Study of the Optimal Design of a DC Contactor with an Electromagnetic-Thermal Coupling Analysis Workflow

The demand for protection devices for Direct Current(DC) in major systems applied to LVDC (Low Voltage Direct Current) and electric vehicles systems. To ensure these systems for electrical conducting function(I
th
), it is necessary to fulfill the IEC (International Electro-technical Commission) standard level (△ K: less than 65°C). To explore various design conditions and meet these thermal design criteria, it is essential to deal with an electromagnetic-thermal analysis workflow including contact electromagnetic(EM) loss in natural convection environment. In this paper, the error of analysis and test measurement data were secured at a level of 4-10% by using electromagnetic(EM)-thermal coupling workflow. Using this multiphysics solution technique, we were able to explore the optimal design points through Taguchi techniques.