DUAL Crimping technique – Elpress Innovation
The DUAL technology combines the desired properties from an optimal hexagonal crimp with those of a limited indent crimp. This results in tight contact surfaces without damage to the conductor strands.
This technique has been developed by Elpress and is recommended as our first hand choice for crimping with conductors class 5 and 6. This is to meet the hard combined requirements from manufacturers to get the best result.
The hexagonal crimp gives good mechanical properties and with gentle touch on conductor wires. While the punch crimp improves contact surfaces.
Crimping Sequence
The contact crimping takes place in a two-stage movement, first a hexagonal crimp that provides optimal symmetrical contact with the conductor, which means that no wires are broken or come apart in the edge facing the connector. This is followed by indent crimping, which provides 30% better electrical properties than a convectional hexagonal crimping.
Learn more:
Elpress General Crimping Guidelines
High-temperature solutions for tomorrow’s challenges
An innovative and secure system of copper connectors and the DUAL tool system for crimping of flexible copper power cables rated for a max continuous temperature of 150ºC and cover the area range of 35 – 240 mm².
Increased demand for high-temperature solutions globally
The increasing need for more resilient and innovative electrical solutions is growing extremely fast in a world with constantly rising technological needs and demanding climate changes.
Today’s electrical market has noticed an increasing need for high-temperature solutions globally. The request is exceptionally high for tomorrow’s robust electrical connectors, which need more resilience against thermal stress, especially in locations where climate is warmer than average.
Successful test and full approval
This increased need has prompted us to extend the standard approval at 90ºC continuously maximum temperature deriving from the IEC 61238-1 standard to this level (150ºC).
To achieve this and maintain existing good properties regarding resilience against vibration and corrosion in the KRF/KSF type range in combination with the DUAL tool system was chosen for a test setup at 150ºC.
For the assembling and running of the test, the same criteria and demands as for IEC 61238-1 has been used with the only difference being the use of an elevated cycling temperature, 150ºC. The result is a full approval at 150ºC according to IEC 61238-1.
Outstanding resilience against thermal stress
As seen in the following charts, the connector max temperature was about 10ºC lower than the conductor and with a good and stable resistance factor, all through the test, indicating outstanding resilience against thermal stress.
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For crimping of flexible Cu conductors according to IEC 60228, type class 5
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For extra harsh environments such as cars and trains, where the terminals in addition to electrical properties are also exposed to, for example, corrosion, mechanical durability and vibration
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Meets IEC/EN 61238:1
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Corrosion requirements according to DIN V 40 046-37
The requirements for vibration according to EN 50 155
The requirements of mechanical strength according to SEN 24 50 10