Terminal crimping, as a common process in the field of electrical connections, plays a crucial role in ensuring the stable operation of electrical systems. The "precision sewing technique" in the industrial sector, the crimping technology born in 1941, is like putting custom suits on wires and terminals - using precise pressure to make the metal "skin match" and achieve inseparable electromechanical integration connection. This seemingly simple process controls the lifeline of modern equipment: from signal interruption to equipment burnout, it can explode in the moment of crimping error. The terminal crimping process has attracted much attention due to its uniqueness. One article explains the content of terminal crimping technology

　　The Five Golden Rules of Crimping Process

　　Ensure that the correct rated current, rated voltage, wire diameter specifications, bonding force, wire gauge compatibility, structural design, termination method, and safety characteristics are all met in order to achieve perfect connector selection. Terminal crimping, as a common process in the field of electrical connections, requires sufficient attention from manufacturers.

　　01 Calculation of wire diameter range and material thickness for crimping structure

　　02 Adjust the crimping height for crimping different wire diameters

　　03 Achieving Low Cost through Continuous Stamping Production

　　04 Crimping automation

　　05 Stable performance in harsh environments

　　Firstly, it is important to understand that terminals have three main parts: plug-in area, transition area, and crimping area.

　　The plug-in area is the part where the terminal is plugged into the other half of the connecting terminal. This part is designed by the connector designer to be combined with the docking terminal and work in a certain way. If the joint deforms during the crimping process, it will reduce the performance of the connector.

　　The transition zone is also designed to be unaffected during the crimping process. If you change the position of the elastic piece or terminal stopper, it will also affect the performance of the connector. The crimping area is the only part of the design that is affected by the crimping process. Use the termination device recommended by the connector manufacturer to clamp the crimping area and securely connect to the cable. Ideally, all the work of crimping the terminals onto the cable only occurs in the crimping area.

　　The correct example of crimping is shown below. The insulation crimping area compresses the insulation layer, but does not puncture it. The distance that the wire core (or wire brush) extends from the front of the conductor crimping area is at least equal to the diameter of the cable conductor. Introduction to Terminal Crimping Method In electrical and electronic equipment, terminal crimping is a commonly used connection method used to reliably connect wires or other conductors to equipment or components.

　　What are the main issues with terminal crimping

　　1.The crimping height is too small

　　The crimping height refers to the cross-sectional height of the conductor crimping area after crimping, which is the most important characteristic of good crimping. The connector manufacturer provides crimping heights for each cable size designed for the terminal. The correct crimping height range or tolerance for a given cable may be as small as 0.002 ". Under such strict specifications, it is important to verify whether the crimping machine is set correctly to obtain good crimping.

　　Too small or too large a crimping height cannot provide the specified crimping strength (retention force on cable terminals), which will reduce the cable pulling force and rated current, and generally cause a decrease in the performance of the crimping joint under abnormal working conditions. A too small crimping height can also crimp the wire core or break the metal in the conductor crimping area.

　　2.Excessive crimping height

　　Excessive crimping height cannot compress the wire core correctly, causing ineffective gaps in the crimping area due to insufficient metal to metal contact between the wire core and terminal metal.

　　The solution to excessive or insufficient crimping height is simple: adjust the crimping height of the conductor on the crimping machine. When using the crimping machine for the first time, the vernier caliper or micrometer used should be used to check that the crimping height is within the specified range, and it should be rechecked at the required frequency during the work process to maintain the correct crimping height.

　　3.The insulation crimping area is too small

　　Due to the diversity of insulation types and thicknesses, connector manufacturers generally do not provide the crimping height of the insulation layer. Insulation crimping provides stress relief for the conductor crimping area, so that the wire core will not break when the cable is bent. A too small insulation crimping area will cause excessive metal stress in the insulation crimping area, weakening its stress relief function.

　　4.The insulation crimping area is too large

　　Most types of crimping tools can adjust the insulation crimping height independently of the conductor crimping height. The correct adjustment ensures that the terminal clamps the insulation layer at least 180 degrees and does not puncture the insulation layer. When the outer diameter of the insulation crimping part of the terminal is close to the outer diameter of the cable insulation layer, it is recommended to use IDT (Insulation Displacement Connection) technology.

　　5.The crimping is too forward

　　A more obvious crimping problem is that the transition zone is partially damaged, and the vertical protrusion is a design feature called the "terminal stopper". Its function is to prevent the terminal from being inserted too deeply into the housing. If the stopper is completely damaged, the terminal may continue to shift towards the inside of the housing, resulting in excessive insertion.

　　Solution: The cause of this problem is the incorrect position of the terminal and metal strip (the metal strip to which the terminal is connected when you receive the goods from the manufacturer) relative to the crimping machine. Simply loosen the substrate of the interchangeable tool and realign the crimping machine to solve the problem.

　　The above provides a detailed introduction to the golden rule of terminal crimping and the issues related to terminal crimping. As a process of tightly connecting wires and terminals, crimping plays a crucial role in modern industry. Correct crimping can ensure the reliability of electrical and mechanical connections, while unqualified crimping may result in the product being unusable or even damaged. Therefore, it is crucial to choose the appropriate crimping tool and perform the crimping operation correctly.