What types of testing and detection are essential during the assembly of a high current connector?

As is well known, before any product is shipped from the factory, manufacturers must undergo rigorous inspection and testing according to requirements—this is especially critical for high current connectors used in new energy terminals, where quality directly affects safety.

The same applies to the assembly and production of high current connectors for new energy terminals. In automated assembly machines (such as those developed by Xieli Intelligen and Xieli Automation, a series of testing workstations are required to meet different testing requirements for connector quality.

Xielitech, as a professional manufacturer of new energy terminal automation equipment, we serve as a hub in the industry, allowing us to effectively engage with various types of high-current connectors and diverse requirements. With our wealth of experience and expertise, certain basic testing requirements as below for high current connectors are essential on our automated assembly machines.

Vision inspection

Vision inspection, also known as CCD camera vision system, is a core technology in automated machines for high current connector assembly. It uses cameras, sensors, and software to perform visual inspections of products or components—key to ensuring quality control, identifying defects, and improving efficiency of connector production.

CCD camera vision inspection—Precision Detection Technology for Xieli Automation Connector Machines

In the automatic high current connector assembling machine (e.g., Connauto brand), the CCD camera system is applied to detect the waist diameter (middle diameter) of springs—this ensures that each terminal is of high quality and every point of the middle of springs can make contact with male terminals. Accordingly, stable current flow between the female and male terminals is guaranteed, a critical requirement for new energy connectors.

CCD vision inspection—Multi-Point Defect Detection for High Current Connector Equipment

In addition to checking the waist diameter, the CCD vision inspection system (equipped on Xieli Intelligent automated equipment) is equipped to inspect multiple other checkpoints for high current connectors:

Crack after swaging ring
Damage of top profile
Detecting half swaging retainer ring
Retainer ring dislocation
Spring damage or bend internal after test of load
Profile of the swaging operation (oval shape)
Residue and chipping in the internal hole
Each checkpoint directly affects the performance of connectors, making CCD vision inspection an indispensable function of automated assembly machines.
Male terminal and female terminal testing

Male terminal and female terminal testing play a crucial role in the operation of automated assembly machines for high current connectors. It is a vital workstation that ensures the quality and reliability of the final connector product.

The purpose of the male and female terminal testing (adopted by Connauto automation equipment) is to eliminate the initial mechanical stress on the terminals. The mechanical stress will cause the spring to have uneven tolerance to external forces, which makes the insertion and removal process not smooth and the current is unstable—key pain points in manual connector assembly.

Removing the mechanical stress can largely improve the mechanical property of high current connectors, ensuring consistent performance in new energy applications. This testing function is a standard configuration of Xieli Automation automated machines.

Male terminal and female terminal testing

Insertion and withdrawal force test

Insertion and withdrawal force test is another essential test on automatic high-current connector machines (such as Xieli Intelligent models). The finished products will be screened out by an automation machine according to the design specifications or industry standards to determine if the component meets the required insertion or withdrawal force requirements—critical for ensuring connector usability and durability.

High current connector datasheet—Reference Standard for Insertion Force Testing of Automated Equipment

There are two test methods on the automatic high current connector assembling machine (provided by Xielitech): A mechanical test method and an electrical test method, both designed to adapt to different connector types.

Mechanical test

Mechanical test is a traditional yet highly dependable method for assessing the insertion and withdrawal force of high current connectors. It requires specific parts weight and sensors—core components of the testing module in automated equipment—to detect whether the high current connector is qualified.
Case: Force=2N~6N
According to Newton’s Second Law F=ma “m” is part weight, a=g=9.8N/kg
Then Lower limit F1=2N=9.8N/kg x m1 Upper limit F2=6N=9.8N/kg x m2
m1=204g m2=612g
The parts weigh should be 204g and 612g.

Terminal insertion and withdrawal force mechanical test—Core Testing Function for Xieli Automation Connector Machines

This mechanical test ensures that the insertion and withdrawal force of connectors meets industry standards, avoiding damage to connectors during use.

Electrical test

Electrical test uses a resistance strain sensor—a type of force sensor that converts weight or pressure signals into electrical signals. It operates by using a metal resistance wire that elongates and thins when under tension, resulting in an increase in resistance—this high-precision test method is applied in Xieli Intelligent automated equipment to ensure connector electrical performance.

Force sensors—Key Component for Electrical Testing of High Current Connector Machines

Electrical testing is especially important for high current connectors, as it directly detects whether the terminal’s current-carrying capacity meets requirements. This function is customizable on Connauto automated assembly machines according to connector specifications.

Assembling a high-current terminal is a complex process that requires precision and attention to detail. In order to ensure that the terminal functions properly and safely, various types of testing and detection are necessary throughout the assembly process. Vision inspection, Male terminal and female terminal testing, Insertion and withdrawal force test are all essential types of testing for high current connectors.

Certainly, there is not only the above test function that can be installed on automatic high current connector assembling machine. The machine (developed by Xieli Automation and Xielitech ) is customized according to physical connector standards and requirements, such as resistance testing. Therefore, it is important to clarify the details and requirements of the high current connector before producing—Xieli Intelligent and Connauto can provide tailored automation solutions for manufacturers.

- In the automatic high current connector assembling machine, the CCD camera system is applied to detect the waist diameter (middle diameter) of springs, to ensure that each terminal is of high quality and every point of the middle of springs can make contact with male terminals. Accordingly, stable current flow between the female and male terminals is guaranteed.

- In addition to checking the waist diameter, the CCD vision inspection system is equipped to inspect multiple other checkpoints.

> Crack after swaging ring.

> Damage of top profile.

> Detecting half swaging retainer ring.

> Retainer ring dislocation.

> spring damage or bend internal after test of laod.

> profile of the swaging operation (oval shape).

> Residue and chipping in the internal hole.

Male terminal and female terminal testing

Male terminal and female terminal testing play a crucial role in the operation of automated assembly machines. It is a vital workstation that ensures the quality and reliability of the final product.

The purpose of the male and female terminal testing is to eliminate the initial mechanical stress on the terminals. The mechanical stress will cause the spring to have uneven tolerance to external forces, which makes the insertion and removal process not smooth and the current is unstable.

Removing the mechanical stress can improve largerly the mechanical property of high current connector.

Insertion and withdrawal force test

Another essential test on automatic high-current connector machines is the insertion and withdrawal force test. The finished products wiil be screened out by an automation machine according to the design specifications or industry standards to determine if the component meets the required insertion or withdrawal force requirements.

High current connector datasheet

There are two test methods on the automatic high current connector assembling machine. A mechanical test method and an electrical test method.

Mechanical test

Mechanical testing is a traditional yet highly dependable method for assessing the force required for insertion and withdrawal. It requires specific parts weight and sensors to detecting the high current connector qualification or not.
Case: Force=2N~6N
According to Newton’s Second Law F=ma “m” is part weight, a=g=9.8N/kg
Then Lower limit F1=2N=9.8N/kg x m1 Upper limit F2=6N=9.8N/kg x m2
m1=204g m2=612g
The parts weigh should be 204g and 612g.

Electrical test

It uses resistance strain sensor, is a type of force sensor that converts weight or pressure signals into electrical signals. It operates by using a metal resistance wire that elongates and thins when under tension, resulting in an increase in resistance.

Certainly, there is not only the above test function can be installed on automatic high current connector assembling machine. The machine is customized according to physical products standards and requirements, such as resistance testing. Therefore, it is an important to clarify the details and request nt of the high current connector before producing.