Electric Connector Research Articles

An investigation of the electrical contact failure of JPT electric connectors used in automobiles under multiple stresses

The primary mode of failure in electric connectors is contact failure, one of the reasons is which occurs as a result of external vibrations in the environment. This failure arises due to the reduction in positive pressure on the electric connector terminal caused by the vibration, leading to fluctuations in the electrical contact resistance (ECR). When both vibrational stress and plug/pull stress is simultaneously present, the contact area of electric connectors experiences fretting wear and shear stress, resulting in a more intricate failure mechanism for the electrical connector. Thus, this study presents an accelerated degradation testing method designed to investigate the reliability of the junior power timer (JPT) electric connector employed in automobiles. A temperature resistance test, plug/pull test (sliding wear) and vibration test (fretting wear) were conducted for the JPT electric connector. The electrical contact failure mechanism of the JPT electrical connector was analyzed, with specific focus on its correlation with the concentration of oxides in the contact area.

Rancang Bangun Mesin Pembuat Pellet Berbais Internet Of Things (IOT) Untuk Mengotomatisasi Produksi Pakan

This study aims to build an Internet Of Things (IOT)-based pelletizing machine to automate the production of poultry feed, in order to save time and save costs with the machine. In this study, farmers still buy pur/pellets so that feed on ducks is more expensive than making their own, while with Pagar Alam conditions which have agriculture such as rice fields and extensive plantations there are many materials that can be processed such as bran, milled corn, fish meal and Tofu pulp is very good for duck feed, therefore it is necessary to make a poultry feed making machine. In making duck feed, you can use the Internet of Things (IOT), the advantage of using the Internet of Things (IOT) is to simplify and speed up operations. The mixer is used as a mixer for the dough ingredients and a mill for the dough maker, the water pump acts as a driver, the relay functions as a breaker and an electric current connector, the NodeMCU ESP8266 is programmed to disconnect and connect the electric current, using the blynk application. In this study using the Raqid Application Development (RAD) development method using Expert Review testing to test the validity. To obtain data in this study, data collection techniques were carried out including observation, interviews, literature studies and questionnaires. The results of this study resulted in the automation of poultry feed production so as to save time and save costs using an Internet Of Things (IOT)-based pellet making machine. Comparison of the manual mixing and manufacturing process with the automation of poultry feed production, which is 1 kg, it takes 6.40 minutes, while the automation only takes 2 minutes, can be seen in table 4.12. and test the validity of all very valid questions.

Numerical Investigation on Crack Detection Technique for Electric Connector with Joule Heating Effect

Using the electro-thermo-structural coupled-field finite element analysis, the crack detection technique with the Joule heating effect for the electric connector is studied and discussed. The physical behavior of the electric connector with an edge crack is investigated numerically. The electric current density, Joule heating temperature and structural deformation are obtained. As a result, the electric current concentration and Joule heating effect can induce a local hot spot or hot band region around the crack tip. Furthermore, the crack tip location can be determined according to the temperature distribution. For the accurate crack detection, two better electric loading conditions are found as follows: (a) shorter electric operating time (tp), (b) larger electric current (I0). The optimal condition , I0 = 100 A and tp = 0.001 s, is found for this crack detection research.

Control of Cu-doping behavior in n-type Cu0.01Bi1.99Te2.7Se0.3 polycrystalline bulk via fabrication technique change

Bi–Te-based alloys are potential candidates for use in thermoelectric (TE) modules for low-mid-temperature energy harvesting. However, n -type Bi–Te–Se alloys are inferior to their p -type counterparts in terms of TE performance. It has been found that doping Cu atoms into n -type Bi–Te–Se alloys is effective in improving the TE properties; however, different studies have reported contrasting roles of Cu dopants in the transport properties of Bi–Te–Se alloys. This is attributed to the complex doping behaviors of Cu atoms. In this study, it is demonstrated that employing an appropriate fabrication technique can enable more Cu dopants to be directed to specific atomic sites than others. As part of the study, two n -type polycrystalline Cu 0.01 Bi 1.99 Te 2.7 Se 0.3 bulk samples are respectively fabricated via melt-spinning followed by spark plasma sintering, and via ball-milling followed by spark plasma sintering. The majority of Cu dopants in the melt-spun sample are suspected to exist in between Te 1 –Te 1 atomic layers (van der Waals gap), given the elongated c -axis, increased Hall carrier concentration, and improved non-degenerate mobility (intercalated Cu generates one electron and acts as an electric connector). Resultantly, a ~30% enhancement in the TE figure-of-merit (~0.92 at 360–400 K) is achieved in the melt-spun sample, relative to the ball-milled sample, wherein Cu atoms substitute Bi atoms.

A Systematic Approach for the Reliability Evaluation of Electric Connector

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.

Maintenance of Filter at The Gas Turbine Compressor Intake and Electric Transformer Connector Based on Operational Reliability

The article analyzes the operational reliability of filter on the gas turbine compressor intake and the operational reliability of electric transformer connector. Empirical data (statistical sample) were collected to determine the failure density function f (t), the hazard function λ (t), and the expected value of mean time to failure MTTF. The numerical model was created in the Minitab 19 software tool. The Anderson-Darling test was used to accept or reject the hypothesis.

Thermal performance analysis of electric vehicle charging connectors

In order to obtain the thermal characteristics of the electric vehicle connector in operation. Firstly, the thermal circuit diagram of the connector is obtained by using thermoelectric simulation method. Then, based on Newton?s cooling equa?tion, the natural-convection heat transfer coefficient of the connector is calculated, which provides accurate input parameters for thermal simulation calculation. Finally, the thermal performance of the connector and the influence of component size and material are analyzed based on ANSYS software. When the working current is 250 A and the ambient temperature is 25?C, the temperature rise of connector shell and conductor can meet the thermal performance requirement. In order to reduce the temperature and uniform temperature difference of each part of the connector, the following optimization schemes are put forward: the optimal length of the insulator is 44 mm, the shell length should be increased as far as possible if conditions permit, and liquid crystal polymer with high thermal conductivity is selected as the insulator material, and aluminum alloy with high thermal conductivity and blackness is selected as the shell material.

Smart charging of mobile electric vehicles

The paper proposes to create a digital economy for the development of electric charging networks of mass-use road transport in a business environment, in fact, these are mechanisms of public-private partnership. To go along the path of purchasing electric charging stations of Korean, Japanese, and German manufacturers and placing them for their own money on communications of Federal or territorial highways or in organizations and enterprises of various forms of ownership is a poorly managed and not rational process. It is proposed to move away from the schemes of location of specific electric charging stations and switch to the schemes of non-powered sockets. The technical solution refers to the technical means of electric charging (recharging) of mobile electric vehicles. The goal is to reduce the cost of creating a network electric charging infrastructure for electric vehicles. The technical result is the ability to ensure the charging mode of the electric vehicle directly from the existing distributed power supply system in space, by using the phase state modes of the electric connector cable that is powered or not powered by electric current. Based on the materials of the paper, patents of Russia and Kazakhstan were obtained.

Accelerated Life Test Planning for Minimizing Misclassification Risks

The optimal plan of a time-censored accelerated life test (ALT) depends on unknown parameters in the ALT model. The general strategy for coping with this problem is to replace the unknown parameters with their a priori estimated values, after which we can design test plans that are robust to deviations of the estimated values. In an ALT with log-location-scale lifetime distribution and linear acceleration relation function, the slope parameter of the acceleration relation function usually has the highest uncertainty. Instead of prespecifying the slope parameter in the ALT design, in this article, we propose a new design criterion that minimizes the risk of misclassifying whether the product's pth quantile meets the design specification. Through a case study of a circular electric connector, we illustrate the proposed method, and compare it with other test criteria. The comparison result shows that the proposed plan exhibits good performance in both estimating and s-testing the product's pth quantile.

Research on Plugging Technology of J30JH Electric Connector without Tail Cover

By analysing the plug-in condition of a J30JH low frequency connector, we can find that technological tests were carried out on both the prototype and the normal sample satellites, the plug-in tooling was studied, the plug-in method was optimized, the operation process was solidified, the connection reliability of low frequency connectors in spacecraft assembly and test was improved, the product quality was ensured, and the plug-in of low frequency connectors was implemented smoothly. Lay a solid foundation.

전기커넥터 조립용 그리퍼 설계를 위한 전기커넥터 파지 및 조립특징 분석연구

Automation of electronic connectors has been in demand, based on automation of assembly of electronic products. In this study, we propose a new classification of electronic connector, for grasping and assembling. We analyze characteristics of electrical connectors often used at actual industrial sites, from the perspective of the robot, not a person. As a result, it is appropriate to classify the grasp, according to the shape of the electric connector. For the assembly, we suggested that classification should be based on directions are different, because of interference of the electric wire and peripheral parts. We hope that this research will become a new basis, for electrical connector assembly.

Design an Optimal Accelerated-Stress Reliability Acceptance Test Plan Based on Acceleration Factor

A reliability acceptance test is used to investigate the reliability of products delivered by producer before buyer accepts them. However, the traditional reliability acceptance test based on lifetime data, which is conducted under a comparative low stress level, is time consuming. It is an interesting and useful issue to study how to design an optimal accelerated-stress reliability acceptance test (ASRAT) to improve test efficiency. An inverse Gaussian process was applied to model degradation data of products. Acceleration factor constant principle was applied to derive the expression of acceleration factor for the inverse Gaussian degradation model, so the termination time of ASRAT was obtained through acceleration factor. The asymptotic variance of termination time was selected as an objective function to establish the optimization model of the ASRAT plan. The decision variables, including accelerated stress level, sample size, and the number of measurement were optimized by minimizing the asymptotic variance of termination time under a total cost constraint. Then, an automatic algorithm based on MATLAB procedure was developed to help efficiently design optimal ASRAT plans. Finally, the proposed method was used to design an optimal ASRAT plan for a type of electric connector. Sensitivity analysis indicates that the optimal ASRAT plan is robust to small bias of parameter estimation. Moreover, simulation tests were conducted to demonstrate the usefulness of ASRAT and investigate the impact of degradation model misspecification on designing an optimal ASRAT plan.

Electric connector assembly based on vision and impedance control using cable connector-feeding system

In this study, a method for the electric connector-mating process in a wiring harness assembly system is proposed. In connector-assembly tasks, grasping the electric connector is a crucial step. Therefore, a cable connector-feeding system is developed to align cable connectors so that they can be grasped straight and held firmly by the robot. After the grasping problems are solved, a tilt strategy with impedance control is used to overcome the position errors caused by the vision system. The location of the connector header (Female part of connector) is detected using visual servoing with markers. Then, impedance control is adopted to achieve compliant contact motion and minimize position/orientation errors. The performance of the proposed electric connector-assembly strategy is evaluated by a series of experiments using a six-degree of freedom industrial robot equipped with a force/torque sensor and an eye-in-hand camera.

Analysis of Deep Drawing Process for Stainless Steel Micro-Channel Array.

The stainless steel bipolar plate has received much attention due to the cost of graphite bipolar plates. Since the micro-channel of bipolar plates plays the role of fuel flow field, electric connector and fuel sealing, an investigation of the deep drawing process for stainless steel micro-channel arrays is reported in this work. The updated Lagrangian formulation, degenerated shell finite element analysis, and the r-minimum rule have been employed to study the relationship between punch load and stroke, distributions of stress and strain, thickness variations and depth variations of individual micro-channel sections. A micro-channel array is practically formed, with a width and depth of a single micro-channel of 0.75 mm and 0.5 mm, respectively. Fractures were usually observed in the fillet corner of the micro-channel bottom. According to the experimental results, more attention should be devoted to the fillet dimension design of punch and die. A larger die fillet can lead to better formability and a reduction of the punch load. In addition, the micro-channel thickness and the fillet radius have to be taken into consideration at the same time. Finally, the punch load estimated by the unmodified metal forming equation is higher than that of experiments.

An Approach to a Flexible Thermoelectric Generator Fabricated using Bulk Materials

Abstract A prototype flexible thermoelectric generator fabricated with bulk materials is presented. Mineral-fiber band and copper tape are used as flexible substrate and electric connectors, respectively, to coil up the constructed thermoelectric device under investigation. The applied active thermoelectric materials are C a 3 C o 4 O 9 ${\rm{C}}{{\rm{a}}_{\rm{3}}}{\rm{C}}{{\rm{o}}_{\rm{4}}}{{\rm{O}}_{\rm{9}}}$ ceramic and Cu-Ni alloy for hole and electron conduction, respectively. Thermal parallel and electric series connections of the mentioned materials were realized in the prototype flexible thermoelectric generator. The device delivered an open-circuit voltage of 16.52 mV and a short-circuit current of 19.40 μ A ${\rm{\mu A}}$ with a temperature difference of Δ T T E G = 31 K ${\rm{\Delta}}{{\rm{T}}_{{\rm{TEG}}}}{\rm{= 31\ K}}$ for the hot side temperature of 420 K. The device exhibits an approximately 3 cm long stripe that include four basic units (n-p pair and electric connector).

Force characteristic of a magnetic actuator for separable electric connector based on conical airgap

This article presents a magnetic actuator for use in a separable electric connector based on conical airgap. The magnetic flux lines in conical airgap are almost vertical to the edge face of the yoke and armature, showing that the actual flux length in conical airgap is smaller than the axial stroke, which reduces magnetic reluctance over large stroke. Parameter improvement is analyzed based on modeling, and optimal results of the magnetic actuator are adopted to improve the rate of force to volume. The experimental results show that there is friction force of 10–12 N existing in the moving armature of the prototype, and the nominal value is in accordance with the simulation one. The results show that the design of conical airgap in the magnetic actuator is available to improve the initial force and reliability of the separating process and has the advantages of compact structure, short transmission, high reliability, large force with 50 N at the initial displacement of 2.5 mm, and fast response with 16.5 ms over the traditional actuator.

Research on Temperature Stress for Contacts Reliability of Electric Connector

Temperature induced degradation is a widely recognized failure phenomenon.However, the basic mechanisms that control the onset and progression of such behavior are not well understood and are a topic of considerable interest in the electrical connector community. In this paper, the simulation analysis of temperature field on this topic are described. The distribution graph of temperature field for the electrical connectors and the highest temperature of the surface of electrical connector was achieved by analyzing a single blade/receptacle contact pair FEA model. A mathematical model was developed that related the early stage temperature levels for the connectors.Additionally, the thermal deformation caused by the temperature had little effect on the contact stress based on temperature - structure coupling field analysis for the electrical connector, the impact of temperature on the electrical connector was mainly reflected in the rate of oxidation of the metal surface. The failure physical process of the electric connector was drawn under temperature stress through the model and theory analysis for the electrical connector , and reliability growth program of the electrical connector was achieved under the temperature influence. The same transfer functions for one type of contact pair were obtained from the simulation, and the results showed that for this limited system, finite element modeling and analysis have great potential for evaluating the influence of design variations on degradation behavior.

일정 변위 진폭조건에서의 은도금한 커넥터의 미동마멸부식 거동

Fretting corrosion tests are conducted with a constant displacement amplitude using silver-plated brass coupons to investigate the effect of contact pressure on fretting corrosion. Three behaviors are identified based on the change in electric resistance and friction coefficient during the fretting test period, and the identified behaviors are dependent on the magnitude of the applied load. The failure cycle (Nf) with an electric resistance of 0.1 D cannot be achieved due to the adhesion behavior of the metal and metal contact under the higher applied load of 0.45 N. This suggests that an average contact pressure higher than 159 MPa for the silver-coated con- nector is desirable to gain an almost infinite lifetime. The relationship between the electric contact resistance (R) and the average contact pressure (p) can be written as p = 106.2 × Ω �1.5 . Keywordscontact pressure (접촉압력 ), fretting corrosion (미동마멸부식 ), friction coefficient (마찰계수 ), electric connector (전기 커넥터), electric resistance (전기저항)

Film-type connection system toward flexible electronics

A thin electric connector has been required for use in mobile electronics. Although an anisotropic conducting adhesive technology, e.g., the use of an anisotropic conductive film (ACF), has been developed to meet the demand, the technology is not suitable for flexible electronic devices based on plastic materials, since the plastic films used will change their mechanical properties by pressure and heat. To address these limitations, we have developed a novel film-type connector composed of a base material such as polyimide, an adhesive layer that deforms elastically against pressure, and electrodes arranged on the adhesive layer. In this study, the contact resistance of a film-type connector is investigated and compared with that of an ACF joint through four tests related to reliability. Results of the tests show that the film-type connector is more useful than the ACF joint in areas such as future flexible fine-pitch interconnections.

Numerical modeling and optimization of laser soldering for Micro‐USB electric connector

SummaryThe laser soldering process was introduced in Micro‐USB electronic packaging in this paper. Numerical modeling and analysis was used for laser process parameter design, because experimental measurements of peak temperature and soldering stress are expensive and often intractable. Accurate knowledge of the residual stress and distortion is a prerequisite for the reliability of the electric connector. The present work proposes a three‐dimensional transient heat transfer model of Micro‐USB package laser soldering process. The calculated thermal cycles and distribution are subsequently used to calculate the distortion and thermal stresses. Meanwhile, the effect of process parameters on residual stress and pin distortion was discussed, and the tensile strength, microstructure, and residual stresses of laser soldering were tested. It can be concluded that the proper laser soldering parameters and power can improve the mechanical property of solder joints on Micro‐USB connector. Copyright © 2014 John Wiley & Sons, Ltd.