CN108535266B - Electrical connector fretting wear detection system and method based on infrared thermal imaging technology - Google Patents
Electrical connector fretting wear detection system and method based on infrared thermal imaging technology Download PDFInfo
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- 239000000428 dust Substances 0.000 claims abstract description 28
- 238000012360 testing method Methods 0.000 claims abstract description 27
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- 238000003466 welding Methods 0.000 claims description 4
- 230000001105 regulatory effect Effects 0.000 claims description 3
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- 229910001220 stainless steel Inorganic materials 0.000 description 2
- 239000010935 stainless steel Substances 0.000 description 2
- 229910001369 Brass Inorganic materials 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
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- 229910052790 beryllium Inorganic materials 0.000 description 1
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000010951 brass Substances 0.000 description 1
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- 238000004891 communication Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
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Abstract
The invention relates to an electric connector fretting wear detection system and method based on infrared thermal imaging technology, wherein the system comprises a plug device for enabling an electric connector to be detected to generate abrasive dust through a plug test and a detection device for acquiring an infrared thermal image in the plug test of the electric connector to be detected; the plugging device comprises a clamping unit; the clamping unit comprises a pin clamp for clamping pins of the electric connector removed shell and a jack clamp for clamping jacks of the electric connector, and the jack clamp and the pin clamp are arranged in a centering manner; the jack fixture is arranged at the front end of the mobile platform; the detection device comprises a direct-current voltage-stabilizing and current-stabilizing source, an infrared thermal imager and a computer, wherein the infrared thermal imager is used for shooting an infrared thermal image in a plug test of the electric connector to be detected, the infrared thermal imager is connected with the computer, and the infrared thermal imager is opposite to the electric connector to be detected. The detection system can perform nondestructive real-time detection of the contact, and can intuitively, rapidly and accurately position the abrasive dust distribution condition among the contact of the electric connector.
Description
Technical Field
The invention relates to the technical field of electric connector state detection, in particular to an electric connector fretting wear detection system and method based on an infrared thermal imaging technology.
Background
An electrical connector is one of the important electromechanical components used to make and break electrical and signal. Because the electric connector has the characteristics of high quality and high reliability, the electric connector is widely applied to the fields of aerospace, national defense, electronic communication and the like. In addition to meeting general performance requirements, an electric connector has to achieve good contact, reliable operation, and convenient maintenance, and its reliability directly affects the normal operation of electric and electronic devices. When the electric connector is stored, transported and operated, the electric connector is accompanied by repeated plugging or vibration, and the contact pin and the jack can relatively displace, so that a micro-motion phenomenon is generated, the mechanical abrasion of the contact part is caused, and abrasion fragments are generated and accumulated at the periphery of the abrasion area; the wear debris and the exposed base metal due to wear react with the oxidizing gas in the atmosphere to form oxides, which increases the contact resistance of the connector and eventually leads to contact failure, thereby affecting the contact performance of the electrical connector and even stopping the electrical device, possibly causing significant losses.
At present, most of the detection of fretting wear of the electric connector adopts a special contact sample, and the special contact sample is not a real electric connector, can not reflect the abrasive dust distribution condition of the real electric connector, and does not relate to the formation and evolution process of abrasive dust. For example, a contact sample is first prepared by a scholars (Ren Mobin, jiao Yu, guofu. Overview of electrical connector fretting studies [ J ]. Electromechanical elements, 2010,30 (1): 28-38.) such as Mo Bin, and then the surface topography of the sample is observed by means of a Scanning Electron Microscope (SEM), an X-ray dispersive spectroscopy (EDS), a Transmission Electron Microscope (TEM), electron scattering measurements, etc. for each test. If the detection method is used for observing the distribution condition of the abrasive dust, the abrasive dust can be detected after each abrasion experiment is finished, and the sample can be destroyed after each experiment due to the slicing mode, the same sample can not be continuously tested, namely, each sample can only be subjected to one abrasion detection and cannot be subjected to real-time detection.
Disclosure of Invention
Aiming at the defects of the prior art, the invention aims to provide the electric connector fretting wear detection system and the method based on the infrared thermal imaging technology, wherein the detection system can perform nondestructive real-time detection of contact pieces and can intuitively, quickly and accurately position the distribution condition of abrasive dust among the contact pieces of the electric connector. According to the method, the infrared thermal imaging instrument is used for shooting an infrared thermal image of the electric connector in the plugging test, and the infrared thermal image is processed and analyzed, so that the distribution condition of the abrasive dust can be intuitively and rapidly given.
The technical scheme adopted by the invention for solving the technical problems is that an electric connector fretting wear detection system based on an infrared thermal imaging technology is provided, and the system is characterized by comprising a plugging device for enabling an electric connector to be detected to generate abrasive dust through a plugging test and a detection device for acquiring an infrared thermal image in the plugging test of the electric connector to be detected.
The plug device comprises a mounting base, a moving platform, a control unit for controlling the running speed and direction of the plug device, a driving unit for driving the moving platform to move forwards and backwards and a clamping unit; the clamping unit comprises a contact pin clamp for clamping a contact pin of the electric connector removed shell and a jack clamp for clamping a jack of the electric connector, and the jack clamp and the contact pin clamp are arranged in a centering manner; the jack fixture is arranged at the front end of the mobile platform;
the pin clamp is an L-shaped bent plate and comprises a vertical plate and a bottom plate, wherein the vertical plate is provided with a spigot which is the same as the shape of an electric connector pin insulator to be detected, a plurality of threaded through holes are uniformly formed in the vertical plate around the periphery of the spigot, a left baffle ring and a right baffle ring are covered on the vertical plate provided with the threaded through holes, the left baffle ring and the right baffle ring enclose a circular ring, the inner diameter of the circular ring is consistent with the diameter of the jack insulator, the left baffle ring and the right baffle ring are respectively provided with an annular groove, and the space of the annular grooves can just accommodate the plurality of threaded through holes in the vertical plate; the left baffle ring or the right baffle ring is provided with a brake key for preventing the electric connector from rotating, the brake key is welded with the corresponding baffle ring, and the brake key is matched with a groove on an insulator of a pin of the electric connector to be detected; the electric connector to be detected is fixed on the vertical plate by the left baffle ring and the right baffle ring through bolts; the bottom plate is fixed with the mounting base through bolts;
the detection device comprises a direct-current voltage-stabilizing and current-stabilizing source, an infrared thermal imager and a computer, wherein the infrared thermal imager is used for shooting an infrared thermal image in a plug test of an electric connector to be detected, the infrared thermal imager is connected with the computer, the electric connector to be detected is electrically connected with the direct-current voltage-stabilizing and current-stabilizing source, and the infrared thermal imager is opposite to the electric connector to be detected.
The method for detecting the fretting wear of the electric connector based on the infrared thermal imaging technology uses the electric connector fretting wear detection system based on the infrared thermal imaging technology, and utilizes the phenomenon that the surface temperatures of the electric connector contact piece are different due to the difference of contact resistances of a worn part and a non-worn part when the direct current voltage-stabilizing and current-stabilizing source is used for heating to identify the distribution condition of abrasive dust, and comprises the following specific steps:
1) Preparing a detected piece: removing a metal shell of the electric connector, sawing off a black insulator outside one jack of the electric connector to expose a complete contact reed, coating a layer of black ink on the surface of the contact reed to be photographed, airing or pasting a black tape, or placing the thermal infrared imager and the electric connector in the same camera bellows; welding wires on the processed electric connector, and mounting the electric connector on a plugging device for plugging test after the electric connector is determined to reach a thermal balance state;
2) The electrical connector in the plug-in is horizontally placed in front of the thermal infrared imager, a circuit is connected, and the output current of a direct-current voltage-stabilizing and current-stabilizing source is regulated, so that the electrical connector is in a normal working state;
3) During detection, setting parameters of the thermal infrared imager according to the properties of the coating or pasting material on the contact reed of the electric connector to be detected, wherein the parameter settings comprise emissivity;
4) Shooting an infrared thermal image of the contact in the plugging test by using an infrared thermal imager;
5) By means of infrared thermal image processing software installed on a computer, piecewise linear gray stretching and temperature ranges are set, and therefore an infrared thermal image graph of abrasive dust distribution is obtained.
Compared with the prior art, the invention has the beneficial effects that:
1. the detection system of the invention enables the electric connector to be clamped by redesigning the pin clamp of the clamping unit of the plugging device so as to remove the pin of the metal shell, thereby providing convenience for the test.
2. The infrared imaging detection can intuitively, rapidly and accurately position the abrasive dust distribution state among the contact pieces of the electric connector, and has simple operation and high practical application value.
3. Compared with methods such as a Scanning Electron Microscope (SEM), an X-ray dispersion energy spectrum analyzer (EDS), a Transmission Electron Microscope (TEM), electron scattering measurement and the like, the detection method does not need destructive sampling sections, can directly carry out nondestructive detection on the contact piece, and saves sample consumption in experimental study; and continuous tests and tests can be realized, and the distribution condition of the abrasive dust and the evolution process of the distribution change can be obtained.
4. The detection time is short and the speed is high; the maintenance cost of the test equipment is low.
Drawings
FIG. 1 is a flow chart of the method of the present invention;
FIG. 2 is a schematic diagram of a perspective structure of a plugging device of an electrical connector fretting wear detection system based on infrared thermal imaging technology according to the present invention;
FIG. 3 (a) is a schematic view of an isometric structure of a pin holder of the present invention;
FIG. 3 (b) is a schematic diagram of the front view of the pin fixture;
FIG. 3 (c) is a schematic cross-sectional view of the A-A plane in FIG. 3 (b);
FIG. 4 is a schematic top view of the pin fixture of the present invention;
FIG. 5 is a schematic diagram of a left-hand construction of the pin clamp of the present invention;
FIG. 6 is a schematic diagram of the detection system of the present invention;
FIG. 7 is an IR thermography chart of example 1 with 200 plugs;
FIG. 8 is an IR thermography chart showing the method of inserting and extracting the sample in example 1 800 times;
in the figure, a 1-mounting base, a 2-driving unit, a 3-moving platform, a 4-contact pin clamp, a 5-jack clamp, a 41-spigot, a 42-annular groove, a 43-right baffle ring, a 44-left baffle ring, a 45-brake key, a 46-bolt, a 6-direct current voltage and current stabilizing source, a 7-electric connector, an 8-infrared thermal imager and a 9-computer.
Detailed Description
The present invention is further explained below with reference to examples and drawings, but is not to be construed as limiting the scope of the present application.
The invention discloses an electric connector fretting wear detection system (a system is referred to as a figure 2 for short) based on an infrared thermal imaging technology, which comprises a plugging device for enabling an electric connector to be detected to generate abrasive dust through a plugging test and a detection device for acquiring an infrared thermal image in the plugging test of the electric connector to be detected.
The plug device comprises a mounting base 1, a control unit (not shown in the figure), a driving unit 2, a moving platform 3 and a clamping unit (the connection of the specific parts is shown in patent ZL 201510257895.1), wherein the control unit consists of a stepping motor driver, a controller and a 24V direct current power supply, and the stepping motor driver provides instructions for the stepping motor to control the running speed, the running direction and the like of the plug device; the driving unit comprises a stepping motor and a screw nut, the stepping motor drives the screw nut to move, so that the jack of the electric connector is driven to complete the insertion and the extraction, and the driving unit drives the moving platform to move forwards and backwards; the clamping unit comprises a pin clamp 4 for clamping pins of the electric connector removed shell and a jack clamp 5 for clamping jacks of the electric connector, and the jack clamp 5 and the pin clamp 4 are arranged in a centering way; the jack fixture 5 is arranged at the front end of the mobile platform;
the pin clamp 4 is an L-shaped bending stainless steel plate, in practical application, the pin clamp 4 can also be made of other materials, and comprises a vertical plate and a bottom plate, wherein the vertical plate is provided with a spigot 41 which has the same shape as an insulator of a pin of an electric connector to be detected, a plurality of threaded through holes are uniformly formed in the vertical plate around the periphery of the spigot 41, the vertical plate provided with the threaded through holes is covered with a left baffle ring 44 and a right baffle ring 43, the left baffle ring 44 and the right baffle ring 43 are enclosed into a circular ring shape, the inner diameter of the circular ring is consistent with the diameter of the jack insulator, the left baffle ring 44 and the right baffle ring 43 are respectively provided with an annular groove 42, and the space of the annular groove 42 can just accommodate the plurality of threaded through holes in the vertical plate; a brake key 45 for preventing the electric connector from rotating is arranged on the left baffle ring 44 or the right baffle ring 43, the brake key 45 is welded with the corresponding baffle ring, and the brake key 45 is matched with a groove on the pin insulator of the electric connector to be detected; the electric connector to be detected is fixed on the vertical plate by a left baffle ring 44 and a right baffle ring 43 through bolts 46; the bottom plate is fixed with the mounting base 1 through bolts;
the detection device comprises a direct-current voltage-stabilizing and current-stabilizing source 6, an infrared thermal imager 8 and a computer 9, wherein the infrared thermal imager 8 and the computer 9 are used for shooting an infrared thermal image in a plug test of an electric connector to be detected, the infrared thermal imager 8 is connected with the computer 9, the electric connector 7 to be detected is electrically connected with the direct-current voltage-stabilizing and current-stabilizing source 6, and the infrared thermal imager 8 is opposite to the electric connector 7 to be detected; in practical applications, the current level of the dc voltage-stabilizing and current-stabilizing source 6 may be changed according to practical situations.
In the present invention, a digital display type plugging force meter for displaying plugging force data is mounted on the mobile platform 3.
In the invention, 8 threaded through holes are arranged around the spigot on the vertical plate and distributed at equal intervals, and the annular grooves on the left baffle ring or the right baffle ring cover the four threaded through holes.
In the invention, 4 threaded through holes are arranged on the bottom plate and distributed at equal intervals, and the bottom plate and the mounting base are fixed together.
In the invention, the size of the spigot on the vertical plate is slightly larger than that of the pin insulator.
In the invention, the circular inner diameter formed by the left baffle ring and the right baffle ring is the diameter of the jack insulator, and the thickness of the circular inner diameter is the distance between the contact pin insulator of the electric connector and the jack insulator.
In the invention, the groove widths of the annular grooves on the left baffle ring and the right baffle ring are slightly larger than the diameter of the threaded through hole.
In the invention, the metal shell is required to be removed, the black insulator outside one jack of the electric connector is sawed off by about one third to expose a complete contact reed, and then a layer of black ink is coated on the surface of the contact reed to be photographed and dried; and mounting the electric connector on a pluggable instrument for pluggable test.
The electrical connector contacts may be coated with black ink, adhered with black tape, or placed in the same camera bellows as the thermal infrared imager and electrical connector to reduce reflectivity and reflected energy. In practical application, the material of the contact of the tested electric connector can be other metals (such as tin bronze, beryllium bronze and the like), the core number and the pin diameter of the electric connector to be tested can be changed, and pin clamps with corresponding specifications can be selected for the electric connectors to be tested with different specifications.
When the detection system works, a direct-current voltage-stabilizing and current-stabilizing source is used for powering on and heating the electric connector, so that the temperature of the electric connector is increased. In the heating process, when current flows through the worn part of the contact, the contact resistance of the worn part is relatively large, so that the heating of the contact is more serious than that of the unworn part, namely the temperature of the worn part is higher than that of the unworn part.
The invention provides an electric connector fretting wear detection method based on an infrared thermal imaging technology, which utilizes the phenomenon that the surface temperatures are different due to the difference of contact resistances of a worn part and a non-worn part in an electric connector contact piece when a direct current voltage-stabilizing and current-stabilizing source is heated to identify the distribution condition of abrasive dust. The specific implementation steps are as follows:
the method comprises the following specific steps:
1) Preparing a detected piece: removing a metal shell of the electric connector, sawing off a black insulator outside one jack of the electric connector to expose a complete contact reed, coating a layer of black ink on the surface of the contact reed to be photographed, airing or pasting a black tape, or placing the thermal infrared imager and the electric connector in the same camera bellows; welding wires on the processed electric connector, and mounting the electric connector on a plugging device for plugging test after the electric connector is determined to reach a thermal balance state;
2) The electrical connector in the plug-in is horizontally placed in front of the thermal infrared imager, a circuit is connected, and the output current of a direct-current voltage-stabilizing and current-stabilizing source is regulated, so that the electrical connector is in a normal working state;
3) During detection, setting parameters of the thermal infrared imager according to the properties of the coating or pasting material on the contact reed of the electric connector to be detected, wherein the parameter settings comprise emissivity;
4) Shooting an infrared thermal image of the contact in the plugging test by using an infrared thermal imager;
5) By means of infrared thermal image processing software installed on a computer, piecewise linear gray stretching and temperature ranges are set, and therefore an infrared thermal image graph of abrasive dust distribution is obtained.
Example 1
In this embodiment, the thermal infrared imager is a Shanghai Mega MAG13, and the thermal infrared image processing software installed on the computer is thermo X.
The embodiment provides an electric connector fretting wear detection system and method based on an infrared thermal imaging technology, and the specific implementation steps are as follows:
1) Preparing a detected piece: the method comprises the steps that a metal shell is required to be removed from the electric connector, about one third of a black insulator outside one jack of the electric connector is sawed off, a complete contact reed is exposed, and then a layer of black ink is coated on the surface of the contact reed to be photographed and dried; and welding wires on the processed electric connector, and after the electric connector is determined to reach a thermal balance state, installing the electric connector on a plugging device for plugging test, wherein 200 times and 800 times are taken as examples in the embodiment.
2) The circuit is connected, the electrical connector in the plug is horizontally placed in front of the thermal infrared imager, and the electrical connector is heated by adjusting the output current of the direct current voltage and current stabilizing source by 10A, so that the electrical connector is in a normal working state;
3) In detection, the emissivity is set to be 1.0 of an ideal blackbody because the contact reed is coated with black ink in the experiment;
4) Shooting an infrared thermal image of the contact in the plugging test by using an infrared thermal imager;
5) Setting the piecewise linear gray scale stretching to 0-255 and the temperature range to 29-30 ℃ by means of infrared thermal image processing software installed on a computer, so as to obtain an infrared thermal image graph of abrasive dust distribution;
6) And comparing and analyzing the shot infrared thermal image of the abrasive dust distribution of different plugging times to obtain the change condition of the abrasive dust distribution after the contact piece moves relatively.
The material of the electrical connector contacts in this embodiment is brass. The core number and the pin diameter of the tested electric connector are respectively 2 cores and 3.5mm, the current of the direct-current voltage-stabilizing and current-stabilizing source is 10A, and the pin clamp is a stainless steel plate.
As shown in fig. 7 and 8, the infrared thermal images are respectively obtained by 200 times and 800 times of plugging, and as can be seen from the figures, the area of the bright part in fig. 8 is obviously larger than that in fig. 7. This is because, as the number of times of insertion and extraction increases, the number of wear debris between the contacts increases, and the contact resistance increases. In fig. 7, the abrasive dust is mainly concentrated on the front half part of the inner surface of the contact reed of the jack and the middle part of the contact pin, and with the continuous pushing and grinding in the inserting and pulling process, a part of abrasive dust is concentrated on the edge of the abrasion area in fig. 8, and the abrasive dust is in a large particle shape, so that the abrasive dust on the inner surface of the contact reed and the contact pin part is gradually increased. Depending on the degree of wear, the distribution of swarf between the contact elements is represented by different colours. The distribution condition of the abrasive dust among the contact pieces can be detected well by using the thermal infrared imager, and the abrasive dust distribution change after the contact pieces relatively move.
The invention is applicable to the prior art where it is not described.
Claims (5)
1. The electric connector fretting wear detection system based on the infrared thermal imaging technology is characterized by comprising a plugging device and a detection device, wherein the plugging device is used for enabling an electric connector to be detected to generate abrasive dust through a plugging test, and the detection device is used for acquiring an infrared thermal image in the plugging test of the electric connector to be detected;
the plug device comprises a mounting base, a moving platform, a control unit for controlling the running speed and direction of the plug device, a driving unit for driving the moving platform to move forwards and backwards and a clamping unit; the clamping unit comprises a contact pin clamp for clamping the contact pin of the electric connector after the shell is removed and a jack clamp for clamping the jack of the electric connector, and the jack clamp and the contact pin clamp are arranged in a centering manner; the jack fixture is arranged at the front end of the mobile platform;
the pin clamp is an L-shaped bent plate and comprises a vertical plate and a bottom plate, wherein the vertical plate is provided with a spigot which is the same as the shape of an electric connector pin insulator to be detected, a plurality of threaded through holes are uniformly formed in the vertical plate around the periphery of the spigot, a left baffle ring and a right baffle ring are covered on the vertical plate provided with the threaded through holes, the left baffle ring and the right baffle ring enclose a circular ring, the inner diameter of the circular ring is consistent with the diameter of the jack insulator, the left baffle ring and the right baffle ring are respectively provided with an annular groove, and the space of the annular grooves can just accommodate the plurality of threaded through holes in the vertical plate; the left baffle ring or the right baffle ring is provided with a brake key for preventing the electric connector from rotating, the brake key is welded with the corresponding baffle ring, and the brake key is matched with a groove on an insulator of a pin of the electric connector to be detected; the electric connector to be detected is fixed on the vertical plate by the left baffle ring and the right baffle ring through bolts; the bottom plate is fixed with the mounting base through bolts;
the detection device comprises a direct-current voltage-stabilizing and current-stabilizing source, an infrared thermal imager and a computer, wherein the infrared thermal imager is used for shooting an infrared thermal image in a plug test of an electric connector to be detected, the infrared thermal imager is connected with the computer, the electric connector to be detected is electrically connected with the direct-current voltage-stabilizing and current-stabilizing source, and the infrared thermal imager is opposite to the electric connector to be detected.
2. The infrared thermal imaging technology-based electrical connector fretting wear detection system according to claim 1, wherein a digital display type plug force meter for displaying plug force data is installed on the mobile platform.
3. The infrared thermal imaging technology-based electrical connector fretting wear detection system according to claim 1, wherein 8 threaded through holes are formed around the spigot on the vertical plate and distributed at equal intervals, and annular grooves on the left baffle ring or the right baffle ring cover four threaded through holes.
4. The infrared thermal imaging technology-based electrical connector fretting wear detection system of claim 1, wherein the left and right stop rings form a circular ring having a thickness that is the distance between the electrical connector pin insulator and the receptacle insulator.
5. The method for detecting the fretting wear of the electric connector based on the infrared thermal imaging technology, which uses the electric connector fretting wear detection system based on the infrared thermal imaging technology according to any one of claims 1 to 4, and utilizes the phenomenon that the surface temperatures of the electric connector contact piece are different due to the difference of contact resistances of a worn part and a non-worn part when the direct current voltage-stabilizing and current-stabilizing source is used for heating to identify the distribution condition of abrasive dust, comprises the following specific steps:
1) Preparing a detected piece: removing a metal shell of the electric connector, sawing off a part of a black insulator outside one jack of the electric connector to expose a complete contact reed, coating a layer of black ink on the surface of the contact reed to be photographed, airing or pasting a black tape, or placing the thermal infrared imager and the electric connector in the same camera bellows; welding wires on the processed electric connector, and mounting the electric connector on a plugging device for plugging test after the electric connector is determined to reach a thermal balance state;
2) The electrical connector in the plug-in is horizontally placed in front of the thermal infrared imager, a circuit is connected, and the output current of a direct-current voltage-stabilizing and current-stabilizing source is regulated, so that the electrical connector is in a normal working state;
3) During detection, setting parameters of the thermal infrared imager according to the properties of the coating or pasting material on the contact reed of the electric connector to be detected, wherein the parameter settings comprise emissivity;
4) Shooting an infrared thermal image of the contact in the plugging test by using an infrared thermal imager;
5) By means of infrared thermal image processing software installed on a computer, piecewise linear gray stretching and temperature ranges are set, and therefore an infrared thermal image graph of abrasive dust distribution is obtained.
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