Preventive Measures For Poor Contact In Pre-insulated Sleeves

There are many ways to prevent pre insulated sleeve contact defects. Different standards exist; Europe and the United States have their own specific testing methods based on their respective standards. However, many testing objectives are interchangeable. Here, we introduce three of the most common and mature methods, which are essential components of production quality control.

There are also many ways to prevent pre insulated junction sleeve contact defects. Different standards exist; Europe and the United States have their own specific testing methods based on their respective standards. However, many testing objectives are interchangeable. Here, we introduce three of the most common and mature methods, which are essential components of production quality control.

Prevention Method 1: Continuity Testing

Prior to 2012, manufacturers of insulated joint sleeve generally did not perform this test during the acceptance testing of their products after production, which led to many drawbacks. Firstly, users had to perform continuity testing themselves after receiving the product, wasting production time, and potentially causing other problems due to unfamiliarity with the product. Secondly, it increased the manufacturer's burden of later maintenance and warranty. What was intended to speed up production actually backfired, causing damage to both parties. Therefore, for some critical products at key nodes, individual treatment methods should be adopted, ensuring 100% individual testing. Any seemingly insignificant oversight can cause huge losses to the user.

Prevention Method Two: Intermittent Contact Testing

Due to specific production working environments, some terminal connectors are used in systems that are moving or vibrating. Therefore, conducting only static tests in experiments is insufficient to meet actual requirements. This is because it cannot guarantee that loosening or detachment will not occur during actual operation. In this case, the connector may experience momentary power interruptions during vibration. Therefore, the experiment should simulate sudden impacts, shaking, rapid starts, and sudden stops to test the firmness of the connection. Strict standards should be applied, taking into account the specific conditions of actual application, so that the test results are meaningful. Prevention Method Three: Single-Hole Separation Force Testing

First, let's explain the concept of single-hole separation force. It refers to the force generated when a connected component changes from a static state to a moving state.  An important function of this force is to quantitatively represent the interaction between the "hole" and the "pin." Generally, the separation force of a single hole is usually too small, which may lead to signal loss or interruption under external force. Therefore, new materials and processes can be applied to improve the adhesion and contact force of the connector's contact surface. This not only improves product quality but also reduces subsequent maintenance tasks and increases the user's production efficiency.