Testing Safety parameters of electrical connectors Cables

Insulation Resistance of Electrical Connectors
Insulation resistance refers to the resistance value that occurs when a voltage is applied to the insulating part of the connector to cause leakage current in or on the surface of the insulating part. It is mainly affected by factors such as insulating materials, temperature, humidity, and fouling. The insulation resistance values provided on electrical connector samples are generally index values under standard atmospheric conditions. Under certain environmental conditions, the insulation resistance value will drop to varying degrees. In addition, attention should be paid to the test voltage value of insulation resistance. According to the insulation resistance (MΩ) = voltage applied to the insulator (V) / leakage current (μA) to apply different voltages, there are different results. In the test of the connector, the applied voltage generally has three levels of 10V, 100V, and 500V.

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Rated voltage of electrical connector
The withstand voltage is the critical voltage that can withstand a higher than the rated voltage within a specified time between the mutually insulated parts of the contact pair or between the insulated part and the ground without breakdown. It is mainly affected by contact pair spacing and creepage distance and geometry, insulator material and ambient temperature and humidity, atmospheric pressure.

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Mechanical life of electrical connectors
1) The mechanical life of the connector refers to the plugging life, which is usually specified as 500 to 1000 times. When the specified mechanical life is reached, the contact resistance, insulation resistance and withstand voltage of the connector should not exceed the specified value. Strictly speaking, the mechanical life should have a certain relationship with time, 500 times in 10 years and 500 times in 1 year are obviously different.

Number of contact pairs and pinholes of electrical connectors
Firstly, the number of contact pairs can be selected according to the needs of the circuit, while considering the size of the connector and the total separation force. The larger the number of contact pairs, the larger the volume of course, and the larger the total separation force. In some cases where the reliability is high and the volume is allowed, two pairs of contact pairs can be connected in parallel to improve the reliability of the connection.
In the plug and socket of the connector, the pins (male contacts) and jacks (female contacts) are generally interchangeable. In actual use, it can be selected according to the charging conditions at both ends of the plug and socket. If the socket needs to be charged frequently, a socket with a jack can be selected. Because the live contacts of the socket with the jack are buried in the insulator, the human body is difficult to touch the live contacts, which is relatively safe.

Circular electrical connector parameters

Vibration, shock and collision of electrical connectors
2) Mainly consider the electrical continuity of the contact pair when the connector vibrates, impacts, and collides under specified frequency and acceleration conditions. Instantaneous disconnection of the contact pair occurs under this dynamic stress condition. The specified transient time is generally 1μs, 10μs, 100μs, 1ms and 10ms. Attention should be paid to how to judge the momentary failure of the contact pair. It is currently believed that when the voltage drop across the closed contact pair (contact) exceeds 50% of the electromotive force of the power supply, it can be determined that the closed contact pair (contact) has failed. That is to say, there are two conditions for judging whether an instantaneous interruption occurs: duration and voltage drop, both of which are indispensable.

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Connection method of electrical connector
3) The connector is generally composed of a plug and a socket, where the plug is also called a free end connector, and the socket is also called a fixed connector. The connection and disconnection of the circuit is realized by plugs, sockets and mating and separation, so various connection methods of plugs and sockets are produced. For circular connectors, there are mainly three methods: threaded connection, bayonet type connection and pin-type connection. Among them, threaded connection is the most common, which has the advantages of simple processing technology, low manufacturing cost and wide application range. However, the slow connection speed is not suitable for occasions that require frequent plugging and fast connection.
The bayonet type connection is faster because of the longer leads of the three bayonet slots, but it is more complicated to manufacture and the cost is higher. The marble connection is the fastest connection among the three connection methods. It does not need to perform rotary motion, but only needs to perform linear motion to realize the functions of connection, separation and locking. Since it is a direct push-pull connection, it is only suitable for connectors with low total separation force. Generally more common in small connectors.

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