Author: Emily

How to Crimp Terminals

When connecting an electrical component to a circuit or anther component, safe and durable connections are essential. One method of creating secure connections is by using conductive crimp terminals.

Knowing how to crimp connections is critical to ensuring safety. When done correctly, wire crimping is a reliable method to ensure safe and secure electrical connections.

Overview of Electrical Crimping

In this context, electrical crimping is the process of joining a wire to a terminal connector by compressing a metal barrel around the stripped end of a wire. On power cables, wire crimping is typically performed at the wire ends. Terminal connectors join the cable with a power connector, plug, or directly to the equipment.

As an alternative solution to soldering, wire crimping uses mechanical force to create a secure and durable conductive connection. Crimped connections are resistant to vibration, stress, and corrosion, making them a reliable method for creating electrical connections.

Material List for Crimping Terminal Connectors

Before starting, be sure you have the right tools and gear. Standard electrical crimping tools include:

  • Wire stripper: Used to remove insulation without damaging the wire.
  • Crimping tool: Select the correct size for the terminal you are
  • Terminal connectors: Choose compatible crimp connectors for your wire gauge.
  • Safety glasses: Protect your eyes while crimping.
  • Heat shrink (optional): Adds insulation and extra protection.

How to Crimp Terminals: A Step-By-Step Guide

1. Choose the Correct Terminal Connectors and Wire

The terminal must match your wire gauge. Using the wrong size can result in an incorrect connection or damage. Select the right type of crimping terminal for your wire and connection.

2. Strip the Wire

Use a wire stripper to strip the end of your wire. Remove approximately ¼ inch (6-7mm) of insulation. Avoid nicking or cutting the copper strands, as this can weaken the connection.

3. Insert the Wire into the Terminal

Slide the stripped end of the wire into the terminal until all of the exposed copper is fully inside. The wire’s insulation and the terminal barrel should sit flush, with no gap in between.

4. Align the Terminal in the Crimping Tool

Crimping tools often have multiple sizes. Position the crimping terminal into the correct size, ensuring the wire remains inside the terminal.

5. Crimp the Terminal

Apply pressure by squeezing the crimping tool until the jaws fully compress the terminal barrel around the wire. This creates the crimp.

6. Inspect the Crimp

Gently tug on the wire to confirm the connection is secure. If the wire is easily pulled out, the crimp was not performed correctly and needs to be redone. Always use a new terminal connector to redo the crimp.

7. Apply Heat Shrink (Optional)

Slide the heat shrink tubing over the connection and apply heat until the tube molds around the wire and the terminal. While this step is optional, it is typically recommended as an additional measure of protection, insulation, and durability.

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Electric Vehicle Part 1

EV plug 1

Electric vehicles have become a way of life. To prove that is true is the new Corporate Average Fuel Economy (CAFE) standard put into place by the Obama Administration. By 2025, every new vehicle sold in the United States will need to reach at least 54.5 mpg. In order to operate, the plug-in hybrid EVs that function on batteries need to be charged occasionally. No more trips to the over-populated, busy gas stations. You can fill up right at home overnight or at work during the day. The car simply plugs in while it is immobile for a given period of time. It can also charge while being driven – once the car is coming to a stop and the brakes are applied, kinetic energy is transformed into chemical energy in the battery.

In order to operate, the plug-in hybrid EVs that function on batteries need to be charged occasionally. No more trips to the over-populated, busy gas stations. You can fill up right at home overnight or at work during the day. The car simply plugs in while it is immobile for a given period of time. It can also charge while being driven – once the car is coming to a stop and the brakes are applied, kinetic energy is transformed into chemical energy in the battery.

Continue reading Electric Vehicle Part 1

How an Electrical Cable is made

Electrical cables are the backbone of a powered society. They carry electrical currents, allowing us to connect to power in all aspects of our lives. From industrial machinery and manufacturing equipment to medical equipment and everyday devices and appliances, these cables ensure that electricity moves safely and efficiently where needed.

But how are electrical cables made? Keep reading to learn more!

What Is an Electrical Cable?

Electrical cables are designed to carry an electrical current from one element to another. They consist of conductors, which are insulated wires suitable for carrying electrical current. Electrical conductors are made from metals such as copper and aluminum. Most wires are made from copper because it conducts electricity with high flexibility and very little resistance.

Electrical wires come in solid-core, stranded, or braided configurations to form a single assembly. The ends connect to two devices, allowing electrical signals to transfer between them. Electrical cables are assemblies of multiple conductors bundled together to transmit electrical power and signals.

How Electrical Cables Are Made: The Process

Step 1

The first stage in the manufacturing process of a conductor is the wire-drawing. Wire-drawing involves gradually reducing the wire’s diameter to its final size. After the diameter is reduced, the wire is drawn further to achieve the required size for each conductor type.

Step 2

In the second stage of this process, the wires undergo a heat treatment called annealing. Annealing is a process of heating metal and slowly cooling it to remove internal stresses and toughen the metal. The purpose of this treatment is to increase the wire’s conductivity.

Step 3

The next step is to add insulation. Because the current runs along the outside of the copper wires, there must be insulation between the inner conductor and the outer conductor. Insulation is the layer of synthetic materials that is applied over conductors for electrical isolation between other wires, conductive surfaces, or from the ground. An inner conductor insulation also prevents any current leakage.

Step 4

Some cables may require additional elements to improve protection. For instance, electrical coverings called “screens” insulate the signals that circulate in the cable, shielding the power cables from external interference.

Step 5

Once the cable’s inner insulation is applied, it requires an outer insulation, called the jacket. The jacket is applied over the insulation for mechanical, environmental, chemical, and electrical protection.

Contact Quail Electronics, Inc. Today to Order Power Cables

Quail Electronics, Inc. has over 30 years of industry experience. Our wide selection of electrical products includes:

With low minimum order requirements, competitive pricing, and same-day shipping on in-stock items, we get you precisely what you need when you need it at prices that work for you.

Contact us for more information or request a quote today to get started on your order.

Hospital-Grade Labels: Explained

In medical environments, electrical safety is non-negotiable. Every electrical component, from monitors to cables to patient beds, must meet strict performance standards to ensure safety at all times. In North America, all cords used to power medical equipment must carry a “hospital-grade” label. This stems from UL standards requiring that patient care equipment used in a patient’s vicinity must have hospital-grade attachment plugs.

Hospital-grade labels are used to identify specific electrical components, verify compliance with predetermined standards, and allow users to easily confirm a product is safe, reliable, and approved for use in medical areas.

Continue reading Hospital-Grade Labels: Explained