【摘要】 针对J186H压接型电连接器在地面对接试验中出现的单个插孔无法正常插入问题，采用技术归零方法开展研究。通过故障树分析与排查，排除了插孔设计、批次质量及压接、插孔送入等工艺环节的影响，确定故障根源为保持力测试中平头插针的倾斜插入。平头插针与插孔内鹰爪结构发生刚性接触，导致应力集中，进而引发鹰爪塑性变形。机理分析表明，当插针斜插角度超过7°时，平头插针无法通过基座导向，而球头插针则可实现应力分散。通过对接试验复现故障后，制定了优化方案，即：将测试插针统一更换为球头插针，并规范垂直插入操作。试验验证结果显示，优化后插合无损伤，且分离力满足要求。更多还原

【Abstract】 To address the issue where a single jack of the J186H crimp-type electrical connector failed to insert normally during a ground docking test for aerospace applications,a study was conducted using the technical zeroing method. Fault tree analysis and investigation ruled out the influences of jack design, batch quality, and process steps such as crimping and jack insertion. The root cause was identified as the inclined insertion of a flat-head pin during the retention force test. The rigid contact between the flat-head pin and the claw structure inside the jack caused stress concentration,which led to plastic deformation of the claw. Mechanism analysis showed that when the inclined insertion angle exceeded 7°,the flat-head pin could not be guided by the base,whereas a ball-head pin could disperse the stress effectively. After reproducing the fault through the docking test,an optimization plan was formulated,namely:the test pins were replaced with ball-end pins,and the vertical insertion operation was standardized. Test verification demonstrated that the optimized insertion caused no damage,and the separation force met the required specifications.更多还原