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<p>The hot-swapping capability of power connectors is urgently needed for special industrial applications. The accumulated mechanical wear and arc erosion during repeated insertions and withdrawals under current load extremely limit the electrical contact performance of connectors. A series of electrical endurance experiments are carried out with the use of copper alloy contact pairs under 50&#xa0;V/25A load conditions. The typical waveforms of contact voltage drop, contact current and normal force are obtained. The electrical contact performance degradation process is analyzed explicitly by using the extracted sensitive parameters, including stable contact voltage drop, unstable contact duration, arcing time, normal force and erosion surface morphology. It is found that the synergistic effects of arc erosion and sliding wear lead to the fluctuating increase in contact voltage drop and temperature of contact spots, subsequently high temperatures promote oxidation and melting at the contact interface. The formed copper oxide covering the wear track is the root reason for the open-circuit failure of connectors.</p>

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Research on the Electrical Contact Performance Degradation Process of Power Connectors under Hot-Swapping Conditions

  • 期刊论文

  • 发表日期：

    2025年9月1日

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  • Chang Sun,
  • Yubin He,
  • Chao Zhang,
  • Wanbin Ren

摘要

The hot-swapping capability of power connectors is urgently needed for special industrial applications. The accumulated mechanical wear and arc erosion during repeated insertions and withdrawals under current load extremely limit the electrical contact performance of connectors. A series of electrical endurance experiments are carried out with the use of copper alloy contact pairs under 50 V/25A load conditions. The typical waveforms of contact voltage drop, contact current and normal force are obtained. The electrical contact performance degradation process is analyzed explicitly by using the extracted sensitive parameters, including stable contact voltage drop, unstable contact duration, arcing time, normal force and erosion surface morphology. It is found that the synergistic effects of arc erosion and sliding wear lead to the fluctuating increase in contact voltage drop and temperature of contact spots, subsequently high temperatures promote oxidation and melting at the contact interface. The formed copper oxide covering the wear track is the root reason for the open-circuit failure of connectors.