Common Problems And Solutions In Quality Inspection Of Neutral Blocks
In the quality inspection of neutral blocks, common problems mainly include poor contact, substandard insulation performance, defects in crimping process, and poor fixation. The existence of these problems may cause circuit faults and even safety hazards. The following is a detailed analysis of specific problems and solutions:
poor contact
Problem manifestation: The contact resistance between the terminal and the wire is too high, resulting in poor current transmission, which may cause local overheating or signal interruption.
Solution:
Optimize the crimping process: Use standardized crimping molds to ensure that parameters such as crimping height, width, and support angle meet design requirements. For example, the crimping height should be adjusted according to the terminal manufacturer's instructions, and the crimping wing drop should be less than 1 time the thickness of the terminal material.
Material selection: Choose copper alloy materials with excellent conductivity to avoid a decrease in contact force due to insufficient elasticity of the material.
Surface treatment: Wear resistant treatments such as gold plating and silver plating are applied to the terminal contact surface to reduce friction damage during insertion and removal.
The insulation performance does not meet the standard
Problem manifestation: Aging of insulation materials, pollution, or defects in molding processes leading to electrical leakage and short circuits.
Solution:
Strict material control: Select insulation materials that are resistant to high temperatures and corrosion, and regularly inspect the quality of material batches.
Clean production environment: During the insulation molding process, avoid the entry of metal residues, dust, and other pollutants to prevent the release of harmful gases from the insulation layer.
Process optimization: High precision injection molds are used to ensure uniform wall thickness of the insulation body and avoid the risk of breakdown caused by too thin wall thickness.
Defects in crimping process
Problem manifestation: The crimping height exceeds the tolerance, burrs are too large, or the conductor compression is insufficient, which affects the mechanical strength and electrical performance.
Solution:
Profile analysis: Use an electron microscope and calibration software to cut and analyze the crimping area, measure parameters such as crimping height, width, and bottom material thickness to ensure compliance with standards.
Tensile test: Conduct a tensile test on the crimped terminals to verify whether their tensile strength meets the wire diameter requirements.
Mold maintenance: Regularly check the wear of the crimping mold, replace damaged parts in a timely manner, and avoid poor crimping caused by decreased mold accuracy.
Fixed defects
Problem manifestation: Loose terminal housing, failed positioning lock, resulting in unreliable contact or product disassembly.
Solution:
Interchangeability check: Conduct plug and socket tests on the same series of terminals to ensure stable connection between the plug and socket, and avoid fixing failure due to size deviation.
Torque endurance test: Simulate the vibration and impact in actual use to verify the firmness of the terminal structure.
Assembly specification: Develop a standardized assembly process to ensure that the terminal housing is free of scratches and burrs, and that the screw torque meets the requirements to avoid fixing problems caused by improper assembly.
