Crimping machine

Types of crimping machines

A crimping machine is a specialized tool used for securing the fittings (crimps) on hydraulic hoses. It is an essential piece of equipment in the hydraulic hose fitting industry. However, hydraulic crimping machines also play an equally important role in the electrical wiring industry.

There are multiple ways to categorize a crimping machine based on its application, the materials it works with, and its design and operating mechanism.

• Application: This refers to what the crimper is used for. Hoses are reinforced with high tensile steel for use in heavy-duty industrial settings. Crimpers for these industries will focus on hydraulic applications. The same goes for electrical wiring. Wiring that deals with high voltage will require a special-duty crimper.
• Material: Crimping machines can be made to work with different pipe materials, including plastic, rubber, PEX, and PVC. Crimpers that work with plastic pipes will differ significantly from those that handle rubber pipes.
• Design: Crimping machines are primary categorized into bench-top, manual, electric, and nylon crimping tools. Manual machines require physical effort to operate. Bench-top machines are the ones that sit flat on the work bench. Pneumatic crimpers use air pressure to function, whereas electric crimpers are powered by electricity. Electric crimpers are easier to use and more efficient than manually operated machines.

Crimping machines are further divided based on their capacities and sizes. Small machines can handle low jobs, whereas bigger, industrial-grade machines handle bulk requirements.

Specifications and maintenance of crimping machines

Specifications

• Operating voltage

  The working volts for a hydraulic crimper are usually between 12 and 48. Base this on the type of machine. An alternating voltage of 220-240 is needed for a bench-top electric crimper.

• Operating current

  A crimping machine works with low voltage and high currents. Handheld crimpers use between 200 and 400 amperes. Battery-powered crimping tools offer higher amperage talks. Bench-top machines have a higher operating current since they perform larger jobs.

• Dies

  The die sets for the crimper indicate what type of fittings the machine can handle. The die sets can handle many types of materials, like hydraulic rubber hose ends and wire connectors. Usually, the die sets are indicated in fractions, for example, 1/4-1/8. Some may indicate the size in millimeters.

• Cable Crimper

  A specific crimper makes connections for coax cables, Ethernet, audio, and video cables. The dies required for this job will vary. Also, the size of the connector or pin will differ with each type of cable.

• Hydraulic Crimping Machine

  A hydraulic crimping tool has a ram that applies the force to compress the connector onto the wire. A handheld hydraulic crimper is more portable for smaller jobs or at least. Bench-top machines do not require pumping force and work at about 20 tons of pressure. Large machines used for industrial or digging jobs will have specifications showing that they can apply more than 200 tons of force.

Maintenance

• Speed:

  A crimping machine puts a lot of stress on the wire when joining two parts. It does not stretch when the crimp is too loose or crimp higher than the recommended max. There are many ways to control the speed and force of the tool. A hydraulic crimper uses fluid pressure to control the force. Some tools use electric motors with gearboxes to increase torque and control speed.

• Force:

  Check moving parts so they are working well over time. The ram has a protector that needs to be greased to protect it from wear and tear. Examine and lubricate any exposed connectors or moving parts.

• Receiver

  Replace crimping dies based on the type of wire and connector used. Changes may be needed for different shapes, sizes, or products.

• Hydraulic oil

  Whether it is a hand-held or bench-top crimper, all machines use some lubricant or oil to keep it working smoothly. Check to see if it is shiny and does not have any metal shavings indicating wear. If it looks dirty, change it. If the machine makes noise, check for any worn-out parts.

• Wear and tear

  Change crimping dies based on the type of wire and connector used. Changes may be needed for different shapes, sizes, or products.

Industry scenarios of crimping machines

Crimping machines serve various purposes in different industries. In the electrical industry, they are used to attach lugs, connectors, and other terminals to wires and cables. As mentioned earlier, this process involves exerting force to make strong and secure joints that facilitate the smooth flow of electrical currents.

The plumbing industry also heavily relies on crimping machines. Here, the machines are used to join pipes, especially those made of copper, including gas, water, and HVAC pipes. Crimping machines provide quick and affordable solutions for plumbing issues and ensure strong joints that guarantee leak-free services.

Crimping machines also find extensive use in the automotive industry. Manufacturers and mechanics use them to attach terminals and connectors to automotive wires and harnesses. Crimping machines ensure proper crimping of connectors that will eventually support vehicle electrical systems like ignition, sensors, and lighting.

Construction companies use crimping machines when implementing various electrical and plumbing solutions. They use the tool to join metal pipes, wires, cables, and HVAC components. Crimping machines provide strong and durable joints that enhance the reliability of electrical and plumbing systems.

As highlighted earlier, hydraulic crimping machines are popular in the cable and wire industry. They are used to make audio cables, battery cables, and fiber optic cables, just to mention a few. Crimping machines ensure the cables are properly and uniformly crimped to improve performance and make them easy to use.

When it comes to mass-producing products that require crimping, companies turn to automated crimping machines. These machines use advanced technology to automate the crimping process, increasing efficiency and productivity. Automation crimping machines find extensive use in the electrical, automotive, and plumbing industries.

How to choose a crimping machine

The following tips can help buyers select a good crimping machine.

• Industrial requirements analysis

  Before buying a crimping machine, buyers should analyze their specific needs. They should know the application industry and type of material to be used. Understanding the kind of hose and fitting shape to be crimped will help buyers select a machine designed for those specific requirements. Buyers will select a more complex or industrial-grade crimping machine if they need greater accuracy.

• Production volume consideration

  The machine's type should depend on production volume. A handheld crimper may suffice for low volumes or occasional use. In contrast, an electric or hydraulic machine will be better for mid- to high-volume production.

• Machine sizing and dies

  Buyers should consider the machine's size and the number of crimping dies. The die types and sizes differ, and a versatile machine allows for faster changeovers and crimping of various products.

• Die change process

  It is essential to determine how quickly and easily the machine can change crimping dies. A machine with easy-to-use dies minimizes downtime. Please, also, examine the durability and quality of the crimping dies that come with the machine.

• Quality and Support

  Have a preference for manufacturers that comply with international standards and have certifications. Check the physicals and operational capabilities of the machines offered for sale. Also, consider the technical support and spare parts supply.

Crimping machine Q&A

Q1. What is a crimping machine used for?

A1. A crimping machine connects two pieces of materials together. It permanently joins electrical wires and connectors and forms various mechanical joints for different industries.

Q2. Are automatic crimping machines worth it?

A2. An automatic crimping machine is more expensive than manual and semi-automatic models. However, it adds greater production efficiency. Businesses that manufacture large parts in different sizes can consider investing in the automatic model to save time.

Q3. What are the advantages of a crimping machine?

A3. A crimping machine creates a close, reliable connection. It produces consistent crimps with uniform shapes. The machine eliminates the need to solder wires to connectors, reducing labor costs and turnaround time.

Q4. What are the types of crimping machines?

A4. The main types of crimping machines are the flywheel type, electromotive type, and hydraulic type. The flywheel machine uses the flywheel as its power source. It is suitable for small parts. The hydraulic machine has a motor-driven pump and high-pressure hydraulic oil. It works with high operating pressure. Electromotive crimping machines use an electric motor for heavy-duty crimping works.

Q5. What are the parts of a crimping machine?

A5. The crimping machine has a frame that supports all components. The hydraulic cylinder performs crimping actions, while the cutting die set has various dies that change according to the material and shape. Other parts include the control system, pump assembly, sensor, and ejector system.