ClassA Motor

Purchased component

Lead Wires & Connectors

Cut, strip & crimp → Crimp verification → Housing insertion & continuity test

✓ Expert reviewed All content on this page has been reviewed by a senior motor engineer.

Process flow

3 main process steps, with the equipment and instruments used at each step, their main suppliers, and the technical control points.

  1. 1

    Cut, strip & crimp

    Wires are cut and stripped, and terminals crimped automatically.

    ⚙ Automatic Cut-Strip-Crimp MachineAutomated
    International
    KomaxGuangzhou, SchleunigerShenzhen
    Mainland China
    To be added

    Technical control points:

    • ▪Strip length — Per terminal spec, typically ±0.5 mm; no nicked strandsCheck: Gauge; first piece and each reel
    • ▪Crimp height and width — Terminal maker's value, typically ±0.03–0.05 mmCheck: Crimp-force monitor 100%; micrometer at setup and each reel
  2. 2

    Crimp verification

    Cross-sections and pull tests verify each setup and lot.

    ⚙ Crimp Cross-section Analyser & Pull TesterTest instrumentSemi-automaticManual
    International
    To be added
    Mainland China
    To be added

    Technical control points:

    • ▪Crimp cross-section — Symmetric, no voids, all strands captured, bell-mouth presentCheck: Cross-section analyser; each setup and shift
    • ▪Pull-out force — ≥ IEC 60352-2 value for the wire sizeCheck: Pull tester; each setup and shift
  3. 3

    Housing insertion & continuity test

    Terminals are inserted into connector housings and the harness is continuity-tested.

    Technical control points:

    • ▪Pin position — Matches wiring diagramCheck: Continuity tester; 100%
    • ▪Terminal latching — Fully seated; withstands push-back testCheck: Push-back / pull check; 100%
    • ▪Opens and shorts — NoneCheck: Continuity tester; 100%

Incoming inspection & approval tests

  • Wire voltage and temperature ratingUL 758 (AWM)
  • Terminal pull-out forceIEC 60352-2 / customer standard
  • Mating force and mating cyclesConnector datasheet
  • Flex lifeAgreed per application

Buyer FAQ

Which lead wire should I use?
UL 1007 / 1569 PVC wire for 80–105 °C and 300 V; UL 3266 or 3321 cross-linked wire for higher temperature; silicone or PTFE for the hottest applications. Match the wire's temperature and voltage rating to the motor's insulation class.
What matters at the crimped terminal?
Correct terminal and wire size, crimp height within the terminal maker's window, and pull-out force tests. Crimp-force monitoring on every crimp catches missing strands and bad crimps.
How do I protect leads where they leave the motor?
Use a grommet, strain relief or cable gland so the wire is not cut by sharp edges or pulled off the winding; vibration and pulling at the exit are a common field failure.