German ABL SURSUM plug, ABL SURSUM model, ABL SURSUM price

ABL SURSUM plug terminal blocks, as a type of connector, are important components in the electrical industry, playing an irreplaceable and significant role. Since engineering technicians start inspections from the interfaces, i.e., the terminals, during maintenance, the design of terminal blocks is particularly crucial. Terminal blocks can be classified into: European-style terminal block series, plug-in terminal block series, transformer terminal blocks, building wiring terminals, barrier-type terminal blocks, spring-type terminal blocks, DIN rail terminal blocks, wall-through terminal blocks, and optocoupler terminal blocks. The plastic insulation materials and conductive parts of terminal blocks directly affect their quality, determining the insulation performance and conductivity respectively.

ABL SURSUM plug applications

Mainly applied in lighting, communications, security, and other industries. Plug-in terminals have the widest range of applications, such as in variable frequency drives, explosion-proof equipment, CNC panels, access control controllers, sensors, PLC, instruments, power supplies, servo drives. The common requirements for plug-in terminals in these industries are: smooth insertion and extraction force, low contact resistance, and sufficient service life and fatigue resistance, which imposes high demands on the metal spring material. This requires product designers to have considerable experience in structure and material selection. Barrier-type terminals are mainly used in: power supplies, relays (especially double-layer terminals), inverters, elevator industry (less common), and air conditioners. Requirements for this series include high torque requirements for screws during wire clamping, the distance when the screw is retracted to its highest position must be greater than the maximum wire clamping range, long-position terminals must not warp or deform, and screws must have high corrosion resistance.

ABL SURSUM plug material

1) The material for female or male terminals shall be copper alloy, or plated copper alloy, nickel, or nickel alloy. [Exception: If the structure of the appliance or device permits, female or male terminals may be plated sheet metal or non-plated but corrosion-resistant alloy. 2) Formed female terminals or trimmed male terminals, if appearing in the form of terminal strips, will be curled and separated from the strip when continuously fed into processing tools; in this case, the edge where the terminal connects to the strip does not require plating. Standard terminals used in temperature and thermal cycling tests shall be tin-plated sheet or corrosion-resistant steel, with a hardness of Rockwell 30T hardness 68 ± 5 according to the Rockwell hardness standard. Exception: If the female terminal is only suitable for connecting to male terminals made of copper alloy, then standard terminals made of C26000 copper alloy shall be used for testing. 2.3) According to the Rockwell 30T hardness standard, the hardness of standard terminals made of brass is 62 ± 7.

ABL SURSUM plug troubleshooting

During electrical assembly, it is often found that individual core crimped wires are not fully inserted, or cannot be locked after insertion, resulting in unreliable contact. The analysis indicates that burrs or dirt in the threads of individual mounting holes cause jamming. Especially in the last few mounting holes of a plug/socket already assembled by the manufacturer, once this defect is discovered, all previously crimped wires in other holes must be removed one by one, and the plug/socket must be replaced. In addition, improper matching between wire diameter and crimping hole size, or errors in the crimping process, can lead to insecure crimping. Therefore, manufacturers must perform a pass-through test on all mounting holes of sample plugs/sockets before delivery, using loading/unloading tools to simulate inserting wires with pins or sockets to check if they can be locked. According to product technical specifications, pull-out force checks are performed on each crimped wire. Without reliable terminal blocks, there is no reliable system engineering. Failure and reliability are two aspects of a contradictory entity that correspond to and interact with each other. Through reliability screening of terminal blocks, various failure modes and mechanisms are identified, providing valuable lessons and eliminating hidden dangers, offering a scientific basis for improving design, processes, inspection, and usage. It is also an important basis for revising and establishing technical conditions for terminal blocks. The ultimate goal of failure analysis is to find measures to prevent failures and achieve the transformation from failure to reliability.

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