Let me talk about the common faults of insulators.

1. Poor contact

The metal conductor inside the terminal is the core part of the terminal, which transmits the voltage signal from external wires or cables to the corresponding contacts of its matching connector. Therefore, due to unreasonable structural design, incorrect material selection, unstable molds, rough surfaces, unreasonable surface treatment processes such as heat treatment and electroplating, improper assembly, poor storage and usage environment, and improper operation, poor contact may occur between the contact parts and the matching parts.

2. Poor insulation

The function of the insulator is to keep the contacts arranged in the correct position. Therefore, insulating parts need to have excellent electrical performance, mechanical performance, and process moldability, especially as the density increases, the effective wall thickness of the insulator becomes thinner. This imposes stricter requirements on insulating materials, injection mold precision, and molding processes. Insulation defects such as short circuits, leakage, breakdown, and low insulation resistance can occur due to the presence of metal residues, flux, and other contaminants on the surface or inside of the insulator, as well as moisture, organic substance precipitation, and the formation of ion-conductive channels due to the adsorption of harmful gas films and surface water films, leading to moisture absorption, mold growth, and aging of the insulating materials.

3. Poor fixation

Insulators not only serve an insulating function but also typically provide precise centering and protection for extending contacts. Additionally, they have the function of mounting, positioning, and locking in place on the equipment. Poor fixation may affect the reliability of the contact, causing momentary power outages and severe product disintegration. Disassembly refers to the abnormal separation of the pins from the sockets during terminal insertion due to unreliable structure caused by materials, design, processes, etc., which can lead to serious consequences for the interruption of power transmission and signal control in the control system. Improper selection of molding processes, poor quality in heat treatment, molds, assembly, welding, etc., and insufficient assembly can also lead to poor fixation.

In addition, common issues such as peeling of plastic shells, corrosion, bruising, flash, breakage, and poor appearance caused by deformation of rough processing of contact parts, poor fit of positioning and locking dimensions, inconsistent processing quality, and excessive total separation force leading to poor interchangeability can generally be detected and eliminated in a timely manner during inspection and use.