Production And Installation Of Terminal Blocks: Common Problems And Solutions

As the core component of electrical connections, the production and installation quality of terminal blocks directly affects the stability and safety of circuits. The following are common problems and solutions during the production and installation process of terminal blocks:

1、 Common problems and solutions during the production phase

The crimping is not firm enough

Reason: Insufficient crimping force, loose wire cross-section, or poor terminal material quality.

Solution: Adjust the pressure of the crimping tool to ensure that the crimping height meets the standard; Use wires that meet the requirements to avoid loose multi strand wires; Choosing reliable terminal materials, such as tin plated copper terminals, can enhance conductivity and corrosion resistance.

Case: A certain automated production line caused a short circuit due to loose terminal crimping caused by the lack of torque tools. Later, by regularly calibrating crimping pliers and adding limiters to fix terminal blocks, the failure rate was reduced by 40%.

Damage or breakage of wires

Reason: Excessive crimping force, fragile wire cross-section, or excessively long wire stripping.

Solution: Control the crimping force to avoid excessive deformation; Use wires that meet the cross-sectional area requirements; The stripping length shall strictly follow the standard, such as 6-8mm, to prevent the copper wire from being exposed.

Data support: According to the IEC 60947-7-1 standard, the wire must withstand a tensile force of ≥ 50N without displacement, and the crimping quality can be verified through tensile testing.

Terminal overheating

Reason: Excessive contact resistance, current overload, or material not resistant to high temperatures.

Solution: Optimize the crimping process to ensure good contact; Choose high-temperature resistant materials such as fiberglass tubes or high-temperature silicone protection; For high current circuits, it is preferred to use closed terminals or double hole terminals to enhance the contact surface.

2、 Common problems and solutions during the installation phase

Loose terminal block

Reason: Failure to use torque tools, aging guide rail buckles, or lack of installation of limiters.

Solution: Use a torque screwdriver to tighten with standard torque, such as M4 screws, recommended 0.8-1.2N · m; Regularly replace the buckle with self-locking structure; Add limiters to fix the ends of the non-standard cabinet.

Case: A certain ship's equipment had a terminal block offset due to vibration caused by the absence of limiters. The hidden danger was eliminated by optimizing the installation method.

insulation failure

Reason: Excessive voltage difference between adjacent terminals, humid environment, or aging insulation material.

Solution: Install isolation board when voltage difference>300V; Choose flame-retardant reinforced nylon material for humid environments, such as UL94 V-0 grade; Regularly replace aging insulation materials.

Matching degree issue

Reason: Terminal and wire specifications do not match, aperture is too large or too small.

Solution: Strictly follow the principle of "copper to copper, aluminum to aluminum", and copper aluminum connections must use copper aluminum transition terminals; The terminal diameter is exactly the same as the nominal cross-section of the cable conductor, such as 16mm ² wire with 16mm ² terminal.