Integrated design of insertions-extractions performance and contact reliability of spring-wire socket electrical connector

With the improvement of the reliability and lifespan of electrical connectors, the traditional single objective design focusing solely on performance or reliability has become inadequate to meet the requirements. This paper analyzes the failure mechanism of a specific electrical connector under the conditions of insertions-extractions. It establishes a contact degradation model and an integrated design model that considers mechanical properties and reliability. By analyzing the integrated design model, the optimization variables have been defined as the radius of the spring wire, the radius of the pin, the inner radius of the inner sleeve, the length of the inner sleeve, and the inclination of the spring wire. Additionally, the objective function of optimization has been determined. The optimal solutions that satisfy the constraints were calculated using the global optimization algorithm. The optimization results not only achieve the goal of high reliability but also the goal of extended mechanical life.