Precision Requirements For Pressure Control Of Cold-press Needles

The male crimp contact crimping process requires compressing the metal terminals to a specific size, ensuring an airtight contact between the copper core of the conductor and the inner wall of the terminal. Manual crimping tools rely on operator force, resulting in pressure fluctuations of up to ±20%, which can lead to excessive contact resistance at some crimping points. The fully automatic crimping machine is equipped with a servo motor and pressure sensor, achieving a crimping force control accuracy of ±2%. The equipment retrieves the corresponding pressure curve from a database based on the crimp contact specification and conductor cross-sectional area, monitoring force changes in real time during the crimping process.

When the pressure reaches a set threshold, the system automatically holds the pressure for 0.5 seconds before retracting. This brief holding phase allows the metal grains to flow fully, filling the gaps in the terminal teeth. The pressure sensor, with a sampling frequency of 1000Hz, can capture abnormal peaks during the crimping process. If the pressure curve deviates from the standard range, the equipment immediately stops and marks defective products to prevent them from entering the next process.