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Crimping
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== Terminal ==
[[File:CrimpTerminals.jpg|thumb|Crimp Terminals. Image reproduced from [https://commons.wikimedia.org/wiki/File:Kabelschuh_verschiedene_commons.jpg here]]]
For quite a number of applications, it is economically impractical for connector manufacturers to design terminals to accept a single wire size, a single wire stranding, and a single insulation diameter (UL type) as well as Mil Specification ( United States defense standard, often called a military standard). Most terminals accommodate many wire sizes, stranding, and a range of insulation diameters, and the terminals are designed to meet acceptable levels over this entire range. <refname = "ref3">https://www.rbracing-rsr.com/downloads/wiring_pdfs/crimp_molex.pdf</ref>
== Wire ==
The wire stranding and insulation type and stranding can vary widely a lot within one wire size. Wire strands can be made of copper, can be tinned, over coated, or top coated. Wire insulation materials, thickness, materials and durometers vary from application to applicationdiameters are different for different applications. <ref name = "digikey">https://media.digikey.com/pdf/Data%20Sheets/Molex%20PDFs/Quality%20Crimp%20Handbook.pdf</ref>
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'''Additional Information'''
'''AWG''' - American Wire Gauge is a standardized wire gauge system used since 1857 predominantly in North America for the diameters of round, solid, nonferrous, electrically conducting wire. <ref>https://en.wikipedia.org/wiki/American_wire_gauge</ref>
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Wires are of two types:<ref>http://www.awcwire.com/conductor-stranding</ref>* '''Solid:''' Solid conductors consist of just one a single strand of metal. They are easier It is easy to terminate these than stranded conductors. They These wires are also mechanically tough and . They are inexpensive. The However, they have a major disadvantage of solid conductors is their lack : Lack of flexibility.*'''Stranded:''' Stranded conductors are composed consist of multiple metal strands bunched together in any number of configurations. They overcome the drawback of solid conductors because they are much more flexible than solid conductors, and the . The higher the strand count, the more flexible they areis the flexibility of the wire. While this can add some increase the cost, it is essential quite necessary for any wire or cable that will need to withstand any kind of flexing, or any other movement or flexing. <br \>A finely stranded wire improves crimped joint performance. A wire composed made up of a few larger sized strands of larger size will tend to act as a solid wire in the crimp. Some There are some stranded wire crimp configurations which are not satisfactory unsatisfactory for solid wire. More deformation must are essential to be imposed in order to form wire and barrel into a solid mass. On Finer strands, on the other hand, finer strands will more readily fill the inside corners of the crimp shape and more evenly distribute the forces of the crimp. <ref name = "digikey"/>
[[File:SolidSolid2.pngjpg|frame|left|SolidElectric cable with solid copper wires. Image reproduced from [https://en.wikipedia.org/wiki/Electrical_cable here]]][[File:StrandedStranded2.pngjpg|framethumb|center|300px|StrandedWire. Image reproduced from [https://commons.wikimedia.org/wiki/File:Stranded_lamp_wire.jpg here]]]
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== Procedure <ref name = "ref3" /> ==
=== Prepare the Wire ===
===Setup and Operate a Hand Crimp Tool===
#Insert the wire.
#Squeeze the handle.
#Inspect for proper crimp location.
== Importance of Proper Crimping <ref name = "digikey"/> ==
Proper attachment of terminal to the wire is critical. Mechanical as well as electrical connections are important - The result of a properly crimped joint is a reliable mechanical and electrical connection. <br \>
The mechanical connection is refers to the crimping of the terminal to the conductor. It must be so secure enough that it does not to vibrate loose or to be pulled off through normal use. <br \>The electrical characteristics are just as equally important. The major concern is the amount of electrical resistance caused by the mechanical joint which crimp is a major concern, because it determines the crimped joint’s ability of the crimp joint to conduct current.
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One indication of the importance of proper crimping is evidenced in a study for the Space Shuttle Program that traced 28% of all defects to improperly assembled wiring and connectors.<ref name = "digikey"/>
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== Tips for Crimping <ref name = "instructable">http://www.instructables.com/id/How-to-Make-A-Quality-Crimped-Joint/</ref>==
=== Step 1: Choosing the Wire ===
=== Step 2: Determine the wire size ===
=== Step 3: Choosing the Crimp Terminal ===
=== Step 4: The Crimping Process ===
See https://www.robotshop.com/blog/en/how-to-crimp-connectors-4225. <br \>
You can also watch a video tutorial here: https://www.youtube.com/watch?v=kjSGCSwNuAg
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'''Pre-Insulated Terminals<ref name = "instructable"/>''' <br \>If you are using pre-insulated terminals have a heat sleeve to grip the wire insulation.All terminals are sold with a defined wire size range- this should be listed on the packet, but if not and you are using pre-insulated parts you can tell the wire size by looking at the colour of the sleevecolor.
The generally adopted standard is:
* '''Red Insulation:''' 0.5-1.5mm2 / 22-16 AWG
* '''Blue Insulation:''' 1.5-2.5mm2 / 16-14 AWG
* '''Yellow Insulation:''' 4.0-6.0mm2 / 12-10 AWG
There are other colours around, but you are unlikely not likely to come across these unless you are doing industrial, aerospace or military work.
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== References ==