Views: 40 Author: Site Editor Publish Time: 2019-09-03 Origin: Site
Failure of any electrical connector will lead to failure of the whole system engineering. In order to ensure the quality and reliability of wire connectors and prevent some fatal faults, it is suggested that according to the technical conditions of products, relevant screening technical requirements should be studied and formulated, and the following targeted reliability tests for failure prevention should be carried out.
(1)Conduction Detection
In 2012, the product acceptance test of the general electrical wire connector manufacturer did not have this item, and the user generally needs conduction testing after installation. Therefore, it is suggested that manufacturers should increase the point-by-point conduction detection for some key types of products.
(2)Instantaneous Detection
Some cable connectors are used in dynamic vibration environment. Experiments prove that only checking the static contact resistance is qualified can not guarantee the reliability of contact in dynamic environment. Because the connector with qualified contact resistance still breaks down instantaneously when it is tested in the simulated environment such as vibration and impact, it is better to test its contact reliability by dynamic vibration test.
(3)Single-hole Separation Force Detection
The single-hole separation force refers to the separation force in which the contact member in the engaged state changes from static to moving, and is used to indicate that the pin and the jack are in contact. Experiments show that the single-hole separation force is too small, which may cause signal transients when subjected to vibration and shock loads. It is effective to check the contact reliability by measuring the single hole separation force to measure the contact resistance. Inspection found that the single hole separation force is too poor, the measured contact resistance is still qualified. To this end, in addition to the development of a new generation of flexible plug contacts with stable and reliable contact parts, the production plant should not use the automatic insertion force tester for multi-point measurement of key models. Single-hole separation force inspection should be carried out for finished products, so as to prevent signal interruption due to the relaxation of a jack.
(1)Inspection of Insulating Material
The quality of raw materials has a great influence on the insulation performance of insulators. Therefore, the selection of raw material manufacturers is particularly important. Manufacturers should not blindly reduce the cost and lose the quality of materials. They should select large-scale materials with good reputation. What's more, they should carefully check the important information such as batch number, material certification and so on for each batch of materials.
(2)Inspection of Insulation Resistance
Some factories require that the electrical performance be tested after the finished product is assembled. As a result, the insulation resistance of the insulator itself is not up to standard, so the whole batch of finished products have to be scrapped. Reasonable process should be 100% process screening in the state of insulator parts to ensure that the electrical performance is qualified.
(1)Interchangeability Inspection
Interchangeability checks requires that the same series of plugs and sockets can be mated to each other. It can be found whether there are some reasons, such as the size of insulators, contacts and other parts are out of tolerance, missing parts or assembly is not in place, which can not be inserted, positioned and locked. Another function of interchangeability check is to find out whether there are metal redundancies affecting insulation performance by inserting and connecting threads and clamps. Therefore, the small wire connectors for some important purposes should be checked to avoid such major fatal failures.
(2)Endurance Torque Inspection
Endurance torque inspection is a very effective method to check the reliability of electrical connector structure. As stipulated in the US Military Standard MIL-L-39012, each batch of samples should be sampled according to the standard for endurance torque inspection to detect problems in time.
(3)Measurement of Crimped Conductors
When installing, it is often found that the individual core crimping wires are not in place, or cannot be locked after being sent to the position, and the contact is unreliable. The reason for the analysis is that there are burrs or dirt stuck in the screw holes of the individual mounting holes. Especially when using the last few installation holes that the factory has installed into a plug seat, after discovering the defect, we have to remove all the other holes that have been installed and replace the plug seat one by one. In addition, due to the improper matching of the wire diameter and the crimping aperture, or due to the operation of the crimping process, the crimping end is not secure. For this reason, the manufacturer should check all the installation holes of the sample of the delivered plug (seat) before the finished product leaves the factory. That is to say, the wire with pins or sockets by loading and unloading tools to check whether it can be locked. And according to the technical requirements of the product, the pull-out force of the crimping wires is checked one by one.
Without reliable electrical connectors, there can be no reliable system engineering. Through the reliability screening of electrical connector, various failure modes and failure mechanisms can be found. A lot of experience and lessons can be drawn and hidden dangers can be eliminated. It provides a scientific basis for improving design, process, inspection and use. It is also an important basis for revising and formulating technical conditions of electrical connector. The ultimate goal of failure analysis is to find measures to prevent failure and realize the transformation from failure to reliability.