Automotive Connector Failure Analysis

Connector, one of the important components of automobile parts, is the bridge of various automobile systems and the core component of automobile circuits. Its quality will directly affect the quality and performance of automobiles. Therefore, when designing automotive connectors, in addition to meeting the basic performance requirements of the automobile, the quality requirements of the product itself are also very high. According to the complex application environment of automotive connectors, how to effectively evaluate connectors has become an urgent need for automotive OEMs and connector manufacturers.

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Complex automotive connector failure causes include design failure, production failure, detection failure, etc. 1. Product design failure: stress concentration, insufficient application specifications, unevaluated revision, thermal stress, unreasonable crimping height, tolerance compliance, poor introduction, insufficient strength, poor coating erasure, poor application linearity, insufficient dimensional optimization. 2. Manufacturing failure: mold, assembly process pollution, electroplating, deviation, stamping, heat treatment, turning, sealing, engraving, tapping, excessive use. 3. Detection failure: Improper detection method. What are the specific sources of automotive connector failures? The failure of automotive connectors in the application can be traced back to all the following stages: 1. R&D and design stage. Incomplete consideration of the actual application environment. Improper material selection. The structural design is unreasonable. 2. Manufacturing stage. Lack of focused craftsmanship. Critical process parameters are out of control. 3. Product quality inspection stage. Test items are missing. The detection accuracy is not enough. The test method is insufficient to support the validation conclusion. 4. Commodity shipment stage. Shipping specifications do not meet customer requirements. The shipment specifications do not meet the established quality levels.

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