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Common faults and solutions of wiring terminals

Wiring terminal is an accessory product used to realize electrical connection, which belongs to industrial connector. From the perspective of use, the function of the terminal should be: the contact part must be reliable contact. Insulating parts should not lead to reliable insulation.

Terminal blocks have three common forms of fatal failure

1. Poor contact

2. Poor insulation

3. Poor fixation

1. Prevent poor contact

1) Continuity test: generally, this item is not included in the product acceptance test of the manufacturer of wiring terminals. Users generally need to conduct continuity test after installation. However, we conduct 100% continuity test on wiring harness products of terminal blocks to ensure the good performance of users.

2) Instantaneous disconnection detection: some terminals are used in dynamic vibration environment. Experiments show that only checking whether the static contact resistance is qualified cannot guarantee the reliability of contact in dynamic environment. Usually, in the simulated environment test such as vibration and shock, the connector with qualified contact resistance will still be powered off immediately.

2. Prevent poor insulation

Insulation material inspection: the quality of raw materials has a great impact on the insulation performance of insulators. Therefore, the choice of raw material manufacturers is particularly important. We should not blindly reduce costs and lose material quality. We should choose large factory materials with good reputation. And carefully check the inspection batch number, material certificate and other important information of each batch of materials, and do a good job in the traceability data of material use.

3. Prevent poor fixation

1) Interchangeability inspection: interchangeability inspection is a kind of dynamic inspection. It is required that the plugs and sockets of the same series can be connected with each other, and find out whether there are insertion, positioning, locking and other faults caused by excessive size of insulators, contacts and other parts, missing parts or improper assembly, or even disassembly under the action of rotating force.

2) General test of crimping wire: in the process of electrical installation, it is often found that individual core crimping wires are not delivered in place, or cannot be locked after delivery, and the contact is not reliable. The reason analyzed is that there are burrs or dirt on the screws and teeth of each mounting hole. Especially when using the factory to install the electrical into the last few mounting holes of the connector. After defects are found, the other installation holes must be removed one by one, the crimping wires must be removed one by one, and the plugs and sockets must be replaced. In addition, due to the improper matching of wire diameter and crimping aperture, or the incorrect operation of crimping process, accidents will also occur at the crimping end.

Post time: Jul-20-2022