红外热成像技术在电连接器插拔磨损检测中的应用研究

Research on application of infrared thermal imaging technology in plug-in wear detection of electrical connector

接触件是电连接器的核心元件,因插拔产生的磨损会导致其电接触性能退化甚至失效。针对上述问题,提出了一种电连接器插拔磨损检测方法。基于设计的检测装置开展电连接器插拔试验,并在试验过程中对电连接器接触件进行定时红外热成像检测;同时,分析插拔过程中电连接器接触件间磨屑的分布特征及变化规律,并通过表面形貌分析和能谱分析来验证红外热成像分析结果。研究发现,电连接器插孔簧片的主要磨损区域为端部,其根部有少量磨屑且聚集区域相对分散;随着插拔次数的增加,电连接器接触件间的磨屑逐渐增多,磨损区域面积逐渐增大,且磨屑聚集的位置也随着插拔运动发生变化,随机地分布在接触件间;因存在加工误差,电连接器的插孔簧片非对称分布,使得不同插孔簧片的磨损程度存在差异。结果表明,所提出的检测方法可有效观察电连接器接触件插拔磨损的变化过程,可作为电连接器磨损程度在线监测及剩余寿命预测的有效手段。研究结果可为电连接器性能退化机理和失效分析提供依据。

The contact is the core component of the electrical connector, and the wear caused by plugging will lead to its electrical contact performance degradation or even failure. In view of above problems, a plug-in wear detection method for the electrical connector was proposed. Based on the designed detection device, the plug-in test for the electrical connector was carried out, and the contacts of the electrical connector were detected by timed infrared thermal imaging during the test process;at the same time, the distribution characteristics and changing law of wear debris between electrical connector contacts during plugging process were analyzed, and the infrared thermal imaging analysis results were verified by the surface morphology analysis and the energy spectrum analysis. It was found that the main wear area of the electrical connector jack reed was on the end part, and the root part had a small amount of wear debris and the aggregation area was relatively dispersed;with the increase of plugging times, the wear debris between the electrical connector contacts and the wear area gradually increased, and the location of the wear debris accumulation also changed with the plugging movement and was randomly distributed among the contacts;due to machining errors, the jack reed of the electrical connector was asymmetrically distributed, which made the wear degree of different jack reeds different. The results showed that the proposed detection method could effectively observe the charge process of the plug-in wear of electrical connector contacts, and could be used as an effective means for the on-line monitoring of wear degree and residual life prediction of the electrical connector. The research results can provide a basis for the performance degradation mechanism and failure analysis of electrical connectors.