Views: 0 Author: Site Editor Publish Time: 2023-04-27 Origin: Site
Trial analysis of several common contact parts in the application of new energy vehicles high-voltage connectors
Introduction: Connectors are used in every automobile, the device uses electrical and optical signals with the help of its control of the corresponding mechanical force connection, disconnection, conversion, and then realize the corresponding circuit or optical channel conversion of a functional component, and with the help of ECT electrical and optical signals can also effectively prevent its signal distortion and the corresponding energy loss, and thus ensure the efficiency of the conversion. At the same time, connectors in new energy vehicles in the application of high-voltage connectors are mostly used in its terminal applications, and thus enhance the corresponding transmission sensitivity performance, while the advanced nature of the device will also affect the level of development of automotive transmission technology.
In recent years, the world's pollution has intensified, in order to cope with this serious situation, China has advocated green development, the automotive sector is no exception, which has led to significant progress in the new energy vehicle industry. And in the process of this industrial development, high-voltage connectors as one of the core components, play a huge role, playing an unparalleled value, in the new energy vehicles, charging facilities are used. The device mainly consists of contact parts, insulator, shell, accessories and other parts. In these parts, the contact is its core, and also shoulders the line, the system in driving light, electricity and other signal connections, so it can be seen as its pivotal parts; and the insulator when the insulation protection role, mainly is isolated from the external environment; shell is fixed and auxiliary protection, and even as a base; the last accessories are more extensive, need to be set according to the specific application needs to target, of course, mainly to assist in completing the connection of the cable. Of course, the main auxiliary to complete the protection of connecting cables or other components, and this is also to ensure that the work environment to meet the requirements of important auxiliary units.
And to achieve the connection function is its central contact parts, any poor contact is the source of failure. This paper concludes that more than 70% of the causes of system failure or malfunction in new energy vehicles are caused by the failure of this type of component, and among them, more than 40% are due to contact failure, which shows the importance of contact parts in new energy vehicles.
The authors of this paper have been working on aspects related to high voltage connectors in new energy vehicles. In the research and development, it is not only necessary to circumvent similar patents, but also to find suitable components. The core structure of this is its contact parts, for them, especially the structure, performance and material of its jack has a significant impact on the corresponding performance.
· Structure of contact parts
The overall structure of the new energy vehicle connector is not complex, basically using a metal shell of the circular connector, and with the development of various engineering materials in recent years, plastic connectors are also more common. However, the basic structure is basically the same, generally include pins and jacks are two parts, through the plug to achieve connection. The general use of pins in order to pursue its connection performance, basically using rigid pins, flexible jacks. Of course, for some of the existence of special needs of the contact parts also need to be plated, silver or gold plating mostly.
· Performance of electrical connector contacts
The basic properties are electrical, mechanical, and environmental resistance of these three. The former are to meet the contact resistance, insulation withstand voltage, insulation resistance of these three requirements, which is to ensure the reliable transmission of optical and electrical signals to guarantee. The mechanical aspects need to consider the plugging force, mechanical life factors. Most of the components of the type of its overall life is more than plugging 50 times.
· Materials for electrical connector contacts
The selection of the pin and jack material should first ensure that it has a high mechanical strength, second, to prevent damage and loosening; contact force should also be strong, while the jack material also needs to ensure that it has a high degree of elasticity. Both fatigue resistance, processing and molding performance need to have a certain guarantee, the current choice of pin material is mostly brass.
· Contact form
The contact forms are point, line and surface. Usually it is point contact. But when its range is expanded to a certain extent both line or surface contact. Relatively speaking, the more contact points, its corresponding contact resistance will be smaller, and the actual use will be better.
· Contact pressure
In general, the transient contact resistance is higher for all forms of contact. And as its contact area and the corresponding number of points purpose to increase, because the corresponding contact resistance is constantly reduced, the transient voltage will be reduced. This is particularly important in the selection of jack elastic structure.
· Temperature effects
When the operating temperature of the contact rises to a certain level, the hardness of the pin and jack material will decrease with the increase in temperature, but the lower the contact resistance, the less obvious this problem will be; higher temperatures will accelerate the oxidation of the contact surface of the two, which in turn will aggravate the aging, so some suppression is needed.
· Substances that corrode metals
There are two types of chemical and electrochemical corrosion. Mostly due to external environmental pollution causing this problem, such pollutants will cause the metal surface to appear oxide layer, which will cause its corresponding contact resistance to rise.
· Material properties
The properties of the pin and jack materials have a significant impact on the effectiveness of the final contact as well as the life of the parts, both of which can include material resistivity, hardness, chemistry, high temperature and other related properties. This, the most direct influence is the resistivity of the material. The next influencing factor is both hardness.
· Surface quality
In comparison, a flat and rougher contact surface can effectively increase the number of contact points between the two, and the friction force is also greater, which can effectively remove the oxide layer, so that the contact resistance can be effectively reduced.
· Analysis of the characteristics of contact parts
The reliability of electrical connectors and their own internal structure is closely related, which is the core of the contact. Pins and jacks are the main structure of the contacts, of course, in order to achieve the desired electrical, resistance, reliability, the type of choice is also critical.
The specific application of new energy vehicles corresponding to the use of high-voltage connector requirements are relatively more, because in order to respond to its possible unpredictable conditions, we choose the basic performance of the contact parts as well as the structure need to have a certain degree of relevance, the specific characteristics of the selected structure as shown in Table I. Of course, if the structure of the pin is basically the same, but the corresponding production materials will also exist some differences, in our country its basic materials are mostly used copper or copper alloy; corresponding to several jack forms as shown in Table II. And Table II also briefly describes the main features of the corresponding.
Table I Basic structural characteristics of contact parts
Table II Summary of characteristics of contact parts
· Selection of contact parts
The above three types of jacks are the most basic conditions for the selection of contact parts, new energy ware cars for the above three jack forms are generally more suitable. But in most cases more than the actual needs of the customer according to their given size to produce or customize the corresponding connector. And the body material is not necessarily copper or copper alloy, beryllium bronze, silver-plated plug-ins have now become more common, so the choice of centralized contact parts is also required according to the actual needs of targeted selection.
New energy vehicles with high-voltage connectors selected by the contact cow stomach need to work again under relatively harsh working conditions, the pieces are a very careful process. Usually, we must first ensure that the reliability of the application of the go, followed by the need to consider the economy, process and other related factors, according to the actual needs of customers, there are trade-offs. Of course, with the gradual maturation of this type of technology, the corresponding future pursuit of performance, the quality of the connector and performance requirements will gradually change, high performance, low cost has become an important development trend. This is also the ultimate pursuit of research and development of highly reliable electrical connectors.
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