1. Simulation of Electrical Connectors using ANSYS AIM
Matt Wilhite
4th CADFEM ANSYS Simulation Conference Ireland & UK
12th and 13th October, Engineers Ireland, Dublin

2. Company Overview
PRODUCT-iQ was launched in 2010 in response to industry’s need for independent connector expertise:
Develop requirements specifications
Leverage industry contacts and technologies
Product design
Sourcing of production solutions and partners
Organisational development

3. Services Supporting Customers Through the full Product Lifecycle
Product Design
Prototypes
Testing
Mfg. Solutions
Supporting Customers Through
the full Product Lifecycle

4. Technology Partners Customers Technology, Simulation,
Components, Tooling,
Technology, Simulation
Components, Tooling

5. Connectors 101
“An electro-mechanical system that provides a separable interface between subsystems, that does not induce an unacceptable effect on the overall system performance.”
- Electronic Connector Handbook
complexity
Stacked Power Over
Ethernet (POE) Jack
Spade Terminal

6. Microstructure of separable interface
Connectors 101
Microstructure of separable interface
KEY: low & stable
contact resistance

7. Design for Progression Stamping
Design for Processing
Design for Automation
Design for Progression Stamping
Typical Design
Elements
Customer Application
Spring Design
Housing / Mould Design

8. Typical Drivers Signal speeds increasing – data hungry consumers
Power efficiency – battery life, reliability, safety
Size reduction – thin devices
Ruggedness – waterproof, shockproof
Low cost tooling and part price – to compete with Asia

9. High- Performance Materials
Resulting Needs
Mechanical, electrical
Efficient selection tools
High- Performance Materials
On products
On tooling
Micron Tolerances
Realistic mat’ls / finish
Tighter tolerances
Rapid Prototypes
Multiphysics
Optimization
Fast Turnaround Times
Simulation

10. Why CADFEM / AIM? Long term experience in simulation Location
Successful consulting support in past
Multiphysics
Short learning curve

11. We All Know the Benefits of Simulation …
Cost of changes
# Changes
Cost of changes
Cost of changes
Development Cycle

12. The Benefits to Product-iQ
Increased number of projects and repeats
Ability to tackle new market-specific problems
Some suppliers have become customers!
Higher profit vs subcontracting simulation
Deeper understanding of underlying physics
Customer loyalty due to the investment
Become better integrated with customers
The Benefits to Product-iQ

13. 2017 vs 2016
+30%
+35%
+23%

14. Conduct critical simulation …
Simulation Workflow

15. Case: Magnetic Tablet Connector
Magnetic Force
Magnetic Field Intensity

16. Case: Solar J-Box Joule Heating
Contact Resistance
current
current
I DC
RESULTS
Trise
Calculated Minimum
16.16°C
Calculated Maximum
29.33°C
Calculated Average
23.46°C

17. Thank You
I would like to thank the CADFEM team for the huge support provided in terms of:
Listening to our needs and help selecting the right software tools
Training and follow-up
Consulting and problem solving
Support on AIM, Amazon cloud set-up, hardware advice

18. Contact Details Matt Wilhite Product IQ Consulting Limited
Managing Director
Product IQ Consulting Limited
Address:
9 The View, Robswall Malahide, Co. Dublin, K36 E088 Ireland
VAT No.: IE D
Irish Co. Reg.:
Phone: +353 (0)
Skype: product-iq
Web: