Method for evaluating locking force of high-end terminal connecting piece

Abstract

The invention provides a high-end terminal connecting piece locking force evaluation method, which comprises the following steps of: acquiring a press-in depth and a contact area during crimping, a terminal deformation quantity and a locking force attenuation amplitude, and establishing a crimping operation record; according to the tooth-shaped side wall stress deviation value and the locking force attenuation amplitude, identifying the tooth-shaped spacing expansion amplitude, recording the tooth-shaped tip end grinding width and the tooth-shaped spacing expansion amplitude under different crimping times, and establishing a tooth-shaped wear record table; the contact area, the terminal deformation quantity, the tooth-shaped tip grinding width and the side wall stress deviation value are integrated, a wear characteristic threshold value is determined, and the tool wear level is determined according to the wear characteristic threshold value; and obtaining real-time crimping frequency records in the crimping equipment, calculating the remaining service life of the remaining tool by combining the tool wear level and the locking effect degradation rate, and generating a tool replacement demand prompt according to the remaining service life of the tool.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of information technology, and in particular to a high-end terminal connector locking force evaluation method. BACKGROUND

[0002] As a core component that ensures stable connection in electrical equipment, the locking force of terminal connectors is directly related to the safety and reliability of the circuit. In the high-end manufacturing field, any slight deviation in locking force can lead to poor contact and even cause equipment failure. The performance of the crimping tool directly affects the quality of the terminal connection, and there is a complex interaction between tool wear and the degradation of locking effect, which needs to be further studied to improve process stability. Existing methods usually rely on periodic inspection or experience judgment when evaluating the performance of the crimping tool, such as visually detecting the degree of tooth shape wear or testing the locking force of the terminal. However, these methods often fail to capture the changes in tool state in real time, and it is difficult to accurately quantify the specific impact of wear on the locking effect. For example, traditional detection may overlook the subtle changes in tooth tip blunting, leading to failure to timely detect insufficient crimping depth. This static or lagging evaluation method makes it difficult to accurately identify the correlation between tool wear and crimping quality degradation. Moreover, during the crimping process, the blunting degree of the tooth tip is a key technical factor affecting the locking effect. Tooth tip blunting not only directly leads to insufficient crimping depth, but also causes uneven stress on the tooth side wall, disrupting the matching relationship between tooth depth and spacing. For example, in wire harness production, if the tooth tip becomes blunt due to long-term use, the terminal may not be able to fully embed the conductor during crimping, resulting in a decrease in locking force and even an increase in contact resistance. Therefore, how to quantitatively measure the impact of tooth tip blunting on crimping depth and locking force in real time during the crimping process and establish an accurate correlation between the two has become a key problem in improving crimping quality and tool management efficiency. SUMMARY

[0003] The present application provides a high-end terminal connector locking force evaluation method, comprising:

[0004] Collecting the crimping depth, contact area, terminal deformation, and locking force decay amplitude of the crimping operation, and establishing a crimping operation record containing the crimping depth, contact area, terminal deformation, and locking force decay amplitude;

[0005] Extracting the crimping depth, contact area, and terminal deformation from the crimping operation record, measuring the tooth tip flattening width of the terminal contact area, and determining the tooth side wall stress deviation value caused by insufficient crimping depth according to the tooth tip flattening width;

[0006] The change in the center distance between adjacent teeth is measured based on the deviation value of the force on the tooth sidewall and the attenuation of the locking force to obtain the expansion of the tooth spacing. The wear width of the tooth tip and the expansion of the tooth spacing are recorded to establish a tooth wear record table.

[0007] Extract the increment of the tooth tip wear width and the increment of the locking force attenuation amplitude per unit number of crimping cycles from the tooth wear record table, calculate the wear degradation index and generate an early warning signal;

[0008] By integrating the contact area, the terminal deformation, the grinding width of the tooth tip, and the force deviation value of the tooth sidewall, a wear characteristic threshold is determined, and the tool wear level is classified according to the wear characteristic threshold;

[0009] The real-time number of crimping operations of the crimping equipment is obtained, and the remaining life of the tool is calculated by combining the tool wear level and wear degradation index, and a replacement reminder signal is generated.

[0010] Furthermore, the pressing depth, contact area, terminal deformation, and locking force attenuation amplitude of the pressing operation are collected, and a pressing operation record including the pressing depth, contact area, terminal deformation, and locking force attenuation amplitude is established, including:

[0011] The depth data of the toothed indentation into the conductor is collected by a displacement sensor, and the vertical distance between the bottom of the tooth and the conductor surface is recorded to obtain the indentation depth; the depth deviation value is calculated based on the difference between the indentation depth and the standard depth value.

[0012] The actual contact area data between the tooth and the conductor is collected by a contact area sensor, and the terminal deformation is determined based on the contact area data.

[0013] Record the attenuation of the locking force to generate a crimping operation record that includes the pressing depth, the depth deviation value, the contact area, the terminal deformation, and the attenuation of the locking force.

[0014] Furthermore, the step of extracting the pressing depth, the contact area, and the terminal deformation from the crimping operation record, measuring the grinding width of the tooth tip in the terminal contact area, and determining the force deviation value of the tooth sidewall caused by insufficient pressing depth based on the grinding width of the tooth tip includes:

[0015] The tooth profile of the terminal contact area is obtained by image recognition, and the width of the ground-down tip of the tooth is measured.

[0016] The effective indentation depth of the tooth is calculated based on the ratio of the ground width of the tooth tip to the original height of the tooth.

[0017] If the effective indentation depth is lower than the standard depth threshold, stress distribution data of the tooth sidewall is collected by strain gauges, the distance of the pressure concentration point from the tooth centerline is calculated, and the force deviation value of the tooth sidewall is determined.

[0018] Furthermore, the width of the ground-down tooth tip in the contact area of ​​the measuring terminal is used to determine the force deviation value of the tooth sidewall caused by insufficient indentation depth, including:

[0019] The top contour data of the terminal tooth tip is acquired by a 3D scanner, and the grinding width of the tooth tip is measured; the angle between the tooth sidewall and the vertical direction is obtained to obtain the sidewall tilt angle.

[0020] Calculate the lateral extension distance of the top plane based on the difference between the ground width of the tooth tip and the standard depth;

[0021] Pressure data of the tooth sidewall is collected by a stress sensor array, the distance between the centroid of the pressure distribution and the geometric center of the tooth is calculated, and the force deviation value of the tooth sidewall is determined.

[0022] Furthermore, the step of determining the change in the center distance between adjacent teeth based on the force deviation value of the tooth sidewall and the attenuation amplitude of the locking force, obtaining the tooth spacing expansion amplitude, recording the tooth tip grinding width and the tooth spacing expansion amplitude, and establishing a tooth wear record table includes:

[0023] The crimping quality degradation coefficient is calculated by the force deviation value of the toothed sidewall and the attenuation amplitude of the locking force;

[0024] If the crimping quality degradation coefficient exceeds the threshold, the difference between the center distance of adjacent teeth and the standard spacing is measured to obtain the tooth spacing expansion range;

[0025] Record the grinding width of the tooth tip and the expansion of the tooth spacing to generate a tooth wear record table containing the grinding width of the tooth tip and the expansion of the tooth spacing under different pressing times.

[0026] Furthermore, determining the change in the center distance between adjacent teeth based on the force deviation value of the tooth sidewall and the attenuation amplitude of the locking force, to obtain the tooth spacing expansion amplitude, includes:

[0027] The pressure distribution function of the toothed sidewall is constructed by the force deviation value of the toothed sidewall to identify the pressure concentration area;

[0028] The terminal springback distance and the tooth root deformation depth are extracted from the locking force attenuation amplitude.

[0029] The asymmetric load on the tooth sidewall is calculated based on the pressure distribution function, the change in distance between adjacent teeth is measured, and the expansion of the tooth spacing is determined.

[0030] Furthermore, the step of extracting the increment of the tooth tip wear width and the increment of the locking force attenuation amplitude per unit number of pressing cycles from the tooth wear record table, calculating the wear degradation index, and generating an early warning signal includes:

[0031] Calculate the difference in the grinding width of the tooth tip between adjacent crimping cycles to obtain the grinding width increment of the tooth tip;

[0032] Extract the locking force attenuation amplitude data from the tooth wear record table, and calculate the increment of the locking force attenuation amplitude.

[0033] The wear degradation index is obtained by multiplying the normalized width increment and the locking force attenuation increment; a warning signal is generated by comparing the wear degradation index with a threshold.

[0034] Furthermore, the process of integrating the contact area, the terminal deformation, the grinding width of the tooth tip, and the force deviation value of the tooth sidewall to determine a wear characteristic threshold, and classifying the tool wear level based on the wear characteristic threshold, includes:

[0035] The contact area, the terminal deformation, the grinding width of the tooth tip, and the force deviation of the tooth sidewall are dimensionless and weighted summed to obtain the comprehensive wear evaluation index.

[0036] The wear characteristic threshold is determined by a clustering algorithm; the tool wear level is classified according to the correspondence between the comprehensive wear evaluation index and the wear characteristic threshold.

[0037] Furthermore, the step of obtaining the real-time crimping count of the crimping device, calculating the remaining tool life based on the tool wear level and wear degradation index, and generating a replacement reminder signal includes:

[0038] The real-time number of crimping operations is read from the crimping equipment, and the ratio to the rated number of operations is calculated to obtain the proportion of the service life that has been consumed.

[0039] The remaining tool life is calculated based on the wear and degradation index and the remaining rated number of cycles; a replacement reminder signal is generated by comparing the remaining tool life with a threshold.

[0040] The technical solutions provided by the embodiments of the present invention may include the following beneficial effects:

[0041] This invention discloses a method for evaluating the locking force of high-end terminal connectors. Addressing the business scenario where terminal tooth wear during crimping leads to degraded locking effect and reduced tool life, the method collects data on the crimping depth, contact area, terminal deformation, and locking force attenuation during crimping to construct a crimping operation record. It extracts the width of the tooth tip wear and the increase in tooth spacing to establish a tooth wear record table. The method analyzes the relationship between wear increment and locking force attenuation per unit of crimping cycle, identifies the degree of locking effect degradation, and generates early warning signals. Simultaneously, it integrates multi-dimensional wear characteristics to determine the tool wear level and predicts the remaining tool life based on real-time crimping cycles, generating replacement reminders. This invention, through data-driven wear characteristic analysis and life prediction, significantly improves the accuracy and efficiency of crimping tool maintenance and reduces quality risks caused by wear. Attached Figure Description

[0042] Fig. 1 This is a flowchart of a method for evaluating the locking force of a high-end terminal connector according to the present invention.

[0043] Fig. 2 This is a schematic diagram of a method for evaluating the locking force of a high-end terminal connector according to the present invention. Detailed Implementation

[0044] To further understand the content of this invention, a detailed description of the invention is provided in conjunction with the accompanying drawings and embodiments. The specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention. It should also be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.

[0045] like Figs. 1-2 This embodiment of a method for evaluating the locking force of a high-end terminal connector may specifically include:

[0046] Step S101: Collect the pressing depth and contact area, terminal deformation and locking force attenuation during crimping, and establish a crimping operation record.

[0047] The pressing distance of the crimping tool applied to the terminal is obtained. The actual depth of the toothed section pressed into the conductor is collected using a displacement sensor. The vertical distance between the bottom of the toothed section and the conductor surface is recorded to obtain the measured pressing depth. The difference between the measured pressing depth and the standard depth value is used to determine the degree of tooth embedding and output a depth deviation value. Based on the depth deviation value, the actual contact area between the toothed section and the conductor under the corresponding crimping state is collected. The plastic deformation of the terminal under the action of the crimping tool is determined by the change in contact area. The attenuation of the locking force from the initial value to the current value is recorded, establishing a crimping operation record that includes the measured pressing depth, depth deviation value, contact area, terminal deformation, and locking force attenuation.

[0048] In one embodiment, at the start of the crimping operation, a displacement sensor is mounted on the actuating shaft of the crimping clamp to monitor the displacement changes in real time during the toothed pressing process. As the toothed part contacts the terminal and continues pressing, the sensor records the vertical distance from the initial contact point to the crimping termination position; this distance is the measured crimp depth. A standard depth value is preset according to the conductor specifications, typically 65% ​​to 75% of the conductor diameter. The depth deviation is calculated by the difference between the measured value and the standard value.

[0049] Specifically, a positive depth deviation value indicates excessive indentation, potentially causing the teeth to pierce the conductor and cause damage; a negative deviation value indicates insufficient indentation, with the teeth failing to fully embed into the conductor. Based on the magnitude of the depth deviation value, the crimping system adjusts the range of subsequent measurement parameters.

[0050] For example, the contact area is obtained through image recognition methods. A camera captures the cross-section of the terminal after crimping, identifying the actual contact profile between the teeth and the conductor. The plastic deformation is determined by measuring the change in the outer diameter of the terminal before and after crimping, while the attenuation of the locking force is determined by measuring the displacement of the terminal under a standard pull-out force using a tensile tester. All measurement data are compiled into a crimping operation record, providing basic data support for subsequent tool wear assessment.

[0051] Step S102: Extract the pressing depth, contact area and terminal deformation from the crimping operation record, identify the width of the tooth tip grinding in the terminal contact area, and determine the force deviation value of the tooth sidewall caused by insufficient pressing depth based on the degree of tooth tip blunting.

[0052] The crimping depth and contact area data are extracted from the crimping operation record. The tooth profile of the terminal contact area is obtained through image recognition. The lateral width of the top plane of the tooth tip is measured, and the deviation of this lateral width from the initial sharp state is determined to obtain the tooth tip grinding width. The effective depth of the tooth pressed into the conductor is calculated based on the ratio of the tooth tip grinding width to the original tooth height. If the effective depth is lower than a preset standard crimping depth threshold, stress distribution data of the tooth sidewall is collected using strain gauges to determine the distance of the pressure concentration point from the tooth centerline. Using the pressure concentration point deviation distance and the terminal deformation, the stress difference of the tooth sidewall under non-uniform stress is obtained by inputting the pressure concentration point deviation distance and deformation into the stress distribution calculation formula. Based on the ratio of the stress difference to the standard stress value, the stress deviation value of the tooth sidewall caused by insufficient crimping depth is determined.

[0053] For example, in one implementation, the identification of the flattened width of the tooth tip is achieved using a high-resolution industrial camera. After crimping, the camera captures the crimped area of ​​the terminal from a vertical angle, and image processing software extracts the tooth profile edge, identifying the flat area of ​​the tooth tip through an edge detection algorithm.

[0054] Specifically, the new tooth tip has a sharp, pointed shape and a lateral width close to zero; while the worn tooth tip forms a platform-like structure with a lateral width that gradually increases from 0.1 mm to more than 0.5 mm.

[0055] It should be noted that there is an inverse relationship between the width of the worn-down tooth tip and the effective indentation depth. When the tooth tip is worn from a sharp state to a flat state, the actual indentation depth into the conductor will decrease accordingly.

[0056] In one possible implementation, the effective depth is calculated using the formula: the effective depth equals the measured indentation depth minus half the grinding width. The formula is as follows: De = Dm - W / 2, where De represents the effective indentation depth (in millimeters), Dm represents the measured indentation depth (in millimeters), and W represents the grinding width of the toothed tip (in millimeters). Since the platform-like structure formed after the toothed tip wears down is symmetrically distributed, the center of the platform corresponds to the theoretical indentation point of the original tip. Furthermore, the conductor material is obstructed by the edges of the platform during indentation, meaning the actual effective indentation point is located at the edge of the platform rather than the bottom. Therefore, it is necessary to deduct the distance from the center of the platform to the edge, i.e., half the grinding width, to reflect the actual indentation depth loss caused by the blunting of the toothed tip. This calculation method considers the actual situation where the blunted toothed tip cannot fully penetrate the conductor. When the effective depth is lower than a preset threshold, it indicates that the crimping quality has been affected.

[0057] Preferably, strain gauges are arranged on the toothed sidewall surface of the crimping clamp, with 2 to 4 strain gauges configured for each tooth, located on both sides and at the center of the tooth. During the crimping process, the strain gauges collect minute deformations of the sidewall in real time and convert them into stress values. Under normal conditions, the stress is symmetrically distributed on both sides of the tooth centerline; when the tooth tip becomes blunt, resulting in insufficient indentation, the stress concentrates at the tooth root, forming an eccentric stress state. The distance of the pressure concentration point from the centerline is determined by comparing the stress values ​​at each measuring point. The greater the deviation of the pressure concentration point, the more severe the unevenness of the stress. The calculation method for the deviation of the pressure concentration point is as follows: obtain the stress values ​​at each strain gauge measuring point on the toothed sidewall, and label the coordinates of each measuring point along the tooth height direction as H1, H2, ..., H n The corresponding stress values ​​are denoted as σ1, σ2, ..., σ; then the stress center location H is calculated using the weighted average method. c = (σ1×H1+σ2×H2+...+σ×H) n) / (σ1+σ2+...+σ); Finally, calculate the deviation distance D of the pressure concentration point D=|H c -H0|, where H0 is the position coordinate of the tooth profile centerline.

[0058] For example, in wire harness terminal crimping applications, when the terminal material is copper alloy (elastic modulus E = 110 GPa), the effective length of the toothed sidewall L = 3 mm, the terminal deformation ε = 0.15 mm, and the pressure concentration point deviation distance d = 0.8 mm, the stress difference ΔS = (110 × 0.15 × 0.8) / 3 ≈ 4.4 MPa. The stress distribution calculation formula is: ΔS=(E×ε×d) / L, where ΔS represents the stress difference of the tooth sidewall (unit: MPa), E represents the elastic modulus of the terminal material (unit: GPa), ε represents the terminal deformation (unit: mm), d represents the distance of the pressure concentration point from the tooth centerline (unit: mm), and L represents the effective length of the tooth sidewall (unit: mm). The ε value is obtained by collecting deformation data from strain gauges, the location of the pressure concentration point is determined by stress distribution data, and the d value is calculated. The E value is retrieved from the material database according to the terminal material type, and the L value is obtained by measuring the length of the tooth sidewall from the tip to the root. Substituting these parameters into the formula yields the stress difference ΔS. Under non-uniform stress conditions, the stress on one side of the tooth can reach 1.5 to 2 times that on the other side. This stress difference directly reflects the degree of degradation in crimping quality. By comparing the stress difference with the stress value under standard uniform stress conditions, a specific stress deviation value is obtained, which becomes an important indicator for assessing the wear of the crimping tool.

[0059] Obtain the crimping depth and contact area of ​​the terminal contact region from the crimping operation record. Collect the top plane width of the terminal tooth tip and the tilt angle of the tooth sidewall. Analyze the expansion range of the top plane of the tooth tip when the crimping depth is lower than the standard depth. Evaluate the degree of change of the tilt angle of the tooth sidewall after the contact area is reduced. Determine the width value of the tooth tip from a sharp state to a flat state. Identify the force deviation of the tooth sidewall caused by uneven pressure distribution.

[0060] The crimping depth and contact area are obtained from the crimping operation record. The top contour data of the terminal tooth tip is acquired using a 3D scanner, and the lateral width of the top plane is measured. Simultaneously, the angle between the tooth sidewall and the vertical direction is obtained as the sidewall tilt angle, yielding the tooth's geometric reference parameters. Based on these parameters, the difference between the crimping depth and the standard depth is calculated. If the difference exceeds a preset threshold, the lateral expansion distance of the tooth tip's top plane under crimping force is identified. By comparing the changes in the top contour before and after crimping, the expansion range of the tooth tip's top plane is determined. The expansion range value is used to evaluate the reduction ratio of the contact area, obtaining the offset of the tooth sidewall tilt angle relative to the standard tilt angle. Based on the ratio of the offset to the standard angle, the width at which the tooth tip changes from a sharp to a flat state is determined. Based on the width value and the tooth sidewall angle offset, pressure data from various parts of the tooth is collected using a stress sensor array. The distance between the pressure distribution centroid and the tooth's geometric center is calculated, identifying the force deviation caused by uneven pressure distribution on the tooth sidewall.

[0061] For example, in one implementation, data acquisition for the crimping operation is achieved through multi-sensor fusion. The data acquisition module of the crimping equipment automatically records the crimping depth and contact area during each crimping operation; this basic data forms the foundation for subsequent tooth wear assessment. The 3D scanner employs the principle of laser triangulation, emitting a laser beam to scan the tooth surface of the terminal, receiving reflected light, and calculating the 3D coordinates of each scan point. The scanning accuracy reaches the 0.01 mm level, accurately capturing minute geometric changes at the tooth tip.

[0062] Specifically, the acquisition process for the tooth tip profile data involves data fusion from multiple scanning sections. Starting from the tooth tip, the scanner acquires a cross-sectional profile every 0.05 mm along the vertical direction. By comparing the sharp tip profile of the new tooth with the flat tip profile after use, the lateral width of the top plane is measured. The tooth sidewall tilt angle is obtained by fitting the angle between the sidewall profile line and the vertical baseline. The sidewall tilt angle of the new tooth is typically in the range of 15 to 25 degrees, and this angle gradually increases with repeated use.

[0063] It should be noted that the calculation of the difference between the crimping depth and the standard depth involves a comprehensive consideration of multiple influencing factors. The standard depth is preset in the crimping parameter library based on the conductor material, wire diameter, and terminal type. When the measured crimping depth is lower than the standard depth by more than a preset threshold, it indicates that tooth wear has affected the crimping quality.

[0064] In one possible implementation, the expansion of the top plane of the tooth tip exhibits a gradual change. In the initial use stage, the tooth tip shows only slight blunting, with a top plane width of less than 0.1 mm; in the intermediate wear stage, the top plane gradually expands, reaching a width of 0.2 to 0.3 mm; in the severe wear stage, the top is completely flattened, with a width exceeding 0.5 mm. The expansion range is obtained by comparing the profile data of adjacent crimping cycles, reflecting the rate of wear development.

[0065] Preferably, the assessment of the contact area reduction ratio is achieved using image processing methods. After crimping, a terminal cross-sectional image is acquired using a microscopic imaging device. By performing grayscale processing on the terminal cross-sectional image, the edge lines of the tooth profile and conductor profile are extracted. By setting a gradient threshold, areas with significant grayscale changes in the image are identified as the actual contact boundaries between the tooth profile and the conductor, and the contact area is calculated. Under normal crimping conditions, the tooth profile can be completely embedded in the conductor, and the contact area reaches more than 95% of the theoretical value. When the tooth tip becomes blunt, the actual contact area will be significantly reduced, and the reduction ratio is positively correlated with the degree of flattening of the tooth tip.

[0066] For example, the offset of the tooth sidewall tilt angle reflects the change in force during the crimping process. When the tooth tip changes from a sharp state to a flat state, the transmission path of the crimping force changes. The pressure that was originally concentrated at the tip is distributed to a larger contact surface, resulting in an increase in the component force borne by the sidewall, and the tilt angle increases accordingly. When the ratio of the offset to the standard angle reaches 1.2, it indicates that the tooth has entered a wear stage that requires attention; when the ratio exceeds 1.5, the tooth wear is severe, and the crimping quality cannot be guaranteed.

[0067] In one embodiment, the stress sensor array employs piezoelectric sensors, with four sensors arranged at each tooth position of the crimping clamp, forming a rectangular array. The sensors acquire dynamic pressure data in real time during the crimping process, with a sampling frequency reaching 1000 Hz, enabling them to capture instantaneous changes in pressure distribution.

[0068] For example, the calculation of the pressure distribution centroid is based on a weighted average of the measurement points of each sensor. The pressure value of each sensor is used as the weight, and the corresponding spatial coordinates are used as the position parameters. The position of the pressure distribution centroid is obtained through moment calculation. Ideally, the pressure distribution centroid coincides with the geometric center of the tooth profile; when tooth wear causes uneven pressure distribution, the centroid will deviate from the geometric center, and the deviation distance is the force deviation.

[0069] Understandably, the deviation in force directly affects the locking effect of the terminals. A larger deviation indicates a more uneven pressure distribution, potentially leading to stress concentration or insufficient pressure in localized areas, thus impacting the reliability of the electrical connection. By continuously monitoring the trend of force deviation, the remaining service life of the crimping tool can be predicted, enabling preventative maintenance.

[0070] Step S103: Identify the tooth spacing expansion range based on the force deviation value of the tooth sidewall and the locking force attenuation range, record the tooth tip grinding width and tooth spacing expansion range under different pressing times, and establish a tooth wear record table.

[0071] Based on the deviation value of the force on the tooth sidewall and the attenuation of the locking force, the crimping quality degradation coefficient is obtained by multiplying the deviation value by the attenuation. If the degradation coefficient exceeds a preset threshold, it indicates that tooth wear has led to a significant decrease in crimping quality. The difference between the center distance of adjacent teeth and the standard spacing is then measured to determine the tooth spacing expansion value, further assessing the degree of tooth geometric deformation. Using the tooth spacing expansion value, combined with the current crimping count record and the corresponding tooth tip grinding width, a wear process curve showing the change in grinding width with the number of crimping counts is obtained through data fitting. The wear rate pattern is identified from the change in the curve slope. Based on the wear rate pattern, the increment value of the tooth tip grinding width from the previous cycle to the current cycle is recorded within each crimping cycle, along with the periodic increment value of the tooth spacing expansion value. The grinding width and spacing expansion data under different crimping counts are summarized to establish a tooth wear record table.

[0072] For example, in one embodiment, the crimping quality degradation coefficient is calculated by multiplying the toothed sidewall stress deviation value by the locking force attenuation amplitude.

[0073] Specifically, the stress deviation value reflects the degree of abnormal stress distribution of the tooth profile under non-uniform stress, while the attenuation amplitude reflects the degree of decline in terminal locking performance. The product of the two forms a comprehensive evaluation index.

[0074] For example, when the force deviation is 0.6 and the locking force attenuation is 0.5, the crimping quality degradation coefficient is 0.6 × 0.5 = 0.3. When the degradation coefficient is equal to or exceeds the preset threshold of 0.3, it indicates that the crimping quality has deteriorated significantly. The system automatically triggers tooth spacing measurement and wear process analysis to provide a basis for tool replacement decisions.

[0075] It should be noted that the measurement of the tooth pitch widening is achieved using optical measuring equipment. Under normal conditions, the center distance between adjacent teeth remains constant. However, with increasing pressing cycles and accelerated tooth wear, plastic deformation occurs at the tooth root, causing the distance between adjacent teeth to gradually increase. The specific value of the tooth pitch widening is obtained by measuring the difference between the actual center distance and the standard pitch.

[0076] Preferably, the wear process curve is fitted using a multinomial regression method. The number of pressing cycles is used as the independent variable, and the wear width of the tooth tip is used as the dependent variable. The wear process curve is obtained by fitting using the least squares method. The slope of the curve represents the wear rate. The slope is small in the initial wear stage, and gradually increases with the extension of service time, exhibiting accelerated wear characteristics. By analyzing the inflection point of the slope change, the critical point at which wear transitions from the stable period to the accelerated period can be identified.

[0077] In one possible implementation, each crimping cycle is defined as 100 consecutive crimping operations. At the end of the cycle, the current wear width and gap widening value are recorded, and the difference from the previous cycle is calculated to obtain the increment value. These increment values ​​reflect the rate of wear development; a sudden increase in the increment value indicates that the tool is about to enter a rapid failure phase.

[0078] For example, the tooth wear record table includes four main fields: number of pressing cycles, grinding width, pitch increase, and cycle increment. The record table is stored in a database, supporting historical data queries and trend analysis. Through statistical analysis of the data in the record table, a wear prediction model is established to achieve accurate prediction of tool life.

[0079] The pressure distribution of the tooth sidewall during crimping is obtained from the force deviation value of the tooth sidewall. The springback distance of the terminal and the deformation depth of the tooth root are collected from the locking force attenuation amplitude after crimping. The distance change between adjacent teeth when the pressure distribution of the tooth sidewall is uneven is analyzed. The degree of increase in the deformation depth of the tooth root after the terminal springback distance increases is evaluated. The expansion range of the distance between adjacent teeth from the initial spacing to the current spacing is determined.

[0080] Pressure data at various measuring points during the crimping process are obtained from the force deviation values ​​of the toothed sidewall. A continuous pressure distribution function of the toothed sidewall is constructed using interpolation methods to identify the boundary positions of pressure concentration areas and pressure deficiency areas, resulting in a pressure distribution map of the toothed sidewall. The degree of pressure unevenness is identified based on this map. The elastic recovery ratio of the terminal after the crimping force is released is extracted from the locking force attenuation amplitude. The springback distance of the terminal after the crimping force is removed is measured using a displacement sensor, and the permanent deformation depth of the tooth root relative to its initial position is collected. Using the pressure gradient values ​​in the pressure distribution map, the asymmetric load borne by the toothed sidewall is calculated. If the asymmetric load exceeds a preset threshold, the difference between the actual distance and the standard distance between adjacent teeth is measured to determine the distance change between adjacent teeth. Based on the distance change and the deformation depth value at the tooth root, the deformation depth increment caused by the increase in springback distance is evaluated by comparing the deformation depth values ​​at different springback distances of the terminal. Combined with the initial tooth spacing, the expansion range of the distance between adjacent teeth from the initial spacing to the current spacing is determined.

[0081] For example, in one implementation, the construction of the pressure distribution map on the tooth sidewall is based on multi-point pressure acquisition and data fusion. During the pressing process, pressure sensors arranged at different heights on the tooth sidewall collect contact pressure data in real time. Each tooth is configured with 8 to 12 measuring points, forming a dense pressure monitoring network. The discrete measuring point data is converted into a continuous pressure distribution function using a quadratic spline interpolation method. During the interpolation process, the pressure values ​​between adjacent measuring points are connected by a smooth curve to avoid abrupt pressure changes. Pressure concentration areas are represented by local maxima of the function value, usually appearing in the middle of the tooth; pressure deficiency areas correspond to local minima of the function, mostly distributed at the top and root edges of the tooth.

[0082] Specifically, the pressure distribution map uses tooth height as the vertical axis and circumferential position as the horizontal axis, with pressure values ​​represented by color depth or contour lines. Under normal crimping conditions, the pressure distribution exhibits a centrally symmetrical elliptical shape, with the pressure peak located near the geometric center of the tooth profile. When tooth wear leads to uneven crimping, the pressure distribution map shows a significant eccentricity, with the high-pressure zone shifting towards the tooth root and a large low-pressure area appearing at the top. This uneven pressure distribution directly affects the terminal locking effect and becomes an important basis for assessing the degree of tool wear.

[0083] It should be noted that the extraction of the elastic recovery ratio involves the analysis of material mechanical properties. The attenuation of the locking force includes both elastic recovery and plastic deformation. The proportion of elastic recovery is calculated by relating the attenuation range to the elastic modulus of the terminal material. The terminal undergoes total deformation under the crimping force. After the crimping force is removed, the elastic deformation portion recovers, while the plastic deformation portion remains. The rebound distance is the displacement caused by elastic recovery, measured using a high-precision displacement sensor with an accuracy of 0.001 mm.

[0084] Preferably, the permanent deformation depth at the tooth root is measured using a laser rangefinder. During measurement, the initial position of the tooth root is used as the reference zero point. After pressing and releasing the pressure, the distance difference between the new position of the root and the reference zero point is measured; this distance is the permanent deformation depth. This depth value reflects the degree of plastic flow of the material at the tooth root and is a key parameter for evaluating the integrity of the tooth structure.

[0085] In one possible implementation, the pressure gradient value is calculated based on the differential processing of the pressure distribution map. The pressure gradient represents the rate of change of pressure in space; a larger gradient value indicates a more uneven pressure distribution. By taking the partial derivative of the continuous pressure distribution function on the tooth sidewalls, the pressure gradient components in each direction are obtained, and then synthesized to obtain the gradient vector field. The asymmetric load is obtained by integrating the distribution of the pressure gradient on the tooth sidewalls, reflecting the unbalanced moment borne by the tooth. When the asymmetric load exceeds 30% of the material's yield strength, the tooth structure begins to exhibit irreversible deformation, and the distance between adjacent teeth changes.

[0086] For example, the measurement of the distance variation between adjacent teeth is performed using an image recognition method. A high-speed camera captures the crimping area axially from the terminal, and image processing software automatically identifies the center position of each tooth and calculates the actual distance between adjacent centers. The standard distance is preset according to the design parameters of the crimping tool, typically 2 to 3 millimeters. The difference between the actual distance and the standard distance is the distance variation, which gradually accumulates with the increase of the number of crimping operations.

[0087] For example, when evaluating the relationship between springback distance and deformation depth, multiple sets of comparative tests are required. Different compression force levels are set, and the corresponding springback distance and deformation depth are measured to establish a correlation curve between the two. An increase in springback distance is usually accompanied by an increase in deformation depth, but the relationship is not linear. In the elastic deformation stage, the springback distance increases while the deformation depth remains essentially unchanged; after entering the plastic deformation stage, the deformation depth increases sharply while the springback distance tends to stabilize.

[0088] Understandably, calculating the deformation depth increment requires considering the work hardening effect of the material. As the number of crimping cycles increases, the material at the tooth root hardens due to repeated stress, resulting in a gradual decrease in deformation depth under the same crimping force and a smaller deformation depth increment. By recording the deformation depth values ​​at different crimping stages and calculating the incremental changes between adjacent stages, the development trend of material hardening can be identified. Furthermore, the final determination of the tooth spacing expansion rate comprehensively considers multiple influencing factors. The initial spacing is obtained through calibration measurement of the new tool and serves as a benchmark reference value. The current spacing is obtained through real-time measurement, and the difference between the two is the absolute expansion amount. The expansion rate is calculated as the ratio of the absolute expansion amount to the initial spacing and expressed as a percentage. When the expansion rate exceeds 15%, the crimping quality significantly decreases, and the electrical performance and mechanical strength of the terminals fail to meet the usage requirements.

[0089] Step S104: Extract the increment of the tooth tip wear width per unit number of pressing cycles and the increment of the locking force attenuation per unit number of pressing cycles from the tooth wear record table, identify the degree of degradation of the locking effect caused by tooth wear, and send a warning signal.

[0090] Extract the tooth tip wear width data of adjacent crimping cycles from the tooth wear record table, calculate the width difference between each cycle and the previous cycle, divide it by the number of crimping cycles within the cycle, and obtain the tooth tip wear width increment per unit number of crimping cycles. Based on the time period corresponding to the width increment, extract the locking force attenuation amplitude data of the same cycle from the tooth wear record table, obtain the locking force attenuation amplitude increment per unit number of crimping cycles through differential calculation, and normalize the width increment and attenuation amplitude increment by their respective reference values. Multiply the normalized values ​​to obtain the wear degradation index. Compare the wear degradation index with a preset degradation threshold. If the degradation index exceeds the first threshold but is lower than the second threshold, the degree of degradation of the locking effect is identified as moderate degradation and a yellow warning signal is generated; if it exceeds the second threshold, it is identified as severe degradation and a red warning signal is generated and sent to the crimping equipment controller.

[0091] For example, in one implementation, the tooth wear record table is stored in a database format, with each record containing fields such as timestamp, number of pressing operations, grinding width, and locking force. The pressing cycle is defined as 100 or 200 consecutive pressing operations, flexibly adjusted according to production rhythm and tool wear rate. Data from adjacent cycles are linked via timestamps to ensure accurate data extraction.

[0092] Specifically, the increment of the tooth tip wear width per unit number of crimping cycles is obtained through differential calculation. Assuming the wear width in the Nth cycle is W(N), in the (N-1)th cycle it is W(N-1), and the number of crimping cycles is C, then the increment calculation formula is [W(N) - W(N-1)] / C. This increment value reflects the instantaneous wear rate; a larger value indicates a more significant wear acceleration.

[0093] It is important to note that the selection of the reference value for normalization is crucial. The reference value for the grinding width increment is typically the average increment over the first 10 cycles of a new tool, representing the normal wear rate; the reference value for the locking force attenuation increment is the standard attenuation rate corresponding to the terminal specification. The normalized values ​​range from 0 to 1, facilitating comprehensive evaluation of data with different dimensions. The wear degradation index is obtained by multiplying the two normalized values, comprehensively reflecting the coupling effect of geometric wear and functional degradation.

[0094] Preferably, the degradation threshold is set based on statistical analysis of a large amount of historical data. The first threshold is set to 0.3, corresponding to a light wear state, at which point the tool can still be used normally but requires close monitoring; the second threshold is set to 0.6, indicating that the accelerated wear stage has begun, and the crimping quality begins to fluctuate. When the wear degradation index is between the two thresholds, it is identified as moderate degradation, triggering a yellow warning signal.

[0095] For example, the warning signal is sent to the crimping equipment controller via the industrial Ethernet protocol. Upon receiving a yellow warning, the controller displays a warning message on the operating interface, reminding the operator to prepare spare tools; upon receiving a red warning, it automatically reduces the crimping speed or suspends production to avoid batch quality problems. The warning signal is also simultaneously recorded in the maintenance management system, providing data support for tool replacement planning.

[0096] Step S105: Integrate the contact area, terminal deformation, tooth tip grinding width, and sidewall force deviation value to determine the wear characteristic threshold, and determine the tool wear level based on the wear characteristic threshold.

[0097] By integrating the distribution patterns of contact area, terminal deformation, tooth tip grinding width, and sidewall force deviation values ​​in historical data, the evaluation index is divided into three cluster centers using the K-means clustering algorithm. The midpoint between adjacent cluster centers is taken as the boundary point to determine two wear characteristic thresholds. Using these wear characteristic thresholds, the evaluation index space is divided into three intervals, establishing a correspondence between the evaluation index intervals and wear levels. Based on the current interval position of the evaluation index, the tool wear level is determined to be light, moderate, or severe wear.

[0098] For example, the standard value of the contact area is taken as the theoretical contact area under new tooling conditions; the standard value of the terminal deformation is determined based on the yield strength of the terminal material; the standard value of the tooth tip grinding width is set to 0.5 mm, corresponding to a moderate wear condition; the standard value of the sidewall force deviation is taken as 3 times the deviation value under uniform force. After dividing each parameter by the corresponding standard value, the numerical range is unified to between 0 and 2.

[0099] It should be noted that the weighting coefficients are determined based on the degree of influence of each parameter on the crimping quality. Through orthogonal experimental analysis, the weight of the contact area is set at 0.3, reflecting its direct impact on the electrical connection; the weight of the terminal deformation is 0.2, reflecting the mechanical locking effect; the weight of the tooth tip grinding width is 0.35, serving as the main indicator of wear; and the weight of the sidewall force deviation value is 0.15, reflecting the uniformity of pressure distribution. The sum of the weighting coefficients is 1 to ensure the normalization of the evaluation index.

[0100] Specifically, the K-means clustering algorithm is implemented in three stages: initialization, iteration, and convergence. During initialization, three evaluation index values ​​are randomly selected from historical data as initial cluster centers, corresponding to typical wear states of mild, moderate, and severe wear, respectively. During iteration, the Euclidean distance from each data point to the three cluster centers is calculated, and the data point is assigned to the nearest cluster. Then, the center position of each cluster is recalculated. The algorithm converges when the distance the cluster center moves is less than 0.01 or the number of iterations reaches 100.

[0101] Preferably, the wear characteristic threshold is determined through statistical analysis of the clustering results. The first threshold is taken as the arithmetic mean of the cluster centers of the light wear and moderate wear classes, typically between 0.35 and 0.45; the second threshold is taken as the average of the cluster centers of the moderate wear and severe wear classes, typically between 0.65 and 0.75. This method ensures the objectivity and adaptability of the threshold setting.

[0102] For example, when the comprehensive wear evaluation index is less than the first threshold, the tool is at the level of light wear and can continue to be used but needs to be inspected regularly; between the two thresholds is moderate wear, and it is recommended to prepare to replace the tool; exceeding the second threshold is severe wear, and the machine should be stopped immediately for replacement to avoid the generation of batch defective products.

[0103] Step S106: Obtain the real-time crimping count record in the crimping device, calculate the remaining tool life based on the tool wear level and the rate of degradation of the locking effect, and generate a tool replacement requirement reminder based on the remaining tool life.

[0104] The system acquires real-time crimping count records from the crimping equipment, reads the current cumulative crimping count from the equipment counter, finds the corresponding rated usage count based on the tool wear level, and calculates the ratio of the current count to the rated count as the consumed lifespan ratio. Based on the consumed lifespan ratio and the locking effect degradation rate, the degradation rate is multiplied by the remaining rated count to obtain the predicted attenuation amount. The predicted attenuation amount is subtracted from the remaining rated count to obtain the remaining tool lifespan. The remaining tool lifespan is compared with a preset reminder threshold. When the remaining lifespan is less than 30% of the rated lifespan, a yellow replacement reminder is generated; when it is less than 10% of the rated lifespan, a red emergency replacement reminder is generated, and the reminder signal is sent to the crimping equipment controller.

[0105] For example, in one embodiment, the counter of the crimping device records each crimping action via a Hall sensor. The sensor is mounted on the drive shaft of the crimping mechanism and generates a pulse signal after each crimping cycle is completed. The counter accumulates the number of pulses to obtain the real-time crimping count. The rated number of uses is preset according to the tool material and machining accuracy. The rated number of uses for high-speed steel crimping tools is typically 10,000 to 15,000 times, while that for carbide tools can reach 20,000 to 30,000 times.

[0106] It should be noted that there is a correlation between tool wear levels and rated number of uses. Slight wear corresponds to 100% of the rated number of uses; moderate wear, due to accelerated wear, reduces the rated number of uses to 70% of the initial value; and severe wear corresponds to only 40% of the initial value. The percentage of used life is calculated by dividing the current cumulative number of uses by the adjusted rated number of uses, reflecting the actual degree of tool use.

[0107] Specifically, the locking effect degradation rate is extracted from historical data and represents the decrease in locking force per unit number of crimping cycles. During the normal wear phase, the degradation rate remains stable; after entering the accelerated wear phase, the degradation rate increases exponentially. The predicted degradation amount equals the product of the degradation rate and the remaining rated number of cycles; this degradation amount reflects the impact of accelerated wear on lifespan. The actual remaining lifespan needs to be calculated by subtracting the predicted degradation amount from the theoretical remaining number of cycles.

[0108] Preferably, the warning threshold is set considering the preparation time for tool replacement and the requirements of production continuity. When the remaining lifespan drops to 30% of the rated lifespan, it is equivalent to 3,000 to 4,500 uses remaining, which is sufficient to complete the current production batch and prepare a spare tool. A yellow warning signal is displayed as a flashing icon on the equipment screen to remind maintenance personnel to pay attention to the tool status.

[0109] For example, when the remaining lifespan is less than 10% of the rated lifespan, the tool is nearing failure, and crimping quality may be compromised at any time. A red emergency replacement reminder is issued via an audible and visual alarm, and the equipment automatically reduces its operating speed to prevent sudden malfunctions. After receiving the warning signal, the crimping equipment controller displays detailed tool status information on the human-machine interface, including the number of uses, estimated remaining uses, and recommended replacement time.

[0110] The above description is merely a specific implementation of this specification. Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, modules, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here. It should be understood that the scope of protection of this specification is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this specification, and these modifications or substitutions should all be covered within the scope of protection of this specification.

Claims

1. A method for evaluating the locking force of high-end terminal connectors, characterized in that, include: Collect the pressing depth, contact area, terminal deformation, and locking force attenuation of the crimping operation, and establish a crimping operation record that includes the pressing depth, contact area, terminal deformation, and locking force attenuation. Extract the pressing depth, the contact area, and the terminal deformation from the crimping operation record; measure the grinding width of the tooth tip in the terminal contact area; and determine the force deviation value of the tooth sidewall caused by insufficient pressing depth based on the grinding width of the tooth tip. The change in the center distance between adjacent teeth is measured based on the deviation value of the force on the tooth sidewall and the attenuation of the locking force to obtain the expansion of the tooth spacing. The wear width of the tooth tip and the expansion of the tooth spacing are recorded to establish a tooth wear record table. Extract the increment of the tooth tip wear width and the increment of the locking force attenuation amplitude per unit number of crimping cycles from the tooth wear record table, calculate the wear degradation index and generate an early warning signal; By integrating the contact area, the terminal deformation, the grinding width of the tooth tip, and the force deviation value of the tooth sidewall, a wear characteristic threshold is determined, and the tool wear level is classified according to the wear characteristic threshold; The real-time number of crimping operations of the crimping equipment is obtained, and the remaining life of the tool is calculated by combining the tool wear level and wear degradation index, and a replacement reminder signal is generated.

2. The method for evaluating the locking force of high-end terminal connectors according to claim 1, characterized in that, The pressing operation data, including pressing depth, contact area, terminal deformation, and locking force attenuation, is collected to establish a pressing operation record containing the pressing depth, contact area, terminal deformation, and locking force attenuation. The depth data of the toothed indentation into the conductor is collected by a displacement sensor, and the vertical distance between the bottom of the tooth and the conductor surface is recorded to obtain the indentation depth; the depth deviation value is calculated based on the difference between the indentation depth and the standard depth value. The actual contact area data between the tooth and the conductor is collected by a contact area sensor, and the terminal deformation is determined based on the contact area data. Record the attenuation of the locking force to generate a crimping operation record that includes the pressing depth, the depth deviation value, the contact area, the terminal deformation, and the attenuation of the locking force.

3. The method for evaluating the locking force of high-end terminal connectors according to claim 1, characterized in that, The step of extracting the pressing depth, contact area, and terminal deformation from the crimping operation record, measuring the width of the tooth tip grinding in the terminal contact area, and determining the force deviation value of the tooth sidewall caused by insufficient pressing depth based on the width of the tooth tip grinding includes: The tooth profile of the terminal contact area is obtained by image recognition, and the width of the ground-down tip of the tooth is measured. The effective indentation depth of the tooth is calculated based on the ratio of the ground width of the tooth tip to the original height of the tooth. If the effective indentation depth is lower than the standard depth threshold, stress distribution data of the tooth sidewall is collected by strain gauges, the distance of the pressure concentration point from the tooth centerline is calculated, and the force deviation value of the tooth sidewall is determined.

4. The method for evaluating the locking force of high-end terminal connectors according to claim 3, characterized in that, The width of the ground-down tooth tip in the contact area of ​​the measuring terminal is used to determine the force deviation value of the tooth sidewall caused by insufficient indentation depth, including: The top contour data of the terminal tooth tip is acquired by a 3D scanner, and the grinding width of the tooth tip is measured; the angle between the tooth sidewall and the vertical direction is obtained to obtain the sidewall tilt angle. Calculate the lateral extension distance of the top plane based on the difference between the ground width of the tooth tip and the standard depth; Pressure data of the tooth sidewall is collected by a stress sensor array, the distance between the centroid of the pressure distribution and the geometric center of the tooth is calculated, and the force deviation value of the tooth sidewall is determined.

5. The method for evaluating the locking force of high-end terminal connectors according to claim 1, characterized in that, The process involves determining the change in center distance between adjacent teeth based on the force deviation value of the tooth sidewall and the attenuation amplitude of the locking force, obtaining the tooth spacing expansion amplitude, recording the tooth tip grinding width and the tooth spacing expansion amplitude, and establishing a tooth wear record table, including: The crimping quality degradation coefficient is calculated by the force deviation value of the toothed sidewall and the attenuation amplitude of the locking force; If the crimping quality degradation coefficient exceeds the threshold, the difference between the center distance of adjacent teeth and the standard spacing is measured to obtain the tooth spacing expansion range; Record the grinding width of the tooth tip and the expansion of the tooth spacing to generate a tooth wear record table containing the grinding width of the tooth tip and the expansion of the tooth spacing under different pressing times.

6. The method for evaluating the locking force of high-end terminal connectors according to claim 5, characterized in that, The step of determining the change in the center distance between adjacent teeth based on the force deviation value of the tooth sidewall and the attenuation amplitude of the locking force, to obtain the tooth spacing expansion amplitude, includes: The pressure distribution function of the toothed sidewall is constructed by the force deviation value of the toothed sidewall to identify the pressure concentration area; The terminal springback distance and the tooth root deformation depth are extracted from the locking force attenuation amplitude. The asymmetric load on the tooth sidewall is calculated based on the pressure distribution function, the change in distance between adjacent teeth is measured, and the expansion of the tooth spacing is determined.

7. The method for evaluating the locking force of high-end terminal connectors according to claim 1, characterized in that, The step of extracting the increment of the wear width of the tooth tip and the increment of the attenuation of the locking force per unit number of pressing cycles from the tooth wear record table, calculating the wear degradation index, and generating an early warning signal includes: Calculate the difference in the grinding width of the tooth tip between adjacent crimping cycles to obtain the grinding width increment of the tooth tip; Extract the locking force attenuation amplitude data from the tooth wear record table, and calculate the increment of the locking force attenuation amplitude. The wear degradation index is obtained by multiplying the normalized width increment and the locking force attenuation increment; a warning signal is generated by comparing the wear degradation index with a threshold.

8. The method for evaluating the locking force of high-end terminal connectors according to claim 1, characterized in that, The process integrates the contact area, terminal deformation, tooth tip grinding width, and tooth sidewall force deviation to determine a wear characteristic threshold. Based on this threshold, tool wear levels are then classified, including: The contact area, the terminal deformation, the grinding width of the tooth tip, and the force deviation of the tooth sidewall are dimensionless and weighted summed to obtain the comprehensive wear evaluation index. The wear characteristic threshold is determined by a clustering algorithm; the tool wear level is classified according to the correspondence between the comprehensive wear evaluation index and the wear characteristic threshold.

9. The method for evaluating the locking force of high-end terminal connectors according to claim 1, characterized in that, The process of acquiring the real-time crimping count of the crimping device, calculating the remaining tool life based on the tool wear level and wear degradation index, and generating a replacement reminder signal includes: The real-time number of crimping operations is read from the crimping equipment, and the ratio to the rated number of operations is calculated to obtain the proportion of the service life that has been consumed. The remaining tool life is calculated based on the wear and degradation index and the remaining rated number of cycles; a replacement reminder signal is generated by comparing the remaining tool life with a threshold.

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