Продам: What are the factors that affect the crimping of high-voltage wiring harness terminals for new energy vehicles?

The main function of the high-voltage wire harness terminal is to realize the interconnection between the terminal and the wire. Now, the influence of terminal crimping on its performance is mainly discussed from the aspects of the terminal itself and the selection of wires.

1. The influence of the terminal on the crimping performance

1. Selection of terminal materials

(1) Consider the strength, ductility, hardness and other mechanical properties of the terminal;

(2) The electrical conductivity of the terminal material is proportional to the thermal conductivity, and the electrical conductivity is closely related to the electrical conductivity of the terminal and its own resistance, and the thermal conductivity affects the heat dissipation performance of the terminal;

(3) The terminal is divided into a crimping part and a connecting part. The elastic-plastic deformation of the crimping part causes stress between the terminal and the wire. If the stress is relaxed, the contact between the terminal and the wire will become weak; if the connecting part of the terminal is To connect through plug deformation, it is necessary to consider whether there is a stress relaxation problem.

2. Selection of terminal coating materials

The surface of the high-voltage wire harness terminal usually needs to be electroplated. In order to prevent the oxidation and corrosion of the metal on the terminal surface, the commonly used terminals are tin-plated, gold-plated, silver and other plating methods.

Tin plating on the terminal surface is a common terminal plating process, because tin has good chemical stability, good ductility, and is relatively soft, which can make the mechanical sliding parts get better running-in.

Gold has good corrosion resistance, high temperature resistance, easy welding, excellent electrical conductivity, and certain wear resistance, but the gold-plated layer is thin, and the immature process in actual production is easy to cause microporous corrosion of pores, affecting protection. performance, commonly used in the connection part of the terminal to reduce the contact resistance of the connection,

Silver-plated terminals actually have better corrosion resistance and welding performance, and also have good electrical and thermal conductivity, but the surface of the silver-plated layer is prone to contact with some halides in the air to undergo halogenation reaction, resulting in surface discoloration and greatly reducing its electrical conductivity. , and microporous corrosion will also occur when exposed to moisture.

There are various plating materials for terminals, and we need to choose the appropriate plating material according to the actual situation and the environment of use.

2. The influence of the wire on the crimping performance

1. Selection of wire material

The more common conductor materials for high-voltage wire harnesses are bare copper or bare aluminum, but in practical applications, it is usually necessary to select suitable conductor materials according to the use environment. In a sulfur-containing environment, the wire should be plated with tin. When the contact resistance of the wire is relatively high, silver plating can be used to reduce the contact resistance.

2. Selection of insulating materials

In general, the higher the resistance and resistivity of the insulation, the better. Under high frequency and high voltage, insulating materials with small dielectric loss tangent should be used.

3. Conductor current carrying capacity

With the same wire diameter, the current carrying capacity of copper wire is larger than that of aluminum wire, and the weight of copper wire is also relatively large. The conductor is often selected according to the current carrying capacity of the target.

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