RAST 5 Series crimping

RAST 5 (Raster Anschluss Steck Technik 5 mm) is a standardized connector system with a 5.0 mm pitch, widely used in appliance, automotive, and industrial applications. Crimping in RAST 5 Series refers to the process of securely attaching terminals to wires before they are inserted into the connector housing. This ensures reliable electrical connections with high retention strength and durability. 

1. Key Features of RAST 5 Crimping

• 5.0 mm Pitch: Designed for power and control connections, offering secure wire-to-board and wire-to-wire interconnects.
• Crimped Terminals:
• Typically made from copper alloys (brass or phosphor bronze) for conductivity and mechanical strength.
• Plated with tin, gold, or silver to enhance corrosion resistance and contact reliability.
• High Current Capacity: Supports currents up to 16A per circuit, depending on wire gauge and terminal type.
• Pre-Crimped Wire Solutions: Available as pre-assembled crimped wires, simplifying production and assembly.
• Locking & Coding Options:
• Keying mechanisms to prevent incorrect connections.
• Secondary locking features for additional retention in high-vibration environments.
• Automation Friendly: Compatible with automated crimping and insertion processes to increase efficiency in mass production.

2. RAST 5 Crimping Process

1. a) Wire Preparation

• Wires (typically AWG 16-22) are cut to the required length.
• The insulation is precisely stripped to expose the correct length of conductor.

1. b) Terminal Crimping

• The terminal is placed onto the exposed wire strands.
• A crimping machine or tool compresses the terminal’s crimping tabs around the wire, creating:
• A gas-tight electrical connection to prevent oxidation.
• A secure mechanical bond to ensure durability.
• The crimped terminal undergoes quality inspection (force measurement, visual checking).

1. c) Terminal Insertion into RAST 5 Housing

• The crimped terminal is pushed into the connector housing until it clicks into place.
• Some versions use automated insertion systems for higher efficiency.

1. d) Quality Control & Testing

• Pull Force Testing: Ensures the crimped connection withstands required tension.
• Electrical Testing: Measures contact resistance and ensures continuity.
• Environmental Testing: Checks for heat, humidity, and vibration resistance.

3. Applications of RAST 5 Series Crimping

• Household Appliances (e.g., dishwashers, washing machines, refrigerators)
• Automotive Electronics (e.g., power distribution, climate control, lighting)
• Industrial Control Systems (e.g., motor controllers, automation modules)
• HVAC Systems (e.g., thermostats, fan controllers)
• Power & Energy Systems (e.g., solar inverters, battery packs)