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Comprehensive Analysis of Wheel Wire Harness Crease Issues in Automobiles (Part 1)

  1. Background: Wheel wire harnesses in automobiles consist of a variety of materials, including ABS cable sheaths, EPB cable sheaths, twisted pairs, single-core wires, protective tubes, rubber parts, injection molded parts, terminals, rain plugs, connectors, and tapes. Challenges arise when the design software cannot identify potential crease problems from different wire harness directions, and […]

Precautions for wire stripping

As the main carrier of circuit connection, copper wire will be stripped and exposed at the terminal crimping position first. Copper wires are often damaged during the stripping process. The number of conductor strippable copper wires calculated based on the conductor area must be rounded to one decimal place. For example, for a 0.5 wire, […]

Precautions for the crimping process

From the point of view of the manufacturing process, three things need to be done: neat terminal feeding, level terminal placement, and alignment of mold jaws The orderly feeding of terminals means that when feeding, it is necessary to ensure that the terminals do not collide with the surrounding parts, so that the terminals can […]

Effect of Crimp Height on Terminal Electrical Performance

The contact between the terminal and the wire is not completely in contact, but scattered at some points on the contact surface. The difference between the actual contact area and the theoretical contact area may reach thousands of times. The resistance formed by the contact between conductor and conductor is called contact resistance, which is […]

Performance comparison of different wires

1. Ordinary wire Regular wire is usually made of many strands of thin copper wire. The multi-strand form has good bending resistance and is not easy to break due to repeated vibrations. Common conductors consist of two parts: a copper core and insulating material. Polyvinyl chloride material is usually used for insulation and has the […]

How to choose the wire?

Wire is an important part of terminal crimping, and the main factors to consider when selecting wire are conductor material, insulation material, and ampacity. 01 conductor material In the case of the same wire diameter, the current carrying capacity of the copper wire is greater than that of the aluminum wire, but the weight of […]

Effect of Crimp Height on Mechanical Properties of Terminals

The tensile strength of the terminal mainly depends on the contact pressure between the terminal and the wire. The contact pressure is mainly provided by the elastic deformation and plastic deformation of the terminal and the wire. An important factor that determines the elastic deformation and plastic deformation of the terminal and the wire is […]

What is the difference between different plating materials of terminals?

Electroplating on the surface of the terminal is a technical method to solve the oxidation and corrosion of the metal on the surface of the terminal, enhance the conductivity of the terminal, and reduce the contact resistance. Besides gold, silver, and nickel or chrome plating, tin plating is most commonly used in terminal plating. Gold […]

How to choose terminal material?

When selecting a terminal material, the following characteristics should be considered: ① Mechanical properties of materials. Strength, ductility, yield strength, hardness, etc. ②Electrical conductivity and thermal conductivity of the material. The electrical conductivity is directly proportional to the thermal conductivity, the thermal conductivity is related to the electrical conductivity of the terminal and its own […]

Environmental Performance of Connectors

① Temperature resistance: At present, the maximum working temperature of the connector is 200°C (except for a few high-temperature special connectors), and the minimum temperature is -65°C. When the connector is working, the current generates heat at the contact point, causing the temperature to rise. Therefore, it is generally believed that the working temperature should […]