CN112540323A - In-situ simulation and online diagnosis method for contact failure of electric connector - Google Patents

In-situ simulation and online diagnosis method for contact failure of electric connector Download PDF

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CN112540323A
CN112540323A CN202011495633.6A CN202011495633A CN112540323A CN 112540323 A CN112540323 A CN 112540323A CN 202011495633 A CN202011495633 A CN 202011495633A CN 112540323 A CN112540323 A CN 112540323A
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contact resistance
electric connector
diagnosis
simulation
contact
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CN112540323B (en
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朱蒙
贾润川
李明
任万滨
王玲
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China Aero Polytechnology Establishment
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China Aero Polytechnology Establishment
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01RMEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/50Testing of electric apparatus, lines, cables or components for short-circuits, continuity, leakage current or incorrect line connections
    • G01R31/66Testing of connections, e.g. of plugs or non-disconnectable joints

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Testing Of Short-Circuits, Discontinuities, Leakage, Or Incorrect Line Connections (AREA)
  • Manufacturing Of Electrical Connectors (AREA)
  • Measurement Of Resistance Or Impedance (AREA)

Abstract

The invention provides an in-situ simulation and online diagnosis method for contact failure of an electric connector, which is characterized in that the method can carry out in-situ simulation and online diagnosis on a plurality of contact failure working modes during actual use of the electric connector, and the simulation and online diagnosis are carried out by using a simulation diagnosis device. The invention can simulate various contact failure working modes in the actual using state of the electric connector in situ, and simultaneously monitor the main performance parameter contact resistance of the electric connector in the failure process in real time, thereby reproducing the intermittent contact failure phenomenon of the electric connector product and providing data support for the failure of the electric connector and providing basis for the performance improvement of the electric connector.

Description

In-situ simulation and online diagnosis method for contact failure of electric connector
Technical Field
The invention relates to the technical field of fault simulation and online diagnosis, in particular to an in-situ simulation and online diagnosis method for contact failure of an electric connector.
Background
At present, the phenomenon that various environmental tests are passed but external field faults occur frequently occurs frequently in an electric connector, and the phenomenon that signals are interrupted instantaneously but the electric connector is recovered to be normal when being tested off line, so that the failure phenomenon can not be reproduced and diagnosed. The reason for this may be due to two aspects, namely that the simulation of the true operating conditions of the electrical connector in a conventional test environment is not in place; and secondly, the real-time monitoring of key performance parameters such as contact resistance in the whole test process of the electric connector is not carried out, so that the fault phenomenon is not monitored or recorded in the test process. Therefore, how to simulate the actual working state of the electric connector in situ so as to further cause the coating of the electric connector to be worn, further cause the contact failure of the electric connector to comprise the exposure recurrence of the intermittent failure phenomenon, and can monitor and record so that engineering technicians can capture the main phenomena and characteristics of the electric connector, thereby having practical significance and having important significance for improving the reliability of the electric connector.
At present, a simulation diagnosis device for performing a contact failure fault mode on an electric connector product is still in a blank stage, and a corresponding simulation and online diagnosis method is not formed. The electric connector is only installed and fixed through the test fixture when vibration and plugging tests are respectively carried out on the electric connector, vibration stress is applied, plugging and unplugging are carried out, the electric connector is far away from the actual using state of the electric connector, and meanwhile, the main performance parameter contact resistance of the electric connector in the diagnosis process cannot be monitored in real time, so that the intermittent contact failure phenomenon of an electric connector product cannot be reproduced, and data support cannot be provided for the failure of the electric connector and a reference basis cannot be provided for the improvement of the performance of the electric connector.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides an in-situ simulation and online diagnosis method for the contact failure of an electric connector, and the designed in-situ simulation diagnosis device can realize the multi-axial vibration simulation of the electric connector product in a normal insertion state and an eccentric insertion state and realize the in-situ simulation of the real working state of the electric connector; and the contact resistance and the instantaneous shake-off signal of the electric connector are monitored on line in real time in the simulation and on-line diagnosis processes.
Specifically, the invention provides an in-situ simulation and online diagnosis method for contact failure of an electric connector, which comprises the following steps:
s1, simulating and diagnosing fretting wear failure continuously occurring in a normal insertion state on line, and specifically comprising the following steps:
s11, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s12, installing and fixing an electric connector pin on the sliding end face of the electric sliding table through a pin end clamp, installing and fixing an electric connector jack end on the movable end face of the angular position table through a jack end clamp, fixing the angular position table on the sliding end face of the first three-dimensional sliding table, adjusting the angular position table and the first three-dimensional sliding table to enable the jack end of the electric connector to be completely overlapped with the axis of the pin, and setting the insertion depth of the pin to enable the electric sliding table to drive the electric connector pin to be inserted into the electric connector jack along the axis of the electric connector pin;
s13, controlling the electric sliding table to do reciprocating sliding motion with fixed amplitude and fixed frequency, simultaneously respectively connecting two ends of the electric connector into a contact resistance testing instrument to obtain a contact resistance real-time waveform, and recording the response frequency and amplitude of the contact resistance;
s14, setting simulation diagnosis stopping conditions, and stopping simulation diagnosis when the contact resistance meets any one of the following conditions;
one of the conditions is: observing the corresponding relation between the response frequency and amplitude of the contact resistor and the reciprocating sliding frequency, recording the reciprocating sliding cycle times when the peak value of the response frequency of the contact resistor is 3 times of the initial contact resistance value, and stopping analog diagnosis;
the second condition is as follows: when the contact resistance has 3 instantaneous shake-off signals, recording the times of the reciprocating sliding period, and stopping the simulation diagnosis;
s2, simulating and diagnosing the sliding wear failure which continuously occurs in the normal insertion state on line, and the method comprises the following specific steps:
s21, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s22, mounting the electric connector on the simulation diagnosis device according to the method of the step S12;
s23, controlling the vibration table to perform sine frequency sweep vibration, wherein the sine frequency sweep vibration adopts fixed frequency and fixed vibration acceleration, and meanwhile, two ends of the electric connector are respectively connected to a contact resistance testing instrument to obtain a contact resistance real-time waveform and record the response frequency and amplitude of the contact resistance;
s24, observing the response frequency and amplitude of the contact resistance, and recording the response peak value of the contact resistance, namely the vibration frequency point or frequency range with violent fluctuation degree of the contact resistance peak value;
s25, setting simulation diagnosis stopping conditions, and stopping simulation diagnosis when the contact resistance meets any one of the following conditions;
one of the conditions is: selecting proper power spectral density to carry out fixed-frequency random vibration, monitoring the response of the contact resistor in real time, recording the reciprocating sliding cycle times when the response peak value of the contact resistor is 3 times of the initial contact resistance value, and stopping analog diagnosis;
the second condition is as follows: when the contact resistance has 3 instantaneous shake-off signals, recording the times of the reciprocating sliding period, and stopping the simulation diagnosis;
s3, simulating the plug contact failure in the eccentric insertion state and carrying out online diagnosis, and the method specifically comprises the following steps:
s31, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s32, installing and fixing an electric connector pin on a sliding end face of an electric sliding table through a pin end clamp, installing and fixing an electric connector jack end on a movable end face of an angle position table through a pin end clamp, fixing the angle position table on a sliding end face of a first three-dimensional sliding table, adjusting the angle position table and the first three-dimensional sliding table to enable the jack end to deviate from a pin hole central axis by +/-3 to +/-5 degrees, adjusting the position of a jack end force sensor through adjusting a second three-dimensional sliding table, setting the insertion depth of the pin, and driving the electric sliding table to eccentrically insert the electric connector pin into an electric connector jack;
s33, after the electric connector is installed and fixed, simultaneously, two ends of the electric connector are respectively connected into a contact resistance testing instrument, the plugging times and the plugging speed are set, an electric sliding table drives a contact pin to be plugged into and pulled out of a jack, and the waveform of the dynamic contact resistance is recorded;
s34, setting simulation diagnosis stopping conditions, and stopping simulation diagnosis when the contact resistance meets any one of the following conditions;
one of the conditions is: observing the corresponding relation between the response frequency and the amplitude of the contact resistor and the reciprocating sliding frequency, stopping the simulation diagnosis when the response peak value of the contact resistor is 3 times of the initial contact resistance value, and recording the reciprocating sliding cycle times;
the second condition is as follows: when the contact resistance has 3 times of instant shake-off signals, stopping the simulation diagnosis and recording the times of the reciprocating sliding period;
stopping the simulation diagnosis and recording the plugging times when the peak value of the dynamic contact resistance is 3 times of the initial contact resistance value; when the contact resistance has 3 times of instant shake-off signals, stopping the simulation diagnosis and recording the plugging times;
s4, simulating and diagnosing vibration impact contact failure in an eccentric insertion state in the actual use process of the electric connector on line, wherein the specific steps are as follows:
s41, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s42, after the electric connector is well installed and fixed according to the step S31, the electric sliding table drives the contact pin to be eccentrically inserted into the jack;
s43, simultaneously, respectively connecting two ends of the electric connector into a contact resistance testing instrument, controlling a vibration table to apply standard impact response vibration to the electric connector, performing an impact test, and recording the dynamic contact resistance waveform of the electric connector in the impact test process;
s44, setting simulation diagnosis stopping conditions, and stopping simulation diagnosis when the contact resistance meets any one of the following conditions;
one of the conditions is: observing the response frequency and amplitude of the contact resistor and the corresponding relation between the response frequency and the reciprocating sliding frequency, recording the reciprocating sliding cycle times when the response peak value of the contact resistor is 3 times of the initial contact resistance value, and stopping analog diagnosis;
the second condition is as follows: and when the contact resistance generates 3 instantaneous shake-off signals, recording the times of the reciprocating sliding period, and stopping the analog diagnosis.
Preferably, the insertion depth of the pin is greater than or equal to 70% of the minimum hole depth of the receptacle.
Preferably, the fixed amplitude value interval of the electric sliding table is controlled to be 0-10 um in step S12, and the fixed frequency value interval is controlled to be 1-10 Hz.
Preferably, the fixed frequency range in step S22 is 0 to 2000Hz, and the fixed vibration acceleration range is 1 to 10g, where g is 9.8m/S2
Preferably, the range of the power spectral density in step S24 is 0-1 g2/Hz。
Preferably, the value range of the power spectral density suitable in step S24 is specifically tailored according to the environment in which the product is used.
Preferably, the contact resistance testing instrument is a contact resistance testing instrument capable of monitoring the contact resistance instantaneous value in real time and having a function of monitoring a chattering-off signal of 1 us.
Preferably, the value range of the plugging times in the step S32 is 0-500 times, and the value range of the plugging speed is 1-10 mm/S.
The invention has the following beneficial effects:
in the simulation diagnosis method, the arrangement of the vibrating table, the electric sliding table and the three-dimensional sliding table is added to the simulation diagnosis device, so that the in-situ simulation of various actual use states of an electric connector product is realized on hardware;
the simulation diagnosis method can most closely simulate the actual use state of an electric connector product through the arrangement of four detection modes, and detects the electric connector product in the actual use process, thereby improving the in-situ simulation and online diagnosis capability of the contact failure of the electric connector;
the simulation diagnosis method provided by the invention monitors the key performance parameter contact resistance of the electric connector in real time, provides real-time data, and provides data support and an improvement basis for the performance of the electric connector when the electric connector fails.
Drawings
FIG. 1 is a front view of a simulation diagnostic device for the in-situ simulation and online diagnostic method of electrical connector contact failure of the present invention;
FIG. 2 is a top view of a simulated diagnostic device of one embodiment of the present invention;
FIG. 3 is a graph of contact resistance versus inching period for mode one of an embodiment of the present invention;
FIG. 4a is a graph showing the variation of the instantaneous value and the periodic average value of the contact resistance of 0 to 50s in mode two according to an embodiment of the present invention;
FIG. 4b is a graph showing the change in contact resistance of 20 to 21s in mode two according to the embodiment of the present invention;
FIG. 4c is a 20-21 s contact resistance power spectral density plot for mode two of one embodiment of the present invention;
fig. 5 is a trend graph of the contact resistance of the electrical connector in the off-center state and the normal state according to the third mode of the present invention.
In the figure:
1-shaking table, 2-base, 3-electronic slip table, 4-contact pin end anchor clamps, 5-electric connector contact pin, 6-motor, 7-electric connector jack, 8-jack end anchor clamps, 9-support, 10-angular position platform, 11-displacement sensor, 12-contact pin end force sensor, 13-jack end force sensor, 14-first three-dimensional slip table, 15-the three-dimensional slip table of second.
Detailed Description
Hereinafter, a specific embodiment of the present invention will be described with reference to fig. 1 to 5.
In order to realize the in-situ simulation and online diagnosis of the contact failure of the electric connector, the invention provides a simulation diagnosis device, which comprises: the device comprises a vibrating table 1, a base 2, an electric sliding table 3, a pin end clamp 4, an electric connector pin 5, a motor 6, an electric connector jack 7, a jack end clamp 8, a support 9, an angular table 10, a displacement sensor 11, a pin end force sensor 12, a jack end force sensor 13, a first three-dimensional sliding table 14 and a second three-dimensional sliding table 15.
Shaking table 1 can provide the multiaxis vibration excitation, electronic slip table 3, first three-dimensional slip table 14, the three-dimensional slip table of second 15, displacement sensor 11 sets gradually on the up end of base 2, contact pin end anchor clamps 4 are installed at the up end of electronic slip table 3, contact pin end anchor clamps 4 and contact pin end force sensor 12, electric connector contact pin 5 is threaded connection in proper order, electric connector jack 7 and jack end anchor clamps 8 threaded connection, jack end anchor clamps 8, angular position platform 10 and first three-dimensional slip table 14 are threaded connection in proper order, install the up end at the three-dimensional slip table of second 15 after motor 6 and the 9 bolted connection of support, motor 6 and jack end force sensor 13 threaded connection. Wherein: the electric sliding table 3 has the following functions: the pin 5 end of the electric connector can be driven to be inserted into the jack end along the axis of the electric connector, and the pin end is driven to be inserted into and pulled out of the jack end in a reciprocating mode. The first three-dimensional slide table 14 functions as: the electric connector jack 7 end clamp and the angle position table 10 are fixed on the first three-dimensional sliding table 14, and the first three-dimensional sliding table 14 can adjust whether the electric connector jack 7 end and the axis of the pin end are in the same horizontal position or not, so that the pin can be smoothly inserted into the jack. The three-position sliding table 15 has the functions: the position of the jack end force sensor 13 can be adjusted when the electrical connector jack 7 end is off-axis from the pin end axis.
Role of the angular table 10: the angle station 10 is fixed on the first three-dimensional sliding table 14 and can swing, the angle and the position of the electric connector jack 7 can be accurately adjusted through the matching structure of the angle station 10 and the three-dimensional sliding table, and the coincidence and the deviation of the axes of the contact pin and the jack are achieved.
Based on the simulation diagnosis device, the invention provides an in-situ simulation and online diagnosis method for the contact failure of the electric connector, which is used for carrying out in-situ simulation and online diagnosis on the contact failure of the electric connector.
Specifically, the in-situ simulation and online diagnosis method for the contact failure of the electric connector comprises the following steps:
s1, simulating and diagnosing fretting wear failure which continuously occurs in a normal insertion state on line;
the step can realize fretting wear of the electric connector product in the actual use state, and the electric connector product in the equipment is always in the insertion state in the actual use process and always suffers from the influence of the vibration environmental stress. The micro relative displacement can be generated between the electric connector pinholes under the vibration stress, so that fretting wear continuously occurs in the contact area of the pinholes, the contact area, the contact pressure and the like are influenced, the functional performance of an electric connector product is further influenced, and the phenomenon of contact failure or intermittent failure can occur in severe cases. The step can carry out in-situ simulation on the situation, and the electric sliding table 3 is used as an excitation source to drive the reciprocating tiny relative displacement between the contact pin and the jack, so that fretting wear occurs in a contact area, and the contact failure, namely the wear degree, is diagnosed on line. The method comprises the following specific steps:
s11, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s12, installing and fixing the electric connector pin 5 on the sliding end face of the electric sliding table 3 through the pin end clamp 4, installing and fixing the electric connector jack 7 on the movable end face of the angle table 10 through the jack end clamp 8, fixing the angle table 10 on the sliding end face of the first three-dimensional sliding table 14, adjusting the angle table 10 and the first three-dimensional sliding table 14 to enable the axis of the electric connector jack end to be completely overlapped with the axis of the pin end, and setting the insertion depth of the electric connector pin 5, enabling the electric sliding table 3 to drive the electric connector pin 5 to be inserted into the electric connector jack 7 along the axis of the electric connector pin 5, wherein the insertion depth of the pin 5 is required to be more than or equal to 70% of the minimum jack depth.
S13, controlling the electric sliding table 3 to do reciprocating sliding motion with a fixed amplitude (recommended to be 0-10 um) and a fixed frequency (recommended to be 1-10 Hz), wherein the maximum speed of inserting and pulling out is 300 times/h.
Simultaneously, two ends of the electric connector are respectively connected into a contact resistance testing instrument (the instantaneous value of the contact resistance can be monitored in real time, and the function of shaking off signals of 1us can be monitored), so that the real-time waveform of the contact resistance is obtained, and the response frequency and the amplitude of the contact resistance are recorded and obtained;
s14, observing the corresponding relation between the response frequency and amplitude of the contact resistance and the reciprocating sliding frequency, and stopping the simulation diagnosis and recording the reciprocating sliding cycle times when the response peak value of the contact resistance is 3 times of the initial contact resistance value. When the contact resistance appears with 3 instant chattering signals (not necessarily continuous), the analog diagnosis can be stopped, and the number of reciprocating sliding cycles is recorded. When the contact resistance meets any one of the above conditions, the simulation diagnosis is stopped;
s2, simulating and diagnosing the sliding wear failure which continuously appears in the normal insertion state on line;
the step can be used for simulating the sliding abrasion of the electric connector in the equipment, the electric connector product in the aviation equipment is always in a vibration state in the actual use process, and the electric connector product is in different cabin sections and positions due to different transmitted signals or functions. Generally, the magnitude of the vibration environmental stress experienced by the electric connector located in the rear fuselage cabin section is large, so that sliding abrasion is easily generated in the contact area between the contact pin and the jack in the electric connector, the sliding mark is deep and long, the contact quality is affected, the contact performance is good and bad, and the main reason why the electric connector is prone to intermittent contact failure is also provided. The method comprises the steps of firstly carrying out frequency sweep vibration test on the electric connector, aiming at obtaining the vibration sensitive frequency of the electric connector which is most prone to performance reduction, then carrying out random vibration test on an electric connector product under the vibration sensitive frequency, accelerating the probability of contact failure of the electric connector product, and inspecting the environmental adaptability level of the electric connector. The method comprises the following specific steps:
s21, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s22, mounting the electric connector on the simulation diagnosis device according to the method of the step S12;
s23, controlling the vibration table 1 to perform sine frequency sweep vibration, wherein the frequency range is recommended to be 0-2000 Hz, the vibration acceleration range is 1-10 g, and g is 9.8m/S2Simultaneously, two ends of the electric connector are respectively connected into a contact resistance testing instrument (the instantaneous value of the contact resistance can be monitored in real time, and the function of shaking off signals of 1us can be monitored), the waveform of the contact resistance is obtained, and the response frequency and the amplitude of the contact resistance are recorded and obtained;
s24, observing the response frequency and amplitude of the contact resistance, and recording the vibration frequency point or frequency range of the contact resistance response peak value (namely the fluctuation degree of the contact resistance peak value is severe);
s25, selecting proper power spectral densityRecommended value is 1g2and/Hz, performing fixed-frequency random vibration at the frequency point or within the frequency range (refer to the random vibration test method in the GJB 360B-2009), monitoring the response of the contact resistance in real time, and stopping the simulation diagnosis when the response peak value of the contact resistance is 3 times of the initial contact resistance value. When the contact resistance meets any one of the above conditions, the simulation diagnosis is stopped;
s3, simulating and diagnosing the plug contact failure in the eccentric insertion state on line;
the step can realize the plugging simulation of the eccentric state of the electric connector product in the actual use process, and the plugging operation of the electric connector product is often carried out in the process of airplane overhaul or daily crew inspection by taking an aviation electric connector product as an example. When the staff is plugging, the phenomenon of operation irregularity or even misoperation appears easily, and at the moment, because the electric connector contact pin 5 does not correspond with the jack and completely causes the fault phenomena of poor needle hole coaxiality or even bent needle, broken needle and the like, when the product is used again, the contact failure phenomenon is very easy to appear. This kind of test mode can carry out the normal position simulation to the plug of eccentric state, and 5 ends of electric connector contact pin insert and extract the jack end under the skew condition of axiality, can make contact area's sliding wear degree and abrasive dust distribute inhomogeneous, influence the size of product in-service use contact resistance, and this step can be more real realization exposes the simulation of contact failure phenomenon to outer place. The method comprises the following specific steps:
s31, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s32, installing and fixing an electric connector pin 5 on a sliding end face of an electric sliding table 3 through a pin end clamp 4, installing and fixing an electric connector jack 7 end on a movable end face of an angle table 10 through a jack end clamp 8, fixing the angle table 10 on a sliding end face of a first three-dimensional sliding table 14, adjusting the angle table 10 and the first three-dimensional sliding table 14 to enable a jack end to deviate from a center axis of a pin hole by +/-3 to +/-5 degrees, adjusting the position of a jack end force sensor 13 through adjusting a second three-dimensional sliding table 15, setting the insertion depth of the electric connector pin 5, and driving the electric sliding table 3 to eccentrically insert the electric connector pin 5 into the electric connector jack 7;
s33, after the electric connector is installed and fixed, simultaneously, two ends of the electric connector are respectively connected to a contact resistance testing instrument, the plugging times are set, 0-500 times are recommended, the plugging speed is recommended to be 1-10 mm/S, the electric sliding table 3 drives a contact pin to be inserted into and pulled out of an insertion hole, and the dynamic contact resistance waveform is recorded;
and S34, stopping the simulation diagnosis and recording the plugging times when the peak value of the dynamic contact resistance is 3 times of the initial contact resistance value. When the contact resistance has 3 instant jitter signals (not necessarily continuous), the analog diagnosis can be stopped, and the plugging times can be recorded. When the contact resistance meets any one of the above conditions, the simulation diagnosis is stopped;
s4, simulating and diagnosing vibration impact contact failure suffered by the electric connector in an eccentric insertion state in the actual use process;
this step allows to simulate the vibration shocks to which the electrical connector product is subjected in the condition of eccentric insertion. The electric connector as a goods shelf product is subjected to a series of identification tests before delivery and successfully passes, but the external field faults are frequent, and the external field fault phenomenon cannot be reproduced by the existing simulation diagnosis room test method. Impacts can have an adverse effect on the structural and functional integrity of the overall electrical connector, which can increase when the impact duration coincides with the inverse of the product's natural frequency or the primary frequency component of the input impact environment waveform coincides with the product's natural frequency. The step provides a more rigorous assessment mode for the electric connector product, and the contact failure process of the electric connector product is accelerated by performing impact simulation in an eccentric state. The method comprises the following specific steps:
s41, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s42, after the electric connector is well installed and fixed according to the step S31, the electric sliding table 3 drives the contact pin to be eccentrically inserted into the jack;
s43, simultaneously, respectively connecting two ends of the electric connector into a contact resistance testing instrument, controlling the vibration table 1 to apply standard impact response vibration to the electric connector, wherein the standard impact response vibration can be performed according to the impact test in GJB150A-2009, and recording the waveform of the dynamic contact resistance of the electric connector in the impact test process;
s44, when the peak value of the dynamic contact resistance is 3 times the initial contact resistance value, the simulation diagnosis is stopped and the number of vibration cycles is recorded. When the contact resistance appears with 3 instant chattering-off signals (1us, not necessarily appearing continuously), the analog diagnosis can be stopped, and the vibration cycle number can be recorded.
The specific embodiment is as follows:
the first embodiment is as follows:
simulating and diagnosing fretting wear failure continuously occurring in a normal plugging state on line;
and performing an initial contact resistance test on a qualified electric connector, wherein the initial contact resistance of the J599 series electric connector is 1.5m omega.
Then, the end of an electric connector pin 5 is fixedly installed on the sliding end face of the electric sliding table 3 through a pin end clamp 4, the end of an electric connector jack 7 is fixedly installed on the movable end face of the angle table 10 through a jack end clamp 8, the angle table 10 is fixedly arranged on the sliding end face of the first three-dimensional sliding table 14, and the angle table 10 and the first three-dimensional sliding table 14 are adjusted to enable the axis of the pin end and the axis of the pin end to be completely overlapped. Set up the depth of insertion, electronic slip table 3 can drive electric connector contact pin 5 and insert the jack along its axis.
After the electric connector is confirmed to be in a complete inserting state, the electric sliding table 3 is set to perform reciprocating sliding motion at the amplitude of 5um, the frequency of 1Hz and the micro-motion speed of 20um/s, so that the in-situ simulation of the real working state of the electric connector is realized; meanwhile, two ends of the electric connector are respectively connected into a contact resistance testing instrument, the instantaneous value of the contact resistance is synchronously monitored in real time, and the obtained corresponding relation between the contact resistance and the micro-motion period is shown in figure 3.
As can be seen from FIG. 3, in the initial stage of the inching, the contact resistance instantly rises from the initial value of 1.5m Ω to 2m Ω and fluctuates, when the inching period reaches 130000 times, the contact resistance starts to intermittently increase and decrease, the intermittent failure of the contact resistance becomes more and more obvious along with the progress of the test, the peak value of the contact resistance even rises to 4.5m Ω and reaches 3 times of the initial value, and the fluctuation range of the peak value is close to 3m Ω.
Example two:
simulating and diagnosing the sliding wear failure which continuously occurs in a normal plugging state on line;
and carrying out an initial contact resistance test on a qualified electric connector, wherein the initial contact resistance of the electric connector is 1.5m omega.
The electric connector pin 5 end is fixedly installed on the sliding end face of the electric sliding table 3 through the pin end clamp 4, the electric connector jack 7 end is fixedly installed on the movable end face of the angle table 10 through the jack end clamp 8, the angle table 10 is fixed on the sliding end face of the first three-dimensional sliding table 14, and the axis of the pin end are completely overlapped by adjusting the angle table 10 and the first three-dimensional sliding table 14. Set up the depth of insertion, electronic slip table 3 can drive electric connector contact pin 5 and insert the jack along its axis. And simultaneously, two ends of the electric connector are respectively connected into a contact resistance testing instrument.
Controlling the vibration table 1 to perform sine frequency sweep vibration within the range of 0-100 Hz and under the condition that the vibration acceleration is 1g, and realizing the in-situ simulation of the real working state of the electric connector; and synchronously monitoring the real-time variation trend of the contact resistance peak value in the vibration test process, and analyzing to obtain a vibration frequency point with severe fluctuation degree of the contact resistance peak value of the electric connector of the type as 10 Hz.
At room temperature of 20 ℃, random vibration test is carried out with the amplitude of 5mm, the frequency of 10Hz, the vibration maintenance of 40s (namely 400 vibration periods) and the excitation current of 100mA, and the change trend of the contact resistance is monitored in real time, as shown in figure 3. Fig. 4a shows the variation of instantaneous value of contact resistance and the variation of the average value of the period, which is the average value of the contact resistance calculated with a vibration period of 0.1 s. Before vibration, the average value of the contact resistance is 3.436m omega in 1-6 s. The contact resistance rapidly increased after the 6s vibration started, the fluctuation peak reached 4.953m Ω at maximum and 2.028m Ω at minimum, the peak reached 2.925m Ω, and the 46s vibration ended, and the contact resistance rapidly decreased. The average value of the contact resistance of 46-50 s is 3.222m omega, which is 0.214m omega less than that before vibration. FIG. 4b shows the contact resistance of 20-21 s, the contact resistance is approximately sinusoidal, the peak value is 2.181m Ω, and the fluctuation frequency is 10Hz and the vibration excitation frequency are the same. FIG. 4c is the power spectral density of 20-21 s contact resistance, as shown in FIG. 4c, the power spectrum is largest at zero frequency, followed by 10Hz, and the power spectral magnitudes at other frequencies are close to zero.
Example three:
and performing simulation and online diagnosis on the plug contact failure in the eccentric insertion state.
Initial contact resistance testing was performed on a qualified electrical connector, recording an initial contact resistance of 3.325m Ω (including tail attachment).
Install connector contact pin 7 through contact pin end anchor clamps 4 and be fixed in on the slip terminal surface of electronic slip table 3, through jack end anchor clamps 8 with connector jack 7 end installation on the movable terminal surface of being fixed in angle position platform 10, angle position platform 10 is fixed on the slip terminal surface of first three-dimensional slip table 14, adjustment angle position platform 10 and first three-dimensional slip table 14 make the skew pinhole positive axis 3 degrees of jack end, adjust the position of jack end force transducer 13 through adjusting three-dimensional slip table 15 of second, set up the depth of insertion, electronic slip table 3 drives connector contact pin 5 eccentric insertion connector jack 7. And simultaneously, two ends of the electric connector are respectively connected into a contact resistance testing instrument.
The plugging times are set to 2000 times, the electric sliding table 3 at the pin end is started, and the electric sliding table 3 drives the pins to be inserted into the jacks. Realizing in-situ simulation of the real working state of the electric connector; the contact resistance values are monitored in real time during the eccentric plugging process, and the change conditions of the eccentric state and the contact resistance values during the normal plugging test are shown in table 1 and fig. 4 a-c.
As can be seen from the data in the following table and fig. 4a-c, the number of times of plugging and unplugging is within 500 times, the contact resistance of the electrical connector in the eccentric plugging and unplugging state and the normal plugging and unplugging state changes more stably, and after the number of times of plugging and unplugging exceeds 500 times, the contact resistance continuously rises along with the continuous increase of the number of times of plugging and unplugging. When the connector is plugged and pulled 2000 times, the contact resistance of the electrical connector in the eccentric plugging state reaches 11.92m omega, which is about 3 times of the initial value, while the contact resistance of the electrical connector in the normal state is only 5.389m omega, and the abrasion degree of the contact area of the pinhole of the electrical connector in the eccentric plugging state is obviously much larger than that in the normal plugging state from the variation trend of the contact resistance of the electrical connector in the two states. In the range of 500 times of plugging and unplugging, the change of the contact resistance is relatively stable because the surface film layer of the pin hole contact area is continuously damaged at the stage, the gold-plated layer and the base metal of the contact element are not abraded, and the resistance of the film layer in the contact resistance is continuously reduced due to the damage of the surface film layer, so that the contact resistance is lower than that of the contact resistance when the contact resistance is plugged and unplugged for 500 times rather than 250 times. After more than 500 times of plugging, the reason that the contact resistance rises is that along with the increase of the plugging times, the contact surface is rough due to continuous abrasion of the contact surface coating and the substrate, the contact area is reduced, under the eccentric plugging state, because the coaxiality of the pin hole is slightly poor, the contact surface abrasion degree and the abrasive dust distribution are unbalanced, and meanwhile, after repeated plugging and unplugging for many times, the elasticity of the sleeve at the end of the pin hole is reduced, the contact positive pressure is reduced in the plugging process, and the contact resistance is increased.
TABLE 1 table of the variation of the contact resistance of the electric connector with the plugging times in the eccentric state and the normal state
Figure BDA0002842068590000121
The trend of the contact resistance of the electrical connector in the eccentric state and the normal state along with the change of the plugging times is shown in fig. 5.
Example four:
the method is used for simulating and diagnosing the vibration impact contact failure suffered by the electric connector in an eccentric insertion state in the actual use process.
Initial contact resistance testing was performed on a qualified electrical connector and recorded as 3.064m Ω (including tail attachment).
Then through the installation of contact pin end anchor clamps 4 with connector contact pin 7 be fixed in on the slip terminal surface of electronic slip table 3, through jack end anchor clamps 8 with connector jack 7 end installation be fixed in on the activity terminal surface of angle station 10, angle station 10 is fixed in on the slip terminal surface of first three-dimensional slip table 14, adjust angle station 10 and first three-dimensional slip table 14 and make the jack end deviate from pinhole positive axis 3 degrees, adjust the position of jack end force transducer 13 through adjusting second three-dimensional slip table 15, set up the depth of insertion, electronic slip table 3 drives connector contact pin 5 off-centre and inserts connector jack 7. And simultaneously, two ends of the electric connector are respectively connected into a contact resistance testing instrument.
The electric sliding table 3 at the end of the contact pin is started, and the electric sliding table 3 drives the contact pin to be inserted into the jack. Starting the vibration table 1, and according to the functional impact control vibration table 1 of the program I in the impact test method in the GJB150A-2009, applying impact excitation to the electric connector product, wherein the frequency range is 5-2000 Hz, the duration time is 15ms, the peak acceleration is 20g, and the frequency break point is 45 Hz. Realizing in-situ simulation of the real working state of the electric connector; the contact resistance values and the instant shake-off conditions of different contact elements of the electric connector are respectively monitored in real time in the impact test process, the peak value of the contact resistance of the electric connector and the number of times of instant shake-off signals appear in the test process are counted, and the results are shown in the following table.
TABLE 2 statistical table of contact resistance and instantaneous chatter-break conditions of different contact elements of electric connector in impact test process
Number of impacts Contact resistance peak (m omega) Number of instant jittering signal
1 st time 10.26 2
2 nd time 9.53 4
3 rd time 15.98 8
4 th time 20.29 5
5 th time 18.37 7
In summary, in the analog diagnosis method of the present invention, by adding the vibrating table, the electric sliding table, and the three-dimensional sliding table to the analog diagnosis device, in-situ simulation of various actual use states of the electric connector product is realized on hardware; through the arrangement of the four detection modes, the actual use state of an electric connector product can be simulated most closely, the detection is carried out in the actual use process, and the in-situ simulation and online diagnosis capability of the contact failure of the electric connector is improved; the contact resistance of the key performance parameter of the electric connector is monitored in real time, real-time data is provided, and data support and improvement of the performance of the electric connector are provided for the failure of the electric connector.
The above-mentioned embodiments are merely illustrative of the preferred embodiments of the present invention, and do not limit the scope of the present invention, and various modifications and improvements made to the technical solution of the present invention by those skilled in the art without departing from the spirit of the present invention shall fall within the protection scope defined by the claims of the present invention.

Claims (8)

1. An in-situ simulation and online diagnosis method for contact failure of an electric connector is characterized by comprising the following steps:
s1, simulating and diagnosing fretting wear failure continuously occurring in a normal insertion state on line, and specifically comprising the following steps:
s11, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s12, installing and fixing an electric connector pin on the sliding end face of the electric sliding table through a pin end clamp, installing and fixing an electric connector jack end on the movable end face of the angular position table through a jack end clamp, fixing the angular position table on the sliding end face of the first three-dimensional sliding table, adjusting the angular position table and the first three-dimensional sliding table to enable the jack end of the electric connector to be completely overlapped with the axis of the pin, and setting the insertion depth of the pin to enable the electric sliding table to drive the electric connector pin to be inserted into the electric connector jack along the axis of the electric connector pin;
s13, controlling the electric sliding table to do reciprocating sliding motion with fixed amplitude and fixed frequency, simultaneously respectively connecting two ends of the electric connector into a contact resistance testing instrument to obtain a contact resistance real-time waveform, and recording the response frequency and amplitude of the contact resistance;
s14, setting simulation diagnosis stopping conditions, and stopping simulation diagnosis when the contact resistance meets any one of the following conditions;
one of the conditions is: observing the corresponding relation between the response frequency and amplitude of the contact resistor and the reciprocating sliding frequency, recording the reciprocating sliding cycle times when the peak value of the response frequency of the contact resistor is 3 times of the initial contact resistance value, and stopping analog diagnosis;
the second condition is as follows: when the contact resistance has 3 instantaneous shake-off signals, recording the times of the reciprocating sliding period, and stopping the simulation diagnosis;
s2, simulating and diagnosing the sliding wear failure which continuously occurs in the normal insertion state on line, and the method comprises the following specific steps:
s21, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s22, mounting the electric connector on the simulation diagnosis device according to the method of the step S12;
s23, controlling the vibration table to perform sine frequency sweep vibration, wherein the sine frequency sweep vibration adopts fixed frequency and fixed vibration acceleration, and meanwhile, two ends of the electric connector are respectively connected to a contact resistance testing instrument to obtain a contact resistance real-time waveform and record the response frequency and amplitude of the contact resistance;
s24, observing the response frequency and amplitude of the contact resistance, and recording the response peak value of the contact resistance, namely the vibration frequency point or frequency range with violent fluctuation degree of the contact resistance peak value;
s25, setting simulation diagnosis stopping conditions, and stopping simulation diagnosis when the contact resistance meets any one of the following conditions;
one of the conditions is: selecting proper power spectral density to carry out fixed-frequency random vibration, monitoring the response of the contact resistor in real time, recording the reciprocating sliding cycle times when the response peak value of the contact resistor is 3 times of the initial contact resistance value, and stopping analog diagnosis;
the second condition is as follows: when the contact resistance has 3 instantaneous shake-off signals, recording the times of the reciprocating sliding period, and stopping the simulation diagnosis;
s3, simulating the plug contact failure in the eccentric insertion state and carrying out online diagnosis, and the method specifically comprises the following steps:
s31, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s32, installing and fixing an electric connector pin on a sliding end face of an electric sliding table through a pin end clamp, installing and fixing an electric connector jack end on a movable end face of an angle position table through a pin end clamp, fixing the angle position table on a sliding end face of a first three-dimensional sliding table, adjusting the angle position table and the first three-dimensional sliding table to enable the jack end to deviate from a pin hole central axis by +/-3 to +/-5 degrees, adjusting the position of a jack end force sensor through adjusting a second three-dimensional sliding table, setting the insertion depth of the pin, and driving the electric sliding table to eccentrically insert the electric connector pin into an electric connector jack;
s33, after the electric connector is installed and fixed, simultaneously, two ends of the electric connector are respectively connected into a contact resistance testing instrument, the plugging times and the plugging speed are set, an electric sliding table drives a contact pin to be plugged into and pulled out of a jack, and the waveform of the dynamic contact resistance is recorded;
s34, setting simulation diagnosis stopping conditions, and stopping simulation diagnosis when the contact resistance meets any one of the following conditions;
one of the conditions is: observing the corresponding relation between the response frequency and the amplitude of the contact resistor and the reciprocating sliding frequency, stopping the simulation diagnosis when the response peak value of the contact resistor is 3 times of the initial contact resistance value, and recording the reciprocating sliding cycle times;
the second condition is as follows: when the contact resistance has 3 times of instant shake-off signals, stopping the simulation diagnosis and recording the times of the reciprocating sliding period;
stopping the simulation diagnosis and recording the plugging times when the peak value of the dynamic contact resistance is 3 times of the initial contact resistance value; when the contact resistance has 3 times of instant shake-off signals, stopping the simulation diagnosis and recording the plugging times;
s4, simulating and diagnosing vibration impact contact failure in an eccentric insertion state in the actual use process of the electric connector on line, wherein the specific steps are as follows:
s41, carrying out initial contact resistance test on the qualified electric connector to obtain an initial contact resistance value;
s42, after the electric connector is well installed and fixed according to the step S31, the electric sliding table drives the contact pin to be eccentrically inserted into the jack;
s43, simultaneously, respectively connecting two ends of the electric connector into a contact resistance testing instrument, controlling a vibration table to apply standard impact response vibration to the electric connector, performing an impact test, and recording the dynamic contact resistance waveform of the electric connector in the impact test process;
s44, setting simulation diagnosis stopping conditions, and stopping simulation diagnosis when the contact resistance meets any one of the following conditions;
one of the conditions is: observing the response frequency and amplitude of the contact resistor and the corresponding relation between the response frequency and the reciprocating sliding frequency, recording the reciprocating sliding cycle times when the response peak value of the contact resistor is 3 times of the initial contact resistance value, and stopping analog diagnosis;
the second condition is as follows: and when the contact resistance generates 3 instantaneous shake-off signals, recording the times of the reciprocating sliding period, and stopping the analog diagnosis.
2. The method of in-situ simulation and in-line diagnosis of contact failure of an electrical connector of claim 1, wherein the insertion depth of the pin is greater than or equal to 70% of the minimum hole depth of the receptacle.
3. The in-situ simulation and online diagnosis method for contact failure of the electrical connector according to claim 1, wherein in step S12, the fixed amplitude value interval of the electric sliding table is controlled to be 0-10 um, and the fixed frequency value interval is controlled to be 1-10 Hz.
4. The method for in-situ simulation and online diagnosis of contact failure of electrical connector according to claim 1, wherein the fixed frequency range in step S22 is 0-2000 Hz, and the fixed vibration acceleration range is 1-10 g, wherein g is 9.8m/S2
5. The in-situ simulation and online diagnosis method for contact failure of the electrical connector as claimed in claim 1, wherein the suitable power spectral density in step S24 has a value range of 0-1 g2/Hz。
6. The method for in-situ simulation and online diagnosis of contact failure of an electrical connector according to claim 5, wherein the range of power spectral density suitable in step S24 is specifically tailored according to the environment in which the product is used.
7. The method for in-situ simulation and online diagnosis of contact failure of electrical connector according to claim 1, wherein the contact resistance tester is a contact resistance tester capable of monitoring instantaneous values of contact resistance in real time and having a function of monitoring a chattering-off signal of 1 us.
8. The in-situ simulation and online diagnosis method for contact failure of the electrical connector according to claim 1, wherein the range of the plugging times in the step S32 is 0-500 times, and the range of the plugging speed is 1-10 mm/S.
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