Electrical Testing Methods
Electrical testing validates that the connector transmits current and signals with minimal loss. Common methods include:
- Continuity Testing
A multimeter check to confirm that each pin completes a circuit. Straightforward yet essential during assembly or when diagnosing issues. - Voltage Drop Testing
Current flows through the connector while voltage is checked across it. Even a slight drop of 50 mV under high current can generate sufficient heat to speed up deterioration. - Contact Resistance (LLCR)
Defined in EIA-364-23, this measures the resistance at the pin interface. A rise in resistance often points to oxidation, plating wear, or poor crimps. - Insulation Resistance
This measures leakage between pins and housing. It’s particularly important in humid environments where microscopic moisture films can form.
Dielectric Withstanding Voltage (Hi-Pot Test)
A voltage higher than normal operating levels is applied across insulation. Passing this test confirms the connector can resist breakdown during voltage spikes.
Mechanical Testing
Mechanical performance determines whether connectors hold up under real-world use.
- Insertion and Extraction Force
As specified in EIA-364-13, this test verifies that connectors have appropriate insertion and extraction forces—preventing them from being too loose to remain securely engaged or so tight that contact damage occurs during mating. - Durability (Mating Cycle Test)
Connectors are repeatedly mated and unmated—sometimes up to 500 cycles—while monitoring electrical stability. - Tensile Strength / Pull Test
Each wire termination is subjected to a pulling force until failure. A secure crimp should outlast the wire insulation itself. - Vibration and Shock Testing
Simulates harsh conditions in vehicles, aircraft, and machinery. A connector that loosens under vibration is a failure waiting to happen.
Environmental Testing
Environmental testing replicates the harsh conditions connectors face throughout their service life.
- Thermal Cycling & Thermal Shock
Alternating extreme hot and cold highlights material expansion and contraction issues, often causing cracks in plastics or seals. - Humidity & Damp Heat
Long-term exposure to high humidity accelerates corrosion. Post-test insulation resistance reveals whether moisture compromised performance. - Salt Spray / Corrosion Resistance
Common in marine, automotive, and outdoor applications. A connector’s plating is judged by how long it resists corrosion in a salt mist chamber.
Dust and Water Ingress (IP Ratings)
Verifies sealing. For instance, IP67-rated connectors can resist temporary submersion in water, whereas IP69K-rated ones are built to endure high-pressure, high-temperature washdowns.
Practical Tips and Best Practices
Testing isn’t just for labs—technicians can apply these practices in the field:
- Visual Inspections
Deformed contacts, unusual coloring, or softened casing often serve as early indicators of potential malfunction. - Use Proper Tools
Invest in calibrated crimpers, torque wrenches, and breakout boxes. The wrong tool can invalidate test results. - Log Test Data
Track failures, replacements, and mileage or operating hours. Over time, this creates predictive data to schedule maintenance proactively.
For mission-critical systems—from EV charging to wind farms—specify connectors qualified under relevant standards and validated with rigorous testing. The upfront effort reduces downtime, warranty claims, and safety risks, often saving multiples of the testing cost.