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Indent Crimping Profile

Different indent crimpings:

  • Indent crimping: for copper and aluminium
  • Indent crimping: for copper and insulated materials
  • Quad-point indent crimping: for copper

Indent crimping: for copper and aluminium
Indent crimping is one of few crimping profiles which require no cross-section dependent pressing inserts. This allows, for example, the Klauke EKM 60 ID to achieve a crimping range of 10-240 mm² with copper and 50-240 mm² aluminium. This is made possible by two technical innovations. The first is a simple 2-stage telescopic cylinder in the hydraulic cylinder. Because of the different piston diameters and the patented design of the two hydraulic cylinders, the crimping head in the initial area exerts twice the force through the larger hydraulic cylinder than it does towards the end, where only the smaller hydraulic cylinder is in action. The larger cross-sections are therefore processed with a greater force than the smaller ones. This guarantees that all cross-sections are compressed with sufficient force, and that smaller cross-sections are not damaged by excessive force. The second innovation is that the indent has a special design, which is adapted to the diameter of the cross-section.

As well as helping to save money on parts and equipment, this has another advantage for the user. Even very heavily thinned-out or compact conductors can be processed with this mould without any problems, as the device only shuts off once the desired compression has been reached. With this crimping profile, it is possible to process tubular cable lugs for fine and flexible conductors, solderless terminals and aluminium cable lugs and connectors. This crimping profile can also be used to process fine stranded conductors in the tubular cable lugs.

Due to the properties of the materials, the number of crimping marks in the tubular cable lugs and the aluminium cable lugs is equal to that of wide crimping marks. When processing aluminium cable lugs, it must be ensured that the tool is positioned offset by 180° for every crimping. Otherwise, the aluminium cable lug can become deformed. The solderless terminals must always be pressed once onto the soldering seam. For tubular cable lugs for fine stranded conductors, up to 185 mm² must be crimped once, and over 240 mm² must be crimped twice.

Advantages of indent crimping at a glance:

It is not possible to confuse or mismatch the parts.
Flexible: The mould can be used flexibly for different conductor classes, and is also suitable for thinned-out or compact ladders.
Economical: It is not necessary to buy any additional parts.

From the Klauke range:

> Crimping tool EKM 60 ID (10 - 240 mm²) 

> Crimping tool  EK 120 ID (35 - 500 mm²) 

> Crimping head  PK 60 ID (10 - 240 mm²) 

Indent crimping: for copper and insulated materials
The indent crimp was developed for producing connections with cable lugs according to DIN 46234 and connectors according to DIN 46341 Part 1, profiles A+B, which are in turn suitable for mounting Class 2, 5 and 6 conductors according to DIN EN 60228.

Cable lugs and connectors in these standards have a large inner diameter to easily cover all conductor classes. Indent crimpings deform the individual stranded wires so as to create a good electrical and mechanical contact.

Indent crimping is similar in cross-section to the shape of a half-moon. This crimp is also described as deep-working since, during crimping, the individual stranded wires are bunched together and taper outwards. Despite the large internal diameter, a permanently compact and reliable connection can be guaranteed thanks to the coaxially-centred bundling.

This crimping profile is particularly suited to tubular cable lugs, solderless terminals according to DIN 46234 with and without insulation and cable lugs for fine stranded conductors.

Indent crimping is not a standard crimping profile – but is used with standard cable lugs. In this case, it is essential to ensure that materials and crimping tools are compatible, as otherwise there is a risk that individual stranded wires will become squeezed thereby impairing mechanical and electrical properties.

From the Klauke range:

> Crimping tools

> Pressing inserts

Quad-point indent crimping: for copper
Quad-point indent crimping has made its way from the USA into German control cabinet construction. In this area, it is used up to 1 kV. These have already proven successful for other connections, for example in train drive units. This crimping profile is suitable for tubular cable lugs and connectors with cross-sections of 10 mm² to 300 mm² in combination with conductor types of DIN EN 60228 classes 2, 5 and 6.

The advantage of quad-point indent crimping over normal indent crimping is the centric force and simple processing, as this does not require any different crimping dies. Only a single crimping tool is required in the aforementioned cross-section range – this is extremely practical. The quality of the crimping therefore depends on the effort and tool used. However, quad-point indent crimping is not suitable for insulated connectors, as the insulation can become damaged by the indent.

From the Klauke range:

Crimps (10 - 240 mm²) with open head:

> EK 60 VP battery powered hydraulic tool 

> HK 60 VP manual hydraulic tool 

> PK 60 VP crimping head 

Crimpings  (16 - 300 mm²) with closed head:

> EK 60 VP/FT battery powered hydraulic tool 

> HK 60 VP/FT manual hydraulic tool 

> PK 60 VP/FT crimping head