Description of Driving Event:
Recessed electrical contacts in connectors, with replaceable pins or sockets, were observed as a result of a functional failure or during visual examination. The contacts were either not properly locked or became unlocked in the connector insert. During connector mating, the mating contact would push the contact backwards. Improper locking was often the result of deformed or broken retention clips. The Scout Program fabricated a set of push test tools. These tools have the proper mating contact and permit the application of an appropriate force on the contact in an assembled connector. After initial wiring and modifications of the electrical connector, a push test was performed on each contact in the connector. Contacts and connectors failing the push test were rejected per established procedures.
Lesson(s) Learned:
Electrical connector contacts with replaceable pins or sockets may not function properly from damage caused by the mating processes.
Recommendation(s):
Perform a push test prior to mating to detect and screen for unlocked contacts where the connector has replaceable contacts.
Evidence of Recurrence Control Effectiveness:
This test significantly reduced the problem of recessed contacts in electrical connectors and decreased costly replacement in the field.
Documents Related to Lesson:
N/A
Mission Directorate(s):
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Additional Key Phrase(s):
- Hardware
- Parts Materials & Processes
- Test & Verification
Additional Info:
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