Abstract
In high complexity electrical systems such as those used in the automotive industries, electric connectors play an important role. The automotive industry is gradually shifting its attention to electric cars, which means more electrical connectors for sensors and data collection. A fault in connectors for sensors used in a vehicle can cause drastic damage to capital equipment and, in the worst case, the loss of life. The studies of faults or degradation of electrical contacts are essential for safety in vehicles and various industries. Although such faults can be due to numerous factors (such as dust, humidity, mechanical vibration, etc.) and some yet to be discovered, high contact resistance is the main factor causing erratic behavior of electrical contacts. This paper presents a study on the computation of electrical contact resistance of two metal conductors (in the form of a disk) with analytical relations and a numerical computation model based on the finite element method (FEM) in COMSOL Multiphysics. The contact spots were considered to have a higher electrical resistivity value (ρcs) than those of the two metal conductors (ρCu). Studies such as the one in view that is carried out on a microscopic level are often difficult to investigate experimentally. Therefore, with the help of a simplified numerical model, the consequences of the degradation of electrical contacts are investigated. To validate the FEM model, the numerical results were compared to those obtained from analytical models.
Highlights
Electric contacts are one of the essential components in electronics and automotive systems
Despite all the assumptions considered in the analytical models, the present study aims to explore the limits of numerical calculation for the contact resistance in the case of a simplified model
This paper presents a study on contact resistance of a model of two metallic disks made of copper that communicate via 28 homogenous circular spots
Summary
Electric contacts are one of the essential components in electronics and automotive systems. Estimating the contact resistance determines the accuracy of connectors. In machinery assembly, evaluating the reliability and tightness of contact can be done using the contact resistance of metals contact surface. For better conductivity and lower resistance, the point of contact between two bodies must have a large area with fewer impurities [1]. The growing number of electronic devices that equip electric vehicles calls for an increase in the number of electric connectors to be adapted in the vehicles’ electrical system. The automotive market demands optimum safety requirements and software-enabled features at a low price; to attain this, automotive manufacturers are trying to miniaturize electrical contacts to reduce weight by manufacturing them with high-performing alloys such as CuNiSi
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