How-To: Identify a Properly Crimped Terminal

by Mike Noonan September 23, 2021

A properly crimped terminal ensures a reliable connection with its conductor (strands of copper wire) and eliminates deformities that may affect its ability to properly engage with its mating terminal. In this blog, I guide you through the terms mentioned in the image above to explain what it takes to achieve a properly crimped terminal.

BEND DOWN: A terminal crimped without a locator supporting the bottom of the terminal has tendency to distort and bend downward; affecting the insertion of the terminal in its connector cavity.

BEND UP: A terminal crimped without a locator applying downward pressure on the terminal has a tendency to distort and bend upward; affecting the insertion of the terminal in its connector cavity.

CABLE SEAL CRIMP HEIGHT: The measurable height from the top to bottom of the cable seal INSULATION CRIMP BARREL is defined by the terminal manufacturer to ensure proper retention of the cable seal (or wire insulation).

CABLE SEAL CRIMP WIDTH: The measurable width from the side to side of the cable seal INSULATION CRIMP BARREL is defined by the terminal manufacturer to ensure proper retention of the cable seal (or wire insulation).

CONDUCTOR CRIMP BARREL: The terminal segment that captures the conductors (strands of copper wire) should have a uniform SEAM and a BELL MOUTH at the conductor entry to avoid any excessive strain on the copper strands.

CONDUCTOR CRIMP HEIGHT: The measurable height from the top to bottom of the CONDUCTOR CRIMP BARREL is defined by the terminal manufacturer to ensure proper retention of the conductors.

CONDUCTOR CRIMP WIDTH: The measurable height from the side to side of the CONDUCTOR CRIMP BARREL is defined by the terminal manufacturer to ensure proper retention of the conductors.

STRIP LENGTH: The length of wire insulation to be removed prior to termination is defined by the terminal manufacturer. The amount of insulation removed should allow for full CONDUCTOR CRIMP BARREL engagement with a small amount of visible strands, or BRUSH, extending beyond the crimp.

ROLLING: Terminals crimped with general repair tools typically roll in the CRIMPING NEST; creating a non-uniform CONDUCTOR CRIMP BARREL and loose connection.

TWISTING: Terminals crimped with general repair tools typically demonstrate a twisting effect because they are not properly supported by a locator during the crimping process.