1) conduction detection
At present, there is no such item in the product acceptance test of general terminal manufacturers, but users generally need to conduct continuity test after installing equipment. Therefore, it is suggested that manufacturers improve the point-by-point conduction detection of some key models by 100%.
2) Instantaneous open circuit detection
Some terminals are used in dynamic vibration environment. Experiments show that only checking whether the static contact resistance is qualified can not guarantee the reliability of contact in dynamic environment. As the connectors with qualified contact resistance often experience instantaneous power failure when conducting vibration, impact and other simulated environmental tests, it is best to conduct 100% dynamic vibration test for some terminals with high reliability requirements to evaluate their contact reliability.
3) Single-hole separation force detection
Single-hole separation force refers to the separation force that the contact in the inserted state changes from static to moving, which is used to characterize the contact between the pin and the socket. Experiments show that the single hole separation force is too small, which may cause the signal to break instantly when it is subjected to vibration and impact load. It is more effective to check the contact reliability by measuring the single hole separation force than to measure the contact resistance. It is found that the contact resistance of the socket with poor single-hole separation force is often still qualified. Therefore, in addition to developing a new generation of flexible plug-in contacts with stable and reliable contact, manufacturers should not use key models of automatic plug-in force testing machines for measurement at the same time, and should check the single-hole separation force of finished products point by point at 100% to prevent the signal from being interrupted instantly due to the relaxation of individual jacks.
2. Prevent poor insulation
1) Insulation inspection
The quality of raw materials has a great influence on the insulation performance of insulators. Therefore, the choice of raw material manufacturers is particularly important. We can't blindly reduce the cost and lose the quality of materials. We should choose materials from reputable manufacturers. For each batch of materials, important information such as batch number and material certificate should be carefully checked and checked, and traceability information of material use should be made well.
2) Insulator insulation resistance inspection
At present, some manufacturers stipulate that electrical properties should be tested after assembly into finished products. As a result, because the insulation resistance of the insulator itself is unqualified, the whole batch of finished products will be scrapped. The reasonable process should be to screen 100% in the state of insulator parts to ensure the electrical performance is qualified.
3. Prevent poor fixation
1) interchangeability check
Interchangeability check is a dynamic check. It requires that plugs and sockets of the same series can be plugged into each other, and it can be found out whether there are any parts that cannot be plugged, positioned and locked because of the size error of insulators, contacts and other parts, missing parts or improper assembly, or even disintegration under the action of rotating force. Another function of interchangeability inspection is to find out whether there is any metal surplus that affects the insulation performance in time by inserting threads, bayonet, etc. Therefore, this project should check some important terminals of 100% to avoid such fatal accidents.
2) Torque resistance inspection
Torsion test is a very effective test method to evaluate the reliability of terminal structure. For example, MIL-L-390 12 stipulates that according to the standard, each batch of samples should be sampled for torsional inspection, and problems should be handled in time. For more information, please visit the transmission and distribution equipment network.
3) Overview of Crimping Conductors
In electrical installation, it is often found that individual core wires are not sent in place, or they cannot be locked after being sent in place, and the contact is unreliable. The reason is that there are burrs or dirt on the screw teeth of individual installation holes. In particular, the user's factory installed the last few installation holes of a plug socket. After discovering the defects, he had to remove the crimped wires of other holes that had been installed one by one and replace the plugs and sockets again. In addition, the crimping end will be unstable due to improper selection and matching of wire diameter and crimping aperture, or improper operation of crimping process. Therefore, before the finished products leave the factory, the manufacturer should make a general survey of all the installation holes of the delivered plugs (sockets), that is, use the loading and unloading tools to simulate the placement of wires with pins or sockets to check whether they can be locked. According to the technical requirements of the product, check the pull-off force of the crimping wires one by one. Without a reliable terminal, there is no reliable system engineering. Failure and reliability are two aspects of a corresponding and interrelated contradiction. Through the reliability screening of the terminal, various failure modes and failure mechanisms are found, which can draw a lot of lessons and eliminate various hidden dangers, provide scientific basis for improving design, technology, inspection and use, and also provide an important basis for revising and formulating terminal technical conditions. The ultimate goal of failure analysis is to find measures to prevent failure and realize the transition from failure to reliability.
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