Method and device for measuring effective contact length of connector terminal

Abstract

The invention discloses a method and equipment for measuring the effective contact length of a connector terminal, and the method comprises the steps: separating a pin terminal and a jack terminal of a to-be-detected product at equal speed and equal interval, displaying a current interval on a display screen of a tester, starting a low-resistance testing system for detection, and displaying a current resistance value on the display screen of the tester, testing the resistance value when the contact is carried out once when the current distance is moved by 0.1 mm, and recording the moving distance and the corresponding resistance value; and carrying out data analysis on the recorded moving distance and the corresponding resistance value, and adopting the displacement before the abnormal change of the resistance value as the effective contact length of the terminal. The invention provides a new detection thought, which is combined with a connector terminal contact design principle, and judges whether the terminal is in effective contact according to the change of the contact resistance, so as to carry out effective length detection entity quantification on the automobile connector terminal; and the detection accuracy can be ensured.

Description

Technical Field

[0001] The invention relates to the technical field of high-voltage interlocking electric connectors, in particular to a method and a device for measuring the effective contact length of connector terminals. Background Art

[0002] In today's automotive connector industry, especially in the new energy vehicle connector industry, quality accidents due to insufficient effective contact length of connector terminals occur frequently, such as instantaneous interruption of current or electrical signal transmission, gap break, etc., which seriously affect the safety of the entire vehicle; according to incomplete statistics, among many accidents such as instantaneous interruption of current or electrical signal transmission, gap break, etc., insufficient effective contact length of connector terminals accounts for more than 50%; in view of the above reasons, in the design stage of new energy vehicle connectors, it is necessary to focus on analyzing and verifying the effective contact length of terminals. Since there are many methods for analyzing and verifying the effective contact length of terminals, most of them use digital model verification and dimensional chain analysis without physical verification, that is, the effective contact length of terminals is not discussed on the actual connector.

[0003] According to industry research, in order to ensure the effective length of terminals in the new energy vehicle connector industry, there are generally two methods: one is digital model verification, and the other is dimensional chain analysis. Both of the above methods belong to the category of theoretical analysis and cannot detect the effective contact length of the actual terminals.

[0004] In summary, it can be seen that the existing terminal effective length measurement methods in the new energy vehicle connector industry do not take the actual situation into consideration and cannot accurately measure the effective length of the terminal. Summary of the invention

[0005] In order to solve the above technical problems, the purpose of the present invention is to provide a method and device for measuring the effective contact length of connector terminals. In combination with the contact design principle of connector terminals, a low resistance tester is used to monitor the contact resistance of the terminals in the connector, and whether the terminals are in effective contact is determined based on the change in contact resistance, thereby realizing the measurement of the effective contact length.

[0006] The present invention solves the above problems through the following technical solutions:

[0007] A method for measuring the effective contact length of a connector terminal, comprising:

[0008] The pin terminals and the socket terminals are respectively installed into a connector consisting of a plug and a socket for plug-in connection to form a product to be tested;

[0009] Place the product to be tested into the product positioning mechanism of the automatic load testing machine, and keep the pin terminals and the socket terminals in the inserted position, and then clamp the test wire clamps of the low resistance tester at the ends of the cables connected to the pin terminals and the socket terminals, respectively, to achieve conduction between the low resistance tester and the product to be tested;

[0010] Then, the load test system of the automatic load tester is controlled to start the test, and the products to be tested are separated at equal speed and spacing through the product positioning mechanism, and the current spacing is displayed on the tester display screen. The low resistance test system of the low resistance tester is started to test and the current resistance value is displayed on the tester display screen. The resistance value at the time of contact is tested every 0.1mm displacement of the current spacing, and the moving distance and the corresponding resistance value are recorded;

[0011] The recorded moving distance and the corresponding resistance value were analyzed, and the displacement before the resistance value showed an abnormal change was taken as the effective contact length of the terminal.

[0012] As a further improvement, the method for determining the abnormal change is:

[0013] If the rate of change Mn between the nth resistance value and the n-1th resistance value is greater than 10% of the rate of change M of the previous two adjacent resistance values, the nth resistance value is considered to be an abnormal change, and it is considered that the socket of the socket terminal is in contact with the original corner of the top of the pin of the pin terminal.

[0014] As a further improvement, the method for determining abnormal changes further includes:

[0015] Determine whether the effective contact length of the terminal used is accurate. If the rate of change Mx of the resistance value detected after the nth resistance value is greater than or equal to the rate of change Mn of the nth resistance value and the n-1th resistance value, then the effective contact length of the terminal used is considered to be accurate.

[0016] At the same time, the present invention also solves the above problems through the following technical solutions:

[0017] A connector terminal effective contact length measuring device is used to implement a connector terminal effective contact length measuring method as described above, wherein the detection system consists of a low resistance tester and an automatic load testing machine, wherein the low resistance tester is provided with a low resistance test system, a test wire clamp and a tester display screen, and the automatic load testing machine is provided with a load testing system, a product positioning mechanism and a testing machine display screen.

[0018] As a further improvement, the product to be tested is composed of a pin terminal and a jack terminal that are inserted into a connector; the connector includes: a plug and a socket that are plug-connected, the pin terminal is arranged in the socket, and the jack terminal is arranged in the plug, so as to realize the connection between the pin terminal and the jack terminal by plugging the plug and the socket; the tail of the jack terminal and the pin terminal are both connected with cables to form a jack terminal wiring harness and a pin terminal wiring harness respectively, and after the jack terminal and the pin terminal are respectively installed in the plug and the socket with the jack terminal and the pin terminal, they are fixed by plugging the plug and the socket, so that the pin terminal is inserted in the jack terminal.

[0019] As a further improvement, the low resistance tester has a low resistance tester shell, two test wire clamps are connected to the low resistance test system and extend out of the low resistance tester shell, the tester display screen is connected to the low resistance test system and is arranged on the outer surface of the low resistance tester shell, and the low resistance test system clamps the terminal wiring harness of the product to be tested respectively through the test wire clamps to achieve conduction so as to measure the current resistance value of the product to be tested through the low resistance test system, and display it through the tester display screen.

[0020] As a further improvement, the automatic load testing machine is overall in an "L"-shaped structure, the control panel of the load testing system is arranged outside the "L"-shaped structure, the positioning mechanism and the testing machine display screen are respectively connected to the load testing system and arranged on the "L"-shaped structure, the positioning mechanism is used to clamp the plug and socket of the product to be tested, so as to adjust the distance between the plug and the socket, that is, the pin terminal and the socket terminal through the positioning mechanism, and display the distance through the testing machine display screen.

[0021] As a further improvement, a slide rail is formed on the vertical part of the automatic load testing machine, and the upper end of the positioning mechanism can be slidably arranged in the slide rail. A load sensor is arranged on the upper end of the positioning mechanism, and the lower side of the load sensor is connected to the upper part of the clamp, so that the plug and socket of the product to be tested can be clamped by the upper part of the clamp and the lower part of the clamp fixed on the horizontal part of the automatic load testing machine, and the load sensor measures the force on the upper part of the clamp and converts it into a corresponding electrical signal for output.

[0022] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0023] The present invention provides a new detection idea. Combining with the connector terminal contact design principle, a low resistance tester is used to monitor the terminal contact resistance in the connector. Whether the terminal is in effective contact is determined according to the change of the contact resistance. This can effectively avoid the problem that the current terminal effective length detection means in the automotive connector industry cannot be quantified in kind. This measurement method can be combined with an automatic load testing machine to simultaneously realize automatic program control monitoring, high-speed and high-precision monitoring, which can effectively avoid the distance error caused by manual movement during the test, thereby ensuring the accuracy of the detection. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the explosion of the product to be detected in the present invention;

[0025] Figure 2 This is a schematic diagram of the structure in which the product to be tested in the present invention is assembled in place;

[0026] Figure 3 It is a cross-sectional schematic diagram of the product to be tested in the present invention after being assembled in place;

[0027] Figure 4 This is a schematic diagram of terminal matching after the product to be tested in the present invention is assembled in place;

[0028] Figure 5 It is a schematic diagram of the contact between the original angle of the top of the jack and the pin during the test of the product to be tested in the present invention;

[0029] Figure 6 This is a schematic diagram showing that the jack and the pin are completely out of contact during the testing process of the product to be tested in the present invention;

[0030] Figure 7 It is a structural schematic diagram of the low resistance tester in the present invention;

[0031] Figure 8 It is a structural schematic diagram of the automatic load testing machine in the present invention;

[0032] Fig. 9 It is a schematic diagram of the coordination of the detection device of the present invention.

[0033] Figure numerals: 1. test product; 1-1. plug; 1-1-1. jack terminal; 1-1-1-1. jack terminal wiring harness; 1-2. socket; 1-2-1. pin terminal; 1-2-1-1. pin terminal wiring harness; 2. test system; 2-1. low resistance tester; 2-1-1. low resistance test system; 2-1-2. low resistance display screen; 2-1-3. test wire clamp; 2-2. automatic load testing machine; 2-2-1. load test system; 2-2-2. positioning mechanism; 2-2-2-1. load sensor; 2-2-2-2. upper part of the fixture; 2-2-3. load display screen; 2-2-4. slide rail. DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solutions and advantages of the present application clearer, the technical solutions in the embodiments of the present application will be described in more detail below in conjunction with the drawings in the preferred embodiments of the present application. In the drawings, the same or similar reference numerals throughout represent the same or similar parts or parts with the same or similar functions. The described embodiments are part of the embodiments of the present application, not all of the embodiments. The embodiments described below with reference to the drawings are exemplary and are intended to be used to explain the present application, and should not be construed as limitations on the present application. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present application.

[0035] The embodiments of the present application are described in detail below with reference to the accompanying drawings.

[0036] In the description of this application, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, or it can be an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in this application can be understood according to specific circumstances.

[0037] In the description of the present application, it should be understood that the terms "upper", "lower", "front", "back", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating orientations or positional relationships, are orientations or positional relationships based on the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the referred device or element must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present application.

[0038] In addition, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, for example, a process, method, system, product, or display that includes a series of steps or elements is not necessarily limited to those steps or elements explicitly listed but may include other steps or elements not explicitly listed or inherent to such process, method, product, or display.

[0039] The following will be combined Figure 1-9 , a connector terminal effective contact length measurement method and device involved in the embodiment of the present application are described in detail. It is worth noting that the following embodiments are only used to explain the present application and do not constitute a limitation on the present application.

[0040] Embodiment 1:

[0041] A method for measuring the effective contact length of a connector terminal of this embodiment is implemented by a detection system and a product to be detected. The detection system is composed of a low resistance tester, an automatic load tester, etc., wherein the low resistance tester is provided with a low resistance test system and a test wire clamp and other structures, and the automatic load tester is provided with a load test system and a product positioning mechanism and other structures; the method includes:

[0042] Inserting the pin terminal and the socket terminal pair into the connector to form the product to be tested, the connector consisting of a plug and a socket for plug-in connection;

[0043] Place the product to be tested into the product positioning mechanism of the automatic load testing machine, keep the pin terminal and the socket terminal in the inserted position, and then clamp the test wire clamps of the low resistance tester at the ends of the cables connected to the tail ends of the pin terminal and the socket terminal, respectively, to achieve conduction between the low resistance tester and the product to be tested;

[0044] Then, the load test system of the automatic load tester is controlled to start the test, and the products to be tested are separated at equal intervals through the product positioning mechanism and the current interval is displayed on the tester display. At this time, the low resistance tester test system starts the test and displays the current resistance value on the tester display of the automatic load tester. The contact distance between the pin terminal and the socket terminal is moved. The resistance value at the time of contact is tested every 0.1mm displacement of the current interval, and the moving distance and the corresponding resistance value are recorded;

[0045] The recorded moving distance and the corresponding resistance value were analyzed, and the displacement before the resistance value showed an abnormal change was taken as the effective contact length of the terminal.

[0046] Specifically, when the resistance value changes abnormally, the socket of the socket terminal just touches the original corner of the top of the pin of the pin terminal; until the resistance value becomes infinite, the socket and the pin are completely out of contact.

[0047] In an optional embodiment, the method for determining abnormal changes is:

[0048] If the rate of change between the nth resistance value and the n-1th resistance value is M n When it is greater than 10% of the rate of change M of the two previous adjacent resistance values, the nth resistance value is considered to be an abnormal change, and it is considered that the socket of the socket terminal is in contact with the original corner of the top of the pin of the pin terminal.

[0049] In another optional embodiment, the method for determining abnormal changes further includes:

[0050] Determine whether the effective contact length of the terminal is accurate. If the change rate of the resistance value after the nth resistance value is M x are greater than or equal to the rate of change M between the nth resistance value and the n-1th resistance value n , then it is considered that the effective contact length of the terminal used is accurate.

[0051] Embodiment 2:

[0052] See attached Figure 1-9 A connector terminal effective contact length measuring device is used to implement a connector terminal effective contact length measuring method as described in Example 1, including a detection system and a product to be detected. The detection system is composed of a low resistance tester, an automatic load testing machine, etc., wherein the low resistance tester is provided with a low resistance test system, a test wire clamp and a tester display screen and other structures, and the automatic load testing machine is provided with a load testing system, a product positioning mechanism and a testing machine display screen and other structures.

[0053] Specifically, the product to be tested is composed of a pin terminal 1-2-1 and a socket terminal 1-1-1 inserted into a connector, and the connector includes: a plug 1-1 and a socket 1-2 connected to each other, the pin terminal 1-2-1 is arranged in the socket 1-2, and the socket terminal 1-1-1 is arranged in the plug 1-1, so as to realize the connection between the pin terminal 1-2-1 and the socket terminal 1-1-1 by plugging the plug 1-1 and the socket 1-2; the socket terminal 1-1-1 and the pin terminal 1-2-1 are connected to each other. 1 are connected with cables at the tail to form a socket terminal harness 1-1-1-1 and a pin terminal harness 1-2-1-1 respectively. After the socket terminal 1-1-1 and the pin terminal 1-2-1 are respectively installed into the plug 1-1 and the socket 1-2, the plug 1-1 and the socket 1-2 are fixed by plugging and fixing, so that the pin terminal 1-2-1 is inserted into the socket terminal 1-1-1 to ensure that the pinhole terminals are in mating contact.

[0054] The detection system 2 is composed of a low resistance tester 2-1, an automatic load testing machine 2-2, etc.;

[0055] The low resistance tester 2-1 includes: a built-in low resistance test system 2-1-1, two test clips 2-1-3 connected to the low resistance test system 2-1-1 and extending out of the low resistance tester housing, and a low resistance display screen 2-1-2 connected to the low resistance test system 2-1-1 and arranged on the outer surface of the low resistance tester housing; the low resistance test system 2-1-1 clamps the jack terminal harness 1-1-1-1 and the pin terminal harness 1-2-1-1 of the product to be tested respectively through the test clips 2-1-2 to achieve conduction so as to measure the current resistance value of the product to be tested through the low resistance test system 2-1-1 and display it on the display screen.

[0056] The automatic load testing machine 2-2 is in an "L"-shaped structure as a whole, comprising: a built-in load testing system 2-2-1, a positioning mechanism 2-2-2 connected to the load testing system 2-2-1 and arranged on the "L"-shaped structure, and a load display screen 2-2-3 connected to the load testing system 2-2-1 and arranged outside the "L"-shaped structure; the plug 1-1 and the socket 1-2 of the product to be tested are clamped by the positioning mechanism 2-2-2, so that the height of the positioning mechanism 2-2-2 can be moved up and down to adjust the distance between the plug 1-1 and the socket 1-2, that is, between the pin terminal 1-2-1 and the jack terminal 1-1-1, and the distance is displayed through the load display screen 2-2-3.

[0057] Specifically, a slide rail 2-2-4 is formed on the vertical portion of the automatic load testing machine 2-2, and the upper end of the positioning mechanism 2-2-2 can be slidably arranged in the slide rail 2-2-4. The slide rail 2-2-4 plays a guiding role during the movement of the positioning mechanism 2-2-2; a load sensor 2-2-2-1 is arranged on the upper end of the positioning mechanism 2-2-2, and the lower side of the load sensor 2-2-2-1 is connected to the upper part of the clamp 2-2-2-2, so that the plug 1-1 and the socket 1-2 of the product to be tested are clamped by the upper part of the clamp and the lower part of the clamp fixed on the horizontal part of the automatic load testing machine 2-2, and the load sensor 2-2-2-1 measures the force on the upper part of the clamp and converts it into a corresponding electrical signal for output.

[0058] Its working process is as follows: the product 1 to be tested is placed in the positioning mechanism 2-2-2 of the automatic load testing machine 2-2, and the plug 1-1 and the socket 1-2 of the tested product 1 are kept in the inserted position by adjusting the load testing system 2-2-1 of the automatic load testing machine 2-2; the test wire clamps 2-1-2 of the low resistance tester 2-1 are respectively clamped at the ends of the matching socket terminal harness 1-1-1-1 and the pin terminal harness 1-2-1-1; the test is started again by controlling the load testing system 2-2-1 of the automatic load testing machine 2-2, and the separation rate is 6mm / min, so that the product 1 to be tested is separated at a constant speed and equal spacing;

[0059] At this time, the low resistance test system 2-1-1 of the low resistance tester 2-1 starts the test and displays the resistance value on the low resistance display screen 2-1-2. The initial position displacement is 0. Starting from the initial position, the contact resistance value is tested every time the separation displacement is superimposed by 0.1mm. The experimenter records the displacement data and the corresponding resistance value. When the resistance value changes abnormally, the initial test resistance value*1.1 is used in this embodiment. At this time, the jack contacts the original angle of the top of the pin. Figure 5 , stop testing until the resistance value is infinite, at which point the jack and the pin are completely out of contact, refer to Figure 6 ;

[0060] After the test is completed, the recorded displacement-contact resistance data table is analyzed. It can be seen that when the separation displacement is 5.2mm, the contact resistance value abnormally changes, exceeding the upper limit of 1.1 times the initial resistance, and has a trend of continuous increase as the displacement continues to increase; when the socket and the top of the pin are in contact at 5.2mm, refer to the attached figure. Figure 5 , 5.2mm later stage can correspond to Figure 5-6 The displacement process is shown; at this point, it can be concluded that the effective contact length of the terminal is 5.2mm.

[0061] Record displacement-contact resistance data table:

[0062]

[0063] The present invention combines the contact design principle of connector terminals, adopts a low resistance tester to monitor the contact resistance of the terminals in the connector, and determines whether the terminals are in effective contact according to the change of the contact resistance, which can effectively avoid the problem that the effective length detection means of the terminals in the current automotive connector industry cannot be quantified in kind; the measurement method combined with the automatic load testing machine can simultaneously realize automatic program control monitoring, high-speed and high-precision monitoring, which can effectively avoid the distance error caused by manual movement during the test process.

[0064] Although the present invention is described herein with reference to the illustrative embodiments of the present invention, the above embodiments are only preferred embodiments of the present invention, and the embodiments of the present invention are not limited to the above embodiments. It should be understood that those skilled in the art can design many other modifications and embodiments, which will fall within the scope and spirit of the principles disclosed in this application.

Claims

1. A method for measuring the effective contact length of a connector terminal, characterized in that: include: The pin terminals and the socket terminals are respectively installed into a connector consisting of a plug and a socket for plug-in connection to form a product to be tested; Place the product to be tested into the product positioning mechanism of the automatic load testing machine, and keep the pin terminals and the socket terminals in the inserted position, and then clamp the test wire clamps of the low resistance tester at the ends of the cables connected to the pin terminals and the socket terminals, respectively, to achieve conduction between the low resistance tester and the product to be tested; Then, the load test system of the automatic load tester is controlled to start the test, and the products to be tested are separated at equal speed and spacing through the product positioning mechanism, and the current spacing is displayed on the tester display screen. The low resistance test system of the low resistance tester is started to test and the current resistance value is displayed on the tester display screen. The resistance value at the time of contact is tested every 0.1mm displacement of the current spacing, and the moving distance and the corresponding resistance value are recorded; The recorded moving distance and the corresponding resistance value were analyzed, and the displacement before the resistance value showed an abnormal change was taken as the effective contact length of the terminal.

2. A method for measuring the effective contact length of a connector terminal according to claim 1, characterized in that: The method for judging the abnormal change is: If the rate of change Mn between the nth resistance value and the n-1th resistance value is greater than 10% of the rate of change M of the previous two adjacent resistance values, the nth resistance value is considered to be an abnormal change, and it is considered that the socket of the socket terminal is in contact with the original corner of the top of the pin of the pin terminal.

3. A method for measuring the effective contact length of a connector terminal according to claim 2, characterized in that: The method for determining abnormal changes also includes: Determine whether the effective contact length of the terminal used is accurate. If the rate of change Mx of the resistance value detected after the nth resistance value is greater than or equal to the rate of change Mn of the nth resistance value and the n-1th resistance value, then the effective contact length of the terminal used is considered to be accurate.

4. A connector terminal effective contact length measuring device, used to implement a connector terminal effective contact length measuring method as claimed in any one of claims 1 to 3, characterized in that: The detection system consists of a low resistance tester and an automatic load tester, wherein the low resistance tester is provided with a low resistance test system, a test wire clamp and a tester display screen, and the automatic load tester is provided with a load test system, a product positioning mechanism and a tester display screen.

5. A connector terminal effective contact length measuring device according to claim 4, characterized in that: The product to be tested is composed of a pin terminal and a socket terminal inserted into a connector; the connector includes: a plug and a socket for plug-in connection, the pin terminal is arranged in the socket, and the socket terminal is arranged in the plug, so as to realize the connection between the pin terminal and the socket terminal by plugging the plug and the socket; the tail of the socket terminal and the pin terminal are both connected with cables to form a socket terminal wiring harness and a pin terminal wiring harness respectively, and after the socket terminal and the pin terminal are respectively installed into the plug and the socket, they are fixed by plugging the plug and the socket, so that the pin terminal is inserted into the socket terminal.

6. A connector terminal effective contact length measuring device according to claim 4, characterized in that: The low resistance tester comprises a low resistance tester housing, two test wire clamps connected to the low resistance tester system and extending out of the low resistance tester housing, a tester display screen connected to the low resistance tester system and arranged on the outer surface of the low resistance tester housing, and the low resistance tester system clamps the terminal wiring harness of the product to be tested respectively through the test wire clamps to achieve conduction so as to measure the current resistance value of the product to be tested through the low resistance tester system and display it through the tester display screen.

7. A connector terminal effective contact length measuring device according to claim 4, characterized in that: The automatic load testing machine is in an "L"-shaped structure as a whole. The control panel of the load testing system is arranged outside the "L"-shaped structure. The positioning mechanism and the testing machine display screen are respectively connected to the load testing system and arranged on the "L"-shaped structure. The positioning mechanism is used to clamp the plug and socket of the product to be tested, so as to adjust the distance between the plug and the socket, that is, the pin terminal and the socket terminal through the positioning mechanism, and display the distance through the testing machine display screen.

8. A connector terminal effective contact length measuring device according to claim 7, characterized in that: A slide rail is formed on the vertical part of the automatic load testing machine, and the upper end of the positioning mechanism is slidably arranged in the slide rail. A load sensor is arranged on the upper end of the positioning mechanism, and the lower side of the load sensor is connected to the upper part of the clamp, so that the plug and socket of the product to be tested can be clamped by the upper part of the clamp and the lower part of the clamp fixed on the horizontal part of the automatic load testing machine, and the load sensor measures the force condition of the upper part of the clamp and converts it into a corresponding electrical signal for output.

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