Thermal Analysis And Contact Reliability Study Of High Temperature Electrical Connector

The electrical connector is an element used for terminating conductor, and inserting,isolating the corresponding components to realize the circuit. Tens of thousands of electricalconnectors are used in the center of many cutting-edge technology and large civilian ormilitary systems. The system fault cases due to the failure of electrical connector have occurredtime to time, which not only cause great economic losses, but also may lead to seriousconsequences. China’s new generation of weapons and delivery systems, especially thehigh-speed cruise missiles, huge load rocket develop rapidly. In order to make them worknormally in the complex space and electromagnetic environment, the high temperatureelectrical connector installed in the weapon systems, space transportation systems and groundequipment needs to withstand high temperature much more. Therefore, it’s necessary to analyzethe work condition of high temperature resistant electrical connector in the environment ofhigh temperature or failure, also study the contact reliability in the outside world under the hightemperature, providing the method and basis for the design of high temperature resistantelectrical connector.The main work is as follows:Firstly, the paper gives an overview of the research background and significance. It brieflydescribes the development of reliability engineering, the current situation of the development ofthe electrical connector, summarizes and analyzes the research status of electrical connectorreliability and problems, and introduces the research situation and application of the thermalanalysis technology, presenting this paper based on those research contents.Secondly, this paper introduces the structure of the high temperature electrical connectorYF30series, analyzes the failure of the electrical connector, establishes the electricalconnector failure fault tree, analyzes the effect of high temperature environment on electricalconnector reliability, which provides base for the thermal analyses of the finite element in thehigh temperature electrical connector and the assessment of high-temperature plug contactreliability.Thirdly, establish the finite element model based on the overview of the basic theory ofheat transfer analysis.Simulate the electrical connector under different temperatures ofoutside environment by using the finite element analysis software Ansys Workbench. As aresult, get the changing rules of its internal pin, socket contact parts of the temperature withtime. And the use of electromagnetic heating device and the variation of the contacttemperature under different temperatures with time in the thermocouple test verifythe correctness of the finite element thermal analysis. On the basis of this, considering therandomness of the performance parameters, use Monte Carlo simulation method to get that thecontact temperature electrical connector at the temperature of400DEG C65s obeys normaldistribution. And also get the mean value and variance of the distribution, which lays thefoundation for the reliability of the contact evaluation in high temperature environment.Fourthly, the paper establishes the contact resistance model of high temperatureresistant electrical connector, analyzes the effects of contact pressure on the contact resistance,determines to use insertion force to reflect the contact pressure from the point of viewof engineering application, thus reflecting the contact resistance.And design theconnector insertion force test device under high temperature. Analyze the pulling force test ofcontact under different temperatures and the variation of insertion force. Get contact’sinfluence on the temperature and the stable value of the insertion force. Combining with the engineering, determine the maximum temperature of contact (i.e. contact failure threshold),which meets the working requirements. So get the contact reliability characteristic of hightemperature resistant electrical connector.Finally, the paper summarizes all the study,and points out that the high temperatureelectrical connector reliability needs further research.