Contact Characteristics Analysis and Optimization of Connector

doi:10.16628/j.cnki.2095-8188.2022.10.008

Abstract

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

CLC Number:

TM572.2

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

Figures/Tables 19

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

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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