High current terminals are widely used in various applications such as automotive, aerospace, renewable energy, and industrial equipment. The increasing demand for high-performance electrical systems has increased the demand for high current connectors. To meet the growing demand in the market, more and more manufacturers worldwide are joining the industry of manufacturing high current connectors.
High current connectors utilize electrical contacts to minimize resistance between conductors and ensure reliable energization.
These contacts employ a spring component between the socket and pin contact to achieve superior contact stability, making them a critical determinant of connector performance.
What the large current terminal consists of?
The large current terminal includes socket contact/terminal (Female terminal) and pin contact/terminal (Male terminal), The soclet terminal consist of female terminal, spring (sleeve), and retainer ring. And pin terminal is only male terminal.
What equipments are needed?
The manufacturing of large current terminals requires different machines to perform various processing steps.
- Main parts (Female or male terminal)
High precision CNC machines to complete cutting, shaping, and forming of materials.
A secondary punching machine is also required for processing relief holes needed for parts plating.
- Spring (Sleeve) and retainer ring
High-speed stamping machine is required for retainer ring and spring cutting, shaping and crimp forming.
After the completion of material processing and forming, the assembly of large current terminals requires specific machines or tools. To optimize this process, we can implement an automated assembly machine and an automatic spring twisting machine. These machines can be custom-designed based on a detailed analysis of the assembly process, ensuring that they can handle the unique size, shape, and material requirements of the terminals.
Automatic spring torsioning machines
There are two types of torsioning machines that are suitable for different stages of spring processing.
- The semi-automatic spring torsioning machine is suitable for low-volume initial production of various types of springs. It can accommodate springs ranging from 3mm to 12mm in diameter.
- The fully automatic spring torsioning machine is suitable for high-volume production of various types of springs, its productivity is 20-25 pcs per mintute. 3-12mm springs are also avaiable.
The torsion angle of a spring is crucial to the performance of a large current terminal, as it determines the contact engaging and separating force. When the same spring is twisted at different angles, it can significantly affect the contact cross-sectional area between the male and female terminals.
On these two devices, angles can be freely set, including advance torsion angles and rotation angles, ensuring the correct torsion angle of the spring.
In large-scale current terminal production, the automatic spring torsion machine effectively addresses the requirements for various spring torsion angles and insertion/extraction forces.
Automatic large current terminal assembling machines
After preparing all the components, the large current terminal will be finished assembling in an automated machine. The machine can ensure terminal’s production and stable quality.
The machines basic function includes the follow
- Automatic feeding system
It is tailored to the specific materials, structures, dimensions, and loading speed required for optimal performance.
- Automatic assembling machinery
Utilizing precision positioning, clamping, movement, riveting, inserting, and other specialized processes to efficiently and accurately finish the assembly of complex and intricate parts.
- Automatic detecting functions
By using fiber optic sensors, photoelectric switches, detection instruments, camera inspection, and a stable and reliable suspension method, the detection of high-current terminals is completed to ensure the quality of the final product.
In conclusion, In the production of high-current terminal, in addition to standard machines such as high-speed presses and CNC machines that shape the product, customized automated assembly equipment is also required to increase production capacity and control product quality.
