Hexagonal crimping: This crimping method is commonly used for large square terminals, especially in new energy high-voltage terminals. The advantage of hexagonal crimping is that it can provide higher terminal holding force, which is very important for wiring harnesses that can withstand high currents and pressures. In addition, hexagonal crimping also has good electrical and mechanical properties, which can ensure the stability and safety of the wiring harness.
2. B-type crimping: B-type crimping is a common terminal crimping method that is suitable for various wire diameters and terminal types. The main characteristics of this crimping method are simple structure, easy operation, and suitability for various types of wire harnesses and terminals. The key to B-type crimping lies in the correct crimping height and width, as well as good mechanical and electrical performance. In the manufacturing of automotive wiring harnesses, the crimping process is crucial for ensuring the electrical and mechanical performance of the harness. Proper crimping can ensure good contact between wires and terminals, thereby improving the reliability and service life of the wiring harness.
Which is better to manufacture wire harnesses on flexible cables: hexagonal crimping or B-crimping?
What happens in crimped connections and rigid cable enclosures: In crimped connections, current is transmitted from one wire to another, forming a charging path from the cable to the terminal. Each transition from one chain to another generates a total resistance. In the case of rigid cables, the number of large strands is limited. After crimping, due to the limited number of intersecting strands, the impact of poor contact between strands on the overall contact resistance is limited. Therefore, hexagons are widely used and suitable for such applications, with limited risk of overheating.
Most applications require the use of flexible cables: hybrid and electric vehicles, railways, aerospace, and higher technologies in most modern OEM designs require flexible cables to achieve. Flexible cables have a small bending radius and are easy to bend, making them the preferred choice for applications in narrow spaces. Most wire harness manufacturers used for cars, airplanes, and trains are accustomed to using flexible cables, but they are difficult to use because the stripped strands will expand and take up more space than rigid cables. Inserting flexible cables typically results in the use of larger gun barrels and associated larger crimping tools. This combination can lead to poor link connections and many gaps between links.