Electromechanical Crimping Tools For High Volume Applications

Published 04 Sep 2018

Electromechanical Crimping Tools

Electromechanical Crimping Tools Manufactured by Klauke

  • uploaded by Chris Dodds - Thorne & Derrick Sales & Marketing Manager

Thorne & Derrick International, based in the UK, are leading suppliers of cable crimp lugs and associated crimping tools for Low, Medium & High Voltage Cables and Power Systems – this series of articles by Klauke discusses the theory and practise of installing compression type cable lugs and connectors using ratchet, hydraulic, battery-operated or electromechanical crimping tools.

Klauke cable lugs and crimping tools are used by Jointers, Linesmen, Panel Builders and Electrical Engineers to install underground cables and overhead line conductors on power, transmission and distribution networks including LV MV & HV systems, 11kV-33kV.

➡ Download 2018 Klauke Cable Lugs catalogue and see the complete range of tools for cutting and crimping cables.

In this Article we cover the advantages of using Electromechanical Crimping Tools:

  • With a manual force of up to 20 kilograms per crimp, excessive strain in the wrist and forearm can occur over time when cable crimping
  • There is a good case here for taking measures to safeguard against such conditions and prevent expensive employee absences and injury
  • Electromechanical cable crimping tools reduce the physical effort, achieve the best crimping results and also guarantee the consistently high quality
  • For specialist operations in which large numbers of crimped connections have to be processed quickly, purchasing such crimping tools is justified
  • DIN 46234 standard compliance and cable lug connector installation

Cable Crimping & Health & Safety

It usually begins innocuously: first a numb feeling in the thumbs, index and middle fingers during the night. But then later, pain and sensory disorders throughout the day too. The hand becomes less sensitive, the fine motor skills start to dwindle and the hand gets weaker.

Day-to-day tasks become increasingly difficult and certain professional activities are difficult or even impossible to accomplish. This is caused by what is known as carpal tunnel syndrome. A nerve in the hand is permanently trapped against a constricted area that is inflamed – here are the typical signs and symptoms:

Carpal Tunnel Syndrome - Cable Crimping

Carpal Tunnel Syndrome – Cable Crimping

One suspected cause of this widespread condition is one-sided strain, which is often encountered in the electrical trade for example. There is a good case here for taking measures to guard against such conditions and prevent expensive employee absences.

Choosing the correct electromechanical crimping tools can help reduce workplace injuries and improve site and worker Health & Safety.

One of the most commonly recurring tasks in switch cabinet construction and installing LV cable joints is the crimping of cables. This task is usually carried out using mechanical type, ratchet crimping tools and in most cases, is completed without any problem at all. It can be become critical, however, when it has to be carried out by employees on a recurring basis. With a manual force of up to 20 kilograms per crimp, excessive strain in the wrist and forearm can occur over time.

Employee Health & Safety - less physical effort with electrically-driven cable crimping tools

Employee Health & Safety – less physical effort with electrically-driven cable crimping tools

One key factor is considered to be the number of cable crimp operations that are carried out on a regular basis. While a young and healthy employee who has not previously experienced excessive strain can easily achieve 100 to 150 crimps per day without their health being adversely affected, the use of a cable crimping tool with motorised drive is recommended for higher numbers of repetitive crimps.

Leading manufacturers now recommend tools that allow work to be carried out much more comfortably with far less physical strain.

The electromechanical crimping tool Klauke Micro with 10.8 V lithium-ion battery, for example, requires a manual force of just two kilograms per crimp.

In other words: the force that needs to be delivered from the hand and forearm is around 90% less than that required for a crimping tool operated purely by hand.

“When we developed our Electromechanical Micro, the aim was to manufacture a cable crimping tool that is easy to use and would allow ergonomic and health-promoting work, thereby combining the benefits of a manual crimping tool with the ease of a cordless one in a single cable tool device”, explains Lutz Remmel, Product Manager at Klauke.

Klauke Tool

To make the day-to-day tasks of a qualified electrician easier and benefit from the time-saving, the selected crimping tool should cover the broadest range of tasks possible.

The electromechanical tool from Klauke is able to process cable cross-sections from 0.14 to 50sqmm with a cable crimping force of up to 15KN, with a long-term time saving compared to the mechanical crimping tool.

Klauke Tool Kit

Because, in terms of the system concept, the electromechanical crimper tool is designed to take the interchangeable die sets from Klauke’s 50 series, it is also suitable for crimping various cable types, cable end-sleeves, and also tubular cable lugs, insulated solderless terminals and pin cable lugs.

This not only makes the cable tool a versatile companion for switch cabinet construction, it is also gentle on the installer physicals joints and allows consistently fast operations for numerous other manual, industrial and high voltage cable crimping applications.

Klauke Tool Kit Contents

The sequence is always the same: first, the manual pre-clamping. When the operating lever is actuated, the crimping jaws of the tool close in order to fix the electrical cable connectors.

During this particular step, the cable lug or connector material can be precisely aligned and positioned. In the second step, the cable crimp is achieved by the force of the motor.

The operating lever simply needs to be depressed fully and the crimping tool automatically starts the crimp process, which takes no more than 1.5 seconds, depending on the material.

Once the cable crimp has been made, the operating lever is released to initiate the return movement, also fully-automatic, into the original position.

Electromechanical Crimping Tool Operation

Electromechanical Crimping Tool Operation

Electromechanical crimping tools reduce the physical effort, and offer the following advantages: they achieve the best crimping results for minimum force, they also guarantee the consistently high quality of these electrical connection results for years afterwards.

This is because a suitable cable crimping tool in faultless condition (properly maintained) is crucial to avoiding under-crimps and over-crimps. Otherwise, the consequences can be hazardous: incorrectly-made crimps can, for example, increase joint resistance which can in turn cause temperature rises and ultimately trigger cable fires.

When choosing a crimping tool, simple and reliable operability is the key to ensuring safety.

Incorrect Crimping

Cable Tools & Costs v Benefits

When Is Investment Returned?

Profitability, of course, is the question posed by any investment. The cost of a branded electromechanical crimping tool is around 180 Euro (?), or more for a manual crimping tool.

Any concerns about the durability and reliability of the electrical variant of crimping tools are unfounded. For its Micro model, for example, Klauke states a long service life if the service intervals are maintained (at 35,000 press or crimp cycles).

The cable crimping tool is equipped with a multi-function LED for maintenance display and data transfer, which can also be used to transfer crimp and tool data to a PC via a USB adapter from the tool accessories range. Test reports showing date and time can readily be created as a PDF for recording completed crimp operations. An effective way of demonstrating a safe and correct working method.

Purely mechanical manual crimping tools do not offer this option of displaying wear and creating documentation.

And also the lithium-ion batteries now used in most cable crimping tools give no cause for technical concern. These energy sources conform to a perfected technical standard that applies today in practically all sectors in which rechargeable batteries are used. Lithium-ion batteries are set apart by short charging times without memory effect and a constant, uniform power output.

DIN 46234

The charging time for the battery installed in the Klauke tool is around 40 minutes. A fully-charged battery, can then achieve some 300 crimps on copper cables with a cross-section of 10sqmm in accordance with DIN 46234. Despite this high efficiency, the total weight of the tool, including the battery, is just 960 grammes.

  • DIN 46234 Standard – Terminal Ends For Solderless Connections, Ring Type, Without Insulating Sleeve (Copper Conductors)

Yet a far more important factor for assessing profitability, is sustaining the employee’s physical strength. The cost of sick leave due to carpal tunnel syndrome, which is mentioned at the beginning, tendinitis or tennis elbow, far outweigh those of procuring electromechanical crimping tools in the short-term.

Electromechanical crimping tools are preferred by panel builders for carrying out the termination and connection of LV MV HV cable conductors into electrical control panels.

Panel Builders

Klauke Tools


Electromechanical Crimping Tools

The decision to invest in an electromechanical crimping tool should be made according to economic calculations. For specialist operations in which large numbers of electrical cable connections or cable lugs have to be processed quickly, purchasing such cable tools makes is clear sense.

Electromechanical crimping tools not only increase the efficiency of work processes but also protect the health of employees. Since maintaining good health also means sustaining physical strength, such an added investment can benefit employer and employee in equal measures. Especially in light of demographic change and the shortage of specialists this brings about, physical fitness has become an economically valuable asset which must be sustained for as long as possible.

Contact Thorne & Derrick to discuss the optimum Electromechanical Crimping Tools for your budget, application or to arrange a product demonstration.

Further Reading

Review other Blogs in this series of articles about Cable Lugs, Crimping Cables & Tools:

Cable Lugs – Crimping Applications & Standards

Copper Cable Lugs For Special Applications

Indent Crimping Of Cables – Benefits & Limitations

Cable Lugs & Crimps – Hexagonal v Indent Methods of Crimping

Cable Lugs & Crimping Using The Hexagonal Crimp Method

DIN Standard – Crimping & Compressing Aluminium Cable Lugs & Connectors

Copper & Aluminium – Crimping CU-AL Cables


LV MV HV Cable Accessories & Substation Electrical Equipment

Thorne & Derrick are Specialist Distributors of leading manufacturers of Cable Accessories, Jointing & Installation Equipment.

LV MV HV cable accessories used to joint, terminate, connect, cleat and gland power cables to air and gas insulated substations, transformers, switchgear and overhead line networks.

Hover over our Interactive Electricity Grid to learn more about our product ranges.

LV 600/1000V ◊ MV 11kV 33kV ◊ HV 66kV 132kV 

3M Pfisterer CONNEX Prysmian Nexans Euromold Elastimold Ellis Patents Furse CMP Cable Glands Cembre


Substation & Overhead Line Electrical Safety Equipment

Manufactured by CATU Electrical to enable the safe construction, maintenance and repair of underground cables and overhead lines network up to EHV (400kV).


Further Reading