This might appear complicated at first glance, but a second look shows that this is not the case. Every day, electrical engineers are confronted with a host of different conductor types, each of which calls for different cable lugs and connectors to ensure professional processing. Once matching components have been selected, the question is, which crimp profile is most likely to produce a reliable connection. The most suitable crimp profile depends on material, design and application:
Hexagonal crimping: for aluminium and copper
Hexagonal crimping is the most common method of crimping cable lugs and connectors. Hexagonal crimping is among the conventional crimp profiles. It is the most frequently used in practice, as it is suitable for both copper and aluminium conductors. In this crimp profile, the individual strands are deformed over a large horizontal area.
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Indent crimping: for copper and aluminium
Indent crimping produces a lasting, reliable and deep-penetrating connection. The indent crimp is one of the few crimp profiles that require no cross-section-dependant crimping dies. For example, the Klauke EKM 60 ID an process a crimping range of 10-240 mm² for copper and 50-240 mm² for aluminium.
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The quad-point crimp: for copper
The benefits of quad-point crimping lie in the central force application and the simple processing. This crimp profile is suitable for tubular cable lugs and connectors with cross-sections from 10 mm² to 300 mm² in combination with conductor types to DIN EN 60228, Classes 2, 5 and 6.
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The notch crimp: for copper
The notch crimp is the oldest and presumably also the original best-known crimp profile in the electrotechnology sector. It is still used in control cabinet construction to 1 kV today. It is set apart by a deep point-specific deformation of the cable lug. However, it is suitable only for processing copper.
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