What is the process for setting the crimp height of automotive wiring harness terminals?

At the end of the wire harness, there are many terminals responsible for completing the conduction of the wire harness product under various working currents. Different terminals match different wire diameters, so how can the terminals be better connected to the wires to ensure good conduction performance? This article mainly introduces the process of setting the terminal crimping height. The following content is the method I have been using since I started my career and is for reference only.

A. Generally, well-known terminal/connector suppliers have specifications and specifications, such as Tyco and MOLEX, which have recommended matching crimping combinations and corresponding crimping parameters. They are all verified by the original factory and are more authoritative. As long as the crimping die blades are made according to the recommended crimping parameters, acceptance and release will be OK. In addition, customer review is also easier to explain. If the parameters are set according to the parameters recommended by the original supplier, there will be no further questions about the production process of the crimping parameters.

B. If the terminal/connector supplier cannot provide the recommended crimping parameters for the crimping combination, we can refer to the following verification process to make the crimping parameters, and the verification records must be kept for customer review and traceability!

The standard definition of compression ratio is clearly defined in USCAR21: The screenshot is as follows