools
pay for themselves in improved operator performance,
consistently high quality crimps and reduced
work-related injuries.
