CONNECTION TECHNOLOGIES

Connection Techniques

Crimping is a connection technique where cables and conductors are pressed into connectors using a crimping tool. A metallic sleeve (crimp sleeve) is placed over the corresponding cable and compressed with the crimping tool. For example, in a coaxial cable, the inner conductor is inserted into a ferrule and crimped. A crimp connection can only be undone with the appropriate tool. The crimping technique is often used in the production of electrical connections. Connectors with crimp connections are particularly suitable for high-volume production and pre-assembly due to the speed of this technique. The crimping process requires minimal space. A notable advantage of this technique is the consistent quality during compression. Crimping is a popular connection technique, especially for round and rectangular connectors, as it allows for the easy creation of a secure connection.

The screw connection technique is a global standard for connection methods. In this technique, the stripped conductor is clamped into a hole or sleeve of the contact element using a screw. This connection is removable, meaning it can be easily disconnected if necessary. The advantages of screw connections include the straightforward, intuitive process for making connections and the minimal tool requirements. Screw connections with wire protection can also be used for stranded wires.

In this technique insulated conductors are pressed into and fixed within a cutting clamp. The advantage of this method is that the conductors do not need to be stripped or soldered, thanks to the sharp edges of the cutting clamp, which saves a significant amount of time and effort. In the IDC method, the contacts are pre-installed in the housing. The benefit is that multiple conductors can be connected with a single pressing operation. This creates a gas-tight connection between the conductor and the cutting clamp. IDC connectors come in various forms with either single or double clamping. The cutting clamp must always be matched to the intended conductor type and its insulation material. It can accommodate stranded, solid, and enamel-coated wires with cross-sections ranging from 0.01 mm² (enamel-coated wire) to about 6 mm². This method is particularly suitable for solid conductors, especially those with small cross-sections.

In this connection technique, the conductor ends are fixed within the insulation body using a spring clamp, creating a vibration-resistant connection. A screwdriver is used to open the so-called cage clamp spring, allowing the conductor to be clamped. This simple handling makes cage clamp connections suitable for field assembly, as no special tools are required. The cage clamp connection technique enables quick and easy processing and ensures high operational reliability. Compared to screw terminal connections, this method allows for shorter installation times and is therefore increasingly used in control panel construction and electrical installation technology. Cage clamp connections are suitable for solid and stranded conductors with cross-sections from 0.14 to 2.5 mm². The clamping force increases with larger conductor cross-sections.

The axial screw connection is a combination of screw and crimp connections. It merges the easy handling of screw connections with the compact size of crimp contacts. This type of connection is notable for its resistance to vibration and shock. The axial connection allows for the reliable attachment of larger conductor cross-sections in a space-saving manner and without special tools. The cable is connected to a connector using an axial clamping screw, where the individual wires press against the contact area from the inside, clamping them between the axial clamping screw and the connection area. Axial screw connections are suitable for both fine-wire conductors and large cross-sections.