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With the development of new energy vehicles, the number of high-voltage wiring harnesses is gradually increasing, and the main form of its terminals is closed terminals. Open terminals are commonly used in wire harnesses, and the crimping method is relatively simple, so no more analysis will be made here. Today, this paper mainly analyzes the crimping mode of closed terminal and shielding ring in high voltage cable harness. Ring crimping is a unique crimping type in high-voltage Wire Harness, which mainly plays the role of shielding connection, so the function will not be described in detail here. Tubular terminal crimping methods mainly include: 6-sided crimping; 6-face 2-point crimping; MW type crimping; 4 point crimping. The shielding ring crimping methods mainly include: 6-sided crimping; 6-face 2-point crimping; 6 point crimping. Let's analyze them from the way of crimping.
1) Crimping method of terminal 6. 6-sided terminal crimping is generally applicable to the crimping of wires with more than 8 square meters. When the square of wires and terminals are completely matched, the profile and pull-off force of terminals can be qualified after crimping. The crimping equipment mainly uses hydraulic equipment, which ensures the soft crimping of the terminal during the crimping process and avoids the occurrence of terminal cracks. In the sampling stage, most of the six-sided hydraulic equipment is used without changing the mold. In batch, the special hydraulic equipment is reused according to the crimping method.
2) 6-face 2-point crimping method. 6-sided 2-point crimping (6-sided 2-point crimping) is generally applicable to wires with more than 8 square meters. Crimping can be carried out when the wire and terminal are slightly smaller than the terminal diameter. After crimping, the terminal profile and pull-off force are also qualified. The crimping equipment mainly uses hydraulic equipment, generally including imported crimping equipment and domestic crimping equipment, all of which can meet the crimping quality, but the imported equipment is more stable. Because the country of high-voltage wire harness has not issued a formal standard, the crimping method is not completely unified, and the 6-face 2-point crimping method is widely used.
3) MW type crimping mode. MW-type crimping is generally suitable for crimping when the wire is more than 8 square meters and the matching between the wire and the terminal is slightly smaller than the diameter of the terminal. However, in order to ensure the deformation of the terminal crimping part and the good contact and cooperation of the wires, MW crimping can be preferred, and the profile and pull-off force of the terminal also meet the requirements after crimping. With the increasing number of new energy vehicles, the stability of crimping is gradually enhanced. MW crimping is a superior crimping method based on 6-face and 2-point crimping, and it is worth popularizing from terminal deformation to profile effect analysis.
The patent of this crimping method has been accepted.
4) 4-point crimping method. 4-point pressure welding (square pressure welding or square double pressure welding) is generally applicable to wires below 6 square meters. When the wires and terminals cooperate well, the terminal profile and pull-off force are also qualified after pressure welding. The square number of wires commonly used in point crimping is 3 square, 4 square and 6 square, among which 3 square wires and 4 square wires are more. In the crimping process, it is necessary to put the wire into the terminal crimping hole first, and then hold the wire and the terminal for crimping. In the crimping process, it is necessary to prevent the terminal from coming off, which will affect the operation efficiency.
1) 6-sided crimping method. The 6-face crimping of shielding ring is generally suitable for wires with more than 3 square meters. It is a crimping method with good coordination between wire shielding net and shielding ring. After crimping, the pull-off force is qualified. Usually, when the gap between shielding ring, shielding net and conductor is small and the fit is tight, this kind of crimping method is widely used, and it is one of the commonly used crimping methods of shielding ring.
2) 6-face 2-point crimping method. The 6-face 2-point crimping of shielding ring is generally applicable to the crimping method of the wire shielding net with more than 8 square meters and the shielding ring, and the pull-off force is qualified after crimping. Usually, when the gap between shielding ring, shielding net and wire is slightly larger, this crimping method is adopted. The number of crimping points is determined according to the length and size of shielding ring, and it is also one of the commonly used crimping methods of shielding ring.
The patent of this crimping method has been accepted.
3) 6-point crimping method. The 6-point crimping of shielding ring is generally applicable to the crimping method of 10 square conductor shielding net and shielding ring. After crimping, the pull-off force is qualified. Usually, when the gap between shielding ring, shielding net and conductor is large, this crimping method is adopted. The main reason for this mode of use is that the shielding ring of the Connector does not match the conductor, which requires high toughness of the shielding ring material. Otherwise, cracks will appear after the shielding ring is crimped with the conductor, and the quality defects of the shielding ring will lead to unqualified product quality, which cannot meet the production needs. The patent of this crimping method has been accepted.
In the actual production process of high-voltage wire harness, crimping is rated as the key characteristic, and it is one of the important production links in the process of making wire harness. In the process of developing crimping dies, the crimping engineers of Kable-X should carefully analyze the matching of connector structure and wires. During this period, the work content of crimping engineers is particularly important. It is necessary to analyze connector assembly instructions, find out the connector structure state, and put forward the development list and requirements to die developers, so as to ensure that there are no problems in the use of dies after development. Through the above analysis, each crimping method has its own characteristics, and as long as careful analysis is made, a suitable crimping die can be developed to meet the crimping requirements and ensure the product quality.
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