Electrical resistance change of automotive connectors submitted to vibrations and temperature

Abdi, R. El; Carvou, Erwann; Benjemaa, N.

doi:10.1109/ecce.2015.7309929

“…When electrical connectors operate under harsh mechanical vibration and shock environments, which are common in vehicle and flight systems, these connectors can experience sudden increases in electrical contact resistance (ECR) at the interface (commonly referred to as "electrical chatter") [6]. This can lead to a critical distortion of electrical signals and discontinuities or power transfer loss [2,3,[7][8][9][10][11]. However, the underlying physics governing electrical chatter is not fully understood due to the multi-scale and multi-physics nature of this phenomenon.…”

Section: Introductionmentioning

confidence: 99%

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

Dankesreiter,

Talukder,

Yeo

et al. 2024

Acta Mech

0

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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 an 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 with respect to the structural stiffness and damping ratio. At the onset of structural vibration, the system shows a high frequency ECR 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 the stiffness than the damping ratio.

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“…Researchers have studied the dynamic characteristics of ECR through experimental and analytical techniques [8,[12][13][14]. When electrical connectors were placed under cyclic motion with relatively small amplitude, the contacting electrodes' surface developed fretting wear and the enlarged slip amplitude led to faster increase in ECR [15,16].…”

Section: Introductionmentioning

confidence: 99%

Dynamic Response of Electrical Contact Resistance (ECR) under Structural Vibration

Talukder

¹

,

Dankesreiter

²

,

Yeo

³

et al. 2022

Preprint

0

View full text Add to dashboard Cite

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 an 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 with respect to the structural stiffness and damping ratio. At the onset of structural vibration, the system shows a high frequency ECR 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 the stiffness than the damping ratio.

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“…Therefore, remaining useful life (RUL) prediction models are required, although there is a scarcity of literature for power connectors. In [ 21 ], the joint effect of vibration and temperature stresses on the value of the contact resistance of automotive connectors was evaluated with the aim of determining the minimum vibration amplitude for fretting-corrosion degradation. In [ 22 ], the mechanical behavior and fatigue lifetime of micro electrical connectors were estimated based on the effect of fretting wear.…”

Section: Introductionmentioning

confidence: 99%

On-Line Remaining Useful Life Estimation of Power Connectors Focused on Predictive Maintenance

Riba

¹

,

Gómez-Pau

²

,

Martinez

³

et al. 2021

Sensors

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Connections are critical elements in power systems, exhibiting higher failure probability. Power connectors are considered secondary simple devices in power systems despite their key role, since a failure in one such element can lead to major issues. Thus, it is of vital interest to develop predictive maintenance approaches to minimize these issues. This paper proposes an on-line method to determine the remaining useful life (RUL) of power connectors. It is based on a simple and accurate model of the degradation with time of the electrical resistance of the connector, which only has two parameters, whose values are identified from on-line acquired data (voltage drop across the connector, electric current and temperature). The accuracy of the model presented in this paper is compared with the widely applied autoregressive integrated moving average model (ARIMA), showing enhanced performance. Next, a criterion to determine the RUL is proposed, which is based on the inflection point of the expression describing the electrical resistance degradation. This strategy allows determination of when the connector must be replaced, thus easing predictive maintenance tasks. Experimental results from seven connectors show the potential and viability of the suggested method, which can be applied to many other devices.

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Electrical resistance change of automotive connectors submitted to vibrations and temperature

Cited by 12 publications

References 3 publications

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

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

Dynamic Response of Electrical Contact Resistance (ECR) under Structural Vibration

On-Line Remaining Useful Life Estimation of Power Connectors Focused on Predictive Maintenance

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