Mechanical Insertion Force and Electrical Contact Resistance of By-Pass Switches with Axially Canted Coil Springs

By-pass switches play a crucial role in high-power electrical equipment, where reliable mechanical insertion and stable electrical contact are essential for safety and performance. However, few computational models have been developed to characterize the coupled mechanical–electrical behavior of by-pass switches with axially canted coil springs, which limits the understanding of their structural parameter effects. Motivated by this gap, this work investigates the mechanical insertion force and electrical contact resistance of by-pass switches with axially canted coil spring by combining analytical modeling and finite element simulation. The variations in mechanical insertion force, contact force and associated contact resistance as functions of the insertion displacement are presented. The total electrical contact resistance could comprise three components of resistance, that is, constriction resistance between multiple turns of coil spring wires and pin, constriction resistance between multiple turns of coil spring wires and V-shape groove, and the bulk resistance. The effects of structure feature parameters (including turns, spring wire diameter, inclination angle of axially canted coil spring wire, cylindrical pin chamfer radius and V-shape groove angle) are evaluated. Subsequently, the associated empirical formulas are established to guide the design of by-pass switches with axially canted coil springs.