Cable termination process tutorial: cutting tool selection, crimping steps and insulation treatment specifications

Cable termination process and crimping specifications

Electrical Engineering Fundamentals - Crimping Standards - Safety Practices

I. Cable cutting

Before cutting the cable, the appropriate cutting tool should be selected according to the specification and material of the cable, as shown in Figure 17-7, to ensure the cutting effect and safety.

Figure 17-7: Demonstration of Common Industrial Cable Cutting and Stripping Tools

There are two things to keep in mind when cutting cables:

1. Security:
When cutting cables, use appropriate protective equipment such as gloves and goggles to prevent injury from flying debris.

2. Correct operation:
Determine the length of the cable cut according to the needs, and follow the instructions for the tool to operate correctly, as shown in Figure 17-8, taking care to avoid damage to the tool or injury to personnel due to improper operation.

cc4a2e8b1baa2e3202f8d48cd041092b Figure 17-8 Cable Cutting

In short, the selection and use of cable cutting tools should be based on the actual situation to ensure that the cutting process is safe and the cutting end surface is flat.

II. Processing of cable ends

The process of crimping cable ends consists of the following key steps:

1 intend

Ensure that the cable and terminal (or terminal) specifications match, as shown in Figure 17-9, select the appropriate crimping tool and mold. Strip off the outer jacket of the cable first, and then strip off the insulation layer (be careful not to hurt the conductor), to expose the internal wires, the length of which should meet the crimping requirements. Clean the surface of wires and terminals (or terminals) to ensure that there is no oxidized layer, oil or other impurities.

Figure 17-9: Cold Pressed Terminal Blocks and Copper Noses, Various Sizes

2 end crimp

Insert the stripped wire into the end (or terminal), making sure that the insertion depth is appropriate and that the wire is evenly distributed within the end. Use the crimping tool to crimp the end and wire, as shown in Figure 17-10. Crimping, should ensure that the pressure is uniform, moderate, to avoid too much pressure to cause the end rupture or too little pressure to cause the crimp is not solid.

[Image showing a manual or hydraulic crimping tool performing a compression on a cable lug and conductor]

Figure 17-10: Hydraulic crimping pliers for end crimping of cables with large cross-sections.

3 end handling

After the crimping is completed, check whether the crimped part is tight and firm, and whether there is any looseness or deformation. At the same time, check whether the contact resistance between the wire and the end meets the requirements. Perform necessary insulation treatment on the crimped part, such as wrapping insulating tape or installing insulating sleeve, etc., as shown in Figure 17-11, to prevent electrical short circuit or electric shock accident.

Figure 17-11: Terminal Block Heat Shrink Tube Insulation Header Process

⚠️ 4. Cautions

(1) In the crimping process, safety operation procedures should be strictly observed to ensure personal and equipment safety.
(2) Selection of suitable crimping tools and molds is very important, wires, crimps, ends need to match each other, they directly affect the quality and effect of crimping.
(3) Cables and ends (or terminals) should be carefully inspected and prepared before crimping to ensure that there are no defects or damage.
(4) Upon completion of the crimping, the necessary tests and inspections shall be performed to ensure the quality and reliability of the crimp.