Analysis on the Hidden Danger of Cable and Terminal of Automobile Electrical Connector

The most prone to failure of automotive electrical connector systems is cable and terminal connection problems. Cables and terminals are often connected by crimping, which is more economical and easy to operate than welding, but the reliability is lower than welding.

In order to improve the reliability of crimping, there is a new type of crimping tool that can work on traditional crimping presses with typical high-speed crimping methods. When an ordinary crimping operation is performed on either side of the terminal chuck area, the compression stroke is first passed, and when the punching machine and the anvil are separated, the crimping will relax slightly, which can effectively improve the condition of the stranded wire and will not be as compact as before. Together, it can effectively increase the resistance value. After the end of the compression stroke, the crimping die is crimped in the middle of the collet portion. This novel method helps to eliminate compression rebound, but also strengthens and stabilizes the cold welding produced by the crimping zone, and improves the reliability of crimping.

If the electrical connector is plugged improperly, it will cause its failure. In order to prevent this problem, various connector locking devices have been developed at present, such as spring lock. When the two halves of the electrical connector are plugged together, the spring device will compress. If the plug is correct, the spring lock will make the two connectors fit together correctly. If the plug is incorrect or not completely plugged in place, after the plug is completed, when the electrical connector is released, the spring will spring off the two halves, indicating that the connection has failed.

Electrical connectors for automotive exterior and under-hood applications not only require high stability, ease of assembly and low price, but also require sealing with respect to electrical contacts. In high density and multi-pin systems, the sealing method may employ a gasket seal or a porous seal ring. In the design, the use of this type of seal, need to insert the terminal through the sealing hole, which requires the square or rectangular terminal through a circular sealing hole, in order to prevent the cable from bending, but also need to effectively control the combined insertion force of the terminal; If the different wire diameter sealing, in order to apply to different wire diameter sealing, need to use the sealing hole smaller, elastic seal, however, this increases the likelihood of damage to or tearing of the seal. In order to avoid this possibility, the sealing element cable with the terminal can be assembled into the electrical connector, and the sealing element is further compressed by using the wiring cover, so that the sealing pressure and force generated during the assembly process are relatively small, but the sealing pressure and force obtained in actual application are relatively large, which can effectively reduce the damage or tearing of the sealing element.

In order to meet the increasing requirements of the market, electrical connector manufacturers in addition to constantly improve product design, but also bold innovation. In the future, in order to improve the reliability of automobiles and solve various failures of automotive electrical connectors, it is believed that there will continue to be various new methods.