Automatic Measurement System for Contact

Resistance of Terminals and Research on Their

Related Factors

64

(terminal)(electrical connector)

i
 ABSTRACT

TitleAutomatic Measurement System for Contact Resistance of Terminals and

Research on Their Related Factors Pages64
SchoolNational Taipei University of Technology
DepartmentGraduate Institute of Mechatronic Engineering
TimeJuly, 2009 DegreeMaster
ResearcherLi-Wei Lin AdvisorShuang-Yuan Chen

KeywordsTerminal, Contact Resistance, Temperature Rise, Automatic

MeasurementTaguchi Method

The terminals are a critical part of the connectors. Their contact resistances
are referred as the most important properties of the connectors. In the past, the
researchers measured the contact resistance in the laboratory manually. It is not
only time-consuming and hard to gain abundant data, but also influenced the
validity of data with various operators. According to this reason, this research built
an automatic measurement system for the contact resistance in the terminals.
Besides automation, the other feature of this system is that it can calculate the
theoretical maximum current capacity of a terminal pair and the parameters of
temperature rise from the temperature rising behavior of terminals and their wires.
Therefore, it is able to save lots of time by avoiding the trial-and-error method of
the USCAR standard and acquire the test data quickly.
Then the researcher selected some terminals of several kinds of general
materials and coatings, and treated them with various levels of external forces and
roughness. These varieties are taken as the factors of contact resistance. Then the
researcher designed experiments with Taguchi method to find out the set of
terminal pair with the smallest contact resistance. The experimental results
indicated that the terminal pair with smooth surface, no coating, and heavy normal
force tends to have a smaller contact resistance.

ii


SNDRC

iii


.....................................................................................................i
.....................................................................................................ii
.............................................................................................................iii
.............................................................................................................iv
.........................................................................................................vi
.........................................................................................................viii
.............................................................................................. 1
1.1 .............................................................................................. 1
1.2 ...................................................................................... 1
1.3 ............................................................................... 3
1.4 ........................................................................................... 4
................................................................... 5
2.1 ........................................................................... 5
2.1.1 USCAR ................................................................ 6
2.1.1.1 ................................................................... 6
2.1.1.2 ....................................................... 8
2.1.2 ...................................................................... 9
2.1.2.1 Nissan Voltage Drop and Temperature Rise Test ............. 9
2.1.2.2 Mitsubishi Voltage Drop and Temperature Rise Test .......12
2.1.2.3 GM Dry Circuit Resistance and Maximum Current Rating Test .14
2.2 ...........................................................................18
2.2.1 ............................................19
2.2.2 ..................................................................19
2.3 ........................................................................21
2.3.1 Ragnar Holm .................................................21
2.3.2 ...................................................24
2.3.3 ...................................................26
2.4 ................................................................28
...........................................................................29
3.1 ...............................................................29
3.1.1 ...................................................29
3.1.2 ....................................32
3.1.3 .......................................................34
3.2 ......................................................................................41
3.2.1 ...............................................................41
3.2.2 ..........................................................................44
3.3 ......................................................................................46
...........................................................................51
4.1 ...........................................................................51

iv
 4.1.1 ...................................................52
4.1.2 ......................................................................56
4.2 ......................................................................................58
..............................................................................................61
5.1 ..............................................................................................61
5.2 ...........................................................................61
.....................................................................................................62
.....................................................................................................64

2.1 .................................... .................. 7

2.2 Nissan Voltage Drop Test .............................10
2.3 Nissan Voltage Drop Test ...............................................10
2.4 Nissan Voltage Drop Test ...........................................11
2.5 Nissan ....................................................................11
2.6 Nissan Temperature Rise Test ........................................11
2.7 Nissan Temperature Rise Test ....................................12
2.8 Mitsubishi Voltage Drop Test ...................13
2.9 Mitsubishi Voltage Drop Test .. 13
2.10 Mitsubishi Voltage Drop Test .......................................13
2.11 Mitsubishi Voltage Drop Test ...................................13
2.12 Mitsubishi Temperature Rise Test ....................................14
2.13 GM Dry Circuit Resistance Test ...............................15
2.14 .........................................................................19
3.1 .............................................................................30
3.2 .........................................................................31
3.3 Mazda ........................................... .......37
3.4 L8(27)........................................... .......................................42
3.5 ......................................... .......................................44
3.6 L9(34)......................................... .........................................44
3.7 .............................................................................45
3.8 .............................................................................46
4.1 ........................................... ......................53
4.2 .........................................................................53
4.3 619223/323 .......................54
4.4 618504/604 . ......................55

vi
 4.5 619223/323 ........................................... ..........56
4.6 618504/604 .....................................................57
4.7 605031/605332 ..............59

vii


1.1 ................................................ ................................ 2

2.1 ......................................................................... 6
2.2 ............................................ ..................... 7
2.3 ............................................ .......... 8
2.4 .......................................................... 9
2.5 Nissan Voltage Drop Test ...........................................10
2.6 Mitsubishi Voltage Drop Test ....................................12
2.7 GM Dry Circuit Resistance Test ................................15
2.8 GM Maximum Current Rating Test ...........................16
2.9 GM Maximum Current Rating Test Base Curve .................................17
2.10 GM Maximum Current Rating Test Total Curve................................18
2.11 Fretting Corrosion ........................................................20
2.12 Fretting Corrosion ...................................................20
2.13 Fretting ............................................ ...............21
2.14 a-spot............................................ ..............................22
2.15 a-spot ..............................................................22
2.16 ..............................................................23
2.17 ............................................ .....................24
2.18 ............................................ .........................25
2.19 ..............................................................25
2.20 .............................................................................26
3.1 ......................... ....................... ...................................32
3.2 ......................... ....................... ............33
3.3 ......................... .....................34
3.4 ......................... ....................... ....................35
3.5 ......................................... ............................39

viii
 3.6 SN ...........................................................................43
3.7 .............................................................................43
3.8 .............................................................................45
3.9 RA ......................................... ......................46
3.10 .............................................................................47
3.11 .............................................................................47
3.12 ......................................... ........................48
3.13 ..........................................................49
3.14 618604 ......................................... ......................49
3.15 619223 ......................................... ......................50
3.16 ......................................... .......................................50
4.1 619323 ........................................................51
4.2 619223 ........................................................51
4.3 618504 ........................................................52
4.4 618604 . .......................................................52
4.5 619223/323 .......................54
4.6 618504/604 .......................55
4.7 619223/323 SN ........................56
4.8 618504/604 SN ........................57
4.9 605031/605332 25A .....59
4.10 ......................... ......60

ix


1.1

GPS

(connector)

(terminal)
(male terminal)(female terminal)
(contact
resistance)

1.2
(electrical connector)

1
 z
z
z
Mroczkowski contact
interface
contact finish
contact spring
(connector
housing) [16] 1.1

1.1 [16]

100g [3]

(constriction)

2
 (constriction
resistance)(surface film resistance)

(degradation)
(surface corrosion)(pore corrosion)(electromigration)

(electrical contact)
IEEE

know-how

1.3

3
1.4

Ragnor Holm

Ragnar Holm

(Bell Laboratory)

(Society of Automotive Engineer/

United States Council for Automobile Research, SAE/USCAR)[6]

2.1

5
2.1.1 USCAR
SAE/USCAR 2004 5
[6](SAE/USCAR-2, Revision 4, Performance Specification for Automotive Electrical
Connector Systems)

2.1.1.1
(crimp)

723mm
40mm
40mm

2.1

2.1 [6]

6

2.2

2.2 [6]

30
5A/ 2

USCAR (blade portion width)

2.1

2.1 [6]

(m)
0.64mm 20.0
1.5mm 10.0
2.8mm 5.0
6.35mm 1.5

20 m

7
2.1.1.2

USCAR (draft free)

10

50mm 2.3

2.3 [6]

50%
55 10% 80%
5% 55(
) 90%
2.4
USCAR 2.1.1.2
2.1

8
 2.4

2.1.2
GM Nissan Mitsubishi /

2.1.2.1 Nissan Voltage Drop and Temperature Rise Test

(1) Voltage Drop Test

(i) 205 65%20%

(ii) 200mm

2.5

9
 2.5 Nissan Voltage Drop Test [21]

(iii) 2.2

2.2 Nissan Voltage Drop Test [21]

(iv) 2.3 Y-Y ( 400mm )

2.3 Nissan Voltage Drop Test [21]

10
 (v) Y-Y

2.4

2.4 Nissan Voltage Drop Test [21]

2.5 Nissan [21]

(2) Temperature Rise Test

(i) 2.6

(ii) 2.6

2.6 Nissan Temperature Rise Test [21]

11
 (iii) 2.7

50

2.7 Nissan Temperature Rise Test [21]

2.1.2.2 Mitsubishi Voltage Drop and Temperature Rise Test

(1) Voltage Drop Test

(i) 100mm

2.6

2.6 Mitsubishi Voltage Drop Test [22]

(ii) 2.8 2.9

12
 2.8 Mitsubishi Voltage Drop Test [22]

2.9 Mitsubishi Voltage Drop Test [22]

(iii) 2.10 Y-Y( 200mm )

2.10 Mitsubishi Voltage Drop Test [22]

(iv) Y-Y

2.11

2.11 Mitsubishi Voltage Drop Test [22]

Initial Condition Very Small Current

13
(2) Temperature Rise Test

(i)

(ii) 2.9

(iii) 2.12

2.12 Mitsubishi Temperature Rise Test [22]

2.1.2.3 GM Dry Circuit Resistance and Maximum Current Rating Test

(1) Dry Circuit Resistance Test

(i)

20mV 100mA

(ii)

(iii) 300mm 2.7

ABC A

14
 2.7 GM Dry Circuit Resistance Test [23]

(iv) 1503mm

(v) AB BC RDE=RAB

RBC(initial)

(vi) 10 11

(vii) AB BC RDE=RAB

RBC(post-test)

(viii)

RDE 2.13

2.13 GM Dry Circuit Resistance Test [23]

15


(2) Maximum Current Rating Test

(i)

2.8

2.8 GM Maximum Current Rating Test [23]

(ii)

(iii) 10

16
 11

(iv) 2.7 AB

(v) 0A 14Vdc

15 (<1/min)

Isp 50%Isp

5%Isp

Isp 50%~80% 10%Isp

80%Isp 5%Isp

15

(vi) Base Curve 2.9

IL TA TL

2.9 GM Maximum Current Rating Test Base Curve.[23]

17
 (vii) Base Curve 80% Derating Curve 2.10

2.10 GM Maximum Current Rating Test Total Curve.[23]

1 2

3 4 base curve derating curve

2.2

(erosion)

(corrosion)
(Fretting Corrosion)

18
2.2.1

2.14

2.14

J. Swingler J. W. McBride
(corrosion)

[1]

[1](corrosion
migration)(pore corrosion)

2.2.2
(Fretting Corrosion)
2.11

19


[18] 2.12

2.11 Fretting Corrosion [18]

2.12 Fretting Corrosion [17]

Tetsuya Ito Shigeru Sawada 2008

[19] 2.13

20


2.13 Fretting [19]

2.3

2.3.1 Ragnar Holm

20 Ragnar Holm
Holm

(contact interface)
1.1 a-spot a-spot

21
 2.14
a-spot 1/100
2.15
(constriction resistance, Rc)[16]

2.14 a-spot[16]

2.15 a-spot [16]

22
 Holm Rc =/2a
a Rc =/a
Rc (2.1)

Rc = Ra + RD = + (2.1)
na D
n D
Ra =0(2.1)(2.2)

H
Rc = k = k (2.2)
D Fn

k Fn
(2.2)

2.16

2.16 [16]

23
2.3.2
2.17 AB

A.
RTA=2Rnw+2Rw+2Rp+Rbm+Rc+Rbf (2.3)
B.
RTB=2Rn+Rbm+Rc+Rbf (2.4)
RTARTB

2.17

1 Rb
b (bulk) Rbm Rbf m (male)
f (female)
lm
Rbm= m ; Am , m
Am

lf
Rbf= f ; A f , f
Af

Am , A f m , f

2.18

24
 2.18

2 Rn
RnRnw 2.19

2.19

3 Rc Rp
RTARTB Rb Rn (2.4)
Rc(2.3) Rp

25
2.3.3

(
[1])()

AuPd

( Sn
)Ag
2.20

Pa

2.20

26
 Pd 0.1 m Au
WE1 Cu 69 % + Ag 25 % + Pt 6 %
Pd 80 % + Ni 20 %
Pd 60 % + Ag 40 %
Pd 80 % + Co 20 %
Ni Co Pd Ag
Sn 93 % + Pb 7 % Sn 60 %
+ Pb 40 %

()

(electromigration) 2-4 um





(i)
(ii) Au > Pd > Pd (80 % + Ni 20 %)
(iii)
(iv) (125)

(v)
100

[3~5]

27

4 ~ 5 Cu C1500, C19400, C19500, C17410

2.4

[15] v i
dt

vidt = cdT + (k (T T ) + k
1 0 2 (T 4 T04 ))dt (2.5)

c T k1
k2 T0 i
c
k1k2 (2.5)

vi = i 2 R = c
dT
dt
(
+ k 1 (T - T0 ) + k 2 T 4 - T04 ) (2.6)

R
(2.7)

R = aT 2 + bT + R0 (2.7)

abR0 0
Th Ih

Ih =
( )
k 1 (Th - T0 ) + k 2 Th4 - T04 (2.8)
aTh2 + bTh + R0

k1 abR0
abR0
(2.8)

28


3.1
PC-Base

3.1.1

(Resolution)
m
10-4V
USCAR 5A/mm2
3.0mm 35.32A
10-5V 10-6V

Seebeck

3.1

29
 3.1

30
 LabVIEW
LabVIEW NI
LabVIEW NI

I/O
USCAR

USCAR ( 2.1.2
)
3.2 3.1

3.2

31
 3.1

3.1.2
PC-Base

32
(1)

<1>
NI2503
NI2605
NI4065 3.1
NI2605 NI2503

NI4065 3.2

3.2

33
 <2>
TBX-68T
NI4351 NI4351 T
NI4065
3.3

3.3

<1>

3.1.3
LabView8.5 NI

34
 (1)
USCAR
Mazda 3.4

3.4

Step 1.

35


Step 2.

0.2A

Ch0

Step 3.
USCAR Mazda

USCAR
USCAR-2 Rev.4 5.3.2 Voltage Drop
2.1.2

Mazda
HL3060
Mazda
1A5A
3.3

36
 3.3 Mazda
(mm) (A)
0.3 8
0.5 11
0.85 14.5
1.25 18
2 25
3 33
5 45
8 57

Step 4.

USCAR
i. ()
ii.
iii. ()
Mazda
i.
ii. ()

Step 5.

Step 6.

Step 2

37
 Power Supply

Power Supply

(2)
USCAR Mazda

<1>
(2.5)~(2.8)
Matlab

USCAR

<2>

<3>
USCAR
USCAR
3.5

38
 3.5

39

Step 1.
Step1.

Step 2.
Step2.

Step 3.
USCAR

USCAR 2.1.3

Step 4.

Step 5.

Step 2

Power Supply

40
3.2

3.2.1
1950

(loss function)(3.1)

L(y) = k(y - m) 2 (3.1)

L(y)k y m

SN (Signal to Noise Ratio)

SN
SN (3.2)

1 n
SN SB = 10 log y 2i (3.2)
n i =1
y
m
(Large the Best, m)(Small the Best, m0)(Nominal
the Best, mk)SN SN
(3.2) SN (3.3)(3.4)

41
 1 n 1
SN LB = 10 log 2 (3.3)
n i =1 y
i

y2
SN NB = 10 log 2 (3.4)
S

y m
y (factor)

(level)

Ln(ab) n
a b L8(27)
3.4

3.4 L8(27)

42

SN SN
3.6 SN
SN
m 3.6 A2B3C1D3
A 2 B 3 C 1 D
3

3.6 SN

3.7

3.7

43
3.2.2
y
(3.2)
SN 2.3.1 Holm (2.2)

3.5

3.5

1 2 3
A. MF202 C50715 K75
B.
C.
D.

3.5 L9(34)
3.6

3.6 L9(34)

A. - MF202C50715K75
3.7

44
 3.7

MF202 C50715 K75

Cu Cu Cu
Sn 1.7~2.3 Sn 1.7~2.3 Cr 0.3
Ni 0.1~0.4 P 0.0025~0.04 Si 0.1
(W%) Zn 0.2 Fe 0.05~0.15 Ti 0.02
P 0.15
Fe 0.1
Pb 0.02
(Hv) 150~185(H) 170~200(H) 140~170(R 460)

(GPa) 125 120 138

(%IACS) 32 35 77.6

(MPa) 490~590 540~620 460~540

(W/mk) 155 150.7 310

B. -
3.8 ()

3.8

C. -

45
 RA 3.9 RA

3.9 RA

3.8 Original
0.3m0.6m0.85m

3.8

I II III
RA0.1m Original RA =1.2~1.8m

D. -

200g
400g

3.3
USCAR
2.3.2
2.3.2 USCAR 3.10
3.11

46
 3.10

3.11

3.12

47
 3.12

48
 3.13

3.14 3.15

3.13

3.14 618604

49
 3.15 619223

3.16
1A
1300g

3.16

50


4.1
619223/619323
618504/618604( 605031/605332()

4.1 619323

4.2 619223

51
 4.3 618504

4.4 618604

4.1.1
Holm
Holm

619223 0.446mm
618604 0.35mm 619323 618504 0.6mm
0.154mm 0.25mm
4.1

52
 4.1

(g)

C50715 345.4

619223 K75 358.2

MF202 389.45

C50715 879.1

618604 K75 940.85

MF202 884.5

4.2

4.2

1 MF202
2 MF202
3 MF202
4 C50715
5 C50715
6 C50715
7 K75
8 K75
9 K75

4.3 4.4 619223/323 618504/604

4.5 4.6
4.3 4.4 Au-Sn-
No-S-N-R-

AuS
SnN

53
 4.3 619223/323

AuR SnN NoS AuN SnS NoR AuS SnR NoN

(g) MF202 MF202 MF202 C50715 C50715 C50715 K75 K75 K75

0 2.111 2.276 2.131 2.185 1.806 2.47925 1.817 1.89 1.767

100 2.022 2.251 2.047 2.122 1.789 2.41525 1.804 1.886 1.76
200 1.994 2.238 2.068 1.993 1.783 2.401 1.794 1.884 1.75
300 1.981 2.226 2.062 1.930 1.786 2.355 1.787 1.87 1.75
400 1.986 2.223 2.043 1.918 1.785 2.3495 1.788 1.867 1.748
500 2.014 2.223 2.04 1.897 1.787 2.32725 1.79 1.856 1.749
600 2.023 2.22 2.034 1.853 1.778 2.3315 1.787 1.854 1.746
700 2.013 2.225 2.05 1.845 1.773 2.333 1.781 1.852 1.74
800 2.008 2.219 2.057 1.813 1.772 2.363 1.779 1.855 1.737
900 2.027 2.22 2.047 1.793 1.773 2.34125 1.776 1.852 1.734
1000 2.005 2.2195 2.042 1.793 1.772 2.3615 1.774 1.85 1.733
1100 1.993 2.22 2.055 1.786 1.767 2.36125 1.777 1.853 1.732
1200 2.002 2.218 2.054 1.777 1.765 2.362 1.779 1.855 1.733
1300 2.025 2.221 2.073 1.753 1.763 2.33875 1.774 1.856 1.728

619223-323 -

2.6
2.5
AuR+MF202
2.4
SnN+MF202
2.3
NoS+MF202
(m)

2.2 AuN+C50715
2.1 SnS+ C50715
2 NoR+ C50715
AuS+K75
1.9
SnR+ K75
1.8
NoN+ K75
1.7
1.6
0 200 400 600 800 1000 1200 1400
(g)

4.5 619223/323

54
 4.4 618504/604

AuR SnN NoS AuN SnS NoR AuS SnR NoN

(g) MF202 MF202 MF202 C50715 C50715 C50715 K75 K75 K75

0 2.326 2.355 2.297 2.894 3.232 2.848 2.433 2.460 2.487

100 2.282 2.332 2.192 2.756 3.093 2.697 2.263 2.298 2.333
200 2.269 2.325 2.213 2.626 2.880 2.637 2.222 2.241 2.260
300 2.259 2.318 2.200 2.578 2.827 2.589 2.138 2.200 2.262
400 2.230 2.321 2.129 2.548 2.820 2.535 2.039 2.103 2.167
500 2.215 2.289 2.141 2.513 2.788 2.493 1.985 2.089 2.193
600 2.167 2.251 2.083 2.473 2.715 2.482 1.967 2.076 2.185
700 2.151 2.226 2.076 2.445 2.666 2.471 1.965 2.070 2.175
800 2.129 2.166 2.092 2.422 2.636 2.452 1.962 2.072 2.182
900 2.118 2.183 2.053 2.413 2.623 2.448 1.906 2.018 2.130
1000 2.078 2.135 2.021 2.416 2.642 2.435 1.880 1.996 2.112
1100 2.066 2.157 1.975 2.404 2.629 2.422 1.859 1.972 2.085
1200 2.059 2.171 1.947 2.360 2.563 2.396 1.835 1.957 2.079
1300 2.048 2.168 1.928 2.365 2.589 2.381 1.848 1.980 2.112

618504-604 -

3.5

3.3
AuR+MF202
3.1
SnN+MF202
2.9 NoS+MF202
(m)

2.7 AuN+C50715
SnS+ C50715
2.5
NoR+ C50715
2.3 AuS+K75
SnR+ K75
2.1
NoN+ K75
1.9

1.7
0 200 400 600 800 1000 1200 1400
(g)

4.6 618504/604

55
4.1.2
(1) 619223/323
4.3 (3.2) SN
619223/323 4.7

4.7 619223/323 SN

4.7 K75---
SN
4.5

4.5 619223/323

K75>>C50715>MF202
>>>
>>
>>>

56
(2) 618504/604
4.4 (3.2) SN
618504/604 4.8

4.8 618504/604 SN

4.8 618504/604 K75-

--
4.6

4.6 618504/604

K75> MF202>>C50715
>>
>>
>>>

(3)
(i) 619223/323
618504/604 K75-

57
 --
(ii) MF202 C50715 K75 MF202
K75
3.7
(iii)

[1][2]
(iv)

(v)

(vi)
K75---

K75---
MF202---
MF202---
C50715---

4.2
605031BSS()/605332BSS()
2.1.1.2 USCAR

25A 10 1
5 4.9

58
 4.9 605031/605332 25A [15]

MATLAB 2.4 (2.5)(2.6)

(2.8) 55 K
4.7

4.7 605031/605332 [15]

1 2 3 4 5
55(A) 24.81 25.05 24.22 24.47 25.46
55(A) 27.5 27.5 25 26.25 26.25
USCAR (A) 24.75 24.75 22.5 23.625 23.625

USCAR
( 25A) 4.7
4.7 4.10
5%
55K

50 80
3 8~11 27~37

59
 USCAR

USCAR
28

27.5

27

26.5

26

25.5

25

24.5

24
1 2 3 4 5

4.10 [15]

60

5.1
NI
PXI LabVIEW PC-base

K75
K75---

K75---

5.2

5 ~10

61


[1] J. W. McBride, Electrical contact and connectors in automotive systems, IEE

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