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contact resistance
The terminal to terminal contact resistance plus the resistance of each terminal's wire to the crimped connection. For end plate type connections, it only includes the resistance from one wire to the terminal connection. Including the 'body resistance' of the terminal material itself.
Contact resistance testing is a key test for evaluating the electrical performance of connectors or terminals, used to measure the contact resistance between terminals and the resistance at the crimping point between wires and terminals. The magnitude of contact resistance directly affects the electrical performance and reliability of the connection. Excessive contact resistance may lead to heating, energy loss, and even connection failure. The following are the key elements and steps of contact resistance testing:
1. Test objectives
Contact resistance: Measure the contact resistance between terminals.
Crimp resistance: measure the resistance at the crimping point between the wire and the terminal.
Body resistance: including the resistance of the terminal material itself.
Electrical performance: Ensure low resistance and high reliability of connectors or terminals in electrical connections.
2. Testing conditions
Test current: Low current (such as 1A) is usually used to avoid heating affecting measurement accuracy.
Test voltage: Low voltage (such as millivolts) is usually used to avoid breakdown or damage to the connector.
Environmental conditions: Test under standard conditions (such as temperature of 25 ° C and humidity of 50%), or simulate extreme environments for additional testing.
3. Testing equipment
Micro ohmmeter: used for precise measurement of low resistance (such as milliohm level).
Four wire tester: eliminates the influence of lead resistance on measurement results.
Constant current source: provides stable testing current.
Data logger: Record the resistance value during the testing process.
4. Testing steps
prepare
Clean the connectors and terminals to ensure that there is no dust or oxide layer affecting the test results.
Check the crimping quality of the wires and terminals to ensure a secure connection.
Connection tester:
Connect the micro ohmmeter using the four wire method to ensure measurement accuracy.
Apply current:
Start the constant current source and apply a specified current (such as 1A).
Measure resistance:
Use a micro ohmmeter to measure the contact resistance between terminals and the resistance at the crimping point between wires and terminals.
Record data:
Record the resistance value measured each time.
Analysis:
Calculate the total sum of contact resistance, crimping resistance, and body resistance.
Evaluate whether the electrical performance of the connector meets the requirements.
5. Judgment criteria
Contact resistance: It is usually required that the contact resistance does not exceed the specified value (such as 10m Ω).
Crimping resistance: It is usually required that the crimping resistance does not exceed the specified value (such as 5m Ω).
Total resistance: The sum of contact resistance, crimping resistance, and body resistance should comply with relevant standards.
6. Improvement measures
Optimize contact design: increase contact area or improve contact surface treatment (such as gold plating, silver plating).
Improve crimping quality: Ensure that the crimping between the wire and the terminal is firm and reduce contact resistance.
Material selection: Choose materials with better conductivity (such as copper alloys) to reduce body resistance.
Cleaning and maintenance: Regularly clean connectors and terminals to avoid oxidation or contamination that increases resistance.
7. Common standards
IEC 60512: Testing standard for electronic device connectors.
EIA-364-23: Contact Resistance Test Standard for Electronic Connectors.
GB/T 5095: Chinese Electronic Equipment Connector Testing Standard.
MIL-STD-202: Military Electronic Component Testing Standard.
8. Precautions
Test accuracy: Use the four wire method to measure and eliminate the influence of lead resistance.
Environmental control: Avoid testing in high humidity or high pollution environments.
Multiple tests: Ensure consistency of test results.
Safe operation: Avoid excessive current or voltage during testing to prevent connector damage.
Through contact resistance testing, the electrical performance of connectors or terminals can be evaluated to ensure their low resistance and high reliability in electrical connections, thereby meeting design and application requirements.
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