Magnetic Pulse Crimping of Power Cables: Process Simulation & Performance Characterization
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Date
2025-08-26
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Abstract
Magnetic Pulse Crimping (MPC) represents an interesting alternative to mechanical
crimping. This solution is a contactless process using dynamic Lorentz forces induced by
high pulse power electrical discharge through a coil. MPC has proven to be effective for
cables terminals with both high electrical and mechanical performances. This solution
differs from conventional methods for cables with large cross-sections for high voltages
especially those manufactured for electric vehicles. The challenge lies in the high thickness
of the terminal and the cable to be crimped together while maintaining the performance of
the connection during use and ageing, that can be hard to hold with traditional processes.
The aim of this work is to characterize the electrical resistance of 120 mm² power cables
terminals that are assembled by MPC, with the goal of reducing the process width and
potentially reduce the lug mass. First, a numerical study of the process is performed in order
to design and characterize the crimping level depending on main process parameters, in
particular through the compaction level of the assembly. Then, an experimental study has
been carried out by testing assemblies with different crimping widths and generator
energies, in order to reduce the crimped length without degrading the performance and
repeatability. For each case, the electrical resistance of the cable/lug interface is measured,
before and after exposure to thermal and humidity cycling representative of real-life
conditions. The results are compared with samples produced using mechanical crimping to
compare the performances and repeatability of each process respectively.
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Keywords
High Pulse Power (HPP), Multiphysics Simulation, Power Cable, Magnetic Pulse Crimping (MPC)
Subjects based on RSWK
Crimpen, Elektromagnetisches Verfahren, Elektrisches Kabel, Multiphysics, Simulation, Experiment