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Simulationsbasierte Lebensdauervorhersage für flexible Kupferleitungen

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Description

Moderne Fahrzeuge sind voller flexibler Leitungen, welche konfliktfrei verlegt werden müssen. Neben rein geometrischen Fragestellungen (Analyse des nötigen Bauraums, kritische Biegeradien etc.) sind auch Untersuchungen der auftretenden Lasten und der zugehörigen Schädigung wichtig. Insbesondere für neue Leitungsverlegungen bzw. neue Leitungstypen im Zuge der Elektromnobilität sind - aufgrund weniger oder schlicht fehlender Erfahrungswerte - solche Aussagen in frühen Entwicklungspasen sehr wertvoll.
Zur effizienten Simulation der flexiblen Leitung wird ein geometrisch nichtlineares Stabmodell gewählt. Die resultierenden Kräfte und Momente entlang der Leitung werden anschließend auf Pseudo-Oberflächenspannungen abgebildet und per Rainflow-Zählung die Lastwechsel identifiziert. Für die abschließende Schädigungsrechnung werden Wöhlerparameter benötigt, welche für flexible Kupferleitungen, bestehend aus vielen einzelnen Kupferdrähten, Isolationsmaterial sowie ggf. Schirmungen, in der Regel nicht zur Verfügung stehen.
Mittels generischer Wählerparameter sind dennoch vergleichende Lastdatenanalysen möglich, basierend auf Pseudo-Schädigungswerten. Um jedoch auch absolute Lebensdauervorhersagen zu ermöglichen, wird ein Konzept zur Ermittlung von Leitungs-Wöhlerlinien vorgestellt. Dabei ist es essentiell, dass die ermittelte Wöhlerlinie unabhängig von der Leitungsverlegung ist. Hierzu werden verschiedene Leitungsverlegungen in Lebensdauertests bis zum definierten Ausfall geprüft, die zugehörigen lokalen Lasten aus der entsprechende Simulation gewonnen und per Maximum-Likelihood-Methode die Wöhlerparameter der Leitung bestimmt. Eine Validierung demonstriert die erfolgreiche Anwendung der Methodik: die Lebensdauervorhersage für zuvor nicht geprüfte Leitungsverlegungen.

Reference: Cu-2025-568

Title: Simulationsbasierte Lebensdauervorhersage für flexible Kupferleitungen
Author(s): F. Schneider-Jung, K. Dreßler, M. Speckert
DOI: 10.48447/Cu-2025-568
Event: Auslegung von Bauteilen aus Kupfer und Kupferlegierungen - Tagung 2025
Year of publication: 2025
Publication type: conference paper (PDF)
Language: German
Keywords: Effiziente Kabelsimulation,Lastdatenanalyse für Kabel,Kabel-Wöhlerlinie

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Author(s): R. Rennert, M. Hupka, M. Wächter, C. Müller, A. Esderts

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Statischer Festigkeitsnachweis für Bauteile aus Kupferwerkstoffen

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Experimentelle und numerische Untersuchungen zur Schwingfestigkeit von laserstrahlgeschweißten Kupferflachleitern

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€25.00

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Grundlegende Eigenschaften geschweißter hochreiner Kupferverbindungen

Publication type: conference paper (PDF)

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Bruchmechanisches Verhalten einer Kupferlegierung

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€25.00

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Editor(s): A. Esderts, R. Rennert

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€25.00

Online only New

Author(s): M. Weber, L. Morand, A. Butz, D. Helm, K. Pfeffer, F. Bauer, U. Klotz, M. Eisenbart

Effiziente Charakterisierung und Modellierung von Kupferwerkstoffen auf Basis von Maschinellem Lernen und Finite-Element-Simulationen

Publication type: conference paper (PDF)

German

€25.00

Online only New

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€25.00

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€25.00

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Author(s): R. Rennert, M. Wächter, A. Esderts

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1

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€25.00

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Author(s): P. Thumann, P. Schmauser

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1

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€25.00

Online only New

Author(s): R. Wagener

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1

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€25.00

Online only New