Electronics > Mechanical & Automation Engineering

what the fuc are "heavy duty" and "standard" wall thickness lugs?

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I have no idea, I thought sargent would be good for lugs.

I find it very suspicious that you have to use a AWG4 die for an AWG8 cable and lug.
For me all alarm bells go off. I would get my mony back and buy a decent hydraulic crimptool second hand on ebay or try some third party hydraulic crimpers if you do not have to crimp dayly (hobby use)

Crimp connectors and tooling are the wild wild west of electronics assembly.

Ever if you stick to genuine 1st world brands, public specs for the crimp dies are extremely rare, and it generally comes down to manufacturer X stating that the only approved tooling for their product range N is manufacturer Y's model numbers A, B or C  crimp tool/die.   Also, manufacturer Y usually doesn't offer a compatibility table for which manufacturers specific products crimp in a model A tool/die, so after investing $\$\$\$\$$ for the tool you are locked in to manufacturer X, unless you stumble across another manufacturer recommending the same tooling.   Maybe things are better if you are buying 1000,000 units of the crimps, and they'll actually let you have the die specs, but that's not something I've ever been involved with.   Frankly it all smells like an organized crime family to me!

If you are using tooling approved by the crimp terminal manufacturer with a (real) cable CSA within the specified range for that crimp terminal, and the terminal is specified for the metal of the cable, it should 'just work'.  If anything's not as specified it probably wont.   The only factor that's easy for you to control is the amount of copper CSA in the cable, as you can experiment by stripping or adding strands till you find the limits for a particular terminal and tooling, then buy cable with a CSA that's comfortably within the limits.  However some crimp tools/dies will *NEVER* make an acceptable crimp on a particular terminal as they don't match the terminal well enough, and either squish it too much or not enough.

To me it makes sense to swap dies since the thing runs on total mass of copper and the wall thicknesses are different, so you have a different amount of copper in the lug, so not sure how much difference there is between making the wire thinner and the crimp thicker or vise versa, since they want a uniform pressure material... so it did not set off alarm bells
now that I think about it a long time ago I think I did look into strand count of wires and the chinese ones had less then digikey but I forgot about that research.. years ago..

i gotta count this crap


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