线束90%以上的失效发生在压接点。压接是"冷焊"过程：铜丝与端子筒在压力下互相扩散咬合，压轻了接触电阻大、压重了铜丝断裂。判定压接好坏有三个层次：尺寸、拉力、截面。
Over 90% of harness failures happen at crimps. Crimping is a "cold weld": too light means high resistance, too heavy means broken strands. Judge crimps on three levels: dimensions, pull force, cross-sections.
1. 压接高度：第一道关1. Crimp height: the first gate
压接高度（导体压接区的宽度方向尺寸）直接决定压接质量，公差通常控制在±0.02-0.05mm。端子厂商的规格书会给出标准值，生产中用量具抽测。高度偏大=压接不足（电阻高、拉力低），偏小=过压（铜丝断股）。
Crimp height, tolerance typically ±0.02-0.05mm per terminal spec, decides everything. Oversize = under-crimped; undersize = broken strands.
2. 拉力测试：量化机械强度2. Pull force: quantified strength
用拉力机以恒速拉拽线材直至导体脱出或断裂，读数须≥规格书最小值。典型参考：22AWG约30N起、18AWG约60N起、14AWG约100N起（具体以端子规格书为准）。量产中按首件+定时抽检执行，压接机参数漂移会直接反映在拉力数据上。
Pull tests at constant speed must meet spec minimums — roughly 30N for 22AWG, 60N for 18AWG, 100N for 14AWG. First-article plus periodic sampling catches press drift.
3. 截面分析：看清内部真相3. Cross-section analysis: the inside truth
把压接区剖开抛光（或用专用设备成像）观察：合格截面的铜丝应均匀变形、紧密填充、无大空隙、底部绝缘压接翼包裹到位。行业经验值：压缩比（导体压缩后与压缩前截面积之比）在75%-90%区间为佳。截面分析是首件确认的必做项。
Polished cross-sections should show uniformly deformed strands, tight fill, no voids, and proper insulation crimp. Compression ratio around 75-90% is the sweet spot; cross-sections are mandatory at first article.
4. 绝缘压接不能省4. Don't skip the insulation crimp
端子的绝缘压接翼固定线皮、吸收振动应力。跳过或压不良，所有振动应力都由导体压接区承担，是隐性失效的常见来源。
Insulation wings anchor the jacket and absorb vibration stress; skipping them loads the conductor crimp and causes hidden failures.
写在最后Final words
金承鑫对关键压接点执行"首件截面+批量拉力抽检+导通全检"三重控制，欢迎审厂：18407551752 / eric@muyenda.com。
We run first-article cross-sections, batch pull sampling and 100% continuity. Audit visits welcome: +86 184 0755 1752 / eric@muyenda.com.