Cable Terminals - Crimping Core wings

Cable terminals - crimping core wings

Insulated cable terminals

Crimping core wings, shape




Terminal crimping occurs in an enclosed core crimp.
An enclosed core crimp on a cable terminal has a soldered sleeve with an insulating layer of material around it. The cable is inserted in the core wings and crimped in place using a drift type crimp tool.
The cover around ring cable terminals is color coded to indicate the cable area.
Normally this type of terminal does not have insulation wings.
The illustration shows a cross section of a terminal crimping using a crimp tool intended for insulated terminals, referred to in New cable terminal New Cable Terminal Seal sws and plug Seal SWS and Plug.

Uninsulated cable terminals

Terminal crimping is carried out in either an open or enclosed contact.

Enclosed type




An enclosed core crimp on a cable terminal has a soldered sleeve. The cable is inserted in the core crimp and crimped in place using a drift type crimp tool.
The illustration shows a cross section of a terminal crimping using a Volvo crimp tool p/n 981 2451 Crimping tool 981 2451 Crimping Tool , shown in New cable terminal New Cable Terminal Seal sws and plug Seal SWS and Plug.

Open type




On the open type the cable terminals core crimp is U-shaped. The cable is inserted in the core wings from the top. The crimp tool then applies a roll crimp to the contact during crimping.
This type normally has insulation wings.
The illustration shows a cross section of a terminal crimping using the crimp tool from repair kit p/n 981 4235 Replaced by 9512644 981 4235 Replaced by 951 2644 , which is described in the following Choice of crimp tool Choice of Crimp Tool.

Core wings and insulation wings

The cable terminal crimping section consists of two parts which are formed simultaneously in the crimp tool.





Core wings
The core wings (1) are designed to make the electrical connection with the stripped section of the cable (the copper core).

Insulation wings
The insulation wings (2), relieve the core crimp wings from mechanical stress and are located on the insulating sheath around a cable.
The illustration shows a crimped cable terminal without seal.

Core crimp - electrical efficiency
The electrical characteristics for conduction for a contact are that it should be as least as efficient as the cable to which it is connected and provide good contact.
These characteristics are dependent partly on the crimping process to fix the terminal on the cable and partly on the contact made between the two terminals (male and female) in the connector.
The goal is to get a joint with the lowest possible transient resistance and to retain a low resistance even after extended periods of exposure (temperature extremes, mechanical wear etc.)

Core crimp - mechanical efficiency
The joint in the core wings must retain the cable and support it so that it is not subjected to excessive bending forces at the entry point.