This seemingly simple yet precise process plays a critical role in modern industrial environments where all cables and wires must function flawlessly. The basics of crimping include the selection of the right tool and metal contacts, which together ensure that the electrical current can flow smoothly through the system. Cable and crimping in the automotive industry plays a key role in the reliability and safety of vehicles, as wiring must withstand the stresses of everyday use while remaining securely connected to components. Our blog post explains what crimping is and what failures are most common.
Crimping: definition and importance
Understanding the meaning of crimping in the automotive industry is key to ensuring reliable and efficient performance. Strict standards guarantee the highest quality that can be achieved through crimping. Every application, whether it's a simple vehicle or part of a more complex system, requires that wires and crimps fit properly. This determines not only the mechanical performance but also the electrical performance. The consistency of the material and crimping technique ensures that the connections remain durable and reliable, thus meeting the requirements.
Early detection is key to preventing crimping problems. When crimping is on the agenda, it is essential to be aware of the potential consequences of failures. Improper crimping or wire preparation can often cause mechanical and serious electrical failures.
An incorrectly crimped wire also compromises operational reliability as well as safety: a poorly positioned or undersized crimp cannot perform as expected over the long term. However, by detecting and repairing such faults early, future problems can be avoided, ensuring smooth system operation and durability.
Crimping: testing
Firstly, an enlarged cross-sectional image is taken, which allows a detailed visual inspection using special analysis software. This method measures the crimp’s geometric accuracy with great precision, ensuring that everything is made to the manufacturer's specifications.
The preparation of the cross-sectional analysis consists of several steps. First, the sample is cut and then lightly grinded to ensure a smooth surface. This is followed by etching, which enhances the effectiveness of the analysis by bringing out the fine details of the crimp structure.
During the analysis, the height and width of the crimp are determined, while attention is also paid to counting the number and arrangement of wire strands to avoid air gaps. To achieve optimal crimping, a thorough investigation of crimping anomalies is essential.
Such checks help to increase product reliability and ensure that they perform flawlessly under the most extreme conditions.
Typical crimping failures
During the crimping process, several typical errors can occur that can affect the quality and reliability of the final product. In particular, the selection and positioning of the wrong crimp can be a problem. This occurs when the size, type or position of the crimp is not correctly matched to the wire. In such cases, a visual inspection, a Crimp Cross-Section Analysis and a pull-off force measurement are carried out. These steps will help to identify the cause of the improper fastening and ensure correct sizing.
Incorrect preparation of wiring is another critical failure. This includes, among others, errors in blanking length or inproper insulation removal. Such preparation errors can lead to poor electrical connection. Inspections include a visual check to determine whether the wiring preparation meets the specifications.
It is also important to pay attention to the correct choice of crimping force. Applying too much force can lead to deformation or breakage of the crimp, while too little force will result in a non-airtight crimp. In both cases, the mechanical and electrical properties are significantly impaired. To ensure the correct application of force, the completed crimps are inspected by visual inspection, checking the required dimensions and measuring the pull-out force.
To avoid such typical crimping errors, various test methods are available to optimise the connection quality and ensure the reliability of the final product.
ProDSP's laboratory tests play a prominent role in optimising this process. Electrical testing of cables and pull-out force measurement enables us to check the manufactured product’s quality. Post-production testing reveals defects in the manufacturing process, ensuring that the manufacturing process is improved. Crimp Cross-Section Analysis provide a visual picture of the accurate execution of crimps, while pull-off force tests guarantee the reliability of crimps.
Such thorough laboratory testing helps maintain quality, ensuring the durability and performance of cables used in industry.
