In order to ensure the quality and reliability of wiring terminals and prevent the occurrence of the above faults, it is recommended to study and formulate corresponding screening technical requirements according to the technical conditions of products, and carry out the following targeted reliability inspection to prevent failure.

1. Prevent poor contact

1) Conduction detection

Generally, there is no such item in the product acceptance test of the manufacturer of the wiring terminal, but the user generally needs to conduct continuity test after installation. Therefore, it is suggested that manufacturers should increase 100% point by point conduction detection for some key models of products.

2) Instantaneous break detection

Some terminals are used in dynamic vibration environment. Experiments show that only checking whether the static contact resistance is qualified can not guarantee the reliable contact in dynamic environment. Because the connectors with qualified contact resistance still have instant power failure during vibration, impact and other simulated environmental tests, it is better to conduct 100% dynamic vibration test on some wiring terminals with high reliability requirements to assess their contact reliability.

3) Single hole separation force detection

Single hole separation force refers to the separation force of the contact in the inserted state from static to moving, which is used to indicate that the pin and Jack are in contact. The experimental results show that the single hole separation force is too small, which may cause signal instantaneous break under vibration and impact load. The method of measuring the separation force of single hole is more effective than measuring the contact resistance. The contact resistance measurement of the jack with out of tolerance single hole separation force is often still qualified. Therefore, in addition to developing a new generation of flexible plug-in contacts with stable and reliable contact, the manufacturer shall not use automatic plug-in force tester for multi-point simultaneous measurement for key models, and 100% point-to-point single hole separation force inspection shall be carried out for the finished products to prevent signal instantaneous disconnection due to individual Jack relaxation.

2. prevent poor insulation

1) Insulation material inspection

The quality of raw materials has a great influence on the insulation performance of insulators. Therefore, the selection of raw material manufacturers is particularly important. We should not blindly reduce the cost and lose the material quality Should choose reputable large factory materials And for each batch of incoming materials, carefully check the batch number, material certificate and other important information Do a good job in the traceability data of material use

2) Insulation resistance inspection of insulator

By 2012, some manufacturers required to test the electrical performance after assembling the finished products. As a result, the insulation resistance of the insulator itself was unqualified, so the whole batch of finished products had to be scrapped. The reasonable process should be 100% process screening in the state of insulator parts to ensure qualified electrical performance.

3. Prevent poor fixation

1) Interchangeability check

Interchangeability check is a dynamic check. It requires that the same series of matched plugs and sockets can be inserted and connected with each other, and it can be found whether they cannot be inserted, positioned and locked due to out of tolerance of insulator, contact and other parts, lack of installed parts or inadequate assembly, or even disintegrate under the action of rotating force. Another function of interchangeability inspection is to timely find out whether there are metal residues that affect the insulation performance through plug-in connections such as threads and bayonets. Therefore, 100% of the terminals for some important purposes should be inspected to avoid such major fatal failure accidents.

2) Torque resistance inspection

Torque resistance inspection is a very effective inspection method to evaluate the structural reliability of wiring terminals. As specified in mil-l-39012 According to the standard, each batch of samples should be sampled for torque resistance inspection to find problems in time

3) Through test of crimped conductor

During electrical installation, it is often found that individual core crimping wires are not sent in place, or cannot be locked after being sent to the position, and the contact is unreliable. The reason is that there are burrs or dirt at the screw teeth of individual installation holes. In particular, the user has installed electricity into the last few installation holes of a plug base. After finding the defect, he has to remove the crimping wires of other installed holes one by one and replace the plug base again. In addition, due to the improper selection of wire diameter and crimping aperture, or due to the wrong operation of crimping process, it will also cause the accident of loose crimping end. Therefore, before the finished products leave the factory, the manufacturer shall conduct a through test on all the installation holes of the samples of the delivered plug (seat), that is, use the loading and unloading tool to send the wires crimped with pins or jacks to the right place to check whether they can be locked. Check the pull-out force of crimped wires one by one according to the provisions of product technical conditions.

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