A framework is proposed for improving electrical connector design according to ultimate vibration load based on finite element model and physics of failure model. The relationship model among environmental load, design parameters and local response is established through orthogonal experimental design, hierarchical modeling and regression analysis. Combined with the physical model of contact failure of electrical connectors, the quantization model among environmental load, design parameters and life could be established, which can help determine the ultimate vibration load based on the given life requirement. Based on this, the application technique of ultimate vibration load is given, and a case of single scheme optimization is illustrated to verify the technique above.
