One of the most comprehensive methods to check this is the Crimp Cross Section Analysis, which allows us to inspect the internal structure of the crimp visually. How is the Crimp Cross Section Analysis performed? Let’s explain the process!

Laboratory cable testing

ProDSP is committed to the highest standards of laboratory cable testing, especially under the stringent requirements of automotive standards. One of our priority tests is the Crimp Cross Section Analysis, a special method for evaluating the structure and quality of crimped joints.

The Crimp Cross Section Analysis test allows us to review the connection between the cable and the connector and to assess the crimp cross-section. In the next part of this blog post, we will discuss this test further, but before we go into more detail, it is worth mentioning the other test methods used at ProDSP.

In addition to testing cable crimping, measuring the pull-off force is also a key factor in assessing crimping reliability. This test measures the force required to separate the cable from the crimp, which helps ensure that the mechanical and electrical connections meet the requirements of the standard. The procedure involves pulling the crimped cable at a constant speed until breakage occurs, while the measuring instrument accurately records the force.

Automated electrical cable testing also helps to verify the quality and safety of products. During such tests, electrical wiring is inspected, detecting cable breaks, short circuits, pole changes. 

Through these tests, ProDSP ensures that cables and connectors meet the highest quality standards, which is essential for their use. The tests help to eliminate manufacturing defects and ensure that cables and connectors continue to perform reliably over the long term.

Cable crimping tests: Crimp Cross Section Analysis

This analysis is performed through a magnified image, where special analysis software is used to check the crimp geometry and the compression of the conductor wire. To achieve optimal wire crimp, particular attention is paid to the uniformity of the strand compression, which ideally results in a honeycomb-like structure.

Crimp samples are prepared by precision cutting, grinding and etching. The crimps are then assessed in several key areas, such as crimp height, width, number of wire strands and the presence of any air gaps. Such detailed inspection ensures that the crimps have the correct mechanical strength and optimum electrical conductivity.

Cross-section analysis in ProDSP's laboratory allows us to investigate the structure and size of the crimps in depth. This allows us to verify the quality of the production and to ensure that our products will perform reliably over the long term, even under extreme environmental conditions.

The dimensions of the crimps must fit exactly within the range specified by the manufacturer. This ensures the correct electrical connection, which is essential for safe and efficient operation. The Crimp Cross Section Analysis is therefore a technical procedure and a guarantee of quality that our customers can always rely on.

Why work with ProDSP?

Working with ProDSP is extremely beneficial for those in the automotive industry looking for the highest quality. We are committed to performing tests up to the highest industry standards, which includes thorough testing of crimped cables. Our unique test laboratory allows for electrical testing of cables, pull-out force measurements and crimp cross-section analysis.

These tests are crucial at any stage of the manufacturing process, and can also be applied to existing, manufactured products. Laboratory tests enable fault detection and correction and contribute to the calibration of pre-production equipment, ensuring the reliability of crimps and cables.

The services offered by ProDSP guarantee quality and stand out for innovative approach, which increases customer satisfaction and confidence in our products.