COMSOL 6.4 - Busbar Assembly Geometry

Create the geometry of the angle connector as the intersection of two solid objects: the extrusion of the side view and the extrusion of the top view. Start with drawing and extruding the side view.


Name	Expression	Value	Description
a_c_h_part	6[mm]	6 mm	Angle connector height
e_c_h_part	10[mm]	10 mm	Elbow connector height
c_g_w_part	400[mm]	400 mm	Cell Grid Top width
b_di_part	20[mm]	20 mm	Bolt to boundary distance
b_r_part	6[mm]	6 mm	Bolt radius

Work Plane 1 (wp1)

In the toolbar, click

In the window for , locate the section.

From the list, choose .

Since the work plane is only needed for geometry creation it does not need to be displayed in the part instances.

Locate the section. Clear the checkbox.

Leave the Sketch mode and create the geometry by entering the polygon coordinates.

Work Plane 1 (wp1) > Plane Geometry

at the top of the window.

In the toolbar, click

to toggle the Sketch visualization off.

Work Plane 1 (wp1) > Polygon 1 (pol1)

In the toolbar, click

In the window for , locate the section.


xw (mm)	yw (mm)
0	0
0	60[mm]
e_c_h_part	90[mm]
e_c_h_part	c_g_w_part/2+b_di_part*2
e_c_h_part+a_c_h_part	c_g_w_part/2+b_di_part*2
e_c_h_part+a_c_h_part	90[mm]
a_c_h_part	60[mm]
a_c_h_part	0

Work Plane 1 (wp1) > Plane Geometry

Add to some of the corners. First, zoom in to the region of the bend on the cross section.

Work Plane 1 (wp1) > Fillet 1 (fil1)

In the toolbar, click

On the object , select Points 2 and 7 only.

In the window for , locate the section.

In the text field, type 20[mm].

Work Plane 1 (wp1) > Fillet 2 (fil2)

In the toolbar, click

On the object , select Points 5 and 6 only.

In the window for , locate the section.

In the text field, type 20[mm]-a_c_h_part.

You can use both input and local parameters directly in the feature.

Extrude 1 (ext1)

In the window, under > > right-click and choose .

Select the first row in the table.

Click below the section.

Expand the section and select .

In the window for , click

The solid object extruded from the side view is now ready. Continue by drawing and extruding the top view of the angular connector.

button in the toolbar.

Work Plane 2 (wp2)

In the toolbar, click

In the window for , locate the section.

Clear the checkbox.

Work Plane 2 (wp2) > Plane Geometry

In the window, click .

In the toolbar, click .

Draw a rectangle somewhere on the canvas and then adjust its size and position.

Work Plane 2 (wp2) > Rectangle 1 (r1)

In the window, click .

In the window for , locate the section.

In the text field, type c_g_w_part/2+b_di_part*2.

In the text field, type a_c_w_part.

Locate the section. In the text field, type 0.

In the text field, type 0.

Fillet all corners of the rectangle.

button in the toolbar.

Work Plane 2 (wp2) > Plane Geometry

In the toolbar, click

Adjust the fillet radius.

button in the toolbar.

In the window, click .

Select one vertex of and drag it inward to create the fillets.

Work Plane 2 (wp2) > Fillet 1 (fil1)

In the window, click .

In the window for , locate the section.

In the text field, type 5[mm].

Work Plane 2 (wp2) > Circle 1 (c1)

Add the next feature from the toolbar. This allows you to enter the parameters for size and shape directly in the feature.

In the toolbar, click

In the window for , locate the section.

In the text field, type b_r_part.

Locate the section. In the text field, type b_di_part.

In the text field, type a_c_w_part/4.

Work Plane 2 (wp2) > Array 1 (arr1)

In the toolbar, click

and choose .

Select the object only.

In the window for , locate the section.

In the text field, type 2.

Locate the section. In the text field, type c_g_w_part/2.

In the text field, type a_c_w_part/2.

Work Plane 2 (wp2) > Difference 1 (dif1)

In the toolbar, click

and choose .

Select the object as .

Activate the section, and select the objects , which are the four circles.

In the window for , click

Extrude 2 (ext2)

In the window, under > > right-click and choose .

In the table, enter 2*.

Press Ctrl + Space to open the menu.

Expand the section and select

In the window for , click

Intersection 1 (int1)

In the toolbar, click

and choose .

button in the toolbar.

In the window for , locate the section.

Select the checkbox, to make sure that this selection will be accessible from an instance of the geometry part when inserted into a geometry sequence.

Continue with creating two work planes for the positioning of this connector part. The work planes will be available in the part instances, and we will use them later on when inserting the part into a geometry sequence.

The edit field is already activated. Click on the edge located at the front left hole to place the Work Plane.

button in the toolbar, for a better view of the edges without rotating the geometry.

Elbow Connector Position

In the toolbar, click

In the window for , type Elbow Connector Position in the text field.

Locate the section. From the list, choose .

On the object , select Edge 74 only. This is one of the lower edges of the front right hole.

Click to expand the section. In the text field, type b_r_part.

Click somewhere in the window to update the local coordinate system.

Bolt Position

Right-click and choose .

In the window for , type Bolt Position in the text field.

On the object , select Edge 26 only.

The geometry part for the angle connector is now ready. Continue with adding one more geometry part where you will insert several of the already created parts to create a subassembly.

button in the toolbar.

Geometry Parts

In the toolbar, click

In the window for , type Anode Top Assembly in the text field.

Locate the section. In the table, enter the following settings:


Name	Default expression	Value	Description
a_c_w_asm	90[mm]	0.09 m	Angle connector width
r_d_asm	20[mm]	0.02 m	Rod diameter

Locate the section. From the list, choose .

Local Parameters

In the window, expand the node, then click .

In the window for , locate the section.


Name	Expression	Value	Description
c_g_w_asm	400[mm]	400 mm	Cell Grid Top width
r_c_h_asm	6[mm]	6 mm	Rod Connector height

The individual geometry parts contain different selections, open the window for a quick access to these selections as we work with the geometry part.

Selection List

In the toolbar, click

to open the window.

Spine 1 (pi1)

In the toolbar, click

and choose .

In the window for , click to expand the section.

Cumulative selections are useful when the output of several geometry operations is contributing to the same selection. Here the cumulative selections will collect the domains with similar material assignments.

In the dialog, type Titanium in the text field.

As soon as a new selection is added and the corresponding entity level is selected, it is displayed in the lower part of the window.

Select from the list to add the part to this selection.

In the window for , click

Central Column 1 (pi2)

In the toolbar, click

and choose .

Link the input parameter of this part instance of Central Column 1 with a parameter of the part Anode Top Assembly.

In the window for , locate the section.


Name	Expression	Value	Description
r_d_part	r_d_asm	20 mm	Rod diameter

Locate the section. In the table, enter the following settings:


Name	Keep	Instances	Contribute to
Revolve 1		√	Titanium

To position the part for the central column at the center of the spine, use a coordinate system already defined by the appropriate work plane in the geometry part for the spine.

to make it easier to identify the output of the geometry features.

Spine

Central Column Position (wp2)

In the window, expand the > > node, then click .

Returning to the geometry sequence of the Anode Top Assembly, use this work plane to position the part for the central column.

Central Column 1 (pi2)

In the window, under > > click .

In the window for , locate the section.

Find the subsection. From the list, choose .

From the list, choose .

Rod 1 (pi3)

In the toolbar, click

and choose .

In the window for , locate the section.


Name	Expression	Value	Description
r_d_part	r_d_asm	20 mm	Rod diameter

Locate the section. Find the subsection. From the list, choose .

From the list, choose .

Locate the section. Click .

In the dialog, type Copper in the text field.

In the window for , locate the section.


Name	Keep	Instances	Contribute to
Cylinder 1		√	Copper

Rod Connector 1 (pi4)

In the toolbar, click

and choose .

In the window for , locate the section.


Name	Expression	Value	Description
a_c_w_part	a_c_w_asm	90 mm	Angle connector width
r_d_part	r_d_asm	20 mm	Rod diameter
r_c_h_part	r_c_h_asm	6 mm	Rod connector height

Locate the section. Find the subsection. From the list, choose .

From the list, choose .

Locate the section. In the table, enter the following settings:


Name	Keep	Instances	Contribute to
Extrude 1		√	Copper

button in the toolbar.

Copy 1 (copy1)

To obtain another copy of the already inserted geometry parts we can use the operation.

In the toolbar, click

and choose .

button in the toolbar.

In the window for , locate the section.

In the text field, type c_g_w_asm/2.

button in the toolbar.

Elbow Connector 1 (pi5)

In the toolbar, click

and choose .

In the window for , locate the section.


Name	Expression	Value	Description
a_c_w_part	a_c_w_asm	90 mm	Angle connector width

Locate the section. Find the subsection. From the list, choose .

Find the subsection. From the list, choose .

From the list, choose .

Find the subsection. In the text field, type 90[deg].

Locate the section. In the table, enter the following settings:


Name	Keep	Instances	Contribute to
Union 1		√	Copper

The selection we are interested in is defined on the point level in the Elbow Connector.

Locate the section. Select the checkbox, to make selections from this part available in instances of the Anode Top Assembly part.

In the window toolbar, click

next to

, then choose . You can now see the named selection listed in the lower part of the window.

Zoom to the highlighted vertices.

button in the toolbar for a better view of this selection.

Selection List

Go to the window.

In the tree, select .

Reset the view rendering by activating and deactivating .

Angle Connector 1 (pi6)

In the toolbar, click

and choose .

In the window for , locate the section.


Name	Expression	Value	Description
a_c_w_part	a_c_w_asm	90 mm	Angle connector width

Locate the section. Find the subsection. From the list, choose .

Find the subsection. From the list, choose .

From the list, choose .

Locate the section. In the table, enter the following settings:


Name	Keep	Instances	Contribute to
Intersection 1		√	Copper

Bolt Small

In the toolbar, click

and choose .

In the window for , type Bolt Small in the text field.

Locate the section. Find the subsection. From the list, choose .

From the list, choose .

Find the subsection. In the text field, type -r_c_h_asm.

Locate the section. In the table, enter the following settings:


Name	Keep	Instances	Contribute to
Cylinder 1		√	Titanium

Use the mouse to get a better view of the inserted part.

Bolt Large

In the toolbar, click

and choose .

In the window for , type Bolt Large in the text field.

Locate the section. In the table, enter the following settings:


Name	Expression	Value	Description
size	2	2	Size selection 0 = small, 1 = medium, 2 = large

Locate the section. Find the subsection. From the list, choose .

From the list, choose .

Find the subsection. In the text field, type -r_c_h_asm.

Locate the section. In the table, enter the following settings:


Name	Keep	Instances	Contribute to
Cylinder 1		√	Titanium

Mirror 1 (mir1)

In the toolbar, click

and choose .

Select the objects and only.

In the window for , locate the section.

Select the checkbox.

Locate the section. In the text field, type 190[mm], which is half of the length of the spine.

Locate the section. In the text field, type 1.

In the text field, type 0.

Next, add a work plane that will help position this part.

Intercell Busbar Position

button in the toolbar.

In the toolbar, click

In the window for , type Intercell Busbar Position in the text field.

Locate the section. From the list, choose .

From the list, choose .

Finally, set up a selection that includes all objects in this geometry part. It will come in handy when building the busbar geometry.

Box Selection 1 (boxsel1)

In the toolbar, click

and choose .

In the window for , locate the section.

From the list, choose .

All geometry parts are now ready. Next, add the global parameters for controlling the busbar dimensions. Then, add a 3D model component where you can build the busbar geometry.

button in the toolbar.

Global Definitions

Parameters 1

In the window, under click .

In the window for , locate the section.

In the following we will set up separate selections to collect the titanium and copper parts.


Name	Expression	Value	Description
a_c_w	90[mm]	0.09 m	Angle connector width
r_d	20[mm]	0.02 m	Rod diameter

Add Component

In the toolbar, click

and choose .

Geometry 1

In the window for , locate the section.

From the list, choose .

Cell Grid Top 1 (pi1)

In the toolbar, click

and choose .

In the window for , click to expand the section.

In the dialog, type Titanium in the text field.

In the window for , locate the section.

Click again to define a selection for the copper parts.

In the dialog, type Copper in the text field.

In the window for , locate the section.


Name	Keep	Physics	Contribute to
Block 1		√	Titanium

Click to expand the section. In the table, enter the following settings:


Name	Keep	Physics	Contribute to
Electrolyte Boundary	√	√	None

Anode Top Assembly 1 (pi2)

In the toolbar, click

and choose .

In the window for , locate the section.


Name	Expression	Value	Description
a_c_w_asm	a_c_w	90 mm	Angle connector width
r_d_asm	r_d	20 mm	Rod diameter

Locate the section. Find the subsection. From the list, choose .

From the list, choose .

Click to expand the section. In the table, enter the following settings:


Name	Keep	Contribute to
Box Selection 1	√	None

Locate the section. In the table, enter the following settings:


Name	Keep	Physics	Contribute to
Titanium		√	Titanium
Copper		√	Copper

Click to expand the section. In the table, enter the following settings:


Name	Keep	Physics	Contribute to
Bolt Medium Position (Elbow Connector 1)	√		None

In the window toolbar, click

next to

, then choose , to highlight the objects.

Move 1 (mov1)

In the toolbar, click

and choose .

In the window for , locate the section.

From the list, choose .

Locate the section. In the text field, type 0 -400[mm]. By using a displacement vector, the input objects are moved to each of the positions specified by the vector.