BlockMaster Electronics has been focusing on the design and manufacturing of various terminal blocks and connectors since 1994, including high-power PCB terminal blocks, pluggable terminals, European bar-type terminal blocks, multi-row barrier isolation blocks, screwless types and many other series. The rated current ranges from a few amperes to 380 A. The product models are abundant, supporting customization and fast delivery. It also has a local value-added processing center for quick sample response and special marking processing.
One, common failure types and causes analysis of domestic connectorsPoor Contact
The reason: problems such as floating dust, machining burrs, material aging, and fatigue of pin springs lead to an increase in contact impedance, which may cause heating or intermittent failures.
2. Loose Wire / Poor Fixation
It often occurs in situations such as improper screw tightening, insufficient structural force of the spring, or inconsistent tolerances of the mold, and in severe cases, it may lead to power failure or contact failure.
3. Overheating / Overloading
Exceeding the rated current of the connector, poor contact causing high resistance, or poor system heat dissipation can all lead to insulation aging and even trigger safety accidents.
Corrosion / Oxidation
High humidity environment or chemical medium erosion can lead to oxidation of metal contacts, increasing contact resistance, and affecting the reliability of conduction.
5. Insulation Failure
Material quality is not up to standard or process control is not strict, which may easily lead to hidden dangers such as short-circuit, leakage, or breakdown of the insulation layer.
Targeted solutions to improve the reliability of domestic connectorsStrengthen manufacturing and quality control
Import 100% on/off test, dynamic vibration reliability test, and single hole separation force detection to ensure high contact stability in both static and dynamic environments.
Conduct strict inspections of insulation structures and materials batches to ensure the insulation strength and consistency of each batch of products.
Optimize structural design and material selection
● Designed with spring clip or cage clamp, enhancing wiring fixation force and vibration resistance performance.
● Select corrosion-resistant electroplating (gold, tin) and high-temperature engineering plastics to enhance weather and environmental resistance.
Standard installation and maintenance procedures
●Recommended to use a torque screwdriver to control the tightening torque to avoid over-tightening or under-tightening.
●Regularly check the connection status, clean off the oxidation layer and impurities, and prevent contact degradation.
Strengthen product selection and safety margin
●Choose a rated current higher than the actual requirement (it is recommended to leave a 50% safety margin) to ensure long-term safe operation.
Optimize the heat dissipation channel of the system design to avoid excessive heating of the connector.
Domestic connectors have great potential in terms of conduction stability, reliability, and cost-effectiveness. The key lies in robust manufacturing processes, strict quality control, reasonable structural design, and scientific installation and maintenance. With these solutions, domestic connectors are fully capable of reaching performance levels comparable to imported BlockMaster products, especially in terms of contact reliability, safety and stability, and service life.
If you are interested in domestic alternatives to the BlockMaster Electronics brand, or have purchasing needs, or possess production or sales channels for the domestic alternatives of this connector, and wish to engage in in-depth cooperation or communication, please contact us through the following contact information:
Manager Zhang (18665383950, same WeChat number)Looking forward to working with more industry partners to jointly promote the reliability improvement of domestic connectors.
