Almost wire harness manufacturers are concerned about that how they can produce reliable,

long lasting joint and efficiently with easy training. First of all,we should learn the crimping terminal’s each part description and function. 

 

Mark No.	Part name	Function
1	Insulating crimping position	(1)Prevent wire insulation from falling off. (2)When the wire is prevented from being oscillated, the terminal is pulled off and the conductor is cut off.
2	Conductor crimping position	(1)Contact function (2)Maintain normal circulation between the conductor and the terminal
3	Pressurized line	(1)Enhances conductivity. (2)Enhance tensile strength.
4	Transition position	When the conductor crimping position is crimped, the crimp height is formed.
5	Barb	(1)Keep the terminals are contact with housing tightly. (2)Prevent the matching parts from falling off when inserting into it.
6	Terminal tail	After the terminal is cut from the terminal chain, the tail retains 0.3-0.5mm. If it is too long easy to short-circuit ,if it is too short can't not protect the terminal.
7	Terminal Chimerism position	Contact position between the terminal and insert parts
8	Bell mouth	Prevent the terminal from swinging back and forth and cut the core wire.

 

 Precautions for crimping;

1.Check there is problem on crimping equipment( example, the applicator if loose,

if the terminal on the right position, there is any waste on applicator etc).

2.Operation method, Incorrect operation will result in different defective products.

 

The following describes the various crimping methods and poorly crimping example

 

Analysis for bad crimping;

Main Cause:  incorrect operation method or improper adjustment of the baffle result crimping the insulation too deep.

Result:  poor current circulation or open circuit.

 

Main Cause: incorrect operation method or crimping terminal speed too fast.

Result:  Insufficient tension, easy to break directly affect product performance.

 

Main Cause: incorrect operation method or the wire conductor scattered when crimping.

Result:  Insufficient tension,Leakage,Short circuit etc.

Main Cause: the terminal is not in proper position or damaged the applicator blade

Result: Not acceptable and insufficient tension.

Main Cause: The crimping position of the terminal and the position of the die cutter are not adjusted, or the terminal feeding is unstable.

Result: Affect the insertion force when insert the terminal into the matched parts.

 

Main Cause: The crimping position of the terminal and the position of the die cutter are not adjusted, or the terminal feeding /material guide plate is unstable.

Result: Affect the insertion force when insert the terminal into the matched parts or short circuit etc.

 

Main Cause: the blade for crimping core wires is not adjusted well.

Result: easy to hurt core wires result insufficient tension and use life time.

Main Cause: materials problem, bad crimp or damaged it during the move.

Result: can’t assembly it tight and the product easy to fall off.

Main Cause: upper mold and lower mold are not well matched or the blade stick terminal.

Result: product  can’t be assembly tightly and the product easy to fall off.

 

Main Cause: upper mold and lower mold are not well matched or the blade stick terminal.

Result: product  can’t be assembly tightly and the product easy to fall off.

 

Main Cause: the knife value is too small or the blade is not well installed during stripping wires, and the wire is too bent, which usually occurs in the fully automatic terminal machine.

Result: Non-conductive, directly affecting the electrical conductivity of the product.

 

Main Cause: stripping length too long or incorrect operation.

Result: The raised core wire easily buckles the socket, causing insufficient insertion and the wire is easily fall off from the housing.

 

 

 Main Cause: terminal crimping blade damaged or blade in wrong position or damaged during move.

Result: can’t insert to housing or No insertion force.