Reliability Analysis And Optimum Design Of Key Component Of The Locking Separation Mechanism Of Electrical Connector

Separation electrical connector is a kind of aerospace electrical connector. It is mainly used for the electrical connections and automatic disconnection of circuit between the rocket systems.The locking mechanism is the key mechanism, which achieves the function of locking and separation. Its failure can affect the safety and reliability of the system operation. Danghuan is important bearing impact load component of the locking mechanism, which plays a determinant role for reliability of the locking mechanism. This paper takes JF2-126 TD type separation electrical connector as the research object and uses the method combining the theoretical analysis and finite element simulation to study the force of Danghuan. Meanwhile, parametric modeling, optimization design and failure probability analysis were carried out for Danghuan to improve the safety and reliability of separation electrical connector. The main research contents are as following:Firstly, briefly stated the background and significance of the study, introduced the research status of electrical connectors’ reliability and structural reliability, and then proposed the objects and work of this research.Secondly, analyzed the structure and function of the connector; analyzed the working principle and character of locking mechanism detailed. The criticality matrix of locking mechanism was established by FMECA and the failure mode occurred during working.According to the unlocking experiment and the criticality matrix of locking mechanism, the main failure mode and the weakness of locking mechanism were obtained, that influenced the reliability of the locking mechanism.Thirdly, according to the electromagnetic unlocking processes of the locking mechanism,the collision force calculation model of Danghuan was established by mechanical analysis.Three-dimensional model of the separation mechanism was established by using Pro/E software,and the collision force curve was calculated in ADAMS. Carried out simulation analysis for the model, the stress and distribution of Danghuan was researched.Fourthly, used the optimization module of finite element analysis software ANSYS Workbench to parametric model and finite element analyze for Danghuan. The key parametersaffecting the equivalent stress were obtained through sensitivity analysis. Taking the stress at the maximum equivalent stress concentration point as target function with the geometric mass of Danghuan as the design variable. The Danghuan body structure design was carried out on how to improve the structure of Danghuan body to reduce the stress concentration and optimize the structural size. Using six sigma module and latin hypercube sampling method, the probability of maximum stress was obtained. The results show that the reliability of Danghuan structure is improved from 88.03% to 99.97% after the optimization.