Rotary crimping tool assembly

A method of crimping a structure, the method comprising:

• positioning a portion of the structure to be crimped into a crimping chamber of a rotary crimping tool assembly;
• pressing one or more crimp wheels into the portion of the structure to be crimped, wherein the pressing comprises forming one or more initial crimps into the portion of the structure;
• and
• rotating the one or more crimp wheels relative to the portion of the structure to form one or more full crimps in the portion of the structure, wherein the one or more crimps are configured to secure the first portion of the structure to a second portion of the structure;
• wherein each of the one or more crimp wheels comprises a conductor crimp member and a sealing crimp member, wherein the conductor crimp member has a different shape than the sealing crimp member, wherein the conductor crimp member includes a smooth, arcuate outer surface having a central equator from which lateral portions recede, wherein the sealing crimp member has a plurality of seal-indenting features, wherein the conductor crimp member has a first height and the sealing crimp member has a second height, wherein the first height exceeds the second height, the conductor crimp member is configured to form a first crimp at a first depth into the portion of structure, and the sealing crimp member is configured to form a second crimp at a second depth into the portion of structure, and wherein the first depth is deeper than the second depth.

A rotary crimping tool assembly configured to crimp a terminal housing of a contact terminal into an insulated wire, wherein a conductive portion of the insulated wire is within the terminal housing, the rotary crimping tool assembly comprising:

• a tool housing defining a crimping chamber;
• an adjustable mount configured to be moved within the crimping chamber;
• and
• one or more crimp wheels within the crimping chamber, wherein the crimping chamber is configured to receive the terminal housing in proximity to the one or more crimp wheels, and wherein the adjustable mount is configured to urge the contact terminal into the one or more crimp wheels, and wherein the tool housing is configured relative to the terminal housing to form one or more crimps in the terminal housing;
• wherein each of the one or more crimp wheels comprises a conductor crimp member and a sealing crimp member, wherein the conductor crimp member has a different shape than the sealing crimp member, wherein the conductor crimp member includes a smooth, arcuate outer surface having a central equator from which lateral portions recede, wherein the sealing crimp member has a plurality of seal-indenting features, wherein the conductor crimp member has a first height and the sealing crimp member has a second height, wherein the first height exceeds the second height, the conductor crimp member is configured to form a first crimp at a first depth into the terminal housing, and the sealing crimp member is configured to form a second crimp at a second depth into the terminal housing, and wherein the first depth is deeper than the second depth.