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Your Input Desired for RoadTesting Electrical/Electronic Connectors

rscasny

While the meat of roadtested products come down to development boards or test equipment, I'd like to find some way to roadtest electric or electronic connectors. Now this may be in conjunction with a tool (e.g., crimping tool)...

 

539635-1539635-1Crimp Tool Ratchet AMP MCP Series 8-968970-18-968970-1Connector Housing MCP Series 1241392-1 -  Contact, MCP 2.8 Series
imageimageimage

 

...or another product. I am experimenting with different options. But, the connector testing is central to what I want to do.

 

Sure, connectors may not seem exciting to many of you makers. But the fact is they are neccesary for interconnection, termination, and/or environmental protection

 

So, I would like to ask the roadtest group to respond to some of my ideas regarding the roadtesting of connectors. These ideas are not meant to prescribe how a connectors roadtest should be accomplished; rather, it is to offer a variety of options for testing them.

 

If you have any comments about this topic, feel free to include them in the comments below. Thanks.

 

1. The connectors were visually inspected for correct use of materials, proper construction, correct part number and insert markings and overall quality of workmanship.

 

2. Mate connectors and measure contact resistance.

 

3. Build circuit with variable current source, connector and standard resistive load. Increase current up to rating. Measuring contact resistance.

 

4. Measure insulation resistance.

 

5. Build a test bed such that the connector's IP rating and or vibration withstand capability can be tested.

 

6. For connectors that are user assembled with housing and custimizable contact system, conduct experiments on the ease of assembling the connector

 

7. Conduct experiments to review the contact rention capabilities of the connector

 

8. In the event a roadtester has access to a hi pot tester, measure the dielectric withston voltage. (This really would be beyond the capabilities of most roadtesters. So, not that important to me.)

 

9. Maintenance aging -- re-instertion test -- durability test: reinsert the plug and receptacle "x" number of times to verify their functionality with use. (I added this because I was curious about the snarky comments I would get. I would not expect any roadtester to re-insert something 100 or 1000 times! Although maybe one of you could design a rig to do it!)

 

10. Temperature test to maintain continuity

 

11. fretting corrosion test--vibration test

 

12. immersion test (water/salt spray/oil/other lubricant)

 

13. cable pull test

Parents

  • 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 image. 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

Reply

  • 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 image. 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

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