In order to ensure the quality and reliability of terminal blocks and to prevent the occurrence of the above-mentioned fatal failures, it is recommended that the following targeted reliability tests for the prevention of failures be carried out in accordance with the technical conditions of the products and the research and development of the corresponding screening technical requirements.

1. Prevention of poor contact

1) Conductivity testing

In 2012, the general terminal manufacturers product acceptance test without this project, and users are generally required to conduct a conduction test after installation. Therefore, it is recommended that the manufacturer of some key models of products should be point by point conduction test.

2) Instantaneous break detection

Some terminals are used in dynamic vibration environment. Experimental proof only with the test static contact resistance is qualified, and can not guarantee the dynamic environment using a reliable contact. Because, often contact resistance qualified connector in vibration, shock and other simulation environment test still appear instantaneous power off phenomenon, so for some high reliability requirements of the terminal block, it can be dynamic vibration test to assess its contact reliability.

3) Single-hole separation force testing

Single hole separation force refers to the plug state of the contact parts from the static into the movement of the separation force, used to characterize the pin and jack is in contact. Experiments show that: single hole separation force is too small, in the vibration, shock load may cause signal transient break. Checking the contact reliability by measuring the separation force of a single hole is more effective than measuring the contact resistance. Inspection found that the single hole separation force exceeds the poor jack, measuring the contact resistance is often still qualified. For this reason, the production plant in addition to the development of a new generation of flexible plugging contact with stable and reliable contact parts, should not be used for key models using automatic plugging force testing machine multi-point test, the finished product should be single-hole separation force check point by point to prevent the signal transient break caused by individual jack slack.

2. Prevention of poor insulation

1) Inspection of insulating materials

The quality of raw materials has a great influence on the insulation performance of the insulator. Therefore, the choice of raw material manufacturers is particularly important, and it is important not to lose the quality of the material simply by reducing the cost. You should choose a good reputation of the big factory materials. Each batch of material should be carefully checked for batch numbers, material certificates and other important information. Do a good job of material use traceability information.

2) Insulation resistance inspection of insulators

As of 2012, some production plants were required to test the electrical properties after assembly into finished products, and as a result, the whole batch of finished products had to be scrapped because the insulation resistance of the insulator itself failed. A reasonable process should be to carry out process screening in the state of the insulator parts to ensure that the electrical properties are qualified.

3. Prevention of poor fixing

1) Interchangeability check

The interchangeability check is a dynamic check. It requires the same series of matching plugs and sockets to be connected to each other, from which to find out whether there is a failure to fit, position and lock due to poor dimensions of insulators, contacts and other parts, missing parts or poor assembly, even under the action of rotational forces that cause disintegration. Interchangeability check is another role is through the thread, bayonet and other plugging connection can be found in time whether there is a metal surplus to affect the insulation performance. Therefore, for some important purposes of the terminal block should carry out this project inspection, in order to avoid such a major fatal failure accident.

2) Endurance torque inspection

Endurance torque inspection is a kind of assessment terminal structure reliability is very effective inspection method. Such as the U.S. military standard MIL-L-39012 standard provisions. According to the standard should be sampling samples of each batch of endurance torque inspection, timely detection of problems

3) Crimp wire through test

In the electrical installation is often found when individual core crimp wire is not sent to the place, or sent to the place after the lock can not be, contact is not reliable. Analysis of the reason is the individual mounting holes at the screw teeth have burrs or dirty jamming. In particular, the use of the plant has been installed to a plug behind the seat of several installation holes, found that the defect only after the installation of other holes have been installed to crimp the wire one by one to unload, to replace the plug seat. In addition, due to the wire diameter and crimping hole diameter selection with improper, or due to crimping process errors, will also cause crimping end of the accident is not firm. To this end, the production plant in the finished product factory before delivery of the plug (seat) samples of all installation holes through the test, that is, with loading and unloading tools will be crimped with pins or jacks of the wire touch intended to the bit, check whether it can be locked. According to the technical conditions of the product, the crimped wire by wire to check the pull-off force.

Without a reliable terminal, there is no reliable system engineering. Failure and reliability are corresponding and interlinked two aspects of a contradictory body. Through the terminal reliability screening to find a variety of failure mode and failure mechanism, can lead to a large number of lessons learned and eliminate a variety of hidden dangers, for the improvement of design, technology, inspection and use to provide a scientific basis, it is also the revision and development of terminal technical conditions of the important basis. Looking for measures to prevent failure, to achieve the transformation from failure to reliability, is the purpose of failure analysis.