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WHY IS A POOR CONNECTOR PRONE TO FIRE?

The junction boxes and connectors of photovoltaic modules are small parts that are not noticeable. However, if the quality of these two widgets is not high enough, it will be a huge safety hazard! At present, there should be too many fires in the country due to overheating of connectors, causing huge losses to power stations.

Previously, a well-known foreign agency Fraunhofer ISE and TÜV jointly investigated the fire causes of photovoltaic systems and found that the first and third fire causes were related to the connector.

Failure analysis caused by metal parts

The metal part is the main body of the connector and the most important flow path. When operating in various environments, stable resistance is a prerequisite to ensure the normal operation of the connector.

1. Failure analysis of resistor Rco

The resistance Rco is the resistance of the overlapped part of the metal part after the connector is mated. If Rco increases abnormally, it will cause the temperature to rise, which will cause a fire in the middle of the connector.

2. Failure analysis of resistor Rcr

The crimping resistance Rcr is mainly related to the crimping quality and crimping process. We can judge the quality of the crimp by the compression ratio and crimp section. Good crimping requires a tight profile without gaps and a regular shape. For commonly used 4mm2 cable crimping and contact resistance at the crimping point, the standard IEC2742 / 05 also puts forward the requirement of less than 0.2mΩ, while IEC60352-2 stipulates that the pull-out force of the crimping end must be greater than 310N.

Failure analysis due to sealing performance

Because the connector is outdoors, it has strict requirements for sealing performance.

For example, some connectors have IP65 and IP68 protection levels. Because the connector is mated to the cable, when it comes to tightness, the choice of cable becomes very important. In general, different connector models correspond to different cable outer diameters, and the purpose is to ensure sealing performance.

For example, the MC4 connector can match photovoltaic cables with an outer diameter of 3-9mm (conductor cross-sectional area of 1.5-10mm2), but its corresponding models are up to 6 types. In order to verify the matching of the cables, after the connectors are assembled, relevant tests are performed, such as IP tests, wet insulation tests, and withstand voltage tests.

Failure analysis caused by insulation materials

The choice of insulation material directly determines the quality of the connector. A good connector needs to choose the right insulating material, and whether it is suitable is mainly determined by the requirements of the connector, such as weather resistance, heat resistance, flame retardancy, mechanical properties, and insulation properties of the material. Photovoltaic connector insulation The choice of material is the result of comprehensive consideration of these several properties. Choosing the right material can reduce the probability of misfire under high temperature rise.

In addition, it is not possible to use regrind for photovoltaic connectors. The reason for this is because the use of regrind has its extremely strict regulations and product inspection measures. Only in this way can it ensure that the performance of its products does not drop much. The photovoltaic connector is required to be used for more than 25 years in many clients, which means that it has very high requirements for materials.

Although the use of recycled materials can reduce product costs, it increases the probability of product failure at the end of use, so connector manufacturers should eliminate them.

To sum up

Photovoltaic connectors account for a relatively low cost in photovoltaic power plants, but they are a key component. In the early stage of power station construction, the risk of failure caused by the connector is often not taken seriously, but in the later stage it will become a pain point for the operation and maintenance of the power station.

The operation and maintenance costs caused by the failure of the connector include the loss of power generation revenue, the cost of spare parts, labor costs, and safety risks. These operation and maintenance costs will ultimately affect the investment return of the power station. Photovoltaic connectors provided by suppliers with reliable quality and rich experience in production and assembly are one of the foundations to ensure the normal and stable operation of photovoltaic power stations, and the normal operation of power stations is one of the prerequisites to ensure the owners’ maximum benefits.

Sunkye is a qualified mil spec military connector manufacturer and supplier, who support custom connectors for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

Mil spec connector, also called military grade connector or military style connector or military standard connector or military power connector, has been developed to satisfy the market requirements for ultra-tiny size, high performance, great quality, and top qualified customized connector. Sunkye mil grade connector is widely applied for the board to board, system to system, application to application, equipment to equipment. Specially designed for extreme environments like the defense industry, but our mil spec connectors can also be used in a variety of commercial tasks. Our automotive terminal connectors can withstand the harsh conditions of the road and off-road transportation. The combination of Sunkye’s mil grade connectors provides reliable solutions for improving the connectivity of critical systems.

CHINA’S CONSUMER ELECTRONICS MARKET IS BECOMING SATURATED, INDUSTRIAL CONNECTORS ARE PROMISING

With the rapid development of electronic information technology, the upgrading speed of electronic products is getting faster and faster. The production and sales of consumer electronics products, mainly flat-panel TVs, notebook computers, digital cameras, smart phones, and other products, have continued to grow, which has also contributed to the continuous growth of the consumer electronics connector market.

Once upon a time, the development of connectors in the field of consumer electronics was quite smooth, but with the maturity of consumer electronics technology and the increasing number of connector companies entering the consumer electronics industry, the market appeared to be in oversupply. Domestic connector companies, especially in the field of consumer electronics, have a fierce price war on connectors.

Not only that, with the USB TYPE-C interface occupying the market and the emergence and application of wireless technology, not only will most of the interface specifications be unified to reduce the interface, but also the connector technology on consumer electronics tends to be thinner and shorter Technically, a large part of domestic small and medium-sized connector companies have been eliminated. With shrinking market share, meager profits, and improved market access qualifications, the consumer electronics market is no longer as attractive as before.

Compared with the current consumer micro electrical connectors market, the industrial connector market has larger capacity and higher profits. At the same time, it has relatively more demanding military-grade connectors, and the market access qualification should be loose, which can meet most connector companies. Participate in competition. The country will vigorously develop the manufacturing industry, which is also good news for industrial connectors. Therefore, it is natural for domestic connector companies to turn their attention to the industrial connector market.

Seeking a way out in industrial connectors has become a coincident choice for connector manufacturers.

Sunkye is a global solutions provider of connector solutions and differentiated products to the world-wide interconnector industry.

METHODS TO IMPROVE THE HIGH-SPEED MICRO-PITCH INTERCONNECT PERFORMANCE OF CONNECTORS

For military connector manufacturers, in addition to their productivity, they also care about product quality. When it comes to product quality, many aspects will be involved, such as the performance of high-speed micro-pitch interconnects for connectors.

In general, there are nine main methods to improve the high-speed micro-pitch interconnect performance of military connectors:

1. Connector products, in the early stages of design, need to perform multiple simulation cycles to accurately quantify product performance before starting an expensive processing process.

2. When the connector is mated, the stub in the contact area should be minimized. The longer the stub, the better the reliability, but the stub is an electrical load like an antenna.

3. Simplify contact geometry and improve signal path performance.

4. Shorten the pin length to minimize the distance that the signal must travel.

5. Add asymmetric footprints and contacts as much as possible, because the alternating design reduces pair-wise crosstalk between rows of pins and between rows. It can also be said that footprint should drive connector performance.

6. Optimize the connector branch area (BOR). Think of the connector as a key node in the link, not only focusing on the node, but also the link.

7. Where space permits, incorporate a common ground plane into the connector.

8. The choice of plastic molding will obviously affect the performance of the connector. These attributes should be carefully considered: high-temperature plastics suitable for RoHS, matching Dk to obtain the required impedance control, dimensional stability of temperature and time.

The shorter and straighter the contact between the signal path and the connector, the better its signal integrity. But the balance function is that the connector must have sufficient normal force and exit force, and it also needs to have a certain degree of robustness.

Sunkye is a global solutions provider of connector solutions and differentiated products to the world-wide interconnector industry.

PRODUCTION PROCESS OF CONNECTOR CONTACTS

The structure of the contact parts varies according to the conditions of use and requirements.

The typical structure and process of the commonly used contacts:

1. Mechanical processing

(1) Slitting automatic lathe:

It is suitable for processing parts with complex geometric shapes and high surface quality requirements. And slender rod parts. A set of tooling such as cams and circlips is required for each type of part. Machine adjustment is more complicated

Suitable for medium batch or large batch

(2) CNC slitting automatic lathe processing method:

It is suitable for processing parts with complex geometry and high precision. Tune

It is easy to adjust and easy to replace parts. But the cost of machine tools is too high

Suitable for small batches

(3) Single-axis forming and cutting automatic lathe processing method:

Suitable for processing parts and raw materials with simple geometric shapes

Directly processed by disc-shaped silk material. The cost of machine tools is high. The tool quality and adjustment technical requirements are high.

Suitable for large batch or medium batch

(4) Multi-station disc material automatic machine tool processing method

Suitable for parts processing in large batches and continuous production for several months.

The disc-shaped silk material is formed by several or even dozens of processing steps.

The cost of the machine tool is very high, and the adjustment of the machine tool is difficult.

Suitable for extra large quantities

2. Stamping

(1) Multiple sets of mold forming methods

The lath material is punched and formed through multiple processes. The cost of the mold is low, and the machining accuracy of the parts is not high.

Suitable for large quantities

(2) Progressive die forming method

It is suitable for the processing of punched parts or punched and bent parts. Mold costs are higher. High precision parts and good dimensional consistency.

Suitable for extra large quantities

3. Cold extrusion processing

(1) Multiple sets of mold forming methods

Low mold cost and low machining accuracy

Suitable for large quantities

(2) Combined mold forming method

High mold cost and high precision of parts processing

Suitable for large quantities

Sunkye is a qualified mil spec military connector manufacturers and supplier, who support custom connectors for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

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Sunkye Connection Technologies provides a wide product portfolio with a complete interconnect solutions offering. Sunkye connectors and cables assemblies are complementary with Sunkye backshells and conduits.

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Sunkye is a global solutions provider of connector solutions and differentiated products to the world-wide interconnector industry.

THE SECOND GENERATION CIRCULAR MILITARY CONNECTOR

The basic characteristics of the second-generation circular connector are:

1) There are three types of plug and socket connection: threaded connection, bayonet connection and push-pull connection, but the bayonet connection is the main method.

2) The termination methods of pins, jacks and wires are soldered and crimped.

3) There are two types of jacks: open type and closed type, but the main type is closed type.

4) The minimum working diameter of the male contact (pin) is 1 mm, which is a medium-density electrical connector.

5) The applicable ambient temperature of the electrical connector is -60 ℃ ～＋ 150 ℃.

6) There are categories of electrical connectors such as unsealed, sealed and wall-penetrating; installation methods include square plates and discs, square plates have component sockets and cable sockets, and there are two types of front installation and rear installation; Normal key position and four variable key positions; tail attachments include straight, curved and shielded varieties.

Compared with the first-generation circular electrical connectors, the second-generation circular connectors have the following technological advances:

1) The density of micro electrical connectors increases, that is, the volume and weight decrease relatively. This is a very important consideration for the selection of aerospace and aerospace electrical connectors.

2) The bayonet connection is added to the connection method of the electrical connector. The advantage of threaded connection is high connection reliability, which is suitable for long-term strong vibration environment, but the disadvantage is that the coupling separation speed is slow and the connection is not convenient. The advantage of the bayonet connection is that the connection ring can rotate up to 120o to realize the insertion and separation, which is very convenient. Therefore, the bayonet-connected electrical connector is also called a quick-release electrical connector. Therefore, in addition to the long-term use of screw-connected electrical connectors in a strong vibration environment, the rest often use bayonet-connected electrical connectors.

3) In addition to welding, the termination of the contact piece and the wire is also crimped.

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HOW TO DETECT MEDICAL CONNECTORS

Medical connectors are connector products used in the medical field. The product quality of medical connectors should be strictly checked, and it is the responsibility of each factory to do the testing of medical connectors.

The detection method of medical connectors is basically the same as that of ordinary connectors, mainly involving twelve aspects:

1. Plug-in force test

Fully insert or pull out the connector at the specified rate, and record the corresponding force value.

Check whether the insertion force of the medical connector meets product specifications.

2. Durability test

Continue to insert and remove the connector at the specified rate until the specified number of times.

Detect the impact of repeated insertion and removal on medical connectors, and simulate the insertion and removal of connectors in actual use.

3. Hot and cold shock test

Evaluate the impact value of the connector on its functional quality under rapid large-scale changes.

4. Withstand voltage test

Apply a specified voltage between the connector contact and the contact, and between the contact and the housing for a specified time, and observe whether the sample has a breakdown or discharge phenomenon.

Verify whether the connector can work safely at the rated voltage and whether it can withstand the potential of overpotential, so as to assess whether the insulation material or insulation gap of the connector is appropriate.

5. Contact resistance test

By passing a prescribed current to the connector, the voltage drop across the connector is measured to obtain the resistance value.

Verify the resistance value generated when current flows through the contact surface of the contact.

6. Vibration test

Verify the impact of vibration on the performance of the electrical connector and its components. The types of vibration are random vibration and sinusoidal vibration.

7. Mechanical shock test

Verify the impact resistance of the connector and its components or assess whether its structure is firm. Test waveforms: half-sine wave, square wave.

8. Insulation resistance test

A voltage is applied to the insulated part of the connector, so that a leakage current is generated on the surface or inside of the insulated part to show the resistance.

Verify whether the insulation performance of the connector meets the requirements of the circuit design or is subjected to environmental stress such as high temperature and humidity, and whether its resistance value meets the requirements of the relevant technical conditions.

9. Salt spray test

Evaluate the resistance of connectors, terminals, and coatings to corrosion by salt spray.

10. High temperature test

Evaluate whether the performance of the terminal and insulator changes after the connector is exposed to a high temperature environment for a specified period of time.

11. Temperature and humidity combined cycle test

Evaluate the impact of the connector on the performance of the connector after storage in a high temperature and high humidity environment.

12. Mixed gas corrosion test

Evaluate the corrosion resistance of connectors exposed to different concentrations of mixed gases and the impact on their performance.

Sunkye supports medical grade connectors for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

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D-sub connectors are bulky and durable, which made them suitable for being applied in harsh environments where durability is extremely important. They can also be compatible with many old-fashioned devices. For these advantages, D-sub is widely used in factories, manufacturing workshops and industrial environments.

HOW TO CHOOSE THE SIGNAL CONNECTOR FOR INDUSTRIAL APPLICATIONS?

The key factors for determining signal connectors in industrial applications include: cost, environment, vibration, connector density, signal integrity, installation method, and safety requirements.

Where are the signal transmissions in industrial and semi-industrial environments? Everywhere. Devices such as sensors, actuators, switches, valves, and cameras all require signal connections to perform control and monitoring processes. As more and more smart devices are added to factory production, safe and reliable connections become more important. Modern devices must handle a variety of functions and ensure more efficient, reliable, and safe operation.

The environment around the signal connection often affects the reliability of the signal. These factors include: dirt, moisture, oils, chemicals, high and low temperatures, and ultraviolet and ozone, which must be considered in the selection of materials and sealing capabilities. In addition, electromagnetic interference (EMI) from nearby drives, motors, and other noise-generating equipment should also be considered. Without proper shielding, signal loss or unreliable signal transmission may result. Using connectors and cables to provide end-to-end signal shielding will eliminate electromagnetic interference and ensure signal integrity.

Many connections in industrial applications are exposed to mechanical shock and vibration. This impact on connector contacts, wire ends, or PCB solder joints can cause signal loss. When selecting connections for high-strength vibration applications, it is necessary to verify the connector design of anti-vibration structural elements, such as: locking threads or mechanical latches, radial O-rings, mounting flanges, fixing screws and spring technology.

Every application requires a reliable connection, and signal integrity may be destroyed by any breakpoints along the line. In addition to the wire end to the contact, the quality of the contact material is the most important factor affecting performance. When evaluating contact designs, the use of gold plating should be determined. Gold is a precious metal with good electrical properties and is not affected by corrosion. Preventing contact corrosion and having a high mating contact force are two key reasons for using gold plating in industrial applications.

Quick connection is also necessary for equipment installation, especially when the job requires a large number of connections. The shortest installation time can reduce the total cost. The connection is usually located in an inconvenient area or in a place with poor lighting. Finger fatigue and incorrect fastening will affect the success of rapid installation. By designing quick connection devices, such as spring cages or insulation displacement contacts (IDCS), at the PCB end, some of these problems can be prevented. On site, these devices provide quick plug connections, including half-turn technology or push-pull connections. When the equipment connection requires on-site wiring, the use of external connection, IDC or spring connection can save a lot of time. Because these technologies can achieve more connections in a shorter time. Research has proved that some IDC connectors can save 60% of the installation time. Compared with traditional screw joints, spring contact connectors can save 80% of the time.

Eliminating potential connection errors is a major concern for end users and field technicians, but equipment manufacturers and engineers can prevent potential erroneous connection factors during the design phase. When multiple connectors in the same space are used in a device, connector keying can eliminate confusion and effectively prevent users from inserting the wrong connector into the wrong socket. For example, in a typical signal connection scheme, engineers can select circular connectors with keyed changes, including: A, B, C, D, S, T, X, or Y. The terminal module connector can also be keyed in several modes to ensure that only the correct plug can be matched with the appropriate socket.

Marking and color coding can also reduce false matches. The most common mistakes made by technicians in the field are misconnections. Incorrect line terminals and incorrect terminal assignments may delay system commissioning and equipment startup. The use of color coding or other indicator marks on all line connection points can eliminate confusion and reduce the time spent troubleshooting on site.

When selecting signal connections for industrial applications, many variables that affect performance must be evaluated, including: cost, environment, vibration, connector density, signal integrity, installation method, and safety requirements. High-quality industrial connectors will help to ensure that terminal devices comply with international standards and provide safe and durable performance.

Sunkye provides custom connectors for a complete range of high-performance applications. A wide variety of mil spec electrical connectors options are available to you, feel free to contact us.

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INDUSTRY & SOLUTION

Sunkye is a global solutions provider of connector solutions and differentiated products to the world-wide interconnector industry.

AUTOMOTIVE CONNECTORS

Sunkye automotive series connectors onboard power applications in the rail market allow for multiple customer-defined configurations, enable easy assembly and further enhance flexibility with the ability to integrate local cabling and components.

Sunkye provides high-quality mil spec connectors and custom connectors for automotive, on and off-highway, and hybrid and electric vehicles to electrically and mechanically join wires and cables, printed circuit boards, integrated circuit packages, and batteries. Automotive power connectors are built to withstand tough conditions and suit the needs of varying applications.

Features of Sunkye Automotive Power Connectors

The series’ removable and interchangeable modules also simplify new and retrofit installations.

Mitigate maintenance requirements, lower the total cost of ownership, and provide space and weight savings.

Sunkye automotive electrical connectors include Ip68 waterproof connector, D108 circular electrical connector, MIL-DTL-26482 small circular connector, are Qualified for harsh-environment, high temperature, anti-oil working environment.

High performance to supports multi-parallel for the testing programming for the high-performance sports racing cars parallel durability and performance programs covering more than 50,000 km, with various 24- and 36-hour tests being completed by multiple Race Prototype (RP) cars under the extreme pressure of endurance racing. The latest high-performance sports racing cars aerodynamics match with the lightweight design carbon fiber materials developed to deliver even greater levels of stability and aerodynamic efficiency than its road car stablemate.

Meanwhile, the Sunkye automotive terminal connectors also support multi-lane of sensors and data analysis capabilities developed in automotive.

When deciding which Mil-Spec automotive connector will suit your needs, there a few things to consider:

Each connector kit is sold as pictured, with contacts as well as insert / removal tools.

A “Matched Set” is comprised of a plug and receptacle.

Accessory threads are provived for backshells and SB adapters. Sold seperatley.

Heat shrink boots are available and sold seperatley. See product listings for details.

If you are looking for reliable professional automotive connector manufacturers, Sunkye will be your best choice!

SUNKYE TYPES OF MIL SPEC CONNECTORS

HOW TO PREFABRICATE CABLES FOR WATERPROOF CONNECTORS?

For some industries, the waterproof connector is very necessary, so that it can protect the safety of the product, and it is also a guarantee for personal safety.

How to prefabricate cables for waterproof connectors?

XLPE insulated cables above 110kV level mainly use metal sheath to make the cables meet the waterproof requirements. The biggest feature of the metal sheath is that it is completely impermeable, so the cable with a metal sheath has very good radial water resistance. The main types of metal sheath are: hot-pressed aluminum sleeve, hot-pressed lead sleeve, welded wrinkled aluminum sleeve, welded wrinkled steel sleeve, cold drawn metal sleeve, etc.

The power cable can provide the input power for the waterproof connector system. This power supply uses the traditional wiring method, or a standard waterproof plug is installed on the power supply end, and a required socket connector can be prefabricated on the other side.

The extension cable needs to be installed with an inner socket or plug at the end of the relevant cable, and the wiring cable needs to be equipped with a plug and a bare wire end for the waterproof plug to connect the final device.

Breakout connector: The waterproof plug can be pre-installed on site to provide direct wiring for electrical user devices. All waterproof connectors are delivered with a stress-reduced housing and are compatible with all common types of cables. According to the requirements, the waterproof plug has a spring or screw connection technology.

Sunkye is a professional ip68 waterproof power cable connector manufacturer and supplier, who support custom connectors for a complete range of high-performance applications. A wide variety of military connector options are available to you, feel free to contact us.

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THE PERFORMANCE OF AUTOMOBILE CONNECTOR

From the purpose of using automotive connectors,in order to ensure better driving of the car, Sunkye can divide the reliability of the connector into the tightness of the connector in use, the performance of fire protection, the performance of shielding, and the performance of temperature control.

Generally speaking, when discussing the tightness of automotive connectors, it does not only refer to the tightness to water. In this area, the current popular international management specification is IP67, and this specification is now the highest level in the automotive industry. Although the requirements for waterproofing are different in different parts of the car, many car manufacturers will choose IP67 to ensure the tightness of the connector of their car.

In the driving of a car, the power source is a very important energy source, which is not only related to the normal work of the engine, but also often involves the use of the power source when people are driving. So in the car’s power supply system, car connectors have different divisions. Certain sealing measures can be implemented between the male connector and the device, between the male connector and the cable, between the male and female connector, and between the female connector and the cable.

In the realization of the sealing performance of automotive connectors, the seal ring is a commonly used tool. This tool can not only achieve the effect of fixing between different hole positions, but also the effect of sealing. It can not only ensure the stable operation of automobile equipment, but also ensure the waterproof performance of automobile equipment in work.

In the production of seal rings, silicon rubber is mostly used. This material is made by liquid silicon and solid silicon after certain chemical changes.

Now that electronic circuit technology is an important aspect of the automotive industry. In order to ensure the stable operation of electronic circuit technology, people have applied many shielding technologies in the production of automobiles. These shielding technologies not only play a protective role in the electronic circuit of the car, but also play a role in anti-interference and anti-radiation in the parts of the car. In addition, they can also protect the stable operation of the automotive connector.

Shielding technology can be divided into two types: internal shielding and external shielding. When using an external shield to protect a car connector, two identical shield shells are usually assembled to form a shield layer, and the length of the shield layer can cover the entire connector length. It is also necessary to ensure that the shield shell There are enough lock plate structures to ensure the reliable installation of the shielding layer. In addition, the shielding material used must not only be treated by electroplating, but also be treated to prevent chemical corrosion.