How to check the connection quality and performance of plug-in terminal blocks?

1、 Mechanical performance testing
Insertion and extraction force test:
Insertion and extraction force testing is a key step in evaluating the mechanical performance of plug-in terminal blocks. By using a dedicated insertion and extraction force testing instrument, the force required to insert and remove terminals can be measured at different speeds and temperatures. This test aims to ensure that the mechanical structure of the terminal is not damaged during repeated plugging and unplugging, while ensuring the stability of the connection. The insertion and extraction force test can also reveal the insertion and extraction life of the terminal in long-term use, that is, how many times the mechanical performance of the terminal can still be maintained at a stable level after insertion and extraction. If the insertion and extraction force is too high or too low, it may cause unstable connections or terminal damage. Therefore, this test is crucial to ensure reliable terminal connections.

Torque test:
Torque testing is mainly used to evaluate the mechanical strength of screws in plug-in terminal blocks. During the wire pressing process, screws need to withstand significant pressure, so it is necessary to ensure that they have sufficient strength to avoid slipping. During testing, connect a wire of the specified type and rated cross-sectional area to the terminal, and then tighten the screw with a specific torque tool to observe whether the screw breaks, deforms, or the screw head groove is damaged. If the screw remains intact after testing, it indicates that its mechanical strength meets the standard and can ensure a stable connection between the wire and the terminal. This test helps to eliminate connection failures caused by screw quality issues and improve the overall reliability of the electrical system.

Reliability test of pressure line:
The reliability test of crimping is an important method for evaluating the crimping performance of plug-in terminal blocks. During the experiment, connect wires of the specified type and rated cross-sectional area to the terminals, and hang a certain weight on them. Then, rotate the wire at a certain speed for a period of time. This test aims to simulate the pulling and twisting forces that wires may experience in actual use, in order to evaluate the crimping performance of terminals. If the wire does not slide out of the terminal clamp or break near the clamp during the testing process, it indicates that the crimping performance of the terminal is good and can ensure a stable connection between the wire and the terminal. This test helps ensure that the electrical system can maintain good connectivity even in harsh environments.

Pulling test:
Pulling test is another method for evaluating the clamping performance of plug-in terminal blocks. During the testing process, connect a wire of the specified type and rated cross-sectional area to the terminal, and pull the wire towards the axis of the wire with a certain force. This test aims to simulate the tension that wires may experience in actual use, in order to evaluate the clamping performance of terminals. During the testing process, the wires should be observed for detachment or breakage. If the wire remains intact during the testing process, it indicates that the clamping performance of the terminal is good and can ensure a stable connection between the wire and the terminal. This test helps ensure that the electrical system can maintain a good connection state even under tension, avoiding faults caused by connection failure.

Mechanical strength test:
Mechanical strength testing is a key step in evaluating the mechanical performance of plug-in terminal blocks and their enclosures. During the testing process, place the sample into the drum of the testing equipment, rotate it at a certain speed for a period of time, and then take it out for observation. This test aims to simulate the impact and vibration that terminals may experience in actual use, in order to evaluate their mechanical strength. If the terminals are not damaged after testing and there are no cracks or damages on the shell, it indicates that its mechanical strength meets the standards. This test helps ensure that the terminals can maintain good structural integrity in harsh environments and improve the overall reliability of the electrical system.

2、 Electrical performance testing
Contact resistance test:
Contact resistance testing is an important method for evaluating the static contact performance of plug-in terminal blocks. During the testing process, use tools such as a multimeter or resistance meter to measure the resistance value at both ends of the terminal. This test aims to ensure that the terminals have sufficient contact area and good contact quality when connected, thereby reducing contact resistance. If the contact resistance is too high, it may cause unstable electrical connections and even lead to malfunctions. Therefore, potential connection issues can be detected and eliminated in a timely manner through contact resistance testing. During the testing process, it is necessary to ensure that the accuracy of the testing instrument meets the requirements and strictly operate according to the testing standards to ensure the accuracy of the test results.

Voltage drop test:
Voltage drop testing is a key step in evaluating the dynamic contact performance of plug-in terminal blocks. During the testing process, connect the terminals to the circuit and power on, then measure the voltage drop across the terminals. This test aims to simulate the current and voltage that the terminals may withstand in actual use, in order to evaluate their dynamic contact performance. If the voltage drop is too large, it indicates that there is a large resistance or poor contact phenomenon in the terminal when it is powered on, which may cause unstable electrical connections or severe heating. Therefore, potential connection issues can be detected and eliminated in a timely manner through voltage drop testing. During the testing process, it is important to ensure the safety of the testing circuit and strictly follow the testing standards to ensure the accuracy of the test results.

Power frequency withstand voltage test:
The power frequency withstand voltage test is an important method for evaluating the ability of plug-in terminal housings to withstand transient or short-term power frequency overvoltages. During the testing process, connect the terminal housing to the testing circuit and apply the specified power frequency voltage for a period of time. This test aims to simulate the overvoltage that the terminal housing may withstand in actual use, in order to evaluate its insulation performance and safety. If destructive discharge occurs in the terminal housing during the testing process, it indicates that its insulation performance does not meet the requirements and there is a safety hazard. Therefore, potential insulation problems can be detected and eliminated in a timely manner through power frequency withstand voltage testing. During the testing process, it is important to ensure the safety of the testing equipment and strictly follow the testing standards to ensure the accuracy of the test results.

Impact voltage withstand test:
The impulse withstand voltage test is an important method for evaluating the ability of plug-in terminal housing to withstand transient overvoltage. During the testing process, connect the terminal housing to the testing circuit and apply the specified impulse voltage. This test aims to simulate the transient overvoltage that the terminal housing may withstand in actual use, in order to evaluate its insulation performance and safety. If destructive discharge occurs in the terminal housing during the testing process, it indicates that its insulation performance does not meet the requirements and there is a safety hazard. Therefore, potential insulation issues can be detected and eliminated in a timely manner through impact withstand voltage testing. During the testing process, it is important to ensure the safety of the testing equipment and strictly follow the testing standards to ensure the accuracy of the test results. At the same time, it is also necessary to pay attention to safety protection measures during the testing process to avoid safety accidents such as electric shock.

Temperature rise test:
The temperature rise test is an important method for evaluating the temperature rise of plug-in terminal blocks during normal use. During the testing process, connect the terminal to the circuit and power it on, then measure the temperature of the terminal and its surrounding environment. This test aims to simulate the current and voltage that the terminals may withstand in actual use, in order to evaluate their heat dissipation performance and safety. If the terminal temperature is too high during the testing process, it may cause serious consequences such as insulation material aging, deformation, and even combustion. Therefore, potential heat dissipation issues can be detected and eliminated in a timely manner through temperature rise tests. During the testing process, the safety of the testing circuit should be ensured, and the operation should be strictly carried out in accordance with the testing standards. Meanwhile, it is also necessary to pay attention to the temperature and humidity conditions of the testing environment to ensure the accuracy of the test results. If the terminal temperature is found to be too high, timely measures should be taken for heat dissipation treatment to improve the overall safety of the electrical system.