In the field of precision systems engineering at the Ostwestfalen-Lippe University of Applied Sciences, reliability analysis methods for differential assemblies consisting of electrical connectors with integrated wires are developed and applied. The focus is on the fundamentals and technologies of electrical connection technology, particularly on manufacturing, electroplating (Ag, Au, Ni, Sn), testing, analysis, and modeling of electrical contacts. Electrical connectors perform the central function of establishing and disconnecting electrical and mechanical connections between assemblies and are therefore safety- and function-critical key components in technical systems. The contact point is crucial for overall reliability, as thermal, mechanical, chemical, and electrical degradation processes interact directly there.
At the heart of the technology is the quantitative assessment of reliability under realistic thermal and mechanical loads. Long-term damage mechanisms such as micro-movement, wear, oxidation, diffusion, and mechanical stress relaxation are specifically addressed, as they are activated in the field by temperature fluctuations, vibrations, conductor movement, humidity, and corrosive gases. Instead of purely formal qualification approaches, accelerated lifetime tests are used that simulate relevant load collectives without inducing damage unrelated to normal operation.
The methodological approach includes conducting accelerated lifetime tests, determining suitable acceleration factors for thermal and mechanical loads, and statistically modeling the failure behavior using a Weibull distribution. Based on this, the characteristic lifetime (CLT) under laboratory conditions and the predicted lifetime in the field are derived. Reliability is quantitatively described by the FIT rate (failure in time).
The technology enables reliable prediction of reliability under thermal and mechanical loads within a reasonable timeframe. This provides a sound basis for evaluating, comparing, and optimizing modern connector designs and cable systems, particularly considering mechanical factors such as vibration and temperature fluctuations.
The lecture was given as part of the Trend outlook for January 27, 2026 Presented by Prof. Dr.-Ing. Michael Blauth, Ostwestfalen-Lippe University of Applied Sciences.
Further information about the Ostwestfalen-Lippe University of Applied Sciences can be found at: www.th-owl.de
