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

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

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

Technology Partners Customers Technology, Simulation, Components, Tooling, Technology, Simulation Components, Tooling

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

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

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

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

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

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

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

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

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

Conduct critical simulation … Simulation Workflow

Case: Magnetic Tablet Connector Magnetic Force Magnetic Field Intensity

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

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

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 9757386D Irish Co. Reg.: 487977 Phone: +353 (0)85 770 8117 Skype: product-iq Email: matt@product-iq.com Web: www.product-iq.com