Crimp Resistance Drift: How a 0.5% Increase in Terminal Crimp Resistance Becomes a 100mV Ground Offset in 12 Months
The first sign of trouble was a crimp height report that looked perfect. It was December 2023, and a harness line in Suzhou was shipping engine ground cables for a 1.5L turbo program. Every measurement sat dead center: 1.42 mm crimp height, 92 N pull force, 0.82 mΩ four-wire resistance on a 0.75 mm² copper conductor. Twelve months later, three of […]