Author Topic: Tutorial: How to crimp connectors, strip wire and use heat shrink.  (Read 6916 times)

MJLorton

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Video here: http://youtu.be/kjSGCSwNuAg

Add your experiences and pearls of wisdom....

NASA guide / workmanship attached.

Play, discover, learn and enjoy! (and don't be scared to make mistakes along the way!)

SeanB

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Re: Tutorial: How to crimp connectors, strip wire and use heat shrink.
« Reply #1 on: March 16, 2013, 11:07:37 AM »
For joining cables use this RS part  391-980, a solder sleeve that shrinks and provides environmental sealing.

For the adhesive lined ones look at  157-3852, works well, and especially for a battery terminal provides extra corrosion proofing, as then acid will not find it so easy to migrate under the sleeve and corrode the wire from inside and migrate up the wire, corroding it as it goes up.

As well with the crimping tool, the insulated crimping tool you showed has a directionality, as the dies are shaped so as to provide an oval crimp on the copper tube and a star pointed crimp on the insulation, so that the copper of the tube is crimped to the cable evenly while the insulation is gripped in 4 places to provide strain relief.  Put them in backwards and they do not crimp as well. The uninsulated ones do not have this need, so can go in either way, providing the crimp indent is at the middle of the tube, it can go anywhere in the tube but is best on top for consistency, so it is easy to check all have been crimped. Better tools use a 6 sided tool, that crimps the tube all around to reduce the diameter in the middle so as to get the high pressure that makes a gas tight connection.

Aditya

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Re: Tutorial: How to crimp connectors, strip wire and use heat shrink.
« Reply #2 on: September 19, 2013, 11:21:19 AM »
My Questions are
1.We have HT motors the winding is made up of copper and it is provided with a copper lug for termination with the power cable.The Power cable we are using is of aluminium 400 sqmm for a 6.6kv motor.(We can terminate the aluminium cable with copper lug  and connect with the motor copper lug or we can keep aluminium lug to cable and by providing a bimetallic washer we can connect  with the copper lug of motor)Please suggest us the right approach
2.We are finding some punctures at the cable termination end and heating of lug at the termination.The entire heat shrink sleeve portion is becoming very hard due to heating.What can go wrong in this case.
3.Which nut bolt to be used between these lugs ss or ht bolt

AB1BE

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Re: Tutorial: How to crimp connectors, strip wire and use heat shrink.
« Reply #3 on: October 02, 2013, 03:23:22 PM »
More info on crimping good practice can also be found in this NASA Technical Standard - NASA-STD 8739.4 "CRIMPING, INTERCONNECTING CABLES, HARNESSES, AND WIRING". It confirms what Martin noted in his tutorial on crimping. Lots of great info on wiring. For your convenience, I've attached a copy.