Why Do Connectors Fail?

Mating connectors usually have life cycles according to which they perform. For example, if a connector is rated for 8000 mating cycles then you will expect that it will mate up to this figure. But it is not true always. There are many factors that can cause the connectors to fail before their rated time cycle. Improper designing is the major factor due to which the connectors usually fail.

The failing of connectors can also lead to mechanical damage. In this article, we have provided some common factor due to which the connectors fail and the ways of preventing failure.  Let’s have a look!

1) Wearing and tearing of connectors:

If you will connect and disconnect the connectors repeatedly then it will result in the corrosion of the metal placed on the contacts. The corrosion can occur if the metal will be exposed to dust, water, and other elements. Hence, due to corrosion, the mating pin will not be connected properly when they will be inserted into the shell of the connector. You should always check the rate of connectors before using. If the connector is rated according to the cycles you require then you can use it. Here, you can get help for protecting the connectors from corrosion.

2) Unprofessional selection:

There are special connectors for a moist environment. If you will use the simple type n connectors for a humid environment then it will cause problems. By using a standard connector rather than the one with IP68 or IP69 rating or a hermetic design, the moisture in the environment can cause it to fail. Moreover, the size of the connector should also be considered. An undersized connector can affect the efficiency which will result in decreasing the life of a connector.

3) Temperature Issues:

If you are using the connectors which are not rated for extreme temperature conditions, then they will fail. If the connectors are not able to survive high temperature as the insulation of the connectors fail, and their conductivity is also affected. If they will be operated at continued high temperatures, the conductor spikes will bring more increase in temperature which will result in corrosion. Hence, the contact force will be reduced.  Therefore, the electrical signal traveling through the connector and cable assembly will also be affected and it will result in an open circuit.

The high temperatures affect the connectors more as compared to low temperature. But you should choose the low-temperature designs if you are deploying the connectors in the areas where the temperature is cold. If the connectors are exposed to continuous low-temperature then the tin-plated material of the connectors can get soften due to which the contact resistance increases and their plastic shells can also become brittle from prolong exposure.

4) Improper installation of connectors:

 If the connectors are not installed properly then they can experience shock, vibration and other motions which can damage them. Hence, it is important to mount the connectors properly.

We hope that this article will help you in understanding the reason of connector failure. If you have any questions, please feel free to ask in the box below: