WHAT IS TERMINAL CRIMPING?



Cables become much more reliable by going through many processes with today's technology and professional approaches. The cables, which are manufactured and then brought to the factories and subjected to special processes in line with the demands of the customers, maximize safe use. The ends are opened to the cables cut in certain sizes by separating them into groups; Stages such as soldering and nailing are applied. At the end of these processes, the products are taken to the test area by socketing and then banding. Terminal Crimping is carried out with the most suitable devices, special machines, adequate equipment and professional people for cables that pass the test for possible inoperative or non-contact condition.

Crimping is done by deforming the open or closed terminal leg by squeezing it with a mechanical pressure called cold welding on the cable. A connection is established between the cable and the terminal in a way that is not permeable to gas and air. This connection is an interface with such mechanical strength that the cable cannot be removed from the terminal. As is known, mechanical power and electrical efficiency work in inverse proportion. While increasing the electrical efficiency in high crimp power application, it decreases its mechanical strength. The most important point here is that suitable and sufficient tools should be used while doing Terminal Crimping. Since the terminals are made for certain cable sizes and ranges, they apply less pressure in small cables that do not fit these dimensions, and a lot of pressure occurs in large cables. Sufficient experience of this process and necessary equipment should be obtained in order to obtain the desired results.

As ESPA, the main criteria we pay attention to regarding Terminal Crimp; electrical conductivity, corrosion and heat resistance properties. Brass, phosphor bronze, steel and copper are the main metals and alloys used. Terminal coverings provide benefits to the product in many ways. Because it provides a mechanical and electrical integrity that expands the application range for special needs and demands by increasing the corrosion resistance of the product in terminal coatings. Coating can be in the form of pre-coating (raw material being coated) or final coating by electrolysis (coating of the product). The coating made by electrolysis is the best coating system as it covers all sides of the product. The coating can be of different thickness and gloss. Plating can be made with copper, tin, nickel, silver, zinc and precious metals.

Maximum temperature application area in material and coating type; Without brass coating, it is used only if environmental conditions are suitable. Because brass is affected by corrosion. It is tin plated, performs well at high temperature and is corrosion resistant. Silver-plated, high-current loaded brass terminals are suitable for silver plating at high temperature. Material and coating type maximum temperature application area; Without phosphor bronze coating, it is more resistant to corrosion than brass. It is tin plated, performs well at high temperature and is corrosion resistant. Silver plated at high temperature formed on silver plated, high current loaded phosphor bronze terminals is suitable. Steel Nickel plated, Nickel plated steel parts are produced for connections that require high temperature resistance.

Terminal Crimping technique; It is widely used in Automotive, Electric, Electronic and White Goods Sectors. Metal, detachable system elements that carry out the function of power and electrical signal transmission for the safe storage and transportation of information are called terminals. The physical and specific features of the terminals need to function fully in the transfer of information. The purpose here is; To establish electrical contacts, to create a separable mechanical connection, to insulate the conductive parts, to ensure safe connections.

Terminal; It consists of sections such as Isolated Leg, Conductive Foot, Insulated and Conductive Foot Chamfer, Locking Point, Female Terminal Mouth Height and Width, Male Terminal Chamfer.

The functions of these departments can be summarized as follows:
1. Insulated Foot: It prevents slipping and stripping by covering the perimeter of the insulation. It prevents negative effects such as short circuit that may occur due to vibration.
2. Conductive Foot: It covers the stripped end of the cable, that is, the conductive part. It provides a stable (constant) flow of current.
3. Insulated and Conductive Foot Chamfer: It plays an important role in facilitating the process by reducing the friction on the crimp jaws during crimping. Chamfers penetrate the insulating and conductive parts of the cable, strengthening the connection.
4. Locking Point: The point on the lug fits into the locking hole in the male terminal. This point sets a limit for the male terminal and increases the force required to separate the terminals from each other.
5. Female Terminal Mouth Height and Width: These values ​​of the female terminals should be suitable for the male to be used together.
6. Chamfer on Male Terminal: The effect of chamfer here is to make the male to female more easily. Therefore, at the mouth of the male terminal