Simulation methods for heat transfer processes in mechanical and electrical connections

The main purpose of this paper is to derive formulas and algorithms for the calculation of the heat distribution in electrical and mechanical structures connecting cables and electrical devices. Therewith it shall be possible to dimension these connecting structures before construction very fast and with sufficient accuracy for practical use. New simulation tools based on these formulas and algorithms are created and feature an easy handling and very short calculation times. Consequently, they are appropriate for use in industrial applications, but nevertheless, they respect physical effects like increasing electrical resistance because of higher temperatures. Therefore a power balance-based model has been developed allowing the determination of temperatures at critical points of the electrical connections for the stationary case. To compare the results of this simplified and very fast approach, a numerical model, based on partial differential equations that are solved with the finite element method, has been derived. Via this numerical model, simulation results showing the heat generation in the investigated devices very precisely, are obtained. The disadvantage of the numerical method is that it takes longer to generate the geometries and to solve the nonlinear systems what makes this approach less applicable for industrial use. Further pros and cons of both techniques are demonstrated in this work. To ensure the results of both methods to accord with reality's results, some experimental measurements with characteristic parameter values will be performed and serve as a hedge for the simulation results of both methods.