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接線端子|常見致命故障形式

發布者: 時間:2014-7-14 14:16:27 您是第1510位瀏覽者


  接線端子常見的致命故障形式有以下三種:
    1. 接觸不良
    接線端子內部的金屬導體是端子的核心零件,它將來自外部電線或電纜的電壓,電流或信號傳遞到與其相配的連接器對應的接觸件上。故接觸件必須具備優良的結構,穩定可靠的接觸保持力和良好的導電性能。由于接觸件結構設計不合理,材料選用錯誤,模具不穩定,加工尺寸超差,表面粗糙,熱處理電鍍等表面處理工藝不合理,組裝不當,貯存使用環境惡劣和操作使用不當,都會在接觸件的接觸部位和配合部位造成接觸不良。

    2. 絕緣不良
    絕緣體的作用是使接觸件保持正確的位置排列,并使接觸件與接觸件之間,接觸件與殼體之間相互絕緣。故絕緣件必須具備優良的電氣性能,機械性能和工藝成型性能。特別是隨著高密度,小型化接線端子的廣泛使用,絕緣體的有效壁厚越來越薄。這對絕緣材料,注塑模具精度和成型工藝等提出了更苛嚴的要求。由于絕緣體表面或內部存在金屬多余物,表面塵埃,焊劑等污染受潮,有機材料析出物及有害氣體吸附膜與表面水膜融合形成離子性導電通道,吸潮,長霉,絕緣材料老化等原因,都會造成短路,漏電,擊穿,絕緣電阻低等絕緣不良現象。

    3. 固定不良
    絕緣體不僅起絕緣作用,通常也為伸出的接觸件提供精確的對中和保護,同時還具有安裝定位,鎖緊固定在設備上的功能。固定不良,輕者影響接觸可靠造成瞬間斷電,嚴重的就是產品解體。解體是指接線端子在插合狀態下,由于材料,設計,工藝等原因導致結構不可靠造成的插頭與插座之間,插針與插孔之間的不正常分離,將造成控制系統電能傳輸和信號控制中斷的嚴重后果。由于設計不可靠,選材錯誤,成型工藝選擇不當,熱處理,模具,裝配,熔接等工藝質量差,裝配不到位等都會造成固定不良。

    此外,由于鍍層起皮,腐蝕,碰傷,塑殼飛邊,破裂,接觸件加工粗糙,變形等原因造成的外觀不良,由于定位鎖緊配合尺寸超差,加工質量一致性差,總分離力過大等原因造成的互換不良,也是常見病,多發病。這幾種故障一般都能在檢驗及使用過程中及時發現剔除。

 


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