Design Optimization of Electrical Connector Assembly using FEA

Due to the increasing number of devices and systems connected to an electric system, the need for reliable and high-quality electrical connectors has become more prevalent. This project aims to optimize the design of an electrical connector during its two most critical stages: insertion and retention of housing using FEA. A structural analysis is performed during the insertion and retention stages of housing. This process involves calculating the dimensional deformations and maximum strains developed during the steps mentioned above to determine the reliable functioning of electrical contacts. The input geometry is fed to the finite element analysis. The forces applied on the connector’s latch on their respective connection are ensured to be under the limit. The analysis and simulation results are reflected to validate the safe forces in the connector assembly and a proper justification for an experimental set up in the laboratory.