Mechanical simulation and electrical performance analysis of high current connectors

Abstract Automotive high-current connectors are one of the key components in new energy vehicles, used for transmitting high currents within the vehicle. However, vibration is unavoidable during the actual operation of connectors. This vibration directly affects the contact pressure between the connector’s contact points, thereby influencing the electrical contact performance of the connector. This paper simplifies the contact components of the electrical connector using a cantilever beam model and conducts theoretical calculations of the contact pressure. Utilizing Ansys Workbench simulation software, the study investigates the contact pressure of the electrical connector under static and various sinusoidal vibration conditions, followed by sinusoidal frequency sweep vibration experiments. The research findings indicate that under vibration conditions, the contact pressure is lower than that under static conditions, and the electrical resistance fluctuates during the vibration process.