Hengyi HY-0530UJJ Universal Testing Machine for Wire Harness and Terminal Pull-Off Force Testing
| Brand | Hengyi |
|---|---|
| Origin | Shanghai, China |
| Manufacturer Type | Direct Manufacturer |
| Instrument Type | Electronic Universal Testing Machine |
| Model | HY-0530UJJ |
| Load Cell | 5000 N (FS ±0.02% accuracy) |
| Actuation | Panasonic AC servo motor + precision ball screw |
| Control System | 32-bit ARM microprocessor (56 MIPS), 0.5-class system accuracy |
| Test Speed Range | 0.001–300 mm/min (adjustable) |
| Effective Stroke (excluding grips) | 300 mm |
| Dimensions (W×D×H) | 420 × 470 × 800 mm |
| Weight | ~50 kg |
| Grip Configuration | Dedicated wire harness and terminal tensile fixture set |
| Display | High-resolution LCD with real-time force–displacement curve, load, and displacement readouts |
| Software | Integrated PC-based test control and reporting suite compliant with GLP audit trail requirements |
Overview
The Hengyi HY-0530UJJ Universal Testing Machine is an electromechanical force measurement system engineered specifically for quantitative mechanical evaluation of wire harness assemblies, crimped terminals, connectors, plugs, sockets, adhesive bonds, lamp holders, and other compact electro-mechanical components. It operates on the principle of controlled uniaxial tension application—applying precisely regulated axial force while continuously recording load (N), displacement (mm), and time-synchronized deformation data. Designed to meet the repeatability and traceability demands of Tier-1 automotive suppliers, electronics OEMs, and contract manufacturing labs, the system complies with fundamental mechanical testing frameworks outlined in ISO 527-1, ASTM D638, IEC 60512-2, and USP for mechanical integrity assessment of low-force interconnects.
Key Features
- High-fidelity 5000 N load cell from Transducer Techniques (USA), calibrated to ±0.02% full-scale accuracy—ensuring metrological reliability across sub-newton to kilonewton ranges.
- Full-digital Panasonic AC servo drive coupled with a ground-precision recirculating ball screw, delivering smooth motion control, zero backlash, and long-term positional stability over 100,000+ test cycles.
- Dedicated 32-bit ARM-based embedded controller (56 MIPS processing throughput) with real-time closed-loop feedback—enabling sub-millisecond sampling resolution and deterministic response during dynamic pull-off or peel tests.
- Integrated high-brightness LCD interface supporting simultaneous display of live force–displacement curves, numeric load values, crosshead position, and test status—no external PC required for basic operation.
- Industrial-grade sheet metal enclosure with baked enamel finish provides EMI shielding, structural rigidity, and resistance to workshop environmental contaminants including dust, vibration, and minor solvent exposure.
- Modular grip mounting platform compatible with standardized M6 threaded inserts—facilitating rapid interchange of custom fixtures for varying terminal geometries, wire gauges (AWG 30–8), and connector housings.
Sample Compatibility & Compliance
The HY-0530UJJ accommodates specimens ranging from ultra-fine insulated wires (Ø0.1 mm) to multi-pin modular connectors (up to 35 mm width). Its 300 mm effective stroke supports standard crimp-pull configurations per SAE J2223, USCAR-21, and GMW3172 specifications. The system meets mechanical safety requirements per EN ISO 12100 and incorporates dual hardware/software emergency stop logic. Data acquisition adheres to 21 CFR Part 11-compliant software architecture—including electronic signatures, user-level access controls, immutable audit trails, and timestamped raw data export (CSV, XML, PDF). Calibration certificates are traceable to CNAS-accredited national standards.
Software & Data Management
The included Hengyi TestMaster™ v4.2 software enables method-driven test sequencing, real-time curve overlay, statistical batch analysis (mean, SD, CV%, min/max), and automated pass/fail evaluation against user-defined limits. All raw data—including analog sensor outputs, encoder pulses, and thermal drift compensation logs—are retained with metadata (operator ID, sample ID, environmental temperature/humidity tags). Reports conform to ISO/IEC 17025 documentation standards and support configurable templates aligned with internal QA workflows or customer-facing PPAP submissions.
Applications
- Crimp retention force verification for automotive wire harness terminals (Fakra, HSD, USCAR)
- Connector mating/unmating force profiling under controlled displacement rates
- Adhesive bond strength assessment of LED lamp bases and PCB-mounted components
- Peel resistance measurement of heat-shrink tubing and insulative sleeving
- Quality gate screening of incoming connector lots prior to SMT assembly
- Failure mode analysis via load–displacement curve morphology (e.g., brittle vs. ductile failure onset, yield point identification)
FAQ
What standards does the HY-0530UJJ support for terminal pull testing?
It supports test protocols referenced in USCAR-21 Rev. 5, SAE J2223, and ISO/IEC 60512-2-1—particularly for crimp validation at defined crosshead speeds and displacement thresholds.
Can the system be integrated into an existing MES or LIMS environment?
Yes—via TCP/IP or RS232 serial API, enabling bidirectional communication for job dispatch, result ingestion, and equipment status monitoring.
Is third-party calibration certification available?
Certified calibration services—including as-found/as-left reports traceable to NIM (China National Institute of Metrology)—are offered through authorized Hengyi service centers.
Does the software support multi-user role-based permissions?
Yes—administrator, technician, and reviewer roles enforce separation of duties per GLP/GMP Annex 11 requirements.
What is the recommended maintenance interval?
Preventive maintenance is advised every 12 months or after 5,000 test cycles, including ball screw lubrication, load cell zero-drift verification, and encoder alignment check.
