10 Pin 6R0972930A Car Wire Harness Socket Automobile Electrical Connectors 0.6 Series

01Vitreous failure

The insulation structure of the terminal blocks in the rotor compressor is generally a glass body structure, mainly used to ensure the electrical insulation performance and voltage resistance of the terminal blocks. When processing the glass body, it is easy to produce problems such as air holes and materials that are prone to cracking and falling off. Another problem is that the wiring terminals are subjected to high-temperature impact when welded to the shell, which causes crack damage to the glass. Air holes and cracks can cause the electrical insulation and pressure resistance performance of the wiring terminals to fail, leading to the failure of the rotor compressor.

02Poor electrical insulation caused by foreign objects

In high temperature and humidity environments, when the sealing type of the compressor junction box cover and insulation gasket is poor, the wiring base is prone to producing water droplets - this situation can cause water droplets to adsorb on the surface of the wiring terminal, resulting in unqualified insulation resistance, decreased insulation resistance, and abnormal electrical insulation performance. The compressor may experience malfunctions such as non cooling, poor insulation and voltage resistance.

The compressor operates abnormally, and liquid refrigerant enters the compressor and adsorbs on the internal wiring terminals, while its resistance is lower than that of gaseous refrigerant, reducing the insulation resistance and voltage resistance performance of the compressor.

Welding pipelines and air oxidation produce welding oxide skin, residual copper shavings and other metal substances that enter the compressor and come into contact with the wiring terminals, which can also lead to unqualified electrical insulation performance of the wiring terminals.

PS: When the medium is removed or naturally evaporated, the electrical insulation of the wiring terminals returns to normal, which is called pseudo electrical insulation defect.

03Speculation of terminal bursting and bursting out

Anatomical analysis was conducted on the compressor with terminal bursting and bursting, and it was speculated that the cause of its failure was:

Short circuit between turns: The paint film of the enameled wire is damaged, causing a large current to burn out the motor winding. The short circuit between turns generates an instantaneous large current that directly damages the glass body or causes the motor to quickly heat up due to the large current. The abnormal high temperature generated causes the insulation part of the motor to melt, and the lubricating oil carbonizes and adheres to the wire terminal, causing the terminal to ignite. Under the high pressure of the system refrigerant, the wire terminal bursts out.

Foreign objects in the manufacturing process: Foreign objects in the air conditioning system or compressor manufacturing process adhere to the wiring terminals and cannot be washed away, causing discharge of the compressor terminals for a long time, resulting in the melting of the glass body and causing terminal flying out under high temperature and pressure in the compressor cavity.

Compressor overheating: Low voltage, incorrect wiring, etc. can cause the compressor to overheat abnormally. The internal high temperature causes the insulation structure to melt and the lubricating oil to burn and carbonize, and the lubricating oil carbides to adhere to the wiring terminals, causing the compressor to short circuit to ground. In the harsh high-temperature and high-pressure environment inside the compressor, the terminals will burst and burst out.

Vacuum discharge: When the compressor is operating in vacuum, its internal breakdown current is high, and exposed live parts such as wiring terminals will be first broken down, leading to a short circuit, which will cause the wiring terminals to burn out. This confirms that vacuum breakdown will occur between the exposed internal wiring terminals of the compressor.

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