In the field of electric vehicle (EV) charging piles, the electrical and mechanical connection between a wire and a connector is crucial for ensuring the normal operation of high-current appliances. This study employs finite element numerical analysis and experimental testing to investigate the optimization of crimp terminal assemblies and their tensile strength in the manufacturing line of charging piles. Firstly, finite element method is used to simulate the compression process and tensile behavior, then a detailed mathematical model is established, considering the contact, friction, material nonlinearity and other factors, a multi-step analysis method is designed to improve the simulation efficiency. Secondly, the crimping force and tensile force under different crimping heights are experimental tested. The results show that the numerical analysis results are in good agreement with the experimental results, the relative error is between 1.78% and 1.4%, which verifies the high computational accuracy of the numerical model. The model not only significantly reduces the training time of the crimp machine in the manufacturing line, but also reduces the material waste by 74%. In addition, the number of physical tests and the cost of machine training are significantly reduced. The research provides guidance for the construction of machine training data for subsequent structures and lays a foundation for the accurate manufacture of charging pile connection crimp terminals.