Method of electrical connector intermittent fault reproduction

PurposeThis paper aims to reproduce the electrical connector intermittent fault behaviours with step-up vibration stress while maintaining the integrity of the product. Design/methodology/approachA dynamic model of an electrical connector under vibration is established for contact resistance analysis. Next, the dynamic characteristics of contact resistance are analysed, and cumulative damage theory is used to calculate the damage under different stresses during the intermittent fault reproduction test. To reduce damage and improve efficiency, the step-up stress is used for the reproduction test. FindingsThe proposed method can reproduce the intermittent fault behaviour, and the step-up stress test is more efficient than the constant stress test. Research limitations/implicationsStep-up stress is used for intermittent fault reproduction, and the quantitative relationships between intermittent fault and product damage can be further studied. Practical implicationsIt is expected that the proposed methodology can help engineers to reproduce the intermittent fault behaviours to facilitate the detection and diagnosis of intermittent fault and to improve equipment safety. Originality/valueThe mechanism of electrical connector reproduction is analysed and the step-up stress test is used for intermittent fault reproduction.