STABILITY
The stability of the IDC terminal depends on factors such as the spring characteristics of the terminal head and the load capacity of the wire.
From a design perspective, the IDC terminal is easier to control. At the same time, the elimination of external strain capacity prevents movement of the cable termination interface.
For solid wire, with proper stress relief, performance will be better than IDC terminated crimping because of the higher inherent mechanical stability. This is because the terminal deflection energy is stored in the elastically maintained high voltage interface.
Typically, for smaller wires, the terminal is designed to provide several pounds of force and several mils of elastic deflection at the interface. For larger wires, the force may be as high as 15 to 20 pounds.
CRIMPING WORK
- Crimping for Effective Metal-to-Metal Contact: Crimping is highly effective in this domain as it establishes metal-to-metal contact during the process. Through axial compression, the wire retains a small amount of stored elastic energy, enhancing the durability of the joint.
- Potential for Diffusion Welding: With sustained mechanical stability, there’s potential for additional diffusion welding techniques at the interface over time. This reinforces the connection and contributes to long-term reliability.
- Challenges of Stress Relaxation and Creep: Despite initial stability, terminals and wires experience stress relaxation and creep over time. These processes gradually diminish the structural stability of machinery, potentially impacting performance.
- Implications for Equipment Life: Mechanical instability caused by vibration or stress relaxation can lead to reduced equipment lifespan. Similarly, decreased edge strength due to stress relaxation may compromise overall performance, underscoring the importance of robust mechanical system design.
STRANDED WIRE
- Mechanical Stability of Stranded Wire Harness: In the realm of performance, the mechanical stability of a stranded wire harness holds significant importance. Factors such as compressive load, stress relaxation, and creep affect its performance. During relaxation periods, contact force tends to decrease, influenced by the type of stranded wire utilized by the enterprise.
- Factors Influencing Mechanical Stability: The number of strands, twisting, conductor top coating, and insulation type are pivotal in determining mechanical stability. Cables that are easier to cover typically exhibit superior performance compared to solid wire counterparts. These factors collectively contribute to the robustness of the wire harness.
- Impact of Conductivity: Conductivity is influenced by line contact, with the number of lines between them directly affecting overall conductivity. Optimizing conductivity is achievable through processes like tinning the wires. Multi-strand wires require well-designed strain relief mechanisms for enhanced stability, sometimes supplemented by additional IDC slots to ensure mechanical integrity.
