CN111883959A - Electric connector wire harness connection method and electric connector structure - Google Patents

Electric connector wire harness connection method and electric connector structure Download PDF

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Publication number
CN111883959A
CN111883959A CN202010665488.5A CN202010665488A CN111883959A CN 111883959 A CN111883959 A CN 111883959A CN 202010665488 A CN202010665488 A CN 202010665488A CN 111883959 A CN111883959 A CN 111883959A
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socket
conductive element
plug
constant force
wire harness
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CN111883959B (en
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丁桦
刘红武
陈金桂
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Institute of Industry Technology Guangzhou of CAS
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Institute of Industry Technology Guangzhou of CAS
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R24/00—Two-part coupling devices, or either of their cooperating parts, characterised by their overall structure
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/502—Bases; Cases composed of different pieces
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/60—Other road transportation technologies with climate change mitigation effect
    • Y02T10/70—Energy storage systems for electromobility, e.g. batteries

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Abstract

The invention discloses an electric connector structure and a wire harness connection method, which comprise a plug part, a socket part and a constant force device, wherein a plug end wire harness, a plug end wire harness joint and a plug conductive element which are fixedly connected in sequence are arranged in the plug part, a socket conductive element, a socket end wire harness joint and a socket end wire harness which are fixedly connected in sequence are arranged in the socket part, when the plug part is connected with the socket part, the plug conductive element is positioned in the socket conductive element, and the constant force device is used for restraining and fixing the socket conductive element outside the plug conductive element. The connector can be made of materials with good conductivity and low cost; the contact force between the plug conductive element and the socket conductive element is restrained by the main force provided by the constant force device, the contact force is not limited by the elastic deformation of the conductive element, the contact force is large and can be kept for a long time, the contact area between the conductive elements is large, and the occurrence of instantaneous interruption can be effectively avoided even under vibration and impact environments after connection.

Description

Electric connector wire harness connection method and electric connector structure
Technical Field
The invention belongs to the field of wiring harness connection and electric connector timeliness, and particularly relates to a connection technology of high current and high voltage linear speed in a new energy automobile.
Background
With the development trend that intellectualization, electromotion and networking become automobiles, the new energy automobile industry is rapidly developed. As a basic element of current and signal transmission, an electrical connector is widely used in new energy vehicles. Whether the structure of the connector is reasonable or not has an important influence on the reliability and safety of the connection of the electric and electronic equipment of the automobile.
The connector structure is primarily designed to achieve a proper clearance of current flow by maintaining a sufficient amount of contact area and a sufficient amount of contact force between the plug terminals and the terminals within the receptacle. When the contact force between the terminals is small, the difference between the upper limit and the lower limit of the contact resistance is as high as 10 times, and when the contact force reaches a certain value, the micro point of the contact point of the terminal is transited from elastic deformation to plastic deformation, so that the contact resistance is basically kept unchanged. The existing large-current connector structure mainly keeps normal smoothness of current by keeping elastic contact between terminals in a plug and a socket, and changes contact force by deformation of the terminal structure. Generally, the socket terminal has better elasticity, and the plug terminal is a rigid element. When the plug is inserted into the socket, the interference fit between the plug terminals and the socket terminals causes the socket terminals to elastically deform, so that the connector is connected. Thus, the spring properties of the receptacle terminals and the magnitude of the contact force between the terminals determine the reliability of the connector.
For the connection of a large-current and high-voltage wire harness, the structure of the connector requires materials with good conductivity and elasticity. However, among the current connector terminal materials, the material with good elasticity such as beryllium copper has relatively poor conductivity, and the material with good conductivity such as: copper, brass, etc. have poor elasticity and the improvement of the reliability of the connector is limited by material properties. Meanwhile, the price of the terminal material with good elasticity can be several times higher, so that the material cost of the elastic terminal connector is higher.
As the connector is used for a longer time, particularly in a long-term vibration and impact environment during the operation of an electric vehicle, the contact force between the elastic terminals in the existing connector is gradually reduced, and the elastic terminals are subjected to plastic deformation or contact resistance increase due to fatigue and stress relaxation, so that the temperature is increased, and the connector fails. In addition, vibration and shock loads cause terminal deformation, and because of the small contact area, such connectors may also snap. These connector failures pose a safety risk to the operation of the new energy vehicle.
Disclosure of Invention
The invention aims to provide an electric connector structure which can reduce the requirement on the mechanical property of a connector material under the condition of ensuring the current carrying capacity, can keep the contact force unchanged in the service life cycle of the connector, enhances the reliability of wire harness connection and has good application prospect.
Another object of the present invention is to provide a method for connecting a harness of an electrical connector, which can ensure that the connection of the harness is more reliable, the connection performance remains unchanged, and the safety of the connector can be improved.
The technical solution of the invention is as follows: an electric connector structure comprises a plug part, a socket part and a constant force device, wherein a plug end wire harness joint and a plug conductive element which are fixedly connected are arranged in the plug part, a socket conductive element and a socket end wire harness joint which are fixedly connected are arranged in the socket part, when the plug part is connected with the socket part, the plug conductive element is positioned in the socket conductive element, and the constant force device is used for restraining and fixing the socket conductive element outside the plug conductive element.
The plug end wire harness joint is stably connected with the plug conductive element, the socket conductive element is stably connected with the socket end wire harness joint, when the plug portion is connected with the socket portion, the plug conductive element is located in the socket conductive element, the socket conductive element is tensioned through the constant force device and fixed outside the plug conductive element, contact force between the plug conductive element and the socket conductive element is restrained through active force provided by the constant force device and is not limited by elastic deformation of the conductive element, the contact force can be kept large, in the working process, due to the fact that the acting force provided by the constant force device is kept unchanged, the contact force between the conductive elements can be stably kept and is not influenced by external force in the working state, instantaneous disconnection can be effectively avoided under vibration and impact environments, and full connection can be kept. The constant force or constant torque provided by the constant force device generates a set amount of contact force between the plug conductive elements and the receptacle conductive elements. And the elastic deformation generated by the constant force acting mechanism in the constant force device is far larger than the deformation generated by the vibration and impact load in the working process of the connector to the conductive element.
The plug conductive element is cylindrical, and the socket conductive element is a spiral sheet-shaped body. The spiral sheet-shaped body has simple structure, low requirement on materials, large contact area and high connection stability.
The plug conductive element is a cylinder, and the socket conductive element is a plurality of spiral sheet-shaped bodies which are arranged in parallel. The plurality of spiral-shaped platelets may increase the contact area with the plug conductive elements while reducing material constraints on the receptacle conductive elements.
A plug end wire harness joint in the plug part is fixedly connected with a plug end wire harness; and the socket section wire harness joint in the socket part is fixedly connected with the socket end wire harness. The wire harness and the joint are respectively fixedly connected, the overall structure is high in strength, the impact resistance is high, and the use and the work are stable.
The constant force device comprises an extension spring with one end connected to the socket conductive element, and the other end of the extension spring is fixed in the socket part. The extension spring has a simple structure, and the tension value is set to be controllable.
The constant force device further comprises a sliding groove and a sliding block capable of moving along the sliding groove, and the other end of the extension spring is fixed on the sliding block. The slider moves to enable the extension spring to be located at different positions, so that tension values of different sizes are provided, adjustment of the tension values is achieved, and the contact force of the conductive element in the connector is conveniently set according to different working conditions.
And a sleeve is arranged outside the extension spring. The extension spring is prevented from being bent due to the fact that radial external force is received, and the tension is prevented from being constant.
The constant force device comprises an elastic pull rope sleeved outside the socket conductive element. The pull rope can be directly sleeved outside the conductive element and is not required to be directly connected with the conductive element, so that the limitation on the material used by the conductive element is further reduced.
Plug conductive element is including the wedge that is the round platform body, set up the slider in the wedge bottom, socket conductive element include vertical section fall trapezoidal and with wedge matched with gomphosis portion, set up in gomphosis portion bottom electrically conductive plectane, set up electrically conductive plectane with electrically conductive spring between the socket end pencil connects is equipped with the swivelling chute of taking the breach at gomphosis portion top edge, and the breach cooperatees with the slider shape, but the slider holding is in the swivelling chute, the constant force device including set up electrically conductive plectane with a plurality of coil spring between the socket pencil connects. The wedge-shaped block and the embedded part can realize surface contact, the contact area is increased, and under the elastic action of the conductive spring and the spiral spring, enough contact force is generated between the conductive elements, so that the connection is stable and reliable.
The plug conductive element is the cylindricality body that the surface was equipped with a plurality of axial splines, socket conductive element surface with the tip surface of plug conductive element cooperatees, the constant force device includes hollow spline sleeve, sets up be a plurality of spring arbor, a plurality of one end that the circumference array distributes in the socket portion and fix the clockwork spring on the spring arbor, and the other end of clockwork spring is fixed on spline sleeve surface, and the rotatable setting of spline sleeve is in on the socket conductive element. The plug conductive element is inserted into the spline sleeve, the axial spline on the surface of the plug conductive element can be respectively matched with the spline sleeve and the socket conductive element, so that the plug conductive element is connected with the socket conductive element, the spiral spring can form rotating torque on the outer surface of the spline sleeve and provide constant force to be maintained on the socket conductive element and the plug conductive element, the constant torque provided by the constant force device enables contact force with a set value to be generated between the plug conductive element and the socket conductive element, and elastic deformation generated by a constant force action mechanism in the constant force device is far greater than deformation generated by vibration and impact load in the working process of the connector.
And the plug part and the socket part are respectively provided with a locking device matched with each other. The plug part and the socket part are physically connected through the locking device, and the stability of the electric connector is further improved.
The other technical solution of the invention is as follows: an electrical connector harness connection method comprising the steps of: calculating a minimum design value of contact force between a socket conductive element and a plug conductive element according to a relation model between contact resistance and contact force of the conductive element; secondly, calculating and obtaining a minimum constant force value required to be provided by the constant force device according to the minimum design value of the contact force; designing a constant force device capable of providing a pulling force greater than or equal to the minimum constant force value according to the required minimum constant force value; assembling a plug part, and fixedly connecting the plug end wire harness, the plug end wire harness joint and the plug conductive element in sequence; assembling a socket part, and fixedly connecting the socket conductive element, the socket end wire harness joint and the socket end wire harness in sequence; and fifthly, arranging a constant force device, wherein when the plug part is connected with the socket part, the plug conductive element is positioned in the socket conductive element, so that the socket conductive element is restrained and fixed outside the plug conductive element by the constant force device. The constant force or constant torque provided by the constant force device generates a contact force of a set magnitude between the conductive elements of the plug and the receptacle. And the elastic deformation generated by the constant force acting mechanism in the constant force device is far larger than the deformation generated by the vibration and impact load in the working process of the connector to the conductive element.
In the third step, the step of designing an adjusting device capable of adjusting the acting force of the constant force device is also included.
The invention has the advantages that: the elastic property of the conductive element is no longer a key factor influencing the performance of the connector, and the connector can be made of a material with good conductive performance and low cost; the contact force between the plug conductive element and the socket conductive element is restrained by the main force provided by the constant force device, the contact force is not limited by the elastic deformation of the conductive element, the contact force is large and can be kept for a long time, the contact area between the conductive elements is large, the failure of the connector caused by the relaxation and abrasion of the structural stress can be effectively avoided, and the instantaneous interruption can be effectively avoided even under the vibration and impact environment after the connection.
Drawings
FIG. 1 is a schematic structural view of embodiment 1 of the present invention;
FIG. 2 is a schematic structural view of a socket part according to embodiment 1 of the present invention;
FIG. 3 is a schematic view of the structure of the insertion head section in embodiment 1 of the present invention;
FIG. 4 is a schematic structural diagram of a constant force device in embodiment 1 of the present invention;
FIG. 5 is a simplified diagram showing analysis of stress between conductive members in example 1 of the present invention:
fig. 6 is a schematic structural view of a constant force device in embodiment 2 of the present invention;
FIG. 7 is a schematic view of a constant force device according to embodiment 2 of the present invention;
FIG. 8 is a schematic structural view of embodiment 3 of the present invention;
FIG. 9 is a schematic structural view of embodiment 4 of the present invention;
FIG. 10 is a schematic sectional view taken along line A-A in FIG. 9;
FIG. 11 is a schematic structural view of a socket part according to embodiment 5 of the present invention;
FIG. 12 is a schematic view showing an internal structure of a socket part in embodiment 5 of the present invention;
FIG. 13 is a schematic view of the structure of an insertion head section in embodiment 5 of the present invention;
FIG. 14 is a schematic view showing an internal structure of an interposer in embodiment 5 of the present invention;
FIG. 15 is a schematic view of a constant force apparatus according to embodiment 5 of the present invention;
FIG. 16 is a schematic structural view of a socket part in embodiment 6 of the present invention;
FIG. 17 is a schematic view showing a structure of an insertion head section in embodiment 6 of the present invention;
fig. 18 is a schematic structural view of a constant force device in embodiment 6 of the present invention;
FIG. 19 is a schematic sectional view showing a constant force apparatus according to embodiment 6 of the present invention;
1. plug portion, 2, socket portion, 3, plug end harness, 4, plug end harness connector, 5, plug conductive element, 6, socket conductive element, 7, socket end harness connector, 8, socket end harness, 9, constant force device, 10, plug latch, 11, socket latch, 12, tension spring, 13, chute, 14, slider, 15, positioning block, 16, sleeve, 17, shaft, 18, connecting block, 19, support base, 20, rotating frame, 21, sidewall mounting screw, 22, adjusting nut, 23, fixed pin, 24, pull rod, 25, rotating connection, 26, pull rod bolt, 27, spring, 28, mounting screw, 29, load screw, 30, fixed frame, 31, main shaft, 32, load bolt, 33, slack nut, 34, second socket conductive element, 35, third socket conductive element, 36, pull rope, 37, plug conductive element, 6, socket conductive element, 7, socket end harness connector, 8, socket end harness connector, 9, constant force device, 10, plug latch, 23, socket lock, side mounting screw, 22, adjusting, The device comprises a rotary groove, 38, a wedge block, 39, a sliding block, 40, an embedding part, 41, a conductive circular plate, 42, a conductive spring, 43, a notch, 44, a spiral spring, 45, a spiral spring, 46, a spring shaft, 47, a clockwork spring, 48, a first positioning mark, 49, a second positioning mark, 50, a third positioning mark, 51 and a spline sleeve.
Detailed Description
Example 1:
referring to fig. 1-4, an electrical connector structure includes a plug portion 1, a socket portion 2 and a constant force device 9, wherein the plug portion 1 is internally provided with a plug terminal harness 3, a plug terminal harness connector 4 and a plug conductive element 5 which are fixedly connected in sequence, the socket portion 2 is internally provided with a socket conductive element 6, a socket terminal harness connector 7 and a socket terminal harness 8 which are fixedly connected in sequence, when the plug portion 1 is connected with the socket portion 2, the plug conductive element 5 is located in the socket conductive element 6, and the constant force device 9 is used for tensioning and fixing the socket conductive element 6 outside the plug conductive element 5. The plug portion 1 is provided with a plug lock catch 10, and the socket portion 2 is provided with a socket lock holder 11.
The constant force device 9 comprises a sliding groove 13, a sliding block 14 capable of moving along the sliding groove 13, a positioning block 15 arranged on the side edge of the sliding groove 14, a rotating shaft 17 and an extension spring 12, wherein one end of the extension spring 12 is connected to the socket conductive element 6 through a connecting block 18, and the other end of the extension spring is fixed on the sliding block 14. The extension spring 12 can be located at different positions through movement of the slider 14 and can be located through the locating block 15, so that tension values with different sizes are provided, adjustment of the tension values is achieved, and the contact force of a conductive element in the connector can be conveniently set according to different working conditions. When the extension spring 12 is of minimum length, the socket conductive member 6 is in the initial position, maintaining a clearance fit with the plug conductive member 5. The tension spring 12 is externally provided with a sleeve 16 to prevent the tension spring 12 from bending when subjected to a load in the radial direction. The connecting block 20 may be made of a material different from that of the socket conductive member 6 and may rotate around the rotation shaft 17 to keep the socket conductive member 6 moving horizontally. To further prevent the socket conductive member 6 from swinging left and right, a support base 19 is provided on the constant force device 9.
An electrical connector harness connection method comprising the steps of:
1. calculating target design parameters of the contact force between the conductive elements of the connector according to information such as a relation model of the contact resistance and the contact force; the following equation is a common empirical formula for calculating contact force:
F＝(K/RJ)1/m/0.102 (1)
in the formula, F is contact force; k is a coefficient related to the contact material and the surface condition, and is given by experiments, such as copper-copper contact, and the K value ranges from 80 to 140; rJIs the contact resistance; m is a coefficient related to the contact form, for example, m is 0.5 for point contact and 1 for surface contact. The minimum contact force value to be provided by the connector can be obtained by the formula (1).
2. Calculating the minimum constant force value required to be provided by the constant force device based on the target design parameter requirement of the contact force of the conductive element of the connector;
the force analysis of the conductive element is shown in fig. 5 under the condition of neglecting the friction force and the bending moment of the conductive element of the socket: wherein F is the contact force between the conductive elements; t is the pulling force required to be provided by the constant force device, and T is F/cos α.
3. Determining a constant force target value based on the minimum constant force value calculated in the step 2, and designing and manufacturing a constant force device; in this embodiment, the structure of the constant force device is as shown in fig. 4, and during operation, the extension amount of the extension spring 12 is much larger (more than 10 times) than that of the socket conductive element 6, and also much larger than the displacement of the socket conductive element 6 caused by vibration and impact. The extension of the extension spring 12 is substantially constant during operation, i.e. the tension applied by the constant force device to the socket conductive element is substantially constant.
In this structure, the following relationship exists:
Figure BDA0002580237440000071
Figure BDA0002580237440000072
T1＝T2·cosβ (4)
in the formula, T1The applied force (constant force target value, greater than or equal to the minimum constant force value T) borne by the socket conductive element 6, E is the elastic modulus of the material of the socket conductive element 6, A is the area of the cross section of the socket conductive element 6, dL is the elongation of the socket conductive element 6, L is the initial length of the socket conductive element 6, and T is the initial length of the socket conductive element 62The tensile force of the extension spring 12, G is the shear modulus of the extension spring 12, D is the wire diameter of the extension spring 12, X is the elongation of the extension spring 12, D is the pitch diameter of the extension spring 12, n is the effective number of turns of the extension spring 12, and β is the angle between the extension spring and the extension line of the socket conductive element.
The following equations (2) to (4) can be calculated:
Figure BDA0002580237440000073
if T is set1At 200 newtons, the conductive element and the extension spring were brass (elastic modulus about 106GPa, shear modulus about 40GPa), a 4 square millimeters, D15 millimeters, n 8 turns, D2 millimeters, L1 meter, and β 45 degrees. The extension X of the extension spring 12 can be calculated to be more than 200 times the extension dL of the conductive element. The disturbance caused by vibration and impact during operation is also a very small value relative to the elongation X of the tension spring 12, and the spring tension can be kept substantially constant, i.e. the tension experienced by the socket conductive element 6 is kept substantially constant.
4. Assembling the plug part 1, and fixedly connecting the plug terminal wiring harness 3, the plug terminal wiring harness joint 4 and the plug conductive member 5 in sequence; assembling the socket part 2, and fixedly connecting the socket conductive element 6, the socket end harness joint 7 and the socket end harness 8 in sequence;
5. a constant force device 9 is provided such that when the plug portion 1 is connected to the socket portion 2, the plug conductive member 5 is located within the socket conductive member 6 such that the constant force device 9 tightens the socket conductive member 6 against the plug conductive member 5.
The tension spring 12 in this embodiment may be replaced with a constant force clockwork spring.
Example 2:
referring to fig. 6-7, another electrical connector structure is shown, which is different from the embodiment 1 in the structure of the constant force device 9. The rotating frame 20 can rotate around the main shaft 31 in the fixed frame 30. The constant force device 9 housing is connected to the socket part 2 by means of side wall mounting screws 21 and mounting screws 28. One end of the rotating frame 20 is connected to the socket conductive member 6, and the socket conductive member 6 can rotate around the axis on the rotating frame 20. A spring 27 is fixed to the constant force device 9, which spring force is applied to the load screw 29 by the stay bolt 26, the rotary connection 25 and the stay 24. The constant force device 9 sets the initial position of the spring 27 and defines the position with the fixed pin 23, as required by the contact force between the socket conductive element 6 and the plug conductive element 5. When the plug is inserted into the socket to a set position, the fixing pin 23 is pulled out, and the acting force of the constant force device 9 is applied to the socket conductive element 6. The tension can be adjusted by adjusting the position of the turnbuckle 33 on the load bolt 32.
The connector is subjected to vibration and shock during operation, but the magnitude of the pulling force exerted by the constant force device on the socket conductive element 6 can be kept substantially constant, and the operation principle is shown in fig. 7. In fig. 7, point O is the center of the main shaft 31, point a is the axis of the conductive member rotating around the rotating frame 20, point B is the intersection of the pull rod 24 and the load screw 29, and point C is the center of the end of the spring 27 at its original length. F1 is the pulling force of the conductive element to the constant force device 9, F2 is the pulling force of the spring 29 to the load screw 29, and the moments of the rotation of F1 and F2 around the point O are equal in magnitude and opposite in direction. Namely, the method comprises the following steps:
F1·OA·Sinα1＝F2·OB (6)
in the above formula, OA is the length from point O to point A, and OB is the length from point O to point B. It can be demonstrated that when the structure in the figure satisfies the condition that the α 1 angle and the β 1 angle are equal (generally set to 60 degrees), the following relationship exists:
F1＝(K·OB·OC)/OA (7)
in the above formula, K is a spring steelDegree OC is the length from point O to point C, both are constant, and F is known1And the constant force device is kept unchanged after the design of the constant force device is completed.
Example 3
Referring to fig. 8, another electrical connector structure is different from embodiment 1 in that a socket conductive element 6 is disposed in a socket portion 2, the socket conductive element 6, a second socket conductive element 36, and a third socket conductive element 37 are disposed in parallel and respectively formed as spiral sheets, and the socket conductive element 6, the second socket conductive element 36, and the third socket conductive element 37 are respectively connected to a constant force device 9, and can be tightly attached to an outer side of a plug conductive element 5 under a pulling force of the constant force device 9.
Example 4
Referring to fig. 9-10, an electrical connector structure of the present invention is different from embodiment 1 in that: the constant force device 9 comprises an elastic pull rope 36 sleeved outside the socket conductive element 6. The pull rope 36 can be directly sleeved outside the socket conductive element 6, the socket conductive element 6 is a cylindrical body sleeved outside the plug conductive element 5, axial gaps are arranged on the surface of the cylindrical body at intervals, and the cylindrical body can retract inwards to deform under the action of the pull rope 36, so that the cylindrical body is tightly attached to the outside of the plug conductive element 5 to realize tight contact. The restriction on the material used for the conductive elements is further reduced since the pull cord 36 does not have to be directly connected to the conductive elements.
Example 5
Referring to fig. 11-15, an electrical connector structure of the present invention includes a plug portion 1, a socket portion 2 and a constant force device 9, wherein the plug portion 1 is provided with a plug conductive element therein, and the socket portion 2 is provided with a socket conductive element 6 therein. This example differs from example 1 in that: plug conductive element is including the wedge 38 that is the round platform body, set up the slider 39 in wedge 38 bottom, socket conductive element includes that vertical section is down trapezoidal and with wedge 38 matched with gomphosis portion 40, set up in gomphosis portion 40 electrically conductive plectane 41 of bottom, set up at electrically conductive plectane 41 with electrically conductive spring 42 between socket end pencil joint 7 is equipped with the swivelling chute 37 of taking breach 43 at gomphosis portion 40 top edge, breach 43 and slider 39 shape cooperatees, and slider 39 can be held in swivelling chute 37, and the constant force device is including setting up coil spring 44 and coil spring 45 between electrically conductive plectane 41 and socket pencil joint 7. The wedge-shaped block and the embedded part can realize surface contact, the contact area is increased, and under the elastic action of the conductive spring and the spiral spring, enough contact force is generated between the conductive elements, so that the connection is stable and reliable.
When the slider 39 of the plug is aligned with the notch 43, the wedge 38 of the plug is brought into contact with the fitting portion 40 of the receptacle, and the coil spring 44, the conductive spring 42, and the coil spring 45 are compressed and deformed. When the amount of compression reaches the set value, the slider 39 comes into axial contact with the rotation groove 37. At this time, the wedge block 38 is rotated to wrap the rotary slot 37 around the slider 39. After the plug is released, under the pressure of the coil springs 44 and 45, a sufficient contact force is generated between the conductive circular plate 41 and the wedge block 38 of the plug conductive element, so as to meet the design requirement of the connector.
When the contact force reaches the design requirement index, the conductive spring 42 reaches an initial length. The compression deformation amount of the coil springs 44 and 45 is much larger (10 times or more) than the displacement of the conductive disk 41 caused by the vibration and impact, and much larger (10 times or more) than the deformation amount of the fitting portion 40 and the wedge 38 of the plug. In addition, the rigidity of the coil springs 44 and 45 is also much greater (10 times or more) than that of the conductive spring 42.
A method of wiring harness connection of an electrical connector, comprising the steps of:
1. calculating target design parameters of the contact force between the conductive elements of the connector according to information such as a relation model of the contact resistance and the contact force; the following equation is a common empirical formula for calculating contact force:
F＝(K/RJ)1/m/0.102 (1)
in the formula, F is contact force; k is a coefficient related to the contact material and the surface condition, and is given by experiments, such as copper-copper contact, and the K value ranges from 80 to 140; rJIs the contact resistance; m is a coefficient related to the contact form, for example, m is 0.5 for point contact and 1 for surface contact. The minimum contact force value to be provided by the connector can be obtained by the formula (1).
2. Calculating the minimum constant force value required to be provided by the constant force device based on the target design parameter requirement of the contact force of the conductive element of the connector; force analysis of the socket conductive elements as shown in fig. 15, F is the contact force between the conductive elements; f3 and F4 are the pressures required to be provided by the constant force device, and simple calculation can obtain the value of the minimum constant force T (in this example, F3 and F4 can be considered equal).
3. Determining a constant force target value based on the minimum constant force value calculated in the step 2, and designing and manufacturing a constant force device; referring to formula (3) in example 1, the relationship between the geometric dimension and physical parameters of the spring in the constant force device and the constant force value can be known, and the design and manufacture of the constant force device can be completed.
4. Assembling the plug part 1, and fixedly connecting the plug terminal wiring harness 3, the plug terminal wiring harness joint 4 and the plug conductive member 5 in sequence; assembling the socket part 2, and fixedly connecting the socket conductive element, the socket end harness joint 7 and the socket end harness in sequence;
5. the constant force device 9 is arranged, when the plug part 1 is connected with the socket part 2, the wedge block 38 compresses the conductive circular plate 41, then the conductive spring, the spiral spring 44 and the spiral spring 45 are compressed, the compression generated by the spiral spring is far larger than the compression change caused by vibration and impact, the pressure of the spiral spring is basically kept unchanged in the working process, and the contact force between the conductive elements can be kept stable and unchanged in the working process.
Example 6
Referring to fig. 16-19, another electrical connector structure is shown, which is different from embodiment 1 in that: plug conductive element 5 is the cylindricality that the surface was equipped with a plurality of axial splines, socket conductive element 6 surface with the tip surface of plug conductive element 5 cooperatees, the constant force device includes hollow spline sleeve 51, sets up be a plurality of spring arbor 46, a plurality of one end that the circumference array distributes in socket portion 2 and fix clockwork spring 47 on spring arbor 46, clockwork spring 47's the other end is fixed on spline sleeve 51 surface, and spline sleeve 51 is rotatable to be set up on the socket conductive element 6. A first positioning mark 48 is provided on the housing of the socket part 2, and a second shorter positioning mark 49 and a third longer positioning mark 50 are provided on the housing of the plug part 1.
Aligning the second positioning mark 49 with the first positioning mark 48 on the shell of the socket part, which indicates that the outer contour of the plug conductive element 5 is aligned with the inner contour of the spline sleeve 51, then inserting the plug conductive element 5 into the spline sleeve 51, and rotating clockwise until the third positioning mark 50 which is longer on the shell of the plug part 1 is aligned with the first positioning mark 48 on the shell of the socket part 2 again, inserting the end of the plug conductive element 5 into the surface of the socket conductive element 6 to realize fixation, wherein the rotation angle of the spline sleeve 51 is theta angle, and the constant force spring 47 enters a constant force working interval, and the spring tension is basically kept unchanged. After the plug is loosened, under the action of the counterclockwise moment provided by the three springs such as the constant-force spring 47, a contact force which is large enough and basically kept unchanged is generated between the plug conductive element 5 and the socket conductive element 6, so that the design requirement of the connector is met. The plug conductive element 5 has an outer profile with an arcuate shape characteristic to increase the contact area with the receptacle conductive element 6.
A method of wiring harness connection of an electrical connector, comprising the steps of:
1. calculating target design parameters of the contact force between the conductive elements of the connector according to information such as a relation model of the contact resistance and the contact force; the calculation of the contact force can be referred to the formula (1) in example 1, and the minimum contact force value F to be provided by the connector can be determined.
2. Calculating the minimum constant force value required to be provided by the constant force device based on the target design parameter requirement of the contact force of the conductive element of the connector; in this embodiment, the resultant moment of the contact force is balanced with the resultant moment of the constant force spring, i.e., the target value P of the deformation force of the constant force spring can be obtained according to the target value F of the contact force and the geometric parameter.
3. Determining a constant force target value based on the minimum constant force value calculated in the step 2, and designing and manufacturing a constant force device;
one theoretical calculation formula for the deformation force of a constant force spring is as follows: theta
Figure BDA0002580237440000121
In the above formula, P is the deformation force of the constant force spring 49, E is the elastic modulus of the material of the spring, b is the width of the spring, h is the thickness of the spring, and R isnRadius of curvature, R, of the spring coil in its free state0Is the radius of the constant force spring shaft 48. The relationship between the geometric dimension and the physical parameters of the spring in the constant force device and the constant force value can be known, and the design and the manufacture of the constant force device are further completed.
4. Assembling the plug part 1, and fixedly connecting the plug terminal wiring harness 3, the plug terminal wiring harness joint 4 and the plug conductive member 5 in sequence; assembling the socket part 2, and fixedly connecting the socket conductive element, the socket end harness joint 7 and the socket end harness in sequence;
5. the constant force device 9 is arranged, the rotation angle of the plug conductive element 9 is an angle theta, and at the moment, the constant force spring 49 enters a constant force working interval, and the tension of the spring is basically kept unchanged. After the plug is loosened, under the action of the counterclockwise moment provided by three springs such as the constant force spring 49, a contact force which is large enough and basically kept unchanged is generated between the plug conductive element 5 and the socket conductive element 6, so that the design requirement of the connector is met.
The above detailed description is specific to possible embodiments of the present invention, and the embodiments are not intended to limit the scope of the present invention, and all equivalent implementations or modifications that do not depart from the scope of the present invention are intended to be included within the scope of the present invention.

Claims (13)

1. An electrical connector structure, characterized by: the socket comprises a plug part, a socket part and a constant force device, wherein a plug end wire harness joint and a plug conductive element which are fixedly connected are arranged in the plug part, a socket conductive element and a socket end wire harness joint which are fixedly connected are arranged in the socket part, when the plug part is connected with the socket part, the plug conductive element is positioned in the socket conductive element, and the constant force device is used for restraining and fixing the socket conductive element outside the plug conductive element.
2. An electrical connector structure according to claim 1, wherein: the plug conductive element is cylindrical, and the socket conductive element is a spiral sheet-shaped body.
3. An electrical connector structure according to claim 1, wherein: the plug conductive element is a cylinder, and the socket conductive element is a plurality of spiral sheet-shaped bodies which are arranged in parallel.
4. An electrical connector structure according to claim 1, 2 or 3, wherein: a plug end wire harness joint in the plug part is fixedly connected with a plug end wire harness; and the socket section wire harness joint in the socket part is fixedly connected with the socket end wire harness.
5. An electrical connector structure according to claim 4, wherein: the constant force device comprises an extension spring with one end connected to the socket conductive element, and the other end of the extension spring is fixed in the socket part.
6. An electrical connector structure according to claim 5, wherein: the constant force device further comprises a sliding groove and a sliding block capable of moving along the sliding groove, and the other end of the extension spring is fixed on the sliding block.
7. An electrical connector structure according to claim 6, wherein: and a sleeve is arranged outside the extension spring.
8. An electrical connector structure according to claim 4, wherein: the constant force device comprises an elastic pull rope sleeved outside the socket conductive element.
9. An electrical connector structure according to claim 1, wherein: plug conductive element is including the wedge that is the round platform body, set up the slider in the wedge bottom, socket conductive element include vertical section fall trapezoidal and with wedge matched with gomphosis portion, set up in gomphosis portion bottom electrically conductive plectane, set up electrically conductive plectane with electrically conductive spring between the socket end pencil connects is equipped with the swivelling chute of taking the breach at gomphosis portion top edge, and the breach cooperatees with the slider shape, but the slider holding is in the swivelling chute, the constant force device including set up electrically conductive plectane with a plurality of coil spring between the socket pencil connects.
10. An electrical connector structure according to claim 1, wherein: the plug conductive element is the cylindricality body that the surface was equipped with a plurality of axial splines, socket conductive element surface with the tip surface of plug conductive element cooperatees, the constant force device includes hollow spline sleeve, sets up be a plurality of spring arbor, a plurality of one end that the circumference array distributes in the socket portion and fix the clockwork spring on the spring arbor, and the other end of clockwork spring is fixed on spline sleeve surface, and the rotatable setting of spline sleeve is in on the socket conductive element.
11. An electrical connector structure according to claim 1, wherein: and the plug part and the socket part are respectively provided with a locking device matched with each other.
12. An electrical connector harness connection method characterized by: the method comprises the following steps: calculating a minimum design value of contact force between a socket conductive element and a plug conductive element according to a relation model between contact resistance and contact force of the conductive element; secondly, calculating and obtaining a minimum constant force value required to be provided by the constant force device according to the minimum design value of the contact force; designing a constant force device capable of providing a pulling force greater than or equal to the minimum constant force value according to the required minimum constant force value; assembling a plug part, and fixedly connecting the plug end wire harness, the plug end wire harness joint and the plug conductive element in sequence; assembling a socket part, and fixedly connecting the socket conductive element, the socket end wire harness joint and the socket end wire harness in sequence; and fifthly, arranging a constant force device, wherein when the plug part is connected with the socket part, the plug conductive element is positioned in the socket conductive element, so that the socket conductive element is restrained and fixed outside the plug conductive element by the constant force device.
13. An electrical connector harness connection method as claimed in claim 12, wherein: in the third step, the step of designing an adjusting device capable of adjusting the acting force of the constant force device is also included.
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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19744158A1 (en) * 1997-10-07 1999-04-29 Amphenol Tuchel Elect Electrical contact and associated connector
CN202550123U (en) * 2012-03-23 2012-11-21 王兴达 Elastic plug and socket
CN105870685A (en) * 2016-05-31 2016-08-17 于勇 Method for increasing power of socket and plug
DE102016001079A1 (en) * 2016-02-02 2017-08-03 Mbda Deutschland Gmbh connecting element
CN209200288U (en) * 2019-01-29 2019-08-02 北京固融科技有限公司 Electric connection coupler and its socket, automatic rebounding mechanism

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19744158A1 (en) * 1997-10-07 1999-04-29 Amphenol Tuchel Elect Electrical contact and associated connector
CN202550123U (en) * 2012-03-23 2012-11-21 王兴达 Elastic plug and socket
DE102016001079A1 (en) * 2016-02-02 2017-08-03 Mbda Deutschland Gmbh connecting element
CN105870685A (en) * 2016-05-31 2016-08-17 于勇 Method for increasing power of socket and plug
CN209200288U (en) * 2019-01-29 2019-08-02 北京固融科技有限公司 Electric connection coupler and its socket, automatic rebounding mechanism

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