Working Principle and Technical Features of the HSD Wire Harness Crimping Machine
一. Working Principle of the HSD Wire Harness Crimping Machine
The HSD crimping machine is designed specifically for HSD highspeed shielded cable assemblies, ensuring precise and reliable terminal crimping. The basic workflow is as follows:
1. Automatic Wire Feeding & Positioning
A servo/stepperdriven feeding system delivers the HSD cable into the fixture and accurately positions:Outer jacket、Shielding layers、Inner conductors
This ensures perfect alignment before crimping.
2. MultiLayer Stripping & Shielding Handling
Given the complex HSD structure (outer jacket → foil → braid → inner cores), the machine performs:
Segmented stripping of outer insulation、Automatic spreading or fixing of braided shielding、Microblade stripping that avoids damaging inner conductors
Ensuring the cable structure remains intact.
3. Automatic Terminal Feeding & Precision Crimping
Terminals are oriented and fed by a vibrating or linear feeding system.
The servo crimping unit precisely controls:
Crimp height、Crimp length、Crimping force curve。
Achieving micronlevel accuracy required by highspeed signal terminals.
4. CFM Crimp Force Monitoring System
The builtin CFM system continuously monitors the crimp force curve, detecting:Undercrimp、Overcrimp、Terminal misalignment。
Automatically alarming or stopping the machine to ensure process consistency.
5. Automatic Inspection & Output
The system can automatically check:Crimp height、Crimp appearance
Pull force (optional)、Shield integrity (optional)。
Guaranteeing electrical performance of the HSD highspeed cable.
二. Technical Features of the HSD Wire Harness Crimping Machine
1. HighPrecision Servo Crimping System
Crimping accuracy up to ±0.02 mm
Extremely stable and consistent crimping pressure
Supports highfrequency and microterminal applications
2. ShieldingFriendly Stripping Structure
Protects foil shielding and braided mesh from damage
Automatically spreads the braid for stable termination
Ensures impedance consistency
3. MultiLayer Cable Processing Capability
Compatible with:
HSD fourcore cables、USB, LVDS, Fakra, and other multilayer cables
Highaccuracy stripping for insulation, foil, and braid
4. Intelligent CFM Monitoring
Realtime crimp force curve analysis
Automatic stop on abnormal readings
Prevents missing crimp, skewed crimp, or weak crimp
Greatly reduces defect rate.
5. Modular Automation Design
Expandable with:
Automatic cutting、Automatic stripping、Automatic tinning、Automatic terminal crimping、Automated optical inspection。
Ideal for automotive, communication, and ADAS camera cable assembly lines.
6. Impedance Stability Through Precision Control
Highspeed cables are impedancesensitive.
The machine ensures stability through:
Accurate compression ratio control
Positioning fixtures that prevent offset
Maintaining excellent electrical performance.
7. High Durability for 24/7 Production
Built with highstrength aluminum structures and industrialgrade servo systems, suitable for continuous, highload production environments.
