This is super macro shots of how daly crimp their bms cables

[Scph9002]

Find it quite interesting how they just clamp the wire right ontop of the lug like as it was a bubble gum lol. Must be some tremendous force

It is a proper fused crimp tho. The crimped part of cable and the lug is one solid block of metal.

 

[Bob B]

Wow .... never seen it done like that before.

 

[Dinky]

Find it quite interesting how they just clamp the wire right ontop of the lug like as it was a bubble gum lol. Must be some tremendous force

It is a proper fused crimp tho. The crimped part of cable and the lug is one solid block of metal.

Is that a proper crimp, looks like some of the wire strands have been abandoned/orphaned by this method?

 

[Scph9002]

Is that a proper crimp, looks like some of the wire strands have been abandoned/orphaned by this method?

yeah. But the diameter of the joint is thicker than the lug or cable anyway it seems )

 

[ghostwriter66]

Not pretty but well above requirement

 

[Scph9002]

Not pretty but well above requirement

I kinda like it. But anyway.. heatshrink was made to hide bad/ugly solder joins and bad/ugly crimps right?

 

[kenryan]

Find it quite interesting how they just clamp the wire right ontop of the lug like as it was a bubble gum lol. Must be some tremendous force

It is a proper fused crimp tho. The crimped part of cable and the lug is one solid block of metal.

I see how the cable end is formed into a solid block, but how is that block adhered to the lug?

 

[time2roll]

In pic #1 it seems a lot of strands are cut in the process. The wire end of the press die should be tapered/rounded a bit instead of a square edge that separated those strands. Probably works fine even if not pretty.

 

[Scph9002]

I see how the cable end is formed into a solid block, but how is that block adhered to the lug?

If you press 2 metals togheter hard enough they weld/fuse into one single solid piece. Kinda like clay

 

[kenryan]

If you press 2 metals togheter hard enough they weld/fuse into one single solid piece. Kinda like clay

Is there a term for this type of crimp? I googled "connectorless crimp" but did not find any info.

 

[kenryan]

Nevermind. I found something: cold welding. Very interesting!

Resource: https://interestingengineering.com/...ng is mostly applied,alloys, nickel, and gold.

 

[imval]

This looks like Ultrasonic welding