汽车线束和连接器可靠性设计及工艺流程研究

上海交通大学硕士学位论文汽车线束和连接器可靠性设计及工艺流程研究姓名：李小平申请学位级别：硕士专业：电气工程指导教师：常越20070211I:1234IISTUDYONRELIABILITYDESIGNANDPROCESSCONTROLOFAUTOHARNESSANDCONNECTORABSTRACTAutoharnessisanimportantaccessoryforautomobilel,whichiscalledauto-nerve.It’selectricitysignalcontrolcarrier.Itcantransferelectricsignalreliably.Thisarticleguidesdesignimprovingaccordingtodevelopingtrendbasedonroutinedesigningtechnologyandqualitycontrolforharnessandconnector.Accordingtoharnessandconnectorperformancerequirements,wecananalysispotentialfailuremode&effectstoguidequalitycontrolandimprovementforharnessandconnectorduringbatchproducingprocess.Autoharnessesspreadallovertheautomobile.Electricsignalthroughgeneralpoweriscontrolledbyeachswitchandtransferredtoelectricalequipments.Autoharnessisformedbymanymaterialsandparts.Whenwedesignautoharness,materialselectedshouldnotonlyconformtoautoperformancerequirements,butalsothatofharness.Duringassemblingandusingforautoconnectors,termsandhousingselasticitybecomedeformed.Sowedesignconnectorsnotonlymeetingtoelectricandenvironmentalperformance,butalsothatofmechanical.Owingtomanykindsofautoharnessmaterialsandparts&workingprocess,keypointofqualitycontrolistocontroltheproducingprocessperpotentialfailuremodeandeffectsanalysis.Followingisthemainresearchfruitsforthisthesis:1.Selectwiretypecross-sectionconnectorsandtermsdesignharnessesaccordingtoautocircuitsdrawing,electricequipmentsparameterandenvironmentalperformancerequirements.Determineharnessbranchesperassemblyposition.2.Autocontactreliabilitydesignincludingcontactresistance,insertionandwithdrawlforcepositiveforcemaxstressdesignaccordingtoelectriccontacttheory.III3.Autohousingsreliabilitydesignincludingconstructiondesign,materialsdesignassemblyaccessoriescalculatestrengthoncontactpoint&matingintervalbetweenconn.andconn.&conn.andtermsanddimensiontoleranceaccordingtoautoharnessusingandenvironmentalrequirements.4.Advancedproductqualityplanning&potentialfailuremodeandeffectsanalysistoautoharnessproduction.Qualitycontrolplanningforproductionperiodtoreducedefectavoidfailureandimproveharness&connectorquality.KEYWORDSAutoharnessAutoconnectorreliabilitydesignprocesscontrolQualityreliabilityplanning&controlwayVIIPAUdUρLA2mmA()Al(mm2)L1FFsNFµαabnRKmVIINFDEWTlIxnxEyEsP[]τbh200725320072520072511.1,2080,,1.2..10906026100020001450001.31.3.121-1Fig1-1Multinomialelectricallineway,(,)40CANInternetCANControllerAr-eaNetwork(),,CANCANCANCAN1.3.231-2Fig1-2Withoutharnesselectricallineway1113011602270%123456785%,1.3.370BEC(BussedElec-tricalCenter)(8)4,ITE1.3.4,,,(),51-3Fig1-3AutoHarnesslayout1.4PEPVCPPE().()1.5()1-41-561-4Fig1-4Autoharness1-5Fig1-5Autoharnessmap123:720041.612382.12-1Fig2-1Autoharnessdesignflowchart2.1.12-1,192345672.1.2123451231042.1.335%PVCAVSSQVRFLRYAVSSQVR150-55150200ABS150200100MHZ211160-100231U12V24VPPIU=II22-29012102-215W0.10.615W0.30.60.50.5200.50.51.51.90.51.5,dPILIAUUρ==(21)−IPAUdUρLA2mm8102IA=×+(22)−2-3(mm2)0.50.7511.52.54610166079.511.5151925334563100121619243242557510555W12V4.6A5m2-20.3V131.42mm0.6V0.72mm2-4/2mm20/mmΩmm/mm/A(20)/A(50)/A/2mm0.537.11.02.311.07.810.00.824.01.22.515.010.610.01.018.51.42.719.013.510.01.512.71.63.024.017.010.02.57.62.13.732.022.710.04.04.72.74.542.029.810.06.03.13.45.254.038.36.010.01.84.36.673.051.86.016.01.26.08.198.069.66.025.00.77.510.2129.091.64.035.00.58.811.5158.0112.04.050.00.410.313.2198.0140.04.070.00.312.015.5245.0174.03.02IPA=21.44mm23.3Amm20.7mm26.6Amm21.0mm14(4)12-52-6(B)()2-512345678910BWRGYBrBLGrVO2-6123456BBWBYWWRWBWBLWYWGRRWRBRYRGRBLGGWGRGYGBGBLYYRYBYGYBLYWBrBrWBrRBrRBrBLBBLWBLRBLYBLBBLOGrGrRGrRGrBGrGGrB22-721.5mm21.5mm2-8152-71B2W3R4G5Y6Br7Bl8Gr9V10O2-8-VVV-VVVVVVVVVVV--VVVVVVVVVVVV-VVVVV-VV-VVV-VVVV-VVVV161PVC2233PVCPVC200PVC2.22.2.1172-2Fig2-2cylindricalconnector2-3Fig2-3circularconnector2-42-5Fig2-4furcateconnectorFig2-5sliceconnector2-62-7Fig2-6Auto.ContactFig2-7AutoHousing182-8Fig2-8sealedconnector2-8/494293GBT−2.2.22.2.312-9(2-10)19RcfRKCfRRR=+(23)−2-92-10Fig2-9contactzoomindrawingFig2-10contractilitydrawing23420/,/)SnPbPdNi123()14ECU243:3()32-9212-962H(65)H(2)Y(2)Y()Y(2)Y(2YH)(YH)(Normal)Force,,,123RRRR=++(24)−2-11Fig2-11contactresistance2211R,,22R,33R,1(LLCR)..:10mA20mA(0.254mm)0.254mm)232-12PFig2-12LLCR&NormalForcerelationship150150gf37mΩ250gf44nnRndnAnAρρππρ===(25)−ρ:A()Al-(mm2)L-ρ:242-1020(Ag)(Au)(Ba)(Al)(Cu)(Ni)16.223.51082716.861.6290122102350500430113,2640,1312221231.α0.7aR1.5aR2.β123.12Cpk252-11122/mΩ6666/mΩ4.1304.1524.5584.609/mΩ0.44640.46580.47030.4970Cpk1.421.301.010.94/mΩ5.525.545.785.85/mΩ2.762.743.323.34I0.7aRα∏1.5aRα1α2α4345340.7aRCpk262-1230.2N0.5N40.5N0.8N1β0.7aR1.5aR2Cpk2-130.7aRβ1.5aRβ353466460046440423404265Cpk11210467468124624866448946880335703933Cpk1471136546912442472764560.7aRCpk2-1450.2N0.35N60.35N0.5N121.5aR0.7aR34();15666436844560376803670Cpk14213862764326246282-13Fig2-13Insertforcemodel1()NFFtgµα=+(26)−()SNFFtgµα=−(27)−()()11,,,nnFFtgfFabnµα=++(28)−()()12,,,nnFFtgfFabnµα=−+(29)−1FFsNFµαabn;292(0.1)mKRF′=(210)−FRKm0.5m=0.7m=1m=2-142-14Fig2-14Contactresistance&insertforecerelationship13