Powered utility crimpers with prevention through design (PtD) features provide ergonomic benefits and reduced rework or prevent rework for electrical workers.

The application of the prevention through design (PtD) concept in designing tools, such as powered utility crimpers, can help minimize risks for ergonomic injuries and improve working conditions leading to increased productivity. This can be achieved through integrating innovative mechanical features, auto-sensing technologies, as well as reducing the weight or have better balancing of the tool. While the list below is not comprehensive of all powered utility crimpers with PtD features, these are a few types for consideration:

Single-point Dieless Utility Crimper

A single-point dieless utility crimper can determine the correct cable size and apply the appropriate force to connectors during crimps. It uses a single-point system with auto-sensing technology which senses the distance of when it starts to make a crimp and correctly applies the correct amount of force.

The dieless feature can help mitigate work disruption from changing dies. It can also reduce or prevent rework compared to using other types of utility crimpers. For example, a crimper using a quad-point system can cause uneven crimps or a crimper with a single-point crimp (without auto-sensing technology) can cause deformation of connectors when too much force is applied.

Milwaukee Tool M18™ FORCE LOGIC™ 750 MCM Dieless Crimper

The Milwaukee M18™ FORCE LOGIC™ 750 MCM Dieless Crimper (figure 1) utilizes a technology called Auto Distance Control, which produces cULus Classified connections under UL 486A-B for #6 - 750 MCM Cu and Dual Rated connectors for seven major manufacturers (Anderson, Blackburn® Burndy, Ilsco, Panduit, Penn-Union and Thomas & Betts). This enables the battery-powered crimper to sense the instant it contacts the connector, allowing the application for optimal compression with a single crimp across the entire capacity range. The controlling of compression by distance also provides uniform crimp appearance across all sizes for easy installation in tight panels. This also includes a 180° rotating head which provides flexible alignment. The fully enclosed high-speed hydraulic pump delivers up to 90 crimps per charge on a CP2.0 battery. It also enables the storing of real time crimp data, generate professional reports, view historical tool performance data and wireless syncing to the cloud. Additionally, the ONE KEY™ feature includes tool tracking to assist in finding missing tools quicker and improve inventory management.
 

Figure 1. Milwaukee M18™ FORCE LOGIC™ 750 MCM Dieless Crimper (Photo courtesy of Milwaukee Tool)

Product specifications

• Power Source Cordless
• Battery Type: 18 Volt Lithium Ion
• Motor Type: Brushless
• 180 degrees head rotation
• Weight (pound) 20.017
• Length (inch): 20.866
   

Greenlee Tools 12 Ton Crimper Indent

The Greenlee 12 Ton Crimper Indent (figure 2) is equipped with Bluetooth™ Communication enabled via the Greenlee Gator Eye app. It features an LED display screen that reads the pressure and battery levels as well as tool diagnostics with real-time tool feedback.

Figure 2. Greenlee 12 Ton Crimper Indent (Photo courtesy of Greenlee Tools, Inc.)

Product specifications

• Dieless indent style crimping head does not require interchangeable crimping dies
• Intelligent Crimping System Technology includes a pressure sensor that monitors the crimping force of each crimp and provides the operator a visual and audible alert if the force is below specifications
• State of the art 18V lithium ion (Li-ion) battery provides 70% more cycles per charge and faster cycle times
• Automatic Retraction Stop (ARS) which retracts the ram just enough to get ready for the next cycle saving time and energy
• LED light provides the operator with the battery charge and tool maintenance status
• Two-stage hydraulic system provides fast advance and power speeds, saving time
• Forward handle position improves tool balance
• One trigger controls all tool functions
• Crimping head rotates 350°
• Tools automatically retract when the crimping cycle is complete
• Overmolded tacky grip areas make gripping the tool easier and more comfortable
• LED work light illuminates dark work areas
• Smart chargers control the charging current, charging voltage and battery temperature to maximize battery life
• Flip open crimping head will allow crimping of 4 AWG - 1000 kcmil copper or 6 AWG - 1000 kcmil aluminum with no dies to change
• Available with 120V, 12V or 230V battery charger or with 120V or 230V corded adapter in place of batteries and charger
   

Low-force Powered Trigger Utility Crimper

A powered utility crimper can also be designed to reduce finger tendonitis and provide easy access in tight spaces.

Milwaukee Tool M18™ FORCE LOGIC™ 12T Utility Crimper

The M18™ FORCE LOGIC™ 12T Utility Crimper is engineered to reduce weight and improve balance with a 350˚ rotating head and red alignment marks. Predictive Force Monitoring (PFM™) constantly measures force output to deliver consistent speed that won’t bog down on larger connectors while delivering accurate pressure. It provides instant pressure verification with a green indicator. It has pre-crimp battery check that automatically ensures enough battery charge to complete each crimp. Once a crimp is engaged, it has an auto-complete to ensure full pressure is reached. It also enables the storing of real time crimp data, generate professional reports, view historical tool performance data and wireless syncing to the cloud. Additionally, the ONE KEY™ feature includes tool tracking to assist in finding missing tools quicker and improve inventory management.

Figure 3. Milwaukee M18™ FORCE LOGIC™ 12T Crimper (Photo courtesy of Milwaukee Tool)

Product specifications

• Power Source Cordless
• Battery Type: 18 Volt Lithium Ion
• 350 degrees head rotation
• Weight (pound) 11.7
• Length (inch): 16.0

Jean Christophe Le, MPH - CPWR The Center for Construction Research and Training
Terry Sage, CHST - Freestate Electrical Construction