A correctly done crimp will be stronger than a solder joint. Adding solder just makes it more brittle, which is not good in an automotive application subject to vibration. If you say the sky is green, and we know that you are wrong, should anyone bother teling you tha you are wrong and why? Andrea: The article explains why his father was wrong. Is that any better than a statement with no explanation?
What his father may have intended is that if you have wire with sharp ends like when cut on a HV connection, you may get something like a corona discharge from the very tips of the cuts. This can create electrical noise. Sort of like the little balls on the ends of antennas. Maybe something was lost in translation or memories. Just to clarify, soldering a crimp defeats the purpose of the crimp. Basically, if your experience is that soldering a crimped connection makes it last longer, it was improperly crimped in the first place.
I have to disagree with this article. I have been in Electrical and electronics for about 40 years now, and I can confirm that Thomas and Betts connectors were most probably the first.
Very good for wiring things that tended to get hot…. Uncas A Whiticar in Harrisburg, Pennsylvania was the first.
He set up the Whiticar corporation which became Aircraft Marine Products…. His crimps revolutionised the electrical terminations in aircraft wiring , sped up production and facilitated military aircraft production. AMP was truley a global company that thought and acted locally. A fantastic company. Never ever use soldered connections in cars since the tin will crumble and connection will most often fail within a year. Production connectors are crimped for multiple reasons, reliability being most important.
Cable splices are made with ultrasonic welding for reliability. Soldering is only to be used for PCB mounted components and soldered connections should at least be be encapsulated with epoxy. What a horror! Thankfully now we ordered a new tool and proper terminals, no more messing around!
No never again. I smash down the crimp as hard as I can, squish a bit more with needle nose, and carefully apply a little solder for good measure. At work I make my employer buy the correct tool and do it the proper way. That said I have done it to repair a bad crimp in my chinese one hung low brand hot air station.
I agree it should be avoided when possible, but it can work in a pinch. Especially if care is taken so the solder flows the least amount down into the wire as possible and heat-shrink tubing is used when possible to strengthen the crimp and create a little strain relief. Soldering a crimped connection is a bad idea. Do one or the other, not a quarter-assed combination of both. I have seen crimps used to carry Arms and getting really hot.
So if heat was a problem, the high current crimp must have suffered. Also, thermal conductance is high so the temperature difference between crimp and copper is quite low. So far it always worked well, but I love to stand corrected here if this actually is bad.
And please also give a reason, which helps me to understand. All of my welder connections are made with 2 gauge wire smooshed in a piece of copper pipe with a bottle jack, then a hole drilled through. Why is there no standard crimp die form factor like we have with hex screwdriver bits? Or is there? There is, for prosumer-grade stuff. In general this is true. They have a ratchet mechanism and make stable connection. I think they require a little more operating force than the expensive ones, but form low quantity home use this is completely OK for me.
You can get a LOT of mileage out of four crimpers that cover a very wide range of applications:. There are lots of places that will do wire assemblies for cheap. It will work for hobby and prototype stuff though. Just do a pull test on every crimp — twice. These are used for closed barrel contacts, such as made by Mil-Max. In some cases we have taken the tool apart and reassembled into a table, and used a vibratory bowl feeder to supply the contacts, under PLC control. This way we can semi-automate the production.
I have two crimpers, they look identical, the cheap ebay one is garbage, and the real one works like a charm. With the blue handle. It seems good.
Can you watch the video and respond if anything is obviously lacking about this tool? I watched a few mins of the video. The ebay ones I have are different. I have a few of the single wide mentioned above, only crimps one set of ears at a time so every pin you crimp twice and one set of pins I use I have to use two different crimpers to get it right, or chop some length off the ears, or pre-crimp them with one size larger then recrimp them the right size, or… or… or… you get the idea.
The harbor freight or home depot, I forget red handled dual wide was actually pretty decent at crimping. Connectors are the bane of reliability, and have been for a long, long time. Yep — the weak link in any number of technologies, not just electrical ones. Ask anyone in a field that features cable swaging. Right — because everyone knows how to set a compression fitting without ever having been shown how.
Kidder really has a way of vividly painting characters, warts and all. Not as well with rounded connections as on resistors and so forth. But then it is easy to just add a dab of solder to keep the wire wrap from falling off if its an issue. I use to work for Honeywell not too long ago.
When done properly this is an excellent way to connect a wire. But a nightmare to diagnose when it is not done properly. Screws can work lose under vibration or thermal cycling. So they are not the best way for every connection. A proper crimp connection is more reliable. I have a 3-phase power plug in my show-and-tell box that shows what happens when a screw gets loose I occasionally teach a basic electronics class.
I crimped probably thousands of crimps in a past-life… I had no idea the wires deformed so much! That cross-section is pretty cool. You should see what happens after you use the correct crimper on the Anderson PowerPole contacts. It squeezes them so much the crimp barrel actually gets longer. Not necessarily. The photomicrographs show thick black lines around each strand and at the surface of the connector which seems to go against the idea that the materials flow together to make a gas tight joint.
Or did the guy who prepared section specially treat it to show the boundaries? Almost certainly treated with that blue stuff. And I assume that the cutting process separated the strands a bit from each other. Thanks for posting an appropriate video to go with the article rather than some random YouTube video from someone claiming to know crimps.
Google Molex and download the PDF. That varies upon the specification for the cable assembly. I deal with crimps on a daily basis and have spent years specifying crimp tooling, training, and design solutions. As to the others that mentioned cost, yes, lots of money in tooling in that area of the production floor, and JST is usually the worst. I do the electrical repair of a number of older and modern Toshiba milling machines, they use a lot of the Hirose, JST series, and Amphenol connectors..
I jest, but proper proper crimp tooling is just too expensive for the home gamer, while frowned upon I prefer to crimp with a cheap tool, flow a little solder, then heatshrink or tie the cable in such a manor to allow mechanical relief if required. In automotive wiring where i do most my work : biggest issue to wiring is moisture and second vibration.
I occasionally do marine work. So far, so good 4 years Some guys use the Euro style whitish terminal strips that screw down onto bare wire. The expensive tools are necessary only if you need to guarantee that every joint is done correctly — i. Also, many people are saying the problem with a soldered joint is mechanical, that it causes stress risers where the wire emerges from the solder. Copper is a much better conductor than tin or lead, the components of common electrical solder, and the cold-welded joint described in this article provides for lower contact resistance.
A decent crimper will have controlled-cycle — the ratchet-y think that makes you squeeze the tool far enough to get to the required pressure before opening up again. This ensures that every crimp is sufficiently crimped. You can have the most expensive brand X crimper, but if you use brand Y lugs and they are slightly different, your crimps could be crap. The biggest problem with a solder joint is that if it gets hot enough eg excessive current, loose screw , you no longer have a mechanical connection and the wire can come out.
For that reason many standards bodies do not consider just solder as an acceptable connection method for lugs on power conductors. They must be crimped; you can solder afterwards if you insist. I would fear that the large heat cycle of the soldering could weaken the crimp.
Except in an emergency without a useful crimping tool I would prefer a decent crimp connection. Of course, if I had to resort to needle nose pliers or a vice grip for crimping it could be useful to additionally solder. You can use a soldering gun to quickly tin the wire end in the open end of the barrel, to thwart water. HA wait till you get to the large wires. Like 4 ot. OK lets goto mcm Wait I can go more mcm. I think on the amperage.
And here is were you can not crimp. Nanticoke in southern Ontario. Coal firing electrical plant. And Why is it the germans and the japanese think wire is small and easy to bend and crimp. They give us no room to work in the equipment with. Hold on, so how did you make and secure connections? And in normal electrical panels its a Allen Lug assembly you put the wire in and torque down.
Works wonders. My uncle worked at Wisconsin Electric, And when i was a kid he used to go thru and tighten all the lugs on the bus bar systems that carried power. So from working with wires all my life with various connection forms. You can always come back and check for torque some even use thread locker to make this less of an issue. Give me Screw Terminals any day over a mechanical crimp. OK, there is a point where you can not crimp any more, then you have to bolt copper bars together.
But before this stage I have already seen hydraulic power crimping tools, e. Really not sure what you are rambling on about. But when writing a about wire gauge, and buckshot aught is typical to represent zero.
That said, outside of a manufacturing environment, most are NOT properly crimped. I made an actual video for DuPont connectors because it took so much trial and error to crimp those little connectors:. I have seen this to be true as well, but it is the only search term on eBay that consistently leads to buying these cheap connectors.
A good example of crimping is the process of affixing a connector to the end of a cable. Crimping tool. Can you use pliers to crimp? Pliers are not crimpers! Neither are hammers, vises, needle nose pliers or flat rocks. A good crimper when used correctly will make a cold weld between the wire and the barrel of the connector. If you were to cut a well executed crimp in half you would see a solid form of wire and connector.
What can I use if I don't have a crimping tool? You don't need a fancy tool, crimps are very soft, you can use pliers. What does a crimp bead look like? Crimp Beads: Crimp beads are shaped like a hollow round bead and come in a variety of sizes and metals. To secure them to jewelry wire, flatten the crimp bead with a pair of flat or chain nose pliers. The flattened bead grips the jewelry wire. What can I use instead of crimp beads? Are crimp connectors good? Like the solder method, it can be used on solid or stranded conductors, and provides a good mechanical and electrical connection.
What is the advantage of crimping? The benefits of crimping over soldering and wire wrapping include: A well-engineered and well-executed crimp is designed to be gas-tight, which prevents oxygen and moisture from reaching the metals which are often different metals and causing corrosion.
What does crimped hair look like? The crimped hair look is when you style straight or straightened hair with a crimping iron to create a zig-zagged, wavy texture. Different from loose curls and wavy hairstyles, crimped hair provides a purposefully frizzy, super-voluminous look. How do you wire without soldering? What you need: a roll of electrical tape and two wires whose ends have been twisted together.
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