News

Abstract: In high-speed, high-density modern electronic systems, cable assemblies have evolved from simple conductive pathways into critical factors affecting overall system performance and reliability. This article aims to provide an in-depth technical guide that goes beyond basic operational steps, delving into the engineering principles, materials science, and quality control points behind shielding grounding processes. It offers a systematic reference for designing highly reliable, high Electromagnetic Compatibility (EMC) interconnection solutions.

Abstract: Electrical connectors serve as the critical bridges for signal transmission, power delivery, and subsystem interconnection within electronic and electrical systems. Their widespread application across aerospace, defense, maritime, automotive, and industrial sectors makes long-term reliability a paramount concern for end-users. Industry studies indicate that up to 70% of electronic system failures originate from component-level issues, with connectors being responsible for nearly 40% of these component-related failures. This underscores the critical importance of connector reliability. This paper provides a systematic analysis of prevalent electrical connector failure modes, drawing on field data and failure analysis reports. It details underlying mechanisms and proposes a comprehensive framework of mitigation strategies and best practices to enhance connector performance and system integrity.

Terminals serve as the critical components within wire harnesses, enabling electrical connections and transmitting current and signals. The quality of their crimp joints directly determines the harness's overall reliability, durability, and safety. Based on structural design, terminals are primarily classified into two categories: open-barrel (or open-style) and closed-barrel (tubular). Open-barrel terminals are predominantly used in conventional low-voltage harnesses, where the crimping process is well-established and mature. In contrast, closed-barrel terminals, benefiting from their fully enclosed structure which provides superior mechanical strength, enhanced sealing, and improved vibration resistance, have become the mainstream choice for high-voltage harnesses in new energy vehicles. Concurrently, to meet the stringent electromagnetic compatibility (EMC) requirements of high-voltage systems, the crimping of shield rings has also emerged as an essential manufacturing process for high-voltage harnesses. This article aims to provide a detailed examination of the predominant crimping methods for tubular terminals and shield rings in high-voltage harnesses, offering professional guidance for process selection and quality control.

When you use best practices for Wire Harness Testing, you help your projects avoid big problems. Careful testing makes sure your wiring is safe, works well, and follows the rules. If you skip testing steps, you could have safety issues, sudden stops, or costly recalls. Here are some common problems that happen when testing is missed:

In the precise engineering field of wire harness manufacturing, terminal connections are the critical link determining the reliability, safety, and long-term stability of an entire electrical system. Whether it's an automotive wiring harness for the engine bay, an industrial equipment harness for factory automation, a medical device wire harness, or a new energy vehicle high-voltage harness, different connection methods are suited to specific application scenarios and stringent requirements. As a professional wire harness and connector manufacturer with years of industry experience, KeHan Electronics (KeHan Electronics) deeply understands the essence of each connection technology and translates it into the cornerstone for ensuring the excellent performance of our clients' products. This article will systematically analyze various wire harness connection methods and delve into how advanced processes, represented by crimping, provide flawless connection solutions for your custom wire harness projects through scientific management and precise control.