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What are the common failures of the terminals? How to prevent is the key!

  • DATE:2018/4/14 15:26:18

What are the common failures of the terminals? How to prevent is the key!


The connection terminal is an accessory product for realizing electrical connection. It is divided into connectors in industry. With the increasing degree of industrial automation and the strictness and accuracy of industrial control requirements, the demand for terminal is gradually increasing.

From the perspective of usage, the connection terminal should achieve the following functions: the contact part must be connected and the contact must be reliable. Where the insulation part should not be connected, the insulation must be reliable.



There are three fatal failure modes of terminals:

1. Poor contact

Due to unreasonable structure design of contact parts, improper selection of material, unstable mold, super poor processing size, rough surface, heat treatment electroplating, improper surface treatment technology, improper assembly, bad storage and use environment and improper operation, will cause contact defects in contact parts and fit parts of contact parts.

2. Poor insulation

Due to the presence of multiple metal residues in the insulator surface or inside, surface dust, flux and other pollution are damp, the precipitation of organic materials and the adsorption film of harmful gas and surface water film form the ionic conductive channel, which can cause short circuit, leakage, breakdown and low insulation resistance. Bad luck.

3, poor fixation

Due to material, design, technology and other reasons, the abnormal separation between the plug and socket caused by the unreliable structure of the plug and socket will result in the serious consequences of the power transmission and signal control interruption of the control system.

Due to unreliable design, wrong selection of material, improper selection of molding process, poor quality of heat treatment, die, assembly and welding, and so on.

In addition, due to the skin, corrosion, bruising, plastic shell flying edge, rupture, contact parts processing rough, deformation and other causes of the appearance of bad appearance, due to positioning locking with the size of super poor, poor quality of processing, excessive total separation force and other causes of poor interchangeability, is also a common disease, frequently occurring disease. These faults can be found out in time in the process of inspection and use.



In order to ensure the quality and reliability of terminal terminals and prevent the occurrence of the problems mentioned above, it is suggested that according to the technical conditions of the product, the corresponding screening technical requirements are studied and formulated, and the following pertinent reliability inspection of prevention failure is carried out.

1, prevention of poor contact

1) conduction detection
There is no such item in the product acceptance test of the general connection terminal manufacturer, and generally needs conduction test after installing the machine. Therefore, it is suggested that manufacturers should increase 100% of point-to-point detection for some key products.

2) transient detection
Some wiring terminals are used in dynamic vibration environment. It is proved by experiment whether the static contact resistance is qualified or not, and the contact reliability in dynamic environment can not be guaranteed.

Because often contact resistance connectors in the vibration, impact and other simulated environmental tests still appear instantaneous power failure phenomenon, so some of the high reliability terminals, the best can be 100% of its dynamic vibration test to assess the contact reliability.

3) single hole separation force detection
The single hole separation force refers to the separation force from the static state to the moving contact, which is used to characterize the contact between the pin and the socket.

The experiment shows that if the separation force of single hole is too small, it will cause signal transient when subjected to vibration and impact load. It is effective to measure contact reliability by measuring single hole separation force than measuring contact resistance. It is found that the contact resistance is often qualified by checking the hole with a single hole separation force.

Therefore, in addition to developing a new generation of flexible intercalation contact and stable contact parts, the production plant should not use the multi point test of the automatic pulling force test machine for the key model, so that 100% of the point by point single hole separation force check for the finished product should be carried out to prevent the flash of the signal caused by the relaxation of the individual Jack.

2, prevention of poor insulation

1) inspection of insulating materials
The quality of raw materials has great influence on insulation performance of insulators. Therefore, the selection of raw material manufacturers is particularly important. We should not blindly reduce costs and lose material quality. We should choose reputable Dachang materials. And for each batch of materials, check the inspection lot number, material proof and other important information carefully, and make good use of the traceability material.

2) insulators insulation resistance inspection
By 2012, some of the production plant's technical regulations were assembled into finished products, and the electrical properties were detected. As a result, the insulation resistance of the insulators was not qualified, and the whole batch of finished products had to be scrapped. The proper process should be to screen the process on insulator part 100% and ensure the electrical performance is qualified.

3, prevention of immobilization

1) interchangeability check
Interchangeability examination is a dynamic check. It requires that the same series of plugs and sockets can be intercalated with each other. It is found that there is no intercalation, positioning and locking, or even disintegration under the use of rotating force, because of the oversize of the insulators, contact parts and other parts, and the lack of parts or assembly.

Another function of interchangeability inspection is to find out whether there are metal residues that affect insulation performance in time. Therefore, some important use terminals should be checked by 100% to avoid such fatal fatal accidents.

2) inspection of torque resistance
Torque tolerance inspection is a very effective method to check the reliability of terminals. For example, the US military standard MIL-L-39012 standard. According to the standard, every batch should be sampled for endurance test.


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