A method includes a placing step in which an end portion of a covered electric wire is placed on an inner surface of a barrel portion along an axial direction such that a tip of the aluminum core wire overlaps a second portion of a seal member attached close to a terminal portion, and a crimping step in which the barrel portion is wound around and crimped to the end portion, thereby fixing the crimp terminal to the end portion and sealing, with the seal member, a space between the inner barrel piece and the outer barrel piece, an opening of the barrel portion formed cylindrical located on a side of the terminal portion, and a space between the covered portion and the barrel portion.

A tool for stripping and crimping a wire includes a housing. The tool also includes a wire holding system defining a wire holding area and comprising a set of teeth configured to hold the wire as the wire is stripped and crimped. At least a portion of the wire holding system is contained within the housing. The tool further includes a wire stripping system defining a wire stripping area and comprising at least one stripping member configured to penetrate at least a portion of the wire. At least a portion of the wire stripping system is contained within the housing. The wire stripping area is adjacent to the wire holding area. Additionally, the tool includes a lug retainer system configured to position a lug on the wire in the wire stripping area.

An electrical connection device comprises a cable, a ferrule, and a first electrical contact. The cable has an outer conductor surrounding an inner conductor. The ferrule is mechanically connected to the outer conductor. The first electrical contact is electrically connected to the inner conductor.

An electrical connection device comprises a cable, a ferrule, and a first electrical contact. The cable has an outer conductor surrounding an inner conductor. The ferrule is mechanically connected to the outer conductor. The first electrical contact is electrically connected to the inner conductor.

A terminal locator for holding a terminal in a crimping zone of a terminal crimping device includes a housing configured to be positioned forward of crimp tooling defining the crimping zone. The housing has a terminal cavity extending along a terminal axis configured to receive the terminal such that a crimp barrel of the terminal extends rearward of the housing along the terminal axis into the crimping zone for crimping to a wire. A spacer is held by the housing. The spacer has a spacer blocking surface configured to locate the terminal and block axial rearward movement of the terminal. A latch is held by the housing. The latch is deflectable to allow insertion and removal of the terminal from the terminal cavity, the latch having a latch blocking surface configured to locate the terminal and block axial forward movement of the terminal.

A cable assembly includes coaxially arranged inner and outer barrels. The outer barrel overlaps a portion of the inner barrel. The cable assembly further includes a cable that has at least one wire surrounded by an inner insulator that is covered in a metallic shield. The metallic shield is arranged in between the inner and outer barrels. The inner barrel includes a retention feature that is arranged beneath the metallic shield. The retention feature protrudes radially outward from the inner barrel to an outermost diameter. The outer barrel includes a crimped portion that is arranged adjacent to the retention feature and has an innermost diameter that is less than the outermost diameter to capture the metallic shield therebetween and prevent the outer barrel from axial movement relative to the inner barrel.

Systems and methods are provided for wire processing. In certain examples, a wire processing system is disclosed. The wire processing system includes an electrical wire and solder sleeve joining system. The electrical wire and solder sleeve joining system includes an end effector configured to hold a solder sleeve and a split funnel configured to guide insertion of wire into the solder sleeve, allow movement of the solder sleeve through the split funnel in a second position, and prevent movement of the solder sleeve through the split funnel in a first position. The end effector can additionally be configured to remove a slug from the wire.

A method for aligning a crimper of a first tool of a crimping press relative to an anvil of a second tool of the crimping press, wherein the crimper and the anvil make a crimp connection jointly by moving the crimper relative to the anvil in a first direction, includes: determining a lateral offset of a center line of the crimper to a center line of the anvil in a second direction perpendicular to the first direction, wherein the center line of the crimper runs through a center of the crimper and in the first direction and wherein the center line of the anvil runs through a center of the anvil and in the first direction; and moving the crimper relative to the anvil in the second direction for lowering the lateral offset.

A crimping tool exchange device exchanges a first crimping tool for a second crimping tool, wherein each crimping tool, when at a processing position in a crimping press, produces a crimp connection connecting a conductor end of a cable to a crimp contact. The device includes first and second exchange units retaining the first and second crimping tools respectively. When one of the exchange units is arranged in an exchange position the retained crimping tool can be moved in a first direction between the processing position and the one exchange unit. The first exchange unit is moved linearly from the exchange position in a second direction, and the second exchange unit is moved linearly from the exchange position in a third direction that is different from the second direction, the second direction being at an angle relative to the third direction.

A crimping tool exchange device exchanges a first crimping tool for a second crimping tool, wherein each crimping tool, when at a processing position in a crimping press, produces a crimp connection connecting a conductor end of a cable to a crimp contact. The device includes first and second exchange units retaining the first and second crimping tools respectively. When one of the exchange units is arranged in an exchange position the retained crimping tool can be moved in a first direction between the processing position and the one exchange unit. The first exchange unit is moved linearly from the exchange position in a second direction, and the second exchange unit is moved linearly from the exchange position in a third direction that is different from the second direction, the second direction being at an angle relative to the third direction.