In the field of outdoor electrical connections, the quality of outdoor waterproof wire connectors is crucial. It not only ensures the stability and efficiency of power transmission, but also maintains reliable operation under harsh environmental conditions such as wind and rain, dust, extreme temperature and humidity. Our Shenzhen Yongchang Zhixingfeng as a professional waterproof connector manufacturers, has a strict quality testing system for product quality escort.

Raw material inspection, strict screening

Raw materials are the foundation of the quality of outdoor waterproof wire connectors, and any defects in raw materials may lead to the failure of the final product. Therefore, in the raw material inspection link, we must use a variety of advanced testing methods and strict standards.

For metal materials, such as copper, aluminum, etc., chemical composition analysis must first be carried out. The spectral analyzer is used to accurately detect the content of various elements in it to ensure that it meets the alloy composition ratio required by the design. For example, the copper content in copper should be within the specified range, while controlling the content of impurity elements to ensure good electrical conductivity and corrosion resistance. Secondly, mechanical properties are tested, including tensile strength, yield strength, hardness and other indicators. These properties are directly related to the reliability of the connector when it is subjected to external forces, such as not easily deformed or damaged during installation or when subjected to external impact.

Plastic materials are also widely used in outdoor waterproof wire connectors, such as shell materials. During the inspection, the melting index of the plastic should be measured, which reflects the fluidity of the plastic in the molten state and affects the dimensional accuracy of the injection molding process and products. At the same time, thermal deformation temperature tests are carried out to determine the stability of plastics in high temperature environments. In addition, it is also necessary to detect the weather resistance of plastics, by simulating outdoor ultraviolet radiation, temperature changes and other conditions, observe the color change of the material, mechanical property attenuation, etc., to ensure that it will not age and embrittlement in long-term outdoor use.

The rubber material, especially the rubber ring used for sealing, is the key to ensure the waterproof performance of the connector. It is necessary to test the basic properties of rubber such as hardness, tensile strength, elongation at break, and aging resistance test, such as after exposure to high temperature and ozone environment for a certain time, check the performance changes of rubber. In addition, the adhesive strength of rubber and metal and plastic can not be ignored, through a special bonding strength test to ensure that the sealing rubber will not fall off or appear gaps after the connector assembly, so as to effectively prevent water intrusion.

The whole production process quality detection, excellence of the whole process control

In the production process of outdoor waterproof wire connectors, each process is equipped with strict quality inspection points to ensure that each link meets quality standards.

In the parts processing, the dimensional accuracy of metal parts is measured by high-precision measuring tools, such as coordinate measuring instruments. It can accurately detect the length, diameter, aperture, shape position tolerance and other dimensional parameters of the parts to ensure that it is highly consistent with the requirements of the design drawing. Any parts that are out of tolerance will be screened to avoid flowing into the next process. For the injection molding process of plastic parts, in addition to considering the dimensional accuracy control in the mold design, the size of the product will be regularly sampled during the production process, and the appearance will be checked for defects such as flash, lack of materials, and bubbles.

In the assembly process, each connector assembly process has detailed operating specifications and quality inspection standards. For example, during the connection between the wire and the conductive terminal, the fastness of the connection should be checked, and the tension test should be carried out to ensure that the wire will not fall off the terminal under the specified tension. At the same time, check the sealing of the connection part, such as the use of sealant or rubber sleeve for sealing, to ensure that the sealing material is uniform, no bubbles, no cracks, completely wrapped in the connection part. For threaded connections or fasteners, check the tightness of the connection, check whether the torque of the threaded connection meets the requirements through the torque wrench, or check whether the fastener is completely locked without loosening.

In the semi-finished product inspection stage, the connector assembled but not yet in final packaging is fully tested for electrical performance and preliminary waterproof performance checks. The electrical performance test includes the conductivity test, the use of professional conductivity tester to check whether the internal circuit of the connector is good conduction, no break or poor contact phenomenon; Voltage test, apply a voltage several times higher than the normal operating voltage, lasting for a certain time, to check whether the connector can withstand without breakdown; The insulation resistance test measures the insulation resistance value between the conductive part of the connector and the housing to ensure that it meets safety standards and prevents leakage accidents. The preliminary waterproof performance check can use a simple airtight test method, such as placing the connector in a certain pressure airtight box to observe whether there is gas leakage, or using compressed air to blow the connector to check whether there is gas leakage in the sealing part.

Comprehensive testing before the finished product leaves the factory, the final line of defense for quality assurance

The inspection before the finished product leaves the factory is the last checkpoint to ensure the quality of outdoor waterproof wire connectors, which needs to be tested comprehensively, strictly and to simulate the actual use environment.

Water resistance testing is a top priority. Immersion test is one of the commonly used methods, the finished connector is completely immersed in a certain depth of water, soaking time according to the product's waterproof grade requirements, generally ranging from a few hours to a few days. During the soaking process and after removal, it is necessary to check whether there is water intrusion inside the connector and reconfirm whether it works properly through electrical performance testing. For example, for IP67 waterproof connectors, they can still maintain good electrical insulation and conductivity after soaking in 1 meter deep water for 30 minutes; For IP68 grade products, it may be necessary to soak in deeper water for a longer time, such as no abnormality after 72 hours in water 3 meters deep. The airtight test is to fill a certain pressure of gas into the connector through professional airtight test equipment, accurately measure the amount of gas leakage, and ensure that its sealing performance reaches a very high standard.

Electrical performance testing is more rigorous and comprehensive at the finished product inspection stage. In addition to the above conductivity, voltage resistance and insulation resistance tests, contact resistance tests are also performed. Use a microohmmeter to measure the contact resistance at each connection point of the connector, as excessive contact resistance can lead to heating, increased power loss, and even connection failure. For some connectors with signal transmission functions, such as connectors used for data transmission or control signals, signal integrity tests will also be carried out to check the attenuation, distortion, delay and other conditions of the signal during transmission to ensure that the signal can be accurately and quickly transmitted.

Environmental reliability testing is to simulate the harsh outdoor environment to test the connector. The high temperature and high humidity test is to place the connector in an environmental chamber with a temperature of up to 85 ° C and a relative humidity of 85% for a certain period of time, such as 1000 hours, and then check whether its appearance, electrical performance and mechanical properties have changed. The salt spray test is to expose the connector to a salt spray environment containing a certain concentration of sodium chloride solution, simulate the environment of the seaside or industrial pollution areas, and observe the corrosion of its metal parts and the overall performance changes. In addition, vibration tests may also be carried out to simulate the vibration of the connector during transportation or in actual use to check whether its internal structure is stable and whether the connection is loose; And impact test, by applying a certain amount of energy to the impact force, test the impact resistance of the connector to ensure that it can still work normally when it is accidentally collided or dropped.

Through the strict quality inspection system from raw material inspection to the finished product, outdoor waterproof wire connector manufacturers can ensure that each product has excellent quality and can operate stably in the harsh outdoor environment for a long time. Our Shenzhen Yongchang Zhixing Feng can not only provide customers with reliable electrical connection solutions, but also establish a good brand image for the major manufacturers and enhance the market competitiveness.