Crimpers - Crimp Heads, Die Sets

Image	Part Number	Description / PDF	Quantity	Rfq
	CMKDPSXH001P06 JST	DIE SET FOR CMKSL	0
	MKDSSCS4123 JST	DIE SET FOR MKL	0
	MKDSSWPRT001025 JST	STANDARD CRIMP APPLICATOR SET	0
	AD-501 JST	DIE FOR YA-2 CRIMP TOOL	0
	MKDSSPUD00105 JST	DIE SET FOR CRIMP TOOL	0
	AD-901 JST	DIE SET	0
	CMKDPSVH211 JST	TOOL PART DIE SET	0
	MKDSSXH002P06 JST	DIE SET	0
	MKDSSCPTA02105 JST	CRIMPER DIE FOR SCPT-A021GF-0.5	0
	CMKDPC75500 JST	TOOLING DIE SET	0
	IDHVR12 JST	HEAD ADAPTER VR SERIES	0
	CMKDPSYM00106 JST	DIE SET	0
	CMKDPSSHL00302 JST	TOOL DIE SET	0
	IDH-SSR-20 JST	HEAD ADAPTER SSR SERIES	0
	CMKDPSVH2111 JST	DIE SET ASSEMBLY	0
	IDHDR12 JST	HEAD ADAPTER DR SERIES	0
	CMKDPSACH00302 JST	TOOLING DIE SET	0
	BYNT1614 JST	DIE 16-14AWG INSUL	0
	CMKDPSPHD00105 JST	DIE SET FOR SPHD-001T-P0.5	0
	CMKDPSZE00203 JST	DIE SET FOR CMKSL	0

Crimpers - Crimp Heads, Die Sets

1. Overview

Crimpers - Crimp Heads and Die Sets are precision tools used to deform metal components (typically terminals or connectors) to establish secure electrical or mechanical connections. These systems are critical in industries requiring high reliability, such as automotive, aerospace, and electronics manufacturing. Modern advancements focus on automation, precision, and material compatibility to meet evolving industrial standards.

2. Main Types & Functional Classification

Type	Functional Features	Application Examples
Manual Crimp Heads	Hand-operated, adjustable force control	Prototyping, low-volume production
Automatic Crimp Heads	Motor-driven, programmable force/position	High-speed wire harness assembly
Hydraulic Crimp Heads	High-force output, consistent pressure	Heavy-duty cable termination
Dual-Action Die Sets	Multi-stage crimping for complex geometries	Coaxial connector assembly
Quick-Change Die Sets	Modular design for rapid tool swapping	Mass production with frequent changeovers

3. Structure & Components

A typical crimping system consists of: - Frame: Rigid base structure (steel/aluminum) for vibration resistance - Crimping Module: Contains hydraulic/pneumatic actuators or mechanical linkages - Die Set Assembly: Precision-machined upper (punch) and lower (anvil) dies - Positioning System: Linear guides and digital encoders for 0.01mm accuracy - Force Transmission Components: Cam mechanisms or servo-driven systems - Safety Features: Emergency stop circuits and overload protection

4. Key Technical Specifications

Parameter	Importance
Crimping Force (kN)	Determines joint integrity and material compatibility
Working Range (mm)	Defines applicable terminal sizes
Repeatability ( m)	Ensures consistent connection quality
Cycle Rate (units/hour)	Impacts production throughput
Durability (cycles before wear)	Reduces maintenance frequency
Material Hardness (HRC)	Affects die lifespan and precision retention

5. Application Fields

Primary industries include: - Automotive (wire harness assembly lines) - Telecommunications (fiber optic connector termination) - Aerospace (high-reliability avionics connections) - Renewable Energy (solar panel cable termination) - Consumer Electronics (miniaturized connector crimping) - Industrial Automation (PLC terminal block assembly)

6. Leading Manufacturers & Products

Manufacturer	Representative Product	Key Features
TE Connectivity	Crimptool XE3	AI-powered force control, 0.02mm repeatability
KOMAX	Zeta 1200	Multi-axis robotic integration, 4,000 crimps/hour
Sumitomo Electric	CT-Pro2	Laser-guided die alignment system
Yazaki Corporation	WBC-RX7	Hybrid electro-hydraulic actuation

7. Selection Recommendations

Key considerations: - Match crimp force to terminal material thickness (e.g., 1.2mm Cu requires 8-10kN) - Verify compatibility with industry standards (IPC/WHMA-A-620) - Assess production volume requirements (manual vs. automatic) - Prioritize modular systems for multi-product lines - Factor in calibration intervals and die replacement costs - Consider IoT-enabled models for predictive maintenance

8. Industry Trends Analysis

Current developments include: - Integration with Industry 4.0 through real-time data logging - Adoption of carbide-coated dies for 300% longer lifespan - Miniaturization for EV battery connection applications - Growth in demand for 0.1mm precision in 5G infrastructure - Shift toward energy-efficient servo-driven systems (30% power reduction) - Increased adoption of vision systems for automated quality control