What are the three types of automotive connector failures?

Connector manufacturers must identify and analyze the physical and mechanical phenomena in the environment that may affect the performance of the connector. In order to evaluate the stability of the connector according to the application conditions specified by the vehicle manufacturer, the connector manufacturer implements an elaborate test procedure. In the event of a connector failure, one of three failure modes can most likely be identified: fretting corrosion, electrical failure, and connector mating problems. Below, the editor will give you an analysis of the three failure modes of automotive connectors. Corrosive gas, high humidity and strong vibration are the three major conditions that cause oxidation and friction corrosion and lead to connector failure. These environmental factors can have a significant impact on tin and lead-tin contact surfaces, which is the case for 90% of connector surfaces. Cable and terminal connection problems are one of the main causes of warranty and connector system failures. For automotive wiring systems, crimping is a very common method used to attach terminals to cables. This process has proven reliable. Compared with welding, it is more economical and easy to operate in improving the reliability of crimping. When wiring is installed into the vehicle at the assembly plant, improper mating of the connector may cause the connector to fail. To avoid this problem, design engineers have developed a variety of connector locking devices. Another approach is to use a plug assist device to simplify the plugging process for larger connectors.

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