Identifying the root causes of poor contact in wire crimping machines is essential, as it stands as a primary culprit for malfunctions in various devices, from compact smartphones and computers to larger-scale equipment such as wire crimping machines and aviation devices. Given the critical nature of this issue, it demands meticulous attention. Today, let’s delve into the analysis of contact-related challenges in wire crimping machines, courtesy of insights from the Dragon King Terminal Connector Manufacturer.
In the realm of computers, malfunctioning often finds its epicenter in memory modules. However, for wire crimping machines, the crux of poor contact lies within the internal metal conductors of the crimping terminals. These components constitute the heart of the crimping system, facilitating the transmission of voltage, current, or signals from external wires or cables to the corresponding contact points on the connector.
Due to the paramount importance of these components, wire crimping machines must meet stringent criteria, encompassing stable and reliable contact along with commendable electrical conductivity. Now, let’s explore the myriad factors that can lead to compromised contact structures in wire crimping machines.
Unsurprisingly, common culprits include subpar processing dimensions, imprudent surface treatment processes such as heat treatment and electroplating, adverse storage environments, and inappropriate or harsh usage scenarios. These factors collectively pose the risk of inducing poor contact at the critical contact and mating points within automatic wire crimping machines.
Exposing the Achilles’ heel of wiring terminals:
Contact Conundrum:
Within wiring terminals, the internal metal conductor plays a pivotal role, acting as the linchpin for transferring voltage, current, or signals from external wires or cables to the corresponding contact points on the connector. The contact points demand impeccable structure, ensuring stable and reliable contact retention force and optimal electrical conductivity. Design flaws in the contact structure, erroneous material choices, unstable molds, oversized processing dimensions, surface roughness, and irrational surface treatment processes like heat treatment and electroplating can collectively lead to subpar contact at the vital contact and mating points of the crimping terminals.
Insulation Imperfections:
The insulation material’s primary function is to orchestrate the correct arrangement of contact points while providing insulation between these points and between the contact points and the housing. This safeguards the transmission and control mechanisms within the machine. Hence, the insulation component must exhibit stellar electrical performance, mechanical prowess for machine protection, and proficient process molding capabilities. The increasing prevalence of high-density, miniaturized wiring terminals necessitates thinner effective wall thickness for insulation materials, imposing stringent requirements on insulation materials, injection molding precision, and molding processes. Issues such as the presence of metal residues, surface dust, solder flux contamination, moisture absorption, mildew, and aging of insulation materials can lead to short circuits, leakage, breakdowns, and low insulation resistance, manifesting as insulation failures.
Fixation Foibles:
The insulation material, aside from its insulating role, also serves to precisely align and shield the protruding contact points, offering installation positioning and secure fixation on the equipment. Deficient fixation can range from mild disruptions affecting reliable contact and causing momentary power outages to severe consequences like product disintegration. Disintegration refers to abnormal separation between the plug and socket or between the plug pin and socket hole during the plugged state, resulting in severe consequences such as the interruption of power transmission and signal control in the control system’s computerized wire stripping machine. Unreliable designs, incorrect material choices, improper molding process selections, poor quality in heat treatment, molds, assembly, welding, and other processes can all contribute to fixation issues.
Moreover, external appearance defects arising from coating peeling, corrosion, collisions, plastic shell burrs, breakages, rough contact point processing, deformations, etc., are prevalent. Common and recurrent challenges include poor interchangeability due to oversize positioning and locking coordination dimensions, inconsistent processing quality, and excessive total separation force. Fortunately, these issues can generally be identified and rectified during inspection and utilization.
