连接器弹片结构接触特性分析与优化

doi:10.16628/j.cnki.2095-8188.2022.10.008

摘要/Abstract

摘要：

针对交流接触器中连接器弹片常出现局部应力过高,导致弹片结构断裂的问题,采用正交试验的方法来对连接器弹片进行结构优化,研究弹片不同结构尺寸对插入端子插入力、连接器夹紧力和连接器等效应力的影响,并对仿真结果进行试验验证。为了解决接触分析求解效率低下的问题,提出等量替换高效算法,简化插入端子插入连接器弹片过程中的非线性接触计算。结果表明,与常规非线性接触算法相比,两者计算精度相当,等量替换高效算法计算效率提高了87.5%;优化后插入端子插入力下降了71%,弹片最大等效应力降低75%,提高了连接器弹片的使用寿命。

关键词: 连接器弹片, 接触特性, 高效算法, 正交试验, 优化设计

Abstract:

Aiming at the problem of fracture of the connector caused by excessive local stress in the AC contactor,the orthogonal test method is adopted to optimize the structure of the connector.By the method of orthogonal test,the influence of different structural sizes of connector on the insertion force of the insert terminal,the clamping force of the connector and the equivalent stress of the connector are studied.So the test is carried out for the simulation results.In order to solve the problem of low efficiency of contact analysis,an efficient algorithm of equal replacement is proposed to simplify the nonlinear contact calculation in the process of inserting terminals into connector.Compared with the conventional nonlinear contact algorithm,the calculation accuracy of the two algorithms is equivalent,but the calculation efficiency of the proposed algorithm is increased by 87.5%.After the optimization,the insertion force of the terminal is reduced by 71%,and the maximum equivalent stress is reduced by 75%,which can improve the service life of the connector.

Key words: connector, contact characteristics, efficient algorithms, orthogonal test, optimal design

中图分类号:

TM572.2

齐小军, 冯伟杰. 连接器弹片结构接触特性分析与优化[J]. 电器与能效管理技术, 2022, 0(10): 48-55.

QI Xiaojun, FENG Weijie. Contact Characteristics Analysis and Optimization of Connector[J]. LOW VOLTAGE APPARATUS, 2022, 0(10): 48-55.

图/表 19

图1

图2

图3

图4

图5

表1

表2

表3

表4

插入端子最大插入力极差分析N

项目	因素
项目	A	B	C	D
$K 1 —$	1.462	3.955	7.337	1.538
$K 2 —$	3.978	3.785	5.660	3.232
$K 3 —$	4.447	5.607	3.228	5.572
$K 4 —$	8.015	4.555	1.677	7.560
R	6.553	1.822	5.660	6.023

表4

图6

图7

图8

图9

表5

图10

图11

表6

图12

图13

参考文献 22

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设计变量类型	设计变量变化范围
A弹片厚度T_h/mm	0.2 ≤A ≤0.35
B弹片高度H/mm	5.1 ≤B ≤5.7
C弹片内宽W/mm	1.2 ≤C ≤1.8
D弹片长度L/mm	2 ≤D ≤8

水平	因素
水平	A	B	C	D
1	0.20	5.1	1.2	2
2	0.25	5.3	1.4	4
3	0.30	5.5	1.6	6
4	0.35	5.7	1.8	8

编号	水平					T_h/mm		H/mm		W/mm		L/mm		最大F_c/N		F_j/N		最大S/MPa		综合指标
编号	A	B	C	D		T_h/mm		H/mm		W/mm		L/mm		最大F_c/N		F_j/N		最大S/MPa		综合指标
1	1	1	1	1	0.20		5.1		1.2		2		1.19		2.46		602.14		1.42
2	1	2	2	2	0.20		5.3		1.4		4		1.82		3.60		447.01		1.09
3	1	3	3	3	0.20		5.5		1.6		6		1.86		3.47		284.46		0.73
4	1	4	4	4	0.20		5.7		1.8		8		0.98		2.21		134.92		0.31
5	2	1	2	3	0.25		5.1		1.4		6		4.89		10.67		568.71		1.34
6	2	2	1	4	0.25		5.3		1.2		8		8.65		17.41		542.07		1.44
7	2	3	4	1	0.25		5.5		1.8		2		0.48		1.06		180.67		0.42
8	2	4	3	2	0.25		5.7		1.6		4		1.89		4.14		342.35		0.80
9	3	1	3	4	0.30		5.1		1.6		8		6.87		15.98		474.54		1.03
10	3	2	4	3	0.30		5.3		1.8		6		2.38		5.72		231.75		0.50
11	3	3	1	2	0.30		5.5		1.2		4		6.35		13.25		544.82		1.35
12	3	4	2	1	0.30		5.7		1.4		2		2.19		5.12		547.14		1.25
13	4	1	4	2	0.35		5.1		1.8		4		2.87		6.00		288.25		0.71
14	4	2	3	1	0.35		5.3		1.6		2		2.29		5.68		559.41		1.24
15	4	3	2	4	0.35		5.5		1.4		8		13.74		33.39		535.80		0.95
16	4	4	1	3	0.35		5.7		1.2		6		13.16		28.32		570.29		1.41

方案	因素
方案	A厚度 T_h/mm	B高度 H/mm	C内宽度 W/mm	D长度 L/mm
原方案	0.25	5.3	1.4	4
优化方案	0.20	5.5	1.8	8

方案	最大 F_c/N	F_j/N	最大 S/MPa	综合指标 T
原方案	3.10	6.82	558.22	1.30
优化方案	0.91	2.31	104.72	0.29
降幅/%	71	66	75	77