Basic Overview and Defect Analysis of Terminal Harnesses

Terminal Wire Common Specification Model Terminal wire is used to facilitate the connection of wires, is actually sealed in the insulating plastic metal sheet, both ends have holes can be inserted, you can choose the number of wires and spacing, so that the connection is more convenient, greatly reducing the size of the electronic products and production costs, and improve production efficiency, the general specifications of 0.5mm, 0.8mm, 1.0mm, 1.25mm, 1.27mm, 1.5mm, 2.0mm and 2.54mm and other various spacing flexible cable. The processing and application of terminal cables are now widely used in signal transmission and board-board connection of plotters, scanners, copiers, stereos, liquid crystal appliances, fax machines, and all kinds of video disk machines. In modern electrical equipment, almost ubiquitous. Terminal wire crimping appearance considerations joints must be in close contact, can not see the core and PVC; core and PVC crimping, both must be clearly visible; core must be exposed 0.2mm-1mm (terminal specifications are different, different lengths of exposed cores); core and PVC crimping, the joints must be in a straight line, symmetrical on both sides. Several terminal line pressure analysis failed 1.Crimp height unqualified crimp height is to guide the body crimp area crimped cross-section height, is a good crimp the most important feature. Connector manufacturers provide crimp height for each cable size for which the terminal is designed.2. Stripped wire length is too long or too shortIf the stripped wire length is too short, or if the cable is not fully inserted into the conductor crimp zone, the terminal may not be able to achieve the specified tensile force due to the reduction of indirect metal contact between the cable and the terminal. If the stripping length is too long, the core will be exposed, affecting the use.3. Insulation crimp area failure Due to the diversity of insulation types and thicknesses, connector manufacturers usually do not provide the crimp height of the insulation. The insulation crimp provides stress relief to the conductor crimp area so that the core does not break when the cable is bent. An insulation crimp area that is too small puts too much stress on the metal in the insulation crimp area, weakening its stress relief function.4. One of the most vivid crimping problems with banana terminals is the banana crimp. This is because the crimp terminals are banana shaped. This makes it difficult to insert the terminal into the housing and can lead to terminal collisions, although Molex terminals are now very good for a variety of electronics. But due to the current epidemic, this terminal is hard to purchase and the price has gone up time and time again. In addition to the needs of guests, many manufacturers are basically using domestic terminals.5. Tail material is too long in the crimping process, the tail material from the terminal cut off. If the retained tail stock is too long, problems will occur. When the terminal is inserted into the shell, too long metal tail material will extend to the rear of the connector, in the application of high voltage will lead to the connector adjacent to the contact point between the arc. If the tail stock at the front of the terminal is too long, it can interfere with connector mating and cause terminal collisions.

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