Simulation Study On Contact Characteristics Of Contact Pieces And Temperature Field Of Electrical Connector Based On Finite Element Analysis

Electrical connectors as the basic component of the electrical system has a wide range of applications,such as in the small 3C products which widely used in home life,automotive,industrial equipment,and even the equipment of weapons,aerospace and other fields.And its use is so huge that it can reach hundreds of pieces in some systems Its main function is to achieve the electrical connection and signal transmission between the devices and devices,components and components,systems and systems.The electrical connector plays an important role as the basic component of the electrical system.As long as any one of the electrical connector failure,it may cause the entire equipment and system failure because its huge application.So that the results may cause huge economic losses.Its quality and stability of the product during its use will directly affect the entire electrical equipment system security and reliability,so the analysis of the reliability of electrical connectors is necessary.The pin parts and the sockets are the heart of the electrical connectors,the contact performance of the contact pieces directly impact on the performance of the entire electrical connector in the process of insert and pull out of the electrical connector.High temperature is not only an important cause of failure of the electrical connector connection function,but also directly affect its reliability.The two main factors that can cause the electrical connector to fail.In this paper,the electrical connector of multi-core crown-type jack structure has been selected as the research object.Simulation and study have been carried out on the temperature field of the electrical connector under different use environment and the insertion and removal of the pin parts and the sockets.To explore the distribution of temperature field and the change of temperature rise under different application conditions and the contact characteristics of the crown spring during insertion and removal process.(1)According to the classification,the basic components of the electrical connector,the main ways and manifestations of its function failure,the principle cause of the failure of the electrical connector have been deeply analyzed.The results show that the reduction of the contact performance of the pin and the socket when paired is the most important form of the functional failure of the electrical connector,And the main reason for the decrease of contact performance is the lack of contact pressure between the pin and the socket,and the high temperature is the other reason.(2)Three dimensional modeling of the components of the electrical connector have been carried out and the overall structure of the electrical connector model has been built,by using the three-dimensional modeling software Pro/E5.0.The mechanics model of the simply supported beam has been used to analyze the stress of the crown in the process of inserting and separating of the pin and the socket.And the relevant theoretical analysis and calculation have been carried out,and the separation force and the contact pressure value of the single pin and the socket have been obtained.(3)ANSYS Workbench was used to simulate the insert and pull out process of the contact pieces,based on the established solid model of pin and socket.The simulation results show that the equivalent stress of the crown spring shrapnel mainly concentrated on the two sides of the central of each shrapnel.The main contact area of the pin and the crown spring mainly distributed at the center of the crown spring,and the contact area presented as an oval.At the same time,the relationship between the insertion force,separation force and the time during the insertion and removal process have been obtained,as well as the maximum value of the insertion force and the separation force.On the basis of the test results,the insertion force and the separation force have been tested by using a large number of pins and sockets.The test data,the simulated data and the theoretical analysis data were compared.The results show that the difference between the test data and the simulation results is small,the theoretical analysis results are slightly larger.The correctness of the simulation model has been verified.And the influence of the size of the crown spring necking amount on the contact characteristics of the crown spring has been determined,which provides the basis for the determination of the size of the crown spring.(4)Through the simulation of the temperature field of the electrical connector under different ambient temperature,different number of cores and different current conditions,the temperature field distribution and its temperature rise under different use conditions have been obtained.The simulation results show that the temperature distribution of the electrical connector can be divided into high,medium and low temperature zones.The temperature gradually decreases from the inside of the pin and the socket,and the highest temperature appears at the current input(pin terminal)on the electrical connector.Because of the contact resistance in the contact area between the pin and the socket,the temperature is relatively high,and the high temperature area will be changed because of the arrangement of the number of cores.The overall temperature of the electrical connector will increase with the number of cores,the current and the ambient temperature,and the magnitude of the temperature rise will increase gradually in the first two conditions,but in the latter condition the magnitude of the temperature rise is getting lower and lower,and finally close to a steady trend.And the increase in current under the same conditions has a greater effect on the increase in the temperature than the number of cores.In the same environment,the temperature of the electrical connector decreases as the thermal conductivity of the insulator increases,but magnitude of temperature reduction slightly.