As is well known, before any product is shipped from the factory, manufacturers must undergo rigorous inspection and testing according to requirements before being sent to customers or entering the market.
The same applies to the assembly and production of high current connectors for new energy terminals. In automated assembly machines, a series of testing workstations are required to meet different testing requirements.
Xielitech, as a professional manufacturer of new energy terminal automation equipment, we serve as a hub in the industry, allowing us to effectively engage with various types of high-current connectors and diverse requirements. With our wealth of experience and expertise, certain basic testing requirements as below for high current connectors are essential on our automated assembly machines.
Vision inspection
Vision inspection, also known as CCD camera vision system is a technology that uses cameras, sensors, and software to perform visual inspections of products or components. To ensure quality control, identify defects, and improve efficiency.
- In the automatic high current connector assembling machine, the CCD camera system is applied to detect the waist diameter (middle diameter) of springs, to ensure that each terminal is of high quality and every point of the middle of springs can make contact with male terminals. Accordingly, stable current flow between the female and male terminals is guaranteed.
- In addition to checking the waist diameter, the CCD vision inspection system is equipped to inspect multiple other checkpoints.
> Crack after swaging ring.
> Damage of top profile.
> Detecting half swaging retainer ring.
> Retainer ring dislocation.
> spring damage or bend internal after test of laod.
> profile of the swaging operation (oval shape).
> Residue and chipping in the internal hole.
Male terminal and female terminal testing
Male terminal and female terminal testing play a crucial role in the operation of automated assembly machines. It is a vital workstation that ensures the quality and reliability of the final product.
The purpose of the male and female terminal testing is to eliminate the initial mechanical stress on the terminals. The mechanical stress will cause the spring to have uneven tolerance to external forces, which makes the insertion and removal process not smooth and the current is unstable.
Removing the mechanical stress can improve largerly the mechanical property of high current connector.
Insertion and withdrawal force test
Another essential test on automatic high-current connector machines is the insertion and withdrawal force test. The finished products wiil be screened out by an automation machine according to the design specifications or industry standards to determine if the component meets the required insertion or withdrawal force requirements.
There are two test methods on the automatic high current connector assembling machine. A mechanical test method and an electrical test method.
Mechanical test
Mechanical testing is a traditional yet highly dependable method for assessing the force required for insertion and withdrawal. It requires specific parts weight and sensors to detecting the high current connector qualification or not.
Case: Force=2N~6N
According to Newton’s Second Law F=ma “m” is part weight, a=g=9.8N/kg
Then Lower limit F1=2N=9.8N/kg x m1 Upper limit F2=6N=9.8N/kg x m2
m1=204g m2=612g
The parts weigh should be 204g and 612g.
Electrical test
It uses resistance strain sensor, is a type of force sensor that converts weight or pressure signals into electrical signals. It operates by using a metal resistance wire that elongates and thins when under tension, resulting in an increase in resistance.
Assembling a high-current terminal is a complex process that requires precision and attention to detail. In order to ensure that the terminal functions properly and safely, various types of testing and detection are necessary throughout the assembly process. Vision inspection, Male terminal and female terminal testing, Insertion and withdrawal force test are all essential types of testing.
Certainly, there is not only the above test function can be installed on automatic high current connector assembling machine. The machine is customized according to physical products standards and requirements, such as resistance testing. Therefore, it is an important to clarify the details and request nt of the high current connector before producing.
