From the perspective of use, the function of the wiring terminal should be: the place where the contact part is connected must be connected, and the contact is reliable. Where the insulation part should not be connected, the insulation must be reliable. There are three common forms of fatal faults of wiring terminals:

1. Poor contact

The metal conductor inside the terminal is the core part of the terminal. It transmits the voltage, current or signal from the external wire or cable to the contact corresponding to its matching connector. Therefore, the contact must have excellent structure, stable and reliable contact holding force and good electrical conductivity. Due to unreasonable contact structure design, wrong material selection, unstable mold, out of tolerance of processing size, rough surface, unreasonable surface treatment processes such as heat treatment and electroplating, improper assembly, poor storage and use environment and improper operation and use, poor contact will be caused at the contact part and mating part of the contact.

2. Poor insulation

The function of the insulator is to keep the contacts in the correct position and arrangement, and insulate the contacts from each other, and the contacts from the shell. Therefore, the insulating parts must have excellent electrical performance, mechanical performance and process molding performance. Especially with the wide use of high-density and miniaturized wiring terminals, the effective wall thickness of insulators is getting thinner and thinner. This puts forward more stringent requirements for insulating materials, injection mold accuracy and molding process. Short circuit, electric leakage, breakdown, low insulation resistance and poor insulation will be caused due to the presence of metal residues, surface dust, welding flux and other pollution on the surface or inside of the insulator, moisture, organic material precipitates and harmful gas adsorption film fused with the surface water film to form an ionic conductive channel, moisture absorption, mildew growth, aging of insulating materials and other reasons.

3. Poor fixation

The insulator not only plays the role of insulation, but also usually provides accurate centering protection for the protruding contacts. At the same time, it also has the functions of installation, positioning, locking and fixing on the equipment. Poor fixation will affect the reliability of contact, resulting in instantaneous power failure and serious product disintegration. Disassembly refers to the abnormal separation between the plug and socket and between the pin and the jack caused by the unreliable structure of the wiring terminal due to materials, design, process and other reasons, which will cause the serious consequences of the interruption of power transmission and signal control of the control system. Poor fixation will be caused by unreliable design, wrong material selection, improper selection of forming process, poor process quality of heat treatment, mold, assembly and welding, and inadequate assembly.

In addition, it is common to cause defects such as excessive processing, poor matching, poor sealing quality, poor appearance and so on. These faults can generally be found and eliminated in time during inspection and use.

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