Vibration Analysis and Electrical Contact Resistance Assessment for Automotive Relays

Automotive relays are used in vehicles, subject to various mechanical vibration levels during regular operation. Vibration analysis helps ensure that the relay can withstand these vibrations without malfunctioning. It is essential for the relay's durability and long-term dependability. In this work, vibration analysis is carried out for the relay using an electrodynamic shaker, and the electrical contact resistance (ECR) is obtained. Relays used in vehicles undergo vibration because of the environmental and on-road conditions. Hence, vibration analysis is mandatory for automotive relays. ECR is obtained under DC and AC static environments with a frequency of 10 Hz to 70 Hz. Vibration analysis is carried out using an electrodynamic shaker experimental setup. Finite Element Analysis (FEA) using COMSOL Multiphysics is carried out to obtain the electrical and mechanical parameters of relay electrical contact. The highest current density occurs at the contact surface edges that have been visualized. Vibration analysis examines the dynamic behavior of electrical contacts in relays. This study also delves into prescribed displacement, Von Mises stress, and total displacement performance under dynamic conditions.