The high-voltage connector is a functional element that makes the circuit connected and disconnected by means of electrical signals or mechanical forces. It consists of a fixed-end electrical connector (hereinafter referred to as socket) and a free-end electrical connector (hereinafter referred to as plug). .
The structure of a high-voltage connector generally includes: a contact pair, a sealing ring, a docking locking mechanism, a bracket, a housing, a positioning mechanism, a high-voltage interlocking mechanism, a shielding mechanism, an insulating structure, etc. General termination methods include welding, crimping, via connection, screw connection and so on. There are also various installation methods, including panel type, cable type, nut type, through-wall type and so on. The overall structure needs to consider the suitability of manipulation, including the size of the manipulation space, the structure of preventing mishandling, and the indication of the connection in place. The internal structure needs to be considered: the detachability of the contact, the type and structure of the contact, and so on. The performance of high-voltage connectors is quite different from that of low-voltage connectors. The electrical, mechanical and environmental performance of high-voltage connectors have higher requirements. Mainly include the following aspects:
1. High voltage connector electrical performance
Electrical performance includes working voltage, rated current, contact resistance of inner conductor and outer conductor, characteristic impedance, voltage standing wave ratio, shielding performance and anti-interference performance, etc. The rated voltage of the connector must be greater than the peak voltage of the device. Generally, it is necessary to test the withstand voltage, insulation resistance, creepage distance, etc. of the connector according to the standard; at the same time, confirm the normal use current of the device, and the rated current of the connector must be greater than the normal use of the device Current. When there is a peak current, you need to confirm the peak current time. Generally, you need to measure the terminal contact resistance, terminal temperature rise, terminal retention force, cable crimping force, and connector locking device strength of the connector according to the standard. In order to ensure the safety performance of the connection, a high-voltage control loop is generally formed through a high-voltage interlock to avoid potential hazards caused by the disconnection of the high-voltage loop, and the vehicle control system needs to be tested and calibrated. In addition, EMC requirements for high-voltage connectors are becoming increasingly prominent. At present, a shielding design can be required to meet 360-degree shielding. The shielding gap is required to be less than 2mm or electromagnetic sealing gaskets are required. Generally, the shielding effectiveness needs to be measured according to standards.
2. Mechanical properties of high voltage connectors
Mechanical energy mainly includes vibration shock, mechanical life, single hole separation and total separation force. Generally, the number of uses of the product, the reliability of the connection and locking method, etc. will be evaluated. As the part that is not frequently disassembled, the high-voltage connector in the car is generally defined as plugging and unplugging more than 50 times to determine whether the mechanical life of the connector meets the requirements.
3. High voltage connector environmental performance
Environmental performance includes temperature, humidity, vibration, shock, salt spray, dust and sealing performance (including water pressure, rain), etc. First, you need to confirm the maximum ambient temperature of the device. The working temperature of the connector must be greater than the ambient temperature of the device plus the temperature rise of the terminal when the rated current is passed. And whether the working temperature of the connector standard meets, it is necessary to test the aging, temperature and humidity, high and low temperature impact of the connector according to the standard. In terms of environmental resistance performance of high-voltage connectors, IP protection performance has the greatest impact. It is generally verified by means of water tightness test or air tightness test. The airtightness test does not have a negative impact on the product and is currently widely used. In addition, whether the flame retardant performance can meet the standard is also an important safety index.
The high-voltage connector is suitable for connecting 1140V～10kV power cable circuits in the tunnels of coal mining and tunneling in underground coal mines. It can be used for wiring of UGSP monitoring shielded various rubber-sheathed cables in mobile substations for power supply. They can be connected at both ends of the cable for mutual plugging, or half of the explosion-proof connection part can be connected to the mobile substation. The following describes the maintenance and maintenance of high-voltage connectors.
1. During the use and maintenance of high-voltage connectors, prevent the explosion-proof surface from colliding or rusting.
2. During the maintenance process, the high-voltage connector is strictly prohibited from live operation. After the power is cut off, it must be ensured that there is no residual voltage before unplugging and disassembling any part. The residual charge can be discharged by reliable means in accordance with coal safety regulations, and mobile power stations can also be used The operation sequence of decay discharge is as follows:
2.1. Generally, the load switch is kept closed before operation, the high-voltage switch is opened and the "no switch-on" sign is added or locked, and then the connector is operated. If there is feedback from low voltage, the feed switch and load switch should be opened first .
2.2. If the load switch is disconnected when the high-voltage connector is pulled, mark or lock the high-voltage switch before opening the high-voltage switch, and then close the load switch for at least one minute to discharge the residual voltage to ensure safety, and then perform the necessary operations .
2.3. When reinstalling the high voltage connector, it must be fully plugged in before powering on.
2.4. After the flange of the middle shell of the high-voltage connector is unplugged, if it needs to be kept for a period of time, it should be covered with a cover and still sealed with a sealing gasket to prevent moisture intrusion.
Shanghai Huzheng Electronic Technology Co., Ltd. is committed to providing integrated solutions for energy storage connectors, industrial connectors, new energy vehicle connectors, wind power connectors, industrial connectors, high voltage connectors, and photovoltaic energy storage connectors. Product design and application experts. The company's products can be widely used in fields such as new energy vehicles, heavy machinery, trains and railway tracks, solar energy, wind energy, smart grids and machines.
What is a connector: a connector is a component that our electronic engineering and technical personnel often touch; its function is very simple: it establishes a communication bridge between the blocked or isolated circuits in the circuit, so that the current flows and the circuit Realize the predetermined function. Connectors are an essential part of electronic equipment. Looking along the current path, you will always find one or more. The form and structure of connectors are constantly changing. According to different application objects, frequency, power, application environment, etc., there are many types of connectors. For example, connectors for stadium lighting and connectors for hard drives, and lighting rocket connectors are completely different. But in either case, it is necessary to ensure that the current flows smoothly, continuously and reliably.
Why use a connector: Imagine what it would be like without a connector? At this point, the circuit should always be connected to a continuous conductor. For example, if an electronic device is to be connected to a power source, both ends of the connecting wire need to be fixedly connected to the electronic device and the power source through a certain method (such as welding). As a result, there are a lot of inconveniences in production and use.
The basic requirements of the connector: Because of its easy maintenance, improved production process and more flexible design, it has become an indispensable part of electronic equipment. Of course, the quality of the connector is fundamental. Through further understanding of the wiring harness connector, its basic requirements are as follows:
The connector has stable contact resistance;
The connector is easy to install;
The connector size is generally small;
high density and light weight;
Good mesh and separation feel;
Connector engagement force is low;
Sufficient connection performance;
The connector is waterproof;
Easy wiring harness assembly;
The connector is easy to repair;
Insulator: wide temperature range, self-extinguishing
What is a car connector? Judging from the name, it must be related to the car. The role of the car connector is mainly the wide application of electronic engineering technology in the automotive field. The main function of the car connector is to realize, the circuit is different or the circuit is isolated. , The realization of the connection, which is an indispensable need for mobile cars.
Although the structure and design of each car are different, all the functions and main accessories of the car connector are basically the same. The main components of the car connector have contact connectors, which mainly refer to the core part of the power supply. It mainly includes female and male contactors to generate power. There are also shells equipped with different connector types, which mainly protect the motherboard and fix it to the car. There are also important insulators to ensure passengers and car owners. The necessary measures and accessories for safety, plus accessories of different configurations, mainly including small accessories for installation and structure, play a role of fixing and combination. The basic functions of these four major plates constitute its main functions and ensure the effective play of the role of the bridge.
The role of the car connector is huge, ensuring the normal operation of the car during the driving process, then the design of the car connector is based on what standard and design awareness to ensure its normality and safety. First of all, the design standards and factors ensure the safety of the car. The first consideration is the stability and safety of the materials produced and designed. The purchase and use of materials are very cautious and stable, so that it can be guaranteed. Stable performance. Secondly, it is stable and suitable for the voltage and power of the car's vibration, so that the bridge function of the car connector can be stable, safe and reliable. Thirdly, the temperature induced by the connecting wire must be considered in many aspects, not only considering the thermal shock of the huge energy emitted by the car itself, but also fully considering whether the change in the temperature difference caused by the external environment will affect the car connector The performance and safety of the car body. Finally, to ensure the retention of the car connector, such support for the horsepower of the car is an important insurance factor, and a certain amount of support must be provided to ensure the safe design and safe use of the car connector.
Automotive connectors are the perfect combination of the automotive industry and electronic engineering technology, and such development will have a certain market in the future development trend, but although the current design is suitable, because in the Chinese market, everyone’s The sense of service is relatively weak, and the future development road has broad prospects, but it is full of hardships.
Automotive connectors are components that electronic engineering and technical personnel often touch. Its function is very simple: the car connector establishes a communication bridge between the blocked or isolated circuits in the circuit, so that the current flows, and the circuit realizes the predetermined function. The form and structure of automotive connectors are constantly changing. They are mainly composed of four basic structures: contacts, shells, insulators and accessories. Let's introduce these 4 basic components.
Introduction to the four basic structural components of automotive connectors:
1, contacts. It is the core part of the car connector to complete the electrical connection function. Generally, the contact is composed of a male contact and a female contact, and the electrical connection is completed by the insertion of the female contact and the male contact.
The male contact is a rigid part, and its shape is cylindrical (round pin), square column (square pin) or flat (plug). The male contacts are usually made of brass or phosphor bronze. The female contact (ie socket) is the key part of the contact pair. When it is inserted into the pin, it relies on the elastic structure to elastically deform to generate elastic force and form close contact with the male contact to complete the connection. There are many types of jack structures, including cylindrical (opening, necking), tuning fork, cantilever (longitudinal groove), folding (longitudinal groove, 9-shaped), box-shaped (square jack) and hyperbolic wire spring jack, etc.
2, shell. It is the shell of the car connector. It provides mechanical protection for the built-in insulating mounting plate and pins, and provides the alignment of the plug and socket when mating, and then fixes the connector to the device.
3. Insulator. This insulator is also commonly referred to as the base or insert of a car connector. Its function is to arrange the contacts according to the required position and spacing, and to ensure the insulation performance between the contacts and the contacts. Good insulation resistance, withstand voltage performance and easy processing are the basic requirements for selecting insulating materials to be processed into insulators.
4. Accessories. The accessories are divided into structural accessories and installation accessories. Structural accessories, such as clamping ring, positioning key, positioning pin, guide pin, connecting ring, cable clamp, sealing ring, gasket, etc. Install accessories, such as screws, nuts, screws, spring rings, etc. Most accessories have standard configuration parts and general parts.