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The role of the aerospace electrical connector and its components is very important. If it fails, it may cause the spacecraft to malfunction, and the consequences will be unimaginable. This article analyzes and summarizes some common failures of aerospace electrical connectors.
1. There are many reasons for the disconnection of the circuit. For example, the design of the ammonia nitrogen detector is unreasonable or the quality of the heat treatment process is poor, the jack material is hard and brittle and the jack spring is broken, or the jack material is too soft and the jack is loose; the quality of the bonding process Poor, excess glue is stuck to the insertion part of the socket and the pin; the quality of the assembly process is poor, and the secondary locking device is not assembled in place; the wire core is broken due to improper wire stripping or mechanical damage during the production process; crimping The hole does not match the wire diameter. Improper use of crimping pliers causes false pressure, etc. Open circuit performance means that the circuit resistance is higher than the judgment value of the instrument's on-off resistance during the continuity detection of the connector components.
2. Poor contact The contact is the core conductive part of the connector assembly. It will come from the cable connected to the tail of the contact. The voltage or signal of the wire is transmitted to the corresponding contact. Therefore, the contact must have an excellent structure. Stable and reliable contact retention and good electrical conductivity. There are many factors that cause poor connector contact, such as unreasonable contact structure design, wrong material selection, out-of-poor machining size, rough surface, and heat treatment.
3. The terminal contact resistance of the instantaneous power-off connector assembly is mainly related to the contact pressure. When the contact pressure remains unchanged or its change is almost negligible, the corresponding is static contact resistance; if the connector is in vibration. Shock. In a dynamic environment such as a collision, the contact resistance will vary with the magnitude of the contact pressure. The direction and time change. Since this change occurs in a very short period of time, during this period, a pair of mated contact pieces may be squeezed or pulled, which may cause the contact resistance to decrease or increase, and even cause instantaneous power failure.
4. The insulation resistance is mainly affected by the insulator material. temperature. humidity. Defaced. The influence of factors such as the test voltage and the duration of the applied test voltage. Excess metal on or inside the insulator. Surface dust. Contamination of flux, etc. is damp. The organic material precipitates and the harmful gas adsorption film are fused with the surface water film to form ionic conductive channels and mildew spots. The aging of the insulating materials will cause short circuits.
5. Short circuit refers to the failure of the circuit in the connector assembly that should not be conducted, which is a fatal failure that endangers the safe use performance. Insulation materials are of poor quality and are hot and humid. Salt spray. Harsh environmental conditions such as dust, wiring errors and poor crimping quality are all direct causes of short circuits. The withstand voltage test can be used to determine whether there is a short-circuit fault in the connector assembly.
6. Miswiring Miswiring refers to incorrect wiring faults caused by operational errors during the production and assembly of connector components. Some technologies that have been successfully applied to civil connector components can be used for testing.
7. Poor fixation. A pair of connector assemblies in a mated state usually provide accurate centering and protection for the protruding contacts, as well as installation and positioning. Locking and fixing function. Poor fixation can affect reliable contact and cause instantaneous power failure, and more severely cause connector plugs and sockets. Insulators and contacts. The pins and sockets are not properly separated or even disassembled, which leads to the interruption of power transmission and signal control of the control system.
8. Poor sealing In order to adapt to the harsh aerospace use environment and improve the service life and reliability of connector components, many models have selected connector components with sealed contacts with sealing bodies. The main factors that cause the failure of poor sealing are: due to poor interchangeability of the shell. Poor quality of insulator injection molding. Stress concentration at the interface between the insulator and the contact, as well as microcracks and bubbles caused by poor contact mating.
