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Automotive interior and exterior trim - Environmental testing
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Automotive interior and exterior decorations (electronic and electrical components) - IP protection
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Automotive electronic and electrical components - Electrical performance
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Automotive interior and exterior trims - Mechanical performance testing
Contact Us
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400-116-2629
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E-mail: webmaster@lcs-cert.com
Address: Shenzhen City, Baoan District, Shajing Street, Nga side of the school of Wei Juji Industrial Park, Building A 1 ~ 2 floor, Building C 3 floor
Electrical and mechanical connection life
Electrical and mechanical connection life testing is a key test to evaluate the strength of regulating devices, electrical and mechanical connections, as well as the insulation and conductor performance of internal wiring. By simulating the frequency and amplitude of normal use, the reliability of the product in long-term use can be verified. The following are the testing steps and evaluation points:
1. Testing standards
The lifespan testing of electrical and mechanical connections is usually based on the following standards:
IEC 60335-1: General safety requirements for household and similar electrical appliances.
IEC 60950-1: General requirements for the safety of information technology equipment.
UL 61058: Switch Life Test Standard (applicable to the North American market).
GB 14536.1: Special requirements for automatic controllers of household and similar electrical appliances.
2. Testing equipment
Life testing machine: a device that can simulate the normal use of electrical and mechanical connections.
Load device: used to apply specified electrical loads.
Monitoring equipment: used to measure parameters such as conductor voltage drop and insulation resistance.
3. Test parameters
Test frequency: Set according to the product usage scenario (such as 10-30 times per minute).
Test range: Set according to product design (such as switch travel range).
Test frequency: usually 5000~50000 times (according to standards or product requirements).
Electrical load: Set according to the rated current and voltage of the product.
4. Testing steps
Sample preparation:
Select representative product samples.
Ensure that the regulating device and electrical mechanical connections are installed correctly.
Installation sample:
Fix the sample on the lifespan testing machine.
Connect the load device and monitoring equipment.
Set parameters:
Set the testing frequency, amplitude, frequency, and electrical load.
Start testing:
Start the lifespan testing machine and simulate normal usage conditions for testing.
Monitoring test:
Regularly check the status of the samples and record test data (such as voltage drop, insulation resistance, etc.).
5. Post test evaluation
Appearance inspection
Check whether the regulating device and electrical mechanical connections are worn, deformed, or damaged.
Check for insulation damage or conductor breakage in the internal wiring.
Electrical performance testing:
Conductor voltage drop test: Measure the voltage drop at both ends of the conductor to ensure it is within the allowable range.
Insulation resistance test: Measure the insulation resistance to ensure it meets the standard requirements.
Conductivity test: Check whether the conductor is broken or has poor contact.
Mechanical performance testing:
Check the strength of the regulating device and electrical mechanical connections to ensure that they are not loose or malfunctioning.
6. Judgment criteria
By standard:
The regulating device and electrical mechanical connections are undamaged and functioning properly.
The internal wiring insulation is undamaged and the conductor is not broken.
The conductor voltage drop and insulation resistance meet the standard requirements.
Failed to meet the standard:
Damage or failure of regulating devices or electrical mechanical connections.
Internal wiring insulation damage or conductor breakage.
The conductor voltage drop or insulation resistance does not meet the standard.
7. Improvement measures
Design optimization:
Improve the design of regulating devices and electrical mechanical connections to enhance their durability.
Optimize the internal wiring layout and reduce mechanical stress.
Material improvement:
Choose materials that are more wear-resistant and fatigue resistant.
Use high-strength conductors and insulation materials.
Process improvement:
Improve the connection process to ensure the reliability of electrical and mechanical connections.
Strengthen insulation protection to prevent insulation damage.
8. Compliant with standards
International standards: Ensure that testing methods and evaluation standards comply with IEC or UL standards.
Certification requirements: Ensure that the product meets relevant certification requirements (such as CE, UL, CCC, etc.) based on the target market.
Through the above steps, the lifespan and reliability of electrical and mechanical connections can be comprehensively evaluated, ensuring the safety and performance of the product in long-term use.
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