In the fields of new energy, rail transit, military equipment, and high-end manufacturing, the performance of connectors directly affects the stability and safety of the overall system. As a well-known brand under the Amphenol Group that specializes in heavy-duty high-voltage connectors, Amphenol CDI is renowned for its high reliability, high current carrying capacity, and high protection level. Its products are widely used in the fields of new energy electric commercial vehicles, power equipment, construction machinery, and special equipment. However, with the acceleration of the domestic substitution trend, an increasing number of domestic connector manufacturers have begun to copy and benchmark the product specifications of CDI and promote mass delivery. But in the actual production process, the batch testing stage has become the most easily "stuck" link in the domestic substitution projects.
An Analysis of Amphenol CDI Product Test StandardsAmphenol CDI connectors typically undergo the following key testing stages before bulk delivery:
Contact Resistance Test (Ensure Low Impedance for High Efficiency)
Insulation resistance and withstand voltage test (preventing short-circuit breakdown)
Thermal rise test (verification of heat generation performance under rated current)
● Sealing test (IP67/IP69K)
● Mechanical life test (insertion and extraction cycle)
High and low temperature cycle, vibration and shock test
These tests not only constitute a "firewall" for the product's quality upon shipment, but also pose a challenge to the stability of domestic connectors under the same environment.
Two, common problems in the mass testing of domestic connectorsAlthough domestic connector companies are increasingly mature in design specifications, the batch testing stage often exposes the following issues:
Parameter volatility is high.
Individual samples in the same batch of connectors show deviations in contact resistance or voltage resistance tests, which is due to uneven electroplating of copper materials or unstable crimping process.
Inconsistency in sealing integrity
Especially, the waterproof structure at the line end has operational differences during the bulk injection and pressure ring process, which causes water leakage in some products during the IP test.
Insufficient aging test
Batch products often fail to undergo comprehensive cold and heat shock and high-temperature aging tests, leading to performance degradation in customers' later use.
Test fixture does not match
Domestic manufacturers did not fully customize the testing fixtures according to the original CDI standards, resulting in weak reference value of the test data, and even leading to misjudgment of qualified products as unqualified due to incorrect testing.
Solution RecommendationsTo break through these difficulties, domestic connector enterprises need to start from the following aspects:
Establish a standardized testing process: Develop a full set of batch testing SOP in accordance with the Amphenol CDI product standards and strictly enforce it.
Enhance consistency control of raw materials: Strengthen batch management of copper materials, plastics, and sealing parts; supplier audit;
Develop special-purpose automatic detection equipment: improve detection efficiency, reduce human errors, and ensure stable and reliable test data.
✅ Implement batch sampling verification mechanism: Retain typical samples of each batch of shipped products, conduct long-term performance tracking, and enhance customer trust.
Strengthen the quality control of the production process: introduce the cross-review mechanism of IPQC inspection and final inspection to ensure consistency of the products exiting the factory.
The Amphenol CDI connector represents the technical benchmark of high-end connectors, and its rigorous testing system for batch products provides a reference standard and goal for our domestic substitution. Only by optimizing the testing phase on the basis of design benchmarking can domestic connectors truly enter the stage of "mass production reliability" and achieve comprehensive substitution in stringent industries such as new energy, military, and engineering.
If you are interested in the domestic substitute products for this brand connector or have purchasing needs, or if you have production or sales channels for the domestic substitute products of this brand connector and wish to engage in in-depth cooperation or communication, please contact via the following contact information:
Manager Zhang (18665383950, WeChat number the same)Contact us, we look forward to joining hands with more industry partners to move forward together.
