Research And Reliability Design Of High Power Connector

With the rapid development and progress of science and technology,the power of electronic and electrical equipment is also increasing,high power is often accompanied by the generation of large current,and the connector on the market is usually only through dozens of amperes of rated current,it is difficult to deal with the working condition of hundreds of amperes.The wire spring hole structure is a common connector socket structure,and its multi contact characteristics are mostly used in the structural design for high current.Although the high-power connector accounts for a negligible price in the whole system,it has a great impact on the whole system.It involves the reliable operation of the whole system.The failure of the contact part of the connector will affect the normal operation of the whole equipment system,even lead to the failure of other components,resulting in unimaginable consequences,so the reliability of the connector is also worthy of analysis and discussion.In this paper,the rated current of 800A is taken as the main performance index,and the mechanical properties and electro thermal characteristics of the high current wire spring connector are analyzed and studied by combining theoretical calculation and finite element simulation.The contact pressure and stress distribution of a single spring wire and the temperature field distribution of the overall model are obtained.The design to meet the performance index is carried out,and the method of changing the material is discussed Material,structure parameters and other factors to improve the connector performance.The main research contents include:(1)This paper analyzes the basic structure of the wire spring connector,explains the reason for selecting the wire spring hole as the research object,and determines the selection of material and structural parameters through parameter comparison.(2)According to the electric contact theory,material mechanics theory and contact temperature rise index,the contact pressure and maximum stress of a single spring wire in the wire spring hole are obtained by theoretical calculation.Then the contact pressure and maximum stress of a single spring wire under the structural parameters are calculated by ANSYS finite element software.The causes of such errors are analyzed and the solutions are proposed.(3)Using ANSYS finite element software,the thermal finite element calculation of the large current wire spring hole is carried out,the maximum temperature rises and the overall temperature field distribution under the large current environment are obtained,and the influence of external factors on the temperature field is studied.(4)In this paper,the reliability of high current connector is studied,the factors affecting the reliability of electrical contact are analyzed,the main failure modes of electrical connector under high current environment are analyzed and studied,the structure parameter scheme selected before is further improved,the optimization degree of overall performance when single parameter is changed is discussed,and the specific data support is given.