This invention proposes a structural optimization method for high-current connectors based on electro-thermal-mechanical multi-
physics coupling, belonging to the field of
electrical connector design and optimization. The specific implementation steps of this method are as follows: A parametric CAD / CAE model of a 600A high-current connector is established. Geometric meshing, differential
mesh generation, contact pair definition, boundary condition setting, and solution settings are completed using ANSYS APDL.
Insertion and extraction dynamics analysis and electro-
thermal coupling analysis under the
insertion state are conducted separately, and key performance data are extracted. The above
simulation processes are integrated to form two sets of automated
simulation programs for the
insertion and extraction process and the electro-
thermal coupling process under the
insertion state, used for structural design sample
simulation. The optimization objectives and design variables are determined. The design variables are the terminal position, terminal protrusion height, and terminal length of the internal contacts of the 600A high-current connector. 25 sets of samples are generated using an orthogonal experimental method.
Insertion and extraction force and contact area data during the insertion and extraction process, as well as
contact temperature data during the electro-
thermal coupling process, are obtained through automated simulation as optimization objectives. A multi-objective prediction function is constructed through multiple regression, and a
genetic algorithm is used to achieve
global optimization of the multi-objective parameters to obtain the
optimal combination of geometric parameters. This invention effectively solves the problems of
data loss and operational redundancy in traditional
joint simulation of different
software, significantly reduces the convergence difficulty and computation time of multi-
physics coupling calculation, improves the efficiency of model optimization design, and provides a high-fidelity,
fully automated analysis
system and design scheme for the development of high-performance electrical connectors.