Analysis of the key points of aluminum wire end crimping technology

1 Selection and use of crimping tools When implementing aluminum wire end crimping technology, the selection and use of crimping tools is a key link. Appropriate crimping tools can not only ensure that the wire ends are connected securely, but also effectively prevent safety hazards caused by operational errors.

(1) Selection of crimping tools. The selection of crimping tools needs to fully consider the materials, specifications, and application scenarios of aluminum wires. Aluminum wires are less hard and more ductile than copper wires, so when crimping, it is necessary to select tools that can provide sufficient pressure and uniform force distribution. At the same time, the sizes of crimping dies required for aluminum wires of different specifications are also different, so as to ensure that the wire ends can be tightly connected after crimping and meet the expected electrical performance requirements. When selecting crimping tools, you should also pay attention to its quality and durability. Good quality crimping tools usually have higher precision and longer service life, which can ensure stable crimping during long-term use. In addition, for sites where the crimping dies need to be replaced frequently, you can also choose crimping tools that are easy to replace and simple to operate for crimping to improve work efficiency.

(2) Use of crimping tools. The following key points should be followed during use: Ensure the stable connection between the pressing tool and the power supply to avoid the impact of voltage fluctuations on the pressing effect; Pre-process the wire ends before pressing, such as removing the oxide layer, oil stains and other impurities to ensure the quality of the connection after pressing; Maintain appropriate pressure and time during pressing to ensure that the wire ends can be tightly fitted without excessive deformation. To further improve the efficiency and quality of pressing, automated pressing equipment can be used. Automated pressing equipment can realize automatic positioning, clamping, pressing and detection of wire ends, significantly improving work efficiency and pressing quality. At the same time, automated pressing equipment is safer and more stable, which can reduce the safety risks caused by human operation errors.

2 Wire end processing skills Wire end processing skills are also critical in the aluminum wire end pressing process. Reasonable processing of the wire ends can not only improve the pressing quality but also effectively extend the service life of the wire.

2.1 Cleaning before processing The surface of the aluminum wire is prone to form an oxide layer, oil stains and other impurities, which affect the contact area and contact quality between the wire and the pressing mold, and make the pressing effect worse. Therefore, before pressing, it is necessary to clean the wire with a suitable detergent to remove the surface oxide layer, oil and other impurities.

2.2 Pay attention to the wire stripping length and stripping quality during processing. The stripping length should be reasonably selected according to the specifications of the pressing mold and the wire specifications to ensure that the wire end can be tightly fitted after pressing. At the same time, it is necessary to strictly control the quality of stripping to avoid incomplete stripping and excessive stripping that affect the pressing effect. When processing the wire end, pay attention to the bending and twisting of the wire. Aluminum wires have strong ductility and are prone to deformation and stress concentration when bent and twisted. Therefore, when processing the wire end, it is necessary to avoid excessive bending and twisting of the wire to ensure that the wire end is flat and consistent.

2.3 Check the quality after processing. Quality inspection includes appearance inspection and electrical performance test. The focus of appearance inspection is the flatness, smoothness and burr of the wire end; the electrical performance test is mainly to confirm whether the key electrical parameters such as contact resistance and insulation resistance of the wire end meet the specified standards. Through quality inspection, possible quality problems can be discovered and handled in a timely manner to ensure the quality and safety of the wire end.

3. Pressing sequence and force control When pressing the aluminum wire end, controlling the pressing sequence and force is the key to ensure the connection quality and performance. The appropriate pressing sequence can ensure that the wire and the terminal fit tightly together, and the appropriate strength can avoid damage to the wire or the terminal. Only by accurately controlling the pressing force according to the appropriate pressing sequence can the wire and the terminal be tightly connected together, increasing the reliability and safety of the electrical connection.

3.1 The pressing sequence should be carried out in a gradual order from outside to inside. This determines that when pressing, it is necessary to start from the outside of the wire end and gradually press to the inside, and the wire end is inserted into the terminal to ensure that the contact area between the wire and the terminal is appropriate. Then use the pressing tool to gradually apply pressure from the outside of the terminal to the inside to form a tight fit between the wire and the terminal. The step-by-step pressing method can ensure that the contact area between the wire and the terminal is evenly distributed and avoid stress concentration or deformation during pressing.

3.2 The force control needs to be accurately adjusted according to the material, specification and application scenario of the wire and the terminal. Excessive force can cause deformation and damage of the wire or terminal, and even affect the electrical performance; too little force can cause looseness or poor contact. Therefore, when performing the pressing operation, special pressing equipment must be used, and the pressing strength must be adjusted according to the specific situation. At the same time, the quality of the pressed connection points must be checked to ensure that the connection quality meets the standard requirements.

4 Copper-aluminum transition connection technology Copper-aluminum transition connection technology is an effective way to solve the connection problem between copper wire and aluminum wire. Since copper and aluminum have very different physical and chemical properties, electrochemical corrosion is prone to occur when directly connected, which increases contact resistance and affects the reliability and safety of the connection. Therefore, the application of copper-aluminum transition connection technology can effectively solve the above problems. There are two types of copper-aluminum transition connection technologies: using special copper-aluminum transition terminals and adding a layer of special transition material between copper wire and aluminum wire. Regardless of the method used, the core idea is to use transition materials or transition terminals to compensate for the difference between copper and aluminum to achieve a stable and reliable connection. When using the copper-aluminum transition connection technology, the following aspects should be noted: First, appropriate transition materials or transition terminals should be selected to ensure good conductivity and corrosion resistance; second, appropriate connection pressure and contact area should be maintained during connection to ensure stable and reliable connection; third, the quality of the connection points should be checked to ensure that the connection quality meets the standard requirements.

5.1. The influence of electrochemical corrosion on the pressing of aluminum wire ends. Electrochemical corrosion cannot be ignored when connecting aluminum wire ends, because it has a significant impact on the pressing quality and connection reliability. Aluminum is a very active metal. When it comes into contact with air, water or other electrolytes, it is easy to generate an oxide layer, which may cause electrochemical corrosion. When the aluminum wire ends are pressed, if effective measures are not taken to prevent electrochemical corrosion, the corrosion phenomenon will have an adverse effect on the pressing quality. Electrochemical corrosion destroys the surface structure of the aluminum wire end, resulting in a rough and uneven surface. This surface change will directly affect the contact area and contact quality between the wire and the pressing mold, resulting in loose connection points after pressing and reducing electrical performance. For example, in a humid environment, the ends of aluminum wires are prone to form a very thin oxide film. If they are directly pressed together without cleaning, the oxide film on the ends of the aluminum wires will become an obstacle during pressing, thus affecting the quality of the connection between the wire and the terminal. Electrochemical corrosion can also cause stress concentration and deformation at the ends of aluminum wires. Aluminum has good ductility, but its mechanical properties change after electrochemical corrosion, which is prone to stress concentration and deformation. During pressing, these stress concentrations and deformations will cause uneven, loose or poor contact between the wires and terminals, which will have a serious impact on the reliability and safety of electrical connections, and may even cause equipment failures or accidents. In order to alleviate the hazards caused by electrochemical corrosion during the pressing of aluminum wire ends, effective anti-electrochemical corrosion countermeasures must be taken: before pressing the wires, the wire ends should be thoroughly cleaned to remove the surface oxide layer, oil stains and other impurities to reduce the corrosion source; during pressing, appropriate pressing tools and molds should be selected to ensure the pressing quality; after pressing, the quality of the connection points should be checked, such as appearance inspection and electrical performance testing, to ensure that the connection quality meets the specification requirements.

5.2 Material selection and treatment methods for anti-galvanic corrosion In the aluminum conductor end pressing process, the selection of appropriate anti-galvanic corrosion materials and the use of appropriate processing methods are of great significance to ensure the connection quality and extend the service life. According to the characteristics of aluminum conductor galvanic corrosion, effective protective measures can be taken in material selection and treatment methods. The first consideration when selecting materials is the corrosion resistance of the material. For the ends of aluminum conductors, coating materials with excellent corrosion resistance should be selected, such as organic coatings, inorganic coatings or metal platings. These coating materials can form a protective barrier to isolate the aluminum conductor from the external environment to slow down the rate of galvanic corrosion. For example: using thermal spraying technology to coat the ends of aluminum conductors with zinc or aluminum-zinc alloy can effectively improve the corrosion resistance of the conductor. In addition to coating materials, connection materials with better corrosion resistance can be selected. When making copper-aluminum transition connections, copper-aluminum composite terminals or copper-aluminum composite connecting pieces can be selected. This type of material is processed by a special process to make copper and aluminum tightly combined to form a stable transition layer, which effectively prevents galvanic corrosion. In terms of treatment methods, in addition to cleaning treatment, there are also some chemical or electrochemical methods that can slow down the rate of electrochemical corrosion. For example, a passivator can be used to passivate the aluminum wire end, and a dense passivation film can be generated to isolate the aluminum from the external environment. Electrochemical protection methods can be used for cathodic protection and anodic protection, and an applied current can slow down the rate of electrochemical corrosion. Appropriate anti-electrochemical corrosion materials and treatment methods should be selected based on actual conditions. Taking the aluminum wire end used in the marine environment as an example, due to the strong corrosiveness of seawater, it is necessary to use coating materials and connection materials with high corrosion resistance for more rigorous cleaning treatment. If necessary, auxiliary passivation treatment can be used to reduce the occurrence of damage problems.

5.3 Long-term maintenance and monitoring recommendations for anti-electrochemical corrosion In order to ensure the long-term stability and reliability of the aluminum wire end press connection, it is necessary to implement effective long-term maintenance and monitoring measures to prevent electrochemical corrosion from having a negative impact on the connection point.

(1) Establish a regular inspection system. According to the environment and importance of the aluminum wire end, establish a reasonable inspection cycle, and regularly inspect the appearance of the connection point and test the electrical performance. During the inspection process, special attention should be paid to whether there are signs of corrosion, looseness and poor contact at the connection points, and timely measures should be taken to repair them.

(2) Strengthen environmental management. For the environment in which the ends of aluminum wires are located, the temperature, humidity and corrosive gases should be strictly controlled to reduce the incidence of electrochemical corrosion. For example, aluminum wire ends used in humid environments should take moisture-proof measures such as adding sealing covers and using desiccants. In addition, the use of advanced monitoring technology is of great significance for preventing electrochemical corrosion. The ends of aluminum wires can be monitored in real time through electrochemical sensors and infrared thermal imagers to promptly detect and treat corrosion problems and reduce various damages. Electrochemical sensors can monitor the potential changes of connection points in real time to determine the degree of corrosion. Infrared thermal imagers can determine whether there are problems such as poor contact or looseness by monitoring the temperature distribution of the connection points.