Key factors for the reliability of connection terminals
The reliability of automobile high voltage wiring harness connection terminals is affected by many factors. The first is the choice of materials. High-quality conductive materials such as copper alloys have good conductivity and corrosion resistance, which can ensure stable operation during long-term current transmission. The structural design of the terminal is also crucial. Reasonable contact shape and size design can increase the contact area and improve the stability of the connection. For example, the use of a special elastic structure design can maintain close contact under vibration and impact during vehicle driving to prevent loosening or falling off. In addition, the accuracy of the manufacturing process is directly related to the quality of the terminal. High-precision processing can ensure that the dimensional tolerance of the terminal meets the requirements and reduce reliability problems caused by manufacturing defects.
The generation and influence of contact resistance
Contact resistance is a parameter that cannot be ignored in the conductive process of the connection terminal. When current passes through the connection terminal, since the contact surface is not an ideal smooth plane, there are microscopic unevenness, which will cause the current conduction path to become longer, thereby generating contact resistance. If the contact resistance is too large, it will generate too much heat when the current passes through. According to Joule's law Q=I²Rt (Q represents heat, I represents current, R represents resistance, and t represents time), this will not only reduce the energy transmission efficiency, but also may cause the local temperature of the terminal to be too high, accelerate the aging of the insulation material, and affect the overall performance and service life of the wiring harness. In a high-voltage environment, excessive heat may even cause safety accidents such as fire.
Test and evaluation methods
In order to ensure the reliability of the connection terminal and control the contact resistance, a series of test and evaluation methods are required. In the production process, professional equipment such as micro-ohmmeters can be used to measure the contact resistance of the connection terminal, set a reasonable resistance threshold, and screen out products that exceed the range. At the same time, vibration tests and temperature cycle tests that simulate actual working conditions are carried out to observe the contact stability and resistance changes of the terminals under different environments. For example, in the vibration test, the wiring harness sample with the terminal connected is installed on the vibration table, and the vibration frequency and amplitude during the driving of the car are tested. After the test, the contact resistance is measured again. If the resistance change exceeds the allowable range, it means that there is a problem with the reliability of the terminal.
Measures to improve reliability and reduce contact resistance
In response to the above problems, a variety of measures can be taken to improve the reliability of the connection terminals and reduce the contact resistance. In terms of materials, the conductive materials can be surface treated, such as silver plating, to improve their conductivity and oxidation resistance. In terms of structural design, the shape of the contact interface is optimized, and multi-point contact or surface contact is used instead of point contact to increase the contact area. During the assembly process, the assembly torque is strictly controlled to ensure that the tightness of the terminal connection meets the requirements. In addition, regular maintenance and inspection of the Automobile high voltage wiring harness to promptly detect and deal with problems such as looseness and corrosion of the connection terminals is also an important part of ensuring its reliability and stable performance.
