Overly Tight Cold-pressing Needles: How To Accurately Control Pressing Parameters
In the assembly process of heavy-duty connectors and industrial wire harnesses, the crimping quality of crimp contact male is directly related to the stability of the electrical connection. Operators often fall into the misconception that the tighter the crimp, the more reliable the connection. In actual crimping operations between terminals and wires, excessive clamping force can cause excessive deformation of the crimp socket contact, damaging the original metal structure.
Quantitative Standards for Crimping Deformation
Crimping height is a crucial indicator of crimping quality. When the deformation of the crimped area of the female crimp contact exceeds the reasonable range of the conductor cross-sectional area, the metal lattice will slip, resulting in stress concentration.
-
Potential for Core Wire Breakage: Excessive pressure can crush copper wires, especially multi-strand fine strands. Some copper wires may appear "broken" inside the crimping cylinder, directly reducing current-carrying capacity.
-
Abnormal Flaring End: A proper crimp will form a flaring end at the front to buffer the movement of the wire core. Overly tight crimping often causes the flaring end to disappear, making the root of the wire core highly susceptible to fatigue breakage in a vibration environment.
The Hidden Barriers to Tool Compatibility
The selection of crimping tools cannot be based solely on wire diameter range; it must strictly adhere to industry-standard testing methods. Worn jaws or excessively large setting can cause the cold-pressing syringe wall to pierce the insulation layer or press in too deeply. The correct approach is to perform a pull-out force test to verify that the tensile strength of the crimped area meets the requirements of standards such as DIN 46228, rather than simply relying on feel.
