What are the problems that automobile wiring harness often appears?

Automobile wire harness refers to the component of the connecting circuit formed by a wire harness, which is formed by pressing the contact terminals made of copper and crimped with wires and cables.

Hulk insulator or metal hulk is applied outside and bundled with a wire harness. In practical application, the automotive wiring harness is easy to causes extreme safety problems once failure occurs due to high use intensity, bad working environment, substandard production quality and other problems. So the use of an automotive wiring harness is prone to what problems?

 

The cable bundle is worn

 

The cable bundle is worn

Automobile movement will inevitably be jolted, especially chassis wiring harness, wear risk is relatively large. When the friction breakdown down the wire harness and suspension, it will cause lashings, resulting in the failure of the electronic stability system.

 

Wire feed water

If the sealing process is not properly controlled in the production of the harness, the body control module (BCM) or the wiring harness at the connection between the BCM and the body a-pillar may be damaged due to water inflow.

 

Environmental reliability testing equipment

 

Burnt and ablated wire harness

For the automobile, such as installed in the engine, exhaust pipe, water pipe and other heat sources near the wiring harness, often due to the lack of a clip fixed and burned, scorched, resulting in electrical equipment failure, eventually cause spontaneous combustion.

 

Poor wire harness contact

The bad connector of wire harness assembly is a common failure mode of the engine wire harness. Too many bad contact problems occur in the connector, such as poor sheath quality: poor assembly process, unreasonable coating setting, terminal oxidation is one of the reasons. Poor wiring harness contact does not appear to be fatal. But the pitfalls are many, and it’s easy to detract from the experience. Things like headlights not coming on, engines not starting, glass lifters not working, can be caused by it.

 

Wire harness fracture

 

Wire harness fracture

Wire harness fracture is a common fault model of automobiles, and the reasons can be simply listed as: the branch design of wire harness is too short, the manufacturing of wire harness is not standard, and the wire harness is twisted during assembly. Because some line speeds are subject to warping, this kind of fracture risk is often difficult to avoid.

 

Wire feed water

 

Zhejiang Lianhe Electronics Co., LTD., specializing inline production line, board to board, the line to board, automobile connector, wire harness and other products, welcome to visit our official website https://www.lhecn.com/contact-us/ for inquiry

Wire harness connector salt spray test according to standard

The necessity of salt spray testing for wiring harness connectors.

Whether for harness accessories such as connectors, terminals, buckles, or harness assemblies, DV testing cannot bypass salt spray testing.

When a car or truck is walking, the location of the wire harness connector may come into contact with water splashing on the tires, especially after snow in the northern winter, when salt is used to speed up the melting of snow on the road. These connectors usually require salt spray testing to verify corrosion resistance.

The standard for wire harness salt spray test validation

The standard for wire harness salt spray test validation is to check the reliability of contact resistance, not the appearance. These connectors are often used with sealing rings to improve salt spray resistance.

Wire harness connector salt spray test according to standard

IEC 60068-2-11:1981 Environmental testing of electrical and electronic products — Part 2: Test Methods — Ka: W fog test method

IEC 60068-2-52:2017 Environmental tests – Part 2: Test Methods – Kb: Salt spray, alternating (sodium chloride) solution

IEC 60068-2-52:2017 Environmental tests - Part 2

GB/T 2423.18-2012 “Environmental testing — Part 2: Test methods — Kb: Salt spray, alternating petulant sodium) solution”

GB/T 2423.18-2012 "Environmental testing -- Part 2

Which connectors need to be salt – oligonucleated?

Salt spray environment is mainly used for military, special vehicles and marine applications. Generally, salt spray tests are carried out in a salt spray chamber with 5% salt solution and the exposure time is 48-96 hours.

Salt spray is highly corrosive to many materials and has been proven to cause the failure of many connector coating systems, both precious and non-precious metal coatings. If the salt spray is used, connectors intended for use in the application environment will fail during the test.

The purpose of salt spray testing is to evaluate the performance of a product, not to damage it. Salt spray tests are suitable for connectors in Marine environments. The properties of the salt spray tests are appearance detection, weight detection and resistance measurement.

Which products do not need to be tested for salt spray

Which products do not need to be tested for salt spray?

For protected areas of vehicles (e.g. carriages), there is no need to conduct salt spray testing in such environments. In these applications, for noble metal plating applications, the common failure mechanisms are pore corrosion and corrosion screw change, which are evaluated by MFG (HCI, SO2, H2S, etc. Mixed gas flow) tests.

For the contact interface of non-precious metal coatings, the primary failure mechanism is fretting corrosion, which was assessed by vibration and high-frequency temperature and humidity cycling tests.

Connector terminal tinning product salt spray test

Many enterprises use salt spray for incoming inspection of connector terminal tinned products, and to monitor their appearance.

The connectors tested may not be exposed to salt or Marine environments at all, and the products are likely to be installed in a protected environment where the use of salt spray testing does not demonstrate consistency with the actual application.

Connector terminal tinning product salt spray test

There is a layer of oxide film on the surface of tin plating products, and the main failure mechanism is fretting corrosion after coordination. In this case, the salt spray test has no relationship with its failure mechanism.

Even if the oxide layer on the surface turns black after the salt spray test, in practical use, the matching terminal can easily remove the oxide layer and contact the pure tin inside to form a gold connection.

Salt spray tests have no acceleration factor, and salt spray past 48 hours is not indicative of how many years the product will last under certain conditions.

Environmental reliability testing equipment

Environmental reliability testing equipment is widely used in the level from raw materials, components, to the level of a circuit board/module, water heater products such as electronics, electrical appliances, power of constant temperature, constant humidity and temperature changes. 

It also applies to salt fog test, the mixed gas test, ozone ageing test, UV ultraviolet accelerated ageing test, lamp ageing test, sulfur dioxide corrosion test, high Air low-pressure test, IPX1 ~ 8 waterproof rank test, dust/sand dust test, drop test, combustion test, a half-sine wave/trapezoidal acceleration shock test, sine/random vibration test, collision simulation test, drop test, the tensile strength test, fatigue test, the test and highly accelerated life test screening machinery, mechanical stress and environment, climate environmental testing and the integrated environment Pilot project.

How to buy auto connector wiring harness

If you currently need to purchase automotive terminal harness products, or in the future also need to understand the relevant procurement knowledge, let us introduce how to buy for you.

What materials are available

First of all, we need to understand what the material of the car terminal wire harness is, generally aluminium and copper. The difference is that aluminium is lighter but less durable, while copper is heavier but more durable. Depending on the application you need and the appropriate current intensity, some devices may only use terminal wires made of one material.

What materials are available

What types of insulation are available

Automotive terminal wires can often be made of PVC insulation or “crosslinked” insulation because the material is extruded under heat and pressure, changing the molecular structure and allowing it to withstand higher temperatures. Crosslinked insulation is generally more durable, while PVC insulation will be more cost-effective.

Fully understand the electrical wiring used in the equipment. Because cross-linked wires should be used for extremely high-temperature applications such as engine nacelles, PVC insulated wires can be used for general applications.

What types of insulation are available

Which welding method should be selected

Terminals usually have two types of connections, welding and non-welding. The weldless connection quickly disconnects terminals and connectors. This means that for all applications, weldless connections are not too strong, and although weldless connections take longer to complete, they provide a strong connection.

Which welding method should be selected

Cable selection

The longer the wire is required for general applications, the more current needs to flow, the lower the wire specifications. Before purchase, the required terminal cable parameters and specifications should be clear. It is recommended to check the thicker wire side as far as possible to avoid inferior products.

Cable selection

How about, after reading these 4 points, I believe you have a closer understanding of the automobile terminal harness, if you have any questions about the automobile harness contact us at any time.

How to identify the quality of automobile connector terminal copper joint

Under different environmental conditions, it is a trick to choose the appropriate copper joint automobile wiring terminals. Basically, it is ok to master the following points.

Before determining the automobile wiring terminal, we should first make clear what kind of terminal is needed, as according to the functional classification of the terminal, there are ordinary terminal, insurance terminal, test terminal, grounding terminal, etc;

According to the current classification, there are common terminals, high current terminals; According to the appearance classification, can be divided into rail terminal fixed terminal circuit board terminal.

automobile connector terminal copper joint

What needs to be considered is the size of the terminal connection of the automobile connector. For different copper joints, the size and wiring range are not the same. In general, when terminals are needed, it is better to choose a wiring range slightly larger than the actual wire diameter.

Why is that? , the current market standard is quite chaotic, if you choose the same size of wiring aperture and wire diameter, then it may be because the market does not meet the standard production of terminals leading to a smaller wiring range and can not be inserted into the wireframe.

automobile connector

Please pay attention to the impact of the current, for the guide terminal, this has existed in the market for decades of products, the industry is regulated for the current, different models have specific current specifications, the product must meet the standard or exceed the standard.

the impact of the current

Finally, attention should be paid to the size of the space used. For different space sizes, different automobile terminals can be selected, such as double-layer terminals or three-layer copper joints can be selected in a narrow space.

double-layer terminals

After reading this article, I hope to help you avoid bad products when choosing automobile connector terminals. Zhejiang Lianhe Electronics Co., LTD., the main production line of line connector, the line to board connector with the board to board connector, if you have any need, welcome to visit our official website, contact our business inquiry

6 New Trends in Connector Development

Now any industry needs innovation for its own development, and the connector industry is no exception. In order to make the product more convenient to use and carry, how to produce smaller, lighter and more intelligent connectors is a problem that enterprises need to consider.

Six new trends in connector development

Traditional connectors need to achieve three major performances, namely mechanical performance, electrical performance and environmental performance.

In addition to the above basic requirements, the new application market also has new requirements for connectors. That is, the new connector is smaller in size, higher in reliability, and stronger in wireless performance.

It has a certain intelligence, which is the new market demand. For enterprises, connectors can only grasp new market opportunities if they meet such requirements.

Traditional connectors

High frequency and high speed connector technology

In many 5G communication applications, connectors carry the transformation of optical and electrical signals. With the coming of the 5G Internet era, the high data and high transmission requirements of 5G are destined to require the performance upgrade of connectors, and the high frequency and high speed characteristics have become a new requirement.

High frequency and high speed connector technology

Connector Development for wireless transmission

In the era of the Internet of Things, wireless technology will also be everywhere. In addition to realizing contact connection like before, connectors will also be a guarantee to ensure wireless transmission connection in many occasions such as industry and automobile in the future. After all, double protection is the safest.

Smaller and more convenient connector technology

Previous connectors were used for many contacts, packed into many expansion card slots. Of course, in the 5G era, there may be dozens of connectors in a single fiber optic device, which requires smaller connectors for higher performance connections. 

Smaller and more convenient connector technology

More accurate, lower cost connector technology

Due to the very high safety requirements of automobiles, automotive connectors are a very large market. With the development of electric vehicles, the requirements for connectors in terms of precision and cost will be higher.

More accurate, lower cost connector technology

More intelligent connector technology

With the advent of the Al era, the connector may be more than a simple transmission function. In addition to ensuring the data of electrical signals in the future switching power supply, the connector can also simply perform intelligent judgment and protection. To avoid power damage while outputting correct data, of course, this requires the support of IC technology.

More intelligent connector technology

Automatic production technology of connectors

In the traditional connector design and production, the main part of the manual, and with the development of industrial automation, especially the connector precision processing, abrasive and CAD, these advanced machines will become the main force of the industry.

Analysis of Connectors Uneven Electroplating

Many connectors need to be electroplated, but some will be uneven after electroplating. Let’s analyze the Connectors Uneven Electroplating.

Connectors Uneven Electroplating

Uniformity of Cathode Metal Coating Distribution

This is an important factor to determine the quality of the coating. In electroplating production, people always hope to get a uniform coating on the surface of the plated parts.

The function part of the jack contact in the connector is the inner surface of the jack. If the coating on the inner and outer surface of the plated parts can be uniformly distributed, the production cost can be reduced to the maximum.

But in fact, no matter what kind of plating solution is used, there is always the phenomenon of uneven coating thickness.

the metal coating distribution on the cathode

During electroplating, the amount of material precipitated at the cathode is proportional to the amount of electricity flowing through the electroplating solution (electrolyte solution).

From this point of view, the coating distribution of the surface part depends on the current distribution on the surface cathode. As a result, all factors that affect the current distribution on the cathode surface will affect the distribution of the coating on the cathode surface.

In addition, in the electroplating process, the reaction on the cathode is often not simple metal precipitation, but also accompanied by a chlorine reaction or other side reactions. It can be analyzed that the coating distribution is also affected by the coating properties.

In the daily production of contact gold plating, it is found that the uniformity of the coating distribution on the cathode is not only related to the properties of the solution, but also closely related to the shape of the plated part, the choice of the coating method, and the choice of the coating.

During electroplating

Connectors Uneven Electroplating——Current Density

Any plating solution has a range of current densities to obtain a good coating. When the current density exceeds the upper limit value of the process range in the electroplating process, coarse crystal particles are often formed. So the coating obtained under the operation of low current density is more delicate.

For rolling gold plating or vibrating gold plating, a good coating can be obtained when the mass concentration of gold inking gold plating solution is low (generally 2~6 g/L) and the current density is between 0.1 ~ 0.4 A/dm2.

However, when the upper current density is used, [Au(CN)2]- near the cathode will be lacking. It will result in an increased chlorine reaction on the cathode and the current efficiency will be reduced.

Therefore, the production time of electroplating with 0.2a /dm2 current density and electroplating with 0.1a /dm2 current density is not A simple multiple relationships.

Current density

In the low-rate plating processes of barrel and vibration plating, if higher current densities are used, the possibility of tipping increases. In vibratory electroplating, the tip effect is more pronounced because the electroplating tip is always facing the anode (the anode ring outside the shaker) throughout the electroplating process.

Plated edges or pins, and socket tips have a thinner coating on the thick and low ends, resulting in an uneven distribution of coating thickness on the surface of the part.

In applications with low-speed gold plating processes, elongated pinhole contacts generally operate at the lower end of the current density range.

In the process

Zhejiang Lianhe electronic Co., Ltd. specializes in the production of all kinds of wire to board connector, board to board connector, wire to wire connector, etc., all kinds of electronic connectors welcome new and old customers to order. Contact us at email [email protected]

Connector Resistance Meaning

Regardless of which connector you use, the terms Connector Resistance or Connector Contact Resistance will appear in the catalog. Both represent the nature of the connector, the ability to “connect correctly”.

Connector resistance meaning

What is Connector Resistance

Connector Resistance refers to “difficulty of current flow”. Large contact resistance in the case of the connector will lead to easy heating. Wasted power consumption will increase, and will occur in the worst case is poor conduction.

In other words, the smaller the contact resistance, the better. This contact resistance depends on three main elements: the terminal material, cross-sectional area of the current path and the length, the resistance of the contact.

 

Contact resistance

 

In the use of the machine, in order to avoid the connection failure caused by the contact resistance of the connector, it is necessary to discuss the use method. For example, when a large current is required, use multiple pins to make the current flow.

 

Contact resistance consists of the following parts

 

Connector Resistance Parts

Concentrated resistance RC

The resistance RC formed when the clean metal surfaces contact each other by applying a certain pressure is called concentrated resistance.

Due to the small contact area of the connector contact area, the current is compressed together when it reaches the contact area, increasing the current density. The resistance generated by this pair is called concentrated resistance.

 

Film resistance RT

 

Film resistance RT

Metal surfaces form thin films on the surface due to adsorbed gases or oxidation or magnetization of the surface or contamination by adsorbed oxides, which tend to be a poor conductor, resulting in high contact resistance.

Such films are applied to frictional breakage under certain pressure and constant voltage, so they will contact each other with tunnel effect, so the resistance Rt is called tunnel resistance

 

The volume resistance Rb

Insulation resistance

The insulation resistance of the connector is “no leakage current between adjacent terminals”. If the insulation resistance is too small, a short current will occur between adjacent terminals. 

Compared with contact resistance, the higher the insulation resistance, the better. The insulation resistance of the connector depends on the spatial distance between adjacent terminals, the material of the forming part, and the distance along the surface.

 

contact resistance refers

 

In connectors, contact resistance refers to the resistance associated with the “connector and connection part”, electrical resistance associated, and insulation resistance refers to the electrical resistance “between adjacent terminals”.

Zhejiang Lianhe electronics Co., Ltd. specializes in the production of all kinds of wire to board connector, board to board connector, wire to wire, row needle row TT horns, and other kinds of electronic connectors welcome to contact us at  email[email protected]

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Introduction and connection mode of Terminal block

Terminal block is an electrical component used to connect lines in electrical equipment. The number of terminals in each row is different. The model can be determined according to engineering technical parameters.

In the electric power automatic connection system, the emergence of terminal blocks can be said to be the daily operation and maintenance personnel’s salvation, terminal blocks simple structure, rich variety, for the electric power partners to provide thousands of glaze speed solutions.

In particular, when the terminal in the connection is short-circuited due to burnout, the advantages of the terminal will appear. After power failure, it can immediately take out the burned terminal replacement of the same type of new products, thus greatly shortening the maintenance time. For general wiring terminals, they are mainly divided into the following connection modes:

screw connection

Screw Connection

Screw connection adopts screw terminal connection, Ampron electronics reminds you to pay attention to the maximum and minimum cross sections of the allowable connecting wire and the maximum tightening torque of different specifications of screws.

welding

Welding

The most common type of welding is tin welding. The most important part of the solder connection is that the metal continuity should be formed between the solder material and the welded surface. So for wiring terminals, cord end terminals, the most important thing is solderability. The most common coating on the welding end of the wiring ring terminal is tin alloy, silver and gold. The common welding ends of the reed contact pair include the welding end type, the turbid-eye blasting end type and the notched welding end type. The common welding ends of the pinhole contact pair are the drilled arc notched.

crimping

Crimping

Crimping is a technique of connecting wires to contact pairs in order to compress and displace the metal within specified limits. A good crimp connection can produce a metal intermelting flow that causes the wires and contacts to symmetrically deform the material. This connection is similar to the cold welding connection, which can achieve better mechanical strength and electrical continuity, and it can withstand harsher environmental conditions.

It is generally accepted that a correct crimping connection is better than tin explosion, especially when crimping must be used in high current situations. Special crimping pliers or automatic or semi-automatic crimping machine shall be used when crimping. According to the wire cross section of the cord end terminal and the cord end end, the right contact tube should be selected. Note that the crimping connection is permanent connection, can only be used once, can not be reused oh.

wire wrap

Wire Wrap

wire wrap is the direct winding of the wire on the angular contact winding column. When winding, the wire is wound under controlled tension, pressed into and fixed at the edges and corners of the contact-wrapped column to form an air-tight contact. There are several requirements for wire winding: the nominal value of wire diameter should be in the range of 0.25mm-1.0mm; The elongation of conductor material is not less than 15% when the diameter of conductor is not more than 0.5mm. All rights reserved. The elongation of conductor material is not less than 20%. Winding tools include winding guns and stationary winding machines.

puncture successive

Puncture Successive

Puncture connection, also known as insulated displacement connection, is a new technology invented by the United States in the 1960s, with high reliability, low cost, easy to use and other characteristics, has been widely used in a variety of printed board terminals, cold end, ring terminal. It is suitable for connecting ribbon cable.

It is not necessary to strip the insulation layer of the cable when connecting. The tip of the “U-shaped contact reed of the terminal is inserted into the insulation layer, so that the conductor of the cable slides into the groove of the contact reed and is clamped, so as to form a tight electrical connection between the conductor of the cable and the reed of the terminal. It requires only simple tools, but must use a specified cable gauge cable.

Introduction and connection mode of Terminal block

Zhejiang Lianhe electronics to provide you with professional terminal technology, a variety of series terminals for your choice, there are related questions welcome to ask, will try to answer for you!

How is cord end terminal connected to wire generally, what are the precautions

There are three ways to connect a cord end terminal to a cable.

Crimping

Also called cord end terminal. Press the wiring terminals to the corresponding wires using tools or terminal machines. Generally, UL486A,C and other standards are used to check whether the crimping is qualified

Crimping

welding

Solder the terminals to the wire using a solder tool. 

welding

Puncture pressure connection

Use a tool or terminal machine to crimp the punctured terminal with the wire to realize the conduction function of punctured wire. Generally common with aluminum enameled wire.

Puncture pressure connection

When crimping, pay attention to the crimping wing should not touch the wall, if the crimping wing to touch the wall, the terminal crimping wing is easy to fracture for a long time; After touching the wall, it is also easy to cause the gap in the interior of the curl, which is easy to cause oxidation break over a long time.

This section describes the common crimping methods of cord end terminals

We may not be very familiar with the ling crimping terminal, but it is useful in our life. Cord end terminal is mainly a small part used for electrical connection, due to its own specifications and size are not large, can be used in many environments. Now there are many types and styles of cord end terminals in our country, but no matter what kind of specifications of cord end terminals are composed of connectors and air connections.

Cord end terminal

Now there are many kinds of cord end terminals, there are many crimping ways of cord end terminals, there are mainly so several.

Crimping method of cord end terminal – riveting crimping

Riveting crimping mode is more direct, mainly in order to prevent the crimping metal moving range is too large, after the metal is fixed, and then the wire in the cord end terminal connection on a way. Using rivet type crimp mode, our cord end terminal operation strength and current continuity will be better, this is mainly because the rivet type crimp can operate in a more severe environment.

Crimping method for cord end terminals - In-line crimping

Crimping method for cord end terminals – In-line crimping

In-line crimping is a way to directly connect the wire and the connecting plate. When using the in-line crimping mode, we generally choose to connect the cord end terminal with a long length, so that the wire is more convenient to insert the corresponding hole. After the wire is inserted, we will use the immersion method to do a welding. This is a way to do the line crimping or relatively firm, there are many people use this way.

Crimping method of cord end terminal - riveting crimping

The above is our two common crimping way of cord end terminal price comparison, I hope to provide you with a little help, but with the improvement of our industrial technology, now most people are applicable to the first method to do the crimping of cord end terminal.

Terminal Block Knowledge

In recent years, the use of terminal blocks in electronic equipment has become a very common phenomenon. The power of the power terminal itself is getting larger and larger, and the volume of the terminal is also developing in a larger direction. 

Terminal cold knowledge

In addition, their measurement performance and parameters vary in different regions. Some identical products have very different parameters. Understanding these differences is therefore important to keep the terminal low cost and long-term reliable.

In the process of continuous innovation and improvement, the circuit board of wiring terminals will be able to carry more and stronger current. Recently, it has even broken through 110A, completely leading the production level of foreign developed countries.

However, in the process of design, what type of terminal is used to become the biggest problem, but also to fully meet all the needs of the system.

Terminal Block Definition

The unit of the terminal block is “bit”, and one bit is 1 “bit”. Usually, the so-called table is the serial number of terminals. These serial numbers have different definitions in different applications.

“Node” and “bit” mean the same thing, just different names. A group is made up of nodes. The usual terminals are 2 bits, 3 bits, 4 bits, 6 bits, 12 bits, etc., which are divided by number. By capacity: 10A, 20A, 40A, and so on.

In power electronics wiring, when the equipment inside the screen is connected with the equipment outside the screen, some special wiring terminals are needed. When these wiring terminals are combined, they are called terminal block.

The function of the terminal block

Terminal block, commonly used English letters and numbers, or Chinese phonetic alphabet plus numbers, to indicate the maximum contact point current flux, as well as the size of the terminal block and the number of endpoints.

Terminal block

The function of the terminal block is to connect the lines of the devices inside and outside the screen and play the role of signal (current and voltage) transmission. With the terminal block, making the wiring beautiful, convenient maintenance, in the remote line between the connection is mainly firm, convenient construction and maintenance.

The function of the terminal block

Secondly, the terminal line in the tin after the black reason, there are a lot of people think is the climate problem, maybe the weather is too cold, the temperature is too big or too high and so on.

In fact, untreated or tinned copper wire can also oxidize in the presence of tin. Copper in the air in two steps, the first copper reacts with oxygen to form copper oxide. The copper oxide and carbon dioxide in the air and water then react to form a green oxide. The oxidation of copper is a normal chemical reaction.

Wet weather water droplets can adhere to the surface of the product. The larger the water droplet, the less circulation or the lower the air temperature, the harder the surface water is to volatilize, thereby accelerating the oxidation reaction of copper and tin in the air, causing the electronic sky to turn black.

the terminal line in the tin after the black reason

For more technical knowledge about electronic connectors, please click on the official website to contact us, we will respond to you as soon as possible.

What are the 6 things to be aware of when choosing a connector?

Connectors are indispensable parts of electronic equipment. If you follow the path of current flow, you will always find one or more connectors.

It is a coupling device connecting electrical terminals to form circuits, which can realize the connection between wires, cables, printed circuit boards and electronic components, so it is widely used in electronic equipment.

Connectors

The form and structure of connectors vary with the application object, application environment, frequency, and power. There are more and more kinds of common connectors, so when we choose connectors, what should we pay attention to?

Electrical parameters

Connectors are mostly connected to electrical components and are used to transmit current or signals. Therefore, connectors have strict requirements on electrical parameters, including rated voltage and rated current.

Electrical parameters

The rated voltage, also known as the operating voltage, depends on the distance between the insulating material used by the connector and the contact pair. In theory, the connector’s rated voltage should be the manufacturer’s recommended maximum operating voltage, but in practice the connector will work well below the rated voltage.

Rated current is also called operating current. As with rated voltage, connectors generally work well below rated current. When current passes through the contact pair of the connector, the contact pair will heat up due to the presence of conductor resistance and contact resistance, and failure will occur when the temperature exceeds the limit. Therefore, to limit the rated current, is to limit the temperature rise in the connector to not exceed the design specified value.

rated voltage

Environmental parameters

Environment parameters include ambient temperature, humidity, rapid temperature change, and corrosive environment. The environment in which connectors are used, transported, and stored has a significant impact on their performance. Therefore, connectors must be selected according to the actual environmental conditions.

The environment temperature

The metal and insulation materials of the connector determine the operating temperature of the connector. High temperature will destroy the edge material, causing the insulation resistance and pressure performance reduction; For metals, high temperature can make contact pair lose elasticity, accelerate oxidation and coating deterioration.The environment temperature环

The humidity

In a high humidity environment for a long time, it will cause the absorption and diffusion of water vapor on the surface of the insulator, easy to reduce the insulation resistance to physical deformation, resulting in electrolysis, corrosion and cracking. For connectors outside the equipment, environmental conditions such as moisture, water seepage, and contamination should often be considered. In this case, sealed connectors should be used. For water-tight, dust-tight connector, the general use of GB4208 shell protection grade to express.

The humidity

Corrosive environment

According to different corrosion environment, should choose the corresponding metal, plastic, coating structure of the connector. Connectors used in salt spray environments, for example, will deteriorate rapidly if they do not have an anticorrosive metal surface. In an environment with a considerable concentration of SO2, a silver plated contact pair should not be used.

Corrosive environment

The connection method

The connection mode refers to the connection mode between the contact pair of the connector and the wire or cable. At present, the main connection methods are welding, pressing, winding, piercing connection, screw connection and so on. It is also an important aspect of using and selecting connectors to choose the proper way and technology of terminating.

The connection method

Electrical parameters, environmental parameters, and connection mode all affect the performance of the connector. Knowing your application requirements and choosing the right connector can improve the reliability of your project and greatly improve the quality and life of your product.