Your Input Desired for RoadTesting Electrical/Electronic Connectors

Randall

In practice I see a couple of other things.

Orientation ... how easy/hard is it to get around the wrong way. Part of this is the damage that can be done by incorrect insertion.

Removal ... how hard is it to remove. Some people have reduced hand strength so removing a connector might be difficult if it has retention clips.

Repair ... can you remove and repair/replace the connector pin, or do you need an unobtainium tool.

Current .. I know youre easuring the resistance but what about the mechanical strength after a few insert/removals at full rating   is it still okay.

Mounting ... I've seen too many fail at the circuit board because there is no mechnical fixing, so damage after insertion cycles might be worthwhile

Sounds like an interesting challenge, but I'm sure most of the actual figures are done by the manufacturer.

The crimping and assembly could be one area that the user has control over, and can make an otherwise good connector fail.

Mark

Sorry, but my connector useage is mostly JST and 0.10 headers.

For connector testing, the Tier 1 supplier usually has the connector manufacturer do all the ISO testing on the harness side, and they do the testing on the side that's molded into their parts.

For the DIY'er, I don't know anyone who tests connectors, many don't even have a good crimp tool.

For terminals that I don't have a crimp tool for, I use small nose pliers to "crimp" , then solder the wire to the terminal.

I've audited connector suppliers in the past, when I worked for Chrysler and Bosch, and I know that an automated durability test stand can cost hundreds of thousands of $$.

Realistically, you might be able to do some road tests on some hand crimp tools, the rest is based on $$ equipment.

Just to purchase a copy of one SAE spec USCAR2-6 it'll cost you $78

Performance Specification for Automotive Electrical Connector Systems USCAR2-6

https://www.sae.org/standards/content/uscar2-6/

Scott

i have some knowledge of connectors and crimptools and pull testers...i used to work for dmc in florida..it was a crimp tool factory...i used a lot of these tools and crimped a lot of wires..i never saw any re insertion testing though...you could make a manual pull tester to pull test some connections...i used to repair and assemble pneumatic and manual crimping tools...all the tools had small teeth protruding from the crimping dies.those teeth bite and indent two holes into the wire and object being crimped..i hope this helps .feel free to ask questions i will try to answer all.

Its may also be advantageous to group similar styles of connectors from different manufacturers and build up a comparison style road test as well as road tests on specific connectors.

A lot of users would probably be interested in the benefits of one type of connector over another for different types of projects.

Kind regards

It sounds really interesting, the idea of reviews of parts that are quite difficult to know much about without seeing them in the hand and using them.

Often I have to buy different connectors just to see what they are like first, because it is hard to know from the datasheet how that connector will feel, how easy it will be to use in practice, and how easy/hard to assemble with different wires and crimp tools.

For example I just purchased a load of connectors from 2-way to 8-way, but now I've found out that the 2-way connector is physically extremely difficult to unplug : ( Not enough grip area, and lots of force needed.

Also what's interesting is that there are many connectors that are similar, but subtly different - an example being the ring and spade connectors, some of which are awful (from consumer and automotive stores) and some which are excellent (from "real" connector manufacturers like TE Connectivity etc). Comparisons between other connectors that are similar, would be really helpful.

Some connectors have good strain relief, others don't (e.g. various audio connectors).

Trying connectors with a few different wire types would be useful too.

Hi Randall,

Connectors are a lot more reachable for a lot of engineers and hobbyist. There is not much problems associated in road testing and they can be easily done by so many people. The goal I feel is enticement to do the review. I can only speak for myself, a tool like this will be the enticement only. The only way the connectors would be the enticement is if someone is seriously considering these as a real life solution here and now or little in the future. To use myself as an example the recent road test of the Power supply modules would not have been an enticement if it was too specific. The value of the products would limit the amount of reviewing to take place. Again for the PSU, I had a direct project in mind and as suspected is a good product for new products in the future. This is the reason my review took a lot longer than most people would try to consider, as it has long term value.

Could connector be used by myself in the future, possibly. The connectors on their own would not allow me to spend the time on a review as I have no real need in the short of long term vision. The crimping tool though could be an enticement and would way up the considerations based on the supply and usability of the die's that are supplied or the cost and selection of the die's available. I look at my current supplies of connectors and know that I don't use a lot at any one time. I still have many sitting screaming at me when I open the draw . This is the reason why I do not apply for many road-test, unless there is a real specific need to do it or I know that I can produce a time intensive test to be of worth.

So for the items listed in order:

1. Fairly straightforward test, should be applicable to anyone road testing.
2. Mating connectors again fairly interesting. Contact resistance - would require a good low milli-ohm meter or a good two/four wire earth bonding meter that can work to really low resistance readings. I have the Keysight U1461, but many would not.
3. Not sure if my current (pardon the pun) sources would be variable up to the currents required,  but easy to do if available. If data is available then simple job, then would go back to test 2 to ensure it still meets the requirements.
4. My  U1461AU1461A would easily do this
5. I would like to build a test bed like this, although I have a lot of build projects I am working on. This type of jig would come to my favour if I completed my other jigs first. The jig would be build to vary vibration variables to simulate many types of conditions.
6. I put connectors together all the time. another straight forward easy test. The crimping tool would be the key. what you would get though is economical testers may compare it to manually using a pair of pliers and saying you don't need to spend the money. I am not one of those but I do see them posting cheaper alternatives.
7. I would test this similar to mating, although would test this outside the mating plug first as this would give connection test while inside the housing.
8. Hi Pot tester. I don't have a Hi Pot tester per-say, although I do have a 3KV power supply up to 300mA at max voltage. Danger Will Robinson!!!!
9. That would be a lot of work to do. Again an interesting test but would I go to the trouble, I am not sure. I would more than likely create a cam on my drill press too move it up and down a few thousand times. Might be a simple job.
10. Everyone has an oven, access to high temperature insulated wire. Only need a short section in the oven.
    Will they have a marriage after!
11. Test 5
12. Straight forward
13. Same again

All in all it is doable. The issue is would anyone want to go that far to carry out the test. Presently I am looking for mating connectors, not for a short test, but in the medium term. My need are specific and I have a look at the TE catalogue and was not able to find the connector I needed (Medium current guiding connectors). So I would think long and hard in carry out the test needed and whether I wish to apply. I love testing, don't get me wrong, but does it feed the wife and kids, maybe one day if I can get a better camera and lighting (one of my projects).

Cheers

Malcolm

Connectors are not very glamorous but they are an abiding interest, I always take an interest when I see a new series. I have spent a great deal of time sourcing connectors that best suit the particular application or requirement. There are several standard interconnection requirements that are used all the time that need even more careful thought since you are going to invest in tooling and stock. I think a road test should focus on these ubiquitous connector choices since everyone needs to decide how they will be handled. For example 0.1 inch pitch connectors. Most PCBs have some of these and there are many solutions, but which should you invest in?

There are many specs to consider, but for me it usually boils down to cost, size, retention and ease of assembly. For example on size it is important for your standard connectors to be "buttable". Cost, size and retention are pretty easy to deal with in a road test or a data sheet, so the big thing to evaluate is how fast and reliable can connections be made? There needs to be direct comparison between different methods and tools.

Other common connectors that could be considered:

• JST connectors that have metric pitches
• audio connectors and barrel connectors
• BNC
• terminal blocks

I do have an insulation tester, not used it yet but I understand the theory.

What about testing how the connector behaves when current exceeds it's max rating ?

It's no uncommon to use a 1A rated connector on a PCB, but the supply/load connected is capable of much more current in fault conditions.

Examples being battery powered devices, or motor drivers.

Perhaps the road test could include a mechanical force gauge to compare how hard it is to insert/remove different types of connectors.

To the commenters:

I want to thank all of you who have offered your ideas on a connectors roadtest.

Some of the things I originally suggested are probably done by the mfr during its own testing and compliance, etc.

I like the idea of comparing different connectors in a roadtest.

It sounds like the practical stuff can be roadtested removal, retention, and ease of use.

Thanks.

Randall