Simulation prediction method for plugging life of contact of electric connector

Abstract

The invention relates to a simulation prediction method for the plugging life of a contact element of an electric connector, and the method comprises the steps: building a three-dimensional simulation model of a plug end and a socket end of the electric connector, and defining the material attributes and contact relationships of all parts in the three-dimensional simulation model; performing finite element grid discretization on the three-dimensional simulation model; applying a fixed constraint to the socket end, applying a displacement load for simulating the plugging process to the plug end, and performing statics solution to obtain plugging force in the plugging process of the plug end and the socket end and contact pressure data of the plug end contact piece and the socket end contact piece; and mapping a statics solution result into a fatigue analysis module, and simulating, calculating and outputting a life distribution result of the plug end contact element and the socket end contact element under repeated plugging and unplugging loads. The method has the effect of analyzing the stress-strain state of the internal contact element of the electric connector and the fatigue damage of the internal contact element under repeated plugging and unplugging so as to help monitoring personnel to discover the potential mechanical failure problem in time.

Description

Technical Field

[0001] This application relates to the field of electrical connector technology, and in particular to a simulation prediction method for the insertion and extraction life of electrical connector contacts. Background Technology

[0002] Electrical connectors are core components in electronic systems, enabling electrical connections and signal transmission. Their reliability directly affects the normal operation of the entire system. The failure modes of electrical connectors mainly fall into three categories: mechanical failure, electrical failure, and environmental failure. Mechanical failure primarily manifests as a deterioration in mating characteristics, the core evaluation indicator of which is the mating force. The mating force must be maintained within a reasonable range: excessive force leads to operational difficulties, low efficiency, and even physical damage to the connector; insufficient force results in poor contact, increased contact resistance, and the risk of overheating or even open circuits. Therefore, precise control and analysis of the mating force are crucial for ensuring the mechanical reliability and electrical performance of electrical connectors.

[0003] Currently, the evaluation of the mating and extraction performance of electrical connectors mainly relies on experimental testing of physical prototypes. This method has drawbacks such as long cycle time, high cost, and high destructiveness. Furthermore, it is difficult to intuitively and concretely analyze the stress-strain state of internal contacts and their fatigue damage evolution process under repeated mating and extraction during the design phase. Because the mating and extraction life of the contacts cannot be effectively predicted, simulation monitoring personnel cannot promptly detect potential mechanical failures caused by poor mating and extraction performance, and it is even more difficult to conduct targeted structural optimization. Therefore, improvements are needed. Summary of the Invention

[0004] To provide an intuitive and concrete analysis of the stress-strain state of internal contacts of electrical connectors and their fatigue damage under repeated insertion and removal, so as to help simulation monitoring personnel promptly identify potential mechanical failures caused by poor insertion and removal performance and carry out targeted structural optimization, this application provides a simulation prediction method for the insertion and removal life of electrical connector contacts.

[0005] In a first aspect, this application provides a simulation prediction method for the mating and extraction life of electrical connector contacts, including: A three-dimensional simulation model of the plug and socket ends of an electrical connector is established, and the material properties of each component in the three-dimensional simulation model and the contact relationship between each component are defined; wherein the contact relationship between the contact component of the plug end and the contact component of the socket end is a nonlinear frictional contact. The three-dimensional simulation model is discretized using finite element mesh, and the mesh of the contacts at the plug end and the contacts at the socket end is locally refined. In the simulation environment, a fixed constraint is applied to the socket end, and a displacement load simulating the insertion and removal process is applied to the plug end. Static solutions are then performed to obtain the insertion and removal forces during the insertion and removal process of the plug end and the socket end, as well as the contact pressure data between the plug end contact and the socket end contact. The static solution results are mapped to the fatigue analysis module. Based on the low-cycle fatigue theory, the life distribution results of the plug end contact and the socket end contact under repeated insertion and removal loads are simulated and calculated.

[0006] By adopting the above technical solution, this approach allows for the prediction of the mating and extraction performance and lifespan of electrical connectors during the product design phase, even before the physical prototype is manufactured. This significantly shortens the development cycle and reduces R&D and trial-and-error costs. It transcends the limitations of experimental testing, visually demonstrating the stress and strain distribution of the internal contacts during mating and extraction, and accurately calculating the entire process curve of the mating and extraction forces. This enables simulation monitoring personnel to gain a deep understanding of the mechanical behavior. By combining static analysis with low-cycle fatigue theory, it can accurately predict the fatigue life of the contacts after a specified number of mating and extraction cycles, and visually identify the most vulnerable areas for fatigue fracture in the form of cloud maps, providing a clear and reliable basis for design optimization. Based on the lifespan cloud maps and critical node information obtained from simulation, simulation monitoring personnel can make targeted improvements and optimizations to the structure, materials, or processes of the contacts (such as modifying the spring shape or adjusting the interference fit), thereby effectively improving the mechanical mating and extraction lifespan and overall reliability of the electrical connector.

[0007] Optionally, the displacement load applied to the plug end to simulate the insertion and removal process refers to the displacement load in the direction of the preset ideal insertion and removal axis; The method further includes: Based on the life distribution results output by the simulation calculation, the dangerous location is located from the three-dimensional simulation model. The static analysis results are then traced back to solve the stress and strain state of the dangerous location during the insertion and removal process, so as to analyze the damage mode of the dangerous location. The damage mode is correlated with the sensitive offset direction that deviates from the ideal insertion and removal axis, and a mapping relationship between different angular offset loads applied along the sensitive offset direction and the degree of damage at the dangerous location is established and output, so that simulation monitoring personnel can know it. Based on the dangerous locations and the mapping relationship, an optimized structural scheme for the electrical connector contacts is output for simulation monitoring personnel to understand.

[0008] By adopting the above technical solution, this solution correlates the simulated lifespan distribution results with the user's poor operating habits during the insertion and removal of electrical connectors. By analyzing the stress state of the damaged area, it inversely infers how specific poor habits (such as non-horizontal insertion and removal angles) will aggravate the damage to the corresponding damaged area. Based on this inference, targeted design optimizations are carried out (such as strengthening specific areas and adding guide structures), thereby reducing the sensitivity of the electrical connector to the user's poor usage habits (i.e., improving robustness). This achieves a closed-loop strategy from virtual damage to real root causes and then to design prevention, creatively integrating simulation results, human behavior (i.e., user habits), and design prevention.

[0009] Optionally, the method further includes: Based on the lifetime distribution results output by the simulation calculation, at least one high-risk area with a lifetime below a first preset threshold is identified from the three-dimensional simulation model. Based on the geometric features of the high-risk area, an independent sub-component containing only the high-risk area and the main structure excluding the high-risk area are segmented from the three-dimensional simulation model. A detachable connection interface between the independent sub-component and the main structure is designed at the segmentation location of the independent sub-component; wherein, the detachable connection interface includes at least a snap-fit ​​connection and a threaded connection. Based on the detachable connection interface, the contact relationship between the independent sub-component and the main structure is redefined to update the three-dimensional simulation model; After updating the 3D simulation model according to different detachable connection interface schemes, the updated 3D simulation model is simulated and the lifetime distribution results are obtained; the lifetime change of the high-risk area and its impact on the decline of the lifetime of the surrounding area are calculated and compared under each detachable connection interface scheme. Select the interface scheme that ensures the lifespan of the high-risk area meets the requirements while minimizing the impact of lifespan degradation on surrounding areas as the optimal detachable connection interface scheme, and output the optimal detachable connection interface scheme and its corresponding updated 3D simulation model.

[0010] By adopting the above technical solution, the lifespan data predicted by simulation is used as the basis for module division of the structural dimension of the three-dimensional simulation model. Areas with short lifespans and prone to mechanical damage (i.e., high-risk areas) are separated from the three-dimensional simulation model to form independent sub-components. The detachable connection method between this sub-component and the overall three-dimensional simulation model is defined. This effectively solves the problem of the entire electrical connector structure being scrapped due to the lifespan limit of local parts of the three-dimensional simulation model. It achieves the effect of extending the overall service life of the product and reducing maintenance costs. Furthermore, the detachable connection interface itself is incorporated into the simulation verification system as a new "design variable". With "suppressing the ripple effect of lifespan decline" as the optimization goal, the detachable connection method is optimized. Finally, a globally optimized and most reliable three-dimensional simulation model design scheme is output.

[0011] Optionally, the method further includes: For the updated 3D simulation model according to the optimal detachable connection interface scheme, the target high-risk area and its corresponding target surrounding area are determined from the life distribution results output by the corresponding simulation calculation; wherein, the target high-risk area refers to the high-risk area in the life distribution results where the difference between the corresponding life and the life corresponding to the adjacent main structure is higher than a preset difference; the target surrounding area is the surrounding area adjacent to the target high-risk area; the target surrounding area is located between the target high-risk area and the main structure; The surrounding area of ​​the target is restructured, a load is applied to the restructured surrounding area, and a stress distribution cloud map is obtained. Based on the stress distribution cloud map, it is verified whether the surrounding area of ​​the target can reduce the stress amplitude transmitted from the high-risk area of ​​the target to the main structure through its own deformation or energy dissipation. If so, the verification result and the structural reconstruction scheme of the surrounding area of ​​the target are output. The verification result includes at least the life distribution result calculated by updating the three-dimensional simulation model using the restructured surrounding area of ​​the target.

[0012] By adopting the above technical solution, based on optimizing the detachable connection interface between the high-risk area and the adjacent main structure, a surrounding area is further defined as a buffer zone between the high-risk area and the adjacent main structure, and the material and geometry of the surrounding area are optimized to achieve structural reconstruction of the surrounding area. Then, it is verified whether the lifespan of the target high-risk area has been improved in the lifespan distribution result of the updated three-dimensional simulation model corresponding to the target surrounding area after structural reconstruction. If so, it is considered that the target surrounding area can reduce the stress amplitude transmitted from the target high-risk area to the main structure through its own deformation or energy consumption. At this time, the structural reconstruction scheme of the target surrounding area is output to further optimize the design of the three-dimensional simulation model.

[0013] Optionally, the method further includes: By simulating the insertion and removal process, the degradation trajectory of key performance parameters of electrical connectors with the number of insertions and removals is obtained; Based on the degradation trajectory, identify the critical point where the key performance parameter undergoes accelerated degradation and its corresponding critical cycle number, and analyze the root cause of the occurrence of the critical point. Based on the root cause, a corresponding initial design optimization scheme is formulated and implemented, the optimization scheme aiming to postpone the occurrence of the critical point; The simulation verifies whether the optimized design effectively postpones the critical point. If so, the optimized initial design scheme is output.

[0014] By adopting the above technical solution and using finite element simulation, not only is a lifespan distribution map obtained, but more importantly, the degradation trajectory of key performance parameters of electrical connectors can be extracted. This allows for accurate prediction of the performance degradation process throughout the entire lifespan during the product design phase, proactive identification of critical points that accelerate performance degradation, analysis of the root causes of these critical points, and the establishment of a clear "root cause-optimization measure" mapping relationship. With the core objective of "delaying the critical point of accelerated performance degradation," the product maintains stable performance degradation over a longer period, thereby significantly improving its reliability and stability during use. Furthermore, a complete "analysis-optimization-verification" closed loop is provided, and all optimization effects can be quantitatively verified through simulation (e.g., comparing the number of cycles to the critical point before and after optimization), ensuring that design decisions are based on evidence and that the results are reliable and credible.

[0015] Optionally, the method further includes: The degradation trajectory is encapsulated into a prediction model, the input of which is a key performance parameter and the output is the remaining lifetime, for use in predicting the remaining lifetime based on the key performance parameter values. Through a cyclic simulation process, a mapping relationship between easily monitored proxy parameters and key performance parameters is established; The system receives a prediction instruction, maps the value of the key performance parameter corresponding to the current proxy parameter based on the specific value of the proxy parameter contained in the prediction instruction and the mapping relationship between the proxy parameter and the key performance parameter, and inputs it into the prediction model to output the remaining lifespan for maintenance personnel to know.

[0016] By adopting the above technical solution, two key models (predictive model and mapping model) are constructed through simulation, and the predictive model is indirectly driven by easily monitored surrogate parameters, thereby realizing online prediction of remaining life. This avoids the expensive, complex, and unreliable solutions that may be used to directly measure contact pressure (such as embedding sensors at the contact interface). The high-fidelity simulation data (mapping model, baseline degradation trajectory) is deeply integrated with the online monitoring data during the actual use of the electrical connector, enabling the simulation-based predictive model to be dynamically updated according to changes in the actual product status, which greatly improves the accuracy and personalization of remaining life prediction. This endows the electrical connector with self-sensing and self-predictive intelligent functions, transforming it from a passive mechanical part into an intelligent terminal that can provide its own health status information.

[0017] Optionally, the method further includes: Based on the lifetime distribution results, regions in the three-dimensional simulation model that are located in different lifetime gradient ranges are distinguished and displayed according to the preset lifetime gradient range and the preset display method.

[0018] Secondly, this application provides a simulation prediction system for the mating and extraction life of electrical connector contacts, including, The 3D modeling module is used to create 3D simulation models of the plug and socket ends of the electrical connector, define the material properties of each component in the 3D simulation model, and the contact relationship between each component; wherein the contact relationship between the contact element of the plug end and the contact element of the socket end is a non-linear frictional contact. The mesh generation module is used to discretize the three-dimensional simulation model into a finite element mesh and to refine the local mesh of the contact parts at the plug end and the contact parts at the socket end. The insertion and removal simulation module is used to apply fixed constraints to the socket end and displacement loads to the plug end to simulate the insertion and removal process in a simulation environment, and to perform static solutions to obtain the insertion and removal forces during the insertion and removal process of the plug end and the socket end, as well as the contact pressure data of the plug end contact and the socket end contact. The life prediction module maps the static solution results to the fatigue analysis module. Based on the low-cycle fatigue theory, it simulates and calculates the life distribution results of the plug end contact and the socket end contact under repeated insertion and removal loads.

[0019] Thirdly, this application provides a simulation prediction device for the insertion and extraction life of electrical connector contacts, including a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed as described in any of the first aspects.

[0020] Fourthly, this application provides a computer-readable storage medium storing a computer program that can be loaded by a processor and executed as described in any of the first aspects.

[0021] In summary, this application includes at least one of the following beneficial technical effects: This application predicts the mating and extraction performance and lifespan of electrical connectors, significantly shortening the development cycle and reducing R&D and trial-and-error costs. It transcends the limitations of experimental testing, visually demonstrating the stress and strain distribution of the internal contacts during mating and extraction, and accurately calculating the entire process curve of the mating and extraction forces. This allows simulation monitoring personnel to deeply understand the mechanical behavior. By combining static analysis with low-cycle fatigue theory, it can accurately predict the fatigue life of the contacts after a specified number of mating and extraction cycles, and visually identify the most vulnerable areas for fatigue fracture in the form of cloud maps, providing a clear and reliable basis for design optimization. Based on the lifespan cloud maps and critical node information obtained from simulation, simulation monitoring personnel can make targeted improvements and optimizations to the structure, materials, or processes of the contacts (such as modifying the spring shape, adjusting the interference fit, etc.), thereby effectively improving the mechanical mating and extraction lifespan and overall reliability of the electrical connector. Furthermore, the simulation-derived lifetime distribution results are correlated with users' poor operating habits during the insertion and removal of electrical connectors. By analyzing the stress state of the damaged area, it is deduced in reverse how specific bad habits (such as non-horizontal insertion and removal angles) will aggravate the damage to the corresponding damaged area. Based on this reasoning, targeted design optimizations are carried out (such as strengthening specific areas and adding guide structures), thereby reducing the sensitivity of electrical connectors to users' poor usage habits (i.e., improving robustness). This achieves a closed-loop strategy from virtual damage to real-world root causes and then to design prevention, creatively integrating simulation results, human behavior (i.e., user habits), and design prevention. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a flowchart illustrating the simulation prediction method for the insertion and extraction life of electrical connector contacts disclosed in the embodiments of this application.

[0024] Figure 2 This is a structural block diagram of the simulation prediction system for the insertion and extraction life of electrical connector contacts disclosed in the embodiments of this application.

[0025] Figure labeling: 201, 3D modeling module; 202, mesh generation module; 203, plug-in simulation module; 204, lifetime prediction module. Detailed Implementation

[0026] The following is in conjunction with the appendix Figure 1-2 This application will be described in further detail.

[0027] This application discloses a simulation prediction method for the mating and extraction life of electrical connector contacts (hereinafter referred to as the simulation prediction method). The execution subject of the simulation prediction method is a simulation prediction system for the mating and extraction life of electrical connector contacts (hereinafter referred to as the simulation prediction system). The following will be combined with... Figure 1 The specific execution flow of the simulation prediction system for the simulation prediction method is explained.

[0028] S101, establish a three-dimensional simulation model of the plug end and socket end of the electrical connector, define the material properties of each component in the three-dimensional simulation model, and the contact relationship between each component; wherein the contact relationship between the contact component of the plug end and the contact component of the socket end is a non-linear frictional contact.

[0029] S102, the 3D simulation model is discretized into a finite element mesh, and the local mesh of the contacts at the plug end and the contacts at the socket end is refined.

[0030] S103, in the simulation environment, a fixed constraint is applied to the socket end, and a displacement load simulating the insertion and removal process is applied to the plug end. Static solutions are then performed to obtain the insertion and removal forces during the insertion and removal process of the plug end and the socket end, as well as the contact pressure data between the plug end contact and the socket end contact.

[0031] S104 maps the static solution results to the fatigue analysis module. Based on the low-cycle fatigue theory, it simulates and calculates the life distribution results of the plug end contact and the socket end contact under repeated insertion and removal loads. Based on the lifetime distribution results, and according to the preset lifetime gradient range and the preset display method, the regions in the 3D simulation model that are in different lifetime gradient ranges are distinguished and displayed.

[0032] In implementation, firstly, a digital geometric model (i.e., a three-dimensional simulation model) of the charging connector plug end (including pins) and socket end (including sockets) is created in a three-dimensional modeling software, and the contact parts (i.e., pins and sockets) are modeled in detail, especially the structure of the socket (such as leaf springs, crown springs, torsion springs; in this application embodiment, a leaf spring connector is used as an example), because the geometry of these fine structures directly determines the performance of point contacts (such as contact area and stress distribution).

[0033] Next, the 3D simulation model is imported into the simulation platform (such as ANSYS Workbench), and real material properties are assigned to different parts of the 3D simulation model. The key parameters corresponding to the material properties include elastic modulus, Poisson's ratio, and density. Among them, the pin material is set to copper and the socket material is phosphor bronze.

[0034] Then, define the contact relationships between the various parts in the 3D simulation model. For example, set the contact relationship between the pin and the socket to frictional contact, set the friction coefficient to 0.2, select the enhanced Lagrangian algorithm as the contact algorithm, select asymmetric contact behavior in the advanced contact settings of the simulation platform software, and set the contact stiffness to 0.1.

[0035] The three-dimensional simulation model is then divided into tetrahedral meshes. Smaller mesh sizes are used in the contact area (i.e., the surface of the pin and the inner surface of the socket spring) (e.g., 0.4 mm mesh size for the inner surface of the socket spring and 0.5 mm mesh size for the pin surface), while larger mesh sizes (e.g., 1 mm) are used in the non-release area.

[0036] Then, the socket end is completely fixed, i.e., a fixed constraint is applied, simulating its state of being held or mounted on the device during insertion and removal. Based on the coordinate system position in the simulation interface, a horizontal displacement load is applied to the plug end. Combined with the actual insertion and removal displacement during the use of the electric vehicle charging connector, this displacement load can be specifically set to 8mm to simulate the insertion and removal process: within 0-10s, the plug moves 8mm forward (insertion phase), and within 10s-20s, the plug moves 8mm negatively (removal phase). Furthermore, since the simulation of the insertion and removal process of the research object falls under the category of static nonlinear analysis, and the insertion and removal process of the pin in the crown spring involves large deformation of the spring, this application also proposes enabling the large deformation option in the advanced settings of the simulation platform software. Simultaneously, to make the solution converge more easily, the force convergence option is enabled.

[0037] Before solving, set up a probe. The probe is a standard built-in function of the ANSYS Workbench platform. By setting up a force response probe at the plug end, it is used to monitor the reaction force (i.e., insertion and extraction force) of the plug end during the movement process and to plot the curve of the insertion and extraction force as a function of displacement. At the same time, set up a contact pressure probe to monitor the pressure distribution on the contact surface.

[0038] The inputs for the statics solution process are: the material properties of each component in the three-dimensional geometric model and the three-dimensional simulation model, as well as the contact relationships between the components; The output of the statics solution process is: 1. Displacement field data (i.e., the positional change of each point in the three-dimensional geometric model after insertion and extraction), stress field (i.e., the stress magnitude of each point in the three-dimensional geometric model), strain field (i.e., the strain magnitude of each point inside the three-dimensional geometric model (such as equivalent elastic strain, equivalent plastic strain)), and contact state (used to show which areas are in contact, sliding, or separation state).

[0039] The output also includes insertion and extraction force: the reaction force-time (or reaction force-displacement) curve of the entire insertion and extraction process is output through the force response probe; 2. Contact pressure: The pressure distribution and magnitude on the contact surface obtained through a pressure probe. Here, the contact surface refers to the contact surface when the contact parts at the plug end and the contact parts at the socket end come into contact with each other during the insertion and removal process.

[0040] The inputs to fatigue analysis modules (such as the nCode DesignLife module) include: 1. Static solution results, which include the stress and strain results of each component of the three-dimensional simulation model (including the contacts at the plug end and the contacts at the socket end) under load; 2. Load History: The load history refers to the process of stress change within the model caused by the insertion and removal process, calculated by static analysis. It is the entire process of stress change generated inside the material due to a single insertion and removal displacement, read by the nCode DesignLife module.

[0041] 3. Material fatigue properties: namely, EN curve (strain-life curve). The EN curve is the inherent fatigue property of the material, which is data obtained in advance through standard material fatigue tests and pre-stored in the simulation prediction system.

[0042] The output of fatigue analysis modules (such as the nCode DesignLife module) includes: 1. Lifetime Cloud Map (i.e., the lifetime distribution results mentioned above): This refers to the number of cycles required for fatigue failure at each location on the 3D simulation model. For example, the bluest area in the cloud map might indicate a lifetime of 100,000 cycles, while the reddest danger area might indicate a lifetime of 5,200 cycles. This utilizes different colors (i.e., the preset display method mentioned earlier) to distinguish areas within different lifetime gradient ranges. This allows simulation monitoring personnel to compare the displayed number of cycles with the preset target number of cycles, thereby determining whether the lifetime target (e.g., >10,000 cycles) is met.

[0043] 2. Damage Cloud Map: Displays the accumulated damage value at each location in the 3D simulation model after a specified target number of cycles (damage value calculated according to Miner's linear cumulative damage rule). A damage value ≥ 1 indicates that damage has occurred at the corresponding location. This damage value can be used to determine dangerous locations in the 3D simulation model (e.g., locations with damage values ​​close to 1 and a distance difference of less than a preset difference).

[0044] Optionally, the displacement load applied to the plug end to simulate the insertion and removal process refers to the displacement load in the direction of the preset ideal insertion and removal axis; The simulation prediction method also includes the following steps: Based on the life distribution results output by the simulation calculation, the dangerous location is located from the three-dimensional simulation model. The static analysis results are then reviewed to solve the stress and strain state of the dangerous location during the insertion and removal process, so as to analyze the damage mode of the dangerous location. The damage mode is correlated with the sensitive offset direction that deviates from the ideal insertion and extraction axis, and the mapping relationship between different angular offset loads applied along the sensitive offset direction and the degree of damage at the dangerous location is established and output, so that simulation monitoring personnel can know it. Based on the dangerous locations and mapping relationships, the structural optimization scheme for the electrical connector contacts is output for simulation monitoring personnel to understand.

[0045] In practice, as mentioned above, the output of the fatigue analysis module (such as the nCode DesignLife module) is based on simulations under the condition of applying a horizontal displacement load of 8mm to the plug end. In other words, the output of the fatigue analysis module (such as the nCode DesignLife module) is a simulation result obtained by simulating a scenario where the user inserts and removes the electrical connector along the horizontal direction (i.e., the ideal insertion and removal axis described in this paper). However, in actual use, users are prone to poor usage habits (such as inserting and removing the connector off-center from the horizontal direction), which will aggravate the mechanical damage to the electrical connector. In this regard, this application proposes the following solution to reduce the sensitivity of the electrical connector to poor user usage habits (i.e., improve robustness): The simulation prediction system is used to locate dangerous locations (e.g., locations where the damage value is close to 1 and the difference between the damage value and the distance from 1 is less than a preset difference) in the damage cloud map output by the fatigue analysis module. Then, using the "probe" function or time history post-processor in the simulation platform software, the mechanical data of each dangerous location throughout the entire insertion and removal time history is extracted, including: Equivalent stress time history (used to understand its stress level and variation range), stress component time history (focusing on analyzing the first principal stress (responding to the tensile / bending trend) and shear stress (responding to the frictional shear trend)), contact pressure time history (if the critical location is located on the contact surface, it is necessary to obtain the curve of its contact pressure change over time).

[0046] Next, based on the above mechanical data, the damage mode at the dangerous location is comprehensively determined: If the first principal stress amplitude accounts for more than a preset percentage (e.g., 60%) of the total equivalent stress amplitude, and its contact pressure peak is less than a specified percentage (e.g., 10%) of the material yield strength, then the damage mode at the dangerous location is determined to be fatigue cracking damage caused by bending stress. If the peak contact pressure exceeds a certain percentage (e.g., 50%) of the material's yield strength, and the ratio of its shear stress amplitude to the peak contact pressure is greater than 0.2 times the Coulomb coefficient of friction, then the damage mode at this critical location is determined to be wear damage caused by contact compression and friction.

[0047] Based on the determined damage modes, the sensitive offset direction for each damage mode is inferred. The sensitive offset direction refers to any insertion / removal direction deviating from the horizontal insertion / removal direction during actual user operation. This insertion / removal direction will cause the corresponding damage mode to appear at the corresponding dangerous location, thereby leading to a decrease in lifespan. The corresponding inference scheme is as follows: If the damage mode is fatigue cracking damage caused by bending stress, then the sensitive offset direction is considered to be perpendicular to the bending plane; that is, when the user plugs or unplugs the electrical connector in a direction perpendicular to the bending plane, it is easy to cause fatigue cracking damage due to bending stress at the corresponding dangerous position.

[0048] If the damage mode is wear damage caused by contact compression and friction, then the sensitive direction is considered to be the rotation direction around the insertion axis; that is, when the user inserts or removes the electrical connector around the circumferential rotation direction, the corresponding dangerous position is easily subjected to contact compression and friction, resulting in friction damage.

[0049] After determining the sensitive offset direction corresponding to the damage mode at the dangerous location, modify the "apply displacement load to the plug end to simulate the insertion and removal process" in S103, that is: use the sensitive offset direction as the displacement direction of the displacement load (by assigning a specific offset angle value relative to the horizontal direction (such as ±1°, ±2°) as the sensitive offset direction), and then re-execute the operations of S102, S103, and S104, define different offset angle values ​​and perform simulations respectively, and obtain the simulation results corresponding to each offset angle value.

[0050] Extract the critical locations and their damage or lifespan values ​​from each set of simulation results, plot the relationship curve between offset angle and damage / lifespan, and output the curve. This curve quantitatively reveals the degree of influence of user operation offset on lifespan, which is the mapping relationship between different angular offset loads applied along the sensitive offset direction and the degree of damage at the critical location, as mentioned above.

[0051] Finally, for critical locations and their corresponding damage modes, corresponding optimization strategies are output for simulation monitoring personnel to understand and refer to. For example, when the damage mode is fatigue cracking damage caused by bending stress, a geometric strengthening strategy is proposed (such as increasing the local material thickness at the critical location, setting reinforcing ribs, or changing the form of the support structure to improve its bending stiffness, thereby reducing its sensitivity to stress). When the damage mode is wear damage caused by contact compression and friction, a behavioral constraint strategy is adopted (such as designing longer guide grooves, more precise anti-misfit keys, or tapered guide openings in the electrical connector housing. These structures can physically guide and constrain the user's insertion and removal actions, minimizing the probability of harmful angular deviations and preventing destructive conditions from occurring at the source).

[0052] Optionally, the simulation prediction method may also include the following steps: Based on the lifetime distribution results output by the simulation calculation, at least one high-risk area with a lifetime below the first preset threshold is identified from the three-dimensional simulation model. Based on the geometric features of the high-risk area, independent sub-components containing only the high-risk area and the main structure excluding the high-risk area are segmented from the 3D simulation model. Detachable connection interfaces between the independent sub-components and the main structure are designed at the segmentation points of the independent sub-components; wherein, the detachable connection interfaces include at least snap-fit ​​connections and threaded connections. Based on the detachable connection interface, the contact relationship between independent sub-components and the main structure is redefined to achieve the updating of the three-dimensional simulation model; After updating the 3D simulation model according to different detachable connection interface schemes, the updated 3D simulation model is simulated and the lifetime distribution results are obtained; the lifetime changes in high-risk areas and the degree of impact of the decline in lifetime of surrounding areas under each detachable connection interface scheme are calculated and compared. Select the interface scheme that meets the life requirements of the high-risk area and minimizes the impact of life reduction on the surrounding areas as the optimal detachable connection interface scheme, and output the optimal detachable connection interface scheme and its corresponding updated 3D simulation model.

[0053] In implementation, the simulation prediction system identifies high-risk areas (e.g., a circular area with a radius of a specified length centered on the point where the lifespan is below the first preset threshold) from the 3D simulation model based on the lifespan distribution results output by the simulation calculation. The area within a specified distance (e.g., 3 mm) surrounding the high-risk area is then defined as the surrounding region, and its average lifespan L_original is recorded.

[0054] Then, based on the location of the high-risk areas, the original geometry (i.e., the 3D simulation model) is segmented in CAD software or Workbench's DM / SCDM. This involves using planes or surfaces as segmentation tools to perform Boolean segmentation along predetermined boundaries, separating the high-risk areas from the overall model and making them independent geometric entities (i.e., sub-components independent of the overall structure of the 3D simulation model). Ultimately, the initial 3D simulation model is segmented into a 3D simulation model consisting of: independent sub-components corresponding to each high-risk area, and the main structure excluding all independent sub-components.

[0055] In Workbench's Mechanical module, independent sub-components are automatically recognized as new "parts," and the Mechanical module automatically generates contact pairs. Typically, it identifies the contact between the independent sub-component and the main structure as "Bonded." In this case, it's necessary to delete or suppress this automatically generated contact pair and create a new contact pair on the dividing surface between the independent sub-component and the main structure. On this dividing surface, based on the selected connection interface (such as snap-fit ​​or thread), the corresponding geometric structure is designed. For example, hooks and lugs are designed to simulate snap-fit ​​connections, and threaded holes and bolts are designed to simulate threaded connections.

[0056] Next, in the simulation software, for the segmented independent sub-components and main structure, the contact relationships (such as frictional contact, non-separation contact) or joint constraints that can simulate the mechanical properties of the selected detachable connection interfaces are redefined on their contact surfaces. For example, for snap-fit ​​connections: in Workbench, the "nonlinear spring" or "constraint equation" is used to simulate the snap-fit ​​behavior. In the detailed settings, the spring stiffness needs to be defined to characterize the snap-fit ​​elasticity, and the "Behavior" needs to be set to "Nonlinear." The force-displacement curve is input to define the snap-fit ​​and disengagement processes. For threaded connections: the "Bolt Thread" tool is used for simulation. In the detailed settings, the magnitude of the "preload" needs to be determined, and the "Contact Type" is set to "Bonded" to simulate the tightened state, thereby redefining the contact relationships of the 3D simulation model and ultimately updating the 3D simulation model.

[0057] For the 3D simulation models updated according to different detachable connection interfaces, S102, S103, and S104 are re-executed to obtain the lifetime distribution results corresponding to the 3D simulation model under each detachable connection interface scheme. Based on the lifetime distribution results, the average lifetime L_new of the corresponding surrounding area and the lifetime degradation spuriousness η of the surrounding area are calculated respectively: (L_original - L_new) / L_original * 100%. The detachable connection interface scheme with the smallest lifetime degradation spuriousness η of the surrounding area is selected as the optimal detachable connection interface scheme. The optimal detachable connection interface scheme (such as all independent sub-components and connection interface types) and its corresponding updated 3D simulation model are output.

[0058] Optionally, the simulation prediction method may also include the following steps: For the 3D simulation model updated according to the optimal detachable connection interface scheme, the target high-risk area and its corresponding target surrounding area are determined from the life distribution results output by the corresponding simulation calculation. The target high-risk area refers to the high-risk area in the life distribution results where the difference between the corresponding life and the life of the adjacent main structure is higher than a preset difference. The target surrounding area is the surrounding area adjacent to the target high-risk area. The target surrounding area is located between the target high-risk area and the main structure. The structure of the target surrounding area is reconstructed, loads are applied to the reconstructed target surrounding area, and stress distribution cloud map is obtained. Based on the stress distribution cloud map, it is verified whether the target surrounding area can reduce the stress amplitude transmitted from the high-risk area of ​​the target to the main structure through its own deformation or energy dissipation. If so, the verification results and the structural reconstruction scheme of the target surrounding area are output. The verification results include at least the life distribution results simulated and calculated by updating the three-dimensional simulation model using the target surrounding area after structural reconstruction.

[0059] In implementation, based on all the high-risk areas identified in the aforementioned 3D simulation model (i.e., the areas where the lifespan is below the first preset threshold in the lifespan cloud map), it can be seen that the 3D simulation model has already been divided into independent sub-components for each high-risk area, as well as the main structure other than the independent sub-components, and a detachable connection relationship between the independent sub-components and the main structure has been established. On this basis, this application further proposes to delineate a boundary area (i.e., the surrounding area mentioned above) at the location where the main structure and the independent sub-components are detachably connected. This is the area in the main structure that is directly detachably connected to the independent sub-components, or in other words, the area within a specified distance range (e.g., 3mm) around the perimeter of the high-risk area mentioned above.

[0060] Next, the simulation prediction system is also used to calculate the life difference between each high-risk area and its detachable main structure from the life distribution cloud map for all high-risk areas and their corresponding surrounding areas. If the life difference is higher than the preset difference threshold, it means that the life difference between the high-risk area and its surrounding detachable main structure is too large. At this time, the corresponding high-risk area is defined as the target high-risk area, and the corresponding surrounding area is defined as the target surrounding area.

[0061] The simulation prediction system is also used to correct the material properties of the target's surrounding area in the 3D simulation model. For example, by reducing the elastic modulus value, it can simulate replacing the material of the target's surrounding area with a flexible material. By changing the geometry of the target's surrounding area (such as designing thinning grooves, introducing arc-shaped hollows, and creating gradually changing cross-sections), the local stiffness of the target's surrounding area can be reduced, making it easier to undergo elastic deformation. This achieves structural reconstruction of the target's surrounding area. The 3D simulation model is then updated using the reconstructed target's surrounding area. S102 (including the operation of applying loads to simulate real insertion and removal conditions), S103, and S104 are executed again. The finite element solver calculates the stress distribution cloud map of the target's high-risk area, the target's surrounding area, and the main structure of the surrounding area, as well as the new life distribution cloud map obtained by static-fatigue life co-simulation.

[0062] The effectiveness of the structural reconstruction scheme for the target's surrounding area is verified based on stress distribution cloud maps, deformation animations, and new lifetime distribution cloud maps. The specific verification method is as follows: 1. If the stress distribution cloud map shows that, compared with before the structural reconstruction, the stress value of the high-risk area of ​​the target in the updated 3D simulation model after the structural reconstruction is reduced, and at the same time, the stress value of the main structure around the target does not increase significantly (e.g., the increase does not exceed the preset range).

[0063] 2. The new lifetime distribution cloud map shows that the average lifetime of the target high-risk area in the updated 3D simulation model after structural reconstruction is improved compared with that before structural reconstruction.

[0064] If the above two verification results appear, the structural reconstruction scheme is considered effective. At this time, the structural reconstruction scheme (such as the location of the target surrounding area, and the material properties and geometry of the target surrounding area after reconstruction) and the reconstructed and updated three-dimensional simulation model can be output, and the aforementioned new lifetime distribution cloud map and stress distribution cloud map can be output as verification results. Otherwise (i.e., if the above two verification results do not appear), the reconstruction ends, or the material properties and aggregate shape of the target surrounding area are readjusted, and the simulation and verification are further iterated until the above two verification results appear.

[0065] Optionally, the simulation prediction method may also include the following steps: By simulating the insertion and removal process, the degradation trajectory of key performance parameters of electrical connectors with the number of insertions and removals is obtained; Based on the degradation trajectory, identify the critical points where key performance parameters undergo accelerated degradation and their corresponding critical cycle counts, and analyze the root causes that lead to the occurrence of critical points. Based on the root cause, formulate and implement corresponding initial design optimization schemes, with the goal of delaying the occurrence of the critical point; Simulation verifies whether the optimized design effectively postpones the critical point. If so, the initial design optimization scheme is output.

[0066] In implementation, multiple insertion and removal cycles can be simulated in ANSYS through multi-load step analysis or quasi-static analysis. The cycle can be set using APDL scripts or Worksheets in Workbench, and the key results after each cycle can be extracted. The key results here can be the key performance parameter values ​​of the electrical connector, thereby obtaining the curves (i.e., degradation trajectories) of the key performance parameters of the electrical connector as a function of the number of insertions and removals during the multiple insertion and removal simulation. The key performance parameters here can be contact pressure and / or insertion and removal force. In the embodiment of this application, the key parameter is specifically contact pressure.

[0067] In the degradation trajectory, the critical points where key performance parameters undergo accelerated degradation are identified. Specifically, the identification of critical points can be achieved using one or a combination of the following two methods: Method 1: Based on the mathematical characteristics of the performance degradation trajectory, identify the inflection point where the rate of performance degradation changes significantly. That is, the location where the slope of the curve changes abruptly in the degradation trajectory. Specifically, the degradation trajectory can be subjected to Fenix ​​analysis using mathematical algorithms (such as moving average or second derivative to find the inflection point) to automatically identify the point where the slope change is most significant as the critical point. Method 2: Based on the functional requirements of the electrical connector, set a minimum allowable value for the performance indicators, and define the point at which the performance degrades to this minimum allowable value as the critical point. For example, the point corresponding to when the contact pressure drops to the preset minimum allowable value.

[0068] After identifying the critical point, based on the degradation trajectory, the number of insertions and removals corresponding to the critical point is taken as the critical cycle number. Then, the root cause of the occurrence of the critical point is analyzed. The analysis method is as follows: The simulation analysis is stopped at the critical loop number N_critical when the critical point occurs. The finite element contour data obtained during the simulation is extracted when the number of loops is the critical loop number N_critical. Based on the finite element contour data, the root cause is inferred. The inference scheme is as follows: If the maximum equivalent stress value in the observed equivalent stress cloud map exceeds the material's yield strength, then the root cause is inferred to be material yielding. Observe whether there is a non-zero plastic strain region in the equivalent plastic strain cloud map. If so, it is inferred that the root cause is the accumulation of plastic deformation. If the difference between the contact area percentage and the contact area percentage in the contact state cloud map of the previous cycle is greater than the preset difference, it is considered that the contact area percentage has decreased significantly, and the root cause is inferred to be wear leading to contact failure.

[0069] Based on the corresponding root cause, the initial design optimization scheme is implemented, specifically: If the root cause is material yielding or cumulative plastic deformation, the corresponding initial design solution is: increase the fillet radius of the critical area in CAD, or perform a gradient chamfer treatment. Update the Geometry cell and refresh the Mechanical model; in the Mechanical model, reduce the interference fit defined in the model, or lower the coefficient of friction. If the root cause is wear, the corresponding initial design solution is as follows: Modify the shape of the contact parts in CAD, such as optimizing point contact into line contact or surface contact, update the geometry, and refresh the 3D simulation model accordingly. Create a new material in EngineeringData and assign it a higher hardness property. Then assign this material to the worn contact parts.

[0070] Finally, after executing the initial design optimization scheme to update the 3D simulation model, S102, S103, and S104 are executed again based on the updated simulation model, and multiple cyclic simulations are performed to obtain a new degradation trajectory. It is then determined whether the critical point is delayed (i.e., whether there is no critical point, or whether there is a critical point but the corresponding critical cycle count is greater than the critical cycle count before the update). If so, the corresponding initial design optimization scheme and the updated 3D simulation model are output.

[0071] Optionally, the simulation prediction method may also include the following steps: The degradation trajectory is encapsulated into a prediction model, with key performance parameters as input and remaining lifetime as output, for use in predicting remaining lifetime based on key performance parameter values. Through a cyclic simulation process, a mapping relationship between easily monitored proxy parameters and key performance parameters is established; The system receives prediction instructions, maps the values ​​of the surrogate parameters contained in the prediction instructions, and maps the mapping relationship between the surrogate parameters and key performance parameters to obtain the key performance parameter values ​​corresponding to the current surrogate parameters, and inputs them into the prediction model to output the remaining lifetime for maintenance personnel to know.

[0072] In implementation, during the cyclical execution of the insertion and extraction simulation described above, the curve (i.e., degradation trajectory) showing the relationship between the key performance parameters and the number of insertions and extractions for each simulation is recorded. Simultaneously, the peak value of the insertion and extraction force is extracted using a fixed-constraint reaction force probe, resulting in a large number of data pairs consisting of the insertion and extraction force and the contact pressure. The insertion and extraction force is used as a surrogate parameter, and the aforementioned data pairs are analyzed. Through linear regression or neural network fitting, a mapping function between the insertion and extraction force and the contact pressure is established. This mapping function indicates that for any measured insertion and extraction force value, the corresponding estimated contact pressure value can be calculated using this mapping function. This mapping relationship is then stored in the simulation prediction system.

[0073] Furthermore, the degradation trajectory data obtained above is mathematically processed, and a curve fitting algorithm is used to fit the data points to obtain a mathematical expression for the degradation trajectory, defining the failure threshold P_failure for key performance parameters. This threshold is determined based on electrical design specifications, such as the minimum contact pressure necessary to ensure that the contact resistance is below the specified value.

[0074] The corresponding prediction model is the mathematical expression of the degradation trajectory (i.e., a mathematical function). Its input is any key performance parameter value, and its output is the remaining number of plug-in / plug-out cycles (i.e., remaining lifetime) from the current moment until the performance decays to the failure threshold P_failure. This model can be encapsulated as a simple algebraic calculation function or a lookup table.

[0075] For example, the remaining lifetime RUL = -τ*ln( ( P_failure) - P_0) / A ) - N_current; where N_current is the cumulative number of insertion / removal cycles to date; P_0, A, and τ are all preset constants, where P_0 represents the contact pressure that will eventually stabilize when the number of insertion / removal cycles approaches infinity. This can be understood as residual pressure; A represents the total change in contact pressure from the initial value to the asymptotic value P_0, where initial contact pressure = P_0 + A; τ is the key parameter that determines the rate of decay. The larger the value of τ, the slower the decay curve and the longer the lifespan; the smaller the value of τ, the faster the decay and the shorter the lifespan.

[0076] When electrical connectors are put into practical use, force sensors (such as strain gauges or miniature pressure sensors) are integrated on the connectors to monitor and record the specific values ​​of the proxy parameters (i.e., insertion and extraction forces) in real time. When the specific value of the insertion and extraction force is higher than the preset value, it is determined that an insertion and extraction operation is being performed. The monitoring simulation prediction system accumulates the number of insertions and extractions of the corresponding electrical connector N_current (i.e., number of insertions and extractions + 1) each time it determines that an insertion and extraction operation is being performed. In other embodiments, other methods can also be set to determine whether an insertion and extraction operation has been performed. For example, when it is detected that the current has gone through a process from zero to one and then back to zero (i.e., a complete charging phenomenon has occurred), it is considered that an insertion and extraction operation has been completed.

[0077] The monitoring simulation prediction system can periodically trigger prediction commands automatically or receive prediction commands triggered manually. The automatically generated prediction commands will include the insertion and extraction force data obtained at the time the prediction command is triggered. Then, based on the aforementioned mapping relationship, the simulation prediction system determines the contact pressure estimate corresponding to the current insertion and extraction force data, and then substitutes the contact pressure estimate into the prediction model to periodically output the remaining number of insertion and extraction cycles (i.e., remaining lifetime RUL).

[0078] This application also discloses a simulation prediction system for the mating and extraction life of electrical connector contacts. (Refer to...) Figure 2 ,include: The 3D modeling module is used to create 3D simulation models of the plug and socket ends of the electrical connector, define the material properties of each component in the 3D simulation model, and the contact relationships between the components; the contact relationship between the contacts on the plug end and the contacts on the socket end is a non-linear frictional contact. The mesh generation module is used to discretize the 3D simulation model into a finite element mesh and to refine the local mesh of the contacts at the plug end and the contacts at the socket end. The insertion and removal simulation module is used to apply fixed constraints to the socket end and displacement loads to the plug end to simulate the insertion and removal process in a simulation environment. It also performs static solutions to obtain the insertion and removal forces during the insertion and removal process of the plug end and the socket end, as well as the contact pressure data between the plug end contact and the socket end contact. The life prediction module maps the static solution results to the fatigue analysis module. Based on the low-cycle fatigue theory, it simulates and calculates the life distribution results of the plug end contact and the socket end contact under repeated insertion and removal loads.

[0079] Optionally, it also includes a damage tracing module, which is used to locate dangerous locations from the 3D simulation model based on the life distribution results output by the simulation calculation, backtrack the static analysis results, solve the stress and strain state of the dangerous location during the insertion and removal process, so as to analyze the damage mode of the dangerous location; correlate the damage mode with the sensitive offset direction that deviates from the ideal insertion and removal axis, establish and output the mapping relationship between different angular offset loads applied along the sensitive offset direction and the degree of damage at the dangerous location, so as to be known by the simulation monitoring personnel; based on the dangerous location and the mapping relationship, output the structural optimization scheme for the electrical connector contact, so as to be known by the simulation monitoring personnel.

[0080] Optionally, it also includes a model optimization module, used to identify at least one high-risk area with a lifespan lower than a first preset threshold from the three-dimensional simulation model based on the lifespan distribution results output by the simulation calculation; based on the geometric features of the high-risk area, to segment the three-dimensional simulation model into independent sub-components containing only the high-risk area, and the main structure excluding the high-risk area, and to design detachable connection interfaces with the main structure at the segmentation positions of the independent sub-components; wherein the detachable connection interfaces include at least snap-fit ​​connections and threaded connections; It is also used to redefine the contact relationship between independent sub-components and the main structure based on the detachable connection interface, thereby updating the 3D simulation model; after updating the 3D simulation model according to different detachable connection interface schemes, the updated 3D simulation model is simulated to obtain the life distribution results; the life change of the high-risk area and its impact on the life reduction of the surrounding area are calculated and compared under each detachable connection interface scheme; the interface scheme that makes the life of the high-risk area meet the requirements and minimizes the impact on the life reduction of the surrounding area is selected as the optimal detachable connection interface scheme, and the optimal detachable connection interface scheme and its corresponding updated 3D simulation model are output.

[0081] Optionally, the model optimization module is also used to determine the target high-risk area and its corresponding target surrounding area from the life distribution results of the corresponding simulation calculation output for the 3D simulation model updated according to the optimal detachable connection interface scheme; wherein, the target high-risk area refers to the high-risk area in the life distribution results where the difference between the corresponding life and the life corresponding to the adjacent main structure is higher than a preset difference; the target surrounding area is the surrounding area adjacent to the target high-risk area; the target surrounding area is located between the target high-risk area and the main structure; The model optimization module is also used to reconstruct the structure of the target's surrounding area, apply loads to the reconstructed target's surrounding area, and obtain stress distribution cloud maps. Based on the stress distribution cloud maps, it verifies whether the target's surrounding area can reduce the stress amplitude transmitted from the high-risk area of ​​the target to the main structure through its own deformation or energy dissipation. If so, it outputs the verification results and the structural reconstruction scheme of the target's surrounding area. The verification results include at least the life distribution results simulated and calculated by updating the three-dimensional simulation model using the target's surrounding area after structural reconstruction.

[0082] Optionally, the model optimization module is also used to obtain the degradation trajectory of key performance parameters of electrical connectors with the number of mating and unmating cycles through mating and unmating process simulation; based on the degradation trajectory, identify the critical point where the key performance parameters undergo accelerated degradation and the corresponding critical cycle number, and analyze the root cause of the occurrence of the critical point; based on the root cause, formulate and implement the corresponding initial design optimization scheme, with the optimization scheme aiming to postpone the occurrence of the critical point; and verify whether the optimized design effectively postpones the critical point through simulation. If so, the initial design optimization scheme is output.

[0083] Optionally, a lifetime prediction module is used to encapsulate the degradation trajectory into a prediction model. The input of the prediction model is the key performance parameters, and the output is the remaining lifetime, which is used to predict the remaining lifetime based on the key performance parameter values. Through a cyclic simulation process, an easily monitorable mapping relationship between surrogate parameters and key performance parameters is established. The module receives prediction instructions, and based on the specific values ​​of the surrogate parameters contained in the prediction instructions and the mapping relationship between the surrogate parameters and key performance parameters, it maps the key performance parameter values ​​corresponding to the current surrogate parameters to the prediction model, so as to output the remaining lifetime for maintenance personnel to know.

[0084] Optionally, a lifetime display module is used to distinguish and display regions in the three-dimensional simulation model that are in different lifetime gradient ranges based on the lifetime distribution results, according to a preset lifetime gradient range and a preset display method.

[0085] This application also discloses a simulation prediction device for the mating and extraction life of electrical connector contacts. The simulation prediction device for the mating and extraction life of electrical connector contacts includes a memory and a processor. The memory stores a computer program that can be loaded by the processor and executed as described above for the simulation prediction method for the mating and extraction life of electrical connector contacts.

[0086] This application also discloses a computer-readable storage medium that stores a computer program that can be loaded by a processor and executed as described above for simulating and predicting the insertion and removal life of electrical connector contacts. The computer-readable storage medium includes, for example, various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0087] It should be noted that in this paper, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations.

[0088] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit the scope of protection of the application. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on these embodiments, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

Claims

1. A simulation prediction method for the mating and extraction life of electrical connector contacts, characterized in that, include: Establish a three-dimensional simulation model of the plug and socket ends of the electrical connector, define the material properties of each component in the three-dimensional simulation model, and the contact relationship between each component; The contact relationship between the contact element at the plug end and the contact element at the socket end is a non-linear frictional contact. The three-dimensional simulation model is discretized using finite element mesh, and the mesh of the contacts at the plug end and the contacts at the socket end is locally refined. In the simulation environment, a fixed constraint is applied to the socket end, and a displacement load simulating the insertion and removal process is applied to the plug end. Static solutions are then performed to obtain the insertion and removal forces during the insertion and removal process of the plug end and the socket end, as well as the contact pressure data between the plug end contact and the socket end contact. The static solution results are mapped to the fatigue analysis module. Based on the low-cycle fatigue theory, the life distribution results of the plug end contact and the socket end contact under repeated insertion and removal loads are simulated and calculated.

2. The simulation prediction method for the mating and extraction life of electrical connector contacts according to claim 1, characterized in that, The displacement load applied to the plug end to simulate the insertion and removal process refers to the displacement load in the direction of the preset ideal insertion and removal axis. The method further includes: Based on the life distribution results output by the simulation calculation, the dangerous location is located from the three-dimensional simulation model. The static analysis results are then traced back to solve the stress and strain state of the dangerous location during the insertion and removal process, so as to analyze the damage mode of the dangerous location. The damage mode is correlated with the sensitive offset direction that deviates from the ideal insertion and removal axis, and a mapping relationship between different angular offset loads applied along the sensitive offset direction and the degree of damage at the dangerous location is established and output, so that simulation monitoring personnel can know it. Based on the dangerous locations and the mapping relationship, an optimized structural scheme for the electrical connector contacts is output for simulation monitoring personnel to understand.

3. The simulation prediction method for the mating and extraction life of electrical connector contacts according to claim 1, characterized in that, The method further includes: Based on the lifetime distribution results output by the simulation calculation, at least one high-risk area with a lifetime below a first preset threshold is identified from the three-dimensional simulation model. Based on the geometric features of the high-risk area, an independent sub-component containing only the high-risk area and the main structure excluding the high-risk area are segmented from the three-dimensional simulation model. A detachable connection interface between the independent sub-component and the main structure is designed at the segmentation location of the independent sub-component; wherein, the detachable connection interface includes at least a snap-fit ​​connection and a threaded connection. Based on the detachable connection interface, the contact relationship between the independent sub-component and the main structure is redefined to update the three-dimensional simulation model; After updating the 3D simulation model according to different detachable connection interface schemes, the updated 3D simulation model is simulated and the lifetime distribution results are obtained; the lifetime change of the high-risk area and its impact on the decline of the lifetime of the surrounding area are calculated and compared under each detachable connection interface scheme. Select the interface scheme that ensures the lifespan of the high-risk area meets the requirements while minimizing the impact of lifespan degradation on surrounding areas as the optimal detachable connection interface scheme, and output the optimal detachable connection interface scheme and its corresponding updated 3D simulation model.

4. The simulation prediction method for the mating and extraction life of electrical connector contacts according to claim 3, characterized in that, The method further includes: For the updated 3D simulation model according to the optimal detachable connection interface scheme, the target high-risk area and its corresponding target surrounding area are determined from the life distribution results output by the corresponding simulation calculation; wherein, the target high-risk area refers to the high-risk area in the life distribution results where the difference between the corresponding life and the life corresponding to the adjacent main structure is higher than a preset difference; the target surrounding area is the surrounding area adjacent to the target high-risk area; the target surrounding area is located between the target high-risk area and the main structure; The surrounding area of ​​the target is restructured, a load is applied to the restructured surrounding area, and a stress distribution cloud map is obtained. Based on the stress distribution cloud map, it is verified whether the surrounding area of ​​the target can reduce the stress amplitude transmitted from the high-risk area of ​​the target to the main structure through its own deformation or energy dissipation. If so, the verification result and the structural reconstruction scheme of the surrounding area of ​​the target are output. The verification result includes at least the life distribution result calculated by updating the three-dimensional simulation model using the restructured surrounding area of ​​the target.

5. The simulation prediction method for the mating and extraction life of electrical connector contacts according to claim 1, characterized in that, The method further includes: By simulating the insertion and removal process, the degradation trajectory of key performance parameters of electrical connectors with the number of insertions and removals is obtained; Based on the degradation trajectory, identify the critical point where the key performance parameter undergoes accelerated degradation and its corresponding critical cycle number, and analyze the root cause of the occurrence of the critical point. Based on the root cause, a corresponding initial design optimization scheme is formulated and implemented, the optimization scheme aiming to postpone the occurrence of the critical point; The simulation verifies whether the optimized design effectively postpones the critical point. If so, the optimized initial design scheme is output.

6. The simulation prediction method for the mating and extraction life of electrical connector contacts according to claim 5, characterized in that, The method further includes: The degradation trajectory is encapsulated into a prediction model, the input of which is a key performance parameter and the output is the remaining lifetime, for use in predicting the remaining lifetime based on the key performance parameter values. Through a cyclic simulation process, a mapping relationship between easily monitored proxy parameters and key performance parameters is established; The system receives a prediction instruction, maps the value of the key performance parameter corresponding to the current proxy parameter based on the specific value of the proxy parameter contained in the prediction instruction and the mapping relationship between the proxy parameter and the key performance parameter, and inputs it into the prediction model to output the remaining lifespan for maintenance personnel to know.

7. The simulation prediction method for the mating and extraction life of electrical connector contacts according to claim 1, characterized in that, The method further includes: Based on the lifetime distribution results, regions in the three-dimensional simulation model that are located in different lifetime gradient ranges are distinguished and displayed according to the preset lifetime gradient range and the preset display method.

8. A simulation and prediction system for the mating and extraction life of electrical connector contacts, characterized in that, include, The 3D modeling module (201) is used to create a 3D simulation model of the plug end and socket end of the electrical connector, define the material properties of each component in the 3D simulation model, and the contact relationship between each component; The contact relationship between the contact element at the plug end and the contact element at the socket end is a non-linear frictional contact. The mesh generation module (202) is used to discretize the three-dimensional simulation model into a finite element mesh and to refine the local mesh of the contact parts at the plug end and the contact parts at the socket end. The insertion and removal simulation module (203) is used to apply a fixed constraint to the socket end and a displacement load to the plug end to simulate the insertion and removal process in the simulation environment, and to perform static solution to obtain the insertion and removal force of the plug end and socket end during the insertion and removal process, as well as the contact pressure data of the plug end contact and the socket end contact. The life prediction module (204) is used to map the static solution results to the fatigue analysis module. Based on the low-cycle fatigue theory, it simulates and calculates the life distribution results of the plug end contact and the socket end contact under repeated insertion and removal loads.

9. A simulation and prediction device for the mating and extraction life of electrical connector contacts, characterized in that, It includes a memory and a processor, wherein the memory stores a computer program that can be loaded by the processor and executed as described in any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer program is stored that can be loaded by a processor and executed as described in any one of claims 1 to 7.

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