METHOD FOR EVALUATING THE RELIABILITY OF A CONNECTION BETWEEN ELECTRICAL CONTACTS

Abstract

Method for evaluating the lifetime of an electrical connection between connectors, each comprising at least one electrical contact housed in a casing, the casings being configured to be mechanically coupled to each other, comprising the following steps: - measurement of the evolution of the electrical contact resistance between the electrical contacts alone, as a function of a number of displacements of the electrical contacts against each other and for several values ​​of displacement amplitude; - determination, from the previous measurements, of a function defining a maximum number of displacements beyond which the electrical contact resistance exceeds a predefined maximum value representative of a degraded state of the connection, as a function of the displacement amplitude;- Measurement of the displacement amplitudes of each of the housings in which the electrical contacts are intended to be placed, by subjecting the housings to mechanical stresses of varying amplitudes and frequencies; - Determination, from the amplitude measurements, of dynamic transfer functions of the housings defining the displacement amplitude of the electrical contacts as a function of the amplitude and frequency of the mechanical stresses applied to the housings; - Determination, for given values ​​of amplitude and frequency of mechanical stresses applied to the connectors and from the functions previously determined, of the service life of the connection between the connectors. No figure for the abstract.

Description

Title of the invention: METHOD FOR EVALUATING THE RELIABILITY OF A CONNECTION BETWEEN ELECTRICAL CONTACTS technical field

[0001] The invention relates to the field of evaluating the lifespan, and therefore the reliability, of electrical connections between connectors subjected to mechanical stresses, particularly vibrational stresses. The invention is advantageously applicable to the field of electrical connectors used in transport vehicles, particularly aircraft, automobiles, or railways. State of the prior art

[0002] Fretting is a low-amplitude oscillatory relative movement (from a few pm to a few tens of pm) that can be observed at the interface of two parts in quasi-static contact with each other, when these parts are subjected to vibratory constraints and / or relative displacements. In the majority of cases, it is a tangential movement of the parts against each other, and is generally a consequence of the vibratory stresses that the system comprising these parts encounters. For example, in the case of systems embedded in transport vehicles, particularly aircraft, these displacements are caused by the vibrations generated by the vehicles' engines.

[0003] Fretting is a phenomenon observed in many systems (electrical and / or mechanical), and constitutes one of the main causes of damage to parts in contact. It causes a trace of localized wear of small dimensions, generally proportional to the contact surface of the parts and to the amplitude of the movement generated between the parts.

[0004] An electrical connector is composed of a housing with one or more housings in which there are one or more electrical contacts. Connectors are used in particular for connecting two harnesses (bundles each composed of one or more electrical cables surrounded by a protective sheath) to each other, or a harness with electrical equipment. When two connectors are coupled to each other, their electrical contacts make the electrical connection between them. These electrical contacts are generally of the male / female type (or "pin / socket" in English), the plugging of the male contact into the female contact ensuring the electrical connection between them.

[0005] The electrical performance of a connection between two electrical contacts is generally measured by the electrical contact resistance between these two contacts electrical. The lower this electrical resistance, the better the contact. This electrical contact resistance depends on several factors such as the contact surface and force, the resistivity of the electrical contact materials, temperature, etc.

[0006] Electrical contacts are generally made of copper or copper alloy, and often have a coating to ensure protection from the external environment in order to protect the copper or copper alloy against corrosion while ensuring good electrical performance of the contacts. In the case of high-power electrical contacts, these coatings are generally gold or silver plating.

[0007] The connectors can be installed in environments with high vibration constraints and these vibrations then propagate to the interface between the electrical contacts. A relative movement can then be observed between them (corresponding to fretting), and the repetition of this tangential movement to the contact surface can cause contact wear. Fretting causes the degradation of the protective coatings of the electrical contacts, which are then exposed to the external environment. The copper substrate of the electrical contacts then undergoes corrosion and the debris from this wear oxidizes, which significantly deteriorates the electrical contact resistance and the service life of the electrical contacts. The increase in contact resistance leads to localized heating of the contact, which has the effect of increasing its resistance even further. A thermal runaway phenomenon can then be observed, leading in the worst case to a fire..

[0008] In the case of applications related to high power, strong electrical currents can generate greater heating than that observed at the level of low power contacts. This heating causes expansion of the different materials constituting the connector, which allows greater relative movements of the electrical contacts. This heating also has consequences on the degradation of the electrical performance of the contact, since the oxidation phenomenon accelerates with temperature. In a high power context, the risk of wear by fretting therefore no longer allows the reliability of the connectors to be guaranteed and can become a major cause of damage if it is not taken into account.

[0009] Fretting is impacted by several factors that can modify the behavior and wear of the contact, such as the choice of materials, the thickness of the coatings, temperature, humidity, etc. The parameter with the greatest impact on the fretting wear of an electrical contact is the amplitude of movement of this electrical contact when it is subjected to stress. Regardless of the type of coating used to protect electrical contacts, the amplitude of movement has a major influence on fretting wear and therefore on the lifetime of the contacts.

[0010] There are two main modes of sliding when two electrical contacts connected to each other are subject to fretting constraints: - partial sliding: this is a sliding observed when the deflection amplitude is low and less than a threshold amplitude called the "transition amplitude". In this case, the contact is characterized by a so-called "bonded" zone located at the center of the interface between the two electrical contacts and surrounded by a so-called "slip" zone located on the periphery of this interface. At the level of the "bonded" zone, no sliding is observed and therefore the contact does not undergo degradation. In this case, the metal / metal contact between the electrical contacts is maintained over time, and the lifetime of the contact can be considered infinite. On the other hand, the greater the deflection amplitude, the smaller the surface area of ​​the bonded zone, until it is zero when the deflection amplitude is greater than or equal to the transition amplitude, - total sliding: such sliding occurs when the movement amplitude exceeds the transition amplitude. The sliding is then generalized to the entire contact surface and the deterioration leads to an increase in resistance until the electrical failure of the contact.

[0011] The evolution of the endurance of a connection between two electrical contacts, i.e. the number of fretting cycles necessary to lead to the failure of this connection, as a function of the amplitude of deflection, can be modeled by a decreasing power law. The end-of-life criterion of a connection is based on a threshold value of the contact resistance not to be exceeded. For a given material, and for given connection conditions, there is a threshold value of the amplitude of deflection above which the endurance of the electrical contact decreases sharply.

[0012] Thus, the amplitude of the movement that two electrical contacts connected to each other undergo is a determining factor on the endurance, or the lifetime, of the connection of these two electrical contacts, that is to say on the number of fretting cycles necessary to reach a threshold value of contact resistance considered as a damage. The lower the amplitude of movement, the greater the lifetime of the contact. This amplitude of movement is specific to each connection, because it depends on the design of the elements of this connection which is an assembly of technical solutions based on parameters such as the materials used, the contact force applied, the contact surface, etc. It also depends on environmental parameters such as temperature.

[0013] To calculate the risk of wear by fretting of a given connector, it is necessary to know the amplitude of displacement that this connector will undergo in service (for example in flight in the case of connectors used in an aircraft). It also depends on the design of the connector and the “freedom” of movement of the electrical contacts housed in the connector. The elements used to assess this amplitude are: the manufacturing tolerances of each of the parts constituting the connector, the assembly clearances, the elastic deformations of the parts subjected to vibratory constraints, the expansion of the materials depending on the operating temperature. It is therefore very difficult to estimate this amplitude and to be able to guarantee the reliability of the contact, and therefore to assess the risk of wear by fretting within a given connector.

[0014] There are different methods for evaluating the reliability of a connector subjected to vibration constraints.

[0015] A first method consists of carrying out vibration tests according to the NF EN2591 test standard: these are the classic qualification tests for an electrical connector used in the aeronautics field. These tests consist of applying a vibration stress along 3 axes (6 directions) for a defined duration (generally 8 hours). Numerous checks are then carried out, and guarantee that the functional performance of the connector will not be deteriorated. These checks are generally measurements of the coupling / uncoupling forces, the plugging / unplugging forces of the electrical contact(s) of the connector, and resistance measurements of the electrical contact(s). These vibration tests make it possible to verify that the connector is not damaged (in particular at the connector housing) and that the connection is maintained when the connector is subjected to vibrations.

[0016] However, these tests are not long enough to assess the long-term durability of the connector. Furthermore, with this first method, the vibration tests set the entire connector into vibration, but do not guarantee that fretting occurs on the electrical contact(s) of the connector. Indeed, the electrical contacts can move in relative motion (out of phase), which causes fretting, but they can also move together (in phase), in which case no fretting occurs. This is because the connector is composed of parts with different stiffnesses that can dampen the movements, with the result that the electrical contact(s) inside the connector do not move in the same way as the vibrating connector.

[0017] The connector also does not react in the same way depending on the temperature and the vibrational stresses experienced, which makes it difficult to know whether fretting occurs during the vibration test, and if so, it is not possible to know the amplitude of movement between the connected electrical contacts. Indeed, this amplitude of movement seen by the electrical contacts depends on many factors, such as the assembly clearances of the parts constituting the connector, the expansions of the parts due to temperature variations, and the elasticity of the materials subjected to vibration constraints.

[0018] Another method for evaluating the behavior of a connector subjected to vibrational stresses is to subject it to severe vibration tests: these are tests in which the vibration level and / or duration have been increased in order to increase the vibrational stresses experienced by the connector. This increases the possibility / probability of fretting at the contact point. However, for the same reasons as in the previous method, this type of test does not guarantee the occurrence of fretting and does not allow for determining its severity (in particular, the amplitude of movement).

[0019] During the development of a high-power electrical connector intended for use in an aircraft, several physical phenomena are taken into account, and the resulting connector design must ensure its reliability throughout the aircraft's lifetime. Since fretting is also a critical factor for the connector (as it can cause severe failures), it is important to evaluate it and consider it during the connector's development.

[0020] This need to evaluate the lifetime of an electrical connection between two connectors, taking into account the risk of wear by fretting of the electrical contacts of these connectors, is also found in fields other than that of aeronautics, and more generally in the entire field of electrical connections. Presentation of the invention

[0021] An aim of the present invention is to propose a method for evaluating the lifetime of an electrical connection between at least two connectors each provided with at least one electrical contact, taking into account contact wear due to fretting.

[0022] For this, the invention proposes a method for evaluating the lifetime of an electrical connection between at least two connectors each comprising at least one electrical contact housed in a housing, the housings of the two connectors being configured to be mechanically coupled to each other, comprising the following steps: - measurement of the change in the electrical contact resistance between the electrical contacts alone, without the presence of any other element of the connectors, as a function of a number of movements of the electrical contacts against each other and for several values ​​of amplitude of movement of the electrical contacts against each other; - determination, from measurements of the evolution of the electrical contact resistance between the electrical contacts, of a function defining a maximum number of displacements beyond which the electrical contact resistance between the electrical contacts exceeds a predefined maximum value representative of a degraded state of the connection, as a function of the amplitude of displacement; - measurement of displacement amplitudes, at the level of each of the housings of the connectors in which the electrical contacts are intended to be arranged, by subjecting the housings to mechanical stresses of amplitude and frequency of different values; - determination, from displacement amplitude measurements, of dynamic transfer functions of the housings defining the displacement amplitude of the electrical contacts as a function of the amplitude and frequency of the mechanical stresses applied to the housings;- determination, for given values ​​of amplitude and frequency of mechanical stresses applied to the connectors, of the service life of the connection between the connectors corresponding to the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts exceeds the predefined maximum value representing a degraded state of the connection, this maximum number of displacements being determined from the function defining the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts exceeds the predefined maximum value representing a degraded state of the connection as a function of the displacement amplitude,for an amplitude of displacement of the electrical contacts against each other, the value of which is determined by the dynamic transfer functions of the connectors for the given values ​​of amplitude and frequency of the mechanical stresses applied to the connectors.

[0023] The measurement of the change in the electrical contact resistance between the first and second electrical contacts alone implemented in this method corresponds to an evaluation of the endurance of the electrical contacts alone, in particular without a connector housing, when they are subjected to fretting. This measurement makes it possible to know the endurance of the electrical connection formed between the electrical contacts as a function of the amplitude of movement and the fretting conditions to which the electrical contacts are subjected.

[0024] During the method, a determination of the dynamic transfer functions of the housings to the electrical contacts is also implemented by an experimental modal analysis method applied to the connectors. Thus, it is possible to determine the amplitude of displacement of the electrical contacts when the connectors are subjected to external vibrations.

[0025] Finally, a comparison of these results is implemented to conclude on the qualitative reliability of the connection in a vibratory environment. By comparing the amplitude of displacement of the electrical contacts in the housings with the endurance curve at this same amplitude, it is possible to determine the evolution over time of the electrical contact resistance between the electrical contacts when they are housed in the connectors, for given mechanical stresses, and therefore determine the lifespan of the connection formed between the connectors.

[0026] With this method, it becomes possible to know, depending on the vibrational constraints undergone by the connectors, whether or not the electrical contacts of these connectors undergo fretting. It is therefore possible to evaluate the lifetime of this connection depending on the vibrational constraints undergone, and therefore for example depending on the installation area of ​​the connectors in a transport vehicle such as an aircraft.

[0027] From the results obtained, it is possible to determine whether a possible resizing of the electrical contacts (coating thicknesses, contact pressure, etc.) and / or of the parts constituting the connectors (choice of materials with regard to expansions, assembly clearances, etc.) is judicious.

[0028] The proposed method makes it possible to truly take into account the phenomenon of fretting by causing it voluntarily, in a controlled manner, during endurance tests on electrical contacts, unlike the solutions of the prior art based on vibration tests during which fretting may not occur.

[0029] Determining the fretting endurance of the connectors and the dynamic transfer functions of the connectors ultimately makes it possible to determine the reliability of the connection and its limits of use (in particular the possible installation areas thereof). This evaluation of the lifetime of the connection can make it possible to identify areas for improvement in the design of the contacts and / or the connectors if the determined lifetime is not satisfactory.

[0030] Advantageously, the method may be such that: - the evolution of the electrical contact resistance between the electrical contacts alone is measured for several frequency values ​​of the displacements undergone by the electrical contacts during these measurements, and the function defining the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts exceeds the predefined maximum value representing a degraded state of the connection as a function of the displacement amplitude is determined for these different frequency values ​​of the displacements undergone by the electrical contacts, and - a displacement frequency of the housings of the housings is also measured when the housings are subjected to mechanical stresses of amplitude and frequency of different values, and the dynamic transfer functions of the housings are determined such that they also define displacement frequency values ​​of the electrical contacts as a function of the amplitude and frequency values ​​of the mechanical stresses, and - the maximum number of movements beyond which the electrical contact resistance between the electrical contacts exceeds the predefined maximum value represented indicative of a degraded state of the connection is also determined for a frequency of movement of the electrical contacts against each other, the value of which is determined by the dynamic transfer functions of the housings for the given values ​​of the amplitude and frequency of the mechanical stresses.

[0031] In the above configuration, the frequency with which the electrical contacts undergo fretting is also taken into account in the evaluation of the lifetime of the connection, thus improving the accuracy in this evaluation.

[0032] Advantageously, the method may be such that: - the measurements of the evolution of the electrical contact resistance between the electrical contacts alone and of the displacement amplitudes of the housings of the boxes are each carried out under different given environmental conditions for which the values ​​of temperature and / or relative humidity and / or pressure differ from each other, and - the function defining the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts exceeds the predefined maximum value representative of a degraded state of the connection as a function of the displacement amplitude and the dynamic transfer functions of the boxes are determined for each of the different environmental conditions, and - the lifetime of the connection between the connectors is determined from the function defining the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts exceeds the predefined maximum value representative of a degraded state of the connection as a function of the displacement amplitude and the dynamic transfer functions of the housings obtained under identical given environmental conditions.

[0033] In the above configuration, the ambient temperature and / or relative humidity and / or pressure of the environment in which the connectors are located are taken into account in the evaluation of the lifetime of the connection, thus improving the accuracy in this evaluation.

[0034] In a particular configuration, the method may further comprise the steps of - from measurements of the evolution of the electrical contact resistance between the electrical contacts alone, determination of an amplitude value for the displacement of the electrical contacts against each other for which the electrical contact resistance between the electrical contacts remains below a predefined value representative of the beginning of connection degradation, and - determination, for the given values ​​of amplitude and frequency of the mechanical stresses applied to the connectors, of the absence or not of degradation of the connection between the connectors by comparing the amplitude value of the de placement of electrical contacts against each other for which the electrical contact resistance between the electrical contacts remains less than the predefined value representing the beginning of degradation of the connection with the value of the amplitude of displacement of the electrical contacts against each other determined by the dynamic transfer functions of the housings for the given values ​​of amplitude and frequency of the mechanical stresses applied to the connectors.

[0035] In the particular configuration above, the method makes it possible to determine whether, under given operating conditions, the connection is affected or not by fretting.

[0036] Advantageously, the method may be such that: - the displacement amplitudes of the housings of the boxes are measured by accelerometers and / or vibration sensors, and - the mechanical stresses to which the housings are subjected are applied by at least one impact hammer equipped with a head coupled to a force sensor configured to measure the amplitude and frequency of the applied mechanical stresses, or by a vibrating pot, and - the accelerometers and / or vibration sensors, and the force sensor or the vibrating pot, are electrically coupled to at least one spectrum analyzer determining the dynamic transfer functions of the housings.

[0037] One of the electrical contacts may correspond to a male electrical contact, and the other of the electrical contacts may correspond to a female electrical contact.

[0038] The different values ​​of amplitude and frequency of the mechanical stresses may be representative of different locations in a transport vehicle. In this case, the transport vehicle may be an aircraft. Brief description of the drawings

[0039] The present invention will be better understood on reading the description of exemplary embodiments given purely for informational purposes and in no way limiting, with reference to the appended drawings in which: - [Fig.l] represents an example of embodiment of connectors whose lifetime of the connection with each other is evaluated by the method, object of the invention; - [Fig.2] schematically represents the steps of a method for evaluating the lifespan of an electrical connection, the subject of the present invention; - [Fig. 3] schematically represents an example of a function defining a maximum number of displacements beyond which the electrical contact resistance between the electrical contacts exceeds a predefined maximum value representative of a degraded state of the connection, as a function of the amplitude of displacement, determined during a process for evaluating the lifespan of an electrical connection, object of the present invention.

[0040] Identical, similar or equivalent parts of the different figures described below bear the same numerical references so as to facilitate the transition from one figure to another.

[0041] The different parts represented in the figures are not necessarily on a uniform scale, in order to make the figures more readable.

[0042] The different possibilities (variants and embodiments) should be understood as not being mutually exclusive and can be combined with each other.

[0043] Detailed description of particular embodiments

[0044] A method for evaluating the lifetime of an electrical connection between at least two connectors 100, 102 configured to be mechanically coupled to each other is described below.

[0045] An example of the embodiment of the two connectors 100, 102 is visible in [Fig.1].

[0046] Connector 100, referred to as first connector 100, comprises a first housing 104 in which at least one first electrical contact 106 is housed. In the exemplary embodiment shown in [Fig.l], the first connector 100 comprises a first electrical contact 106 of male type. The connector 102, called second connector 102, comprises a second housing 108 configured to be mechanically coupled to the first housing 104 and in which at least one second electrical contact 110 is housed. In the exemplary embodiment shown in [Fig.l], the second connector 102 comprises a second electrical contact 110 of female type and configured to be electrically connected to the first electrical contact 106.

[0047] The steps of the process for evaluating the life of the electrical connection between the connectors 100, 102 when they are mechanically coupled to each other are described below and schematically shown in [Fig.2].

[0048] A step 120 of evaluating the endurance of the electrical contacts 106, 110 is implemented. This step 120 comprises a measurement of the change in the electrical contact resistance between the electrical contacts 106, 110 alone, without the presence of any other element of the connectors 100, 102 (in particular without the housings 104, 108), as a function of a number of movements of the electrical contacts 106, 110 against each other and for several movement amplitude values.

[0049] During these measurements, the electrical contacts 106, 110 are subjected to fretting by moving them, for example longitudinally, against each other, preferably by moving the first electrical contact 106 when the latter corresponds to a male electrical contact and keeping the second electrical contact 110 in a fixed position when the latter corresponds to a female electrical contact.

[0050] These measurements are carried out for different values ​​of amplitude of displacement of the electrical contacts 106, 110 against each other, and for example using a milli- liohmmeter.

[0051] For each of the chosen displacement amplitude values, the change in the electrical contact resistance between the electrical contacts 106, 110 alone is measured until the measured electrical contact resistance value exceeds a predefined maximum value which depends on the specifications of the connectors 100, 102 and which is representative of a degraded state of the electrical connection between the electrical contacts 106, 110, or until a number of displacements of the electrical contacts 106, 110 against each other exceeds a maximum value, for example of the order of 10 million cycles, making it possible to consider that the electrical contacts 106, 110 are not degraded by these displacements.

[0052] After the implementation of step 120, a step 130 is carried out and consists of determining, from the measurements carried out in step 120, a function defining a maximum number of displacements beyond which the electrical contact resistance between the electrical contacts 106, 110 exceeds a predefined maximum value representative of a degraded state of the connection between the contacts 106, 110, as a function of the amplitude of displacement of the contacts 106, 110 against each other. An example of a curve representative of such a function is shown in [Fig. 3], with the amplitude of displacement represented on the ordinate axis and the number of displacements represented on the abscissa axis.

[0053] An experimental modal analysis of the connectors 100, 102 is then implemented. The objective of the experimental modal analysis is to determine the dynamic characteristics of the connectors 100, 102 and to identify the dynamic transfer functions of the housings 104, 108 to the electrical contacts 106, 110, i.e. the dynamic response of the connectors 100, 102 as a function of the mechanical stresses undergone.

[0054] During this analysis, known mechanical stresses are applied to the housings 104, 108 of the connectors 100, 102, and their response transmitted to the housings in which the electrical contacts 106, 110 are located is measured. For this, during a step 140, the housings 104, 108 are subjected to mechanical stresses of amplitude and frequency of different values, and the displacement amplitudes, at each of the housings of the housings 104, 108 in which the electrical contacts 106, 110 are intended to be arranged, are measured.

[0055] Then, during a step 150, from the measurements of displacement amplitudes of the housings carried out previously, dynamic transfer functions of the housings 104, 108 defining the displacement amplitude of the electrical contacts 106, 110 as a function of the amplitude and frequency of mechanical stresses applied to the housings 104, 108 are determined.

[0056] According to an exemplary embodiment, the displacement amplitudes of the housings of the housings 104, 108 are measured by accelerometers and / or vibration sensors. In addition, the mechanical stresses to which the housings 104, 108 are subjected are for example applied by at least one dynamic impact hammer provided with a head coupled to a force sensor configured to measure the amplitude and frequency of the applied mechanical stresses, or by using a vibrating pot. These different elements (accelerometers and / or vibration sensors, and the force sensor or the vibrating pot) can be electrically coupled to at least one spectrum analyzer determining the dynamic transfer functions of the housings 104, 108.

[0057] Once the dynamic transfer functions of the housings 104, 108 have been determined, it is then possible to calculate the potential travel amplitude of the electrical contacts 106, 110 installed in the housings 104, 108, which corresponds to the result given by the dynamic transfer functions of the housings 104, 108, by applying the vibrational stresses that the connectors 100, 102 may experience as input data. These vibrational stresses are, for example, given according to the installation conditions planned for the connectors 100, 102.

[0058] Indeed, knowing that for a given stress, the electrical contacts 106, 110 housed in the housings 104, 108 will move in relative motion with a certain amplitude of displacement, and knowing the endurance of the electrical contacts 106, 110 subjected to such an amplitude of displacement, it is possible to conclude on the lifetime of the connection between the electrical contacts 106, 110 as a function of this stress, and therefore as a function for example of an installation zone of the connectors 100, 102 in a vehicle (such as an aircraft) for which the stresses undergone therein are known.

[0059] Thus, during a step 160, for given values ​​of amplitude and frequency of mechanical stresses applied to the connectors 100, 102, the lifetime of the connection between the connectors 100, 102 is determined. This lifetime corresponds to the maximum number of movements beyond which the electrical contact resistance between the electrical contacts 106, 110 exceeds the predefined maximum value representative of a degraded state of the connection.This maximum number of displacements is determined from the function defining the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts 106, 110 exceeds the predefined maximum value representative of a degraded state of the connection as a function of the amplitude of displacement, for an amplitude of displacement of the electrical contacts 106, 110 against each other whose value is determined by the dynamic transfer functions of the connectors 100, 102 for the given values ​​of amplitude and frequency of the mechanical stresses applied to the connectors 100, 102.

[0060] Advantageously, in addition to the range of motion of the electrical contacts 106, 110, it is also possible to take into consideration the fretting frequency between electrical contacts 106, 110. For this, the steps of the process are implemented as follows: - in step 120, the change in the electrical contact resistance between the electrical contacts 106, 110 alone can be measured for several frequency values ​​of the movements undergone by the electrical contacts 106, 110 alone during these measurements; - in step 130, the function defining the maximum number of movements beyond which the electrical contact resistance between the electrical contacts 106, 110 exceeds a predefined maximum value representative of a degraded state of the connection as a function of the amplitude of movement is determined for these different frequency values ​​of the movements undergone by the electrical contacts 106, 110; - in step 140, a displacement frequency of the housings of the boxes 104, 108 is then also measured when the boxes 104, 108 are subjected to mechanical stresses of amplitude and frequency of different values; - in step 150, the dynamic transfer functions of the housings 104, 108 are then determined such that they also define displacement frequency values ​​of the electrical contacts 106, 110 as a function of the amplitude and frequency values ​​of the mechanical stresses; - finally, in step 160, the maximum number of movements beyond which the electrical contact resistance between the electrical contacts 106, 110 exceeds the predefined maximum value representative of a degraded state of the connection is also determined for a frequency of movement of the electrical contacts 106, 110 against each other, the value of which is determined by the dynamic transfer functions of the housings 104, 108 for the given values ​​of the amplitude and frequency of the mechanical stresses.

[0061] In the method described above, steps 120 to 150 are implemented under given environmental conditions. Advantageously, it is possible to repeat these steps by modifying these environmental conditions each time, that is to say by modifying each time the temperature and / or relative humidity values ​​in which the connectors 100, 102 are located. In this case: - in steps 120 and 140, measurements of the evolution of the electrical contact resistance between the electrical contacts 106, 110 alone and of the displacement amplitudes of the housings of the boxes 104, 108 are each carried out under the different given environmental conditions; - in steps 130 and 150, the function defining the maximum number of movements beyond which the electrical contact resistance between the electrical contacts 106, 110 exceeds the predefined maximum value representing a degraded state of the connection as a function of the displacement amplitude and the dynamic transfer functions of the housings 104, 108 are determined for each of the different environmental conditions; - in step 160, the lifetime of the connection between the connectors 100, 102 is determined from the function defining the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts 106, 110 exceeds the predefined maximum value representative of a degraded state of the connection as a function of the displacement amplitude and the dynamic transfer functions of the housings 104, 108 obtained under identical given environmental conditions.

[0062] In the method and the various variants above, the lifetime of the connection between the connectors 100, 102 is evaluated by determining the number of fretting cycles beyond which the electrical connection between them is degraded.When the mechanical stresses to which the connectors 100, 102 are subjected do not result in a displacement amplitude of the electrical contacts 106, 110 that exceeds the transition amplitude of these contacts, the lifetime of the electrical connection between the connectors 100, 102 can be considered infinite. The method described above can be implemented to determine whether the electrical connection between the connectors 100, 102, subjected to given mechanical stresses, has such a lifetime that can be considered infinite. For this purpose: - from the measurements of the change in the electrical contact resistance between the electrical contacts 106, 110 alone carried out in step 120, a value of the amplitude of movement of the electrical contacts 106, 110 against each other for which the electrical contact resistance between the electrical contacts 106, 110 remains lower than a predefined value representative of the start of degradation of the connection between the electrical contacts 106, 110 is determined, and - for the given values ​​of amplitude and frequency of the mechanical stresses applied to the connectors 100, 102, an absence or not of degradation of the connection between the connectors 100, 102 is determined by comparing the value of amplitude of displacement of the electrical contacts 106, 110 against each other for which the electrical contact resistance between the electrical contacts 106, 110 remains lower than the predefined value representative of a start of degradation of the connection with the value of amplitude of displacement of the electrical contacts 106, 110 against each other determined by the dynamic transfer functions of the housings for the given values ​​of amplitude and frequency of the mechanical stresses applied to the connectors 100, 102.

[0063] In the process and the various variants described above, steps 120 and 130 can be carried out before or after or simultaneously with steps 140 and 150.

Claims

Claims

1. A method for evaluating the lifetime of an electrical connection between at least two connectors (100, 102) each comprising at least one electrical contact (106, 110) housed in a housing (104, 108), the housings (104, 108) of the two connectors (100, 102) being configured to be mechanically coupled to each other, comprising the following steps: - measurement of the change in the electrical contact resistance between the electrical contacts (106, 110) alone, without the presence of any other element of the connectors (100, 102), as a function of a number of movements of the electrical contacts (106, 110) against each other and for several values of amplitude of movement of the electrical contacts (106, 110) against each other; - determination, from measurements of the evolution of the electrical contact resistance between the electrical contacts (106, 110), of a function defining a maximum number of displacements beyond which the electrical contact resistance between the electrical contacts (106, 110) exceeds a predefined maximum value representative of a degraded state of the connection, as a function of the amplitude of displacement; - measurement of displacement amplitudes, at the level of each of the housings of the housings (104, 108) of the connectors (100, 102) in which the electrical contacts (106, 110) are intended to be arranged, by subjecting the housings (104, 108) to mechanical stresses of amplitude and frequency of different values; - determination, from the displacement amplitude measurements, of dynamic transfer functions of the housings (104, 108) defining the displacement amplitude of the electrical contacts (106, 110) as a function of the amplitude and frequency of the mechanical stresses applied to the housings (104, 108); - determination, for given values of amplitude and frequency of mechanical stresses applied to the connectors (100, 102), of the lifetime of the connection between the connectors (100, 102) corresponding to the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts (106, 110) exceeds the predefined maximum value representative of a degraded state of the connection, this maximum number of displacements being determined at

2.

3. from the function defining the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts (106, 110) exceeds the predefined maximum value representative of a degraded state of the connection as a function of the displacement amplitude, for an amplitude of displacement of the electrical contacts (106, 110) against each other, the value of which is determined by the dynamic transfer functions of the connectors (100, 102) for the given values of amplitude and frequency of the mechanical stresses applied to the connectors (100, 102). The method of claim 1, wherein: - the evolution of the electrical contact resistance between the electrical contacts (106, 110) alone is measured for several frequency values of the movements undergone by the electrical contacts (106, 110) during these measurements, and the function defining the maximum number of movements beyond which the electrical contact resistance between the electrical contacts (106, 110) exceeds the predefined maximum value representative of a degraded state of the connection as a function of the amplitude of movement is determined for these different frequency values of the movements undergone by the electrical contacts (106, 110), and - a displacement frequency of the housings of the housings (104, 108) is also measured when the housings (104, 108) are subjected to mechanical stresses of amplitude and frequency of different values, and the dynamic transfer functions of the housings (104, 108) are determined such that they also define displacement frequency values of the electrical contacts (106, 110) as a function of the amplitude and frequency values of the mechanical stresses, and - the maximum number of movements beyond which the electrical contact resistance between the electrical contacts (106, 110) exceeds the predefined maximum value representative of a degraded state of the connection is also determined for a frequency of movement of the electrical contacts (106, 110) against each other, the value of which is determined by the dynamic transfer functions of the housings (104, 108) for the given values of the amplitude and frequency of the mechanical stresses. Method according to one of the preceding claims, in which: - the measurements of the evolution of the electrical contact resistance between

4. the electrical contacts (106, 110) alone and displacement amplitudes of the housings of the boxes (104, 108) are each carried out under different given environmental conditions for which the values of temperature and / or relative humidity and / or pressure differ from each other, and - the function defining the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts (106, 110) exceeds the predefined maximum value representative of a degraded state of the connection as a function of the displacement amplitude and the dynamic transfer functions of the housings (104, 108) are determined for each of the different environmental conditions, and - the lifetime of the connection between the connectors (100, 102) is determined from the function defining the maximum number of displacements beyond which the electrical contact resistance between the electrical contacts (106, 110) exceeds the predefined maximum value representative of a degraded state of the connection as a function of the displacement amplitude and the dynamic transfer functions of the housings (104, 108) obtained under identical given environmental conditions. Method according to one of the preceding claims, further comprising: - from the measurements of the evolution of the electrical contact resistance between the electrical contacts (106, 110) alone, determination of a value of amplitude of displacement of the electrical contacts (106, 110) against each other for which the electrical contact resistance between the electrical contacts (106, 110) remains lower than a predefined value representative of a start of degradation of the connection, and - determination, for the given values of amplitude and frequency of the mechanical stresses applied to the connectors (100, 102), of an absence or not of degradation of the connection between the connectors (100, 102) by comparing the value of amplitude of displacement of the electrical contacts (106, 110) against each other for which the electrical contact resistance between the electrical contacts (106,110) remains lower than the predefined value representative of the start of degradation of the connection with the value of the amplitude of displacement of the electrical contacts (106, 110) against each other determined by the dynamic transfer functions of the boxes (104, 108), for the given values of amplitude and frequency of the mechanical stresses applied to the connectors (100, 102).

5. Method according to one of the preceding claims, in which: - the displacement amplitudes of the housings of the boxes (104, 108) are measured by accelerometers and / or vibration sensors, and - the mechanical stresses to which the boxes (104, 108) are subjected are applied by at least one impact hammer provided with a head coupled to a force sensor configured to measure the amplitude and frequency of the applied mechanical stresses, or by a vibrating pot, and - the accelerometers and / or the vibration sensors, and the force sensor or the vibrating pot, are electrically coupled to at least one spectrum analyzer determining the dynamic transfer functions of the boxes (104, 108).

6. A method according to any preceding claim, wherein one of the electrical contacts (106) corresponds to a male electrical contact, and the other of the electrical contacts (110) corresponds to a female electrical contact.

7. Method according to one of the preceding claims, in which the different values of amplitude and frequency of the mechanical stresses are representative of different locations in a transport vehicle.

8. The method of claim 7, wherein the transport vehicle is an aircraft.

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