线束插接件故障模式及改善对策

Failure Modes and Improvement Countermeasures of Wiring Harness Connectors

近五年来中国汽车市场发生了重大的变化,新能源汽车的占比逐渐提高,2022年新能源汽车市场份额超过25%。新能源汽车的电气功能越多,对应的线束插接件越多,线束插接件的故障逐渐成为影响功能实现的一个重要因素。线束插接件的常见失效模式有插接件端子退针、歪针、扩孔,插接件虚接等多种模式,插接件以上失效模式也不能完全被EOL设备或功能检查所拦截,存在逃逸至客户的风险,所以需要针对各种失效模式从设计、运输、对配、出厂检查多环节去寻找改善方案。

In the past five years,the Chinese automotive market has undergone significant changes,with the proportion of new energy vehicles gradually increasing.In 2022,the market share of new energy vehicles exceeded 25%.The more electrical functions a new energy vehicle has,the more corresponding wire harness connectors there are.The failure of wire harness connectors has gradually become an important factor affecting the implementation of functions.The common failure modes of wire harness connectors include pin withdrawal,skewed pins,hole expansion,and virtual connection of connectors.The failure modes above connectors cannot be completely intercepted by EOL equipment or functional inspections,and there is a risk of escaping to customers.Therefore,it is necessary to find improvement solutions for various failure modes from design,transportation,matching,and factory inspections.