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Innovation: Solutions for compressed cables

Cable manufacturers introduce to market new copper cables RMC Class 2 , which can have a diameter of working conductor up to 15 % less than their counterparts currently used (RM Class 2 ).

 

 kable skompresowane RMC

 

With the new construction, cable manufacturers can produce smaller and lighter wires while maintaining the same electrical parameters as in the past

However, a reduction in working conductor diameter has become a cause of serious problem. All produced cable terminals are designed for cables with a conductor structure of RM class 2 . Reducing the diameter of the wires in the new cable made the currently used cable terminals too big and cannot be properly crimped on the cable with thus far used tools and crimping dies.

 

COMPARISON OF CABLE PROFILES

cross-section

[mm2]

The diameter of the cable conductor profile according to PN-EN 60228 2007

The nominal inner diameter of cable terminals

for RM  Class 2 profile cables according to

DIN 46235  [mm]

kor

Max [mm] Min / Max [mm]

Copper round multi-wire

„RM” Class 2

8

Copper round multi-wire

„RMC” Class 2 (“compressed”)

7

120 14,5 12,3 - 13,5 15,5
240 20,6 17,6 - 19,2 21,5
 

Using the standard produced cable terminal (for RM profile cables) and dedicated to the size of the socket crimping die to crimp on the RMC cable, we are not able to achieve the desired deformation, and thus the parameters of mechanical and electrical crimped connection does not meet requirements of PN -EN 61238-1 2004. It is possible to make a special crimping dies (socket size and shape) , but due to specified in the standard large range of outer diameters of compressed cables, this would require the creation of a number of crimping dies even for the same cross-section, depending on the manufacturer of the cable.
To solve this problem smartly, we have designed a special type of cable lugs CKOR and connectors CKOR, dedicated to copper cables of RMC Class 2 profile.

Both the terminals and connectors have their inner diameters tailored to smaller conductors of new compressed RMC cables. Especially for this set: compressed cable and terminal, we have designed proper crimping dies of appropriate socket size and crimping width.

 
Type – made / size

Copper cable

Class 2 profile

Cross-section 240 mm2

 Ø

Inner

Ø

Outer 

Crimping die

socket size

KOR – for standard cables 

kor

 RM

 21,0

 26,0

 25

CKOR – for compressed cables 

ckor

RMC 

20,6

26,0 

C240 

 

Cable terminals for compressed cables

ckor          

 

 

ckl2 kol
 CKOR CKL
Material: CU Material: CU kab
Surface

tin-plated   

Surface

tin-plated

Standard

compressed

Standard

compressed

Wire

cross-section

10 - 240 mm2

Wire

cross-section

10 - 240 mm2

  

schemat a

  

schemat b

Copper round

multi-wire

„RMC” Class 2 

cable

 

matryca

Developed by our engineers system of terminal / connector and crimping die ensures quality connection on RMC cables in a reliable, fast and efficient way.