Circular piezoelectric sensors play a core role in the management solution of crimping force in terminal machines, providing the possibility for achieving high-precision and traceable crimping processes.
Working principle: Piezoelectric materials generate charges proportional to mechanical stress. The circular sensor is installed on the force transmission path between the crimping die (blade die) and the slider of the terminal machine. When the pressure head is pressed down for crimping, all the pressure acting on the mold will pass through this annular sensor, which then generates a high-precision electrical signal that is strictly proportional to the real-time crimping force.
Core strengths：
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High precision and high rigidity: The piezoelectric sensor itself has extremely high rigidity and will hardly deform under pressure, so it will not affect the accuracy of the crimping process, and can provide extremely accurate force measurement.
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Direct measurement: Directly measuring the pressure force itself, rather than indirect parameters, results in true and reliable accuracy.
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High frequency response characteristics: able to quickly respond to instantaneous changes in pressure, fully capturing the dynamic force curve of the entire crimping process, not just the peak value.
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Circular hollow design: It is very suitable for applications such as terminal machines that require central space to accommodate molds, wires, and other components. It is easy to install and does not interfere with existing structures.
Pain points of traditional terminal crimping management
Before the introduction of piezoelectric sensors, there were usually the following issues with the quality control of crimping in terminal machines:
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Indirect measurement with poor accuracy: Traditional methods rely on monitoring motor current or air pressure to indirectly determine the pressure force, which is susceptible to interference from equipment wear, voltage fluctuations, temperature changes, and other factors, resulting in low accuracy and reliability.
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Unable to monitor in real-time: destructive tensile testing can only be conducted for sampling after crimping is completed, and it is impossible to monitor every crimping point in 100% real-time. Defective products may flow into the next process.
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Lack of process data: Without force displacement curve data for the crimping process, it is difficult to trace the root cause (whether it is a terminal problem, wire problem, or equipment problem) when defective products occur.
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Setting parameters depends on experience: Setting parameters such as pressure and depth heavily relies on operator experience, making it difficult to standardize and optimize.
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Non traceability: Unable to provide quality data reports for every crimping point of the produced products, which does not meet the strict requirements for process data traceability in industries such as automotive and aerospace.
