Study On Numerical Simulation Of Contact Characteristics And Temperature Field Of The Electrical Connector

Electrical connector is the basic element used to realize the transmission and control of electrical signals, realize the electrical connection between different devices. It is widely used in automotive, industrial equipment, aerospace and other fields. Any contact failure in any electrical connectors can lead to the paralysis of the entire system and major accident. Therefore, the quality and reliability level of electrical connector will affect the system’s security directly. In this paper, the30M multi-core electrical connector was the object of study. The main mode of failure of electrical connectors was analyzed. The numerical simulation was studied about contact pressure and temperature which are the main influence factors of contact failureFirstly, the structure of electrical connector, electric conduction properties of the contact body, and the main failure mode were analyzed. The main factors affecting the contact failure of electrical connector was summarized.Secondly, the minimum contact pressure was determined. In order to derive the relationship between contact pressure and geometry parameters, the mathematical model of the contact body of30M multi-core electrical connector was established. And the strength of the socket was checked.Thirdly, the parametric model of contact body was established using UG. The numerical simulation of insertion process of contact body was finished by the co simulation of UG and ANSYS Workbench. Influence of geometric parameters on the contact characteristics was analyzed by changing the geometric parameters of contact body. By the orthogonal test design, the primary and secondary effect of geometric parameters on contact pressure, the optimal level, and optimal level combination was analyzed. The optimized geometric parameters were obtained, and the significance of parameters was analyzed.Fourthly, numerical simulation of thermal-electric coupling on30M multi-core electrical connector was finished by ANSYS Workbench. Temperature field of electrical connector was studied. The temperature field of electrical connector with different core number, the temperature field of electrical connector under different surface contact resistance, and the temperature field of electrical connector under different environment temperature were studied.