Research on the degradation of contact resistance of wire-spring contacts in different wear condition

Electrical connectors are important components in electrical systems, responsible for the transmission and control of electrical signals. In the process of use, frictional wear occurs between the pins and sockets of the contactor in an electrical connector. This phenomenon results in an increase in contact resistance, which can further lead to system failures, so it is critical to ensure the stability of the performance of the contactor. In this paper, a commonly used specification of wire-spring contacts is investigated. Firstly, the mechanical properties of the component were analyzed. Subsequently, the contact component underwent vibration testing under various conditions at room temperature to identify the wear patterns associated with different vibration scenarios. Finally, using the experimental data, a physical model of frictional wear failure was developed for the contact component, enabling the determination of contact failure time as a function of vibration amplitude and frequency.