In all kinds of electrical equipment and systems, the connection reliability of low voltage wiring harness is very important, which directly affects the stability and safety of the whole system.
First of all, high-quality connection terminals are the foundation. The material of the connection terminal should have good conductivity and corrosion resistance. For example, copper alloy material and surface treatment such as tinning can effectively prevent oxidation and ensure long-term stable electrical connection. The design of the terminal should also be reasonable. The crimping part with the wire should adopt a suitable structure, such as a toothed or wavy crimping surface to increase the contact area with the wire, ensure that the wire can be firmly clamped under different working conditions, so that the current can be transmitted smoothly, and reduce the risk of heating and loose connection caused by insufficient contact area.
Secondly, the correct connection process is the key. During the crimping process, the crimping pressure and depth must be strictly controlled. Excessive pressure may damage the wire, and too little pressure cannot achieve a tight connection; inaccurate depth will also affect the connection effect. Using professional crimping tools and regular calibration and maintenance can ensure the consistency of crimping quality. For bolt-connected terminals, they must be tightened according to the specified torque value. Too much torque may cause the bolts to slip, and too little torque may cause them to loosen easily. At the same time, anti-loosening measures can be taken after connection, such as using spring washers, nylon nuts or thread lockers, to effectively prevent the bolts from loosening due to factors such as vibration.
Furthermore, the fixation and protection of the wiring harness cannot be ignored. Reasonably plan the direction of the wiring harness, and use appropriate fixing clips to fix the wiring harness on the equipment or frame to prevent the wiring harness from loosening the connection due to shaking or pulling. Where the wiring harness passes through holes or rubs against other components, a protective sleeve or corrugated tube should be added to prevent the outer skin of the wiring harness from being damaged, thereby affecting the stability of the internal wire connection. In addition, for some low-voltage wiring harnesses used in special environments, such as in humid or dusty environments, waterproof and dustproof sealing measures must be added, such as using sealing rubber sleeves or sealing plugs to prevent moisture, dust, etc. from entering the connection parts, causing poor contact or short circuit failures.
By selecting high-quality connection terminals, following the correct connection process, and controlling the technical points of wire harness fixation and protection, the connection reliability of the low voltage wiring harness can be effectively improved, the occurrence of looseness and poor contact can be reduced, and a solid guarantee can be provided for the normal operation of electrical equipment and the safety and stability of the system.
