步进随机振动下电连接器微动磨损试验及性能退化模型

骆燕燕; 祁侨绅; 王永鹏; 武雄伟

doi:10.13700/j.bh.1001-5965.2024.0350

步进随机振动下电连接器微动磨损试验及性能退化模型

doi: 10.13700/j.bh.1001-5965.2024.0350

骆燕燕^1, ,,
祁侨绅^{1, 2},
王永鹏³,
武雄伟⁴

1.
河北工业大学电工产品可靠性技术省部共建协同创新中心，天津 300401
2.
国家电网天津市电力公司城南供电分公司，天津 300201
3.
国家电网山东省电力公司邹平供电公司，邹平 256200
4.
国家电网河北省电力公司邯郸新区供电公司，邯郸 056000

基金项目:

河北省自然科学基金(E2018202156)

详细信息

通讯作者:
E-mail：luoyy@hebut.edu.cn

中图分类号: TM501
计量
- 文章访问数: 336
- HTML全文浏览量: 169
- PDF下载量: 15
- 被引次数: 0
出版历程
- 收稿日期: 2024-05-23
- 录用日期: 2024-06-14
- 网络出版日期: 2024-06-25
- 整期出版日期: 2026-07-31

Fretting wear test and performance degradation model of electrical connector under step random vibration

1.
Provincial and Ministerial Co-construction Collaborative Innovation Center on Reliability Technology of Electrical Products，Hebei University of Technology，Tianjin 300401，China
2.
State Grid Tianjin Electric Power Company Chengnan Power Supply Branch，Tianjin 300201，China
3.
State Grid Shandong Electric Power Company Zouping Power Supply Company，Zouping 256200，China
4.
State Grid Hebei Electric Power Company Handan New Area Power Supply Company，Handan 056000，China

Funds:

Natural Science Foundation of Hebei Province (E2018202156)

More Information

Corresponding author: E-mail：luoyy@hebut.edu.cn

摘要

摘要:
针对电连接器工作时受步进随机振动作用，产生微动磨损而接触性能降低的问题，开展步进应力随机振动试验，采用电容层析成像(ECT)技术检测微动磨损过程中电连接器接触件间磨屑特征值，通过接触电阻与磨屑特征值研究步进应力随机振动条件下接触件的磨损程度及接触性能的退化规律。引入具有鲁棒性好、可以表征非线性关系的最大互信息系数(MIC)进行磨屑特征值与接触电阻的相关性分析，通过MIC筛选降维以提高模型预测精度。结果表明：步进应力随机振动下磨屑特征值、磨屑特征值总量和接触电阻均呈阶梯状变化趋势；通过MIC计算发现磨屑特征值总量与接触电阻强相关；能谱分析的结果与试验结果相吻合；采用MIC筛选优化的CHIO-Elman的性能退化模型的平均绝对误差百分比小于4%。
- 电连接器 /
- 电容层析成像 /
- 微动磨损 /
- 最大互信息系数 /
- 冠状病毒群体免疫优化算法
Abstract:
In view of the problem that the electrical connector is subjected to step stress random vibration during operation, which leads to fretting wear of the electrical connector and the reduction of contact performance, the step stress random vibration test is carried out. The electrical capacitance tomography (ECT) is used to detect the characteristic value of wear debris between the electrical connector contacts in the process of fretting wear. Contact resistivity and the characteristic value of wear debris are used to study the wear degree and degradation law of contact performance under step stress random vibration conditions. The maximal information coefficient (MIC), which has good robustness and can characterize the nonlinear relationship, is introduced to analyze the correlation between the characteristic value of wear debris and contact resistance, and the dimension is reduced through mic screening to improve the prediction accuracy of the model. The findings demonstrate that under the random vibration of step stress, there is a stepped change trend in the contact resistance, the total characteristic values of wear debris, and the characteristic values of wear debris. Through the calculation of the maximum information coefficient, it is found that the total amount of wear debris characteristics is strongly correlated with the contact resistance. The results of energy spectrum analysis are consistent with the test results. The average absolute error of CHIO-Elman neural network performance degradation model optimized by MIC screening is less than 4%.
- electrical connector /
- electrical capacitance tomography /
- fretting wear /
- maximal information coefficient /
- coronavirus herd immunity optimization algorithm

HTML全文

图 1 电连接器接触件试品示意图

Figure 1. Schematic diagram of electrical connector contacts specimen

下载: 全尺寸图片幻灯片

图 2 电连接器微动磨损试验装置

Figure 2. Fretting wear test device for electrical connector

下载: 全尺寸图片幻灯片

图 3 电连接器接触件试品安装示意图

Figure 3. Installation diagram of electrical connector contacts specimen

下载: 全尺寸图片幻灯片

图 4 振动方向示意图

Figure 4. Schematic diagram of vibration direction

下载: 全尺寸图片幻灯片

图 5 电连接器接触件试品接触区域划分

Figure 5. Contact area division of electrical connector contacts specimen

下载: 全尺寸图片幻灯片

图 6 应力水平示意图

Figure 6. Schematic diagram of stress level

下载: 全尺寸图片幻灯片

图 7 电连接器接触件试品重度磨损接触子区域中电极对2-3和6-7磨屑特征值变化

Figure 7. Variation of wear debris characteristic values of electrode pairs 2-3 and 6-7 in heavily worn contact sub region of electrical connector contacts specimens

下载: 全尺寸图片幻灯片

图 8 电连接器接触件试品磨屑特征值总量变化

Figure 8. Changes in total characteristic values of wear debris in electrical connector contacts specimen

下载: 全尺寸图片幻灯片

图 9 电连接器接触件试品接触电阻变化

Figure 9. Contact resistance change of electrical connector contacts specimen

下载: 全尺寸图片幻灯片

图 10 试品y-1插针根部能谱分析位置

Figure 10. Location of spectroscopy analysis at root of specimen y-1 pin

下载: 全尺寸图片幻灯片

表 1 电连接器接触件试品部分基本性能参数

Table 1. Electrical connector contacts specimen part basic performance parameters

额定电压/V	额定电流/A	工作电压/V	耐电压/V	接触电阻/mΩ	绝缘阻抗/MΩ
500	80	600	3000	0.2	2000

下载: 导出CSV

表 2 试验方案

Table 2. Test plan

试验组别	应力水平/ (g²·Hz⁻¹)	振动方向	试验时间/min	试品编号
1	0.04→0.06→0.08→0.10	x	800	x-1，x-2
2	0.04→0.06→0.08→0.10	y	800	y-1，y-2
3	0.04→0.06→0.08→0.10	z	800	z-1，z-2

下载: 导出CSV

表 3 各子区域的MIC计算结果

Table 3. Results of MIC calculations by sub region

试品编号	MIC(R, ΣΔC)
试品编号	区域A	区域B	上层区域	下层区域	全部区域
x-1	0.51	0.62	0.45	0.68	0.88
x-2	0.53	0.51	0.39	0.65	0.66
y-1	0.47	0.50	0.45	0.52	0.85
y-2	0.39	0.40	0.36	0.44	0.44
z-1	0.59	0.51	0.52	0.58	0.71
z-2	0.53	0.63	0.56	0.60	0.78

下载: 导出CSV

表 4 试品y-1能谱分析各位置元素含量

Table 4. Analysis of element content at each position by specimen y-1 energy spectrum

编号位置	质量百分比/%					原子百分比/%
编号位置	O	C	Ni	Cu	Au	O	C	Ni	Cu	Au
1	17.7		61.1	2.2	11.6	47.4		44.2	1.4	2.5
2	2		80.6	2.5	11.9	7.7		83.5	2.4	3.6
3	30.2		55.2	2.7	8.9	63.7		31.7	1.4	1.5
4	1.3		79.4	2.2	14.3	5.1		85.4	2.2	4.5
5	3.6		57.2	2.1	36.2	15.8		68.5	2.3	12.9
6	33	33	56	1.7	6.8	70.6	70.6	24.4	0.7	0.8
7	1.6		68.9	3	25.7	7		80.5	3.3	8.9

下载: 导出CSV

表 5 不同模型误差比较

Table 5. Comparison of errors between different models

模型	振动方向	E₁	E₂	E₃/%
Elman	x	0.0111	0.0143	4.62
	y	0.0224	0.0297	10.039
	z	0.0131	0.0148	5.12
CHIO-Elman	x	0.0063	0.0073	2.4121
	y	0.0129	0.0146	5.0547
	z	0.0082	0.0102	3.5003
MIC-CHIO-Elman	x	0.0035	0.0168	1.7141
	y	0.0076	0.0094	3.2525
	z	0.0044	0.0049	2.0528

下载: 导出CSV

参考文献(29)

[1]	Braunovic M. Fretting in electrical/electronic connections: a review[J]. IEICE Transactions on Electronics, 2009, 92(8): 982-991.
[2]	Ikeda H, Ito T, Sawada S, et al. Influence of fretting wear on lifetime of tin plated connectors[J]. IEICE Transactions on Electronics, 2009, 92(9): 1215-1222.
[3]	Park Y W, Narayanan T S N S, Lee K Y. Fretting corrosion of tin-plated contacts[J]. Tribology International, 2008, 41(7): 616-628.
[4]	李玲, 李港华, 吕刚, 等. 双粗糙表面的微动磨损行为研究[J]. 表面技术, 2022, 51(2): 193-201. Li L, Li G H, Lv G, et al. Research on fretting wear behaviour of double rough surface[J]. Surface Technology, 2022, 51(2): 193-201(in Chinese).
[5]	何莉萍, 彭金方, 蔡振兵, 等. 不同含氧量环境下紫铜/黄铜电接触微动磨损性能研究[J]. 摩擦学学报, 2022, 42(4): 680-689. He L P, Peng J F, Cai Z B, et al. Electrical contact fretting wear behavior of copper/brass under different oxygen content[J]. Tribology, 2022, 42(4): 680-689(in Chinese).
[6]	刘少杰, 仇原鹰, 白金, 等. 三轴随机振动下电连接器的松动机理及应力-电阻映射关系研究[J]. 振动与冲击, 2021, 40(11): 190-195. Liu S J, Qiu Y Y, Bai J, et al. Loosening mechanism and stress-resistance mapping relationship of electrical connector under triaxial random vibration[J]. Journal of Vibration and Shock, 2021, 40(11): 190-195(in Chinese).
[7]	刘琦, 郁大照, 许振晓, 等. 电连接器接触件微动磨损有限元仿真分析[J]. 海军航空工程学院学报, 2021(2): 165-172. Liu Q, Yu D Z, Xu Z X, et al. Finite element simulation analysis of fretting wear of aviation electrical connector contacts[J]. Journal of Naval Aeronautical and Astronautical University, 2021(2): 165-172(in Chinese).
[8]	郁大照, 张彤. 振动对航空电连接器的影响分析[J]. 装备环境工程, 2021, 18(6): 87-93. Yu D Z, Zhang T. Analysis of the influence of vibration on aviation electrical connectors[J]. Equipment Environmental Engineering, 2021, 18(6): 87-93(in Chinese).
[9]	Wen B H, Pan J, Qian P, et al. Research on the influence of the closing amount of electrical connector contacts on fretting wear under a vibration environment[J]. Electronics, 2023, 12(11): 2469.
[10]	Feng C, Lin X X, Hu J X, et al. Study on the influence of fretting wear on electrical performance of SMA connector[J]. Microelectronics Reliability, 2021, 118: 114047.
[11]	Pompanon F, Fouvry S, Alquier O. Influence of the relative humidity and H₂S-SO₂ polluted air on the fretting wear behavior of silver-plated electrical contacts[J]. Wear, 2022, 508: 204455.
[12]	Liu X L, Li Z H, He J F, et al. Influence of humidity on endurance of electrical contact during fretting wear[J]. Journal of Materials Engineering and Performance, 2022, 31(2): 933-943.
[13]	Siddaiah A, Kasar A K, Khosla V, et al. In-situ fretting wear analysis of electrical connectors for real system applications[J]. Journal of Manufacturing and Materials Processing, 2019, 3(2): 47.
[14]	Liu X L, Li Z H, Xiao Q, et al. Fretting wear of co-Cr-Mo alloys at elevated temperatures[J]. Journal of Materials Engineering and Performance, 2020, 29(11): 7499-7510.
[15]	Xu L, Ling S, Lin Y, et al. Fretting wear and reliability assessment of gold-plated electrical connectors[J]. Microelectronics Reliability, 2019, 100: 113348.
[16]	Liu X L, Cai Z B, Liu S B, et al. Influence of wear test parameters on the electrical contact performance of brass alloy/copper contactors under fretting wear[J]. Journal of Materials Engineering and Performance, 2019, 28(2): 817-827.
[17]	Wang J Y, Feng Y, Cai M, et al. Electrical contact resistance evolution and interface fretting wear characteristics of conductor-parallel groove clamp system response to breeze vibration environment[J]. IEEE Transactions on Components, Packaging and Manufacturing Technology, 2024, 14(1): 43-51.
[18]	Mcbride J W. Developments in fretting studies applied to electrical contacts[C]//Proceedings of the 52nd IEEE Holm Conference on Electrical Contacts. Piscataway: IEEE Press, 2007: 170-180.
[19]	Tamai T, Sawada S, Hattori Y. Contact mechanisms and contact resistance characteristics of solid tin and plated tin contacts used for connectors[J]. IEICE Transactions on Electronics, 2010, 93(5): 670-677.
[20]	Nishimoto M, Naka Y. Analysis of transient scattering by a metal cylinder covered with inhomogeneous lossy material for nondestructive testing[J]. IEICE Transactions on Electronics, 2018, 101(1): 44-47.
[21]	Radha P, Selvakumar N, Sekar J R, et al. A novel ultrasonic based NDT for smart analysis of material defects using IoT[C]//Proceedings of the 6th International Conference on Inventive Computation Technologies. Piscataway: IEEE Press, 2021: 163-168.
[22]	张雯. 振动条件下电连接器接触件步进应力加速退化试验研究[D]. 杭州: 浙江理工大学, 2020. Zhang W. Study on step-stress acceleration degradation test of electrical connector contacts under vibration[D]. Hangzhou: Zhejiang Sci-Tech University, 2020(in Chinese).
[23]	蒋杰, 肖曙红, 汤鹏. 圆形电源连接器随机振动分析与结构优化[J]. 机床与液压, 2017, 45(11): 111-116. Jiang J, Xiao S H, Tang P. Random vibration analysis and structure optimization of circular power connector[J]. Machine Tool & Hydraulics, 2017, 45(11): 111-116(in Chinese).
[24]	Flowers G T, Xie F, Bozack M J, et al. Modeling early stage fretting of electrical connectors subjected to random vibration[J]. IEEE Transactions on Components and Packaging Technologies, 2005, 28(4): 721-727.
[25]	Xu L, Ling S, Li D, et al. Vibration-induced dynamic characteristics modeling of electrical contact resistance for connectors[J]. Microelectronics Reliability, 2020, 114: 113868.
[26]	Krüger K, Yuan H M, Song J. The influence of the vibration test mode on the failure rate of electrical connectors[J]. Microelectronics Reliability, 2022, 135: 114567.
[27]	田海军, 周云龙. 电容层析成像技术研究进展[J]. 化工自动化及仪表, 2012, 39(11): 1387-1392. Tian H J, Zhou Y L. Progress in capacitance tomography technology research[J]. Control and Instruments in Chemical Industry, 2012, 39(11): 1387-1392(in Chinese).
[28]	Lei J, Liu Q B, Wang X Y. Physics-informed multi-fidelity learning-driven imaging method for electrical capacitance tomography[J]. Engineering Applications of Artificial Intelligence, 2022, 116: 105467.
[29]	中国人民解放军总装备部.电连接器试验方法: GJB 1217A—2009[S]. 北京: 中国人民解放军总装备部, 2009. The General Armaments Department of the People’s Liberation Army. Test methods for electrical connectors: GJB 1217A—2009[S]. Beijing: The General Armaments Department of the People’s Liberation Army, 2009(in Chinese).