Consequences of Poor Crimping in Automotive Wire Crimp Terminals
Meaning of Automotive Wire Harness Crimp Terminals
Wire harness crimp terminals are the strong combination of wire and terminal contact surface through external force. This process is realized by the upper and lower blades of the crimping die relying on the force of the crimping machine. It is the operation of the terminal from free bending to correcting bending.
Process of Automotive Wire Crimp Terminals
There are two ways to connect the terminal to the wire, one is a soldering connection, and the other is crimping. In the early years, people usually produce soldering wiring harness terminals, especially when producing products with small batches and relatively simple wiring harnesses. But now, the vast majority factory prefers to choose the crimping process to connect wire crimp terminals. Because this process is simple and very suitable for mass production. Except that, it features reliable contact performance of the wire harness, long service life, and can purify the working environment. In fact, Crimping is a very important process in producing and processing wire harness terminals. It is an effective and reliable method of connecting electrical conductors. And crimping is also important in producing raw materials (terminals, wires, and seals) into wire harness components (circuits).
In a word, Crimping is an important process that determines the electrical and mechanical properties of terminals and wire connections.
Consequences of Poor Crimping in Automotive Crimp Contacts
With society’s increasing emphasis on environmental protection in recent years, new energy vehicles have been rapidly developed and promoted under the country’s vigorous advocacy and policy encouragement, especially in urban public transportation and logistics. New energy vehicles have been widely promoted and become a beautiful landscape for urban development.
The new-energy vehicle crimp terminal is the most important energy transmission carrier on the new-energy vehicle, and its main function is to transmit power energy for the vehicle’s high-voltage electrical components. The crimping level of new-energy vehicle wire terminals affects the resistivity, contact resistance, and insulation performance of high-voltage wiring harnesses.
If the Crimping of the electrical wire terminals of the new energy vehicle is poor, it will easily cause the following consequences:
- If the terminal is not crimped tightly, the maximum pull-out force that the terminal can withstand will not meet the requirements, and the high-voltage wire is easy to loosen from the terminal, causing a safety accident.
- If the terminal is crimped too tightly, the maximum pull-out force that the terminal can withstand will decrease. The crimping structure of the terminal end face will be compact. And the contact performance impedance will increase after the terminal is crimped.
Selection of Raw Materials for Automotive Stamping Terminals
Automotive stamping terminals blocks transmit voltage, signals, and a large amount of data during the vehicle’s operation. But firstly, You need good and suitable raw materials to make a good automotive connector terminals. What are the requirements for the raw material of the automotive connector terminals?
- Conductivity – high conductivity, low resistivity, low contact resistance;
- Ductility – conducive to processing and forming.
- Hardness – Improve mechanical wearability, increase the contact area, and reduce contact resistance.
- Yield Strength – yield strength. In mechanics and materials science, the stress value at which a material begins to deform (deform) plastically, with large displacements in the elastic range.
- Modulus of Elasticity – High elastic modulus surface masks are easily damaged, which helps to reduce the contact resistance of surface masks. Low elastic modulus can increase the contact area for elastic deformation.
- Stress Relaxation – the terminal under long-term stress or high temperature, the load resistance capacity remains unchanged.
- Hardness (Hardness) – reduce the wear and tear of the terminal metal.
Heju Stamping-Your Reliable Automotive Crimp Terminals Manufacturer
Dongguan Heju Precision Electronic Technology Co., Ltd. is a precision stamping manufacturer of producing and designing automotive crimp terminals with 30year stamping experience. It has passed the three major certification systems of ISO9001, ISO14001, and IATF16949. Besides, It has many years of connector terminals design and development experience and a perfect quality inspection system. The thermal and electrical conductivity is stable which meets the quality standards of imported brands. Therefore, If you need new-energy vehicle wiring harness terminals, please feel free to contact us.