| Electric connector is fundamental parts in the electronic and electrical system, take on the responsibility of electrical connections and signal transmission. Reliability and security of the electric connector directly determines the equipment’s reliability. Temperature and vibration are the two important factors have an effect on the reliability of electric connector contacts. The research object of this paper is circle power connector, mainly used in high reliability requirements of aviation fields. Using the method of theoretical analysis, finite element simulation and experimental to study the contact characteristics, thermal characteristics and vibration characteristics of the electric connector. Provide a certain reference for thermal and vibration-proof design of the electric connector. The main contents of this paper are as follows:Introduce the structure and performance of the electric connector and electrical contact theoretical knowledge. Analysis the failure mechanism of electric connector, it turned out that contact failure is the main failure mode of electric connector.And the main factor that causing electric connector contact failure is thermogenesis and vibration stress in the contact area.Through the theoretical calculation, the separation force and contact pressure value of electric connector were obtained. Do a contact analysis of the contact element, the relationship of insertion force and separation with time and the maximum of insertion force and separation force value were gained in the process of insertion and extraction of the contact element. And compare it with the theoretical separation force value, the results show that the difference is small, the theoretical calculation has a certain reference value. By using the Hertz contact theory formula and finite element simulation method to calculate the contact area of contact element, provides a reasonable contact parameters for three dimensional modeling and heat transfer characteristics analysis of electric connector.The contact resistance equivalent body of the electric connector has been for accurate modeling accord to the contact area. Electric connector thermal simulation of finite element model is established, different contact resistance in the same type of electric connector for the steady state thermal analysis has been analyzed. The temperature distribution contour of electric connector was obtained under different contact resistance. And the temperature rise test of electric connector has been done. The results indicate that test results has good consistency with simulation results, by establishing the precise model of contact resistance equivalent body, can improve the accuracy of numerical simulation results of electric connector temperature field. According to the simulation results, from two aspects of reducing contact resistance and enhancing the thermal transfer efficiency, the measures about reducing the temperature rise of the electric connector has been put forward.Each order natural frequency and vibration mode and the maximum stress, value and the contact gap value of electric connector have been gained through the modal analysis and random vibration analysis. Using the orthogonal experiment method, Random vibration analysis was carried out on the electric connector by changing the length, thickness and width of the crown spring of contact element, the result show that, the width of spring crown has the biggest influence on first-order natural frequency, the length of spring crown has the biggest influence on maximum stress, the thickness of spring crown has the biggest influence on contact element clearance. Using the extreme difference analysis method, the influence of crown spring test parameters to the primary and secondary order of test index and the optimal level combination has been obtained. By using the random vibration analysis method, the optimal design scheme were obtained by compared the before optimization and after optimization of electric connector. The fatigue life of electric connector was predicted accord to Miner linear cumulative damage theory and material fatigue life curve equation and the results of random vibration analysis. |
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