Industry Standards For Quality Inspection Of Cold-pressed Needle Crimpers

In the field of precision electrical connections, the core performance of contact crimper is maintained by strict compliance with crimping quality. Electrical industry standards such as IEC 60352-2 and UL 486 have established uncompromising technical benchmarks, defining quantitative requirements from physical characteristics to electrical performance.

Tensile strength testing is the primary verification step for the quality of d sub contact crimper crimping. The standard clearly specifies the minimum pull-out force threshold between the crimped terminal and the conductor. For example, UL486 requires that the pull-out force value must reach a preset percentage of the original strength of the conductor. Inadequate crimping force will directly result in the conductor slipping out of the syringe, leading to connection failure. Tensile testing equipment must be calibrated regularly to maintain data traceability.

Electrical continuity verification is equally critical. IEC 60352-2 emphasizes the use of the millivolt drop method to test contact resistance: under a standard test current (e.g., 100A), the voltage drop across the crimped contact must be below the upper limit (e.g., 50μV). Abnormal pressure drop suggests the presence of micro-air gaps or insufficient deformation at the contact surface, indicating a risk of overheating.

Cross-sectional metallographic analysis provides insights into microscopic quality. After polishing the contact crimping tool crimped section, the conductor strand fill rate, deformation uniformity, and air gap distribution are observed under a microscope. Standards strictly limit the visible air gap percentage (typically below 10%) to prevent oxidation corrosion and reduced current carrying capacity. The conductor end extension length and crimp height tolerances must also match the specification drawings.