Forward force analysis of connector terminal insertion and removal

‌ The forward force on the connector terminal refers to the force that is perpendicular to the contact surface of the male and female terminals of the connector. ‌ It is an important indicator affecting the connector performance. Improving the forward force can reduce the contact resistance and improve the problem of electrical signal breaking when the connector vibrates ‌.

Connector project development usually involves the following types of simulation content.

Connector terminal forward force analysis Case 1:

Product simulation purpose overview:

The forward force and maximum stress of a certain connector are calculated when the downward pressure stroke is 0.5mm, 0.9mm and 1.3mm, respectively

Material parameters:

The yield strength of the connector shrapnel material is 1225Mpa, and the tensile strength of the connector shrapnel material is 1380Mpa

Product model:

Below, the left side is the original geometric model of the product, and the right side is the finite element analysis grid model.

Analysis of working conditions:

The welding fixed surface is set to fixed, and the downward pressure forms the end loading load.

Analysis results:

1. The positive force is 0.78N when the terminal press stroke is 0.5mm. The maximum stress is 602.4Mpa, which is lower than the yield strength of the used material (1225Mpa), and no plastic deformation occurs.

2. The positive force is 1.3N when the terminal press stroke is 0.9mm. The maximum stress is 1063Mpa, which is lower than the yield strength of the used material (1225Mpa), and no plastic deformation occurs.

3. The positive force is 2.1N when the terminal press stroke is 1.3mm. The maximum stress is 1467Mpa, which exceeds the yield strength of the material used (1225Mpa), and plastic deformation occurs locally.

Summary of analysis results:

Factors affecting the positive force include:

‌ material ‌ : The material hardness of plug and socket affects the coefficient of friction, and thus affects the magnitude of the positive force ‌. ‌

Shape ‌ : The shape complexity of plugs and sockets affects the generation of positive force ‌. ‌

Environment ‌ : Temperature and humidity affect the coefficient of friction and electrical properties, which in turn affect the positive force ‌. ‌

Inserting and removing speed ‌ : too fast or too slow inserting and removing speed will affect the generation of positive force ‌

Through CAE simulation, the plug and pull force of the connector is analyzed, which provides a theoretical basis for further improving the structural design, and plays a significant role in improving the reliability of the connector industry, reducing the damage rate of the product and reducing the cost. The following is the insertion and withdrawal force project analysis done by finite element Technology for a connector company.

Connector terminal insertion and removal forward force analysis case:

Product simulation purpose overview:

The insertion and withdrawal forces of the two thickness connectors (0.68mm card connector and 0.84mm card connector) were calculated respectively

Material parameters:

Original drawing model: (as shown below)

Analysis results:

0.68mm card connector

0.84mm card connector

Summary of analysis results:

The role of positive force is mainly reflected in the following aspects:

‌1. Improve connector reliability ‌ : The positive force can increase the friction between the connector plug and socket to prevent loosening or falling off during vibration or impact ‌. ‌

2. Ensure the stability of signal transmission ‌ : by increasing the contact pressure, ensure the stability of signal transmission, reduce signal attenuation and interference ‌. ‌

3. Prevent electric spark ‌ : reduce the resistance when inserting and removing, avoid electric spark and reduce the risk of fire ‌.