This case study covers a customer request to support the approval of a wire crimp. The customer, a global wire harness manufacturer, needed a wire splice assembly to be CSA (Canadian Standards Association) approved. Unlike a terminal crimp, which has established crimp specifications on a known wire range, a wire splice can include a multitude of wire combinations, so establishing fixed crimp specifications is not possible.
Problem: The customer submitted a first round of splices to CSA with acceptable pull tests, but the crimps failed heat rise tests. Our customer requested WireProcess Specialties to assist in the development of crimp specifications that would provide a high probability of passing CSA tests.
Scope: Knowing that heat rise in a terminal crimp is directly attributed to high electrical resistance, and that a cause of high electrical resistance is an under- or over-crimped terminal, we suggested that a crimp study be produced using a range of splices crimped with a sliding range of wire heights and widths. WPS would produce cross-section reports to establish the range of conductor compaction for each crimp height and width. Using a known and generally accepted compression range that provides a stable mix of tensile (pull) force and low electrical resistance, a recommendation of an appropriate crimp height and width spec would be made.
The Solution: After receiving the samples, processing the reports and analyzing the results, WPS recommended a conductor crimp height and width range for resubmission to CSA. Along with this recommendation was a statement that mechanical measurements do not guarantee acceptable performance; electrical testing provides that validation.
Results: Our customer crimped new splice assemblies and re-submitted to CSA. CSA tested and approved the harness, passing all mechanical and electrical tests.
Crimp Quality Solutions is our support for customers to enhance their quality integrity. WireProcess Specialties is ready to engage your organization. Like this case study, let’s write your success story. Connect your way to WPS.
