Terminal harness plays a key role in connection and signal transmission in many electronic devices and industrial machinery, and its durability directly affects the reliability and life of the system.
First, dynamic bending fatigue test is the core means to evaluate the durability of terminal harness. In the test, the performance changes of the harness are observed by simulating the repeated bending actions that the harness experiences in actual use, such as vibration during equipment operation, extension and retraction of the robot arm, etc. The test equipment usually sets a specific bending angle, frequency and number of cycles, and monitors the resistance change, insulation performance and whether the wire is broken or the terminal is loose. For example, the terminal harness in the engine compartment of a car needs to withstand extremely high-frequency bending stress due to the continuous vibration of the engine. The dynamic bending fatigue test can determine its tolerance in such harsh environment, providing key data for product design and quality control.
Secondly, the terminal harness structure is improved based on the test results to improve durability. On the one hand, the selection of wires is crucial. Using wire materials with good flexibility and high fatigue resistance, such as wires made of multiple strands of fine copper wires, can better cope with bending stress and reduce the risk of internal metal fatigue fracture compared to single-strand wires. On the other hand, the connection method between the terminal and the wire needs to be optimized. For example, a more advanced crimping process is used to ensure that the terminal and the wire are tightly connected and evenly stressed to avoid connection failure due to local stress concentration during bending. At the same time, a buffer structure or protective sleeve is added to the connection between the terminal and the wire to reduce the damage to the connection point caused by friction and pulling force during bending.
Furthermore, the overall protective structure design of the wiring harness has a significant impact on durability. Increasing the thickness and strength of the insulating sheath outside the wiring harness and selecting wear-resistant and aging-resistant materials, such as high-performance rubber or plastic, can effectively prevent the wiring harness from being scratched and worn by external objects during repeated bending, resulting in damage to the insulation layer or exposure of the wire. In addition, the wiring direction and fixing method of the wiring harness should be reasonably designed to avoid excessive twisting, entanglement and other undesirable conditions during the movement of the wiring harness, so that the wiring harness can work within the allowable bending range and reduce the probability of fatigue damage.
Finally, in order to further enhance the durability of the terminal harness, the impact of environmental factors should also be considered and targeted design should be carried out. In an environment with high temperature, high humidity or chemical corrosive substances, materials with corresponding protective properties should be selected, such as wire insulation and sheath materials that are resistant to high temperature, moisture and corrosion. At the same time, auxiliary materials such as desiccant or preservative can be added inside the harness to prevent moisture and corrosive gases from corroding the internal wires and terminals, ensuring that the terminal harness can still maintain good durability and operate stably and reliably in complex and harsh environments.
