The reliability and efficiency of crimped electrical connections are critically influenced by their resistivity, a parameter that directly impacts the overall performance of wiring harness systems. This study investigates the role of crimp geometry and individual strand deformation in determining the initial resistivity of crimp joints. By systematically varying crimp geometries and analyzing deformation patterns at the strand level, we establish a direct correlation between geometric features, strand compaction, and the resulting electrical resistance. High-resolution imaging techniques and precision resistivity measurements are employed to capture microstructural changes and their electrical consequences. The findings highlight that optimized crimp geometries, promoting uniform strand deformation and minimizing void formation, significantly reduce initial resistivity. Conversely, irregular deformation patterns and suboptimal geometries contribute to elevated resistance values, potentially compromising joint performance over time. This research offers valuable insights for improving crimp design guidelines and enhancing the long-term reliability of electrical connections in automotive and industrial applications.

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Influence of Crimp and Strand Deformation on Resistivity in Automotive Wiring Harnesses

  • Florin Dragomir,
  • Dacian Ilca,
  • Tiberiu Manescu

摘要

The reliability and efficiency of crimped electrical connections are critically influenced by their resistivity, a parameter that directly impacts the overall performance of wiring harness systems. This study investigates the role of crimp geometry and individual strand deformation in determining the initial resistivity of crimp joints. By systematically varying crimp geometries and analyzing deformation patterns at the strand level, we establish a direct correlation between geometric features, strand compaction, and the resulting electrical resistance. High-resolution imaging techniques and precision resistivity measurements are employed to capture microstructural changes and their electrical consequences. The findings highlight that optimized crimp geometries, promoting uniform strand deformation and minimizing void formation, significantly reduce initial resistivity. Conversely, irregular deformation patterns and suboptimal geometries contribute to elevated resistance values, potentially compromising joint performance over time. This research offers valuable insights for improving crimp design guidelines and enhancing the long-term reliability of electrical connections in automotive and industrial applications.