Crimping Tools for Terminals
(823)Crimping tools for cable lugs (terminals) are indispensable pieces of equipment of every electrical technician. Apart from cable lugs themselves, crimpers should not be missing from your household toolbox either. They serve a vital function, as they help ensure the proper performance of electrical connections in distribution, fuse or junction boxes, receptacles and many other points of the electrical (mains) system . These tools are not expensive (although dedicated, proprietary solutions are sometimes priced in proportion to their precision and durability), but the benefits they provide are hard to put a price on: crimping tools increase the safety of users, reduce the risk of failure, fire, and streamline your work with wiring.
Although cable lug crimpers are relatively simple tools, when choosing the right product that will be suitable for a given job, it is necessary to pay attention to several key parameters (you will read more on this below). It is not worth spending your money on a random product – you should bear in mind that: (1) it will most likely be used in many situations, not necessarily just occasionally; (2) suppliers offer a variety of multi-purpose solutions, so you can easily get a tool that will last for many years and come in handy for many different jobs. These don’t have to be tasks related to power supply systems, as cable lugs are also often used during the installation of control systems in automated machine parks, as well as in the construction and maintenance of electronic devices . Practically speaking, they will be useful when doing any work involving connecting a cable with a stranded conductor to a screw connector (a port, block, terminal), such as a terminal strip.
How to choose the right cable lug crimping tool?
The function of a cable lug (terminal) is to connect firmly all the strands of a conductor to ensure a minimum resistance and firm attachment in a screw terminal or other type of terminal. The choice of a crimping tool will mainly depend on the type of terminals or connectors that you are going to use. The most important feature here is the cross-section of the cable, which in turn is related to the type of system you are working on. Be sure to pay close attention to the cross-section, not the diameter of the wire. Most crimping tools support several cable sizes. If you are working with mains (and other power supply) systems, crimpers that support cross-sections from 1.5 mm2 upwards will be the best choice. Smaller conductors are used inside appliances, in the automotive industry, they are also widely applied in electronics.
Tools of this type can take the form of simple pliers or may feature more complex mechanisms (such as a double lever). The openings in the jaws also come in different shapes (e.g. hexagonal). The TME offer also includes crimpers with z interchangeable jaws, thanks to which you can use one tool for different jobs. A similar advantage is offered by some tools equipped with a multilateral pressure point that handles a wide range of cable lugs with a single slot in the jaws – this eliminates the need to search for a dedicated slot for a given cross-section and speeds up your work. However, it should be mentioned here that the flange of insulated cable lugs comes in a colour that denotes the diameter of the component.
Most good quality crimping tools are made to provide optimum connection at every use. Crimping cable lugs “by feel” not always renders the desired result. One method to prevent errors is to use the handle locking ratchet mechanism – it is released only when the jaws are fully clamped. In this way, you can be sure that the lug has been crimped properly, using the right force. In the case of some models, it is possible to adjust the crimping force with an adjustment knob.
Key features of cable lug crimpers
In addition to the range of diameters supported by a given crimper, you should also pay attention to some other features. The first one is the lever mechanism – when performing frequent and repetitive jobs (for example, when routing complex systems), the ease of use will play a key role, as you may quickly feel fatigue in your hand – professional tools help you avoid problems related to muscle strain. Another important feature is the width of the jaws: in some versions they grip the entire sleeve, in others – they apply pressure to one point (this requires less force, but if you choose the wrong slot, you may cut through the lug).
It is also worth noting that selected models of crimping pliers are provided together with a hardcase or a pouch, so they stay protected when transported in a tool bag, while working in the field, etc. If, on the other hand, you need a crimper for occasional (household repairs) or amateur work, it may be a good idea to purchase an entire kit that includes not only the tool but also cable terminals.
Finally, be aware that most major manufacturers, especially those who specialise in connectors, offer proprietary, dedicated tools. In general, these products are expensive, yet durable and perfectly tailored to a given scope of applications.
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