Temperature, humidity and pressure measurement on automotive connectors

Environmental testing under laboratory-controlled conditions has long been used to evaluate connector performance prior to practical application. There are a number of experimental procedures frequently used in the automotive industry such as the USCAR standard for automotive electrical connector systems to test connectors. However, recent research has shown that these tests appear to evaluate the mechanical stability of the connector housings and terminals, rather than their electrical performance. In order to establish more representative tests to evaluate the electrical performance of contacts, the actual environmental conditions at the contact interface, which are generally unknown, must be measured. This work compares the temperature, humidity and air pressure inside the connector housing to those measured outside. It was found that the conditions inside and outside the connector housing are different and a model relating the conditions is introduced.