The terminal has three main parts: matching part, transition part and crimping part. The crimping part is the only part whose design is affected by the crimping process. Here are some of the most common problems and corrective actions.
1. Conductor crimping height is too small or too large
Solution: adjust the height of conductor crimping on the crimper. Use vernier calliper or micrometre to check whether the crimping height is within the specified range, and recheck according to the required frequency during the operation to maintain the correct crimping height.
2. The insulation crimping area is too small or too large
Most types of crimping tools can adjust the insulation crimp height. The correct adjustment allows the terminal to clamp the insulation at least 180 degrees without piercing the insulation. When the outer diameter of the insulating crimp of the terminal is close to the outer diameter of the cable insulation, the best method is IDT technology.
3. Loose core
Solution: fold up the cable again to form a bundle, and then insert it into the terminal for crimping. If the removal of the insulation from the cable is a separate operation, the cores may be inadvertently separated during handling or bunching. Use half stripping and keep the insulation removed so that the insulation is not completely removed from the cable until the terminal is ready to be crimped to the cable, which helps to minimize the core looseness.
4. Too short stripping length
The stripping length of the cable is too short, and the distance out of the front of the conductor crimping area cannot obtain the required outer diameter of the cable. The solution is simple: increase the stripping length of the stripping equipment to the specified value of the terminal.
5. The cable is inserted too deep
Solution: make sure that no excessive force is used to insert the cable into the crimper to make it over-voltage the cable stop of the crimper, or adjust the position of the cable stop to correctly position the stripped cable axially.
6. Over bending
Solution: adjust the position of the limit pin on the crimper. This pin is located in the crimper and contacts the joint area of the terminal when crimping the cable in the crimping area. During the crimping process, a large amount of metal at one end of the terminal (in the crimping area) moves. Such a large force tends to force the front of the terminal up unless limited by a suitable "limit pin."
7. Crimping too far forward
The reason for this problem is that the terminal and the metal strip (the metal strip connected by the terminal when you receive the goods from the manufacturer) are not in the correct position relative to the crimper. Just loosen the base plate of the interchangeable tool, and then realign the crimper to solve the problem.
8. Too small bell mouth
The correct size of the bell mouth is 2 times the thickness of the terminal material. In essence, it affects the performance of the terminal. If the bell mouth is missing or the thickness of the terminal material is less, there is a risk of cutting the wire core. Reduced core retention reduces termination strength. To correct the problem, make sure that the punch on the crimping device is correctly aligned with the base.
9. The bell mouth is too large
If the bell mouth is too large, the total contact area between the terminal crimping area and the cable will be reduced. The smaller the contact surface between the cable and the terminal, the smaller the cable drawing force. If the crimp height is correct, it may be caused by tool wear and should be replaced.
10. Tail material is too long
Solution: adjust the feeding plate on the crimper to make the terminal correctly centred in the crimper. Another sign that the terminals are not properly centred is that the bellmouth is not properly formed. This occurs because the bell mouth has a spatial relationship with the tool of the tailings.
11. Installation of an intelligent pressure management system
The intelligent pressure management system can monitor the operation of the terminal machine in real-time, find out the abnormal pressure in time, and adjust and maintain the equipment in time as described above! In this way, the machine has been in a good state of operation, thus indirectly reducing the production of defective products!
However, it should be noted that although the pressure management is very sensitive and can be used to evaluate the operation of the machine, in normal production, the tolerance is usually set to a large extent to reduce the number of alarms, so the various adverse conditions described above are basically impossible to detect all without leakage.
The intelligent pressure management system can detect 100% of the fatal problems such as all the core wires are cut off, all the glue is wrapped, and the terminals are deformed. These fatal problems cause great pressure changes. It is the main significance to prevent these fatal problems from flowing to customers!
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