At the end of a development phase, the physical laboratory tests of a terminal block follow. If, in the course of these tests, required values are not achieved or even exceeded, a further development loop will have to be performed in order to optimize the product. Consequently, the sometimes time-consuming tests have to be repeated in the laboratory.
In order to reduce development times and speed up the time to market, the Weidmüller laboratory simulates some of these tests using complex simulation software. These are confirmed and documented at the end of the development phase by the physical and normative required laboratory tests.
An electric current flow always involves heating of the current-carrying component. In this case, there are normative requirements regarding the permissible temperatures of electronic and electromechanical components and the method for measuring them. These sometimes result in long test durations as well as complex test setups and preparations and additional pre-testing. In our laboratory, the implementation of the requirements takes place in two basic steps.
Simulation of physical processes that can be described using differential equations.
Finite Element Method -> Representation of real geometry using simple geometric shapes.
Multiphysical couplings -> simultaneous calculation of mutually influencing physical effects resulting from different mechanisms possible
For a sufficiently accurate simulation, various influencing factors and definitions are required within the software. As a basis, the digital twin is loaded into the software in the form of a CAD model. Here, component-related objects such as variables, functions or "examination probes" can be defined subsequently. The next step is the assignment of materials and their specific properties. What type of conductor is used, what plastics and what mechanical and electrical properties they have. Following the definition of the materials, the physical laws are defined and assigned.
