Vibration of Wire-Connector Systems and its Influence on Micro Motion of Electrical Contacts

The vibration of wire-connector systems influences the relative motion in connectors and consequently the wear and fretting corrosion behavior of electrical contacts. This influence can vary with different wire routings. In this study, the relationship between the vibration of a wire-connector system and the resulting micro motion of the contacts is investigated. It is known that along with the sliding motion, yawing and pitching motions can be present in the contact zone of a connector and that the translational sliding motion between the contact partners leads to a higher wear than the yawing or pitching motion. It is also known that the vibration of a wire-connector system in the insertion direction leads to less severe wear than that of vibration in the perpendicular directions. These findings reveal the influence of wire routing on the fretting wear of connectors used in a vibrational system. In this study a simulation model is established in order to determine the micro motion of the blade of an electrical connector due to wire motion. Validation tests with a single wire and the blade of an electrical connector are conducted with the wire being deflected by means of a shaker. The micro motion is evaluated by two different optical methods, namely by camera and a laser distance sensor. The results of the simulated motion of the blade are validated by laboratory tests. This study is a preliminary approach to a simulation tool for determining vibration of wire-connector systems and its influence on micro motions of electrical contacts. With knowledge of this micro motion and contact force, the wear of the surface in the contact area can be calculated in future works and based on these findings the correlation between the service life of connectors in a vibrational system and wire routing can be estimated.