Crimp Tool Selection
A crimping tool is defined by the die that brings the terminal barrel to the correct profile; different dies are used for ferrules, insulated terminals and lugs. An end crimped with the wrong tool carries an unmeasurable contact resistance and its mechanical grip is uncertain.
Terminal manufacturers define the shape the barrel will take after crimping: square or hexagonal on a ferrule, oval on an insulated terminal, hexagonal on a tubular lug. The tool produces this shape repeatably. Plain pliers or an unsuitable die squash the barrel but do not generate the required pressure.
- Ratchet mechanism: good tools do not open until the crimp is complete; this way every end is crimped with the same force.
- Cross-section range: each die is for a specific mm² range; a nest designed for 0.5 mm² cannot crimp a 6 mm² end.
- Wear: the die opens up over time; check it periodically by crimping a sample and doing a pull test.
Trying to do every job in the field with a single tool is a common mistake. Keep at least two sets: a die-equipped ferrule crimping tool for small cross-section ferrules, and a hydraulic or mechanical lug press for power cable lugs. These two cover almost all the connection types encountered when installing AXI remote controls and drivers.
Context in which this term is used: DC motor and driver fault diagnosis matrix