Investigation On Contact Reliability Of Aerospace Electrical Connector

Aerospace electrical connector act as a connector between aerospace electronic equipment, and every complete aviation system cannot work without it. The species and functions of electrical connector are developing all the time since it was invented. Electrical connector are widely used in in all fields, its contact reliability have been widely researched at the same time.Firstly, the significance of contact reliability of aerospace electrical connector was described, and the contact reliability was simplified summarized. The fretting phenomenon was introduced and the theory of contact resistance and fretting wear were described, the influencing factors were analyzed. The key factors that influence contact resistance were described, such as structure type, contact pressure, temperature and material. The detail process of fretting wear and the key influence factors were described.Secondly, we have researched the mechanical properties of typical open slot aerospace electrical connector contacts. Static analysis and insertion force were analyzed based on finite element method ANSYS. The structure parameters of contacts were optimized to improve the mechanical properties and contact reliability.Thirdly, the thermoelectric-structure coupling fields of contacts were established to research the electrical properties. The contact resistance and temperature rise were obtained. The temperature rise was calculated by simulated, which can provide guidance for practical production. The factors that influence contact resistance and temperature rise were determined by structure optimization.Finally, fret experiment of electrical connector were finished based on fretting experimental platform. The changes of contact resistance under different vibration frequency and amplitude were researched, and the influence mechanism of vibration frequency and amplitude on contact resistance were obtained. The wear on the contacts was analyzed by advanced microscope, and the influence of vibration frequency and amplitude on fretting wear was obtained.