1. Interchangeability Check
Interchangeability inspections are a dynamic check. They require that mating plug and socket pairs from the same series can be interconnected, identifying any issues that prevent insertion, alignment, and locking, such as dimensional differences in insulators, contact parts, missing components, or improper assembly, even under rotational forces that could lead to disassembly. Another purpose of the interchangeability check is to promptly detect any metal excesses that could affect the insulating performance through threaded connections and locking tabs. Therefore, this inspection should be performed on terminal blocks for important applications to prevent such critical and catastrophic failure incidents.
2. Torque Wrench Inspection
Torque resistance testing is a highly effective method for assessing the reliability of terminal connections. As specified in the U.S. military standard MIL-L-39012, it is required to conduct torque resistance tests on samples from each batch in a timely manner to identify any issues promptly.
3. Conduction Wire Crimp Test
During assembly, it is often found that individual core connection wires are not properly inserted or, once inserted, cannot be securely locked, resulting in unreliable contact. The analysis reveals that the cause is burrs or dirt causing jamming in the individual installation hole threads. Particularly, when using the factory's assembled plug socket, the issue was discovered in the last few installation holes, necessitating the removal of the already installed wires from other holes and the replacement of the plug socket. Additionally, improper matching of wire diameter to the crimp hole diameter, or operational errors in the crimping process, can lead to loose crimp connections. To address this, the production factory conducts a thorough test on all installation holes of the delivered plug (socket) samples before shipment, simulating the insertion of crimped wires with pins or sockets using assembly tools to check for secure locking. According to the product technical specifications, a pull-out force test is performed on each crimped wire.
