Parametric Mating Force Model for Partially-filled Connectors

A predictive model for the mating forces of hand-plug connectors has been developed; it calculates the forces in a connector that has empty cavities instead of terminals in every position. Force data is needed as a check to see if connectors meet the latest ergonomic requirements in their as-built configurations. Historically, force data has been generated from physical testing since prior predictive models were not accurate enough. Testing is expensive and slow so a more advanced and accurate model was created. The model presented in this paper is accurate enough to replace mechanical force testing of partially-filled hand-plug connectors.