Cable Termination Crimping Technology: How to Ensure a Reliable Connection?

To ensure a stable connection in crimping terminal technology for harnesses, the following key aspects can be addressed:

The selection and maintenance of crimping tools

Select the appropriate crimping tool: Choose the matching crimping tool based on the type, specification, and crimping requirements of the wire harness terminal. For instance, manual crimping pliers are suitable for small batches and simple crimping work, while pneumatic or hydraulic crimping tools are better suited for large-scale, high-precision crimping operations.

Regular maintenance of crimping tools: Regularly clean, lubricate, and calibrate crimping tools to ensure stable performance. For example, check whether the crimping pliers' pliers mouth is worn out, and replace it in time to ensure the strength and precision of crimping.

Quality control of terminals and cable harnesses

Quality inspection of terminals: Purchase terminals of qualified quality, and check the material, dimensional accuracy, and surface quality of the terminals. The material of high-quality terminals should have good conductivity and mechanical strength, the dimensional accuracy should conform to relevant standards, and the surface should be free of defects such as cracks and burrs.

Wiring harness processing: The material of the wires in the harness should meet the requirements, and the wire diameter should match the terminal. Before crimping, the harness should be cleaned and peeled to ensure that the end of the harness is free of oil and impurities, and the length of the peel should be appropriate, generally slightly longer than the length of the crimping tube of the terminal, to ensure that the wire core can be completely inserted into the terminal.

Setting and control of crimping parameters

Control of crimping force: According to the specifications of the terminals and wire harnesses, determine the appropriate crimping force. If the crimping force is too small, the terminal and wire harness connection is not firm, and poor contact is prone to occur; if the crimping force is too large, it can lead to terminal deformation and wire harness damage. The crimping force can be monitored and adjusted through devices such as pressure sensors.

Control of the crimping stroke: The crimping stroke of the crimping tool is controlled to ensure that the terminal reaches the specified height and shape after crimping. Generally, the crimping stroke should be adjusted according to the type of terminal and the wire diameter of the harness, which can be achieved by setting a limit device on the crimping tool.

Control of crimping speed: The crimping speed should not be too fast, otherwise, it may produce a large impact force, affecting the crimping quality; too slow a speed will affect production efficiency. Generally, when crimping manually, a steady speed should be maintained, and when crimping with pneumatic or hydraulic equipment, it should be adjusted according to the performance of the equipment and the crimping requirements.

Execution and optimization of the crimping process

Correct crimping operation: Insert the wire harness accurately into the crimping tube of the terminal, ensuring that the wire core is not loose or twisted. Then, use the crimping tool to crimp, and keep the tool vertical to the terminal during the crimping process to avoid oblique or eccentric crimping.

Inspection after crimping: After crimping is completed, perform a visual inspection on each crimped point to check if the terminal has deformed, cracks, and whether the connection between the wire harness and the terminal is tight, and whether there is any exposed wire core. At the same time, methods such as tensile testing can be used to check the firmness of the crimping, and the non-conforming crimped points should be reworked in time.

Process optimization: Based on the actual situation during the production process, the crimping process is continuously optimized. For example, by analyzing the causes of crimping defects, adjustments and improvements are made to the crimping parameters and operation methods to improve the quality and stability of the crimping.

Consideration of environmental factors

Temperature control: The temperature of the crimping working environment should be maintained within a certain range, generally between 20℃ and 30℃. Both too high and too low temperatures can affect the material properties of the terminals and wire harnesses, thereby affecting the crimping quality. For example, in a low-temperature environment, the wire harness may become hard and brittle, and is prone to breakage during the crimping process.

Humidity control: Environmental humidity can also affect the crimping quality. High humidity can easily cause rust and oxidation on the surface of terminals and wire harnesses, affecting conductivity and connection stability. Therefore, it is necessary to keep the crimping environment dry, and the humidity is generally controlled between 40% and 60%.