Analysis of factors influencing contact arc erosion under capacitive inrush currents in high-voltage DC relays
High-voltage DC relays are widely used in electric vehicles. Due to the presence of capacitive elements in the circuit, a large inrush current occurs at the moment of power-on, resulting in arcing between the relay contacts. This process erodes the contact surfaces, adversely affecting the relay’s p...
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| Format: | Article |
| Language: | English |
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AIP Publishing LLC
2025-04-01
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| Series: | AIP Advances |
| Online Access: | http://dx.doi.org/10.1063/5.0255511 |
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| author | Haitao Wang Shuge Li Zhen Lin Wei Li Qinneng Liu Wenli Jiang |
| author_facet | Haitao Wang Shuge Li Zhen Lin Wei Li Qinneng Liu Wenli Jiang |
| author_sort | Haitao Wang |
| collection | DOAJ |
| description | High-voltage DC relays are widely used in electric vehicles. Due to the presence of capacitive elements in the circuit, a large inrush current occurs at the moment of power-on, resulting in arcing between the relay contacts. This process erodes the contact surfaces, adversely affecting the relay’s performance and lifespan. Although improvements such as pre-charged circuits are available, capacitive power-on arc erosion remains common. Therefore, this paper presents a two-dimensional simulation model for high-voltage DC relays, based on magnetohydrodynamics. The model incorporates two arc extinguishing methods: high-voltage arc extinguishing medium and magnetic blowout arc extinction. The simulation model is used to examine the dynamic process of arc erosion and the extent of contact erosion. Subsequently, the study selected eight operating conditions for simulations and experiments, then conducted a correlation analysis between the areas of contact melt pools post-simulation and the areas of contact erosion post-experiment. This confirmed the consistency of trends between the simulation results and experimental outcomes. Based on this, the study analyzes the effects of voltage, current, and capacitance on arc erosion, summarizing the physical processes and principles of arc erosion under different factors, and further examines the mechanisms of these factors from perspectives such as maximum instantaneous power and arc energy. Finally, the results indicate that current has the most significant impact on contact arc erosion. The simulation model has broad applicability and provides practical significance for analyzing arc erosion under capacitive inrush currents in high-voltage DC relays, significantly improving research efficiency. |
| format | Article |
| id | doaj-art-aaef949e00314351b8264eaff2726e08 |
| institution | Kabale University |
| issn | 2158-3226 |
| language | English |
| publishDate | 2025-04-01 |
| publisher | AIP Publishing LLC |
| record_format | Article |
| series | AIP Advances |
| spelling | doaj-art-aaef949e00314351b8264eaff2726e082025-08-20T03:48:42ZengAIP Publishing LLCAIP Advances2158-32262025-04-01154045201045201-1510.1063/5.0255511Analysis of factors influencing contact arc erosion under capacitive inrush currents in high-voltage DC relaysHaitao Wang0Shuge Li1Zhen Lin2Wei Li3Qinneng Liu4Wenli Jiang5State Key Laboratory of Intelligent Power Distribution Equipment and System, Hebei University of Technology, Tianjin, Tianjin 300401, People’s Republic of ChinaState Key Laboratory of Intelligent Power Distribution Equipment and System, Hebei University of Technology, Tianjin, Tianjin 300401, People’s Republic of ChinaContemporary Amperex Technology Co., Limited, Ningde, Fujian 352100, People’s Republic of ChinaContemporary Amperex Technology Co., Limited, Ningde, Fujian 352100, People’s Republic of ChinaContemporary Amperex Technology Co., Limited, Ningde, Fujian 352100, People’s Republic of ChinaContemporary Amperex Technology Co., Limited, Ningde, Fujian 352100, People’s Republic of ChinaHigh-voltage DC relays are widely used in electric vehicles. Due to the presence of capacitive elements in the circuit, a large inrush current occurs at the moment of power-on, resulting in arcing between the relay contacts. This process erodes the contact surfaces, adversely affecting the relay’s performance and lifespan. Although improvements such as pre-charged circuits are available, capacitive power-on arc erosion remains common. Therefore, this paper presents a two-dimensional simulation model for high-voltage DC relays, based on magnetohydrodynamics. The model incorporates two arc extinguishing methods: high-voltage arc extinguishing medium and magnetic blowout arc extinction. The simulation model is used to examine the dynamic process of arc erosion and the extent of contact erosion. Subsequently, the study selected eight operating conditions for simulations and experiments, then conducted a correlation analysis between the areas of contact melt pools post-simulation and the areas of contact erosion post-experiment. This confirmed the consistency of trends between the simulation results and experimental outcomes. Based on this, the study analyzes the effects of voltage, current, and capacitance on arc erosion, summarizing the physical processes and principles of arc erosion under different factors, and further examines the mechanisms of these factors from perspectives such as maximum instantaneous power and arc energy. Finally, the results indicate that current has the most significant impact on contact arc erosion. The simulation model has broad applicability and provides practical significance for analyzing arc erosion under capacitive inrush currents in high-voltage DC relays, significantly improving research efficiency.http://dx.doi.org/10.1063/5.0255511 |
| spellingShingle | Haitao Wang Shuge Li Zhen Lin Wei Li Qinneng Liu Wenli Jiang Analysis of factors influencing contact arc erosion under capacitive inrush currents in high-voltage DC relays AIP Advances |
| title | Analysis of factors influencing contact arc erosion under capacitive inrush currents in high-voltage DC relays |
| title_full | Analysis of factors influencing contact arc erosion under capacitive inrush currents in high-voltage DC relays |
| title_fullStr | Analysis of factors influencing contact arc erosion under capacitive inrush currents in high-voltage DC relays |
| title_full_unstemmed | Analysis of factors influencing contact arc erosion under capacitive inrush currents in high-voltage DC relays |
| title_short | Analysis of factors influencing contact arc erosion under capacitive inrush currents in high-voltage DC relays |
| title_sort | analysis of factors influencing contact arc erosion under capacitive inrush currents in high voltage dc relays |
| url | http://dx.doi.org/10.1063/5.0255511 |
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