The Optimal Design Of Contact Reliability Electrical Connector With Wire Spring Jack

Electrical connectors are mainly used to realize the transmission of electrical signals between electrical equipment,and occupy an important position in aerospace and communication systems.The reliability of the electrical connector directly affects whether the system can work reliably.According to statistics,the main reason for the failure of the electrical connector is the contact failure caused by the contact resistance exceeding the standard,and the wire spring hole type electrical connector has a smaller size.Contact resistance and better electrical performance are often adopted by model system equipment.At present,the system equipment puts forward high reliability requirements for electrical connectors and other components.In order to meet the high reliability indicators proposed by the system,this paper takes a certain type of electrical connector with wire spring jack as the research object,establishes and perfects the wire spring Hole contact reliability design model.On this basis,according to the high reliability index requirements of the wire spring-type electrical connector proposed by the system,the optimization design of the contact reliability of the wire spring-type electrical connector is carried out.The specific research content is as follows:In the first chapter,the background and significance of this paper are expounded,and the research status at home and abroad is introduced from reliability design of product reliability,multi-objective optimization design method,global optimization algorithm,contact reliability design modeling of electrical connector and the research of wire spring-type electrical connector.The second chapter analyzes the environmental effects of wire spring-type electrical connectors based on the structure,function and performance requirements of electrical connectors with wire spring jack,and determines the main storage failure modes of wire spring-type electrical connectors Analyzed and revealed the contact failure mechanism of the wire spring-type electrical connector from the perspective of the evolution law of contact pressure and the growth law of surface film.The third chapter considers the actual contact form of the wire spring and the pin.Based on the fixed-supported beam model and Hertz theory,the load distribution law under the contact surface contact is analyzed and deduced,and the structural mechanics model of the wire spring-type electrical connector under the surface contact is established,which is more in line with the engineering practice;the actual measured value of the insertion and extraction force of the wire spring-type electrical connector and the Monte Carlo simulation data of the contact force are used to verify the rationality of the theoretical calculation model of the contact pressure between the contacts in the case of surface contact with the A-D test method;finally,the strength of wire spring is analyzed and checked.The fourth chapter starts with the film growth law and the stress relaxation law of wire spring,establishes the wire spring-type electrical connector’s contact reliability design model,and reveals the mathematical relationship between the wire spring-type electrical connector’s contact reliability and the design parameters such as pin radius,the radius of the wire spring and the length of the inner sleeve;combined with the estimated initial values of the model parameters obtained from the previous study,the existing design parameters of a certain type of wire spring-type electrical connector are substituted into the contact reliability design model of the wire spring-type electrical connector,when temperature stress is T₁=25℃and the storage life is 35 years,the calculation of the contact reliability of the wire spring-type electrical connector is 99.97%,in order to achieve higher reliability index requirements,it can be used for the subsequent contact reliability optimization design.The fifth chapter studies the optimization design of the contact reliability of the wire spring-type electrical connector.With low contact resistance and small insertion force as the optimization goal,through the sensitivity analysis of each design parameter,the wire spring wire radius,the pin radius,the inner sleeve radius,sleeve length,and wire spring wire inclination,which are sensitive to the contact reliability of the electrical connector are determined as design variables.Using multi-objective optimization design methods,a mathematical model for the contact reliability optimization design of the wire spring-type electrical connector is established;after the solve by GlobalSearch algorithm and MultiStart algorithm,and the optimal solution of the design parameters of the wire spring-type electrical connector contact is obtained,which improves the contact reliability of the wire spring-type electrical connector.