Tips on the Use and Maintenance of Hand Crimping Pliers

The cold crimping technology is widely used in the fields of wire harness manufacturing, aerospace, new energy vehicles, rail transportation, connector manufacturing, because of its characteristics of high reliability, simple operation, cost saving and no pollution. This makes manual crimping tools more widely used in related manufacturing industries. Then, do you know how to better use crimping tools to extend tool life? Here I will take M22520 series hand crimping pliers for example to tell you a few about the use and maintenance of crimping pliers.

Tip 1 Crimping pliers are precision tools which can not be transferred to other uses and can not operate the tool indiscriminately. Please crimp with the appropriate force.

YJQ-W1A (M22520/2-01) Hand Crimping Pliers + SK2-2 Crimper Positioner

YJQ-W7A (M22520/7-01) Hand Crimp Pliers + 86-37 Adjustable Crimper Positioner

Tip 2 The right crimping tool should be chose to crimp the terminals and wires. When the size of the terminal does not match that of the crimping pliers, there may be insufficient crimp or excessive crimp. Do not insert rigid steel contacts or solid cylindrical contacts into the crimp hole, otherwise it may cause damage to the crimping pliers.

Different Crimping Tools for Different Terminals

 

Step1 Put the terminal into the crimp hole.

Step2 Insert the wire into the terminal.

                                                  Step3 Press the crimping pliers handle properly to complete crimping.

                                         Simple Instruction of Terminal Crimping Step（YJQ-W2D）

Tip 3 Use with suitable positioners. Install and remove the crimper positioners with the correct method. When you install or remove the positioner, the tool must be in fully open position. After crimping, remove the positioner carefully and store it securely.

Installation of Screw-adjustable Positioner UH2-5(M22520/1-05) 

Installation of TH163 Turret Head

Tip 4 Do not twist the wire to be crimped. Otherwise it will affect the terminal and wire crimping effect, affecting the tension value.

Do not twist the wires to be crimped

Wire Crimping Cross-section after twisting the wire

Tip 5 Keep the indenter tips clean and carefully remove any remaining deposits, but do not immerse the tool directly in cleaning solution.

Indenters tips of YJQ-W2A (M22520/1-01) Manual Crimping Tool

Indenters tips of YJQ-W1A (M22520/2-01) Manual Crimping Tool

  

Tip 6 Crimping pliers should be cleaned and stored in a clean, dry place to prevent dust and impurities from entering the crimp frame, or it will affect the performance of pliers.

The manual crimping tool YJQ-W1A（M22520/2-01）placed in the cleaning box.

Be sure to store it carefully and keep it safe.

Tip 7 Crimping pliers must be regularly inspected and maintained. After being used for a certain period of time, it is necessary to check the accuracy of the crimping pliers with a Go-NOGO gauge. As shown in the picture, operate the tool to the fully closed position. If the “GO” gage end can pass freely, but the NO-GO end can not pass completely, it means the tool is still qualified.

Operation Instruction of Go-NOGO Gauge G125 (M22520/3-01)

            Choose the right one to detect.

Tip 8 If the crimping pliers are broken, parts are scattered or any abnormality is found, stop using them. Do not transform the crimping tool. Do not attempt to disassemble tool or make repairs. Please contact the factory's technical service personnel for repair.

All these use and maintenance knowledge of crimping tools, have you gotten it?

四芯轴压接钳的使用小谈

端子四芯轴压接工具，主要是用于新能源汽车线束及充电桩，充电枪上高电流端子的压接。也用于航空连接器，汽车线束，重载连接器，铜鼻子的四芯轴压接。大家别看这又是航天又是汽车线束的，其实工具的使用并不复杂，只需10个步骤即可完成。如图：

步骤一：准备一把四芯轴压接钳，一根导线，一个端子。今天我准备的是嘉兴市精锐仪器设备有限公司生产的YJQ-W2D压接钳，钳体带了一个调节的绿螺杆定位器（无法取下）。事先已经选取好了适合该端子和导线的档位。

步骤二：钳子处于完全打开状态，将端子放入通孔。

步骤三：将螺旋定位器上调，直至端子露出。

步骤四：再调节螺旋定位器，下调至所需压接位置。

步骤五：锁紧定位器调节螺丝，防止端子走位。

步骤六：将导线放入端子里。请勿随意旋拧剥好的导线。否则会影响端子与导线之间的拉力值。

步骤七：将导线竖立，使之与端子在同一直线。

步骤八：压接。若没有压接到位，钳子无法恢复到完全打开状态。

步骤九：压接完成后，钳子自动打开。

步骤十：取出导线。端子与导线压接完成。

看完之后是不是觉得十分简单呢？

M22520/1-01 YJQ-W2A Aviation Crimping Tool 航空压接钳

飞机、高铁与赛车有个共同特点，那就是速度，当然在保证速度的同时机身内部的连接必须要相当紧密，通常这些连接处都采用美军标的连接器来连接，赛车的连接器跟飞机又不太一样，取决于连接器的适用性。以下是一些相关的连接器。

不管是赛车、高铁还是飞机，经过长时间的运行之后，连接处定需要检查，有时候难免少不了维修工作。其实这些连接器都是由一些线束的插针组成，每一根线束的端头插针需要美军标端子与导线相压接而成。以下的美军标端子要求相当严格。

这时候，连接的关键所在就是端子与导线的压接，这决定了飞机赛车的安全性能。目前各种航空公司和高铁赛车维修上用的都是美军标航空压接钳M22520/1-01(YJQ-W2A provided by Precisetool)，压接的范围是12-26AWG(0.128-3.33mm²).

压接时可适配螺杆定位器M22520/1-05和转塔定位器M22520/1-02、M22520/1-04.

上图中的M22520/1-05又称万能定位器，可用螺杆进行调节端子位置；M22520/1-02与M22520/1-04两种转塔定位器各有三个档位，可适用于三种不同孔径的端子的压接。

压接之后的端子呈现四芯八点，连接极其紧密，形状如下图：

经过长时间的压接之后，需要检验压接钳的精确度，要用到G125通止规。GO端能通过，NO GO端不能通过即表示检验通过。

当然，此工具还适配哈丁连接器的插针端子。取送工具同时可定制。

关于M22520/1-01的压接视频可以查看Youku链接：

http://v.youku.com/v_show/id_XMTg0MDg1MTMzNg==.html

Youtube链接：

https://youtu.be/Yjp6OQm1hL0

Contact:camilla@precisetool.com.cn

Details about Cold-pressed Terminal

Cold-pressed Terminal is the contact of cold-pressed wire, cable or electrical equipment. It is a kind of Accessories Product to achieve electrical connection, divided into the category of connectors. With the ever increase of the industrial automation and more strict and precise industrial control requirements, the dosage of terminal gradually rises. Along with the development of the electronics industry, more and more scope application and kinds of terminals arise.

Cold-pressed Terminal is applied for easy wire connection, it is just a piece of metal inside the ambroin, with two holes in two sides to insert wire. Some with screw can be used to fasten or loosen, for example, two wires, sometimes needing connection, sometimes needing disconnection. This time, we can use terminals to connect them to ensure they can disconnect anytime, and there is no need to weld them or twist them together, so it is convenient. There are all kinds of wiring terminals existing in terminal platoon and terminal box in electric power industry(single, double, current, voltage, ordinary, truncated,etc). A certain crimping area is to ensure reliable contact pressure, to guarantee enough electric current.

Among wiring terminals, the contact force is one of the basic elements. If there isn’t enough contact pressure, it is of no help regardless of good conductive material. If the contact force is too low, displacement will arise between conductor and conducting strip, leading to oxidation stain and overheating caused by contact resistance increasing. Four-indent crimping can well avoid these problems, and the crimped terminals are in stable performance. Precisetool, producing crimping tools for terminals.

Contact:camilla@precisetool.com.cn

Military Connectors in Military Weapons and Equipment

As we all know, peace and development are the two major themes of the world today. The total situation of the world is peaceful. But mankind is still facing the threat of war because hegemonism and power politics still exist. And regional war has never stopped.

Modern war refers to a kind of war that uses a large amount of advanced weapons and technical equipments. The technical level of weapons and military equipments is the main symbol of modern war. Modern war will be of high-tech, high-intensity, high-synthetic. With the improvement of the economic level and technological progress, weapons and military equipments are also constantly updated, precision-guided weapons, long-range weapons, stealth weapons, "soft" weapons and night vision equipment will be a lot of used in the battlefield. In addition, there will be more high-tech weapons and equipments, such as space weapons, directed energy weapons, infrasound weapons, intelligent weapons, remote control vehicles, military robots and so on. Advanced modern weapons and equipments will be an important condition for defeating the enemy in the future warfare.

The quality of weapon and equipments is a big issue concerning the lives of officers and soldiers and the outcome of war. We must take effective measures to improve them. Improving the quality of military connectors is one of the most important part. Military connectors are the basic components that constitute a complete weapon system in electronic systems. The main difference between military connectors and other connectors lies in the robust construction, the manufacturing tolerances and the high level of testing. Therefore, the high reliability and high manufacturing cost is a significant feature of military connectors. Military connectors mainly include circular connectors, rectangular connectors, printed circuit connectors and RF connectors. Meanwhile, military connector is an important driving force in the international connector market. The circular connector is the most commonly used military connector among all types of connectors which can adapt to a wide range of cable and has rugged and reliable structure with fast and convenient connection and extreme resistance to harsh environments. The circular connector is widely used in aerospace, aviation, naval vessels, electronic and nuclear weapons and other equipments. The main criteria for circular connectors are MIL-C-38999, MIL-DTL-5015 and MIL-C-26482. Among them, MIL-C-38999 series connector is the highest level of circular connectors with the US military standards.

The quality of the connectors is closely related to the crimping quality of the wires and terminals in military connectors. Compared with the traditional hexagonal crimping, the performance of four-indent eight-impression crimping is much better in the anti-cold and heat resistance, tensile strength and self-locking capacity. In the military field which has high standards and high requirements, four-indent crimping is widely used, especially in the manufacture of military connectors. Therefore, M22520 series of four-indent eight-impression crimping tools play an increasingly important role in the field of military equipment.

YJQ-W2A Hand Crimping Tool

YJQ-W1Q Pneumatic Crimping Tool（M22520/2-01）

TS-01 Pneumatic Crimping Machine

The quality of weapon and equipments is a big issue concerning the lives of officers and soldiers and the outcome of war. Therefore, to ensure the quality of connector crimping tool is the important responsibility and important mission of its manufacturing enterprises.

轨道交通装备接线端子冷压接工艺研究

随着轨道交通装备业的不断发展，其电气化程度得到了很大的提高。轨道交通装备的内部配线由原来的几十根发展到了几万根。

线缆作为电气传输的媒介，载体，是电气系统的重要组成部分。线缆通常由导线及其两端的接线端子构成，导线与接线端子的电连通效果直接决定了线缆的传输性能。导线和接线端子之间通常采用冷压接，焊接，刺破等方式实现电连通。在各种电连通方式中，由于冷压接的高效，可靠，节省空间等优势，使得轨道交通装备行业中连接工艺已经由最初的焊接方式过渡到了冷压接方式。

端子冷压接原理

冷压接连接技术是在常温下，用压接工具或设备对两个特定的金属表面施加一定的压力，使金属结合部产生恰当的塑性变形而产生可靠的电气连接，具有很好的机械强度，优良的电气性能和耐环境性。

冷压接后的接线端子在压接部位存在由强压变形后所产生的残余应力和导线受压变形后的回复弹力组成的对抗力（对于多芯线来说还具有扭应力更加大了此弹性力）。

工作原理

1、压接方式

压接钳采用曲线推进机构，作用力由右钳柄头部腔内的四条曲线传递给四个压头，压头做向心直线运动，压头前端的压齿压接接触体而完成导线与接触体的压接。压接到位后消除作用在钳柄上的力，在弹簧的作用下，四压头自动复位。四压头进退动作协调，压痕深浅一致，可靠地保证了导线与接触体的压接质量。

2、压接范围的调节

压接钳一般是8档位的调节转盘，将压接范围内精确分成8个档位，
根据不同的导线尺寸来选择相应的档位。

3、压接锁止机构

压接钳有自锁止功能，没有正确完成压接时锁止机构发挥作用，钳柄不能张开，压接工件不能取出，当正确完成压接时锁止机构打开，钳柄可以张开，压接工件可以取出，完成压接。

压接图样

冷压接的压接方式操作简便，适宜在不同场合进行操作。生产效率高。成本低，无污染。省去了浸锡，清洗等工序。既提高了生产效率，又节省了材料，降低了成本。且无有害气体和助焊剂残留物的污染。

不光在轨道交通方面，目前兴起的新能源汽车，航空航天，充电桩，充电枪，电子电工等行业也广泛的运用了我们的冷压接方式。它高效便捷的工艺已经慢慢地走进了我们的生活，充斥着我们的生活，也将我们的高新科技，机器人，宇宙飞船赋予了更加有力的翅膀。推进了科技近一步的发展！