768230321 76823-0321 Half Gold Plated Wire Terminal Male Terminal Crimping Terminal

Cause Analysis of Electrical Contact Failure

(1) Insufficient electrical contact pressure.

The connector conducts electricity through pins and jacks. The jack is an elastic element. Its quality is crucial to the reliability of the electrical connection. The pin inserts into the jack and deforms elastically, thereby generating contact pressure on the pin. , the instability or reduction of contact pressure will affect the instability of contact resistance. Under certain vibration and impact stress, the elastic element will produce restorative elastic deformation. If the vibration and impact stress are large enough and the action time is long enough, it will cause a transient failure. The pin socket is subjected to long-term force and reaction force, the elastic element of the socket gradually produces permanent deformation, and stress fatigue relaxation occurs, especially under the action of the contact point and the ambient temperature, the socket will appear creep phenomenon, and the contact pressure will decrease small, the contact resistance increases.

 (2) Contact wear.

Plugging wear: When the automotive connector is mated and separated, under a certain contact pressure, friction occurs between the pin and the socket due to relative movement. During the friction process, the smoothness of the contact surface will be damaged and the geometric shape will change. , scratches, adhesions, wear debris, material transfer, etc., accompanied by heat generation. As the number of times of insertion and extraction increases, the surface plating metal of the pin socket is worn away, exposing the base metal, and corrosion occurs under the action of the surrounding environment, resulting in poor contact. The degree of wear on the surface of the contact pair is related to the size of the contact pressure, the surface finish of the contact friction part, the type, hardness, and quality of the coating on the contact pair surface, whether the fillet of the contact pair guide part is smooth, and the geometry of the contact part of the socket. In the case of high contact pressure, poor connection between the pin head and the orifice in the socket, high roughness of the contact part, low hardness of the coating material, and poor coating quality, the contact wear is more serious. The plugging life of the connector is also low, and the contact stability is also poor.

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