Failure analysis on bolt-type power connector's application

Electrical Contacts - 1999. Proceedings of the Forty-Fifth IEEE Holm Conference on Electrical Contacts (Cat. No.99CB36343) Pub Date : 1900-01-01 DOI:10.1109/HOLM.1999.795930

Guoping Luo, Jian-guo Lu, Ji-gao Zhang

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引用次数: 11

Abstract

Bolt-type power connectors are widely used in China due to their simple structure and low cost. However, investigation shows that this kind of power connectors needs continuous maintenance and frequent replacement. By analyzing the failed connectors that were collected from different cities and sites, high connection resistance of most samples was found. Clearly high temperature has been occurred at each connector. Bolts of nearly 45% of the testing connectors appeared loosening, which caused low contact pressure, evidently the bolts were stress relaxed. Even the bolts were rusted and locked, the strand wires could still rock in the grooves of the connectors. Sliding and fretting tracks were clearly observed and appeared different kinds of morphologies. Serious contaminants and corrosive film covered on the groove surfaces, which caused high temperature rise and further enhanced stress relaxation. Surfaces of almost 58% samples preserved obvious melting or welding appearance, some of them were even burnt out, evidently there were gaps between wires and connector. Therefore, the structure of the bolt type power connectors can hardly stand for the harsh environment in China. It is also found that the material used for making connectors was not fitted to the standard.

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螺栓式电源连接器应用的失效分析

螺栓式电源连接器因其结构简单、成本低而在国内得到广泛应用。然而，调查表明，这种电源连接器需要持续的维护和频繁的更换。通过对从不同城市和地点采集的故障连接器进行分析，发现大多数样品的连接电阻较高。显然，每个连接处都发生了高温。近45%的试验连接件螺栓出现松动，导致接触压力低，螺栓明显处于应力松弛状态。即使螺栓已经锈迹斑斑，锁住了，绞线仍然可以在连接器的凹槽中晃动。滑动轨迹和微动轨迹清晰，形态各异。严重的污染物和腐蚀膜覆盖在沟槽表面，导致温度升高，进一步加剧应力松弛。近58%的样品表面保留了明显的熔化或焊接外观，部分样品表面甚至被烧毁，电线和接头之间明显存在间隙。因此，螺栓式电源连接器的结构很难承受中国恶劣的环境。还发现用于制造连接器的材料不符合标准。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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Electrical Contacts - 1999. Proceedings of the Forty-Fifth IEEE Holm Conference on Electrical Contacts (Cat. No.99CB36343)

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