Assessing the Impact of High-Pressure Connector Terminal Wear on Geometric Parameters and How it Triggers Contact Failure
In high-pressure electrical systems of vehicles, high-pressure connectors play a crucial role, and their terminal wear directly affects the performance and reliability of the entire system. The wear of the connector terminal mold will significantly affect the geometric parameters, which may lead to parameter drift and ultimately cause contact failure.
The connector terminal mold undergoes wear due to continuous contact and pressure over a long period. Mold wear will directly alter the force distribution during the pressing process and change the shape of the mold, affecting the geometric parameters in multiple ways. For example, blade wear will cause changes in the width and height of the terminal after pressing. When the blade becomes dull, the pressing effect on the terminal decreases, potentially leading to increased width and reduced height. Additionally, side face wear will affect the angle at which the terminal is pressed, resulting in a tilted terminal after pressing, which not only affects the coordination with other components but also changes the current transmission path, increasing resistance.
Changes in geometric parameters will trigger parameter drift, a complex physical process. Parameter drift mainly manifests as changes in resistance and contact force. When the geometric parameters change, the contact area and pressure between the terminal and conductor will also change. A decrease in contact area will increase current density, leading to increased resistance; unstable contact pressure will cause the contact resistance to fluctuate over time and with vibration. This resistance change is a manifestation of parameter drift.
Parameter drift is an important reason for triggering contact failure. Contact failure can lead to a series of severe problems. When resistance increases, more heat is generated, and excessive temperatures can accelerate the aging of terminals and conductors, potentially leading to fires or other safety incidents. Moreover, contact failure also causes signal transmission instability, affecting the normal operation of automotive electronic systems, such as inaccurate battery capacity monitoring in electric vehicle battery management systems, which affects the vehicle's range and safety.
To more intuitively understand these effects, a table is provided below to illustrate the relationships between connector mold wear, geometric parameter changes, parameter drift, and contact failure.
| Connector Mold Wear Situation | Geometric Parameter Changes | Parameter Drift Manifestations | Contact Failure Consequences |
|---|---|---|---|
| Blade Wear | Terminal Width Increases, Height Decreases | Resistance Increases | Heat Generation, Aging Acceleration |
| Side Face Wear | Terminal Pressure Angle Tilted | Resistance Fluctuates | Signal Transmission Instability |
In actual production and use, it is essential to pay attention to the wear of high-pressure connector terminal molds. Regularly inspect and maintain the molds, replacing severely worn-out molds in a timely manner, can effectively ensure press quality, reduce parameter drift and contact failure occurrence, and improve the reliability and safety of automotive high-pressure electrical systems.