Experimental and analytical models of the connector insertion-extraction phase

Studies of connectors for electric and electronic automotive systems have been and still are being pursued. The main criterion for the electrical contact reliability is to minimize the connector insertion force, which mainly depends on the contact force determined by the mechanical design. A non-intrusive technique for contact force determination by deflection measurement of the contact spring during insertion and extraction phase using a laser device has been developed. We have access to the following insertion parameters during the insertion stroke: contact deflection δ which yields the contact force F_c, insertion force F_i and contact resistance R_c. Regarding the results for real connectors, an experimental model of a connector based on a cylindrical pin crossed with a cylindrical spring, is proposed in This work. With this simple setup, we have made an analytical model, which permits analysis of the influence of each parameter (width, spring radius etc). Based on analysis of the influence of the spring width and of the gap, this study offers the possibility of optimizing the design of such connectors for use in the automotive industry.