Detection and Accelerated Testing of Vibration-Induced Connector Wear

Blanks, Henry S.

doi:10.1109/tchmt.1984.1136320

Cited by 12 publications

(6 citation statements)

References 11 publications

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“…Corrosion is accelerated in environments exhibiting high temperature or severe vibration [10]- [12]. Wear appears at the metal of the contact part when the connectors are repeatedly disconnected and reconnected during usage [13]- [15]. Such repeated processes may also flatten or roughen the contact surface.…”

Section: Introductionmentioning

confidence: 99%

Numerical and Experimental Analysis of Potential Causes Degrading Contact Resistances and Forces of Sensor Connectors for Vehicles

Lim

Kim

et al. 2019

IEEE Access

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Faults in vehicle sensor connectors are crucial to the safety of a vehicle. Once the connector is loosened according to the reduction of its contact forces, its electrical contact resistance may be increased, causing unexpected errors in sensor systems. However, such error mechanisms have enormously diverse causes that have not yet been identified. This study proposes a process to analyze the causes influencing the connector contact force and resistance by employing a combination of numerical and experimental methods. Specifically, the causes of variation of contact force are numerically analyzed and their influence on the electrical contact resistance is experimentally studied. Precise 3D models of a commercial vehicle sensor connector are developed based on a 3D tomography, and a 3D finite element (FE) simulation is employed to estimate the connector contact force, considering plastic deformation. After classifying potential causes into three categories, two major factors are selected: manufacturing tolerance occurring during the connector manufacturing process and plastic deformation occurring during the vehicle maintenance process. The factors are observed to substantially reduce the contact force (by ∼14.6 or 19%). The impact of the reduced contact force is validated in sequential experiments, and exhibits a nonlinear relationship between the contact force and corresponding contact resistance. In addition, the experiments also consider simulated manufacturing and maintenance factors, and demonstrate an increased contact resistance by the functions of the decreased contact force with minor measurement errors (<7.5%).

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Section: Introductionmentioning

confidence: 99%

Numerical and Experimental Analysis of Potential Causes Degrading Contact Resistances and Forces of Sensor Connectors for Vehicles

Lim

Kim

et al. 2019

IEEE Access

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“…e ) Material: Non-noble metals tend to oxidize and promote fretting corrosion. Only a few materials cause low values of contact resistance under fretting conditions, such as Au, Ag [ll], Rh [12], and TiN [13]. the contact against corrosive attacks, which may result in low values of contact resistance.…”

Section: A Fretting Corrosionmentioning

confidence: 99%

“…The varying value of the spring force F during the actuator (12) where F, , , denotes the maximum value of F, when the actuator is over the cut (s = h). F is related to spring stiffness K and to the increase in length ( s -h) from the maximum force position (s = h).…”

Section: B Bearing Forcementioning

confidence: 99%

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Reliability of electrically conducting knife-edge bearings of switches

Schopf

Rieder

1995

IEEE Trans. Comp., Packag., Manufact. Technol. A

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Knife-edge bearings are used as electrically conducting elements between the movable and fixed part of the current path in many kinds of switches, e.g., microswitches and snapaction rocker switches. The contact resistance of such bearings may rise to unacceptably high values and may d i m i i h the reliability of the device.Experimental investigations showed that fretting corrosion is the cause of occassionally observed increase and fluctuation of the electrical resistance of nonbouncing knife-edge bearings. In the case of bouncing knife-edge bearings erosion and oxidation-caused by the arc during the repeatedly opening and closing bearing contacts (notch-cut)diminishes the reliability of the bearings.Precautions have been specified in order to improve the reliability of knife-edge bearings in the current path of switches.A detailed description of the results of the investigations, a synopsis of the fundamentals (of fretting corrosion, dynamics of knife-edge bearings, friction, bouncing), and an indication of important correlations facilitate the understanding of the phenomenon occuring in electrically conducting knife-edge bearings.

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“…Constant-stress loading is commonly used due to its simplicity and ease of analysis ( [12], [13], [18], [21]). When the step-stress loading method is applied, the reliability-related information can be acquired in a relatively quick and economic way due to shorter test duration and smaller sample size needed in comparison with the case of constant-stress loading ( [1], [2], [3], [7], [14], [19]). In addition, McLinn [11] suggested a number of useful applications of the step-stress loading method.…”

mentioning

confidence: 99%

Optimal Design of Step-Stress Degradation Tests in the Case of Destructive Measurement

Park

Yum

Balamurali

2004

Quality Technology & Quantitative Management

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In this article, optimal accelerated degradation test plans under step-stress loading (step-ADT plans) are developed under the assumptions of destructive testing, a simple constant-rate relationship between the stress and the performance of a unit, and a cumulative exposure model for the effect of changing stress levels. As an optimization criterion, the asymptotic variance of the maximum likelihood estimator of the th quantile of the lifetime distribution at the use condition is adopted, and the stress levels, the proportion of units measured at each test point, and the stress changing time are optimally determined. Sensitivity analysis and sample size determination procedures are also illustrated with an example. Finally, the optimal step-ADT plan is compared with the corresponding optimal ADT plan under constant-stress loading in terms of statistical efficiency and the total amount of testing time. Computational results indicate that the proposed step-ADT plan is more economical in terms of testing time if only one test equipment can be employed. q

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Detection and Accelerated Testing of Vibration-Induced Connector Wear

Cited by 12 publications

References 11 publications

Numerical and Experimental Analysis of Potential Causes Degrading Contact Resistances and Forces of Sensor Connectors for Vehicles

Numerical and Experimental Analysis of Potential Causes Degrading Contact Resistances and Forces of Sensor Connectors for Vehicles

Reliability of electrically conducting knife-edge bearings of switches

Optimal Design of Step-Stress Degradation Tests in the Case of Destructive Measurement

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