DUAL5 -concept solution for contact crimping of flexible aluminium conductors (class 5 - IEC 60228)
TESTING & DEVELOPMENT
Elpress has been developing new solutions for electrical terminals for decades. Development, validation and testing take place at Elpress in cross-functional teams with high goals regarding functionality, durability, sustainability, repeatability and user-friendliness. Our experience of high demands, in various purposes for electrical terminals, contributes to us developing solutions that meet both the prevailing international standards and the industry requirements in, among other things, wind and solar power plants, distribution and transmission networks and transformer, generator and vehicle manufacturing.
CONTACT CRIMPING SPECIALISTS
Elpress is constantly developing its solutions to meet the changes in conductor materials and their structure, as well as the changing industrial requirements of various segments.
With the patented DUAL crimping technology, Elpress is the first in the world to introduce a technology as simple as comparable traditional crimping techniques, adapted and further developed for highly flexible copper conductors. Repeatability and user-friendliness have been as much in focus as the functional requirements.
The development of the crimping technology for flexible aluminium has had a heavy focus on customer value and focused primarily on further development of the tool systems, rather than adaptation of the terminals.
Aluminium wires in flexible conductors show much lower mechanical stress resistance. In order not to damage the wires, you must perform a "soft" and "even" crimp.
An oxide layer, which has good insulating properties, is immediately formed on the conductors' wires. To break the oxide layer an ”aggressive” crimp must be carried out.
A combination of hexagonal and indented crimping that meets both challenges, combined in one and the same crimping.
1. The die pairs are adapted to the external diameter of the sleeve, which means that the same die pair can be used for several nominal sizes.
2. For optimal mechanical durability, a hexagonal crimp is made, which compresses the conductors' wires in a gentle way without damaging them.
3. The indented crimping then stretches the wires and breaks the oxide layer, which provides optimal and stable conductivity.
DUAL5 is based on further developed crimping technology and new tools, but is based on the same reliable terminals that have been used for many decades. This gives us and the customer security and incredible flexibility, because flexible aluminium conductors can now be easily combined with other conductor materials on the market.
flexible aluminium with
Class 1- Al, Class 2- Al, Class 5- Al
Class 2- Cu, Class 5- Cu, Class 6- Cu
9 sizes can be crimped with 6 die pairs in 2 tools with 1 crimping
* AS is a product example, the same applies to the sizes in the AK/AKS/AKK product programs.
THE CONCEPT SOLUTION
The concept solution for an optimal terminal with flexible aluminium conductors (similar to IEC 60228 class 5) has been tested with very good operating properties during electric thermal cycling according to IEC 61238.
Further development of the concept involves tests and validations with different cable types from
different manufacturers in project form. Contact your nearest Elpress representative for more information.
DUAL5 is tested according to IEC 61238-1-1: 2018 (Compression and mechanical connectors for power cables) for stable conductivity under electrical load. In addition to this fundamental type test, DUAL5 is also tested for environmental stress in the form of corrosion and vibration. The connection is thus certified for the corrosion withstand requirements according to DIN V 40 046-37 and the vibration and withstand requirements according to IEC 61373: 2010.
Bimetallic terminals of the AKK / AKS / AKP types are manufactured in Sweden with precise
processes to ensure the best quality for the final application. This includes checks of raw materials as well as continuous checks of processes, results and documentation.
Elpress' high demands for quality are self-evident - we never compromise on quality. “We check each individual bimetallic terminal by performing a stress test and an inspection. We indicate the quality check to the customer through the small ‘E’ stamped in the copper part of the terminal,
something we will obviously continue to do,” Torbjörn Norell assures us. (Elpress NEWS edition 2-2020 page 6).
Concept solution will be able to meet the requirements in all segments:
For flexible aluminium in the nacelle and a safe transition to transmission lines in the tower,
but also for photovoltaic systems and the connections to converters and transformers.
Weight reduction measure with flexible aluminum. With DUAL5 it is possible to combine copper and aluminium for maximum flexibility. IEC 61373: 2010 tested for railway applications.
Vehicles of various types, including EV vehicles, will be able to benefit from flexible aluminium solutions in the future.
DUAL5 is a concept solution, which means ongoing adaptations of the program and project-oriented development of the technology according to the customer's wishes and requirements.