Cable crimping and welding process


welding First, peel the skin Stripping wire insulation […]


First, peel the skin

Stripping wire insulation can be chemical, thermal or mechanical.

Requirements: 1. The conductor's cut plane is perpendicular to the longitudinal axis of the wire.
2. All strands have the same length.
3. The wire is not scratched, scratched, broken, flattened or otherwise damaged.
4. The incisions of the processed insulation skin are neat, without any puncture, stretching, abrasion, discoloration, charring or burning.

Second, the welding requirements

1. The solder fill is essentially smooth and shows good wetting of the connected parts/wires.
2. The outline of the parts/wires is easy to distinguish.
3. The solder forms a feathered edge on the connected part/wire.
4. The filling is concave.

a) Wire/lead preparation, on tin requirements

1. The strands are evenly coated with a thin layer of solder, and the strands are easily identifiable.

2. The length of the strand near the end of the insulation sheath is not more than 1 diameter.

b) Wire insulation - gap

1. There is a wire size insulation gap between the end of the insulating sheath of the wire and the solder

c) Insulating sleeve

1. The insulation bushing covers the connector terminal and extends the wire insulation 4 times the wire diameter.

2. The spacing between the end of the bushing terminal and the connector terminal into the connector insertion point is equal to 1 wire diameter.

d) Connection requirements

1. 100% solder fill between the wire/lead and post interface.

2. The solder wets the leads/leads and posts to form an identifiable fill that feathers out of a smooth edge.

3. The outline of the wire/lead in the solder connection can be clearly identified.

The key to crimping any wire terminal is the connection of the wire to the terminal post. Terminals include lugs and connectors. all

The hand tool should use a form of mechanical device to control the crimping operation so that once the crimping operation is started, the crimping tool cannot be opened until the entire crimping cycle is completed.

First, stamping joints - open connection tube

a) Press-forming joints - open joints - insulation skin support crimping

1. Insulation all enters and stretches over the insulation flap.

2. Insulation crimping does not cut or damage the insulation.

3. Insulation sheath crimper should be fully covered and clamped.

B) Stamping joints - open joints - insulation inspection window

1. The boundary between insulation sheath and conductor is in the middle of the inspection window

C) Stamping Joints - Opening Connection Tubes - Conductor Brushes

1. The conductor strand protrudes slightly from the crimped end of the conductor.

d) Press-formed joints - opening joints - bell-shaped openings

1. Both segments of the conductor crimp zone have bell-shaped pressure ports.

2. The height of the bell mouth at the entrance of the conductor is 2 times the thickness of the metal material of the joint/post.

Third, the mechanism of joints

a) Mechanism joints - insulation clearance

1. The gap between the conductive insulation sheath and the wire barrel is less than 50% of the outer diameter of the conductor.

B) Mechanism Joints - Conductor Positioning

1. The conductor extends to the bottom of the connector.

2. The conductor strand fills the inspection window.

3. No conductor strand outside the connector.

Three, metal ring crimp

1. The conductor completely fills the metal ring cavity.

2. The conductor insulation is completely placed in the insulation sleeve.

3. The crimped shape is symmetrical. Contact