{"title":"Thermo-mechanical stresses within switching contact systems after arcing events","authors":"Timo Mützel, D. Ma, F. Roters, D. Raabe","doi":"10.1109/HOLM.2017.8088077","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088077","url":null,"abstract":"Silver tin oxide (Ag/SnO2) contact materials are widely used in contactor applications. A general trend in this application field is the steadily ongoing miniaturization of switching devices, resulting in growing energy densities to be handled by the contact system. The higher arcing energy densities in such new designs are inducing increased thermo-mechanical stresses in the contact system. As these stresses cannot be measured, FEM simulation was applied to make them visible for heavy duty break arcs. Focus of the presented studies is the temperature dependent elastic and plastic modeling of the intermediate Ag layer and the braze filler. Based on these simulations, improvements in material stress behavior of the complete system (sub-assembly) should be realized.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"25 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"125627332","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Failure dependent progression of contact resistance in thermal-shock testing of spring-clip contacts","authors":"M. Friedlein, M. Spahr, R. Suess-Wolf, J. Franke","doi":"10.1109/HOLM.2017.8088081","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088081","url":null,"abstract":"Through ever changing terms and regulations on fuel consumption and emissions, weight becomes the number one concern of car manufacturers. Meeting those new regulations and the customer's desire for more options and variations is only possible without adding more weight by changing the wiring harnesses' technology. One solution to face this problem can be found by the application of flexible flat cables (FFCs) instead of common round cable wire systems. For a holistic approach, it is important not only to establish automated ways of cable installation, but also methods of automatically contacting components. Therefore, a new direct contacting method was developed at the Institute for Factory Automation and Production Systems (FAPS). The innovative contacting method enables to contact an automatically mounted one side accessible FFC with kinematic systems of industrial robots in an automated way. However, before new technologies can be applied to serial production, car manufacturers demand standardized climatic tests. In this paper, a correlation was discovered between the progression of contact resistance and failure mechanisms during thermal shock testing. Furthermore, an influence of different peak temperatures and materials was identified and the results were verified via SEM micrographs.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"94 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124731355","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Influence of contact materials and opening velocity on various characteristics of DC high voltage arc","authors":"Kiyoshi Yoshida, K. Sawa, Kenji Suzuki, K. Takaya","doi":"10.1109/HOLM.2017.8088088","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088088","url":null,"abstract":"In this study, we use a apparatus that can be opened at constant speed. The voltage is set to DC 200, 300, and 500 V. The closed contact current is set to constant at 10 A at each voltage. The opening velocity is varied in the range of 1 to 200 mm/s. The contact material is Pd and Pt with low thermal conductivity. The arc duration is obtained from the voltage· current waveforms of the arc discharge, and the arc energy is obtained from the electric power waveform. In addition, arc length and contacts gap length at the time of arc extinction is obtained from the video analysis of the arc discharge light. As a result, it became clear that the arc duration and the arc energy are inversely proportional to the opening speed. These results were similar to that of Ag, W, Ni, and Cu, and the difference due to the contact material was small. The arc length immediately before the arc extinguishment became a constant value determined by the source voltage independent of the contact material and opening velocity. The value was about 30 mm at 200 V, about 60 mm at 300 V and about 110 mm at 500 V.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"13 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114901856","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
M. Leidner, M. Brunner, S. Stotz, M. Myers, H. Schmidt, S. Thoss
{"title":"Experimental verification/comparison between standard sphere against flat and a new wave structured contact surface topography developed using a numerical contact model; as applied to an existing MQS contact design","authors":"M. Leidner, M. Brunner, S. Stotz, M. Myers, H. Schmidt, S. Thoss","doi":"10.1109/HOLM.2017.8088101","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088101","url":null,"abstract":"By using a Papkovich Neuber potential based 3D numerical contact modeling method [1], it has been shown that using a wave structured contact surface topography can reduce contact interface resistance by a factor of 2 at a given normal load. It has been proposed that a wave structured topography can be used to reduce contact normal force as a method to reduce connector mating forces. Since there is more and more pressure to manage/minimize connector engagement forces as advancing technology calls for greater connector circuit/pin counts, using these wave structured topographies represents a way that these demands could be met. A comparative study will show that contacts with wave structured contact surface topographies can meet and exceed the mechanical and electrical performance of similar standard sphere against flat contact interfaces. By applying a wave structure to an existing standard ‘sphere on flat' contact interface design and subsequently reducing the contact normal force by 50% to cut the contact engagement force in half; the current carrying capability of a contact design still increased by 16% and the specified vibration stability requirement for the contacts was still met. If this is done with no normal force reduction, a 22% increase in interface current carrying capacity can be achieved with a vibration stability superior to the standard sphere against flat surfaced contact design. The functionally evaluated electrical characteristics of such wave structured and standard contact interfaces are in agreement with the numerical predictions.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"410 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124363182","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ye Lianhui, Wang Yuanzhong, Liu Benlu, L. Nan, Qiu Kui
{"title":"Research on delamination detection sensitivity of ultrasonic non-destructive testing technology for electrical contact","authors":"Ye Lianhui, Wang Yuanzhong, Liu Benlu, L. Nan, Qiu Kui","doi":"10.1109/HOLM.2017.8088079","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088079","url":null,"abstract":"The basic principle of ultrasonic non-destructive testing technology is introduced, and its theoretical and practical delamination detection sensitivity is deduced and verified by Newton Ring. Then, both of cladding interface and bottom surface of a multi-layer composite contact are tested by ultrasonic testing system to check delamination defect. The delamination defect in the cladding interface is also checked by metallographic microscope and scanning electron microscope to verify the results of ultrasonic testing. This study shows that ultrasonic testing method is a suitable way for testing low-voltage electrical contact welding quality and cladding quality.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"7 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124384347","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Qingya Li, Rui Ji, Jinchun Gao, G. Flowers, G. Xie, Weibin Ye
{"title":"Investigation on RF connector degradation using time domain reflectometry","authors":"Qingya Li, Rui Ji, Jinchun Gao, G. Flowers, G. Xie, Weibin Ye","doi":"10.1109/HOLM.2017.8088078","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088078","url":null,"abstract":"Radio Frequency (RF) connectors play an important part in electronic and communication systems. They are generally subjected to degradation in the contact interface during their service life, which affects signal integrity and communication quality of the systems. In the present work, the characteristics of RF connector degradation were theoretically analyzed and experimentally investigated using Time Domain Reflectometry (TDR). An accelerated test was designed to obtain the degraded connector samples. A series of experiments were conducted to measure the reflected voltages using a Network Analyzer for time domain analysis. Then, the reflection coefficients and load impedance were determined and the location of the degraded contact interface was identified. Based on classical electrical contact theory, transmission lines theory, and experimental results, an equivalent circuit model was developed and the degradation mechanism analyzed. The results showed that inductive characteristics increase with increase of the degradation. As the degradation increases beyond a certain level, the connector exhibits a more capacitive characteristic.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"149 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"129096728","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Development of an arcless DC circuit break using a mechanical contact and a semiconductor device","authors":"S. Zen, Tatsuya Hayakawa, K. Nakayama, K. Yasuoka","doi":"10.1109/HOLM.2017.8088095","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088095","url":null,"abstract":"Direct current circuit breakers (DCCBs) have receive considerable attention due to their increasing demand in DC power transmission and distributed generation. A hybrid DCCB comprising a mechanical contact, semiconductor device (SiC- MOSFET), and metal oxide varistor offers a small contact resistance when the mechanical contact is closed. After opening the mechanical contact, the contact voltage increases because a molten metal -bridge is formed between the contacts as a result of joule heating. This molten-bridge voltage promotes the current commutation from the mechanical contact to the SiC-MOSFET. After the current commutation is completed, a fast current interruption can be achieved by turning off the SiC-MOSFET. Therefore, the hybrid DCCB can achieve both a small contact resistance and a fast current interruption. In our previous papers, an arcless commutation was reported at the initial stage of the hybrid DCCB opening under a special condition. In this report, higher molten-bridge voltage was obtained using 2-pole contacts connected in series and using high-boiling metals. The higher molten-bridge voltage enabled the hybrid DCCB to interrupt larger current without any arc discharge. Finally, we performed DC current (300 V-150 A) interruption experiment, and succeeded in obtaining arcless current interruption with a probability of 100%.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"75 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133699101","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Temperature rise of canted spring contacts during fault current","authors":"B. Novák, L. Szabó","doi":"10.1109/HOLM.2017.8088100","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088100","url":null,"abstract":"During the breaking test of a high voltage circuit breaker, a canted spring contact connecting the busbars of the switchgear melted. This event provided a good opportunity to test the reliability of finite element (FE) temperature rise calculations based on a transient coupled thermal-electromagnetic (EM) model. To properly include the Joule-losses at the tiny contact points in a time-varying ANSYS FE analysis, we had to devise a unique method of contact resistance modelling. The paper shortly describes this method and shares our experience we obtained from the case study of canted spring contact temperature rise.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"25 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"127817522","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Feature analysis in time-domain and fault diagnosis of series arc fault","authors":"Yanli Liu, Fengyi Guo, Zhiling Ren, Peilong Wang, Tuannghia Nguyen, Jia Zheng, Xirui Zhang","doi":"10.1109/HOLM.2017.8088104","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088104","url":null,"abstract":"In order to monitor series arc fault in real-time for electrical connectors and improve the reliability of power supply systems, series arc fault experiments were carried out using an arc fault generator. A three-phase asynchronous motor and a three-phase frequency conversion motor were used as experimental loads. The variance, covariance and number of zero-crossing points of five adjacent periods of current signals were extracted and normalized. The feature vector was constructed by using the above variables such as number of zero-crossing points, variance and covariance. The k-nearest neighbor method was used for pattern recognition of the feature vector. The results showed that this method was effective for the diagnosis of series arc fault in electrical connectors.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"1 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130167625","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
R. Enquebecq, O. Graton, S. Fouvry, E. Rubiola, J. Legrand, L. Petit
{"title":"Effect of fretting wear of connectors regarding phase noise of RF signal: Influence of sliding amplitude and gold coating thickness","authors":"R. Enquebecq, O. Graton, S. Fouvry, E. Rubiola, J. Legrand, L. Petit","doi":"10.1109/HOLM.2017.8088058","DOIUrl":"https://doi.org/10.1109/HOLM.2017.8088058","url":null,"abstract":"High technology domains such as aerospace, aviation and defense require a reliable transmission of RF signals. In these applications, RF connectors are exposed to severe environmental vibrations and are subjected to fretting wear damages. Former investigations on real connectors have shown that fretting wear leads to a dramatic increase of the DC electrical contact resistance (ECR), degrades RF microwave transmission and generates a significant additive phase noise. The present study aims to formalize the correlation between wear mechanisms of top gold layers and the evolution of electrical properties in DC and RF. An original fretting test bench was specifically developed to study a homogeneous double sphere-plan contact under gross-slip regime for different fretting loadings and different conductive films thickness. During the test DC ECR and phase noise are measured simultaneously. To quantify the fretting RF lifetime of the contact, a dedicated phase noise endurance criterion is used (Lm, th = −120 dBC/Hz). This phase noise threshold is shown to correspond to a ΔRth = 0.4 Ω DC contact resistance variation and was related to a quasi-full elimination of gold layer from the fretted interfaces. This experimental investigation suggests that fretting cycle endurance Nc (RF and DC) decreases asymptotically as a function of the sliding amplitude őg∗ but increases exponentially with the coating thickness e. Elemental analysis and 3d profile measurement demonstrate that the evolution of the electrical properties of the contact is driven by the top gold layer wear rate and the trapping of subsurface oxide debris in the interface induced by the fretting wear of NiP interlayer and CuSn4 substrate.","PeriodicalId":354484,"journal":{"name":"2017 IEEE Holm Conference on Electrical Contacts","volume":"26 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2017-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130753760","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}