CN115856722A - Method for predicting contact reliability of electric connector considering friction wear - Google Patents
Method for predicting contact reliability of electric connector considering friction wear Download PDFInfo
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Abstract
The invention discloses an electric connector contact reliability prediction method considering frictional wear, which takes a circular wire spring contact electric connector as an example, mainly considers the contact failure mode of the electric connector caused by frictional wear, and establishes a frictional wear failure physical model reflecting the performance degradation rule of the electric connector under the action of failure inducement (including working stress, environmental stress, time stress and the like) by analyzing the internal reason and mechanism of the electric connector which has the performance degradation such as the reduction of insertion force, the increase of contact resistance and the like under the action of vibration stress, thereby realizing the accurate prediction of the contact reliability of the electric connector. The invention solves the problem that the traditional reliability prediction method is difficult to quantify the influence of the product quality consistency information (material, structure and process data fluctuation) on the product reliability.
Description
Technical Field
The invention relates to a method for predicting the reliability of an electric connector product, in particular to a method for predicting the contact reliability of an electric connector with a circular wire spring contact element by considering a friction and wear mechanism.
Background
The wire spring contact mainly comprises wire spring hole, contact pin, sheath etc. and the electric contact between the pinhole relies on the fixed a plurality of coil spring superposes in inside both ends in wire spring hole to realize, and the coil spring that superposes together can take place elastic deformation when the contact pin inserts, takes place the multiple spot contact with the contact pin, and less deformation volume can provide great elastic force, has the reliable but relatively complicated characteristics of processing assembly of contact.
The frictional wear of the contact generally refers to a phenomenon in which the contact interface of the elastic contact of the electrical connector is damaged due to a long-lasting cyclic reciprocating motion having an amplitude of several tens of nanometers to several hundreds of micrometers occurring at the contact interface due to the presence of a continuous external stress or load, etc. Statistically, 70% of electrical contact failures in electrical systems and more than 60% of failures in automotive electrical systems are associated with frictional wear. The frictional wear of the contact piece is mainly related to the 4 types of influencing factors: (1) Environmental factors, which refer to temperature, humidity, atmosphere, and the like; (2) Contact conditions, which refer to the contact form and contact pressure between the elastic contact pieces, and the like; (3) The performance of the elastic material refers to the material property of the coating material, the coating thickness, the material property of the substrate material and the like; and (4) vibration conditions, namely amplitude, frequency and the like of vibration. The microscopic manifestations of frictional wear are the gradual stripping of plating material, the uncovering and oxidation of base material, and the accumulation of debris at the contact interface of the elastic contact piece during vibration, resulting in the contact resistance of the contact piece rising and thus contact failure. Factors such as temperature, humidity and atmosphere, contact form and contact pressure, material properties (electrical conductivity, hardness and reactivity) and coating thickness of the coating material, amplitude and frequency of vibration directly influence the abrasion rate of a contact interface, the oxidation rate of a substrate material, the accumulation amount and the accumulation rate of pollutants, and macroscopically can be represented as the reciprocating cycle number of vibration when the contact resistance exceeds a failure threshold value.
Due to the influence of external mechanical environment factors such as vibration and impact, the frictional wear occurs on the electrical contact interface of the wire spring contact, the contact characteristics of the electrical connector are seriously damaged, the contact failure becomes one of the main failure modes of the electrical connector, and the frictional wear becomes one of the main failure mechanisms of the electrical connector. The traditional reliability prediction method which only depends on mathematical statistics cannot accurately describe the internal mechanism and rule of performance degradation such as reduction of insertion force and increase of contact resistance of the contact characteristic of the circular wire spring contact electric connector under the action of friction and abrasion, so that the accuracy of prediction of the contact reliability of the electric connector is poor. Therefore, how to realize the contact reliability of the circular wire spring contact electric connector considering the friction wear mechanism is expected to become a problem to be solved urgently.
Disclosure of Invention
In order to solve the problem that the traditional reliability prediction method which only depends on mathematical statistics cannot accurately describe the mechanism and the rule of the performance degradation of the electric connector under the action of failure inducement, so that the prediction accuracy of the contact reliability is poor, the invention provides the electric connector contact reliability prediction method considering friction and wear based on the combination of the failure physics and the mathematical statistics.
The purpose of the invention is realized by the following technical scheme:
an electrical connector contact reliability prediction method considering frictional wear, comprising the steps of:
the method comprises the following steps: establishing a digital prototype model Y = F (X) of the round wire spring contact electric connector according to a design drawing and a process file of the round wire spring contact electric connector, and describing the insertion and extraction force X of the round wire spring contact F Contact resistance X R Equal input parameter X = [ X ] F ,X R ]Complete machine plugging force Y of electric connector with circular wire spring contact element F And the contact resistance Y of the whole machine R Equal output parameter Y = [ Y ] F ,Y R ]An input-output relationship therebetween;
step two: for the wire spring contact (namely the key part of the electric connector), the wire spring contact reliability test research considering the friction and wear mechanism is developed, and the wire spring contact insertion and extraction force and contact resistance degradation data under different environmental conditions E, load conditions L, material parameters M, structural parameters C, process parameters T and other combinations are obtained through the friction and wear contact reliability test, wherein:
the reliability test studies take into account input factors including: environmental conditions E (temperature, vibration amplitude, frequency, etc.), load conditions L (voltage, current, etc.), wire spring contact material parameters M (young's modulus, poisson's ratio, etc.), wire spring contact structure parameters C (size parameters, etc.), wire spring contact process parameters T (processing parameters, assembly parameters, etc.), and output factors include: wire spring contact element insertion and extraction force X F Contact resistance X of wire spring contact element R ；
Step three, establishing a frictional wear failure physical model of the wire spring contact element according to the frictional wear contact reliability test data, wherein the frictional wear failure physical model is used for describing the insertion and extraction force X of the wire spring contact element F And contact resistance X R A rule of degradation with time T under different environmental conditions E, loading conditions L, material parameters M, structural parameters C, process parameters T, and the like, wherein:
the wire spring contact piece frictional wear failure physical model comprises a frictional wear failure physical model X of the insertion and extraction force of the wire spring contact piece F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance of a physical model X of frictional wear failure R ＝P 2 (E,L,M,C,T,X Ro ,t)，X Fo For wire spring contact element insertion and extraction force X F Initial value at time t =0, X Ro For contact resistance X of wire spring contact R Initial value at time t = 0;
step four: the initial value X of the insertion and extraction force of the wire spring contact element caused by the fluctuation of materials, structures and process parameters is obtained through statistics by utilizing the quality consistency information of the production process of the wire spring contact element Fo Initial value X of contact resistance of contact piece of wire spring Ro Distribution mean value of X And standard deviation σ X Based on the Monte Carlo stochastic process theory, according to X Fo And X Ro Fluctuation range mu of X ±6σ X Randomly generating N groups of normally distributed batch wire spring contact piece virtual samples by utilizing independent and identically distributed central limit theorem when t =0Initial value of X o1 ＝[X Fo1 ,X Ro1 ]、X o2 ＝[X Fo2 ,X Ro2 ]、...、X oN ＝[X FoN ,X RoN ]Wherein:
the quality consistency information comprises related data which are generated by the wire spring contact in the process flows of part processing, assembly, debugging and the like on the whole production line and can reflect the process capability of the working procedure;
step five: setting the initial value X of the batch wire spring contact virtual sample constructed in the fourth step at the time t =0 o1 、X o2 、...、X oN Substituting the wire spring contact element insertion and extraction force frictional wear failure physical model X established in the step three F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance frictional wear failure physical model X R ＝P 2 (E,L,M,C,T,X Ro T) obtaining the insertion and extraction force X of the batch of wire spring contacts F And contact resistance X R A rule of degradation over time T under different environmental conditions E, loading conditions L, material parameters M, structural parameters C, process parameters T and the like; then the insertion and extraction force X of the wire spring contact pieces in the batch is used F And contact resistance X R Substituting the rule of degradation along with the time t into the digital prototype model Y = F (X) of the round wire spring contact electric connector established in the step one to obtain the output characteristic Y = [ Y ] of the round wire spring contact electric connector in batch F ,Y R ]A rule of degradation with time T under different environmental conditions E, loading conditions L, material parameters M, structural parameters C, process parameters T and the like, and T is i The output characteristic of a time batch circular wire spring contact electric connector virtual sample is Y 1 (t i )＝[Y F1 (t i ),Y R1 (t i )],…,Y N (t i )＝[Y FN (t i ),Y RN (t i )]；
Step six: according to the complete machine plugging force distributed to the circular wire spring contact electric connector when the electronic system works reliably and the qualified threshold value of the complete machine contact resistance, determining the output characteristic Y = [ Y ] F ,Y R ]Allowable stress σ = [ σ ] F ,σ R ]Using the batch round obtained in step fiveWire spring contact electrical connector dummy sample at t i Output characteristic Y of time 1 (t i )＝[Y F1 (t i ),Y R1 (t i )],…,Y N (t i )＝[Y FN (t i ),Y RN (t i )]And determining the number of contact failures in the sample according to a stress-intensity interference theory so as to calculate the contact reliability at the current moment.
Compared with the prior art, the invention has the following advantages:
the invention solves the problem that the traditional reliability prediction method is difficult to quantify the influence of product quality consistency information (material, structure and process data fluctuation) on the product reliability, and obtains the degradation rule and distribution of the performance parameters of the batch of circular wire spring contact electric connectors along with time by establishing a digital prototype model and a wire spring contact friction wear failure physical model of the circular wire spring contact electric connectors and constructing the batch of wire spring contact virtual samples by using the quality consistency information, thereby obtaining the contact reliability of the circular wire spring contact electric connectors at a certain moment according to the stress-intensity interference theory, and ensuring the correctness and the accuracy of the contact reliability prediction result.
Drawings
FIG. 1 is a flow chart of an implementation of a method for predicting contact reliability of an electrical connector considering frictional wear;
FIG. 2 is a physical modeling flow of wire spring contact friction wear failure.
Detailed Description
The technical solution of the present invention is further described below with reference to the accompanying drawings, but not limited thereto, and any modification or equivalent replacement of the technical solution of the present invention without departing from the spirit and scope of the technical solution of the present invention shall be covered by the protection scope of the present invention.
The invention provides a method for predicting the contact reliability of an electric connector considering frictional wear, which takes a circular wire spring contact electric connector as an example, mainly considers the contact failure mode of the electric connector caused by frictional wear, and establishes a frictional wear failure physical model reflecting the performance degradation rule of the electric connector under the action of failure inducement (including working stress, environmental stress, time stress and the like) by analyzing the internal causes and the mechanisms of the electric connector which have the performance degradation such as the reduction of insertion and extraction force, the increase of contact resistance and the like under the action of vibration stress, thereby realizing the accurate prediction of the contact reliability of the electric connector. As shown in fig. 1, the specific implementation steps are as follows:
the method comprises the following steps: according to the design drawing and the process file of the circular wire spring contact electric connector, a digital prototype model Y = F (X) is established based on the Kriging method and is used for describing the insertion and extraction force X of the circular wire spring contact F Contact resistance X R Equal input parameter X = [ X ] F ,X R ]Complete machine plugging force Y of electric connector with circular wire spring contact element F Contact resistance Y of the whole machine R Equal output parameter Y = [ Y ] F ,Y R ]The input-output relationship between. Wherein the input parameter X is the insertion and extraction force X of the circular wire spring contact piece caused by frictional wear under the vibration stress F Contact resistance X R Characteristic parameter X = [ X ] that degrades over time F ,X R ](ii) a The output parameter Y is the complete machine plugging and unplugging force Y of the circular wire spring contact element electric connector caused by friction and abrasion under the action of vibration stress F Contact resistance Y with the whole machine R Characteristic parameter Y = [ Y ] deteriorating with time F ,Y R ]。
Step two: for wire spring contacts (namely key parts of an electric connector), wire spring contact reliability test research considering a friction wear mechanism is carried out, and input factors considered in the test research comprise: environmental conditions E (temperature, vibration amplitude, frequency, etc.), load conditions L (voltage, current, etc.), wire spring contact material parameters M (young's modulus, poisson's ratio, etc.), wire spring contact structure parameters C (dimensional parameters, etc.), wire spring contact process parameters T (machining parameters, assembly parameters, etc.), and the output factors considered by experimental research include: wire spring contact element insertion and extraction force X F Contact resistance X of wire spring contact element R And obtaining the wire spring contact element insertion and extraction force and contact resistance degradation data under different combinations of environmental conditions E, load conditions L, material parameters M, structural parameters C, process parameters T and the like through a friction, abrasion and contact reliability test.
Step three: establishing a frictional wear failure physical model X of the insertion and extraction force of the wire spring contact element according to frictional wear contact reliability test data F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance of a physical model X of frictional wear failure R ＝P 2 (E,L,M,C,T,X Ro T) for describing the insertion and extraction force X of a wire spring contact F And contact resistance X R Law of degradation with time T under different environmental conditions E, loading conditions L, material parameters M, structural parameters C, process parameters T and the like, wherein X Fo Is the insertion and extraction force X of the wire spring contact element F Initial value at time t =0, X Ro For contact resistance X of wire spring contact R Initial values at time t =0, i.e.:
X Fo ＝P 1 (E,L,M,C,T,t＝0)X Ro ＝P 2 (E,L,M,C,T,t＝0)(1)。
as shown in FIG. 2, a frictional wear failure physical model X of the wire spring contact piece insertion and extraction force is established according to the following steps F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance of the frictional wear failure physical model X R ＝P 2 (E,L,M,C,T,X Ro ,t)：
Step three, firstly: under the conditions of known environmental conditions E, load conditions L, material parameters M, structural parameters C, process parameters T and the like, the wire spring contact piece insertion and extraction force X at different time T is measured in an experiment F Contact resistance X R The mass loss m of friction and abrasion and the establishment of the wire spring contact piece insertion and extraction force X F Contact resistance X R Functional relationship X = [ X ] with time t, mass loss m F ,X R ]＝G 1 (m,t,X Fo ,X Ro ) Wherein the wire spring contact insertion and extraction force X at the moment t =0 F And contact resistance X R Is defined as the initial value X of the wire spring contact element insertion and extraction force Fo And initial value X of contact resistance Ro 。
Step three: obtaining a contact positive pressure F between pinholes of the wire spring contact member based on simulation and actual measurement data of a virtual prototype according to the material parameters M, the load conditions L, the structure parameters C and the process parameters T of the wire spring contact member n Establishing wire spring contact needleKong Jianjie tactile pressure F n Functional relationship F with material parameter M, load condition L, structure parameter C and process parameter T n ＝G 2 (M,L,C,T)。
Step three: the frictional wear volume V can be expressed as a wear rate K, an environmental condition E, and a contact positive force F between the pin holes of the wire spring contact according to the Archard wear equation n I.e. V = G 3 (K,E,F n )。
Step three and four: under the condition of known density rho and wear rate K of the surface coating of the wire spring contact piece, the insertion and extraction force X of the wire spring contact piece can be established F Contact resistance X R Functional relation with environmental condition E, load condition L, material parameter M, structure parameter C, process parameter T and time T, namely X = [ X = F ,X R ]＝G 1 (m,t,X Fo ,X Ro )＝G 1 (V·ρ,t,X Fo ,X Ro )＝G 1 [G 3 (K,E,F n )·ρ,t,X Fo ,X Ro ]＝G 1 {G 3 [K,E,G 2 (M,L,C,T)]·ρ,t,X Fo ,X Ro }＝P(E,L,M,C,T,X Fo ,X Ro T) to establish a frictional wear failure physical model X of the insertion and extraction force of the wire spring contact piece F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance of a physical model X of frictional wear failure R ＝P 2 (E,L,M,C,T,X Ro ,t)。
Step four: the initial value X of the wire spring contact insertion and extraction force caused by fluctuation of materials, structures and technological parameters is obtained through statistics by utilizing the quality consistency information of the wire spring contact production process (namely, the wire spring contact is generated in the technological processes of part processing, assembly, debugging and the like on the whole production line and can reflect the relevant data of the process capacity of the process) Fo Initial value X of contact resistance of contact piece with wire spring Ro Distribution mean value of X ＝[μ XFo ,μ XRo ]And standard deviation σ X ＝[σ XFo ,σ XRo ]. Based on Monte Carlo random process theory, according to X Fo And X Ro Fluctuation range mu of X ±6σ X Randomly generating N groups by using independent and identically distributed central limit theoremArray [ X ] conforming to normal distribution Fo1 ,X Ro1 ]、[X Fo2 ,X Ro2 ]、...、[X FoN ,X RoN ]That is, the initial values X of N groups of normally distributed virtual samples of the wire spring contact pieces in the batch at the time t =0 are randomly generated o1 ＝[X Fo1 ,X Ro1 ]、X o2 ＝[X Fo2 ,X Ro2 ]、...、X oN ＝[X FoN ,X RoN ]。
Step five: setting the initial value X of the batch wire spring contact virtual sample constructed in the fourth step at the time t =0 o1 ＝[X Fo1 ,X Ro1 ]、X o2 ＝[X Fo2 ,X Ro2 ]、...、X oN ＝[X FoN ,X RoN ]Substituting the wire spring contact element insertion and extraction force frictional wear failure physical model X established in the step three F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance frictional wear failure physical model X R ＝P 2 (E,L,M,C,T,X Ro T) obtaining the insertion and extraction force X of the batch of wire spring contacts F And contact resistance X R The law of degradation with time T under different environmental conditions E, loading conditions L, material parameters M, structural parameters C, process parameters T and the like. Then the insertion and extraction force X of the wire spring contact pieces in the batch is used F And contact resistance X R Substituting the rule of degradation along with time t into the digital prototype model Y = F (X) = F [ X ] of the circular wire spring contact electric connector established in the step one F ,X R ]In the method, the output characteristics (complete machine plugging force and complete machine contact resistance) Y = [ Y ] of the batch circular wire spring contact electric connector can be obtained F ,Y R ]The rule of degradation with time T under different environmental conditions E, loading conditions L, material parameters M, structural parameters C, process parameters T and the like, namely Y (T) = [ Y F (t),Y R (t)]＝F(X F ,X R )＝F[P 1 (E,L,M,C,T,X Fo ,t),P 2 (E,L,M,C,T,X Ro ,t)]And t is i The output characteristic of a time batch circular wire spring contact electric connector virtual sample is Y 1 (t i )＝[Y F1 (t i ),Y R1 (t i )],…,Y N (t i )＝[Y FN (t i ),Y RN (t i )]。
Step six: according to the complete machine plugging and unplugging force distributed to the circular wire spring contact electric connector when an electronic system works reliably and the qualified threshold value of the complete machine contact resistance, determining the output characteristic Y = [ Y ] F ,Y R ]Allowable stress σ = [ σ ] F ,σ R ]. When the round wire spring contact element electric connector is in use, the whole machine plugging and unplugging force Y F Contact resistance Y with the whole machine R Degradation over time to an acceptable threshold σ F And σ R That is, when the performance strength is lower than the allowable stress, although the circular wire spring contact electric connector does not have the function failure, the whole machine plugging force and the whole machine contact resistance performance are degraded to cause the contact failure. Using the virtual sample of the batch round wire spring contact electric connector obtained in the fifth step at t i Output characteristic Y of time 1 (t i )＝[Y F1 (t i ),Y R1 (t i )],…,Y N (t i )＝[Y FN (t i ),Y RN (t i )]And respectively judging whether each sample has contact failure according to a stress-intensity interference theory.
When equation (2) is satisfied, a circular wire spring contact electric connector dummy sample with the number l is explained at t i Contact failure occurs at all times.
Y l (t i )＝[Y Fl (t i ),Y Rl (t i )]＜[σ F ,σ R ]l＝1,···,N (2)
Definition H d ＝[H F ,H R ]Is t i Set of time contact failure samples, N (H) d ) Is a set H d ＝[H F ,H R ]Number of samples in, the round wire spring contact electric connector is at t i Contact reliability at time R d (t i ) Comprises the following steps:
Claims (7)
1. a method for predicting contact reliability of an electrical connector considering frictional wear, the method comprising the steps of:
the method comprises the following steps: establishing a digital prototype model Y = F (X) of the round wire spring contact electric connector according to a design drawing and a process file of the round wire spring contact electric connector, and describing the insertion and extraction force X of the round wire spring contact F Contact resistance X R Input parameter X = [ X ] F ,X R ]Complete machine plugging force Y of electric connector with round wire spring contact element F Contact resistance Y of the whole machine R Output parameter Y = [) F ,Y R ]An input-output relationship therebetween;
step two: aiming at the wire spring contact, carrying out a wire spring contact reliability test study considering a frictional wear mechanism, and obtaining wire spring contact insertion and extraction force and contact resistance degradation data under different environmental conditions E, loading conditions L, material parameters M, structure parameters C and process parameters T through a frictional wear contact reliability test;
step three, establishing a frictional wear failure physical model of the wire spring contact piece according to the frictional wear contact reliability test data, wherein the physical model is used for describing the insertion and extraction force X of the wire spring contact piece F And contact resistance X R The rule of degradation over time T under different environmental conditions E, loading conditions L, material parameters M, structural parameters C and process parameters T;
step four: the initial value X of the insertion and extraction force of the wire spring contact element caused by the fluctuation of materials, structures and process parameters is obtained through statistics by utilizing the quality consistency information of the production process of the wire spring contact element Fo Initial value X of contact resistance of contact piece of wire spring Ro Distribution mean value of X And standard deviation σ X Based on the Monte Carlo stochastic process theory, according to X Fo And X Ro Fluctuation range mu of X ±6σ X Randomly generating N groups of initial values X of batch wire spring contact virtual samples conforming to normal distribution at the time t =0 by utilizing independent same-distribution central limit theorem o1 ＝[X Fo1 ,X Ro1 ]、X o2 ＝[X Fo2 ,X Ro2 ]、...、X oN ＝[X FoN ,X RoN ]；
Step five: setting the initial value X of the batch wire spring contact virtual sample constructed in the fourth step at the time t =0 o1 、X o2 、...、X oN Substituting the physical model X of the wire spring contact member insertion and extraction force frictional wear failure established in the step three F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance frictional wear failure physical model X R ＝P 2 (E,L,M,C,T,X Ro T) obtaining the insertion and extraction force X of the batch of wire spring contacts F And contact resistance X R The rule of degradation over time T under different environmental conditions E, loading conditions L, material parameters M, structural parameters C and process parameters T; then the insertion and extraction force X of the wire spring contact pieces in the batch is used F And contact resistance X R Substituting the rule of degradation along with the time t into the digital prototype model Y = F (X) of the round wire spring contact electric connector established in the step one to obtain the output characteristic Y = [ Y ] of the round wire spring contact electric connector in batch F ,Y R ]Law of degradation with time T under different environmental conditions E, loading conditions L, material parameters M, structural parameters C and process parameters T, and T i The output characteristic of a time batch circular wire spring contact electric connector virtual sample is Y 1 (t i )＝[Y F1 (t i ),Y R1 (t i )],…,Y N (t i )＝[Y FN (t i ),Y RN (t i )]；
Step six: according to the complete machine plugging force distributed to the circular wire spring contact electric connector when the electronic system works reliably and the qualified threshold value of the complete machine contact resistance, determining the output characteristic Y = [ Y ] F ,Y R ]Allowable stress σ = [ σ ] F ,σ R ]Using the virtual sample of the batch round wire spring contact electric connector obtained in the fifth step at t i Output characteristic Y of time 1 (t i )＝[Y F1 (t i ),Y R1 (t i )],…,Y N (t i )＝[Y FN (t i ),Y RN (t i )]And determining the number of contact failures in the sample according to a stress-intensity interference theory so as to calculate the contact reliability at the current moment.
2. The method for predicting contact reliability of an electrical connector considering frictional wear as set forth in claim 1, wherein in the second step, the reliability test studies considering input factors include: environmental condition E, load condition L, wire spring contact material parameter M, wire spring contact structure parameter C, wire spring contact process parameter T, the output factor includes: wire spring contact element insertion and extraction force X F Contact resistance X of wire spring contact element R 。
3. The method for predicting contact reliability of an electrical connector considering frictional wear according to claim 1, wherein the physical model of frictional wear failure of the wire spring contact comprises a physical model X of frictional wear failure of insertion and extraction force of the wire spring contact in the third step F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance of a physical model X of frictional wear failure R ＝P 2 (E,L,M,C,T,X Ro ,t)，X Fo For wire spring contact element insertion and extraction force X F Initial value at time t =0, X Ro Contact resistance X for wire spring contact R Initial value at time t = 0.
4. The method of claim 3, wherein the physical model X of the wire spring contact insertion and extraction force is a physical model of frictional wear failure F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance of a physical model X of frictional wear failure R ＝P 2 (E,L,M,C,T,X Ro And t) is established as follows:
step three, firstly: under the conditions of known environmental conditions E, load conditions L, material parameters M, structure parameters C and process parameters T, the wire spring contact piece insertion and extraction force X at different time T is measured in an experiment F Contact resistance X R The mass loss m of friction and abrasion and the establishment of the wire spring contact piece insertion and extraction force X F Contact resistance X R Functional relationship X = [ X ] with time t, mass loss m F ,X R ]＝G 1 (m,t,X Fo ,X Ro ) Which isWire spring contact piece insertion and extraction force X at middle t =0 moment F And contact resistance X R Is defined as the initial value X of the wire spring contact element insertion and extraction force Fo And initial value X of contact resistance Ro 。
Step three: obtaining a contact positive pressure F between the pinholes of the wire spring contact based on simulation and actual measurement data of a virtual prototype according to the material parameters M, the load conditions L, the structural parameters C and the process parameters T of the wire spring contact n Establishing a contact positive pressure F between the needle holes of the wire spring contact n Functional relationship F with material parameter M, load condition L, structural parameter C and process parameter T n ＝G 2 (M,L,C,T)；
Step three: the frictional wear volume V is expressed as wear rate K, environmental condition E and contact positive pressure F between wire spring contact pin holes according to Archard's wear equation n I.e. V = G 3 (K,E,F n )；
Step three and four: under the condition of known surface coating density rho and wear rate K of the wire spring contact element, establishing the insertion and extraction force X of the wire spring contact element F Contact resistance X R Functional relation with environmental condition E, load condition L, material parameter M, structure parameter C, process parameter T and time T, namely X = [ X = F ,X R ]＝G 1 (m,t,X Fo ,X Ro )＝G 1 (V·ρ,t,X Fo ,X Ro )＝G 1 [G 3 (K,E,F n )·ρ,t,X Fo ,X Ro ]＝G 1 {G 3 [K,E,G 2 (M,L,C,T)]·ρ,t,X Fo ,X Ro }＝P(E,L,M,C,T,X Fo ,X Ro T) to establish a frictional wear failure physical model X of the insertion and extraction force of the wire spring contact piece F ＝P 1 (E,L,M,C,T,X Fo T) and contact resistance of a physical model X of frictional wear failure R ＝P 2 (E,L,M,C,T,X Ro ,t)。
5. The method for predicting contact reliability of an electrical connector considering frictional wear as claimed in claim 1, wherein the quality consistency information includes data related to the process capability of the wire spring contact during the processes of machining, assembling and debugging the parts on the whole production line.
6. The method for predicting contact reliability of an electrical connector considering frictional wear as claimed in claim 1, wherein in the sixth step, the dummy sample of the electrical connector with the round wire spring contact with number l is judged at t i The method for generating contact failure at the moment comprises the following steps:
Y l (t i )＝[Y Fl (t i ),Y Rl (t i )]＜[σ F ,σ R ]l＝1,···,N。
7. the method for predicting contact reliability of an electrical connector considering frictional wear as set forth in claim 1, wherein in the sixth step, H is defined d ＝[H F ,H R ]Is t i Set of time contact failure samples, N (H) d ) Is a set H d ＝[H F ,H R ]Number of samples in, the round wire spring contact electric connector is at t i Contact reliability of time R d (t i ) Comprises the following steps:
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| CN117761443A (en) * | 2024-02-20 | 2024-03-26 | 青岛铭青机电有限公司 | Test device and method for testing wear degradation of contact parts in electric connector |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116776631A (en) * | 2023-07-05 | 2023-09-19 | 深圳市精微康投资发展有限公司 | Connector performance evaluation method and system based on data analysis |
| CN116776631B (en) * | 2023-07-05 | 2024-02-02 | 深圳市精微康投资发展有限公司 | Connector performance evaluation method and system based on data analysis |
| CN117761443A (en) * | 2024-02-20 | 2024-03-26 | 青岛铭青机电有限公司 | Test device and method for testing wear degradation of contact parts in electric connector |
| CN117761443B (en) * | 2024-02-20 | 2024-05-03 | 青岛铭青机电有限公司 | Test device and method for testing wear degradation of contact parts in electric connector |
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