Study On The Mechanical And Temperature Rise Properties Of Axial Canted Coil Spring In Bypass Switch

With the development of the application of lithium-ion battery packs in spacecraft such as satellites and space stations,the bypass switch has been widely used as a new type of switching device.The axial canted coil spring is the most important part of the bypass switch.Because the contact part of the bypass switch is connected in series in the main road of the spacecraft,if the canted coil spring is unreliable during the operation of the spacecraft,a single point failure of the bypass switch will be formed,which will cause the entire spacecraft to be powered off,resulting in the spacecraft not working properly.Therefore,it is of great significance to study the properties of the axial canted coil spring,and then to ensure the reliability of the bypass switch.This article takes the axial canted coil spring in the 1KP100-1 power bypass switch as the study object,and study the static properties and insertion force properties of axial canted coil springs from the aspects of theory,simulation and experiment.On this basis,the key parameters such as the chute width of the axial canted coil spr:ing are optimized.The temperature rise finite element thermal analysis simulation and experimental test of the contact part of the bypass switch are performed,and it is verified that the axial canted coil spring after optimizing the key parameters such as the width of the spring chute is feasible and effective for improving the reliability of the bypass switch.These provide a reference for the design and development of the axial canted coil spring in the subsequent bypass switch.The main study contents and work of this article are as follows:(1)Modeling of axial canted coil spring mathematical model.Based on the linear normal positive coil spring mathematical model,first deduce the space curve equations of linear canted coil spring and circular normal positive coil spring,then derive the space curve equation of axial canted coil spring.(2)Analysis of the static properties of axial canted coil springs.Discuss the stress distribution of axial canted coil spring of 1KP100-1 power bypass switch.Based on the established mathematical model of the axial canted coil spring,the industrial modeling software UG and the finite element simulation software Ansys Workbench were used to establish the physical model and the finite element model of the axial canted coil spring to simulate the deformation of the axial canted coil spring,in the process,the stress distribution cloud diagram of the first half and the second half of the single coil spring of the axial canted coil spring and the nonlinear simulation relationship curve of the displacement load and the acting force of the axial canted coil spring is obtained.And compared with the relationship curve and mechanical properties of the displacement load of the circular normal positive coil spring,it is concluded that the axial canted coil spring with stable static properties is conducive to the safe and reliable operation of the bypass switch.(3)Study on the insertion force properties of axial canted coil springs.According to the action properties of the contact part of the 1KP100-1 power type bypass switch,the finite element simulation model of the insertion force of the axial canted coil spring under study is established and simplified.Using Ansys Workbench to simulate the contact process of the terminal and the axial canted coil spring,the insertion force of the axial canted coil spring,the contact positive pressure,the equi-alent stress cloud,the maximum stress,the change of displacement load with time,and the relationship between insertion force and contact positive pressure with displacement load are obtained.Moreover,exploring the influence of the chute width of the different axial canted coil spring on the spring insertion force,then the plug-in and pull-out experiment of the axial canted coil spring is carried out.Finally,combining with the finite element simulation and experimental results,it is concluded that the optimized chute width parameter of the axial canted coil spring can strengthen the matching degree of the spring chute groove and the axial canted coil spring,increase the contact reliability of the axial canted coil spring,and improve the safety and reliability of the bypass switch.(4)Temperature rise test of the contact part of the bypass switch.Based on the thermal analysis theory of the contact part of the bypass switch,the finite element thermal analysis simulation software is used to simulate the steady-state temperature rise of the contact part of the 1KP100-1 power type bypass switch after the optimized chute width.The temperature rise result of the contact part of the 1KP100-1 power type bypass switch and the temperature distribution cloud diagram of each part are obtained.Then through the temperature rise experiment of the bypass switch contact part,the temperature rise curve of the 1KP100-1 power type bypass switch contact part is obtained.Combined with the analysis of temperature rise simulation results and experimental results,it is concluded that the temperature rise of the optimized 1KP100-1 power bypass switch contact part conforms to the specified temperature rise technical requirements.