Top

Acta Mechanica

23-04-2024 | Original Paper

Dynamic response of electrical contact resistance (ECR) under structural vibration

Authors: Benjamin T. Dankesreiter, Sujoy Talukder, Chang-Dong Yeo, Robert J. Kuether

Published in: Acta Mechanica

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

Many types of electrical connectors are used in traditional and emerging technology sectors such as electric vehicles, traditional automobiles, and aircraft, in which they need to maintain a stable and low electrical contact resistance (ECR). However, external shock and vibration can cause a sudden increase in ECR, which can lead to system failures due to electrical discontinuities or power transfer loss. In this study, the impact of structural dynamics on the ECR response is investigated using analytical modeling and simulation. A structural vibration of 100 Hz with a surface displacement amplitude of 3 nm is applied to an electrical connector system, and the dynamic ECR response is analyzed concerning structural stiffness and damping ratio. At the onset of structural vibration, the system shows a high-frequency response with large amplitude variation, which decays over the elapsed time. From the parametric simulations and statistical data analysis, it is observed that the magnitude of ECR fluctuation decreases with the structural stiffness and damping ratio. Within the tested range of structural properties, the ECR fluctuation is more sensitive to stiffness than the damping ratio.

Available only for authorised users

Abdi, R.E., Benjemaa, N.: Experimental and analytical studies of the connector insertion phase. IEEE Trans. Compon. Packag. Technol. 31, 751–758 (2008). https://doi.org/10.1109/TCAPT.2008.2001832CrossRef

Swingler, J., McBride, J.W., Maul, C.: Degradation of road tested automotive connectors. IEEE Trans. Compon. Packag. Technol. 23, 157–164 (2000). https://doi.org/10.1109/6144.833055CrossRef

Fu, R., Choe, S.-Y.B., Jackson, R.L., Flowers, G.T., Bozack, M.J., Zhong, L., Kim, D.: Vibration-induced changes in the contact resistance of high power electrical connectors for hybrid vehicles. IEEE Trans. Compon. Packag. Manuf. Technol. 2, 185–193 (2012). https://doi.org/10.1109/TCPMT.2011.2170168CrossRef

Crinon, E., Evans, J.T.: The effect of surface roughness, oxide film thickness and interfacial sliding on the electrical contact resistance of aluminium. Mater. Sci. Eng. A 242, 121–128 (1998). https://doi.org/10.1016/S0921-5093(97)00508-XCrossRef

Nituca, C.: Thermal analysis of electrical contacts from pantograph–catenary system for power supply of electric vehicles. Electr. Power Syst. Res. 96, 211–217 (2013). https://doi.org/10.1016/j.epsr.2012.11.009CrossRef

Zastrow, B.G., Flicek, R.C., Johnson, K.M., Walczak, K.A., Pacini, B.R., Johnson, B., Schumann, C., Rafeedi, F.: Investigation of electrical chatter in bifurcated contact receptacles. 2021 IEEE 66th Holm Conference on Electrical Contacts (HLM), San Antonio, Texas (2021). https://doi.org/10.1109/HLM51431.2021.9671173

Ji, R., Gao, J., Flowers, G.T., Xie, G., Cheng, Z., Jin, Q.: The effect of electrical connector degradation on high-frequency signal transmission. IEEE Trans. Compon. Packag. Manuf. Technol. 7, 1163–1172 (2017). https://doi.org/10.1109/TCPMT.2017.2688023CrossRef

Abdi, R.E., Carvou, E., Benjemaa, N.: Electrical resistance change of automotive connectors submitted to vibrations and temperature. IEEE Energy Conversion Congress and Exposition (ECCE), Montreal, QC, Canada (2015). https://doi.org/10.1109/ECCE.2015.7309929

Wu, G.: Evolution of the electrical contact of dynamic pantograph–catenary system. J. Mod. Transp. 24, 132–138 (2016). https://doi.org/10.1007/s40534-016-0099-1CrossRef

10.

Cheng, T., Gao, W., Liu, W., Li, R.: Evaluation method of contact erosion for high voltage SF6 circuit breakers using dynamic contact resistance measurement. Electr. Power Syst. Res. 163, 725–732 (2018). https://doi.org/10.1016/j.epsr.2017.08.030CrossRef

11.

Filippakou, M.P., Karagiannopoulos, C.G., Agoris, D.P., Bourkas, P.D.: Electrical contact overheating under short-circuit currents. Electr. Power Syst. Res. 57, 141–147 (2001). https://doi.org/10.1016/S0378-7796(01)00081-5CrossRef

12.

McBride, J.W.: The relationship between surface wear and contact resistance during the Fretting of in-vivo electrical contacts. IEEE Trans. Compon. Packag. Technol. 31, 592–600 (2008). https://doi.org/10.1109/TCAPT.2008.2001162CrossRef

13.

Hoble, D.A., Stasac, C.O.: Study on the influence of vibrations on electrical contact resistance. 2015 13th International Conference on Engineering of Modern Electric Systems (EMES), Oradea, Romania (2015). https://doi.org/10.1109/EMES.2015.7158416

14.

Varenberg, M., Etsion, I., Halperin, G.: Slip index: a new unified approach to fretting. Tribol. Lett. 17, 569–573 (2004). https://doi.org/10.1023/B:TRIL.0000044506.98760.f9CrossRef

15.

Waterhouse, R.B.: Fretting corrosion, 1st edn. Pergamon Press, Oxford (1972)

16.

Braunovic, M., Myshkin, N.K., Konchits, V.V.: Electrical Contacts: Fundamentals, Applications and Technology. CRC Press, Boca Raton (2006)CrossRef

17.

Flowers, G.T., Fei, X., Bozack, M.J., Horvath, R., Malucci, R.D., Rickett, B.I.: Modeling early stage fretting of electrical connectors subjected to random vibration. IEEE Trans. Compon. Packag. Technol. 28, 721–727 (2005). https://doi.org/10.1109/TCAPT.2005.859762CrossRef

18.

Ren, W.B., Du, D.Y., Du, Y.: Electrical contact resistance of connector response to mechanical vibration environment. IEEE Trans. Compon. Packag. Manuf. Technol. 10, 212–219 (2020). https://doi.org/10.1109/TCPMT.2019.2935478CrossRef

19.

Segalman, D.J., Feeny, B.F.: Modal methods for contact analysis and contact force reconstruction. Nonlinear Dyn. 1, 185–191 (2017). https://doi.org/10.1007/978-3-319-54404-5_20CrossRef

20.

Hurty, W.: Dynamic analysis of structural systems using component modes. AIAA J. 4, 678–685 (1965). https://doi.org/10.2514/3.2947CrossRef

21.

Craig, R.R., Bampton, M.C.C.: Coupling of substructures for dynamic analyses. AIAA J. 6, 1313–1319 (1968). https://doi.org/10.2514/3.4741CrossRef

22.

Breitfuss, M., Holl, H.J.: Numerical studies on the reduced order modeling of frictionless joint contact interfaces. Shock Vib. Aircraft/Aerosp. Energy Harvest. Acoust. Opt. 9, 167–178 (2016). https://doi.org/10.1007/978-3-319-30087-0_15CrossRef

23.

Dankesreiter, B.T., Serrano, M., Zhang, J., Pacini, B.R., Walczak, K.A., Flicek, R.C., Johnson, K.M., Zastrow, B.G.: Investigating the potential of electrical connection chatter induced by structural dynamics. Nonlinear Struct. Syst. 1, 19–25 (2023). https://doi.org/10.1007/978-3-031-04086-3_3CrossRef

24.

Zeng, Z., Zhou, Z., Li, X., Tang, M., Peng, B.: Numerical modeling and optimization on micro-D electrical connector. Int. J. Numer. Model Electron. Netw. Devices Fields 31, 2256 (2018). https://doi.org/10.1002/jnm.2256CrossRef

25.

Kogut, L., Etsion, I.: Elastic-plastic contact analysis of a sphere and a rigid flat. J. Appl. Mech. Trans. ASME 69, 657–662 (2002). https://doi.org/10.1115/1.1490373CrossRef

26.

Jackson, R.L., Green, I.: A finite element study of elasto-plastic hemispherical contact against a rigid flat. J. Tribol. Trans. ASME 127, 343–354 (2005). https://doi.org/10.1115/1.1866166CrossRef

27.

Brizmer, V., Kligerman, Y., Etsion, I.: The effect of contact conditions and material properties on the elasticity terminus of a spherical contact. Int. J. Solids Struct. 43, 5736–5749 (2006). https://doi.org/10.1016/j.ijsolstr.2005.07.034CrossRef

28.

Ovcharenko, A., Halperin, G., Verberne, G., Etsion, I.: In situ investigation of the contact area in elastic–plastic spherical contact during loading–unloading. Tribol. Lett. 25, 153–160 (2007). https://doi.org/10.1007/s11249-006-9164-yCrossRef

29.

Etsion, I., Levinson, O., Halperin, G., Varenberg, M.: Experimental investigation of the elastic-plastic contact area and static friction of a sphere on flat. J. Tribol. 127, 47–50 (2005). https://doi.org/10.1115/1.1843834CrossRef

30.

Jamari, J., Schipper, D.J.: Experimental investigation of fully plastic contact of a sphere against a hard flat. J. Tribol. 128, 230–235 (2006). https://doi.org/10.1115/1.2164470CrossRef

31.

Johnson, K.L.: Contact mechanics. Cambridge University Press, Cambridge (1985)CrossRef

32.

Derjaguin, B.V., Muller, V.M., Toporov, Y.P.: Effect of contact deformations on the adhesion of particles. J. Colloid Interface Sci. 53, 314–326 (1975). https://doi.org/10.1016/0021-9797(75)90018-1CrossRef

33.

Talukder, S., Yeo, C.-D., Hong, Y.-K., Choi, M., Flicek, R.C., Bishop, J.E.: Analytical modeling and simulation of electrical contact resistance for elastic rough electrode surface contact including frictional temperature rise. AIP Adv. 12, 025204 (2022). https://doi.org/10.1063/5.0073093CrossRef

34.

Slade, P.G.: 1.2 Electrical constriction resistance. In: Electrical Contacts: Principles and Applications, 2nd Edn., pp. pp. 5–7. CRC Press (2014)

35.

Hisakado, T.: Effects of surface roughness and surface films on contact resistance. Wear 44, 345–359 (1977). https://doi.org/10.1016/0043-1648(77)90149-1CrossRef

36.

DeVor, R.E., Chang, T., Sutherland, J.W.: Statistical Quality Design and Control: Contemporary Concepts and Methods, 2nd edn. Pearson, London (2006)

Title: Dynamic response of electrical contact resistance (ECR) under structural vibration
Authors: Benjamin T. Dankesreiter
Sujoy Talukder
Chang-Dong Yeo
Robert J. Kuether
Publication date: 23-04-2024
Publisher: Springer Vienna
Published in: Acta Mechanica
Print ISSN: 0001-5970
Electronic ISSN: 1619-6937
DOI: https://doi.org/10.1007/s00707-024-03943-w

Springer Professional

Dynamic response of electrical contact resistance (ECR) under structural vibration

Abstract

Premium Partners

Springer Professional

Abstract

Please log in to get access to your license.

Premium Partners