Experimental investigations on magnetic pulse crimping of copper lug

One of the most complicated issues in the production of electronic circuit boards, vehicles, aircraft, satellite, and communication components is the crimping of electrical wires to produce a secure connection. Furthermore, terminal crimping is crucial to the safe transmission of electricity; improper crimping causes difficulties like overheating of the plug, power loss, arcing, and mechanical connection failure. Magnetic pulse crimping has the ability to effectively address these difficulties. Magnetic pulse crimping is a non-contact technique creating a uniform pressure without any tool marks on lugs. This technique has better compression of conducting metal wires strands inside the lug and also has less voids compared to conventional mechanical crimping techniques. In this technique the pulsed magnetic field is generated inside the electromagnetic coil by the discharge of capacitor bank current. This magnetic field applies uniform pressure across the circumference of lug and crimp it with cable. 120 sq mm copper lug is magnetic pulse crimped with copper wire at 20 T. Significant improvements in leak rate in magnetically crimped lugs is seem compared to mechanically crimped 120 sq mm copper lugs. This technique also reduces the contact resistance and ultimately the temperature during operation in electrical system.