Research on Intermittent Failure Mechanism of the Electrical Connector of the Missile Launch Vehicle

Abstract

Electrical connector has become an indispensable and important part in aviation, aerospace, and other fields, and its work is normal or not will directly affect the daily use of equipment and the success or failure of the mission. In this paper, aiming the problem of intermittent fault of electrical connector caused by poor contact. Based on the analysis of the failure causes, the test scheme of intermittent failure incentive of the electrical connector is established. The step vibration stress, rapid temperature variation plus vibration stress, high temperature plus vibration stress test were carried out in the system of test and contact resistance monitoring. And the failure mechanism analysis was carried out. The results show that the electrical connector has intermittent failure under the combined action of high temperature and vibration stress. Vibration stress will make the contact of electrical connector fretting wear, resulting in coating surface wear, peeling, and produce plastic debris. The high temperature will not only oxidize the contact surface, but also strengthen the above wear. Contact resistance changes due to contact oxidation, insulating dust, plastic debris, and so on, resulting in intermittent faults such as poor contact. The research results will provide technical support for intermittent failure prevention, fault handling, and improved design of electrical connectors.