What should I pay attention to when maintaining AWG Mechanical Connectors?

AWG mechanical connectors are a crucial part of electrical connections. Proper maintenance can extend their lifespan, ensure the stability of the electrical system, and reduce the risk of failures, which should not be underestimated.

I. Appearance Inspection
Integrity of the Housing
Regularly check whether there are cracks, damages or deformations on the connector housing. If the housing is damaged, the internal components may be exposed and eroded by dust, moisture and other factors, affecting the connection performance and safety. For example, if a slight crack is found on the housing, it should be marked in time and evaluated whether it needs to be replaced.
Pay attention to whether the markings on the surface of the housing are clear and complete. The markings contain important information such as specifications, models and rated parameters. If they are worn or blurred, it may cause troubles during maintenance or replacement. If necessary, the markings on the housing label should be re-labeled or replaced.
Condition of the Connection Parts
Check whether there are signs of looseness at the connection points between the connection terminals and the wires. Gently pull the wires. If there is displacement, it indicates that the connection is loose and needs to be re-tightened. A loose connection will lead to an increase in contact resistance, causing problems such as overheating and sparking, and may even damage the connectors and equipment in severe cases.
Check whether there is oxidation or corrosion at the connection parts. In humid or corrosive gas environments, metal connection parts are prone to oxidation, rusting or corrosion, which will increase the contact resistance. If slight oxidation is found, it can be carefully polished with sandpaper. In severe cases, the connectors need to be replaced.

II. Detection of Electrical Performance
Measurement of Contact Resistance
Use a professional micro-ohmmeter to regularly measure the contact resistance of the connectors. The contact resistance should be within the specified range, and generally it is required to be low and stable. For example, for some precision AWG mechanical connectors, the contact resistance should be less than 10 milliohms. If the measured value exceeds the range, it may be due to poor contact, and the connection points need to be checked, cleaned or repaired.
Compare the measurement data of different periods. If it is found that the contact resistance has a gradually increasing trend, even if it does not exceed the standard value, the reasons should also be analyzed in depth, such as whether there are impurities entering the connection parts or metal fatigue, etc., and preventive measures should be taken in advance to prevent failures.
Testing of Insulation Resistance
Use an insulation resistance tester to test the insulation resistance of the connectors. Its value should meet the requirements of the product standard to ensure good insulation performance and prevent electric leakage or short circuit. Generally, the insulation resistance needs to reach several megohms or even higher. If the insulation resistance is too low, it may be due to aging, moisture or damage of the insulation materials, and the insulation parts or the entire connectors need to be replaced in time.
When testing the insulation resistance, pay attention to the temperature, humidity and other conditions of the testing environment. Try to conduct the test under standard conditions to ensure the accuracy and comparability of the test results.

III. Maintenance of Mechanical Performance
Inspection of Insertion and Extraction Forces
Check the insertion and extraction forces of the connectors according to the specified cycle. The insertion and extraction forces should be moderate. If they are too loose, the connection may be unreliable. If they are too tight, it will be difficult to insert and extract and the connectors are easy to be damaged. For example, for common AWG mechanical connectors, the insertion force is generally between 1 and 5 Newtons, and the extraction force is between 0.5 and 3 Newtons. If the insertion and extraction forces are abnormal, it is necessary to check whether the internal structure is deformed or there are foreign objects stuck.
When inserting and extracting the connectors, follow the correct operation methods and avoid violent insertion and extraction. Hold the main body part of the connectors and apply force evenly to prevent damage to the terminals or the housing.
Inspection of the Internal Structure
Regularly disassemble the connectors (if they can be disassembled) and check whether the internal mechanical structures, such as springs, snap rings, latches and other components, are deformed, broken or worn. If these components are damaged, they will affect the normal operation of the connectors. For example, if a spring loses its elasticity, it may lead to insufficient connection pressure and the damaged components need to be replaced in time.
Check whether the internal moving parts can move flexibly. Apply an appropriate amount of lubricant, but pay attention not to use conductive lubricants to avoid affecting the electrical performance, and ensure the smooth operation of the internal mechanical structure.

IV. Guarantee of Environmental Adaptability
Temperature Management
Pay attention to the temperature changes in the environment where the connectors are used. Excessively high temperatures will cause the aging of the connector materials and the decline of the insulation performance, while excessively low temperatures may cause some components to become brittle. For example, if the environmental temperature exceeds 80 °C for a long time, heat dissipation measures should be considered, such as installing heat sinks or improving ventilation conditions. In a low-temperature environment, appropriate cold protection should be provided for the connectors.
Avoid placing the connectors close to high-temperature heat sources or in areas with rapid temperature changes. For example, they should not be directly installed on the surface of heating equipment such as motors to prevent structural damage caused by thermal expansion and contraction.
Humidity and Protection
Keep the use environment dry to prevent moisture from eroding the connectors. In a humid environment, desiccants or sealed boxes can be used to protect the connectors. If the connectors are already affected by moisture, they should be dried in time, such as drying them in an oven at an appropriate temperature. However, pay attention that the temperature should not be too high to avoid damaging the components.
For connectors with requirements for dust prevention and waterproofing, check their sealing performance. For example, check whether the sealing rings of waterproof connectors are intact, whether there are aging, deformation or damage. If there are problems, the sealing rings need to be replaced in time to ensure that their protection levels meet the requirements.

V. Cleaning and Maintenance
Surface Cleaning
Regularly clean the dust, oil stains and other impurities on the surface of the connectors. Use a clean soft cloth dipped in an appropriate amount of anhydrous alcohol or special cleaner to gently wipe, and avoid using corrosive solvents. When cleaning, pay attention not to let the liquid enter the interior of the connectors to prevent short circuits or damage to components.
For dirt that is difficult to remove, a small brush or compressed air can be used for cleaning, but the pressure should be controlled to prevent blowing away small internal parts or damaging the connection parts.
Internal Cleaning (with Caution)
If it is necessary to clean the interior of the connectors, it should be carried out under the guidance of professionals. Use special cleaning tools and reagents, such as precision electronic cleaners. Spray a small amount of cleaner into the interior and then dry it with clean compressed air. However, make sure that the cleaner has completely evaporated before reconnecting and using them to avoid the residual cleaner affecting the electrical performance.
In conclusion, the maintenance of AWG mechanical connectors covers multiple aspects such as appearance, electrical performance, mechanical performance, environmental adaptability and cleaning. Only by doing all aspects of maintenance work comprehensively and meticulously can we ensure their long-term stable and reliable operation and provide a strong guarantee for the normal operation of the electrical system.