Dynamic Study Of The Drop Process And Reliability Design For Circular Electrical Connectors

When the conditions of electrical connectors are more stringent and the requirements of the performance are higher,it should be considered the drop failure mode and the law of the connectors or their accessories in the course of transport or use.The YDA circular connector is the research object in this paper.Based on the mechanical model of the contact collision and the response to the drop impact,and combined with numerical simulation and experimental analysis,this paper studied the impact response of this model in the process of falling.The main conclusions are as follows:Under the same condition,the paper simulated the whole process of impact response at a height of 100 mm,and studied the distribution of impact stress and the regularity of acceleration response for key parts(pins and shell).The results showed that drop impact of the pin was the most serious,what’s more,the impact stress was concentrated in the top of the shoulder and the maximum was 176.6MPa.Through the drop impact test,this paper got the impact acceleration response of a certain position at the shell of electrical connector.The results show that the response peak was in good agreement with the simulation,and the error was only 2.5%,which proved that the simulation of drop impact was reliable.Under the same condition,by changing the height of the drop,the paper analyzed the variation of the impact response with the drop height.The results showed that the peak impact stress increased with the increase of the drop height,and the growth of the pin in impact stress is larger than that of the shell,in addition,the plastic deformation occurs firstly at the height of1200 mm.The impact acceleration increased rapidly with the increase of the drop height,and lateral impact acceleration of the pin was the most violent.Under the same condition,by changing the angle of the drop,the results showed that the impact stress of the shell wass larger than that when the vertical drop,and the peak impact stress is the largest when the drop angle at60 °.The peak stress of the pin was the largest when the horizontal drop.The results showed that Critical Drop Height of the circular electrical connector was about 750 mm by simulation and calculation at the dangerous angles of pin and shell.The paper carried out the modal analysis of the whole circular electrical connector,and obtained the first five natural frequencies.Compared with the experimental vibration frequency,it was found that the vibration frequency at different drop height can not reach the first natural frequency of the system.The result showed that the circular electrical connector did not resonate in the process of drop impact.The paper studied the influence of the parameters on the response of drop impact after the initial optimizations.Through the sensitivity analysis,it was found that the fillet of shaft shoulder and the thickness of the collar were the key parameters which affected the impact stress,then the paper optimized dimensionally the key parameters of the pin.After optimization,the peak impact stress of the electrical connector was reduced by 59.7% and the impact acceleration was reduced by 44.8%.The results showed that the optimization scheme greatly improved the anti-drop capability of the circular electrical connector.