Minimization by FEM of the transient electrical contact resistance and contact temperature of power automotive connector

摘要

The purpose of this paper is to analyse and optimize by the finite element code the temperature, the electrical contact resistance and the mechanical stress of power automotive connector submitted to high electric current and high contact forces. High current leads to increase contact temperature due to the generation of the Joule heat and can produce metallurgical changes such as softening or even melting of the conducting areas. This requires the minimization of electrical contact resistance and contact temperature. A finite element model with indirect coupling method of mechanical and thermo-electrical fields and with taken into account the plasticity of the material was developed using a commercial code in order to compute the transient numerical values of contact resistance and contact temperature of contact sample with one contact point. The contact sample was made with recent high-copper alloy C19210 which presents good mechanical, thermal and electrical properties. Another finite element model with multipoint contacts was developed in order to minimize electrical contact resistance and contact temperature. Results showed that contact temperature and electrical contact resistance vary exponentially and increase over time until the equilibrium state. Results showed also the obtaining of triple gains for the model with multipoint contacts: minimization of contact resistance, contact temperature and maximum Von Mises stress which is more interesting for the connector designers.