Crimp Cross-Section Analysis for Terminal Quality Verification
In wire harness manufacturing, the quality of a crimped terminal directly affects both mechanical strength and electrical reliability. While pull testing can verify retention strength, a detailed inspection of the crimp structure is often required to evaluate the internal compression and conductor distribution inside the terminal. For this purpose, our laboratory uses the Multicam E22007 Cross-Section Analysis System, manufactured by Yuan Zhou Precision (圓洲精密).
This system allows engineers to prepare and analyze microscopic cross-sections of crimped terminals, providing a clear view of the internal structure of the crimp connection. By examining the conductor compression, crimp geometry, and material deformation, engineers can verify whether the crimp meets industry standards and customer specifications. Cross-section analysis is widely used in wire harness manufacturing as a critical method for validating crimp quality and ensuring long-term connection reliability.
Equipment Overview
The Multicam E22007 Cross-Section Analysis System is designed for precise preparation and inspection of terminal cross-sections. The system typically combines several processes including sample cutting, grinding, polishing, and microscopic inspection. These steps allow the internal structure of a crimped terminal to be exposed and analyzed under magnification.
After the sample is prepared, a digital microscope and analysis software are used to measure important parameters such as crimp height, conductor compression, and deformation patterns inside the terminal barrel. The system allows engineers to document and record measurement data for quality control and product validation.
By visualizing the internal structure of the crimp, engineers can identify potential manufacturing issues that may not be visible during external inspection.
Key Capabilities
The cross-section analysis system supports detailed inspection of crimped terminals used in cable assemblies.
Typical analysis applications include:
• Crimp cross-section inspection of terminals
• Measurement of conductor compression and crimp height
• Evaluation of terminal deformation and wire distribution
• Verification of crimp quality according to industry standards
These measurements help engineers determine whether the crimp process produces consistent and reliable electrical connections.
The crimping process must achieve the correct balance between compression and conductor integrity. If the crimp is too loose, the electrical contact may be unstable. If it is too tight, the conductor strands may be damaged, leading to premature failure. Cross-section analysis allows engineers to visually confirm the internal structure of the crimp and verify that the conductor strands are properly compressed and evenly distributed. This inspection method helps detect issues such as insufficient compression, conductor damage, or improper terminal deformation. Because the internal structure of a crimp cannot be observed externally, cross-section inspection is considered one of the most reliable methods for evaluating crimp quality.
Cross-section analysis is widely used to verify crimp quality according to industry standards such as IPC/WHMA-A-620, which defines requirements and acceptance criteria for cable and wire harness assemblies. The inspection results help confirm that crimped terminals meet both mechanical and electrical reliability requirements. This method is also commonly used during product development, process validation, and supplier quality verification.
At Everbiz Industrial, crimp quality verification is an essential part of our manufacturing and quality control process. By using the Multicam E22007 Cross-Section Analysis System, our engineers can closely examine the internal structure of crimped terminals and verify that the crimping process produces consistent and reliable results. This testing capability helps ensure that every wire harness assembly we manufacture meets strict standards for mechanical strength, electrical performance, and long-term reliability.
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