基于GA-Weibull模型的电连接器插拔特性实验与数值分析

Experimental and Numerical Analysis of Insertion and Extraction Characteristics of Electrical Connectors Based on GA-Weibull Model

摘要: 电连接器的插拔特性对使用寿命和连接可靠性具有重要影响。本文针对D350型电连接器，利用试验和数值仿真方法对其插拔特性进行研究。首先，给出接触压力、分离力和接触电阻的数学模型，并建立了GA-Weibull模型。其次，构建了D350型电连接器的数值模型，并将其导入有限元仿真软件中，实现了插拔过程的数值仿真与分析。然后，采用插拔试验机和JK2511型直流低电阻测试仪进行插拔试验。最后，根据试验和仿真结果，探究插拔力、接触压力和接触电阻随插入深度的变化规律，揭示并修正接触电阻与接触压力的拟合关系。结果表明，接触压力、插入力、分离力和接触电阻的仿真值和试验值的平均相对误差分别为1.83%、4.30%、3.33%和3.47%，均低于5%，说明本文所建立的模型和试验方案具有较高的可靠性；对于试验值和仿真值，反映接触电阻与接触压力关系的GA-Weibull的平均绝对百分比误差为0.1831%和0.1598%，分别低于理论公式拟合的平均绝对百分比误差(0.6922%和0.5731%)，这说明提出的GA-Weibull拟合公式很好地修正了理论公式。

Abstract: The insertion and extraction (IAE) characteristics of electrical connectors wield significant influence over service life and connection reliability. We center on scrutinizing the IAE characteristics of the D350-type electrical connector, utilizing a combination of experimental and numerical simulation methodologies. Initially, mathematical models were introduced to characterize contact pressure, extraction force, and contact resistance, and GA-Weibull model was proposed. Subsequently, a numerical model of the D350-type electrical connector was formulated and imported into finite element software, and numerical analysis of IAE process was facilitated. Thirdly, practical IAE tests were executed using a plug-and-unplug testing machine, alongside a JK2511 DC low-resistance tester. Finally, based on the experimental and simulated values, the trends in IAE forces, contact pressure, and contact resistance concerning insertion depth were elucidated, and fitting relationship between contact resistance and contact pressure was revealed and corrected. Results elucidate that the mean relative errors between simulated values and experimental values of the contact pressure, insertion force, extraction force, and contact resistance are 1.83%, 4.30%, 3.33%, and 3.47% respectively, all of which are lower than 5%. This indicates that the model established in this paper and the experimental scheme have high reliability. For experimental and simulated values, the mean absolute percentage errors (MAPEs) of GA-Weibull fitting, which reflects the relationship between contact resistance and contact pressure, are 0.1831% and 0.1598%. Both are respectively lower than the MAPEs (0.6922% and 0.5731%) fitted by the theoretical formula, indicating that the proposed GA-Weibull model effectively corrects the theoretical formula. These findings will be very helpful in optimization design and increasing the applicability of other electrical connectors.