Common faults in connector use and troubleshooting methods

In order to improve the efficiency of using connector, prevent the possible problems in the process of using connector and find the appropriate solution quickly, we summarized some common faults and corresponding troubleshooting methods in the process of using connector:

There are four types of connector faults: poor contact, poor insulation, poor fixation and poor sealing. We described in four categories:

 Poor contact.
(1) phenomenon: contact resistance increases.
Causes: contact parts positive pressure smaller, elastic parts deformation, jack relaxation.
Rule out: replace contact parts
(2) phenomenon: failure of contact parts to contact causes circuit breaking.
Causes: improper use, by the large diameter of the socket pin or pen expansion caused by permanent deformation.
Rule out: replace the jack.
(3) phenomenon: curtain movement of contact parts.
Causes: contact parts size out of tolerance, claw damage.
Rule out: replace connector or contactor.
(4) phenomenon: circuit on and off
Causes: there are nonmetallic residues or film resistance overtolerance between the contact parts, permanent deformation of the jack after multiple inserts, and insufficient elasticity of the contact parts
Elimination method:
1. Clean with alcohol and blow dry with hot air
2. Reciprocating plug damage oxide film layer, make it meet the requirements
3. Replace or repair contact parts
(5) phenomenon: wire damage, broken cause circuit break
Causes: excessive stress on some wires when wrapping wire harness, allowance left for random position difference among wires not considered in wire assembly, poor end connection technology including virtual welding and virtual pressure, and faulty assembly of wires that did not clamp cable clamp.
Elimination method: replace (press joint) with new contact parts, braze (weld) again, straighten wiring harness.

Poor insulation.
(1) phenomenon: short circuit, insulation resistance out of tolerance
Causes: high humidity, serious pollution, water or other liquids into the insulation, metal surplus fell into the interior.
Elimination methods: improve the use environment, use alcohol to clean the foreign surplus, dry with hot air
(2) phenomenon: broken insulator
Causes: excessive insertion and withdrawal force, internal defect of insulator, damage by external force.
Rule out: replace connectors or insulators

Poor fixation.
(1) phenomena: shell damage
Cause: internal defect of shell, damage by external force
(2) phenomenon: the bayonet connector becomes loose after it is inserted
Cause: corrugated spring fracture
Rule out: replace the plug or corrugated spring
(3) phenomenon: the bayon-hole connector is stuck after it is inserted
Causes: corrugated spring poor quality, elastic instability
Rule out: replace the plug or corrugated spring
(4) phenomenon: plug and socket cannot be plugged together
Causes: misuse, the key position does not match
Troubleshooting method: do not forcibly plug in case of this fault, should check the hole position arrangement and key position, complete the correct placement

Poor sealing.
Phenomenon: sealing damage or leakage rate out of tolerance
Causes: glass insulator stress concentration caused crack damage, installation gasket failure
Rule out: replace the sealed socket or gasket


Post time: Jul-30-2019