How To Detect And Prevent The Failure Of Automobile Wiring Terminals

How to prevent screening of automobile terminal blocks.

In order to ensure the quality and reliability of the car connection terminal and prevent the occurrence of the above failures, it is recommended to study and formulate the corresponding screening technical requirements according to the technical conditions of the product, and carry out the following targeted reliability tests to prevent failure.

1. Prevent bad exposure.

1) Guided detection.

Ordinary automobile terminal manufacturers do not have this product acceptance test, and users generally have to conduct a continuity test after installing the machine. Therefore, it is recommended that the manufacturer should add 100% point-by-point conduction test to some key models.

2) Instantaneous detection.

Some connection terminals are used in dynamic vibration environments. Tests have shown that simply checking whether the static contact resistance is qualified cannot guarantee the reliability of the contact in a dynamic environment. Since the connectors that often have contact resistance will still be powered off when undergoing vibration, shock and other simulated environmental tests, it is best to perform dynamic vibration tests on certain terminals that require high reliability. , Assess its contact reliability.

3) Single-hole separation force detection.

The single-channel separation force refers to the separation force of the contact member in the inserted state from stationary to moving, which is used to characterize the contact between the plug and the socket. The test shows that the separation force of a single hole is too small, and there is a possibility of impact load when subjected to vibration. The single-hole component force method is used to test the contact reliability and the effectiveness of the contact resistance. The contact resistance measurement is often still qualified if the single hole is found to be too poorly separated from the jack. For this purpose, in addition to developing a new generation of stable and reliable contacts for flexible plug contacts, manufacturers should not use automatic plug force testing machines for multi-point simultaneous testing on key models, and perform 100% point-by-point testing of finished products. Check points to prevent instantaneous signal interruption of individual key models.

2. Prevent poor insulation.

1) Insulation material inspection.

The quality of the raw materials is good, which has a great influence on the insulation performance of the insulator. Therefore, the choice of raw materials is particularly important. You should not blindly reduce costs and lose material quality. You should choose raw materials from a reputable manufacturer. And for each batch of materials, you must carefully check the inspection batch number, material certification and other important information. Do a good job. Traceability information on material use.

2) Insulation resistance inspection of insulators.

By 2012, some production factories had process regulations that required electrical performance inspections after the assembly was completed. As a result, the insulators themselves had unqualified insulation resistance and could only be scrapped. A reasonable process should be 100% process screening of the insulator components to ensure that the electrical performance is qualified.

3. Prevent discomfort.

1) Interchangeability test.

Exchange inspection is a dynamic inspection. It is obtained that the plugs and sockets of the same series can be inserted and connected to each other, and find out whether they cannot be inserted due to the insulation, contact parts and other parts are too large, missing parts, or improper assembly. Positioning and locking, even being rotated Disintegration under the action of force. Another function of the interchangeability test is to detect whether there is excess metal in time through the thread. Bayonet and other plug-in connections, which affects the insulation performance. Therefore, 100% inspection should be carried out for some important-purpose automobile terminal blocks to avoid such serious fatal failure accidents.

2) Torque resistance test.

Torque test is a very effective test method to test the reliability of automobile terminal structure. According to the requirements of the US military standard MIL-L-39012, samples should be taken from each batch for durability torque inspection according to the standard, and problems can be found in time.

3) Carry out a comprehensive measurement of the crimping wire.

It is often found during electrical installation that individual core-pressing wires are not delivered in place, or locked after delivery, and the contact is unreliable. There are burrs or dirt on the threads of the individual mounting holes, causing seizure. Especially when the factory uses electricity to install the last few mounting holes of a plug socket, after discovering such a defect, the other crimped wires that have been installed have to be removed one by one and replaced. In addition, due to the unreasonable selection of wire diameter and crimping aperture, or due to incorrect operation of the crimping process, the indenter may also be weak. Therefore, before the finished product leaves the factory, the manufacturer must conduct a comprehensive inspection of all the mounting holes of the delivered plug (base) sample, that is, use the unloading tool to simulate the push-in or plug-in wire into place to check whether it is locked. According to the requirements of the product specification, the pull-off force of the crimped wires is tested one by one.