CN111665267B - Visual detection method for crimping quality of pit-press type contact - Google Patents
Visual detection method for crimping quality of pit-press type contact Download PDFInfo
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- CN111665267B CN111665267B CN202010548751.2A CN202010548751A CN111665267B CN 111665267 B CN111665267 B CN 111665267B CN 202010548751 A CN202010548751 A CN 202010548751A CN 111665267 B CN111665267 B CN 111665267B
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- G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/286—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q involving mechanical work, e.g. chopping, disintegrating, compacting, homogenising
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/32—Polishing; Etching
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/36—Embedding or analogous mounting of samples
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
- G01N21/84—Systems specially adapted for particular applications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/286—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q involving mechanical work, e.g. chopping, disintegrating, compacting, homogenising
- G01N2001/2866—Grinding or homogeneising
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Abstract
The invention provides a visual detection method for the crimping quality of a pit-press type contact, which solves the problems that the existing detection of the crimping quality of a contact body and a wire cannot be intuitively and deeply detected and the crimping quality problem is often hidden. The detection method disclosed by the invention integrates microscopic combination visualization of indentation and metallography, can fundamentally master the compression joint condition of the contact, can recognize quality risks in advance, and can be used as an important basis for acceptance, zero resetting and compression joint research.
Description
Technical Field
The invention belongs to the technical field of contact crimping processes, and relates to a visual detection method for crimping quality of a pit-press type contact.
Background
Wire harness products are the main body of equipment circuit networks, where electrical connection with the wire cores with connectors is the most critical. In order to meet the development of miniaturization of connectors, most of the connectors are pressed by pit pressure, and the problem of pressing quality of the connectors is often hidden, and the connectors are often gradually exposed after long-term use, so that the problem of wire harness products is frequently found in recent years.
The pit pressing type crimping is completed through a crimping pliers, and the contact element pressing cylinder is tightly connected with the lead by controlling the pressure and the jaw displacement to form pit indentation. During the crimping process, under-pressure and over-pressure should be avoided. The undervoltage can cause overlarge gap between the contact and the lead, and the stretching resistance, bending resistance and vibration resistance of the wire harness product can be reduced; the overvoltage can increase the radial shearing of the crimping barrel to the wire core, damage the wire core, and even crush the crimping barrel to influence the electric conduction. The wire core is not fed in place, the gear of the crimping pliers is incorrect, the contact is not taken out normally, and the undervoltage and overvoltage can be caused by the excessive hardness of the contact and the wire core.
The current testing methods specified in the crimping standards are all macroscopic indexes of the environment resistance such as tensile resistance, contact resistance and the like, and are used for indirectly evaluating the crimping quality of the contact, and the testing and analyzing methods of the microstructure are not deep enough, so that visual researches on the microstructure of crimping are generated.
Disclosure of Invention
In order to solve the technical problems, the invention provides a visual detection method for the crimping quality of a pit-press type contact, which integrates the two microcompositions of indentation and metallography for visualization, can fundamentally grasp the crimping condition of the contact, can recognize the quality risk in advance, and can be used as an important basis for acceptance, zeroing and crimping research.
In order to achieve the above purpose, the invention adopts the following technical scheme:
the visual detection method of the crimp quality of the pit-press type contact is used for detecting the crimp quality of the pit-press type contact and a wire, the pit-press type contact comprises a contact body, the tail section of the contact body is a crimp barrel, and an observation hole is arranged on the crimp barrel, and the detection method comprises the following steps:
(1) Taking a contact sample, selecting a lead matched with the contact sample and a clamping jaw gear of a crimping pliers, and crimping a crimping handbook in a standard manner;
(2) Observing the longitudinal compression joint condition of the contact sample after compression joint by adopting an electron microscope to obtain and retain an indentation microscopic image of the sample in the longitudinal direction;
(3) A metallographic microscope is adopted to obtain a transverse section golden phase diagram of the contact sample after crimping;
(4) Taking the indentation microscopic image obtained in the step (2) and the section golden phase image obtained in the step (3) as standard patterns, and taking the standard patterns as the qualified basis for crimping of the contact;
(5) After the contact sample is crimped with an adaptive wire through a crimping clamp, observing the longitudinal crimping condition of the crimped contact to obtain a longitudinal indentation microscopic image of the contact to be tested by adopting an electron microscope, and simultaneously obtaining a transverse section golden phase image of the contact to be tested;
(6) Comparing the indentation microscopic image and the section golden phase image of the contact to be tested obtained in the step (5) with the contact sample standard pattern obtained in the step (4), wherein the indentation microscopic image is used for checking an overvoltage condition, the section golden phase image is used for checking an undervoltage condition, and the indentation microscopic image and the section golden phase image are comprehensively analyzed to obtain the crimping quality of the contact to be tested.
Further, the visual detection method of the crimp quality of the pit-press type contact piece further comprises crimp quality verification, and the specific verification method comprises the following steps:
and (3) respectively selecting a plurality of spare parts in the same state for physical verification aiming at all the contact parts to be tested after crimping, wherein the verification comprises a tensile force boundary test and a bending boundary test, verifying the bearing tensile force and the bearing bending times, and comparing with the crimping quality analysis result of the contact parts to be tested in the step (6) to obtain a final detection conclusion.
Further, the specific method for acquiring the section golden phase diagram comprises the following steps:
step a, cutting: shearing the wire after the contact is crimped by using a wire cutting pliers, and removing the wire outside the crimping barrel of the contact to be tested;
step b, mounting:
selecting the insert powder, feeding the insert powder and the contact into an embedding machine, adjusting the insert powder and the contact to a high-temperature and high-pressure state, heating the contact and the residual wire to 150 ℃, keeping the temperature for 15min, and finally tightly wrapping the contact by the solidified insert powder and exposing the tail end edge of the contact for grinding;
step c, grinding;
step d, etching
Selecting proper corrosive liquid for corrosion according to the contact material;
step e, imaging analysis
And imaging the corroded contact piece by adopting a metallographic microscope, finding a reasonable view field by adjusting the focal length and the position of the objective table, and observing the size of a gap between the contact piece and the wire core and between the wire core and the wire core in the section metallographic diagram.
Further, the insert powder in the step b is thermosetting PF2A4-161J phenolic molding compound powder.
Further, the grinding in the step c is performed in the following steps:
(a) Rough grinding: grinding the tail end of the contact by using a floor grinding machine until the actual press-connection position on the contact press-connection barrel, namely the middle point of the inlet and the observation hole of the press-connection barrel can be observed, and cooling by adopting a water cooling mode to prevent the metal tissues of the contact and the wire from being changed due to heat generated by friction between the contact and the grinding wheel;
(b) Fine grinding: cooling, cleaning and drying the contact piece after rough grinding, grinding on coarse sand paper and fine sand paper, repeating the steps for a certain time in the same direction, and then rotating for 90 degrees to continue grinding;
(c) Polishing: the surface roughness left after fine grinding was polished using a polished infrared carbon sulfur analyzer to reduce the roughness of the contact to ra0.04.
Compared with the prior art, the invention has the following beneficial effects:
(a) Under the ocular lens, the visual observation can be used for drawing conclusions, thus saving the cost of manpower, equipment, time and the like.
(b) The traditional mechanical test has larger destructiveness, the states of the contact and the wire after the test are changed, and the contact and the wire cannot be traced back through secondary review.
(c) The traditional method is an indirect method by measuring the tension, the bending times and the like; the detection method of the invention has more visual observation mode.
(d) The observation mode is clearer, the actual condition of each wire core can be known, and the problem can be fundamentally found.
Drawings
FIG. 1 is a schematic view of a dimple contact of the present invention;
FIG. 2 is an indentation micrograph of a contact sample after crimping;
FIG. 3 is a golden phase diagram of a cross-section of a contact sample after crimping;
FIG. 4 is an indentation micrograph of sample A, sample B, sample C, and sample D of the example;
FIG. 5 is a cross-sectional golden phase diagram of sample A, sample B, sample C and sample D in the example;
FIG. 6 is a schematic view of the contact after fixation with the insert;
in the figure: 1-crimping a cylinder; 2-viewing port.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Example 1
The visual detection method of the crimp quality of the pit-press type contact is used for detecting the crimp quality of the pit-press type contact and a wire, as shown in figure 1, the contact sample and the contact to be detected are pit-press type contacts, and the visual detection method comprises the steps that the tail section of the contact body is a crimp barrel 1 for penetrating and crimping the wire, and an observation hole 2 is formed in the crimp barrel 1;
the detection method comprises the following steps:
(1) Taking a contact sample, selecting a lead matched with the contact sample and a clamping jaw gear of a crimping pliers, and crimping a crimping handbook in a standard manner;
(2) Observing the longitudinal compression joint condition of the contact sample after compression joint by adopting an electron microscope to obtain and retain an indentation microscopic image of the sample in the longitudinal direction, as shown in fig. 2;
(3) The contact sample after crimping is adopted to obtain a transverse section golden phase diagram by adopting a metallographic microscope, as shown in figure 3;
(4) Taking the indentation microscopic image obtained in the step (2) and the section golden phase image obtained in the step (3) as standard patterns, and taking the standard patterns as the qualified basis for crimping of the contact;
(5) The contact piece to be measured, which is the same as the contact piece sample, is taken as a sample A, a sample B, a sample C and a sample D respectively, after the contact piece to be measured is respectively crimped with an adaptive lead through a crimping clamp, the longitudinal crimping condition of the crimped contact piece to be measured is observed by adopting an electron microscope, so that a longitudinal indentation microscopic image of the contact piece to be measured is obtained, the indentation microscopic images of the sample A, the sample B, the sample C and the sample D are shown in fig. 4, and a transverse section metal phase image of the contact piece to be measured, the sample B, the sample C and the sample D is obtained at the same time, as shown in fig. 5;
the specific method for acquiring the section golden phase diagram in the step (3) and the step (5) comprises the following steps:
step a, cutting: shearing the wire after the contact is crimped by using a wire cutting pliers, and removing the wire outside the crimping barrel of the contact to be tested;
step b, mounting:
selecting thermosetting PF2A4-161J phenolic moulding compound powder as inlay powder, enabling the material not to react with alcohol, facilitating wiping before imaging, sending the inlay powder and the contact piece cut in the step a into an inlay machine together, adjusting the inlay machine to a high-temperature and high-pressure state, heating the contact piece and the residual wire to 150 ℃ and then keeping for 15min, finally tightly wrapping the contact piece by the cured inlay powder 3, and exposing the tail end edge of the contact piece for grinding (refer to figure 6);
step c, grinding
The grinding is carried out by the following steps:
(a) Rough grinding: grinding the tail end (the tail end face of the crimping tube 1) of the contact by using a floor type grinder, grinding to an actual crimping position (namely a middle point between an inlet of the crimping tube and an observation hole) on the crimping tube of the contact, and cooling by adopting a water cooling mode to prevent the metal structures of the contact and the wire from being changed due to heat generated by friction of the contact and the grinding wheel;
(b) Fine grinding: cooling, cleaning and drying the contact piece after rough grinding, grinding on coarse sand paper and fine sand paper, repeating the steps for a certain time in the same direction, and then rotating for 90 degrees to continue grinding;
(c) Polishing: polishing the surface roughness left after fine grinding by using a polishing infrared carbon-sulfur analyzer to reduce the roughness of the contact to Ra0.04;
step d, etching
Selecting proper corrosive liquid for corrosion according to the contact material; common contact materials include tin bronze, beryllium bronze, and the like, and according to test experience, corrosive solutions shown in table 1 are used.
TABLE 1 corrosive liquid composition and proportioning concentration table
Step e, imaging analysis
And imaging the corroded contact piece by adopting a metallographic microscope, finding a reasonable view field by adjusting the focal length and the position of the objective table, and observing the size of a gap between the contact piece and the wire core and between the wire core and the wire core in the section metallographic diagram.
(6) Comparing the indentation microscopic image (figure 4) and the cross-section golden phase image (figure 5) of the contact to be tested obtained in the step (5) with the contact sample standard image (indentation microscopic image figure 2 and cross-section golden phase image figure 3) in the step (4), wherein the indentation microscopic image is used for checking an overpressure condition, the cross-section golden phase image is used for checking an underpressure condition, and the two are comprehensively analyzed to obtain the crimping quality of the contact to be tested.
Image contrast and analysis process:
(1) As can be seen by comparing FIG. 4 with FIG. 2, the pressure-welding barrels of the sample A and the sample B have too deep indentations, the observation holes deform, and especially the observation holes of the pressure-welding barrels of the sample A deform seriously, even the wire core torn in the inner part can be seen through the observation holes, and the plating layer is separated in a small part. Thus, sample a and sample B were judged to be overpressure. The cable core is damaged without mechanical tests such as stretching, bending, vibration and the like, the mechanical performance is seriously reduced, and the conductivity is insufficient.
Sample C and sample D are almost the same as the indentations in FIG. 2, and although the indentations of sample D are slightly shallow and the possibility of under-pressure exists by naked eyes, the effect is not obvious and the under-pressure condition needs to be judged by means of a section golden phase diagram.
(2) Through comparing in fig. 5 and fig. 3, although the pits of the sample a, the sample B, the sample C and the sample D are all uniformly distributed along the circumference of the crimping barrel, gaps between the crimping barrels of the sample C and the sample D and between the wire core and the wire core are too large, deformation of the contact piece and the wire core is too small, and even the section of the wire core like the section of the wire core in fig. 3 can not be pressed into a polygon from a circle, and it is obvious that the sample C and the sample D have under-pressure conditions. The wire core is not fully contacted with the contact piece without mechanical test, the pull-out resistance is not enough, and when the wire core is stressed by tension or suffers low temperature (expansion with heat and contraction with cold), the wire core is easy to fall off from the contact piece, so that the reliability is not optimal.
There is little gap between the crimp barrel and the core and between the core and the core of the sample a and the sample B, and there is a possibility of overpressure, but it cannot be directly ascertained that an overpressure condition needs to be ascertained by means of the indentation micrograph described in crimp 3.1.
(3) The visual detection method of the crimp quality of the pit pressure type contact piece further comprises crimp quality verification, and the specific verification method comprises the following steps:
and (3) respectively selecting a plurality of spare parts in the same state for physical verification aiming at all the contact parts to be tested after crimping, wherein the verification comprises a tensile force boundary test and a bending boundary test, verifying the bearing tensile force and the bearing bending times, and comparing with the crimping quality analysis result of the contact parts to be tested in the step (6) to obtain a final detection conclusion.
The two were performed, and the boundary values of the tensile force boundary test and the bending boundary test were averaged, respectively, and the verification results are shown in table 2. The test result proves that the detection method is correct and accords with the rule of crimping.
TABLE 2 physical verification results
The invention synthesizes the detection method of indentation and metallographic two microscopic visualizations, so that an inspector can clearly observe the real tissue overall view of the crimping barrel and the wire, basically grasp the crimping condition of the contact, recognize the quality risk in advance, and can be used as an important basis for acceptance, zeroing and crimping research. And the states of the contact and the wire are basically not destroyed, and the secondary review can be performed.
The principles and embodiments of the present invention have been described herein with reference to specific examples, the description of which is intended only to assist in understanding the methods of the present invention and the core ideas thereof; also, it is within the scope of the present invention to be modified by those of ordinary skill in the art in light of the present teachings. In view of the foregoing, this description should not be construed as limiting the invention.
Claims (5)
1. The visual detection method of the crimp quality of the pit-press type contact is used for detecting the crimp quality of the pit-press type contact and a wire, the pit-press type contact comprises a contact body, the tail section of the contact body is a crimp barrel, and an observation hole is arranged on the crimp barrel, and the visual detection method is characterized by comprising the following steps:
(1) Taking a contact sample, selecting a lead matched with the contact sample and a clamping jaw gear of a crimping pliers, and crimping a crimping handbook in a standard manner;
(2) Observing the longitudinal compression joint condition of the contact sample after compression joint by adopting an electron microscope to obtain and retain an indentation microscopic image of the sample in the longitudinal direction;
(3) A metallographic microscope is adopted to obtain a transverse section golden phase diagram of the contact sample after crimping;
(4) Taking the indentation microscopic image obtained in the step (2) and the section golden phase image obtained in the step (3) as standard patterns, and taking the standard patterns as the qualified basis for crimping of the contact;
(5) After the contact sample is crimped with an adaptive wire through a crimping clamp, observing the longitudinal crimping condition of the crimped contact to obtain a longitudinal indentation microscopic image of the contact to be tested by adopting an electron microscope, and simultaneously obtaining a transverse section golden phase image of the contact to be tested;
(6) Comparing the indentation microscopic image and the section golden phase image of the contact to be tested obtained in the step (5) with the contact sample standard pattern obtained in the step (4), wherein the indentation microscopic image is used for checking an overvoltage condition, the section golden phase image is used for checking an undervoltage condition, and the indentation microscopic image and the section golden phase image are comprehensively analyzed to obtain the crimping quality of the contact to be tested.
2. The visual inspection method for crimp quality of a dimple-type contact according to claim 1, wherein the visual inspection method for crimp quality of a dimple-type contact further comprises crimp quality verification, and the specific verification method is as follows:
and (3) respectively selecting a plurality of spare parts in the same state for physical verification aiming at all the contact parts to be tested after crimping, wherein the verification comprises a tensile force boundary test and a bending boundary test, verifying the bearing tensile force and the bearing bending times, and comparing with the crimping quality analysis result of the contact parts to be tested in the step (6) to obtain a final detection conclusion.
3. The visual detection method for the crimping quality of the pit-press type contact piece according to claim 1, wherein the specific method for acquiring the sectional golden phase diagram is as follows:
step a, cutting: shearing the wire after the contact is crimped by using a wire cutting pliers, and removing the wire outside the crimping barrel of the contact to be tested;
step b, mounting:
selecting the insert powder, feeding the insert powder and the contact into an embedding machine, adjusting the insert powder and the contact to a high-temperature and high-pressure state, heating the contact and the residual wire to 150 ℃, keeping the temperature for 15min, and finally tightly wrapping the contact by the solidified insert powder and exposing the tail end edge of the contact for grinding;
step c, grinding;
step d, etching
Selecting proper corrosive liquid for corrosion according to the contact material;
step e, imaging analysis
And imaging the corroded contact piece by adopting a metallographic microscope, finding a reasonable view field by adjusting the focal length and the position of the objective table, and observing the size of a gap between the contact piece and the wire core and between the wire core and the wire core in the section metallographic diagram.
4. The visual inspection method of crimp quality of a press-in-pit type contact according to claim 3, wherein the insert powder in the step b is thermosetting type PF2A4-161J phenolic molding compound powder.
5. A method for visually inspecting crimp quality of a press-in-pit type contact according to claim 3, wherein the grinding in the step c is performed by:
(a) Rough grinding: grinding the tail end of the contact by using a floor grinding machine until the actual compression joint of the contact compression joint cylinder can be observed, and cooling by adopting a water cooling mode to prevent the metal structures of the contact and the wires from being changed due to heat generated by friction between the contact and the grinding wheel;
(b) Fine grinding: cooling, cleaning and drying the contact piece after rough grinding, grinding on coarse sand paper and fine sand paper, repeating the steps for a certain time in the same direction, and then rotating for 90 degrees to continue grinding;
(c) Polishing: the surface roughness left after fine grinding was polished using a polished infrared carbon sulfur analyzer to reduce the roughness of the contact to ra0.04.
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