Simulation method and system for size and cost optimization of copper-clad aluminum busbar composite material
By establishing a multiphysics coupling simulation model and intelligent optimization algorithm based on Comsol, the problem of parameter optimization in copper-clad aluminum conductor design was solved, achieving efficient copper-clad aluminum busbar specification matching and improving design efficiency and economy.
Patent Information
- Application Number
- CN202511985041.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-26
- Publication Date
- 2026-02-10
AI Technical Summary
In the design of copper-clad aluminum conductors, it is difficult to find the optimal balance between conductor cross-sectional size, copper layer ratio, current carrying capacity and material cost. Existing methods rely on simplified thermal resistance algorithms and empirical formulas, resulting in low design efficiency and insufficient cost optimization.
A simulation model was established using the multiphysics coupled finite element software Comsol. Combined with an intelligent cost optimization algorithm, the copper-clad aluminum busbar specifications that meet the current carrying capacity requirements and have the lowest cost were matched through the simulation database. These specifications included cross-sectional dimensions, copper layer ratio, temperature rise, and current carrying capacity.
It enables the rapid and accurate matching of copper-clad aluminum conductor configurations that meet the target current carrying capacity and have the lowest cost, significantly improving design efficiency and economy.
Smart Images
Figure CN121502850A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of conductor design technology for wires and cables, specifically relating to a simulation method and system for optimizing the size and cost of copper-clad aluminum busbar composite materials. Background Technology
[0002] Copper-clad aluminum conductors, as a novel composite conductive material, consist of a highly conductive copper layer wrapped around a high-strength aluminum core. This structure cleverly utilizes the skin effect, significantly reducing material costs and product weight while ensuring conductivity. Practical applications show that a 10mm*100mm copper-clad aluminum busbar can reduce costs by approximately 45% compared to a pure copper busbar of the same size, while achieving over 85% of the current carrying capacity. However, the design process for copper-clad aluminum conductors faces significant challenges, typically requiring an optimal balance among multiple parameters such as conductor cross-sectional dimensions, copper layer ratio, current carrying capacity, and material cost. Cross-sectional dimensions determine the conductor's cross-sectional area and heat dissipation characteristics; the copper layer ratio directly affects the conductor's conductivity and material cost; and the current carrying capacity depends on the conductor's temperature rise under operating conditions. Material cost needs to be calculated and optimized based on real-time changes in copper and aluminum prices. The complex nonlinear relationships among these parameters make it difficult to find the truly optimal design solution through simple calculations or empirical rules.
[0003] Currently, the most common practice in copper-clad aluminum conductor design is to rely on industry standards and empirical formulas. Reference values for current carrying capacity can be directly obtained from tables based on cable type, laying conditions, and ambient temperature. The core of this method lies in using simplified thermal resistance algorithms and standard conditions. By considering the influence of thermal resistance during cable heat conduction and incorporating correction factors provided by standards, the current carrying capacity under specific conditions can be calculated. In terms of cost calculation, this method typically employs a simple cost-per-unit-length comparison, such as comparing the cost difference between copper busbars and copper-clad aluminum busbars of the same specifications. Summary of the Invention
[0004] To address the aforementioned technical problems, this invention provides a simulation method and system for optimizing the size and cost of copper-clad aluminum busbar composite materials. By combining a systematic simulation database with an intelligent cost optimization algorithm, it achieves automatic mapping from performance requirements to the most economically optimal design.
[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: In a first aspect, this invention proposes a simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials, comprising the following specific steps: A simulation model of copper-clad aluminum busbar composite material based on the multiphysics coupled finite element software Comsol was established; In the simulation model, multiple simulated copper-clad aluminum busbars with different cross-sectional dimensions and different copper layer ratios are established; In the simulation model, multiple physical field parameters and environmental parameters of simulated copper-clad aluminum busbars are set and simulation operations are performed to generate the current carrying capacity of different simulated copper-clad aluminum busbars under different temperature rises, and the data are stored in the database of the simulation model. Obtain the target current carrying capacity and target temperature rise input by the user, and match all candidate copper-clad aluminum busbars that meet the current carrying capacity requirements in the database; Based on the real-time price data of pure copper and pure aluminum materials, the manufacturing cost of each candidate copper-clad aluminum busbar is calculated, and the specification data of the candidate copper-clad aluminum busbar with the lowest cost is used as the simulation output result. The specifications include cross-sectional dimensions, copper layer ratio, temperature rise, current carrying capacity, and manufacturing cost.
[0006] Furthermore, the simulation model also includes material parameter settings, and the material parameter table includes annealed copper and annealed pure aluminum.
[0007] Furthermore, in the step of setting multiple physical field parameters for simulated copper-clad aluminum busbars in the simulation model, the physical field setting adopts a multi-physics coupling mode of electromagnetic field and temperature field. In the electromagnetic field, the electromagnetic module is used to generate Joule heating after current is passed into the simulated copper-clad aluminum busbar, and the heat conduction module in the temperature field is used to simulate the temperature rise of the simulated copper-clad aluminum busbar under the action of Joule heating, and to dissipate heat through natural convection and thermal radiation.
[0008] Furthermore, in the step of setting multiple environmental parameters for the simulated copper-clad aluminum busbar in the simulation model, the environmental parameter settings include setting reference temperature data and the natural convection heat transfer coefficient and surface emissivity data of the geometric structure model surface, and performing mesh refinement settings on the copper-aluminum interface and surface area of the geometric structure model.
[0009] Furthermore, the specific steps for calculating the manufacturing cost of each candidate copper-clad aluminum busbar based on real-time acquired price data for pure copper and pure aluminum materials include: The volume values of copper and aluminum in each candidate copper-clad aluminum busbar are calculated based on the copper layer ratio of each matched candidate copper-clad aluminum busbar. The mass of copper and aluminum is obtained based on the volume value and density, and the manufacturing cost of each candidate copper-clad aluminum busbar is calculated based on the real-time price data of pure copper and pure aluminum materials.
[0010] Furthermore, the step of matching all candidate copper-clad aluminum busbars that meet the current carrying capacity requirements in the database specifically includes matching simulated copper-clad aluminum busbars in the database that meet the target temperature rise conditions and whose current carrying capacity in the database is between the target current carrying capacity and 1.1 times the target current carrying capacity as candidate copper-clad aluminum busbars.
[0011] Secondly, this invention also proposes a simulation system for optimizing the size and cost of copper-clad aluminum busbar composite materials, comprising: The first building module is used to establish a simulation model of copper-clad aluminum busbar composite material based on the multiphysics coupling finite element software Comsol. The second construction module is used to establish multiple simulated copper-clad aluminum busbars based on different cross-sectional dimensions and different copper layer ratios in the simulation model. The current carrying capacity generation module is used to set the physical field parameters and environmental parameters of multiple simulated copper-clad aluminum busbars in the simulation model and perform simulation operations to generate the current carrying capacity of different simulated copper-clad aluminum busbars under different temperature rises and store them in the database of the simulation model. The user interaction module is used to obtain the target current carrying capacity and target temperature rise input by the user, and to match all candidate copper-clad aluminum busbars that meet the current carrying capacity requirements in the database. The results output module is used to calculate the manufacturing cost of each candidate copper-clad aluminum busbar based on the real-time acquired price data of pure copper and pure aluminum materials, and to use the specification data corresponding to the candidate copper-clad aluminum busbar with the lowest cost as the simulation output result. The specification data includes cross-sectional dimensions, copper layer ratio, temperature rise, current carrying capacity, and manufacturing cost.
[0012] The beneficial effects of this invention are: This invention can quickly and accurately match the copper-clad aluminum conductor configuration that meets the target current carrying capacity and has the lowest cost, significantly improving design efficiency and economy. Attached Figure Description
[0013] Figure 1 This is a flowchart illustrating the simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials proposed in this invention.
[0014] Figure 2 This is a schematic diagram of the geometric model construction for simulating the copper-clad aluminum busbar in the simulation method for optimizing the size and cost of the copper-clad aluminum busbar composite material proposed in this invention.
[0015] Figure 3 This is a schematic diagram of the mesh refinement settings in the simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials proposed in this invention.
[0016] Figure 4 This is a schematic diagram of the temperature distribution of the copper-clad aluminum busbar under different currents in the simulation method for optimizing the size and cost of the copper-clad aluminum busbar composite material proposed in this invention.
[0017] Figure 5 This is a framework diagram of the simulation system for optimizing the size and cost of copper-clad aluminum busbar composite materials proposed in this invention. Detailed Implementation
[0018] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.
[0019] like Figure 1 As shown in the figure, this embodiment provides a simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials, including the following specific steps: S1. Establish a simulation model of copper-clad aluminum busbar composite material based on the multiphysics coupling finite element software Comsol.
[0020] S2. Establish multiple simulated copper-clad aluminum busbars with different cross-sectional dimensions and different copper layer ratios in the simulation model; S3. Set multiple physical field parameters and environmental parameters for simulated copper-clad aluminum busbars in the simulation model and perform simulation operations to generate the current carrying capacity of different simulated copper-clad aluminum busbars under different temperature rises, and store them in the database of the simulation model; S4. Obtain the target current carrying capacity and target temperature rise input by the user, and match all candidate copper-clad aluminum busbars that meet the current carrying capacity requirements in the database; S5. Based on the real-time price data of pure copper and pure aluminum materials, calculate the manufacturing cost of each candidate copper-clad aluminum busbar, and use the specification data of the candidate copper-clad aluminum busbar with the lowest cost as the simulation output result; The specifications mentioned above include cross-sectional dimensions, copper layer ratio, temperature rise, current carrying capacity, and manufacturing cost.
[0021] In this embodiment, step S1 is to construct a simulation model based on the multiphysics coupled finite element software Comsol. The purpose of this embodiment is also to realize the optimal selection process of copper-clad aluminum busbar through simulation. Therefore, simulation material parameters based on copper-clad aluminum busbar are also set in the simulation model. In this embodiment, the material parameters are selected from C10200 annealed copper and 1060 annealed pure aluminum in the material library.
[0022] In this embodiment, the construction process of the simulation model mainly involves steps S2-S3. It should be noted that this embodiment is used to simulate copper-clad aluminum busbar composite materials; therefore, a geometric model architecture needs to be established in the simulation model first, namely the simulated copper-clad aluminum busbar in step S2, such as... Figure 2 As shown, the simulation model can generate simulated copper-clad aluminum busbars based on actual cross-sectional dimensions, copper layer ratio, and other data. The dimensions or copper layer ratio can be set according to user needs or commonly used dimensional data in the actual environment. Figure 2This is just a schematic diagram of a simulated copper-clad aluminum busbar. In reality, multiple simulated copper-clad aluminum busbars can be built according to different sizes and copper layer ratios.
[0023] After constructing the simulated copper-clad aluminum busbar or its geometry, the simulation environment needs to be set up. In this embodiment, the copper-clad aluminum simulation model built using the multiphysics coupled finite element software Comsol requires the construction of electromagnetic and temperature field environments. The electromagnetic field environment includes an electromagnetic module to generate Joule heating when current is applied to the simulated copper-clad aluminum busbar. The temperature field includes a heat conduction module to simulate the temperature rise of the simulated copper-clad aluminum busbar under Joule heating, with heat dissipation achieved through natural convection and thermal radiation. Environmental parameter settings include baseline temperature data (e.g., 20℃-25℃) and the natural convection heat transfer coefficient and surface emissivity data of the geometric model surface. Figure 3 As shown, to ensure calculation accuracy, especially in key areas such as the copper-aluminum interface and conductor surface, the mesh is refined in the copper-aluminum interface and surface areas of the geometric model.
[0024] In this embodiment, after the physical field parameters and environmental parameters are set, the simulation operation begins, such as... Figure 4 As shown, in this embodiment, the maximum overall temperature of the copper-clad aluminum conductor is set to 75℃, 90℃, and 100℃ respectively. At this time, the finite element software Comsol will automatically adjust the input current until the highest temperature of the copper-clad aluminum busbar reaches the set temperature rise limit. The corresponding current value is recorded, i.e., the current carrying capacity of different simulated copper-clad aluminum busbars at different temperature rises, and stored in the simulation model's database. It should be noted that in the temperature simulation of the finite element software Comsol, temperature rise refers to the difference between the actual operating temperature and the ambient reference temperature. In this embodiment, the reference temperature is 25℃. According to the application of thermodynamic temperature units in engineering thermal simulation, 50K represents 50℃, 65K represents 65℃, and 75K represents 75℃.
[0025] Table 1 shows the current carrying capacity of copper-clad aluminum of different sizes and specifications, recording the current carrying capacity values of copper-clad aluminum of different sizes and specifications with different copper layer ratios at different temperature rises.
[0026] Table 1 Current carrying capacity of copper-clad aluminum alloys of different sizes and specifications
[0027] The above process achieves simulations of different sizes, copper layer ratios, and other parameters. The purpose of this embodiment is not only to simulate the aforementioned data but also to construct a cost model, i.e., the cost calculation process for copper and aluminum. This is achieved using cross-sectional dimensions b and h, and the default length. Calculate the volume of copper-clad aluminum of different specifications using a 1000mm² area, and then calculate the volumes of copper and aluminum separately based on the copper layer ratio. The density of pure copper is taken as 8900 kg / m³. 3 The density of pure aluminum is taken as 2700 kg / m³. 3 The mass of pure copper and pure aluminum under this specification is calculated based on their volume and density, and the cost is calculated according to the current unit weight price of pure copper and pure aluminum. The resulting price is the cost for this cross-sectional size and the percentage of copper layer. The specific calculation process is achieved through the following expression:
[0028]
[0029]
[0030] In the above expression, V is the volume, b is the width, and h is the thickness. m represents length, with a default value of 1000mm, and m represents mass. Let P be density, P be cost, and C be unit price. It should be noted that the established database already specifies the copper layer percentage for each copper-clad aluminum unit; for example, VPCu=20% indicates a copper layer percentage of 20%. The volume of copper and aluminum, along with their corresponding masses, can be calculated using the above process to obtain their respective costs. Adding the costs of copper and aluminum gives the cost of the corresponding copper-clad aluminum busbar. It should be noted that the model used in this embodiment can automatically retrieve the current unit price of copper or aluminum, which can also be preset in the model; this embodiment does not impose specific limitations. In this embodiment, the cost model is written as function code using Python and added to the software execution program, thereby achieving dynamic cost calculation based on the latest material price input by the user or by calling a preset price list.
[0031] The above process achieves the complete construction of the simulation model, including the database construction of current-carrying capacity data for copper-clad aluminum busbars of different sizes and copper layer ratios, as well as the construction of the cost model. When a user needs to select a specific copper-clad aluminum busbar through the simulation software, the target current-carrying capacity and target temperature rise input by the user are obtained. All candidate copper-clad aluminum busbars that meet the current-carrying capacity requirements are matched in the database. Based on the real-time acquired price data of pure copper and pure aluminum materials, the manufacturing cost of each candidate copper-clad aluminum busbar is calculated, and the specification data corresponding to the candidate copper-clad aluminum busbar with the lowest cost is used as the simulation output result. In this embodiment, the specification data includes cross-sectional dimensions, copper layer ratio, temperature rise, current-carrying capacity, and manufacturing cost. It should be noted that, based on the target current-carrying capacity and target temperature rise input by the user, all copper-clad aluminum specifications that meet the temperature rise requirements and whose current-carrying capacity is between the target current-carrying capacity and 1.1 times the target current-carrying capacity are filtered in the database. In the output results, the copper-clad aluminum cost data can be arranged in descending order, or multiple cost schemes required by the user can be output, and these cost schemes are provided as the optimal design results of this application embodiment for the user to choose from.
[0032] To more clearly illustrate the content of this embodiment, a specific example is given below: When the user inputs a target current carrying capacity of 1000A and a temperature rise of 50K, the database is filtered to select cross-sectional dimensions of 60×8 with a current carrying capacity in the range of 1000A-1100A and a temperature rise of 50K, and copper layer percentages of 20%, 25%, and 30%. Based on the cost calculation module's calculation method, the costs of copper-clad aluminum with three different copper layer percentages are calculated to be: 89.09 yuan / meter, 104.8 yuan / meter, and 120.67 yuan / meter. Therefore, a cross-sectional dimension of 60×8 with a copper layer percentage of 20%-30% can be selected, with the lowest cost being 89.09 yuan / meter. The second dimension is 50×10 with a copper layer percentage of 30%, at which point the cost is 142.15 yuan / meter. The third dimension is 80×6 with a copper layer percentage of 20%, at which point the cost is 89.09 yuan / meter. The optimal cross-sectional dimensions were ultimately selected as 60×8 with a copper layer ratio of 20% and 80×6 with a copper layer ratio of 20%.
[0033] like Figure 5 As shown in the embodiments of this application, a simulation system 500 for optimizing the size and cost of copper-clad aluminum busbar composite materials is also provided, including: The first building module 501 is used to establish a simulation model of copper-clad aluminum busbar composite material based on the multiphysics coupling finite element software Comsol. The second construction module 502 is used to establish multiple simulated copper-clad aluminum busbars based on different cross-sectional dimensions and different copper layer ratios in the simulation model. The current carrying capacity generation module 503 is used to set the physical field parameters and environmental parameters of multiple simulated copper-clad aluminum busbars in the simulation model and perform simulation operations to generate the current carrying capacity of different simulated copper-clad aluminum busbars under different temperature rises and store them in the database of the simulation model. User interaction module 504 is used to obtain the target current carrying capacity and target temperature rise input by the user, and match all candidate copper-clad aluminum busbars that meet the current carrying capacity requirements in the database. The result output module 505 is used to calculate the manufacturing cost of each candidate copper-clad aluminum busbar based on the real-time acquired price data of pure copper and pure aluminum materials, and to take the specification data corresponding to the candidate copper-clad aluminum busbar with the lowest cost as the simulation output result. The specification data includes cross-sectional dimensions, copper layer ratio, temperature rise, current carrying capacity and manufacturing cost.
[0034] The embodiments described in this application are for the purpose of more clearly illustrating the technical solutions of the embodiments of this application, and do not constitute a limitation on the technical solutions provided by the embodiments of this application. As those skilled in the art will know, with the evolution of technology and the emergence of new application scenarios, the technical solutions provided by the embodiments of this application are also applicable to similar technical problems.
[0035] Those skilled in the art will understand that the technical solutions shown in the figures do not constitute a limitation on the embodiments of this application, and may include more or fewer steps than shown, or combine certain steps, or different steps.
[0036] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.
[0037] The embodiments described above are merely examples of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention.
Claims
1. A simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials, characterized in that, The specific steps include the following: A simulation model of copper-clad aluminum busbar composite material based on the multiphysics coupled finite element software Comsol was established; In the simulation model, multiple simulated copper-clad aluminum busbars with different cross-sectional dimensions and different copper layer ratios are established; In the simulation model, multiple physical field parameters and environmental parameters of simulated copper-clad aluminum busbars are set and simulation operations are performed to generate the current carrying capacity of different simulated copper-clad aluminum busbars under different temperature rises, and the data are stored in the database of the simulation model. Obtain the target current carrying capacity and target temperature rise input by the user, and match all candidate copper-clad aluminum busbars that meet the current carrying capacity requirements in the database; Based on the real-time price data of pure copper and pure aluminum materials, the manufacturing cost of each candidate copper-clad aluminum busbar is calculated, and the specification data of the candidate copper-clad aluminum busbar with the lowest cost is used as the simulation output result. The specifications include cross-sectional dimensions, copper layer ratio, temperature rise, current carrying capacity, and manufacturing cost.
2. The simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials according to claim 1, characterized in that, The simulation model also includes material parameter settings, and the material parameter table includes annealed copper and annealed pure aluminum.
3. The simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials according to claim 1, characterized in that, In the step of setting multiple physical field parameters for simulated copper-clad aluminum busbars in the simulation model, the physical field setting adopts a multi-physics coupling mode of electromagnetic field and temperature field. In the electromagnetic field, the electromagnetic module is used to generate Joule heating after current is passed into the simulated copper-clad aluminum busbar, and the heat conduction module in the temperature field is used to simulate the temperature rise of the simulated copper-clad aluminum busbar under the action of Joule heating, and to dissipate heat through natural convection and thermal radiation.
4. The simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials according to claim 1, characterized in that, In the step of setting multiple environmental parameters for simulated copper-clad aluminum busbars in the simulation model, the environmental parameter settings include setting reference temperature data and the natural convection heat transfer coefficient and surface emissivity data of the geometric structure model surface, and refining the mesh at the copper-aluminum interface and surface area of the geometric structure model.
5. The simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials according to claim 1, characterized in that, The specific steps for calculating the manufacturing cost of each candidate copper-clad aluminum busbar based on real-time acquired price data for pure copper and pure aluminum materials include: The volume values of copper and aluminum in each candidate copper-clad aluminum busbar are calculated based on the copper layer ratio of each matched candidate copper-clad aluminum busbar. The mass of copper and aluminum is obtained based on the volume value and density, and the manufacturing cost of each candidate copper-clad aluminum busbar is calculated based on the real-time price data of pure copper and pure aluminum materials.
6. The simulation method for optimizing the size and cost of copper-clad aluminum busbar composite materials according to claim 1, characterized in that, The step of matching all candidate copper-clad aluminum busbars that meet the current carrying capacity requirements in the database specifically includes matching simulated copper-clad aluminum busbars in the database that meet the target temperature rise conditions and whose current carrying capacity is between the target current carrying capacity and 1.1 times the target current carrying capacity as candidate copper-clad aluminum busbars.
7. A simulation system for optimizing the size and cost of copper-clad aluminum busbar composite materials, characterized in that, include: The first building module is used to establish a simulation model of copper-clad aluminum busbar composite material based on the multiphysics coupling finite element software Comsol. The second construction module is used to establish multiple simulated copper-clad aluminum busbars based on different cross-sectional dimensions and different copper layer ratios in the simulation model. The current carrying capacity generation module is used to set the physical field parameters and environmental parameters of multiple simulated copper-clad aluminum busbars in the simulation model and perform simulation operations to generate the current carrying capacity of different simulated copper-clad aluminum busbars under different temperature rises and store them in the database of the simulation model. The user interaction module is used to obtain the target current carrying capacity and target temperature rise input by the user, and to match all candidate copper-clad aluminum busbars that meet the current carrying capacity requirements in the database. The results output module is used to calculate the manufacturing cost of each candidate copper-clad aluminum busbar based on the real-time acquired price data of pure copper and pure aluminum materials, and to use the specification data corresponding to the candidate copper-clad aluminum busbar with the lowest cost as the simulation output result. The specification data includes cross-sectional dimensions, copper layer ratio, temperature rise, current carrying capacity, and manufacturing cost.