The plastic insulation materials and conductive parts of din 41612 type h connectors are directly related to the quality of the terminals, which determine the insulation and conductive properties of the terminals respectively. Failure of any one of the high quality din 41612 type h connectors will result in the failure of the entire system engineering. The painful lessons learned at home and abroad in this regard are very profound.

Prevention is the goal, analysis is the foundation. In a sense, preventing failures is more important than analyzing them. It has a more realistic meaning to guarantee the quality and reliability of high quality din 41612 type h connectors.

high quality din 41612 type h connectors From the point of view of use, the function should be achieved: the contact part of the conductive place must be conductive, reliable contact. The insulation parts that should not be connected must be insulated reliably. high quality din 41612 type h connectors There are three common forms of fatal failure:

1. Poor contact

high quality din 41612 type h connectors The internal metal conductor is the main part of the terminal, which transfers the voltage, current or signal from the external wire or cable to the corresponding contact with its matching connector. Therefore, the contact parts must have excellent structure, stable and reliable contact retention force and good electrical conductivity. Due to the unreasonable structural design of the contact parts, the wrong selection of materials, the instability of the mold, the abnormal processing size, the rough surface, the unreasonable surface treatment process such as heat treatment and electroplating, the improper assembly, the poor storage and use environment and the improper operation and use will cause poor contact in the contact parts and the matching parts.

2. Poor insulation

The function of the insulator is to keep the contacts in the correct position, and to insulate each other between the contacts and the contacts, and between the contacts and the shell. Therefore, the insulation parts must have excellent electrical properties, mechanical properties and process forming properties. Especially with the high density, miniaturization and wide use of high quality din 41612 type h connectors, the effective wall thickness of insulators is getting thinner and thinner. This puts more stringent requirements on insulation materials, injection mold accuracy and molding processes. Due to the existence of metal residues on the surface or inside the insulator, surface dust, flux and other pollution by moisture, organic material precipitates and harmful gas adsorption film and surface water film fusion to form ionic conductive channels, moisture absorption, mildew, insulation material aging and other reasons, will cause short circuit, leakage, breakdown, low insulation resistance poor insulation phenomenon.

3. Improper fixation

Insulators not only insulate, but often provide accurate neutralization protection for extended contacts, but also have the function of installation positioning, locking and fixing to the device. Poor fixation, light impact contact reliable cause instant power failure, serious is the disintegration of the product. Disintegration refers to the high quality din 41612 type h connectors in the plug-in state, due to material, design, process and other reasons caused by the structure is not reliable between the plug and the socket, the abnormal separation between the pin and the jack, will cause the control system power transmission and signal control interruption of serious consequences. Due to unreliable design, wrong material selection, improper selection of forming process, poor process quality of heat treatment, mold, assembly, welding, assembly is not in place, etc., will cause poor fixing.

In addition, due to coating peeling, corrosion, bruises, plastic shell flaring, cracking, rough processing of contact parts, deformation and other reasons caused by poor appearance, due to positioning lock size is poor, poor processing quality consistency, total separation force is too large and other reasons caused by poor interchange, is also a common disease. These faults can generally be found and eliminated in time during inspection and use.

Reliability screening tests for failure prevention

In order to ensure the quality and reliability of high quality din 41612 type h connectors and prevent the occurrence of the above fatal failures, it is recommended to study and formulate the corresponding screening technical requirements according to the technical conditions of the product, and carry out the following targeted reliability tests to prevent failures.

1. Prevent poor contact

1) Conduction detection

In 2012, the general high quality din 41612 type h connectors manufacturers product acceptance test without this item, and users generally need to carry out connectivity testing after installation. Therefore, it is recommended that manufacturers should increase the point-by-point conduction detection of some key models of products by 100%.

2) Instantaneous break detection

Some high quality din 41612 type h connectors are used in dynamic vibration environments. Experiments show that only testing the static contact resistance is qualified, and can not guarantee the reliable use of contact in dynamic environment. Because connectors with qualified contact resistance are often subjected to instantaneous power failure during vibration, shock and other simulated environmental tests, the dynamic vibration test can be 100% performed on some high quality din 41612 type h connectors 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 inserted contact from static to moving, which is used to represent the contact between the pin and the jack. The experimental results show that the single-hole separation force is too small, and the signal may be interrupted when subjected to vibration and impact load. It is more effective to test contact reliability by measuring single-hole separation force than by measuring contact resistance. The inspection found that the single-hole separation force is out of tolerance, the measured contact resistance is often still qualified. To this end, in addition to the development of a new generation of flexible insertion contact stable and reliable contact parts, the manufacturer should not be used for key models with automatic insertion and withdrawal force testing machine multi-point test, should be 100% of the finished product point by point single-hole separation force inspection, to prevent individual jack relaxation caused by signal instantaneous break.

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 choice of raw material manufacturers is particularly important, can not blindly reduce the cost and lose the quality of materials. Should choose a good reputation of the factory materials. And for each batch of materials to carefully check the batch number, material certification and other important information. Do a good job of material use traceability data.

2) Check the insulation resistance of insulator

By 2012, some production plants were required to test the electrical properties after assembly into finished products, and the result was that the insulation resistance of the insulator itself was not qualified, so the whole batch of finished products had to be scrapped. The reasonable process should be 100% process screening in the state of the insulator parts to ensure that the electrical properties are qualified.

3. Prevent poor fixation

1) Interchangeability check

The interchangeability test is a dynamic test. It requires that the same series of matching plugs and sockets can be inserted and connected to each other, from which it is found that there is no insertion, positioning and locking due to the size of insulators, contacts and other parts, missing parts or assembly is not in place and other reasons, and even under the action of rotating force caused by disintegration. Another function of the interchangeability check is to find out in time whether there are metal residues that affect the insulation performance by inserting and removing the thread, bayonet, etc. Therefore, 100% of high quality din 41612 type h connectors for some important applications should be checked to avoid such major fatal failure accidents.

2) Torque resistance check

Torque resistance inspection is a very effective way to check the reliability of high quality din 41612 type h connectors. Such as the United States military standard MIL-L-39012. According to the standard, each batch of samples should be sampled for moment resistance inspection to find problems in time.

3) General test of crimping wire

In electrical installation, it is often found that individual core crimping wires are not sent in place, or they cannot be locked after being sent in place, and the contact is not reliable. The reason is that there are burrs or dirt stuck in the screw of individual mounting holes. In particular, if the defects are found in several mounting holes of a plug socket that have been installed by the factory, the other hole crimping wires that have been installed must be removed one by one and the plug socket replaced. In addition, due to the improper selection of wire diameter and crimping aperture, or due to the crimping process operation error, it will also cause the crimping end is not strong. To this end, the manufacturer should test all the installation holes of the sample of the delivered plug (seat) before the finished product leaves the factory, that is, the loading and unloading tools will press the wire with a pin or jack to the place to check whether it can be locked. According to the technical conditions of the product, the pull-out force of each crimped wire is checked.

Without reliable high quality din 41612 type h connectors, there can be no reliable systems engineering. Failure and reliability are two sides of a contradiction that correspond to and relate to each other. high quality din 41612 type h connectors Reliability screening to discover a variety of failure modes and failure mechanisms, can lead to a large number of lessons learned and eliminate a variety of hidden dangers, to improve the design, process, inspection and use of scientific basis, It is also an important basis for revising and formulating technical conditions for high quality din 41612 type h connectors. The ultimate purpose of failure analysis is to find the measures to prevent failure and realize the transformation from failure to reliability.

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