Explanation on the quality and reliability testing of terminal wires:

In order to ensure the application quality and safety factor of the terminal wire and prevent the occurrence of redundant common faults, it is proposed that according to the technical standards of the products, scientific research should formulate relative technical standards for selection, and carry out purposeful reliability testing to prevent invalidity.

1. Prevent bad contact

1) Instantaneous interruption test

Some terminals are used in dynamic vibration environments. Experiments have confirmed that only detecting whether the static data loop resistance meets the standard cannot ensure that the application touch is reliable in a dynamic natural environment. Because the RF connector with the circuit resistance up to the standard usually turns off the power supply momentarily during the simulation of natural environment experiments such as vibration and shock, it is best to be able to 100 Ω for some terminals with high reliability requirements. % to carry out dynamic vibration experiments to evaluate its touch reliability.

2) Double hole separation force test

The separation force of the double holes refers to the separation force of the contact piece in the insertion state from being stationary to the fitness movement, which is used to qualitatively analyze that the needle insertion and the socket have touched. Test description: The separation force of the double holes is too small, which may cause the data signal to be interrupted instantaneously when subjected to vibration and impact loads. It is more reasonable to check the reliability of the touch by measuring the separation force of the double holes than to measure the resistance of the loop. Check the sockets where the force deviation of the double-hole separation is detected, and the accurate measurement of the loop resistance is usually still up to standard. Therefore, in addition to developing a new generation of soft plug-in contacts with stable and reliable touch parts for new products, manufacturers do not solve the problem of using automatic plug-in force testers for key models and specifications. The product carries out a 100% step-by-step double-hole separation force inspection to avoid the instantaneous interruption of the data signal due to some socket slack.

3) On-off inspection

At this stage, there are no new items in the commodity engineering acceptance test of general terminal wire manufacturers, and customers must generally carry out on-off inspection after one-click installation. Therefore, it is suggested that manufacturers should increase the step-by-step on-off inspection by 100% for some key models and specifications.

2. Prevent poor insulation

1) Conductor and insulator grounding resistance inspection

At this stage, some manufacturers require the processing technology to assemble the finished product and then test the electrical performance. As a result, because the grounding resistance of the conductor and the insulator itself is not sufficient, only the whole batch of finished products can be damaged. The effective processing technology should be 100% of the processing technology selection in the case of conductors and insulator parts to ensure that the electrical performance is up to standard

2) Insulation layer material inspection

The quality of raw materials has a great impact on the dielectric strength of conductors and insulators. Therefore, the selection of raw material manufacturers is particularly critical, and the quality of raw materials cannot be blindly controlled by controlling costs. Large-scale factory raw materials with good reputation should be selected. For each raw material finished product inspection, it is important to carefully check the production batch number, material certification, etc. Information. Do a good job of retrospective materials for raw material applications.

3. Prevent poor fixation

1) Torque resistance inspection

Torque resistance test is a very reasonable test method to evaluate the reliability of the terminal wire structure. For example, the US military standard MIL-L-39012 standard. According to the specification, test samples should be taken to carry out torque resistance inspection every time, and problems should be dealt with in time. Please log in: Power Transmission and Transformation Equipment Network to access other information

2) Exchange check

A commutative check is a dynamic check. It stipulates that the same series of matching power plugs and power sockets can be connected to each other. From this, it is found that there is no reason for the deviation of conductors, insulators, contact parts and other parts specifications, missing parts or untimely installation, etc. Fitting, precise positioning and clamping, and even lead to disintegration under the action of rotating force. Another function of the exchangeability inspection is whether there are unnecessary metal materials that cause damage to the dielectric strength according to the insertion and connection of external threads, interfaces, etc. Therefore, 100% of the terminal wires for some key and main purposes should be inspected for this new project to prevent such major fatal and ineffective safety accidents.

3) General test of socketed transmission lines

In the electrical installation, it is often found that some core crimping power lines are not delivered in time, or cannot be locked after being sent to the position, and the touch is not reliable. The reason for analysis is that some mounting holes have burrs or stains on the screws. Mostly, the application factory has installed many installation holes in a power plug socket. After finding the defect, you can only unload the other installed holes to crimp the power lines one by one, and then replace the power socket again. In addition, due to the poor cooperation between the selection of the wire diameter of the transmission line cable and the socket diameter, or because of the wrong operation of the socket processing process, it will continue to cause safety accidents of weak crimping ends. Therefore, the manufacturer should conduct a thorough test on all the installation holes of the test product of the power plug (socket) supplied before the finished product is original, that is, use a special tool for loading, unloading and handling to simulate the power line connected with the pin or socket. Send it to the position and check whether it can be locked. According to the requirements of the technical standards of the commodity, the pull-off force of the socketed transmission lines shall be checked one by one.

Without reliable terminals, there is no reliable automatic control. Ineffectiveness and reliability are two levels of a contradiction that should be relativistic and interconnected. According to the reliability selection of terminal wires, various failure modes and invalid principles can be found, which can lead to many successful experiences and eliminate various safety hazards. It is also an important link in revising and formulating technical standards for terminal wires. Finding countermeasures to prevent ineffectiveness and completing the transformation from ineffectiveness to reliability is the final goal of failure explanation.