Although each connector has a rated life cycle. But for those connectors used in mechanical equipment, some factors such as incorrect design can also cause the connector to fail prematurely, thereby damaging the expensive mechanical equipment. Therefore, some factors that lead to connector failure are worthy of attention. Below are some common causes of connector failure as explained by connector manufacturers.

Connector

1. The degree of wear of the connector

Repeated connection and disconnection of connectors can cause the metal on the contacts to fray and corrode when exposed to water, dust, dirt and other irritating elements, resulting in the pins that may not engage properly when inserted into the connector housing.

2. Improper selection of connectors

For example, special connectors for wet environments need to be selected. If a standard connector is used in place of an IP68 or IP69 rated or sealed design connector, water can cause the connector to fail. Choosing an undersized connector can also reduce efficiency, thereby shortening the life of the connector.

3. The temperature of the connector

They also fail if the connectors are not rated for very high or very low temperatures. Because the connector is not suitable for high temperatures, the insulation fails and the conductivity peaks. If operated at sustained high temperatures, these spikes can raise temperatures, potentially causing corrosion and reducing contact forces. This affects the electrical signals propagating through the connector and cable assembly.

While low temperature does not affect connectors as much as high temperature, you should consider low temperature designs if you know your application will require them. Exposure to sustained low temperatures can cause tin-plated connector materials to soften, increasing contact resistance. Also, low temperatures can affect other parts of the connector, such as making the plastic shell brittle.

4. Improper connector design and installation

If the application of the connector will encounter destructive factors such as shock, vibration, etc., then the protection design that can produce the lock is very important. If the installation is not secure, the connector contacts, mating housings and even cables can be damaged. Additionally, connectors and cable assemblies have proper strain relief and installation routing, and the use of guide grooves, cable brackets, and cable glands help ensure rated connector assembly life.