Crimping tool options span virtually any need
Someday, perhaps, manually adroit robots will be able to overcome any and every electrical connection challenge for even the most ad hoc application or hit-or-miss prototyping effort. Until then – and probably long after that point – we’ll still often rely on humans wielding manual or powered crimping tools to ensure high-quality connections that defy automation. Automation works best where scale and uniformity can be applied to mass production, justifying the high costs of development, deployment, training, and maintenance. It does not work so well in situations that require flexibility and adaptability, such as prototyping and limited production runs, which can’t promise ROI from investment in automated crimping systems. Field repair and maintenance is another area that is likely to resist automation far into the future. Crimping is invaluable in the solderless joining and termination of conductors. Its roots are said to date back to ancient jewelry making and metalworking. In the modern era, it has had a momentous impact with its adoption across the ever- expanding range of electrical and electronic applications.
Soldering continues to be utilized in electrical engineering, of course, particularly in smaller-scale production runs. But crimping generally is faster and provides reliable, vibration-resistant connections. That’s why it’s been popular across a broad range of automotive, aerospace, consumer electronics, and power applications
The lower cost of many manual crimping tools is an obvious benefit when vendors are unable to justify the price of more advanced options. But powered tools are likely to boost productivity in high- volume productions and improve the quality and consistency of crimps. In either scenario, ease of operation and ergonomics are important to ensure operators achieve the desired crimping results.
Figure 2: Klein Tools’ VDV226-110 tool for stripping and crimping twisted pair wiring. Image source: Klein Tools, Inc.
Figure 4: Molex provides the FA2 mechanical feed crimping applicator for workbench use. Image source: Molex
Figure 6: The 1208199-ND stripping and crimping solution from Phoenix Contact can process up to 1,000 operations per hour. Image source: Phoenix Contact
Selection criteria
Klein Tools also offers Pass-Thru modular crimpers, including the VDV226-110 (Figure 2), for cutting and stripping twisted pair cable and crimping it to its line of RJ45 CAT5E and CAT6 Pass-Thru connectors . For coaxial cables, the ATHT-K3081 (Figure 3) crimp tool kit from Adam Tech includes a rachet crimper with six interchangeable dies, along with a cable cutter and stripper. The toolset comes in a portable storage case and is suitable for cutting and crimping various coaxial cable sizes.
Molex , the manufacturer of connectors and cable assemblies, offers hundreds of crimping tools, ranging from the WM18730-ND basic hand crimper, to high-end mechanical feed applicators such as the FA2 series 900-2157860100- ND (Figure 4). Another vendor with a wide range of crimping tools is Panduit, a global supplier of networking and electrical infrastructure products. Its CT-1701 is a crimp tool with a controlled cycle designed to ensure connections are fully completed
and uniform. At the high end of its product portfolio, the BlackfinÔ CT-2931/STBT (Figure 5) is a battery-powered hydraulic tool that can deliver a force of 12 tons and features a rotating flip-top crimp head. Another high-end option is the Phoenix Contact CF 1000-series 1208199-ND (Figure 6). The AC powered, pneumatic operation machine automates stripping and crimping, processing up to 1,000 operations per hour. Conclusion To sum it up, there is a crimping tool available to suit virtually any specific need. Whether that need is simple or complex, numerous vendors provide tools for a wide variety of crimping applications. This ensures product developers have almost unlimited flexibility in finding the right balance of cost, utility, ergonomics, and productivity to achieve the desired production results.
As always, the needs of the application are the key determinants in selecting the
Crimpers to meet any needs
appropriate crimping tool. But other key factors at play include budget, anticipated ROI, adaptability, and operator productivity. Today, many types of crimping tools are available, most intended for specific applications. They are also available in versions that can be manually operated, powered by battery or AC, utilize hydraulic or pneumatic energy sources, and come in a variety of form factors, from portable to bench-mounted. Costs range from tens of dollars for manual devices to thousands for pneumatic-powered or automated solutions.
It’s impossible to cover all crimping options here, but the following examples illustrate the range of tools available to meet operators’ needs.
Klein Tools offers a popular, versatile ratcheting tool, the
3005CR (Figure 1). Designed for crimping insulated terminals to stranded copper wire, it has three side-entry cavities accommodating the most common wire gauges. The vendor says the rachet ensures a uniform crimp “every time.”
In the modern era, it has had a momentous impact with its adoption across the ever- expanding range of electrical and electronic applications.
Figure 3: Adam Tech’s ATHT-K3081 handy toolkit for coaxial cable cutting, stripping, and crimping coaxial cable. Image source: Adam Tech
Figure 5: Panduit’s hydraulic, battery- operated CT-2931/STBT can deliver 12 tons of force for crimping operations. Image source: Panduit
Figure 1: The 3005CR ratcheting crimp tool. Image source: Klein Tools, Inc.
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