Reliability Evaluation Testing for Automotive Connector Crimp Terminals
The quality of terminal crimps in automotive connectors is a critical factor that determines the overall reliability of a vehicle’s electrical system. We present a comprehensive case study covering everything from initial crimp status verification to durability evaluation under extreme environments.
Objectives of the Testing
The objective is to verify whether the terminal crimp sections used in automotive connectors maintain the designed compression ratio and profile. Furthermore, the test evaluates product reliability by monitoring changes in electrical and mechanical characteristics against various stresses (thermal, vibration, and bending) simulated for long-term field use.
Test Items and Methodology
Our approach encompasses both “Structural Evaluation” of the initial state and “Durability Evaluation” following environmental loading.
Structural and Initial Performance Evaluation
- Crimp Cross-section Observation
The crimp section is cut and polished to verify the compression ratio and crimp shape for any abnormalities using equipment such as microscopes. - Mechanical Characteristics Measurement
We measure the tensile strength of the terminal crimp to confirm its physical retention force. - Electrical Characteristics Measurement
We measure the contact resistance of the crimp section to establish baseline values for conduction performance.
Environmental and Durability Evaluation
Using various testing systems, we observe characteristic changes after replicating the stresses expected in an automotive environment.
| Test Category | Equipment & Test Content |
| Thermal Stress Evaluation | Thermal Shock Testing and High-Temperature Storage Testing. We verify increases in contact resistance caused by expansion and contraction under rapid temperature fluctuations or continuous high-temperature conditions. |
| Environmental Durability Testing | Climate Chambers / Combined Environmental Test Systems. We confirm the degree of degradation under environments combining specific temperature and humidity levels. |
| Physical Stress Evaluation | High-Temperature Bending Testing and Vibration Testing (Sine/Random). We check for wire breakage or contact failure caused by cable routing stresses or vehicle vibrations during operation. |
Test Details
In this evaluation, the following equipment and conditions were utilized:
- Tests Performed: Durability Testing, Sine Vibration Testing, Random Vibration Testing, Connector Evaluation Testing.
- Equipment Used: Thermal Shock Chamber, Climate Chamber, Combined Environmental Test System (Temperature/Humidity/Vibration combined).
IMV’s Connector Evaluation Testing Services
In recent years, the advancement of vehicle electrification (EV) and autonomous driving technology has demanded unprecedented levels of reliability for connectors. As devices become smaller and more densely packed, even a minor contact failure or terminal deformation carries the risk of leading directly to fatal system failures or large-scale recalls.
At IMV, our expert engineers support your verification needs—from testing compliant with international standards such as JIS/IEC to specific internal corporate standards.
Beyond merely providing test data, we offer a one-stop contract testing solution. As your partner in ensuring product quality, we support you from root cause analysis when defects occur to providing technical advice for countermeasures.