Robust design of dynamic characteristics consistency of Busbar-Mounted Electromagnetic Contactor based on a fast calculation surrogate model

The dynamic characteristics of Busbar-Mounted Electromagnetic Contactor (BMEC) directly impact the reliability of system. In design process of BMEC, single product can be designed based on digital prototype methods cored with finite element model (FEM), but for batches of products, the dispersion of some parameters makes the dynamic characteristics out of design tolerance. The consistency of batch products is hard to control in some cases. This paper presents a Taguchi method based robust design method to improve the consistency of batch products using a type of fast calculation surrogate model. The dynamic characteristics of batch products is calculated by establishing a fast calculation surrogate model based on digital prototype data. Then, parameter design and tolerance design are accomplished for the parameters that have a great impact on the static and dynamic characteristics of products through sensitivity analysis and Signal-to-Noise ratio analysis. The effective control of the dynamic characteristics of batch products is implemented and the manufacturing robustness of BMEC is enhanced.