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Durability studies on vibration-loaded electrical contact systems subjected to tribological stress

  • Johannes Schautzgy , Yuriy Ivanov , Benjamin Kröger und Jürgen Wilde
Veröffentlicht/Copyright: 24. April 2019
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Abstract

Electrical connectors for signal applications in the automotive sector are subjected to stringent requirements. These systems must ensure dependable signal transmission throughout the service life of a vehicle, even under high stress conditions. To this end, redundantly structured contact systems with several lamellas are often used. Stress due to vibrations during vehicle operation can lead to relative displacements between the electrical contact partners, especially in the resonant frequency range of the connector. Fretting corrosion then leads to increased electrical resistance at the connection and to failure of the system when a certain resistance threshold is exceeded. For studying the durability of electrical contacts, a fretting test bench was developed that allows the emulation of stress due to vibrations on a contact system with test frequencies of up to 300 Hz. The Wöhler model was used for describing the durability as a function of the relative motion. The test procedure and evaluation for determining the model parameters were based on the pearl string method. The test unit was qualified as electrically failed if the resistance exceeded the 15 mΩ threshold. The studies showed that the lifetime of the redundantly structured contact system can be described via an analytic approach based on the methodology for determining Wöhler curves. The distribution function was based on a logarithmic normal distribution. With the aid of scanning electron microscopic analyses in combination with element distribution images from energy dispersive X-ray spectroscopy, it was possible to attribute electrical failure to the oxidation of the base material in the wear track.


*Correspondence Address, Johannes Schautzgy, M.Sc., ZF Friedrichshafen AG, Zentrale Forschung und Entwicklung, Virtual Engineering and System Validation, Graf-von-Soden-Platz 1, 88046 Friedrichshafen, Germany, E-mail:

Johannes Schautzgy, born in 1988, studied Mechanical Engineering with a specialization in development and engineering design at the University of Applied Sciences Ravensburg-Weingarten, Germany. Subsequently, he received his master's degree in 2015, majoring in product development. Since 2016, he has been working as a research engineer at the Department of Central Research and Development of ZF Friedrichshafen AG, Friedrichshafen, Germany and as a PhD candidate at the Faculty of Engineering of University Freiburg, Germany. His research in the field of testing methods for mechatronic systems mainly focuses on investigations of damage mechanisms of vibration loaded electronic components and the development of lifetime prediction concepts.

Dr.-Ing. Yuriy Ivanov, born in 1966, graduated in 1989 from the Technical University of Kiev, Ukraine, Faculty of Apparatus Engineering, and received his Dr.-Ing. there in 1995 in mechanical engineering. From 1989 to 2001 he worked at the TU of Kiev and the TU of Dresden, Germany, in the fields of mechanical and control engineering in various positions as a researcher and as a university teacher. Since 2001 he he has been working at ZF Friedrichshafen AG, Friedrichshafen, Germany, in the department of Central Research and Development. He is responsible for vibration investigations of mechanical, electromechanical and electronic components and systems, which are developed for automotive applications, focusing on methods development and creating profiles for vibration testing.

Benjamin Kröger, born in 1983, studied at the University of Applied Sciences Ravensburg-Weingarten, Germany, where he graduated in mechanical engineering specializing in vehicle mechatronics and subsequently received a Master's degree in product development. He has been part of the Steinbeis Network since 2005 and was responsible for industrial and scientific projects until the end of 2014. In January 2015, the company was transformed into a legally independent company named Steinbeis-Transferzentrum Werkstoffe Korrosion & Korrosionsschutz GmbH and he was appointed CEO. His expertise in the fields of aerospace, automotive and other industries covers the areas of materials, surface technology, corrosion and corrosion protection, electrochemistry and tribology and wear.

Prof. Dr.-Ing. Jürgen Wilde studied Materials Science at the University of Erlangen-Nuremberg, Germany, where he acquired his Dipl.-Ing. degree in 1982. From 1982 to 1988 he worked as a Research Scientist at the University of Clausthal, Germany. His PhD thesis focused on microstructured composite bonding wires. He worked at the Daimler Research Institute and focused on materials modeling for electronic assemblies, packaging processes and design-for-reliability of electro-vehicles. Since 1999, he has been a Professor at the University of Freiburg, Germany. His present research interests deal with photovoltaic systems, power electronics and sensors, where the influence of processes and packaging materials on performance and reliability are his objects of study. Prof. Wilde is a member of IEEE, VDI and DGM.


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Published Online: 2019-04-24
Published in Print: 2019-02-04

© 2019, Carl Hanser Verlag, München

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