In the field of outdoor lighting, although the cable connector is small, it shoulders the heavy responsibility of ensuring the stable operation of the entire lighting system. Every shining in the city streets, park trails or remote scenic spots behind the lamps, are inseparable from high-quality cable cable connectors as a solid guarantee of power transmission. Behind all this is a set of strict and fine quality control system playing a key role.

Source control: rigorous raw material screening

High-quality raw materials are the cornerstone of excellent cable connectors. For plastic raw materials, the company will use professional testing equipment to simulate outdoor light, temperature changes and humidity conditions for a long time to assess its weather resistance. For example, plastic samples are placed in an accelerated aging test chamber and subjected to hundreds or even thousands of hours of UV exposure, high temperature exposure, and rain cycles equivalent to years of outdoor exposure to observe color changes, surface cracks, and mechanical degradation. Only those plastic materials that can still maintain good physical properties under rigorous testing will be selected for the manufacture of cable connector shells to ensure that they can resist wind and sun for at least ten years in the outdoor environment, without brittleness, deformation and other problems.

In terms of metal materials, the corrosion resistance of cable connectors is mainly tested for key parts such as conductive terminals and fastening components. Taking a commonly used copper alloy as an example, it is immersed in a salt solution simulating the composition of sea water, and the corrosion rate of the metal surface is regularly monitored, and its corrosion resistance is accurately measured by electrochemical analysis method. At the same time, combined with the actual outdoor use scenario, taking into account acid rain, industrial waste gas and other factors, corrosion simulation tests in acidic environment will also be carried out. Only metal materials that meet the requirements of high standards of corrosion resistance can ensure the stable conduction of cable connectors in harsh environments such as the seaside and chemical parks, and avoid poor contact or open circuit failures caused by corrosion.

Rubber material as a key line of defense sealing, its elastic life is crucial. The company will simulate the force situation of the cable connector during installation and use through repeated compression and tensile cycle tests, and observe whether the rubber seal can still maintain good elastic recovery ability after thousands or even tens of thousands of times of deformation, to ensure that it can closely fit the cable and the cable connector body in long-term use, effectively waterproof and dustproof. Maintain internal electrical insulation.

Production escort: Precise process monitoring

Every link in the production process is like a gear on a precision instrument, and it must be tightly fastened and accurately operated to ensure the quality of the final product. Automatic injection molding is a key step in the manufacture of cable connector shells. High-precision injection molding equipment with advanced mold design can shape plastic raw materials. In this process, the online monitoring system real-time tracking injection pressure, temperature, speed and other parameters, once there is a deviation, such as insufficient injection pressure may lead to bubbles, loose shell, excessive temperature may cause plastic degradation affecting mechanical properties, the system will immediately automatically adjust and issue an alarm. Ensure that each enclosure has a uniform wall thickness, smooth surface and good dimensional accuracy, providing a solid foundation for subsequent assembly.

The assembly of the connecting terminals is also not to be underestimated. Workers use professional tools to crimp or weld terminals and cables in strict accordance with standard processes. In the process of crimping, the pressure sensor is used to monitor the pressure relay in real time to ensure that each terminal can be closely fitted with the cable core wire to achieve the specified contact area and ensure good electrical conductivity. Precision welding equipment is used for welding, with inert gas protection, to prevent oxidation, and at the same time, the welding joints are inspected for appearance and electrical performance, to ensure that the welding joints are firm, smooth, no virtual welding, leakage welding phenomenon.

Sealing link is the focus of quality control. For the installation of rubber seals, automatic equipment is used to ensure that its position is accurate, without deviation and distortion. After the installation is complete, an online airtight test is carried out immediately. A certain pressure of gas is filled into the cable connector, and a high-precision pressure sensor is used to monitor the pressure change and determine whether there is a leak point. Only the semi-finished products that pass the airtight test can enter the next process, and the waterproof and dustproof failure caused by sealing problems can be eliminated from the source.

Finished product inspection: rigorous sampling of simulated actual combat

The quality verification of finished products is the key link of quality control system. In order to ensure that the cable connector can cope with the outdoor complex and changeable actual environment, the company will simulate a variety of extreme conditions for sampling. In the simulated rainstorm environment, the cable connector is placed in a special spray test chamber, which is sprayed for several hours from different angles according to the standard far exceeding the daily rainfall intensity, and then the electrical insulation test is carried out to check whether there is a short circuit caused by water; The dust test simulates dusty environments such as deserts and construction sites, so that the cable connector is exposed to the air flow full of dust for a certain period of time, and then detects whether there is sand intrusion inside it, affecting mechanical properties or causing poor contact.

High and low temperature cycle test is the most important. The cable connector is placed in a test chamber with precise temperature control, repeatedly switching between extremely cold low temperatures (such as -40 ° C) and extremely hot high temperatures (such as + 80 ° C), simulating temperature changes from polar to tropical regions, and observing its sealing performance, material performance and electrical performance changes under temperature shock. After dozens of such cycles, only the cable connectors whose performance indicators are still stable and up to standard are judged to be qualified products and allowed to enter the market.

After-sales traceability: a strong backing for continuous protection

Quality control does not stop at the factory, perfect after-sales traceability system is also indispensable. Each cable connector is equipped with a unique identification code, like its "ID card", recording the production batch, raw material source, production process responsible person and other key information. Once there is a fault feedback on the market, by scanning the identification code, enterprises can quickly trace back to the source of production, accurately locate the problem link, whether it is a batch defect of raw materials, or human error in the production process, can identify the cause in the first time.

For example, in the renovation project of street lights in a city, a small number of lamps flicker and go out in some sections, which is suspected to be the fault of the cable connector. Maintenance personnel quickly collect the identification code information of the faulty cable connector and feed it back to the enterprise. Through the traceability system, the enterprise finds that the elasticity of a certain batch of rubber seals decreases under high temperature and high humidity environment, resulting in decreased waterproof performance. Subsequently, the company immediately launched an emergency plan, not only to replace the problem cable connector for the project free of charge, but also to conduct a comprehensive review of the same batch of inventory products, and in-depth analysis of the reasons, optimize the raw material formula and production process, to avoid similar problems.

We Yongchang Zhixing Feng strictly in accordance with the above, from raw material screening, production process monitoring, finished product verification to after-sales traceability of the whole process of quality control measures. It greatly reduces the incidence of failure in the use of the product, provides reliable protection for the lighting system, and maintains its own brand reputation in the stable power transmission again and again, and wins the recognition and trust of the market.