Crimp Cross-section Analyser & Pull Tester

Selection criteria

Image resolution, force range.

Supply chain

Crimp cross-section analysers and pull testers are offered by wire-processing brands and by Chinese instrument makers. Regular cross-sections at each setup are the standard way to prove crimp quality to automotive and industrial customers.

Buyer FAQ

What does a crimp cross-section show?

A polished and etched cross-section shows crimp height and width, strand compaction and voids, symmetry, burrs and whether the wings close properly onto the strands. Crimp height is normally held within about ±0.03–0.05 mm of the terminal maker's specification. Do a section at first-off, after every applicator or wire change and periodically each shift.

What pull-out force should a crimp reach?

IEC 60352-2 gives minimum pull-out forces of roughly 60 N for 0.5 mm², 108 N for 1 mm² and 230 N for 2.5 mm² copper wire; terminal makers and automotive standards may require more. Test at a constant speed of about 25–50 mm/min, and choose a tester with a 500 N–1 kN load cell for typical motor lead wires.

What should I look for when buying a cross-section system?

A complete system includes a precision cutter, grinding and polishing station, etching kit and a microscope camera (at least 5 MP, about 20–200× magnification) with measuring software. Preparation should take under about 10 minutes per sample. Software that stores images and measurements against terminal and wire part numbers makes customer PPAP and audit evidence much easier.

Where it is used