The performance of electrical connectors can be significantly impacted by periodic variations in contact resistance caused by vibrational stress. Intermittent faults resulting from such stress are characterized by their random and fleeting nature, making it difficult to study and replicate them. This paper proposes a novel method for reproducing intermittent faults in electrical connectors. To implement this method, intermittent fault data are first collected from electrical connectors subjected to different vibration loads. Next, a statistical distribution model is constructed using kernel density estimation (KDE). Based on this model, a fault injector is designed to simulate intermittent faults under varying vibration loads. The simulated faults are then compared to real-world intermittent fault signals in a controlled environment to validate the accuracy of the method. The results demonstrate that the proposed method effectively reproduces intermittent faults in electrical connectors under varying vibration conditions. This approach can be used to better understand the behavior of connectors under vibrational stress and to develop more effective testing and fault diagnosis methods.

振动应力引起的接触电阻的周期性变化会对电连接器的性能产生显着影响。这种应力导致的间歇性故障具有随机性和短暂性的特点，因此难以研究和复制。本文提出了一种重现电连接器间歇性故障的新方法。为了实施该方法，首先从承受不同振动负载的电连接器收集间歇性故障数据。接下来，使用核密度估计（KDE）构建统计分布模型。基于该模型，设计了故障注入器来模拟变化振动载荷下的间歇性故障。然后将模拟故障与受控环境中的真实间歇性故障信号进行比较，以验证该方法的准确性。结果表明，所提出的方法可以有效地重现不同振动条件下电连接器的间歇性故障。这种方法可用于更好地了解连接器在振动应力下的行为，并开发更有效的测试和故障诊断方法。