Research On Mechanical And Environmental Characteristics Of Gigabit Ethernet Connector

Driven by information technology,high-speed connectors for connecting and transmitting high-speed digital signals have begun to develop rapidly,with transmission rates reaching and exceeding 10Gbps and moving towards higher transmission rates.High speed times require good signal integrity and electromagnetic compatibility for the electrical performance of the connecting system,but the mechanical and environmental performance of the connector can not be ignored.In this paper,the mechanical and environmental characteristics of gigabit Ethernet connectors are studied by combining theory with simulation.The mechanical characteristics are mainly the plugging and pulling characteristics of electrical connectors,while the environmental characteristics are studied from the thermal and vibration aspects.This paper mainly completed the following four aspects of work,and obtained relevant conclusions:(1)This chapter describes the type,structure,performance,contact resistance model,and failure causes of the gigabit Ethernet connector.It is indicated that the two main factors leading to the electrical contact failure are heat and vibration,both of which will affect the contact pressure and contact resistance of the connector.The mechanical model of the contact part of the Gigabit Ethernet connector was established,and the contact pressure between the contact pin and the single spring was 5.93N,the total contact pressure of the contact part was 11.86N,the maximum stress was 505.60MPa,and the separation force was 2.37N.The contact resistance of the whole contact part is 0.273mΩ.(2)The simulation model of the contact was established by using SolidWorks modeling software,and the static analysis module in ANSYS Workbench was used to complete the simulation analysis of the process of inserting and removing the contact.According to the finite element postprocessing results,the maximum stress value in the process of inserting and removing the contact is 461.1 0MPa,which appears at the root of the spring and does not exceed the yield limit of the contact material beryllium bronze.The maximum insertion force of the pin in the process of inserting the jack is 3.64N,and the contact pressure is 5.81N when the pin is fully inserted.When pulling out,the separation force is 2.3 1N,and the deviation between the contact pressure,stress and separation force and the theoretical calculation value is small,and the insertion force and separation force meet the relevant standards.Analyzed the impact of changes in the size of the socket closure on the contact between contacts:as the closure size increases,the contact pressure,separation force,maximum insertion force,and maximum stress all decrease significantly;When the separation force is too small,it can cause the contact pin and socket to loosen or even detach.However,the standard requires a separation force of no less than 0.19N for a 0.98mm diameter contact pin.Therefore,by linearly fitting the separation force with the socket closure size,the critical value of the socket closure size is 0.95mm.(3)According to the thermoelectric equivalence principle,the thermal circuit diagram of Gigabit Ethernet connector is drawn.The iterative calculation process of the natural convection heat transfer coefficient of the connector was analyzed by combining the heat path diagram and the correlation equation of natural convection experiments,and the critical feature size relationship formula for the rectangular connector to perform natural convection heat transfer was obtained.A calculation program for the natural convection heat transfer coefficient of a rectangular connector was written using MATLAB software,and corresponding GUI interfaces and client software were designed.Simply input the relevant parameters of the connector in the software interface to obtain the natural convection heat transfer coefficient of the connector,saving calculation time and effort.The steady-state thermal simulation of the electrical connector was conducted using the electric thermal coupling module in the finite element software ANSYS.The temperature rise cloud diagram and the highest temperature rise after the connector was connected to a 5 A rated current were obtained,with a maximum temperature rise of 9.10℃,not exceeding 30℃,meeting the requirements.(4)Modal analysis was conducted on the contact part and the first six natural frequencies of the contact were obtained through ANSYS Workbench software,which were 11.38kHz,12.39kHz,34.81kHz,37.92kHz,45.32kHz,and 47.28kHz,respectively.Based on the vibration testing standards for electrical connectors and the actual working environment of gigabit Ethernet connectors,a simulation scheme for forced vibration of the connectors was designed.The fluctuation curve of the contact pressure of the contact part was obtained,and analysis was conducted using vibration theory.The contacts did not experience vibration failure.By analyzing the influence of vibration frequency and amplitude on contact pressure and contact resistance,it is found that the effect of frequency is more significant.This article systematically completes the analysis of the mechanical characteristics of gigabit Ethernet connectors for insertion and removal,as well as the influence of thermal and vibration environments.It innovatively uses iterative methods to calculate the natural convection heat transfer coefficient of the connector,and designs corresponding calculation programs and GUI visualization software platforms.It provides automated tools for users to calculate the natural convection heat transfer coefficient of the connector based on the size and material parameters of the connector,saving calculation time and effort.