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Technical requirements, diagrams and test methods for terminal crimping quality


Technical requirements, diagrams and test methods for terminal crimping quality

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Conductor crimping

Insulation Crimp

Front and back burrs

Terminal deformation

Insulation bending

Fix the terminal, at a distance of 50mm from the conductor crimping area, perform five cycles according to Figure 3 (bend 45° → bend 90° in the opposite direction → repeat Bit, for one cycle) insulation bending test, the lead does not apply tension during the test. After the test, the insulation crimping is good, and the insulationNot protruding from the insulation crimp area.

Profile Analysis

(1)Conductor Crimp Profile

(2)Insulation crimp profile

(3)How to measure crimp height and width

The crimping width is measured with a caliper (accuracy: 1/100);

The crimp height is measured with a crimp height micrometer (accuracy: 1/1000), as shown in Figure 5.

(4)Profile analysis method

· Use special cutting equipment to cut the conductor crimping area and insulation crimping area respectively according to Figure 6. When cutting, it should be cut vertically and longitudinally in the middle of the crimping area, and avoid the groove (reinforcing rib) in the crimping area of the conductor.

·The section after cutting should be flat without deformation, and the curl should not be opened.

·Grind the section after cutting to remove burrs, and care should be taken not to damage the section (such as curling open, cracks, etc.) when grinding.

·Coat the polished section with ferric chloride solution (content: 35%-45%), so that the outline of the wire core and terminal wall can be clearly displayed.

·Use electron microscope and calibrated profile analysis software to analyze and measure the relevant parameters of the profile.

Note: If the terminal is not easy to fix or if there are problems such as section deformation, curling and opening when cutting or grinding, the terminal can be cured in resin before grinding.

Stretching test

(1)Tensile strength

(2)Tensile test method

·According to the test method in Figure 7, release the insulation crimping, remove the insulation at a distance of about 200mm from the conductor crimping area, and reversely weld the end of the conductor on the conductor to form a tension ring.

·Use a special fixture to fix the terminal, and make the lead wire and the conductor crimping area in a straight state, and then perform a tensile test on the tensile ring.

• Explosive force should not be used during the test. The test can be carried out by a tensile testing machine, and the moving speed of the machine head is between 25-50mm/min. Observation record guide during the test

The maximum tensile value of the body should meet the requirements of its wire diameter. Two-wire crimping shall be tested individually for each conductor.

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