Analysis Of Heavy-duty Connector Performance And Manufacturing Process

heavy duty connector 5 pin. Establish a bridge of communication between blocked or isolated circuits in the circuit, so that current can flow and the circuit can achieve the predetermined function. It is also called heavy duty connector 6 pin and socket in China, generally referring to electrical heavy duty electrical contacts. That is, a device that connects two active devices to transmit current or signals.

Performance of heavy duty industrial connector:

1. Mechanical properties: In terms of connection function, plugging and unplugging force is an important mechanical property.

Insertion force is divided into insertion force and pull-out force (pull-out force is also called separation force), and their requirements are different. There are provisions for insertion force and small separation force in the relevant standards, which means that from the perspective of use, the insertion force should be small (so there are low insertion force LIF and no insertion force ZIF structures). If the separation force is too small, it will affect the contact reliability.

Another important mechanical characteristic is the mechanical life of heavy duty male female connector. Mechanical life is actually a durability indicator, which is called mechanical operation in GB5095. It takes one plugging and unplugging as one cycle, and whether heavy duty multi pin connectors can normally complete its connection function (such as contact resistance value) after the specified plugging and unplugging cycle is used as the judgment basis. The plugging and unplugging force and mechanical life of heavy connector are related to the contact structure (positive pressure), the coating quality of the contact part (sliding friction coefficient) and the dimensional accuracy (alignment) of the contact arrangement.

2. Electrical performance: The main electrical properties of heavy duty cable connectors include contact resistance, insulation resistance and electrical strength.

① Contact resistance: A high-quality electrical connector should have a low and stable contact resistance. The contact resistance of the connector ranges from a few milliohms to tens of milliohms.

(2) Insulation resistance: An indicator to measure the insulation performance between the contacts of the electrical connector and between the contacts and the shell, ranging from hundreds of megohms to tens of megohms.

③ Electrical strength: also known as withstand voltage and dielectric withstand voltage, is the ability of the connectors or between the connector and the shell to withstand the rated test voltage.

④Other electrical properties: EMI leakage attenuation is used to evaluate the EMI shielding effect of the connector, and EMI leakage attenuation is used to evaluate the EMI shielding effect of the connector, which is generally tested in the frequency range of 100 MHz ~ 10g Hz.

For RF coaxial connectors, there are also electrical indicators such as characteristic impedance, insertion loss, reflection coefficient, and voltage standing wave ratio (VSWR). With the development of digital technology, a new type of connector, namely high-speed signal connector, has emerged in order to connect and transmit high-speed digital pulse signals. Correspondingly, in terms of electrical performance, in addition to characteristic impedance, some new electrical indicators have also emerged, such as crosstalk, transmission delay, skew, etc.

3. Environmental performance: Common environmental performance includes temperature resistance, moisture resistance, salt spray resistance, vibration and impact resistance.

① Temperature resistance: The current operating temperature of the connector is 200℃ (except for a few high-temperature special connectors) and the temperature is -65℃. When the connector is working, the current generates heat at the contact point, causing the temperature to rise. Therefore, it is generally believed that the operating temperature should be equal to the sum of the ambient temperature and the temperature rise of the contact point. In some specifications, the allowable temperature rise of the connector under the rated working current is clearly specified.

② Moisture-proof: The intrusion of moisture will affect the insulation performance of the connector and corrode metal parts. The constant humidity and heat test conditions are 90%~95% relative humidity (up to 98% according to the product manual), temperature +40 ° C, and the test time is at least 96 hours according to the product regulations. The alternating humidity and heat test is even more severe.

③ Salt spray resistance: When the connector works in an environment containing moisture and salt, the surface treatment layer of the metal structural parts and contact parts may produce electrochemical corrosion, thereby affecting the physical and electrical properties of the connector. In order to evaluate the ability of the electrical connector to withstand this environment, a salt spray test is specified. It is to hang the connector in a temperature-controlled test box and spray a sodium chloride solution of a specified concentration with compressed air to form a salt spray atmosphere. The exposure time is at least 48 hours as specified in the product manual.

④ Vibration and shock resistance: Vibration and shock resistance is an important performance of electrical connectors, especially in special application environments such as aerospace, railway and road transportation. They are important indicators for testing the mechanical structural robustness and electrical contact reliability of electrical connectors. There are clear provisions in the relevant test methods. Peak acceleration, duration, pulse waveform and electrical continuity interruption time should be specified in the impact test.

⑤ Other environmental performance: According to the use requirements, other environmental performance of electrical connectors include air tightness (leakage, liquid pressure), liquid immersion (bad habits of resistance to specific liquids), low air pressure, etc.