A Systematic Approach for the Reliability Evaluation of Electric Connector

Abstract

Under the trend of high density and miniaturization, the current that the connector transmits per unit volume is getting higher and higher, which makes the reliability design of the connector more challenging. Under the pressure of high performance and low cost requirements, the design has to be more accurate and more efficient. Thus, in the design process, a systematic approach for reliability evaluation is required. However, there is no valid enough approach that is integrated, well-organized, and quantitative. In this article, a systematic approach for the reliability evaluation of connector was proposed, and by applying it on a typical object named a blade-spring connector, the validity of this approach was verified. After the framework of this approach has been established, the methods and models needed were provided, including the method to build up material selection criterion and the assessment models of stress relaxation, thermal diffusion, and sliding wear, respectively. Then, the feasibility of a newly developed copper alloy on the connector and the reliability behaviors of this connector were determined through this approach. The unsatisfactory aspects of reliability were pointed out and some possible redesign choices were provided. Results and discussion revealed that the proposed approach is a helpful tool for designing electric connectors, especially on the reliability design.

Modelling the Interwoven Parallel Testing Process in the Automotive Industry

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Contact reliability modeling and assessment of electrical connectors with multi-aperture slotted leaf spring contacts

“…Ren et al 7 summarized some problems of physical failure model and reliability assessment of circular electrical connectors, and proposed a new method combining accelerated degradation test and physical failure modeling. Wang et al 8 proposed a systematic method for the reliability assessment of connector and verified the effectiveness of the method by applying it to leaf spring connectors, and verified the effectiveness of the method by applying it on blade-spring connector. However, a large number of test data showed that the degradation rate of different aperture contact pairs has difference in the same test environment.…”