Analysis on the insulation failure of the electrical connector under low pressure environment

The electrical connector is an electrical contact element for electrical signal transmission and control, which is widely used in the aeronautics and aerospace industry. The environmental adaptability and reliability of the electrical connector directly affect the performance of the weapon system under a variety of harsh conditions. At present, the environmental stress simulation of electrical connectors focuses on temperature stress and vibration stress, but the actual environmental factors affecting electrical connectors are not only temperature and vibration, but also the effect of low pressure in the hanging flight environment. The main failure modes of electrical connectors are contact failure and insulation failure. However, the failure mechanism research mainly focuses on the failure mode of contact failure. Therefore, this paper studies the insulation failure mechanism of electrical connectors, mainly considering insulation failure under low pressure environment. On the basis of analyzing the physical process of air discharge, the physical equation of failure of the electrical connector under low pressure is established. Finally, a certain type of electrical connector is taken as an example to perform low pressure discharge simulation analysis. This research provides a basis for studying the insulation performance of the electrical connector in the low pressure environment and improving the reliability of related products.