JMK high-voltage cable terminal crimping machines provide the controlled force required to terminate large copper cables used in electric vehicles, energy storage systems, charging equipment, photovoltaic installations and industrial power applications.
The range includes 6T–30T pneumatic-hydraulic presses, 20T–50T intelligent servo crimping machines, automatic double-end crimping equipment and configurable crimping stations for high-voltage wire harness production lines. Selected models process conductor cross-sections from 2.5 mm² up to 300 mm².
High-voltage terminal crimping is not simply a larger version of conventional signal-wire crimping. Large conductors, thick cable insulation and heavy copper terminals require sufficient force, rigid tooling and repeatable control of the crimping stroke.
JMK provides two primary drive configurations:
Pneumatic-hydraulic models use compressed air to drive a hydraulic crimping mechanism. They provide a practical solution for manufacturers that need flexible, operator-loaded terminal crimping across different cable and terminal sizes.
Available crimping forces include:
6T
10T
20T
30T
These machines can be operated using a control-panel button or foot switch, allowing the operator to position the cable and terminal before starting the crimping cycle.
Servo-driven models provide programmable control of crimping force and crimping height. They are suitable for production environments that require greater parameter control, recipe storage and repeatable processing across multiple batches.
Available servo crimping forces include:
20T
30T
50T
The appropriate configuration depends on the conductor cross-section, terminal material, terminal wall thickness, die profile and required crimp specification.
The crimping machine should be selected using sample testing and terminal requirements rather than cable size alone.
| Machine configuration | Typical conductor range | Suitable applications |
|---|---|---|
| 6T pneumatic-hydraulic | 2.5–35 mm² | Smaller power cables and industrial terminals |
| 10T pneumatic-hydraulic | 2.5–50 mm² | Medium-size cable terminals |
| 20T pneumatic-hydraulic | 2.5–95 mm² | Automotive and new energy power cables |
| 30T pneumatic-hydraulic | 2.5–180 mm² | Large copper cables and heavy terminals |
| 20T servo | 2.5–95 mm² | Programmable high-voltage cable crimping |
| 30T servo | 2.5–180 mm² | Large new energy cable terminals |
| 50T servo | 2.5–300 mm² | Extra-large cable and high-force crimping |
These ranges provide an initial selection reference. Final suitability must be verified using the actual cable, terminal, crimping die and acceptance standard.
The 6T/10T/20T/30T pneumatic-hydraulic terminal crimping machine is intended for flexible production involving different high-current terminals and cable specifications.
Key characteristics include:
Four available crimping-force levels
Color touch-screen control
Button or foot-switch activation
Replaceable crimping dies
Optional barcode scanner
Optional MES connection
Optional protective safety guard
Compatibility with customized terminal tooling
This configuration is suitable when an operator manually loads the prepared cable and terminal but requires stable press force and controlled crimping movement.
The 20T/30T/50T intelligent servo crimping machine is developed for large new energy cables and other high-current electrical connections.
Its servo system allows crimping force and crimping height to be adjusted for different terminal specifications. The current product series provides positioning accuracy up to ±0.03 mm under the stated machine configuration.
Additional features include:
Programmable crimping parameters
Color touch-screen operation
Optional industrial computer
Barcode-based parameter selection
Reserved MES interface
Automatic lubrication
Quick-change die structure
Safety guard and emergency stop
The servo configuration is particularly useful when manufacturers need to control several crimping recipes and reduce dependence on manual mechanical adjustment.
High-volume cable assemblies may require both cable ends to be crimped within the same automated cycle. The JMK-701 large square cable bare-terminal automatic double-end crimping machine is designed for this type of repetitive production.
Compared with two separate manual crimping operations, automatic double-end processing can reduce:
Repeated cable positioning
Transfers between workstations
Manual length identification
Orientation mistakes
Work-in-process accumulation
Variation between the two cable ends
The cable length, terminal orientation, conductor size and required cycle time should be reviewed to determine whether automatic double-end crimping is suitable.
The crimping die determines the final terminal geometry and must match the terminal design. JMK terminal crimping machines support different die structures, including:
Hexagonal dies
Open hexagonal dies
Quadrilateral dies
Four-point indenting dies
Upper and lower stamping dies
Customized dies for non-standard terminals
A quick-change structure reduces setup time when switching between compatible terminal specifications. However, the correct die, crimping force and crimp height must be validated for each cable-terminal combination.
Selected automotive wire harness terminal crimping machines can be configured with digital production functions according to the customer’s quality-control system.
Available options may include:
Crimp force monitoring
CCD visual inspection
Barcode scanning
Parameter recipe storage
Crimping error alarms
Production count recording
MES connectivity
Defective-product identification
Crimp force monitoring evaluates changes in the force curve during the crimping cycle. It can help identify abnormal conditions, but it does not replace scheduled pull-force tests, terminal cross-section analysis or electrical testing.
CCD inspection is suitable for visible characteristics that can be identified reliably through machine vision. The exact inspection scope must be defined using actual samples.
JMK heavy-duty terminal crimping machines are suitable for cable assemblies used in:
Electric vehicle power distribution
New energy vehicle wiring harnesses
Battery and energy storage systems
EV charging equipment
Photovoltaic power systems
Rail transit electrical connections
Industrial power cabinets
Heavy equipment wiring
High-current copper cable assemblies
The equipment applies controlled crimping force, while the finished connection must still be validated according to the customer’s electrical, mechanical and environmental requirements.
A visually complete crimp does not automatically confirm connection quality. Manufacturers should establish an inspection plan based on the cable, terminal and application.
Common validation methods include:
Crimp height measurement
Crimp width measurement
Pull-force testing
Terminal cross-section analysis
Conductor strand inspection
Electrical resistance testing
Insulation and withstand-voltage testing
Seal and environmental testing where applicable
These tests are separate from the crimping machine unless specifically integrated into a customized production or inspection system.
Please provide the following details when requesting a terminal crimping machine:
Cable conductor material
Conductor cross-section
Cable outer diameter
Terminal drawing and samples
Terminal material and wall thickness
Required crimp shape
Crimp height specification
Pull-force requirement
Required production output
Manual or automatic loading preference
Single-end or double-end processing
Barcode or MES requirements
Required inspection method
We use this information to recommend the press tonnage, drive system, crimping die and optional monitoring functions.
JMK develops terminal crimping equipment for conventional wire harnesses, large copper cables and new energy applications. Our range covers flexible operator-loaded presses and automatic crimping stations for integrated production lines.
We support cable and terminal evaluation, die selection, sample crimping, machine configuration, commissioning and operator training. This process helps manufacturers select a machine according to the actual connection rather than relying only on a nominal tonnage value.
The required force depends on conductor size, terminal material, wall thickness, die shape and target crimp dimensions. Actual cable and terminal samples should be tested before selecting the tonnage.
Pneumatic-hydraulic machines provide flexible heavy-duty pressing with relatively simple operation. Servo machines allow more programmable control of crimp force, height and production parameters.
Selected 50T servo machines support conductor cross-sections up to 300 mm². The applicable range still depends on the terminal and crimping die.
Yes. Multiple standard die profiles and customized terminal dies are available. Die compatibility must be confirmed for the selected machine.
Crimp force monitoring is available on selected equipment or as an optional configuration. It should be configured according to the cable, terminal and defect-detection requirements.
Selected pneumatic-hydraulic and servo models support optional barcode scanning for parameter selection and production management.
MES connectivity is available on supported models. The communication protocol, required data fields and existing factory system must be confirmed before configuration.
No. Crimp force monitoring detects changes during production, while pull-force testing directly measures the mechanical retention of the finished connection. Both serve different quality-control purposes.
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