The production process of neutral blocks: the key to improving product quality
As the core component of electrical connections, the manufacturing process of neutral blocks directly affects the conductivity, durability, and safety of products. From material selection to precision machining, and then to quality inspection, optimizing every step of the process is the key to enhancing product competitiveness.
1、 Material selection: laying the foundation for quality
The material of the neutral block should balance conductivity, corrosion resistance, and mechanical strength. High quality terminals are usually made of high-purity copper (such as C11000), with a conductivity of over 99.9%, which can effectively reduce contact resistance and minimize the risk of heating. Some high-end products will form a protective layer on the surface of the copper substrate through tin plating, silver plating, or gold plating processes, which not only prevents oxidation and corrosion, but also improves the insertion and removal life. For example, tin plated terminals can remain rust free for more than 10 years in humid environments, while gold-plated terminals are suitable for high-frequency signal transmission scenarios to ensure signal stability.
2、 Precision machining: ensuring contact reliability
The machining accuracy of the core structure of the terminal - the spring leaf or spring plate - directly affects the contact pressure. Through high-precision stamping technology, the thickness tolerance of the spring can be controlled within ± 0.01mm, ensuring consistent contact pressure for each terminal. In addition, surface polishing treatment can eliminate machining burrs and reduce contact resistance; And elastic structure design (such as hyperbolic spring) can disperse stress and avoid poor contact caused by plastic deformation after long-term use. For example, a certain brand of terminal has significantly extended the service life of the equipment by optimizing the curvature of the spring, increasing the contact area by 30% and reducing the temperature rise by 5 ℃.
3、 Quality inspection: strict control of factory standards
Finished terminals need to go through multiple testing processes: dimension measurement (such as caliper and projector detection of external tolerances), conductivity testing (such as low resistance tester verifying contact resistance ≤ 5m Ω), withstand voltage testing (such as 2000V AC power without breakdown for 1 minute), and salt spray testing (simulating harsh environments to verify anti-corrosion performance). Some enterprises have also introduced automated detection equipment to detect surface defects through image recognition technology, combined with big data analysis to optimize process parameters and control the defect rate below 0.1%.
The production process of neutral blocks is a combination of technical accumulation and lean management. From materials to processing, and then to testing, precise control at every step can significantly improve product performance, providing solid guarantees for the safe and stable operation of electrical equipment.
