Testing Electrical Connections

[dbarnard]

Can someone help me with some guidance.

Is there a good way to test the integrity of a crimped electrical connection?

Is there equipment that can do this on a completed assembly scale?

 

[itsmoked]

Like everything there are many different aspects. Test for what? Come quickly to mind.

Pull tests are very telling. If it unplugs easily you have problems. If the wire comes out of the terminal you have problems.

Generally if the mechanical tests are passed the electrical are redundant.

Keith Cress
Flamin Systems, Inc.-

http://www.flaminsystems.com

 

[analogkid2digitalman]

Electrical tests may be redundant unless someone does not strip the wire(s) first. Yes, I have seen this occur first-hand.

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"It's the questions that drive us"
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[OperaHouse]

Weak crimps will show up as a higher resistance. There are bond testers from Rod-L and Hypatia that place a high current through the connection for a timed period and report the resistance. These are commonly used to test the ground connection from the chassis through the power cord. This may provide some useful information on a critical application.

 

[Zogzog]

You need a microhmeter, sometimes called a DLRO or Ductor. AVO and AMEC make the best ones.

 

[dbarnard]

Thank you all. Your help is appreciated. I will look into the equipment suggested.

 

[ScottyUK]

AVO and AMEC make the best ones.

Wow, that's a brave statement. Megger, T&R and Cropico will all be pleased to know that...

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If we learn from our mistakes I'm getting a great education!

 

[Mike2468]

"on a completed assembly scale"

Companies like Amp/Tyco have crimping tools with built-in ratchets so the crimps are always identical. If you use the right wire and the right tool, the crimps were identical. Likewise the Amp/Tyco automated bench tools used machined die sets for the same consistency. For quality assembly work, this is the way to do it.

 

[Zogzog]

"Wow, that's a brave statement. Megger, T&R and Cropico will all be pleased to know that..."

AVO and Megger are the same company, never heard of those other ones. Let me rephrase. For people in the power system testing industry AVO (Megger) and AEMC are the most popular choices. Hows that?