In industrial automation, intelligent manufacturing, and IoT devices, communication connectors are crucial despite their small size. It is like a "neural network" in the information world, responsible for lossless transmission of high-frequency and high-speed signals, directly affecting system response, control accuracy, and operational stability.
If the performance of the connector deteriorates, it may lead to signal delay, error code, and even interruption, with serious consequences in scenarios such as high-speed real-time control. With the advancement of Industry 4.0, 5G+Industrial Internet and other technologies, connectors need to have both excellent electrical performance and durability in harsh environments.
How to systematically evaluate the reliability of industrial grade connectors? This article will take you through the core testing standards and performance requirements of common industrial connectors such as M8, M12, and RJ45!
1. Mechanical performance: the 'physical cornerstone' of connection reliability
Communication connectors need to maintain structural stability in harsh environments such as frequent plugging, vibration, and impact.
A. Appearance and size inspection
According to the IEC 60512-1-1 and IEC 60512-1-2 standards, visually inspect and measure the unconnected connectors using measuring tools. Require it to have no defects that affect its functionality, and all dimensions meet the specifications of the design drawings.
B. Insertion and extraction force, retention force, and polarization anti misplacement test
Perform insertion and extraction force testing according to IEC 60512-13-2 standard. For RJ45 connectors, the insertion and extraction force requirement is usually ≤ 30N.
Conduct retention force testing according to IEC 60512-16-5 standard to evaluate the mechanical fixation strength of pins and sockets in the housing.
According to the IEC 60512-13-5 standard, conduct polarization anti misoperation testing to ensure that the connector has the function of preventing incorrect insertion.
C. Durability test
Perform contact insertion and extraction cycle test according to IEC 60512-9-1 standard. After the experiment, the connector function should be normal, and there should be no abnormalities in contact resistance and appearance. The typical cycle requirements for M8/M12 connectors are: 100 gold-plated contacts, 50 silver plated contacts, and 20 tin plated contacts. The required number of cycles for RJ45 connectors is usually 750.
D. Effectiveness of insertion
According to the IEC 60512-15-6 standard, apply an axial tension of 50N to the fully mated RJ45 connector coupling and maintain it for 60 seconds. After the experiment, it is required that the RJ45 connector is not loose, separated, or mechanically damaged.
2. Electrical performance: the "quality protection" of signal transmission
Electrical performance is the core of communication connectors, especially in high-speed transmission.
A. Contact resistance test
According to the IEC 60512-2-1 standard, the four wire method (Kelvin method) is used for measurement to eliminate lead errors. The contact resistance requirement for M8/M12 connectors is usually ≤ 10 m Ω, while the contact resistance requirement for RJ45 connectors is usually ≤ 20 m Ω.
B. Insulation resistance and withstand voltage test
According to the IEC 60512-3-1 standard, the insulation resistance of M8/M12 connectors should be ≥ 100 M Ω under DC 500V test voltage, and the insulation resistance of RJ45 connectors should be ≥ 500 M Ω under DC 100V test voltage.
According to the IEC 60512-4-1 standard, a voltage withstand test is conducted on RJ45 connectors: an AC effective value of 1kV is applied between the contacts, or an AC effective value of 1.5kV is applied between the contacts and the shield for 60 seconds, with no breakdown or arcing required. The withstand voltage test voltage of M8/M12 connectors needs to be determined according to their specific core specifications.
C. Current carrying capacity and temperature rise test
According to the IEC 60512-5-1 (temperature rise test) and IEC 60512-9-2 (current carrying capacity test) standards, the connector is tested with its rated current until its temperature reaches a stable state (with a change of ≤ 2 ° C per hour). Require its temperature rise (relative to ambient temperature) to be less than 30 ° C, and its electrical performance (such as contact resistance) to be normal after the test.
3. Environmental adaptability: the "survival test" of extreme environments
Communication connectors need to adapt to various complex environments, and their tolerance is verified through environmental testing.
A. Vibration and impact testing
According to the IEC 60512-6-4 standard, a sinusoidal vibration test is conducted with a frequency range of 10Hz~500Hz, scanning for 10 cycles, and conducting a 2-hour test on three mutually perpendicular axes in sequence.
According to the IEC 60512-6-3 standard, a half sine wave impulse test was conducted on the M8/M12 connector, with a peak acceleration of 490m/s ² and a pulse duration of 11ms.
During the experiment, the interruption time requirement for M8/M12 connectors is usually ≤ 1 μ s, and the interruption time requirement for RJ45 connectors is usually ≤ 10 μ s. There is no mechanical damage after the test, and the change in contact resistance meets the product specification requirements.
B. Temperature and Damp Heat Test
According to the IEC 60512-11-4 standard, the temperature rapid conversion test is conducted, and the test conditions for M8/M12 connectors are -40 ° C ↔ + 80 ° C, RJ45 connector test conditions are -40 ° C ↔ 70 ° C.
According to the IEC 60068-2-38 standard, a wet heat test is usually required to complete 21 cycles for RJ45 connectors. According to the IEC 60068-2-30 standard, a wet heat test is usually required to complete 6 cycles for M8/M12 connectors.
After the experiment, the electrical performance, mechanical performance, and appearance should all meet the relevant requirements of the product specification.
C. corrosion test
Conduct neutral salt spray testing according to IEC 60512-11-6 standard. Spray a 5% concentration of sodium chloride solution, maintain the pH value of the solution at 6.5-7.2, keep the temperature of the test chamber at 35 ° C, and conduct the test for 48 hours. After the experiment is completed, the coating and metal substrate of the connector metal parts should be free of corrosion, and its main electrical and mechanical properties should meet the product specifications.
D. IP67 waterproof test
According to the IEC 60529 standard, waterproof testing shall be conducted on products in docking state. Immerse the product in water, ensuring that its lowest point is 1 meter below the water surface, and conduct the test for 30 minutes. After the experiment is completed, it is required that no water stains enter the interior of the product.
E. Airtightness test
Perform fine leakage testing according to IEC 60512-14-2 standard. This test is only used for glass to metal sealed connectors that require extremely high sealing performance (such as certain high reliability M12 variants).
*The above testing requirements and methods are compiled from relevant standards published by the International Electrotechnical Commission (IEC). Please refer to the latest effective version of IEC for specific implementation*
Kronz industrial connector
M8, M12, 7/8, Y-shaped splitter RJ45、M12-RJ45
Number of cores: 4, 5, 6, 8 Pin codes: A, B, D, X, Y
*Y-shaped head, on-site wiring, pre cast flange, total terminal resistor, single end pre cast flange, single end pre cast, double end pre cast, pre cast, assembled.
How important is connector system testing?
According to statistics, about 30% of electronic system failures can be traced back to connector performance degradation. Therefore, conducting systematic and rigorous testing on connectors is an important step in ensuring the reliable operation of the entire signal transmission system.
On the basis of strictly following IEC standards to complete connector testing, KRONZ also uses Fluke testing equipment to conduct 100% factory performance testing on each batch of finished connectors. The focus covers the following core performance indicators:
✅ Return loss: Ensure perfect impedance matching of the connector, eliminate signal reflection, and guarantee signal integrity from the source.
✅ Insertion loss: Verify that the attenuation value of the entire link signal is within the standard range, ensuring signal transmission strength and preventing attenuation even at longer distances.
✅ Near end crosstalk: Strictly control the signal interference between the internal wire pairs of the connector to ensure clear signals without "crosstalk" and zero errors in data transmission.
✅ Transfer impedance: Maintain the stability of the entire link impedance to avoid data distortion caused by fluctuations.
By comprehensively covering the above testing items, the aim is to control product quality from the production process and improve the adaptability of connectors in complex application environments.
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