KR101067271B1 - Method for counting dimensions of electrical connector - Google Patents

Abstract

*r_o, 상기 도선 압착부가 상기 와이어 심선을 감쌀 때, 압축높이는 H=2h+2r_c=2*(h+

*r_o) 에 의하여 연산된다.Disclosed is a method of calculating the dimensions of an electrical connector, the inner length and the compression height of which can be easily calculated by the formula. An electrical connector including a cover crimp portion surrounding the sheath of the wire, a wire crimp portion connected to the sheath crimp portion to crimp and wrap the core wire of the wire from the outside in the radial direction to the inside, and an electrode portion connected to the wire crimp portion; As a method for calculating the size of, the inner surface length formed along the radial direction of the wire crimp is calculated by the following formula, and lambda t = 2π *

r _o , when the wire crimp is wrapped around the wire core, the compression height is H = 2h + 2r _c = 2 * (h +

* r _o ).

Electrical connector, inner length, compression height

Description

Calculation method of electrical connector {METHOD FOR COUNTING DIMENSIONS OF ELECTRICAL CONNECTOR}

The present invention relates to a method for calculating the size of an electrical connector, and more particularly, by calculating the inner length and the crimp size of the wire crimping portion by a formula, the dimensioning of the electrical connector that can easily design electrical connectors corresponding to various wires It is about a method.

Recently, since automobiles are increasingly automated, the types and functions of electronic systems are diversified. In line with the diversification of such electronic systems, the proportion of electronic components is also increasing.

In particular, the electrical connector is mounted in a wiring harness (wiring harness) to serve as a power supply and various electrical signals transmission and distribution, it is used for the combination of the electronic unit (UNIT).

Therefore, as the number of wires is increased, a high reliability of an electrical connector connecting the wires to each other is required.

The electrical connector is a crimp attachment part surrounding the sheath by being crimped to the sheath of the wire, a conductor crimp part integrally connected to the sheath crimp part to crimp the core wire, and a terminal connected to the conductor crimp part and supplied with power. Include.

The electrical connector having such a structure is connected to one side of the wire as follows. That is, the wire crimp is placed on the upper portion of the fixed die, the core wire of the wire is disposed inside the wire crimp, and the wire crimp is crimped by using a punch to wrap the outer circumferential surface of the wire core.

At this time, the size of the wire crimp is an important factor when the electrical connector is crimped by a punch to wrap the core of the wire.

That is, when the inner surface length of the wire crimping portion is longer than a predetermined length, when the wire crimping portion is crimped by the punch, both sides of the wire crimping portion may overlap each other, thereby causing a defect.

On the contrary, when the inner surface length of the wire crimping portion is short, defects may occur because both sides of the wire crimping portion are far apart.

In addition, when the compression height of the wire crimping portion is a predetermined length or more, the specified compression ratio is 80% or less, so that the electrical connector may not be stably fixed to the end of the wire, and thus the electrical connector may be separated from the wire.

On the other hand, when the compression height is less than a certain length, the specified compression ratio is 80% or more, so that the electrical connector excessively compresses the wire, such that disconnection of the wire may occur.

As a result, as described above, if the inner length and the compression height of the wire crimp of the electrical connector are out of a certain range, it may cause a defect such as unsatisfactory compression ratio specification and excessive resistance change after crimping, which may affect the electrical performance of the electrical connector. It will have a big influence on the engine and various electric control sensors in the future driving of the car.

In addition, since the resistance of the electric connector changes according to the temperature change of the surrounding environment when driving a car, the contact resistance between the wire crimp and the wire changes according to the temperature change, so the dimensions of the wire crimp must be properly calculated. .

However, in the related art, as the size of the wire crimp is calculated by the designer's experience, it is difficult to calculate an appropriate inner surface length and a compression height corresponding to the diameter of the wire.

Moreover, bar terminals having appropriate dimensions should be selected according to the diameters of various wires, and there is a problem in that the dimensions should be calculated according to the designer's experience every time the terminal dimensions are selected.

Accordingly, the present invention has been made to solve the above problems, an object of the present invention is to provide a method for calculating the size of the electrical connector easy to design the terminal by calculating the inner surface length and the crimping height of the wire crimp unit by the formula. It is.

The present invention is provided to achieve the object as described above, the wire crimping portion for wrapping the sheath of the wire, the wire crimping portion is connected to the wire crimping portion crimping the core wire of the wire crimped inward along the radial direction from the outside As a method for calculating the size of an electrical connector comprising a portion and an electrode portion connected to the wire crimping portion,

The inner surface length formed along the radial direction of the wire crimp is calculated by Equation 1 below.

*r_o ------ 수식1λ _t = 2π *

* r _o ------ Equation 1

(α: compression rate, n is the number of wires, r _o is the radius of one wire core, r _c is the radius of bundle of wire cores after crimping)

When the wire crimp unit wraps the wire core, the compression height is calculated by Equation 2 below,

*r_o) ---수식 2H = 2h + 2r _c = 2 * (h +

r _o ) --- Equation 2

                  (H: compression height, h: wire crimp thickness)

In the above formula 1, the compressibility α is calculated by α = (S _C / S _O ) * 100%,

(S _{C :} Area of wire bundle after crimping, S _{O :} Area of wire bundle before crimping)

S _C of the compressibility And S _O is calculated by Equations 3 and 4 below,

S _C = π * r _C ² ------ Equation 3, S _O = n * π * r _O ² --------- Equation 4

(n: number of wires, r _o : radius of one wire core, r _c : radius of bundle of wire cores after crimping)

The r _c is calculated by Equation 5 below

*r_o -------- 수식 5r _c =

* r _o -------- Equation 5

*r_o로 정의되고,Circumference of the wire bundle λ _c is λ _c = 2π

defined as * r _o ,

Since λc is the same as the inner length of the electrical connector and λc = λt, the inner length and the compression height of the electrical connector can be calculated by Equation 1 and Equation 2. To provide.

As described above, the method for calculating the size of an electrical connector according to the present invention can easily calculate the inner length and the compression height according to a formula, and can quickly and easily calculate the dimensions of the electrical connector corresponding to various standard wires. There are advantages to it.

Hereinafter, a method for calculating the dimensions of an electrical connector according to an embodiment of the present invention will be described in detail with the accompanying drawings.

1 is a perspective view showing an electrical connector according to an embodiment of the present invention, Figure 2 is a view showing a state in which the wire and the electrical connector seated on a fixed die by a punch.

As shown in the drawing, the electrical connector 1 proposed by the present invention is integrally connected to the cover crimping part 3 surrounding the cover by being crimped on the cover of the wire W, and the cover crimping part 3 to be connected to the wire ( A wire wire crimp part 5 for crimping the core wire 2 of W), and an electrode part 7 connected to the wire crimp part 5 and supplied with power.

In the electrical connector having such a structure, the wire crimping portion 5 is seated on the upper surface of the fixed die 9 in an unfolded state. In addition, the core wire 2 of the wire W is seated on the conductive wire crimp part 5.

In this state, the punch 11 is lowered to press the conductive wire crimping portion 5 so that both sides of the conductive wire crimping portion 5 are compressed to surround the outer circumferential surface of the core wire 2.

In this case, when the inner surface length λ _{t of the} wire crimping portion 5, that is, the length of the inner circumferential surface of the wire crimping portion 5 is greater than or less than a predetermined length, the core wire 2 of the wire W may not be stably wrapped. .

That is, when the inner surface length λ _t of the conductive wire crimping portion 5 is short, both ends of the conductive wire crimping portion 5 do not completely wrap the core wire of the wire W, and the inner surface length λ _t is long. The ends are shifted or overlapped.

Therefore, the inner surface length λ _t of the appropriate conductor crimping portion 5 can be calculated through the following calculation method.

That is, as shown in Figure 3, first, the compression rate (α) should be calculated in the pressing process, the compression rate (α) is defined as the ratio of the area of the bundle of the wire core wire (2) before and after the pressing.

α = (S _C / S _O ) * 100%

In Equation 1, S _C is the area of the wire core wire bundle after crimping, S _O means the area of the wire bundle before crimping.

In this case, S _C and S _O may be calculated by Equation 2 below.

S _C = π * r _C ² , S _O = n * π * r _O ²

(n: number of wires, r _o : radius of one wire core, r _c : radius of bundle of wire cores after crimping)

Therefore, the operator measures the number of wires, the radius of one wire core and the radius of the wire core bundle after crimping.

In Equations 1 and 2, r _c is calculated by Equation 3 below.

r_c=*r_o

r _c = * r _o

In addition, the circumferential length λ _c of the wire core wire after crimping may be defined by Equation 4 below.

λ_c=2π*r_o

λ _c = 2π * r _o

(r _c : bundle radius of wire core after crimping, λ _c : circumference of wire core wire after crimping)

At this time, the operator can measure the circumferential length of the wire core wire after the crimp.

In addition, assuming that the inner surface length λ _t of the wire crimping portion 5 before and after crimping does not change, the inner surface length λ _t becomes equal to the circumferential length λ _c of the wire core wire bundle after the crimping.

Therefore, the inner surface length λ _t of the wire crimping portion 5 can be calculated by the following expression (5).

λ_t=λ_c=2π**r_o

λ _t = λ _c = 2π ** r _o

On the other hand, the compression height (H) can be calculated through the calculation method shown in FIG. At this time, the crimping height (H) is closely related to the compressibility of the wire core. That is, the compression rate of the wire core wire 2 is prescribed | regulated to maintain 80%.

Therefore, assuming that the cross-sectional shape after the crimp is circular and the thickness of the wire crimp 5 is unchanged, the crimp height H can be defined by Equation 6 below.

H=2h+2r_c=2*(h+*r_o)

H = 2h + 2r _c = 2 * (h + * r _o )

(h: thickness of wire crimp (terminal), n: number of wires, r _o : radius of one wire core, r _c : radius of bundle of wire core after crimping)

At this time, the worker actually measures the thickness of the wire crimp.

On the other hand, since the inner surface length (λt) and the crimping height (H) of the wire crimping portion 5 calculated by Equations 4 and 5 are theoretical values, they are approximated to the dimensions when the wire crimping portion 5 is actually crimped. It is necessary to correct by reflecting the actual experience values (λ _{t1 ,} H ₁ ).

That is, when the correction coefficient for the experience value (λ _t1 ) of the inner length is 1.4 and the correction coefficient for the experience value (H ₁ ) of the crimp height is set to 0.9, the experience value of the inner length and the compression height is expressed by Equation 7 and It can be calculated by Equation 8.

λ_t1=2π**r_o*1.4

λ _t1 = 2π ** r _o * 1.4

H₁=2h+2r_c=2*(h+*r_o)*0.9

H ₁ = 2h + 2r _c = 2 * (h + * r _o ) * 0.9

Therefore, the dimensions of the wire crimping portion 5 of the electrical connector 1 can be accurately calculated by the above equations.

In order to confirm the compression ratio of the wire crimp section 5 calculated as described above, the following results were obtained by comparing with the compression ratio of the wire crimp section calculated by conventional experience.

Inside length (λt) Compression Height (H) Compression Ratio (α) Example 6.20 1.95 80.20 Conventional 8.40 2.30 102.40

An analysis of the crimping process of the wire crimping part 5 and the wire W of the electrical connector 1 was conducted by a finite element analysis method (FEM), using CABA software ABAQUS Version 6.5.

This finite element analysis method is a mathematical method mainly used to calculate the deformation shape, strength, vibration, stress distribution, etc. of solid materials, machines, structures, etc.

Accordingly, the internal length λ _t and the compression height of the wire crimp unit 5 can be calculated by the finite element analysis method. In this case, the input values used in the finite element analysis are shown in Table 2 below.

Lead Crimp Wire (W) Poisson's 0.30 0.30 density 8,530kg / m3 8,960kg / m3 Coefficient of friction 0.15 0.10 Crimping Speed 0.25mm / sec 0.25mm / sec

As can be seen in Table 1 above, the results of the analysis and the cross-sectional measurement of the crimping process of the electrical connector 1 by the above input values,

In the present embodiment, the inner surface length calculated by the above formula is 6.20 and the compression height is 1.95, in which case the compression ratio is 80.20%. Therefore, no gap was generated in the wire W by approximating the specified compression ratio of 80%.

In addition, the compressed cross-sectional shape forms an ideal "B" shape. This point can also be confirmed in the cross-sectional simulation picture shown in FIG.

Therefore, it can be seen that the inner surface length λt and the compression height of the wire crimping portion 5 calculated by the above equations are preferable.

On the other hand, according to the conventional empirical value, the inner surface length is 8.40 and the compression height is 2.30, in which case the compression ratio was measured to be 102.40%.

This compression ratio did not meet the specified compression ratio of 80%, and it can be seen that poor compression occurs.

In addition, as shown in Figure 4 (b), it can be seen that both wings of the wire crimping portion 5 is excessively curled inward, it can be seen that there are many wire gaps.

Therefore, due to poor crimping will affect the electrical conductivity of the electrical connector (1).

In addition, the resistance change measurement results in the thermal shock test and temperature, humidity test is shown in the graph of FIG.

At this time, the measurement method of the resistance change in the experiment and the resistance change specification values are shown in Table 3 below.

PROCESS After crimping Temperature experiment Humidity Experiment resistance R1 R2 R3 Resistance change Δ1 = R1-R0 Δ2 = R2-R1 Δ3 = R3-R2 SPEC Δ1 <
0.55mmΩ Δ2 <
0.33mmΩ Δ3 <
0.33mmΩ

In Table 3, the resistance value R0 represents the resistance value of the pure wire having the coating before the terminal and wire crimping.

The resistance measurement was performed using a HIOKI 3541 model microohm meter resistance measuring instrument, and the resistance measurement length was set to 75 mm.

As a result of the experiment, as shown in the graph of FIG. 5, in the present embodiment, the resistance change value P1 after crimping is 0.27 mΩ, and in the case of a conventional terminal, the resistance change value P2 after crimping is 0.30 mΩ. mΩ was satisfied.

As a result of measuring the resistance change value in the temperature and humidity experiments, the resistance change value P3 in the temperature experiment was 0.25 mΩ and the resistance change value P4 in the humidity experiment was 0.28 mΩ in the present embodiment. The specification value 0.33 mΩ was satisfied.

However, as a result of measuring the resistance change in the temperature and humidity test of the terminal according to the prior art, the resistance change value (P5) in the temperature test is 0.41 mΩ and the resistance change value (P6) in the humidity test is 0.38 mΩ. The resistance change specification value exceeded 0.33 mΩ.

Therefore, as a result of these experiments, it can be seen that the resistance change in the temperature and humidity experiments is closely related to the inner surface length, the crimp height, and the compression ratio of the terminals. It can be seen that also shows an excellent effect.

1 is a perspective view showing an electrical connector according to an embodiment of the present invention.

FIG. 2 is a view schematically illustrating a state in which the electrical connector illustrated in FIG. 1 is crimped by a punch and a die.

Figure 3 (a) is a view showing a state before crimping the electrical connector shown in Figure 1, Figure 3 (b) is a view showing a state after the crimping.

Figure 4 (a) is a view showing a cross-sectional state after the crimping the electrical connector shown in Figure 1, Figure 4 (b) is a view showing a cross-sectional state of the crimped electrical connector according to the prior art.

Figure 5 is a graph showing the results of the temperature and humidity test of the electrical connector according to the present invention and the prior art.

Claims (2)

An electrical connector including a cover crimp portion surrounding the sheath of the wire, a wire crimp portion connected to the sheath crimp portion, and crimping and wrapping the core wire of the wire from the outside in the radial direction to the inside, and an electrode portion connected to the wire crimp portion. As the dimension calculation method of, The inner surface length λ _t formed along the inner circumferential surface of the wire crimp unit is calculated by Equation 1 below. λ _t = 2π *

* r _o ------ Equation 1 (α: compression rate, n: number of wires, r _o: radius of one wire core) When the wire crimp unit wraps the wire core, the compression height is calculated by Equation 2 below, H = 2h + 2r _c = 2 * (h +

r _o ) --- Equation 2                   (H: compression height, h: wire crimp thickness) In the above formula 1, the compressibility α is calculated by α = (S _C / S _O ) * 100%, (S _C: area of wire bundle after crimping, S _O: area of wire bundle before crimping) S _C of the compressibility and S _O is calculated by Equations 3 and 4 below, S _C = π * r _C ² ------ Equation 3, S _O = n * π * r _O ² --------- Equation 4 (n: number of wires, r _o : radius of one wire core, r _c : radius of bundle of wire cores after crimping) The r _c is calculated by Equation 5 below r _c =

* r _o -------- Equation 5 Circumference of the wire bundle λ _c is λ _c = 2π

defined as * r _o , Since λ _c is equal to the inner length of the electrical connector, λ _c = λ _t is established, The inner length and the compression height of the electrical connector can be calculated by the equations 1 and 2, the dimension calculation method of the electrical connector. The method of claim 1, The empirical value λ _t1 of the inner length of the electrical connector is applied to the correction coefficient, and the correction coefficient is 1.4, so that Equation 1 can be calculated as follows. λ _t1 = 2π *

* r _o * 1.4 The empirical value (H ₁ ) of the compression height of the electrical connector is applied to the correction coefficient, the correction coefficient is 0.9, the equation 2 is H ₁ = 2h + 2r _c = 2 * (h +

* r _o ) * Dimension calculation method of electrical connector, characterized in that it can be defined as 0.9.

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