Using computer simulation to calculate how a component behaves under certain stresses

In a toothed segment for the automatic star-delta motor protection switch of the company Widap AG, we checked the delay between the Y-Δ changeover using the finite element method. The analysis showed that the delay was caused by the gear with damper and that the closing Δ-contacts have increased burn-off due to a too slow closing speed.

With the FEM, we were able to provide the customer with a solution: Stronger damper, but only over half the travel, This causes the gearbox to unhinge and the closing speed is increased. Of course, the gearbox must re-engage when it is reset. This challenge could be met with a spring-loaded tooth segment.

Project management

• Create requirements according to customer needs

Mechanics

• Search for ideas for delayed Y-Δ switching
• Reasoned selection of favourites with customer
• CAD design
• FEM design of the resilient tooth segment
• Prototype procurement

Test lab

• Validation of the simulation and use cases
• Selection of the appropriate damper with regard to switching time

Production

• Construction of prototypes
• Adaptation of production tools