Comprehensive analysis of electro-mechanical characteristics and new regression models of a novel slanted groove electrical connector

Electrical connectors are crucial electro-mechanical components, with insertion, withdrawal, and electrical contact characteristics serving as key indicators of their reliability. Studying the electro-mechanical characteristics and regression models of electrical connectors is vital to enhance their reliability. This work focuses on the M2-type electrical connector, investigating its electro-mechanical characteristics and developing a regression model. A withdrawal force calculation model is established using cantilever beam theory. Simulation and analysis provide data on insertion force, contact pressure, and contact resistance. Experiments on insertion, withdrawal, and electrical contact are conducted using an insertion force tester and a DC low-resistance instrument, comparing experimental results with simulations. The study reveals the fitting relationship between contact pressure and contact resistance for the M2-type connector. Key findings include a stable fluctuation in contact pressure with a relative error of 1.72% between simulated and tested values, an average discrepancy of 3.81% for insertion force, and 2.38% for withdrawal force, with insertion force slightly higher than withdrawal force. Contact resistance shows a U-shaped trend with pin displacement, with an average experimental error 3.70% and 1.16% lower than theoretical values (4.86%). The new regression model (quadratic polynomial fitting) demonstrates mean absolute percentage errors of 0.1458% for simulation values and 0.2219% for experimental values, significantly lower than those obtained using theoretical formulas (0.7046% and 0.3451%). These results provide theoretical guidance for studying electro-mechanical characteristics and designing experiments for electrical connectors, offering valuable insights for designing and ensuring the reliability of new types of electrical connectors.