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Experimental Investigation of the Failure Mechanism for Power Connectors under Hot-Swapping Conditions

  • School of Electrical Engineering and Automation, Harbin Institute of Technology

Research output: Chapter in Book/Report/Conference proceedingConference contributionpeer-review

Abstract

The hot-swapping capability of connectors is demanded for the new designed power distribution unit, but the accumulated mechanical wear and arc erosion extremely limit its reliability and electrical lifespan. In this work, a test apparatus is specially designed to simulate hot-swapping operations and collect the transient variations in contact voltage drop, arcing duration and normal load force. The variation trends of stable contact voltage drop and contact a-spot temperature are systematically analyzed under 50V/25A load conditions. Furthermore, effects of insertion speed and normal load force on the electrical lifespan are investigated experimentally. Finally, it is determined that the wear-induced surface deterioration exacerbates arcing behavior, meanwhile the high temperatures generated by arcing further accelerate material loss and oxidation. The direct consequence is the formation of irreversible insulating oxide layers and structural damage, ultimately leading to open-circuit failure.

Original languageEnglish
Title of host publicationElectrical Contacts 2025 - Proceedings of the 70th IEEE Holm Conference on Electrical Contacts, HOLM 2025
PublisherInstitute of Electrical and Electronics Engineers Inc.
ISBN (Electronic)9798331559960
DOIs
StatePublished - 2025
Externally publishedYes
Event70th IEEE Holm Conference on Electrical Contacts, HOLM 2025 - San Antonio, United States
Duration: 15 Oct 202522 Oct 2025

Publication series

NameElectrical Contacts, Proceedings of the Annual Holm Conference on Electrical Contacts
ISSN (Print)0361-4395

Conference

Conference70th IEEE Holm Conference on Electrical Contacts, HOLM 2025
Country/TerritoryUnited States
CitySan Antonio
Period15/10/2522/10/25

Keywords

  • arc erosion
  • failure mechanism
  • hot-swapping
  • mechanical wear
  • power connector

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