Connectors are an indispensable part of electronic equipment, and their performance and reliability directly affect how the whole system operates. The common test specifications are set out below.

Electrical performance testing

Electrical performance testing is the most basic part of connector testing and mainly covers the following items.

1.1 Contact resistance test. Contact resistance is the resistance that arises where current passes through the contact points of a connector in normal operation, and it directly affects transmission efficiency and signal quality. The four-wire method is normally used, measuring current and voltage to calculate contact resistance.

1.2 Insulation resistance test. Insulation resistance is the resistance between conductors in a connector in normal operation and relates to safety and reliability. A high voltage method is normally used, measuring voltage and current to calculate insulation resistance.

1.3 Dielectric withstand voltage test. This is the maximum voltage a connector can withstand within a specified time. The usual method raises the voltage step by step until breakdown occurs.

1.4 Current carrying capability test. This is the maximum current a connector can carry in normal operation. The usual method raises the current step by step until abnormal behaviour occurs.

Mechanical performance testing

Mechanical performance testing is a very important part of connector testing and mainly covers the following items.

2.1 Insertion and withdrawal force test. This is the force needed to insert and withdraw a connector in normal operation. A dedicated force tester is normally used, evaluating the force profile during mating.

2.2 Mating life test. This is the maximum number of mating cycles a connector can withstand under normal conditions of use. Automated mating equipment simulates the mating action of actual use to evaluate mating life.

2.3 Vibration test. This determines the vibration amplitude and frequency a connector can withstand in normal operation. A vibration table simulates the vibration environment of actual use.

2.4 Shock test. This determines the shock level a connector can withstand in normal operation. A shock tester simulates the shock environment of actual use.

2.5 Fretting wear. Evaluating and preventing the damage fretting wear causes to mechanical parts.

Environmental suitability testing

Environmental suitability testing is a very important part of connector testing and mainly covers the following items.

3.1 Temperature cycling test. This determines the temperature change a connector can withstand within a specified range. A temperature cycling chamber simulates the temperature changes of actual use.

3.2 Damp heat test. This determines the damp heat environment a connector can withstand at specified humidity and temperature. A damp heat chamber simulates the humidity and temperature of actual use.

3.3 Salt mist test. This determines the salt mist corrosion a connector can withstand at a specified concentration and duration. A salt mist chamber simulates the salt mist environment of actual use.

3.4 Low air pressure test. This determines the pressure change a connector can withstand within a specified pressure range. A low pressure chamber simulates the pressure changes of actual use.

Chemical performance testing

Chemical performance testing is a very important part of connector testing and mainly covers the following items.

4.1 Corrosion resistance test. This determines the degree of corrosion a connector can withstand in a specified chemical environment, using chemical reagents to simulate the chemical environment of actual use.

4.2 Chemical reagent resistance test. This determines the attack by chemical reagents a connector can withstand under specified conditions, simulating the chemical reagent environment of actual use.

Signal integrity testing

Signal integrity testing is a very important part of connector testing and mainly covers the following items.

5.1 Propagation delay test. This is the delay of a signal as it passes through the connector. A high speed oscilloscope measures the propagation time to evaluate delay performance.

5.2 Crosstalk test. This is the degree of interference between adjacent signal lines as a signal passes through the connector. A network analyser measures crosstalk to evaluate crosstalk performance.

5.3 Return loss test. This is the loss caused by signal reflection as it passes through the connector. A network analyser measures reflection loss to evaluate return loss performance.