July292022

Crimping pliers for wire tips: methods of application

Crimping pliers for wire tips: types of tools and methods of application

In order for the contact of the electrical wires to be of high quality and contribute to the supply of electricity to the desired object for a long time, it is necessary to perform the connection using appropriate tools. Crimping pliers for wire tips provide a sufficient connection area. It is only necessary to choose the right size of the matrix and consumables – tips and bushings.

For crimping the tips, in order to fix them at the ends of wires of various cross-sections, manual press pliers are used

Tip crimping pliers: professional and household tools

Electrics is a field that requires impeccable compliance with the rules, following precise technologies, and the use of special tools. Special attention should be paid to wire connections. Any inaccuracies and half-measures will necessarily lead to damage or contact breaks.

Crimpers are professional tools for electrical installation, and they are produced by many manufacturers of hand tools

Twists have long been a thing of the past. They are strictly prohibited by the Rules of technical operation of electrical installations of consumers. To date, there is a special tool – pliers for crimping wires. They consist of handles and a replaceable matrix, when choosing which you need to take into account the purpose of the connection and the cross section of the cables.

According to the technical features and the method of operation , the ticks can be divided into two categories:

mechanical (manual);
automatic (powered by electric drives).

Division is also carried out within categories. Mechanical pliers can be household and professional. With the help of household wires, crimping is performed with a small cross section: 1-2.5 mm – copper; 2.5 mm – aluminum. It is possible to use a cable with a cross section of 4 mm to power powerful household electrical appliances.

A powerful, professional tool is used for crimping wires with a cross section of 6 mm or more. Thick power wires and cables in industrial installations are crimped automatically.

Pliers for crimping tips are mechanical and automatic

The main types of crimping pliers for tips

The need to use crimping for wires may arise in two situations: in the case of preparing live parts for fixing to the terminals of various electrical appliances and when connecting wires and cables. Depending on the purpose, one or another crimping tool is used. Based on the design features , the pliers can be divided into two main types:

functioning on the principle of pliers;
diaphragmatic.

The first option is the most common. The pliers are crimped on both sides, they are distinguished from the pliers by special recesses on the sponges, which allow you to make the connections as strong as possible.

The convenience of using this type of tongs is that you do not need to choose the position of the tips, you can perform an action from either side. Some problems appear in situations where the sleeve does not fit into the matrix. In this case, we need another pair of ticks.

Useful advice! Before performing such electrical work, it is necessary to make sure that the dimensions of the tool and consumables match. As a way out, it is worth buying a universal model of ticks with a set of matrices that are fixed on a special cassette.

The crimping of the end with diaphragm press pincers is characterized by a high density

Diaphragm presses for wire tips crimp the sleeves from four or six sides, and they themselves adjust to the thickness of the cable. Crimping the end in this way is characterized by high density.

A special kind should include crimpers. Although many people call any crimping pliers that way, in this article this concept will be applied to a tool for working with computer and Internet connections. About the specifics of this device – further in the materials of the article.

Methods of using press tongs for crimping tips

Wire crimping works can be permanent or episodic. In everyday terms, the second option is more characteristic. In such cases, there is no need to purchase universal wire crimping pliers. It is worth choosing a narrow-focus tool that will help solve specific tasks.

The main functionality of this type of tool includes:

Crimping of sleeves. The tongs required for this type of crimping vary in shape and size of the matrix. A flange may be present as an additional structural element. Its presence will allow you to make a better connection.

Removal of the insulation layer. With the help of pliers, you can remove the necessary section of the insulation coating without directly damaging the core. It is important to set the size correctly. If experience is not enough, it is better to purchase a tool where the size is set automatically. Such models are more expensive, but they provide high-quality work.

Crimping of the tips. Presses for crimping wire tips have a special rod, which is placed on the dividing seam during the execution of the action. The device is designed to work with non-insulated and brass wiring.

Working with twisted pairs. In such a crimping device, the wire is wound into a special connector.

Press pliers are often used when crimping sleeves

Only a properly selected tool will allow you to perform a high-quality connection.

Hydraulic press pliers for crimping wire tips

Hydraulic mechanisms are actively used in the course of electrical installation work. The main components of such pincer presses are:

handles;
axis;
head;
the matrix.

In hydraulic clamps for crimping wire tips, the head can be closed and open. With the closed version, the stopper is first opened, the matrix is pulled out, the wire with the sleeve is laid, closed, and only after that the crimping is performed. In an open-head design, there is no need to carry out preparatory actions, so the crimping takes place much faster.

Each model of hydraulic clamps is designed for a certain size range of wire cross-sections. The maximum index is 400 mm. In everyday life, such cores are not used, but it is convenient to work with a tip for wires for crimping 6 mm with hydraulic pliers. However, there is a danger of pinching.

Hydraulic manual press for crimping cable lugs can have a closed and open head

Useful advice! To work with a soft wire, it is better to purchase a hydraulic press with a limiter. It will avoid overloading the tool.

In order to more clearly imagine the consequences of squeezing a hydraulic press, it is worth understanding the mechanism of its action.

Due to the swing of the handle, the plunger (pump piston) produces translational and reciprocating movements, a certain pressure is created, under the influence of which oil enters the cylinder. The oil moves the cylinder, which, in turn, creates pressure in the matrix, and it acts on the sleeve with the necessary force.

A tool for crimping Internet wire tips

Stable operation of any cable system consists of several indicators. First of all, it is the quality of the material of the cable itself. This is followed by the professional level of the specialists who carry out the installation. The technical condition of the equipment matters. It is completely unreasonable to name the quality of connections among the latter.

Many models of pliers for crimping Internet cables are equipped with special wire cutters

Contacts are quite often the cause of unstable or weak signals. It is possible to avoid problems associated with unprofessionally made connections in the operation of the cable system only by using a special tool – crimping press tongs, which are called “crimper”.

The execution of any cable connection always begins with the removal of insulation from the ends of the wires. For these purposes, there is also a separate type of tool called a “stripper”. With its help, the top layer is removed, there is no danger of damage to the vein. Alternatively, you can purchase a crimper, which has elements that allow cleaning. This is a hole with a blade on one side. By inserting the wire and scrolling it once, you can get the desired result.

Crimpers for crimping tips and stripping wires are actively used by specialists when installing structured cable systems.

Crimper for crimping tips: design specifics, application

The principle of operation of crimpers for crimping wire tips is the same as that of two-hole pliers. The difference is that the latter clamp the sleeve, and the crimper plugs. More precisely, it is not crimping in its standard sense, but there is a displacement of contacts, which leads to tight pressing. This tool is designed to work with twisted pairs.

The cable connection always begins with removing the insulation from the ends of the wires

Before crimping with a crimper, it is necessary to carry out an even pruning of the untwisted conductors. If this is not done, it will not be possible to achieve a uniform position in the connector, and this will affect the quality of crimping. You can do this with ordinary wire cutters, but this does not always give the desired result.

Many models of pliers for crimping Internet cables are equipped with special wire cutters. They are blades that close tightly when the tool handles are pressed.

Important! Before cutting, the straightened wires must be placed in the sequence necessary for the connection (by color).

There are many varieties of crimpers. The principle of operation is the same for all models, but there are differences in connector standards. On the body of the crimping pliers for cables, there are necessarily designations indicating the purpose of the tool. For example, RJ 45 is designated as 8P. This indicates the standard and the maximum number of pairs. RJ 11 – 6P, the maximum number of pairs does not exceed 6.

A typical crimper for crimping has convenient plastic handles and a steel body and sponges

Crimping pliers for crimping wire tips RJ 45

RJ45 connectors are among the most widely used in the field of computer networking. RJ is a Registered Jack, a standardized network interface. The case of this device is much larger than RJ 11. The latter cannot be used for computer connections, it is used when laying telephone cables. The internal content and the principle of functioning of these two types of connectors are almost identical.

The crimping pliers for RJ45 cable lugs are selected according to the marking. As for the general requirements, you should pay attention to such indicators:

Weight. Small most likely indicates the use of insufficiently durable materials for the manufacture, so you should not count on a long service life. Excessively heavy ones will contribute to the rapid fatigue of the hands.

The shape of the handles. It should be ergonomic, comfortable to grip.

The presence of defects. Traces of dents and other mechanical damage may be a consequence of improper assembly. It is worth paying attention to the contact lines of blades, sponges: even minor deviations will affect the quality of crimping.

Among the most popular models of hand press tongs for twisted pairs can be attributed Hanlong NT-500. The tool is designed for both RJ45 connectors and RJ11 and RJ12 variants. The crimper is equipped with blades for trimming and for removing insulation. The price of the product is 1250-15000 rubles. The model should be classified as professional.

The crimping pliers for RJ45 cable lugs are selected according to the marking

Inexpensive 5bites LY-T568R tongs are in high demand. They are also designed for three types of connectors, have blades. The products are lighter, weight – 340 g, less durable (according to user reviews in social networks). They can be purchased for 450-500 rubles.

Varieties of tips for crimping stranded wires

In the above article there is a lot of information about the tool with which the crimping is performed. But for the quality of the connection, it is equally important to choose the right tip. There are also several types of them. Let’s focus on products for stranded wires.

A tool for removing insulation from wires: a variety of devices

Characteristics, scope of use. Types of devices. Types of strippers. Popular models of famous brands.

Copper tips. Externally, they are a copper tube, flattened on one side, in which there is a bolt hole. Such tips are divided into uncoated (TM) and tinned (TML) elements. The latter are used in cases where it is necessary to perform a connection with high anti-corrosion properties. Crimping of wires with tips of this type can be carried out by any type of pliers, the matrix of which corresponds to the cross-section dimensions.

Copper with a control hole. This option is not subject to crimping, soldering is used for the connection. The information is placed for general information. Externally, the tips are similar to the previous ones, they differ only in the presence of a hole through which the position of the conductors is viewed.

Insulated lugs are suitable for stranded wires, non—insulated ones for single-wire rigid ones

Aluminum. Aluminum wires are crimped with tips made of the same material. Externally, they are absolutely similar to copper, marked with MA.

Important! Before crimping, aluminum conductors need to be treated with quartz-vaseline paste. It prevents the appearance of an oxidized film.

Press pliers for crimping tips of this type can be used both hydraulic and manual.

Pinned. With their help, one-piece connections are made. They are designated by the abbreviation NSHVI – insulated pin bushing tip. The wires cleaned of insulation are wound into the sleeve and crimped with the help of pliers.

Copper tips with control holes are not subject to crimping

Tip for crimping wire: ring, hook, fork

To connect to the terminal blocks, you need to use tips that will ensure the most reliable connection. The main condition is that they must match the type of this terminal block. To date , there are three main types of such tips:

Ring. Their purpose is to connect to screw terminal blocks. Providing a large contact surface is one of the advantages of this type of tips. A similar option is used for temporary and permanent connections in low-voltage networks.

Tips of the “hook” type. They create a contact surface a quarter smaller than the annular ones. To crimp the electrical cable with tips of this type and attach to the terminal, you do not need to completely unscrew the mounting screw. Such tips are more often used for temporary connections or in situations where it is impossible to unscrew the screw for some reason.

Forks. Such tips have a contact surface that is 50% smaller than that of ring tips. It is for this reason that they are more often used for temporary connection when a constant change of contacts is required.

There are other types of tips, but they are specific and are used quite rarely, mainly by professional electricians when installing complex circuits.

With the help of press tongs, various types of tips can be pressed: ring, fork, pin

Tool of domestic production: pliers for crimping the tips of wires KW

Among the tools of domestic production, attention should be paid to press pliers for crimping the tips of KW wires. The main enterprise is located in Kaluga. STF sets, which include matrices for crimping insulated and non-insulated tips, and STV sets, which include numbered matrices, are particularly popular.

The set of STV consists of the following subject units:

press tongs;
5 numbered matrices;
a plastic case.

The pliers are equipped with a mechanism for quick replacement of matrices. High-quality steel is used as a material for the manufacture of the tool. In the design of the press there is a lever for unlocking. If the matrix size is incorrectly selected, the crimping process may not end, as a result of which the handles will lock in the intermediate position. In such cases, the tool is returned to the starting point using a lever.

It is worth noting that the handles of the pliers are elongated, this allows you to crimp with two hands. Five matrices make it possible to choose the option needed for a certain type of tip.

Press pliers for crimping the tips of KW wires are quite a popular tool

The CTF set also has 5 matrices. The tip press pliers are not equipped with a device for quick replacement, so a hex wrench should be used. The process of replacing the matrix takes quite a long time, sometimes even more than the crimp itself. The STF kit (unlike the STV) has two additional screws for the matrices in case of loss or damage to the used one.

Important! When inserting matrices, in order not to make a mistake, it is necessary to pay attention to the size of the slot: the large one goes towards the handles, the smaller one goes in the direction of the head of the ticks.

Crimping pliers for wire tips: how to choose

In the variety of crimping terminals offered by manufacturers, it is quite easy to “get lost”. Product descriptions in online stores are full of positive characteristics. The following tips will help you navigate and choose the right tool model:

The choice should begin with a clear definition of tasks. It is based on them that it is necessary to select the size and functionality of the press tongs. If repeated crimping, stripping of contacts and cutting of wires are coming, it is worth purchasing a universal version of the tool.

For crimping and connecting cables with a large cross section, it is more convenient to use a hydraulic mechanism.

Important criteria are the price and the manufacturer of the tool. Proven brands are always more reliable. A small cost is likely to be an indicator of the fragility of use.

When buying, you should definitely check the press pliers for crimping tips for defects and assess the build quality: using visual inspection to identify possible dents and chips, check the correctness of the contact lines of the blades, the position of the handles.

Be sure to pay attention to the shape of the handles. The presence of recesses for gripping contributes to a more reliable tool retention.

It is recommended to hold the tongs in your hands. Possible inconveniences related to shape and weight will definitely manifest.

Among the extensive assortment of crimpers on the market today, everyone can easily choose a tool according to their profile

Performing crimping of wire tips with your own hands

Theoretically, wire crimping is not a complicated process. The availability of tools, appropriate consumables and some physical effort is all that is needed. In reality, the connections may leave much to be desired, and sometimes you even have to repeat the procedure. This sequence of actions when crimping wires will be useful to those who are ready to perform the termination with their own hands:

It is necessary to process the cable, remove the insulation using a special device, leaving a margin of 0.3 – 0.5 cm. If the stripping was still done with a knife, you should make sure that the vein is not touched. If damage is detected, the site will have to be removed.

Put a piece of thermal insulation braid on the wire. Wipe the open part with alcohol, degrease and apply a special paste on it.

Set the desired cross-section size and tip type in the matrix. Insert the tip to the end.

The cable cores in the straightened state should be laid all the way into the tip.

Press the handles of the crimper. After a characteristic click, the compression can be considered completed. The handles should return to their original position.

Return the piece of braid to the junction, warm it up with a construction hair dryer.

The crimping of the wire tips is performed in a certain sequence

There is an opinion (and some do) that it is not difficult to perform crimping without special tools, using ordinary pliers. To a certain extent, this is permissible, but only for wires of small cross-section and, if necessary, make a temporary connection. The tight fit of the tips to the core can only be provided by a matrix. And then the ingress of air, water, metal oxidation is excluded, the connection functions for a long time and reliably.

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