Of the many steps in the process of assembling a wire harness, testing the crimped terminal is a crucial one. If the terminal hasn't been properly attached to the end of the wire, it can cause the wire and eventually the entire wire harness to fail. Most manufacturers use pull testing to assess crimped connections and ensure that terminals are properly attached.

With standards for wire harnesses getting tighter, harness assemblers are increasingly using crimp force monitors to ensure quality connections. However, that technology can only tell you how well the crimping process is working. It can't make the process better.

Size definitely matters when it comes to processing wire. Small wire (26 AWG or higher), for example, presents different challenges than large wire. This is especially true regarding crimping.

SAE AS85049 Specification was established to standardize shield termination bands.

Myriad factors influence how and why harness assemblers set up their shops.

Carbon nanotube wiring is light, strong and efficient in transmitting electrical current.

Many factors can affect crimp quality.

New design optimizes crimped connections to aluminum wire for automotive applications.

New technology solves age-old wire crimping problems.