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Reliability Screening Test for Preventing Failure of Terminal Blocks

In order to ensure the quality and reliability of the wiring terminals and prevent the occurrence of the above-mentioned fatal failures, it is recommended to study and formulate corresponding screening technical requirements according to the technical conditions of the product, and carry out the following targeted reliability inspections to prevent failures.


1. Prevent poor contact


(1) Continuity detection


At present, the general terminal manufacturer's product acceptance test does not have this item, and the user generally needs to conduct a continuity test after installing the machine. Therefore, it is recommended that manufacturers add 100% point-by-point conduction detection to some key models of products.

(2) Instantaneous interruption detection


Some terminal blocks are used in dynamic vibration environment. The experiment proves that it is only used to check whether the static contact resistance is qualified, and it cannot guarantee the reliability of the contact in a dynamic environment. Because connectors with qualified contact resistances often suffer from instantaneous power failure during simulated environmental tests such as vibration and impact, it is best to perform dynamic vibration tests on some terminals with high reliability requirements. Contact reliability.

(3) Single hole separation force detection


The single-hole separation force refers to the separation force of the contact member in the inserted state from being stationary to moving, which is used to characterize the contact between the pin and the socket. Experiments show that if the separation force of a single hole is too small, it may cause instantaneous signal interruption when subjected to vibration and shock loads. The method of measuring the separation force of a single hole to check the contact reliability is more effective than measuring the contact resistance. Inspect the jacks where the single-hole separation force is out of tolerance, and the measurement of contact resistance is often still qualified. For this reason, in addition to researching and developing a new generation of flexible plug-in contact with stable and reliable contacts, the manufacturer should not use automatic plug-in force testing machines for multi-point simultaneous testing of key models, and should conduct 100% point-by-point orders for finished products. Check the hole separation force to prevent instantaneous signal interruption caused by the looseness of individual jacks.


2. Prevent poor insulation


(1) Insulation material inspection


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


(2) Check the insulation resistance of the insulator


At present, some manufacturing plants require that the electrical properties are tested after assembly into finished products. As a result, the entire batch of finished products has to be scrapped due to the unqualified insulation resistance of the insulator itself. A reasonable process should be 100% process screening in the state of insulator parts to ensure that the electrical performance is qualified.