Wire Terminal Endurance Test System

Product Details

The CKINSTO Wire Terminal Endurance Test System is an automated, specialized apparatus designed to assess the long-term reliability and mechanical durability of electrical terminals, crimp connections, and wire harness assemblies. Its primary function is to subject the terminals to repeated mechanical stresses that simulate the operational life and wear and tear experienced in real-world applications (e.g., vibration, bending, pulling, and repeated insertions/extractions). This testing is crucial for ensuring the connections maintain low electrical resistance and mechanical integrity over the entire service life of the product, adhering to standards like IEC, UL, and automotive industry specifications.   Key Applications   The system is used to test the mechanical life and fatigue resistance of various components, including: Crimped Terminals: Evaluating the strength and stability of the crimp joint between the wire and the terminal under repeated stress. Quick Connect/Disconnect Terminals: Measuring the endurance of blade or pin/socket connections through thousands of insertion and extraction cycles. Flexing and Bending Stress: Simulating movement in applications like appliances or automotive wiring where wires are repeatedly bent (e.g., door harnesses). Pull-Out Resistance: Testing the terminal's ability to maintain grip on the wire after being subjected to numerous mechanical cycles.   Core Technical Features   The CKINSTO system is typically a modular, programmable setup with the following components:   1. Mechanical Stress Unit   Actuation: Uses high-precision servo motors or stepper motors to perform controlled movements (e.g., bending, rocking, twisting, or pulling). Fixtures: Equipped with a variety of interchangeable, self-centering grips and clamping fixtures to hold different wire gauges and terminal types securely. This ensures that the stress is applied accurately to the connection point. Movement Profile: Capable of executing complex, programmable motion profiles, including: Oscillation/Bending: Rocking the wire back and forth over a specified angle and radius. Torsion/Twisting: Applying a twisting force. Linear Pull/Push: Repeatedly applying tensile and compressive forces.   2. Electrical Measurement System (Often Integrated)   While primarily mechanical, endurance testing is incomplete without electrical measurement: Resistance Monitoring: Measures the contact resistance or voltage drop across the terminal connection before, during, and after the endurance cycle. Failure Criterion: The test often concludes when the contact resistance exceeds a predefined limit (e.g., $10 \text{ m}\Omega$) or when a wire breaks (open circuit). Current Load: Some systems can pass a small monitoring current through the terminal during testing to simulate operational conditions.   3. Control and Analysis Unit   Control System: PLC-based or PC-controlled with a Human-Machine Interface (HMI) for setting test parameters. Programmable Parameters: The operator can precisely define: Number of Cycles: E.g., 10,000 or 50,000 cycles. Frequency/Speed: The rate at which the cycles are performed. Amplitude/Angle: The degree of bending or distance of pulling.