According to the appearance and cross-section of the terminal after crimping, judge and analyze the crimping effect. Common appearance judgments are: whether there is a bell mouth at the crimping wing of the core wire, whether there is a protruding insulating skin at the insulating crimping wing, and the size of the material tape;

Items of profile analysis: support height/width, burr height and width, compression ratio (different wire diameters), whether the crimping wings are symmetrical, etc.

Judgment method of terminal crimping state of wiring harness

So what is the significance of the terminal crimp profile?

Monitor and ensure that the terminal is stable during batch crimping;

The qualified crimping state ensures the combined electrical performance of the terminal and the wire, thereby improving the electrical performance of the entire vehicle circuit;

How to ensure terminal crimping

There are many factors that affect the crimping state of the terminal. The hardware aspects such as the matching of the machine and the mold, the selection of the mold and the blade, and the maintenance of the mold are not described in detail here. Let's talk about the most fundamental factors: the matching of terminals and wires and the setting of terminal crimping parameters.

Matching of terminals and wires: Under the condition of a certain rated current, the types of optional wires basically limit the types of corresponding terminals. Why is it said that the wire determines the type of terminal? Because the rated current of the electrical appliance is set, the carrying current of the wire is also limited. Therefore, the wire diameter of the wire can be selected, and the matching terminal can meet the size of the current that can be carried and can wrap the wire diameter. After the terminal is matched with the wire, how to set the crimping parameters of the terminal? It is not difficult to find in the parts specification book of Molex/delphi/TE that many terminals will provide the corresponding wire diameter and crimping range of the terminal. This kind of information can be used as the basic reference information when setting the crimping parameters in the mold acceptance stage. , In many cases, the terminal crimping range we need cannot be found in Molex/delphi/TE, what should I do? Yes, in many cases it cannot be found.

I want to complain here. This type of imported connector terminal has entered China very early and has developed many products in cooperation with many car companies. Therefore, as protection, there will be certain barriers in the sharing of information. (The sales drawings can be found very quickly. Regarding the manufacturing information, I am sorry that you have to ask me through the channel!) So in this case, how do we set the crimping parameters of the terminal? There is a way.

As mentioned earlier, crimping judgment has two major items: appearance and profile analysis. Many wiring harness companies have their own corporate standards, which can basically be used as a basis for judgment. We can think about this problem in reverse: there is no reference information, and it can also be judged according to the appearance and cross-section state after crimping. Whether the terminal and the wire match , this method is also commonly used.