Study On Insertion-withdrawal And Electrical Contact Behaviors Of Connectors

Insertion-withdrawal and electrical contact characteristics directly affect the life and reliability of electrical connectors.In order to improve the quality and reliability of connectors,it is necessary to determine the main influencing factors and degradation mechanisms.In this paper,a test rig for simulating the insertion and withdrawal of connectors and measuring the comprehensive characteristic parameters is designed.Firstly,a test and analysis system for the comprehensive characteristic parameters of the connector was designed.The connector clamping module and three-dimensional adjusting module were selected as 3D adjustment unit.The electric sliding table and its accessories were used as the driving unit.And the measurement and control circuit and DAQ card were used as the conditioning and acquisition modules of the insertion/extraction force,voltage,voltage drop and current signals.The control program based on Lab VIEW was designed,which can control the experiment process and has the functions of automatic calculation,display and storage of the characteristic parameters such as force and contact resistance.Secondly,the insertion-withdrawal and electrical contact behavior of the connector were investigated experimentally,and a mathematical model of insertion and extraction force was built.The variations of the force and contact resistance of the connector during the insertion and withdrawal process were analyzed,and the key parameters which reflect the characteristics of electrical connector insertion and electrical contact were determined.The influence of the surface film on the insertion-withdrawal and electrical contact characteristics was studied through comparative experiments.And the influence of mechanical insertion and withdrawal and current on the characteristics of electrical connector was studied by experiments.Finally,the insertion-withdrawal and electrical contact behavior of connector was simulated by the commercial program COMSOL Multiphysics,and a fitting mathematical model of contact resistance was presented.The geometry model of contact pair was established,and the finite element simulation method was proposed.The variations of contact area and contraction conductance as a function of the pin displacement in the insertion and extraction process were analyzed.The mathematical model of contact resistance was presented by data fitting.The influence of pin diameter,number of socket openings and the radius of socket openings on the characteristics was studied.This study not only proposes experimental method and theoretical model for the comprehensive performance evaluation and analysis of electrical connectors,but also provides theoretical basis for the optimal design of products.