Verifying the durability of automotive connectors requires a series of tests to ensure their reliability and stability under various usage conditions. These tests mainly include electrical performance tests, mechanical performance tests, and environmental adaptability tests.
Electrical performance test of automotive connectors
Contact resistance test: used to evaluate the conductive performance of the connector. The contact resistance should be kept within the specified range to ensure stable current transmission.
Insulation resistance test: Verify the insulation performance of the connector to ensure that there is no short circuit or leakage between different circuits.
Withstand voltage and breakdown voltage test: Check the performance of the connector under high voltage environment to ensure that the insulating material will not be broken down.
Current cycle test: Evaluate the thermal stability and conductive performance of the connector in long-term use by repeatedly switching the current on and off.
This test simulates the current load changes in actual use and detects whether the connector can withstand repeated current shocks without overheating or poor contact. By setting different current values and number of cycles, the electrical durability of the connector can be fully evaluated.
Mechanical performance test
Insertion and extraction force test: evaluates the force required to insert and remove the connector to ensure smooth operation and no damage to the connector.
Insertion and extraction test: evaluates the service life and durability of the connector through multiple insertion and extraction operations.
Locking force test: checks the effectiveness of the connector locking device to prevent accidental loosening.
Mechanical shock test: evaluates the structural integrity and electrical performance of the connector by applying a momentary high acceleration shock to the connector.
This test simulates the impact suffered by the vehicle on bumpy roads or in an accident, and verifies whether the connector can withstand these extreme conditions without failures such as breakage, looseness or poor contact. Testing is usually carried out in accordance with relevant standards, such as ISO 16750-3 or SAE J1455.
Environmental adaptability test of automotive connectors
High and low temperature tests: evaluate the performance of connectors under extreme temperatures and detect whether thermal aging or cold brittleness occurs.
Wet heat and salt spray tests: simulate humid and corrosive environments to evaluate the corrosion resistance and sealing performance of connectors.
Vibration and shock tests: verify the mechanical stability of connectors under vibration conditions to ensure that the terminal contact surface is not affected by wear or loosening.
Sealing test: evaluate the waterproof, dustproof and pollution-proof capabilities of connectors. The test usually adopts the IPX grade standard, such as IPX4 for splashproof and IPX7 for temporary immersion.
The test method includes spraying water on the connector, immersing it in water, or using pressure difference to detect leaks. The verification of sealing performance is crucial to ensure the reliability of connectors in harsh environments.
These test methods can comprehensively evaluate the durability of automotive connectors in long-term use, ensuring that they meet industry standards and meet actual application needs. Through these tests, the overall reliability and safety of automotive electronic systems can be effectively improved.