Flag Connector to Quick Connect Cable Assembly

The flag connector to quick-connect cable assembly combines a flag connector with a quick-connect cable, enabling fast and stable docking between devices, and is ideal for scenarios requiring efficient connectivity.

Wire: UL1015 14AWG

Main Connector: 250mm single-ended flag terminals

Secondary Connector 1: PN: 3-521142-2, 14-16AWG QC tab terminals with a 0.250-inch crimping gauge.

Secondary Connector 2: 250mm insulated blue female terminals (14-16AWG), compatible with a wide range of device interfaces.

Heat Shrink Tubing: Made of black double-walled material, heat-shrink-treated to tightly wrap around the contacts, it provides insulation, waterproofing, and corrosion resistance, making it suitable for complex working conditions.

Production process

1. Wire Cutting: The wire cutting process uses a fully automatic wire cutting machine with an accuracy of ±5mm to cut UL1015 14AWG wires according to the designed length to ensure uniform length and avoid length deviation. After cutting, laser inspection is carried out to eliminate unqualified products with surface damage and wire diameter deviation, ensuring the quality of the base material from the source.

2. Wire Stripping: A fully automatic wire stripping machine is used to process both ends of the wire. The stripping length is strictly controlled to 8-10mm (adapting to the terminal crimping size) to avoid damaging the internal copper conductor (conductor integrity reaches 100%). At the same time, the burrs on the edges of the insulation layer at the stripping ends of the main and branch wires are removed to prevent them from being pressed into the terminal together with the copper wire during crimping.

3. Terminal crimping: Multiple terminal crimping is completed in steps, and each step is subjected to tensile test (≥222.5N) and secondary element test.

• Flag Connector Crimping: Crimp 250 single-ended flag terminals to UL1015 14AWG main conductors. The crimping process is divided into two sections: "insulation crimping" and "conductor crimping." Ensure the insulation is tightly wrapped and the conductor is not damaged (conductor cross-sectional deformation ≤ 5% after crimping).
• Blue Female Terminal Crimping: Use a "symmetrical crimping die" to crimp the brass clip to two branch wires, ensuring even force on both wires and 100% contact between the clip and the insulation and conductor.
• Quick Connector Crimping: Crimp PN: 3-521142-2 terminals and 250 female terminals to the branch wires. Keep the terminal blades and sockets clean and free of oxidation. After crimping, insert them into a test fixture to verify smooth insertion and removal.

4. Blowing heat shrink tubing: Use a 150-180℃ hot air gun to heat shrink the double-wall heat shrink tubing to form a sealed protection to adapt to various environments.

Before inserting the sleeve, ensure that the crimping area is free of oil, dirt, and moisture, and that the sleeve coverage extends beyond the crimping area by more than 3mm on both ends. When heat shrinking, heat from the middle to both ends to avoid residual bubbles and ensure that the sleeve shrinks fully (shrinkage ratio ≥ 2:1) and fits tightly with the wire and terminal to form a sealed cavity. After cooling, check that the sleeve is free of cracks and wrinkles, and use a caliper to check the thickness after shrinkage (≥ 0.8mm) to ensure that the insulation strength meets the standard (voltage resistance 600V).

5. Continuity Test: Each product undergoes three core tests using an automated continuity tester:

• Continuity: Tests for electrical continuity between the main terminal and both branch terminals (resistance ≤ 5mΩ);
• Open/Short Detection: Checks for open circuits or false shorts within the conductors and between terminals;
• Insulation Resistance Test: Tests insulation resistance (≥ 10MΩ) at 300V DC to ensure there is no leakage risk.

Test data is automatically archived, ensuring traceability of each product's test results.

This cable assembly is composed of a flag-type connector and a quick-connector cable. It is a one-to-two structure and includes specific wire materials, primary and secondary connectors, and heat shrink tubing. It is manufactured through processes such as wire cutting, stripping, terminalizing, heat shrink tubing blowing, and continuity testing to ensure reliable connections and adaptability to various scenarios.