A Multi-Physics Finite Element Model of a 35A Automotive Connector Including Multiscale Rough Surface Contact

Electrical contacts influence the reliability and performance of relays, electrical connectors, high power connectors, and similar systems, and are therefore a key region which needs to be considered. In the current study, a new inclusive multi-physics (involving mechanical, thermal and electrical fields) finite element model (FEM) of a 35A automotive connector has been developed. The contact resistance is predicted using a multiscale rough surface contact method and is embedded in the multi-physics FEM. The coupled connector model is solved to obtain stresses, contact pressures, electrical and thermal contact resistances, voltage, current density and temperature distributions. The results for the present connector show that the current conducts through a small volume of the connector and more optimal designs are possible that better use the connector material. The model is a powerful tool that can be used for the basic connector characterization, prototype evaluation and design through various material properties and surface finishes.