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Quality control of crimped joint contacts with conductors through thermography
Finc, Matej ; Kek, Tomaž, 1974- ; Grum, Janez, 1946-
Crimped joint contacts with electrical conductors are made in large quantities on automated machinery as assembled joints. To ensure the quality of the wired connections, different standardised ...destructive methods are used. In practice, however, the use of non-destructive testing of joints is desired, since it allows a review and evaluation of each assembled joint. Using the selected thermographic method, we examined the usefulness and reliability of the evaluation of the quality of the selected crimped wire connections. The designed and tested experimental system for non-destructive examination consists of an infrared camera with a computer and a current generator for loading and heating the conductor. Thermographic measurements of different types and quality were performed on the joints. An assessment of the joint quality was made from the thermographic images of the temperature field. The measuring range captured with the thermographic camera was further limited to the central part of the wire joint, with the aim of excluding environmental impacts during the measurement of the current-laden joints. The thermographic measurements carried out on site enabled good quality assessments of the connections. The results of the thermographic measurements were compared with the various standardised destructive methods that are used for cable testing in the white goods industry. By comparing the results of the thermographic method and the standard destructive method, we proved the effectiveness of the proposed approach for assessing the quality of crimped joints. The study confirmed that the optimally-adjusted crimp height of the wire connection may provide a better layout and compression of individual wires in the junction, which results in less contact heating and therefore allows for an extended service life of the conductor.
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