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COMSOL Multiphysics DemoHigh Power Connector

Contact Area Governs Local Current Density

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Step 1: Setup Structural Contact Analysis

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Step 2: Import Geometry from CAD

Import Twice (2 Connectors)

Position to Overlap

Contact Solver Deflects to correct position

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Step 3: Define Contact Pairs

Assembly Modeling

Define Contact pairs (there are two)

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Step 4: Materials & Boundary Conditions

Copper

Built-in Ends

Symmetry

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Step 5: Mesh & Solve For Deflection

Tetrahedral –or– Hexahedral

Automatic –or– Interactive

Augmented Lagrange Contact

Solver

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Step 6: Add Electric & Thermal

Bi-Directionally Linked“Sees” Contact Area from Structural Solution

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Step 7: Materials & Boundary Conditions - Heat

Again Copper

Link Heat to DC

Symmetry

Convective Loss

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Step 8 : Materials & Boundary Conditions - Electric

Again Copper

Conductivity f (T)

Insulative – Most Surfaces

Current-in : One End

Ground Other End

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Step 9: Structural is Also Temperature Dependent

Thermal Expansion

Affects Contact Area

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Step 10: Solve Fully Coupled Problem

Contact Area, Electric Current & Temperature Completely Interdependent