Analysis of the influence of power cord tension and torsion testing machine on product service life

In the fields of electronics, automobiles, medical equipment, and new energy, power cords are critical connecting components whose reliability directly affects the overall performance and safety of products. In order to ensure that the power cord has sufficient mechanical strength and durability during long-term use, the power cord tension and torsion testing machine is widely used in the quality inspection process. This device evaluates the structural stability and connection reliability of wires by simulating mechanical environments such as tension, bending, and torsion that may be encountered in actual use.

1、 Basic principles of tensile and torsional testing

　　Power cord tension and torsion testing machineMainly through the stretching and rotating actions of applying a set direction and force to the wire, simulating the stress situations in daily use such as insertion, bending, and twisting. The testing process is usually based on international standards (such as GB/T 5013, UL 62, IEC 60227, etc.), with a certain number of cycles or a larger withstand value set to determine whether the power cord has problems such as breakage, peeling, conductor breakage, or poor contact.

2、 The impact mechanism on the service life of products

1. Expose design defects in advance

Through standardized testing, potential issues such as improper wire selection, weak terminal crimping, and unreasonable shielding layer structure can be identified, which helps companies optimize their design plans before mass production.

2. Verify the stability of materials and processes

Tensile and torsional tests can effectively verify the fatigue resistance of wires, evaluate the flexibility of insulation materials, the ductility of conductors, and the welding strength of joints, providing data support for production processes.

3. Improve product consistency and qualification rate

Regular sampling and testing on the production line can help control product quality fluctuations, reduce the overall failure rate caused by wire failure, and extend the service life of end products.

4. Meet the requirements of export certification and industry standards

Many countries and regions have clear testing requirements for the mechanical performance of power cords, and only products that pass strict testing can obtain market access qualifications, thereby ensuring the durability and competitiveness of products in the international market.

3、 Reasonably apply test results to guide improvement

Enterprises should establish a quality feedback mechanism based on test data. For example, if a batch of wire frequently breaks during tensile testing, it may be due to substandard conductor material or unstable crimping process; If the outer skin cracks during the torsion test, it is necessary to consider replacing it with a more flexible insulation material or optimizing the cable structure.

　　Power cord tension and torsion testing machineNot only is it an important tool for quality inspection, but it is also a key means to improve product reliability and extend service life. Through scientific testing and data analysis, enterprises can promptly identify and solve potential problems, thereby improving product quality and enhancing market trust. Under the trend of intelligent manufacturing in the future, new testing equipment that integrates automatic recording, remote monitoring, and big data analysis functions will further promote the development of power line quality control towards high efficiency and precision.