A die clearance monitoring system includes a light source, a light detector, and a controller. The light source is disposed along a front side of a die set of a crimping device and emits light towards the die set. The die set includes a first crimp die and a second crimp die that engage and crimp an object along a crimp stroke. The light detector is disposed along a rear side of the die set. The light detector receives the emitted light from the light source that traverses across the die set through a gap defined between the first and second crimp dies and generates light absorption data based on the emitted light that is received. The controller is communicatively connected to the light detector. The controller processes the light absorption data to determine a relative spacing between the first crimp die and the second crimp die.

A method and system of monitoring crimp quality of a crimp terminal in a hydraulic crimping apparatus. The method includes: determining a pressure of a hydraulic fluid supplied to a hydraulic crimping head of the hydraulic crimping apparatus; determining a flow of the hydraulic fluid supplied to the hydraulic crimping head of the hydraulic crimping apparatus; and analyzing the pressure and the flow of the hydraulic fluid to determine if a crimp is defective or not defective.

A method is provided for ensuring and/or checking the quality of a crimping using a crimping machine for crimping a cable with a contact sleeve and using a first optical sensor for detecting and/or recording first image data of the contact sleeve and using an evaluation electronics system. The method includes detecting the first image data of the contact sleeve by the first optical sensor; carrying out, via the evaluation electronics system, a first comparison of the first image data of the first optical sensor with first reference data of a predetermined contact sleeve; checking the first comparison for the presence of a predetermined first criterion; and, if the predetermined first criterion is satisfied, outputting a first signal. The detection of the first image data and the first comparison and the checking for the first criterion and the output of the first signal are carried out before the cable is crimped with the contact sleeve. A crimping machine suitable for carrying out the above method is also provided.

A method for crimp mounting a high-frequency (HF) electrical crimp connecting device to an electrical cable includes the steps of crimping a ferrule into a mounting state wherein its maximum diameter is fixed, and arranging the ferrule in its mounting state over an exposed shielding conductor of the cable. A terminal is crimped onto an inner conductor of the cable, and a shielding contact sleeve is placed over the cable and crimped, at least in the area of the ferrule. A target impedance or impedance range of the resulting cable is set according to at least one of a dimension of at least one crimping tool used to perform the crimping steps, or at least one dimension of at least one of the resulting crimps performed by the at least one crimping tool.

A manufacturing method for an electric wire having a terminal includes a step of connecting a plurality of core wires by an ultrasonic connection process to form a connected core wire. In the step, the core wires are formed into the connected core wire having a cross-sectional shape having a width and a height in a plane orthogonal to an axis of the connected core wire, the width is not longer than a length obtained by subtracting two times a thickness of the terminal from a width of an arch groove of a crimper of a crimping apparatus in a state that a space between a support surface of an anvil of the crimping apparatus and the arch groove defines a predetermined crimped shape.

A crimp tool calibration system for crimping a prepared wire into a corresponding contact wire barrel includes a computer, a positioner having a memory chip storing positioner data, and a tool frame. The tool frame includes a head having a receiving port therethrough, and configured for the positioner to be removably engaged with the receiving port during a crimping operation. The tool frame also includes a plurality of crimping dies positioned around a periphery of the receiving port, an adjustment device to adjust a crimp depth, and a positioner interface coupled to the tool frame. The positioner interface includes a tool memory for storing tool data, a reader, and a transmitter, where the reader is configured to read the positioner data stored on the memory chip of the positioner, and the transmitter is configured to transmit the positioner data and the tool data to the computer.

A crimping tool including a main body, a force-applying device, and at least two crimping jaws for crimping a crimping connection to a conductor. The at least two crimping jaws are moveable relative to the main body by the force-applying device, and a compensating device which allows adoption of at least three processing positions of the at least two crimping jaws depending on a position of the force-applying device relative to the compensating device. A force storage means is arranged on the main body and allows, in a processing position of the at least two crimping jaws, in particular in which substantially no force can be transmitted to the at least two crimping jaws by the force-applying device, a force-locking connection to be made between the crimping connection and the at least two crimping jaws by a movement of the at least two crimping jaws relative to the main body.

An electric wire with a terminal includes an electric wire, and a crimping terminal including an electric wire connection portion crimped by being wound around a core and a cover of the electric wire, a diameter expansion portion which contains a water stop member covering a tip end portion of the core and sealing a gap between the core and the electric wire connection portion is provided in an end portion of the electric wire connection portion on a tip end side of the core, and a sectional area of the diameter expansion portion is greater than a sectional area at a portion on the base end side of the core with respect to the diameter expansion portion.

A crimping hand tool used for crimping a coaxial cable and a coaxial terminal together is provided. The crimping hand tool includes a first body, a second body pivoted to the first body, a first linking body having a first end pivoted to the second body and a second end, a second linking body having a third end pivoted to the first body and a fourth end, a third linking body having a fifth end and a sixth end, a moving assembly, and a crimping assembly, wherein the second, the fourth, and the sixth ends are pivoted coaxially. The moving assembly is pivoted to the fifth end and slidably coupled to the first body along an axial direction. The crimping assembly is disposed on and moves along with the moving assembly to crimp the coaxial cable and the coaxial terminal together.

An assembly includes an elongate conductor, such as a coaxial electrical cable, having a generally circular cross section and a generally cylindrical seamless outer ferrule having a ferrule radius surrounding a portion of the conductor. The outer ferrule is deformed to define four indentations and four projections that are evenly spaced about a circumference of the outer ferrule. The four indentations have a consistent indentation radius that is less than the ferrule radius.