Signal Analysis of Fretting Damages on Electrial Connector Systems

Sammanfattning: Electrical connectors are widely utilized for signal communications in automotive electronic systems whose performance is related to the reliability of the entire system. Electrical connectors are frequently affected by the engine vibration, resulting in fretting damages on electrical connector. In this thesis, the main propose is to find a signal analysis method to predict the fretting damages on fuel pump connector induced by engine vibration. The data of the fuel pump connector is studied from a vibration test of the four-cylinder engine and the dominating frequencies are used in the fretting test to verify the analysis method. The fretting damage is identified through visual inspection by microscope. The model of the connector is built in COMSOL to explain the fretting on the contact surfaces. The results present the signal analysis method can be directly used to predict the risk of fretting damages during the engine vibration. Some significant frequencies are pointed out as guidelines for future tests and optimization.