Crimp Pull Force Testing for Wire Harness Quality Control
Ensuring the mechanical strength of crimped terminals is a critical step in wire harness manufacturing. A weak crimp connection can lead to electrical failure, overheating, or unreliable system performance in demanding applications such as automotive systems, industrial equipment, and electronic devices.
To verify the integrity of every crimped connection, our quality control laboratory is equipped with a motorized push–pull force tester (FE-25W) combined with an ALGOL AK-30 force gauge. This equipment allows us to accurately measure the terminal pull-off force of crimped wires and connectors, ensuring consistent product reliability and compliance with industry standards.
Equipment Overview
Our crimp pull force testing system consists of two primary components:
• FE-25W Motorized Push–Pull Test Stand: provides controlled and consistent vertical movement during testing
• ALGOL AK-30 Analog Force Gauge: measures the applied force during push or pull testing
The motorized stand ensures stable and repeatable test conditions, while the precision force gauge records the maximum force applied before the connection fails.
Key Specifications
| Item | Specification |
|---|---|
| Test Stand Model | FE-25W |
| Force Gauge Model | ALGOL AK-30 |
| Maximum Test Force | 30 kgf (≈294 N) |
| Measurement Type | Push & Pull |
| Measurement Accuracy | ±0.5% of full scale |
| Test Direction | Vertical |
| Speed Control | Adjustable motor speed |
| Fixture | Mechanical vise clamp |
This configuration provides reliable measurement of terminal retention strength and wire crimp performance during product inspection and validation.
The crimp pull tester is used to evaluate the mechanical strength of wire-to-terminal connections. The equipment can perform tests such as terminal crimp pull-off force testing, connector retention force verification, cable tensile strength testing, and mechanical strength evaluation of cable assemblies. During testing, the cable or terminal is secured in the fixture while the force gauge measures the maximum force required to separate the crimped terminal from the wire.
Crimping is one of the most critical processes in wire harness assembly. A properly formed crimp ensures both mechanical strength and reliable electrical conductivity. Pull force testing helps verify correct crimp compression, proper terminal design compatibility, secure mechanical bonding between wire and terminal, and stable manufacturing quality. By performing pull force verification during quality inspection, we ensure that each harness assembly meets the required durability and reliability standards.
Crimp pull force testing supports compliance with widely recognized industry standards, including IPC/WHMA-A-620 Requirements and Acceptance for Cable and Wire Harness Assemblies, UL wiring harness guidelines, and customer-specific mechanical performance requirements. Testing results help confirm that crimped connections meet the minimum retention force requirements specified by these standards.
At Everbiz Industrial, quality assurance is an essential part of our manufacturing process. By using professional testing equipment such as the FE-25W push–pull tester with ALGOL AK-30 force gauge, we are able to verify the strength and durability of crimped connections in every production batch. This testing capability helps ensure that our wire harness products deliver consistent electrical performance, mechanical durability, and long-term reliability in real-world applications.
Know more about our laboratory: Everbiz Industrial Laboratory Page
