Influence of Assembly Speed on Electrical Connector Mating Force

The force required to assemble automotive electrical connectors has been tested using a range of mating speeds in a controlled lab environment. This set of tests answers questions often brought up regarding how mating speed significantly influences the required applied force. Data from these evaluations show small but consistent mate force changes with assembly speed. Sealed and unsealed connectors were found to respond differently to mating speed, which is explained using a theoretical analysis. The mechanical analysis explains what forces are involved and how they are influenced by speed. Practical recommendations are given on how mate force testing should be done to assure results are as useful as possible. Results show that that mating speed has a positive correlation to peak mate force. An opposite, negative, correlation for unsealed connectors was found. Follow-on discussion explains why slow and accurate testing is preferred to testing at the actual speeds seen in the plant. Higher-speed testing is shown to lessen the accuracy of test results based on comparisons of the standard deviations of the slow and fast measurements.