Handmade Terminal Blocks: Detailed Steps And Techniques
Terminal blocks are key components for achieving stable wire bonding in circuit connections, and handmade production can meet the customized needs of special scenarios. The following provides a systematic analysis of the entire process of manually making terminal blocks, from material preparation, production process to key techniques.
1、 Preparation of materials and tools
Core materials
Wire: Choose copper or aluminum core wire according to the current demand, and the cross-sectional area should match the load capacity (such as choosing 1.5mm ² copper wire for household lighting).
Metal terminal strip: It is recommended to use copper or brass material, with a thickness of 0.5-1mm and a width adjusted according to the diameter of the wire (such as 2.5mm ² wire with 8mm wide terminal strip).
Insulation sleeve: heat shrink tubing (temperature resistance above 105 ℃) or PVC insulation tape, with a length covering the junction between the terminal piece and the wire.
necessary tools
Wire stripping pliers: Accurately strip the insulation layer of the wire to avoid damaging the metal core.
Wire crimping pliers: Choose models with adjustable pressure to adapt to different specifications of terminal strips.
Soldering station and soldering wire (optional): used to enhance the electrical stability of mechanical connections.
Multimeter: Check the bonding resistance to ensure the quality of the connection.
2、 Production steps
Wire pretreatment
Use wire stripping pliers to remove the insulation layer at the end of the wire, with a length 2-3mm longer than the terminal strip, exposing the clean metal core.
Terminal block fixation
Insert the metal core of the wire into the terminal block hole, ensuring that there are no loose strands or exposed burrs. If welding is required, apply flux to the contact surface and heat the solder to form a uniform solder joint.
Crimp reinforcement
Use a crimping tool to press the terminal piece twice: first, press the hole vertically around it, and then press it along the length of the terminal piece twice to form an "I" - shaped indentation and increase the contact area.
Insulation treatment
After inserting the heat shrink tube, heat it and shrink it, or wrap 3-4 layers of PVC tape to ensure that the insulation layer overlaps with the edge of the terminal piece by at least 5mm.
3、 Key skills
Pressure control: When crimping, keep the jaws perpendicular to the terminal piece to avoid tilting and causing local loosening.
Resistance testing: Use a multimeter to measure the resistance at the junction, which should be less than 1.5 times the resistance of the same length of wire.
Tensile test: Gently pull the wire to check for detachment. High quality joints can withstand a tensile force of 10-15N.
By standardizing operations and controlling details, handmade terminal blocks can achieve industrial grade connection stability, suitable for equipment maintenance, prototype development, and other scenarios.
