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Problems in the electrical system have long been a problem of automobiles. One of the most common areas of circuit failure is battery connection. Heavy-duty terminals required for large AWG wire harness, such as those used for battery connection, are attracting the attention of manufacturers who provide terminals for the automotive industry. Electrical terminal manufacturers use most of their engineering resources to develop new products or improve existing terminals, so as to meet the demands of industries that also pay attention to cost, increase fuel mileage, reduce lead usage (RoHS) and vehicle weight.
Many factors must be considered when developing terminals for heavy-duty vehicle applications. This report of us Kable-X, will discuss several issues that are crucial to manufacturing strong, heavy-duty automobile electrical connections, which must meet or exceed customer specifications and SAE standards.
A Terminal Material Selection
Since the implementation of RoHS Directive, lead terminals are being replaced by terminals made of other lead-free materials. Terminals can be made of steel and dissimilar alloys with various plating options, including bright and matte finishes. A good material choice for heavy-duty battery terminals is tinned brass. Its performance is superior to that of lead in terms of conductivity, corrosion resistance, tensile strength, hardness and durability. All these metal features provide the best heavy-duty terminals. For those who wish to reduce weight, lead-free stamped battery terminals made of tinned brass are ideal alternatives for heavy-duty cast terminals.
B The Terminal Design and Characteristics
Excellent engineering team will develop the terminal design, make it a part of the best connection, and include design features that are convenient for Wiring Harness manufacturers to handle terminals. In addition to metal selection, they will also consider the following:
1. Overall size and wiring range of terminals. Determine the amount of metal needed to produce the best terminal. Evaluate terminal length and material thickness.
2. Terminal crimping area. The pocket /U-shaped area of the terminal will form the connection with the wiring loom. This part of the design has specific reinforcing ribs and sawtooth features, which will be helpful for the pressure bonding.
3. Coordinate with regional geometry. A part of a terminal, and its opposite part is matched to form a connection. This requires the coupling characteristics to ensure the integrity of the circuit. Matching forms will provide maximum surface-to-surface area contact, thus maintaining a firm bond.
4. Layout considerations for terminal production will include determining the side-by-side or end-to-end structure and its transmission length. Pay attention to the direction of terminal peeling, because it needs to be wound on the reel in a way that meets the needs of the application.
C Terminal Crimping
Crimping is a solder-free crimping method, which is used to fix terminals to wires. There are several types of crimp terminals. One type includes a straight cylinder located at the back of the terminal, and the terminal is inserted into the insulated stripped part of the wire. Then clamp the cylinder on the wire. The collapsed part of the cylinder forms a joint between the terminal and the wire strand. Another type of crimping preferred by most high-quality Wire Harness manufacturers is F-type crimping. This type of crimping has a U-shaped part on the back of the terminal, which is used to form an envelope around the exposed wire strands and move between a stamping and die with appropriate size. The final connection of F-type crimping is a tight joint, so that each strand is obviously reshaped by the geometry and compression force of the crimping tool. Good crimping is very important to keep good retention of wires. Selecting appropriate tools and terminals in the recommended equipment and setting them correctly will always produce high-quality crimping. A good terminal manufacturer will develop and provide tools that can provide the best crimping. A bell mouth with a proper flare on the side of a wire to reduce cutting strands and produce a joint with the lowest resistance and the best wire holding force.
E Types of Terminals
Major manufacturers of automotive heavy-duty terminals will sell battery terminals specially designed to match different geometric shapes of positive and negative terminals. The terminal adopts engineering reinforcing ribs or serrations, which can ensure the best uniformity in connection. These terminals will be clearly printed with - and + symbols to identify them as positive or negative terminals. In addition, various heavy-duty ring terminals can be provided. These terminals are also manufactured according to SAE specifications, and have different hole sizes to meet customers' requirements. Terminals are made of high-quality electrical, durable and corrosion-resistant, and are provided in continuous strips, with crimping wings facing upwards for automatic or manual termination.
F Crimping equipment
The crimping department of a trusted supplier shall provide all necessary equipment to ensure the best crimping of terminal wires. It is recommended that the engineering die and crimping die used in the press can provide the best effect. All kinds of connection equipment shall be provided to suit the manufacturer's terminal range. Heavy-duty crimping dies for heavy-duty terminals are designed for 5-ton electric presses and 10-15-ton heavy-duty air/hydraulic presses. The crimping die should be able to accommodate the terminal of "00" wire, and provide detailed setting and operation instructions. The crimping die can be designed for semi-automatic and full-automatic crimping process. The feeding direction and application type should be clearly stated in the accompanying instructions. Looking for a crimping die designed to terminate multiple terminals.
G Fixation of Terminals and Wires
In some cases, the terminal manufacturer will recommend a higher pull-out force to increase the conductivity, and specify the crimping height to achieve the best all-round crimping performance.
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