Please wait a minute...
Journal of Zhejiang University-SCIENCE A (Applied Physics & Engineering)  2007, Vol. 8 Issue (3 ): 7-    DOI: 10.1631/jzus.2007.A0384
    
Failure analysis of a kind of low power connector
ZHOU Yi-lin, ZENG Ning, XU Liang-jun, JÖRGENS Stefan
Research Lab of Electric Contacts, Beijing University of Posts & Telecommunications, Beijing 100876, China; Lumberg Connect GmbH & Co. KG, Schalksmühle 58579, Germany
Download:     PDF (0 KB)     
Export: BibTeX | EndNote (RIS)      

Abstract  A kind of low power connector used e.g. in household appliances was partly burned in routine experiment. The heat sources were four paralleled contacts constructed by springs (Sn/CuSn-alloy) in socket and a plug sheet (Ni/Steel) while mating. The contact interfaces were detected by scanning electronic microscope (SEM) and X-ray energy dispersive spectroscopy (XEDS), obvious wear tracks and various contaminants, including element Si, Al, Na, K, S, Cl, O, etc., were found. The contamination degrees on the four paralleled contacts were different, so that the ratio of average contact resistance on the four contacts was about 5:8:3:1. The maximum contact resistance on contacts of the plug sheet reached 28 Ω. The main failure reasons were fretting and contamination between the contact interfaces. Fretting simulation showed that connection resistance of connectors was raised up, even to ohms level. When the current increased to 5 A, the socket housing was heated and decomposed. By the thermal analysis, it was estimated that the connector would be burned under the lower current if the current was not evenly distributed on the four paralleled contacts caused by uneven contamination. Improvement methods for connector failure are also discussed.

Key wordsConnector      Thermal failure      Fretting      Contamination     
Received: 19 December 2006     
CLC:  TM5  
Cite this article:

ZHOU Yi-lin, ZENG Ning, XU Liang-jun, JÖRGENS Stefan. Failure analysis of a kind of low power connector. Journal of Zhejiang University-SCIENCE A (Applied Physics & Engineering), 2007, 8(3 ): 7-.

URL:

http://www.zjujournals.com/xueshu/zjus-a/10.1631/jzus.2007.A0384     OR     http://www.zjujournals.com/xueshu/zjus-a/Y2007/V8/I3 /7

[1] Tao Tao, Ying-jun Lu, Xiang Fu, Kun-lun Xin. Identification of sources of pollution and contamination in water distribution networks based on pattern recognition[J]. Journal of Zhejiang University-SCIENCE A (Applied Physics & Engineering), 2012, 13(7): 559-570.
[2] Hai-jian XIE, Yun-min CHEN, Liang-tong ZHAN, Ren-peng CHEN, Xiao-wu TANG, Ru-hai CHEN, Han KE. Investigation of migration of pollutant at the base of Suzhou Qizishan landfill without a liner system[J]. Journal of Zhejiang University-SCIENCE A (Applied Physics & Engineering), 2009, 10(3): 439-449.
[3] TAKAGI Tasuku. Noise properties in breaking and loose contacts and their effect on quality degradation of digital signal[J]. Journal of Zhejiang University-SCIENCE A (Applied Physics & Engineering), 2007, 8(3 ): 3-.
[4] ZHANG Ji-gao. Particle contamination, the disruption of electronic connectors in the signal transmission system[J]. Journal of Zhejiang University-SCIENCE A (Applied Physics & Engineering), 2007, 8(3 ): 4-.
[5] WANG Xin, XU Liang-jun. Finite element model analysis of thermal failure in connector[J]. Journal of Zhejiang University-SCIENCE A (Applied Physics & Engineering), 2007, 8(3 ): 9-.
[6] LV Bin, ZHOU Sheng-jun, ZHAO Lan-yan. Technical research on optimization design of contacts of electrical connector[J]. Journal of Zhejiang University-SCIENCE A (Applied Physics & Engineering), 2007, 8(3 ): 30-.