Test connections or touch connections are integrated into many plugs for the purposes of both measurement and test. As electronics in general continue to find their way into ever-greater applications, the role of electrical connectors—which provide product reliability—has likewise dramatically grown. Of great importance is the ability of the developer to conduct connector tests. Comprehensive electrical connector tests are used, for example, when high reliability is necessary and isolation and continuity are at the top of the measured parameter connector-testing list.
The two main categories of measurements involved are isolation and continuity. Isolation measurements take place between each connector pin or between multiple pins, as well as at the outer shell of connectors. These measurements ensure that signals are not misdirected and insulation is sufficient given the connector’s use. The measure of continuity is accomplished between pins to ensure that once the connector is installed, the electrical signals are properly transmitted. Validation tests are an important part of making sure that products that reach market meet or exceed expectations.
There are many types and sizes of test connectors and test equipment. For example, Phoenix Contact’s 3036709 connector test adapter test plugs make contact in the function shaft of terminal blocks from the CLIPLINE complete system.
Figure 1: The red test plugs from Phoenix Contact. (Source: Phoenix Contact)
The body orientation of the Phoenix Contact 3036709 is straight and the device has one port. Product dimensions are 59.82 mm in length, a depth of 22.3 mm and product height of 4.2 mm.
Phoenix Contact’s 0201744 silver test plug reliably makes contact in the bridge shaft and in all test sockets with a 2.3-mm diameter. The test plugs are inserted in the function shaft of terminal blocks from the Phoenix Contact CLIPLINE system or in the connections provided. CLIPLINE Complete is a modular terminal block system with a variety of available connection methods.
The S1751-06R Test Point Socket by Harwin is a one-contact, solder-termination, surface-mount part. This tape-and-reel device features a contact material of brass and contact plating made of tin lead. Minimum and maximum operating temperatures are -55°C and 125°C, respectively. Dimensions are 3.65 mm x 2.05 mm x 2.0 mm.
Harwin’s new range of PCB-mounted, dual-entry test sockets accepts a 2-mm pin. The M3498-99R sockets feature gold-plated contacts. The surface-mount product features a flat-top area and is available in tape-and-reel packaging for automated assembly using standard pick-and-place machines. These sockets also have a 5 A current rating and 1,500 V voltage rating.
Figure 2: Harwin dual-entry PCB-mounted test sockets. (Source: Harwin)
The new 2.00-mm, low-profile test sockets are only 5.16 mm in height and are available in through-hole and SMT versions and in a variety of colors. The test sockets offer high-reliability performance targeting high-end applications.
The most common types of connector tests include extraction force; insertion force; retention force; contact insertion and extraction; fatigue loading; axial and lateral bending and cable pulling. These tests, and others, are designed to ensure the accurate and repeatable evaluation of electrical connector performance.