Research On The Key Influence Factors Of Power Connector Design

Electrical connectors are universally used in communication,power and other fields.The demand for high-power electronic equipment and accessories are increasing greatly with the rapid progress of communication technologies,the increased functions of electronic products,and the longer distance in communication.In particular,the rise of outdoor mobile electronics and new energy vehicles in recent years has led to an increasing demand for power pluggable(detachable)connectors.According to the specific environment of use,the power plug connector is mainly faced with the temperature rise,mechanical vibration,electromagnetic interference,environmental corrosion,electrical erosion,arcing and other problems,this topic focuses on the problem of temperature rise that is inevitable and serious when the power plug connector is working.Taking a company's gold finger power plug connector as the object,through the combination way of theoretical analysis and finite element simulation,the key factors affecting the design of power plug connector are analyzed and researched.The main contents of research are as follows:In this paper,the design basis and calculation method of the key indicators in the design of gold finger power plug connector are studied.In order to ensure the feasibility of terminal-current-carrying function design,the current-carrying limit of the terminal was evaluated firstly.Secondly,the key indicators influencing the temperature rise in the functional design of the power plug connector of the gold finger,such as the contact resistance,and the key indicators affecting the temperature rise in the reliability design,such as the contact pressure and the equivalent stress,are theoretically analyzed and given calculation method and improvement ideas.Taking into account the actual production process error,in order to increase the control of multi-contact structure design,the minimum number of contacts is determined by the terminal material properties and functional requirements of the structure.On this basis,the calculation ideas and methods of allowable consistency error range among multi-contact structure are given.Finally,based on the theoretical design and analysis of the power plug connector of gold finger,the design ideas and flow of the general power plug connector are summarized.Through the theoretical design calculation and analysis,the design process and the calculation methods of key indicators of the power plug connector of gold finger are clarified.On this basis,a solid model of the reed terminal of power plug connector of gold finger and the gold finger PCB are established in the static structure analysis module of ANSYS Workbench,and the simulation analysis is carried out.Firstly,the contact analysis between the power plug connector of gold finger and gold finger PCB is made,access to its contact stress,contact pressure and equivalent stress,and the deformation and displacement of the contact parts between gold finger power plug connector reed terminals and gold fingers PCB.Secondly,simulate the plugging and unplugging of the connector,and get the friction of insertion and extraction.Then,establish the electro-thermal analysis module,including gold finger PCB,the power plug connector and connector backplane.The electric-thermal simulation analysis of the power pluggable connection system is made.The electric-thermal characteristics of the gold finger power plug connector are obtained,and the temperature distribution map of the gold finger power plug connection system is output.Finally,the simulation results and theoretical calculation results of mechanical and electrical-thermal performance of the gold finger power pluggable connector are compared and analyzed,verifying the rationality of the design thought and theoretical design calculation.