Terminal Crimping Process Optimization for Enhanced Electrical Performance

Terminal Crimping Process Optimization for Enhanced Electrical Performance

• 2025-05-08 11:52:53
• by Admin

Terminal crimping is a key process in wiring harness manufacturing. Whether in automotive electronics, industrial equipment, or medical equipment, its accuracy and consistency are very high.

Terminal crimping refers to applying specific pressure to form a mechanical and electrical connection between the wire and the contact surface of the terminal. This process involves several key parameters:

• Crimp Height: The crimping height directly determines the degree of conductor compression. Too high may cause loose contact, and too low may easily break the copper wire or damage the terminal.
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• Crimp Width: It affects the contact area and structural strength, and should be accurately matched with the terminal model and wire diameter.
• Tensile test: It is an important indicator to determine whether the mechanical connection meets the standard, and generally needs to comply with the IPC/WHMA-A-620 standard.
• Conductor position and insulation support: The conductor must be fully inserted into the terminal tube, and the insulation part must not be over-compressed to prevent loosening or short circuit during long-term use.

Why is terminal crimping so critical?

High-quality terminal crimping connections have many advantages:

• Stable electrical conductivity
• Excellent mechanical connection strength
• Strong vibration and corrosion resistance
• Increase the overall life of the harness

Kaweei's terminal crimping process practice

As a professional custom harness manufacturer, Kaweei has a complete terminal crimping production line and testing system:

Use international brand terminals and molds such as Molex, JST, TE, etc.

Automated crimping equipment to ensure consistency and stability

Implement strict visual and tensile testing

Crimping data recording and traceability system by ISO standards

Kaweei provides one-stop customization services from raw material selection, terminal configuration, to final crimping solution optimization, and widely serves new energy vehicles, medical equipment, industrial automation, and other industries.