Case Study: ABB improves generator circuit breaker reliability with COMSOL multiphysics simulation

ABB boosts generator circuit breaker testing with Comsol, validating peak currents in excess of 500 kA

ABB, a global leader in power grid technology, faced the challenge of continuously improving the safety and reliability of their generator circuit breakers. A critical component, the earthing switch, needed to withstand extreme short-circuit currents without failure. To achieve this, ABB engineers used COMSOL Multiphysics® software to model and analyze the complex electromechanical forces within their tulip contact design.

Using simulation from Comsol, the team efficiently analyzed the electromagnetic forces to ensure their design generated a dominant attractive force, preventing contact separation and enabling high current-carrying capacity. This validated model helped ABB pass rigorous certification tests, including the KEMA power test for peak currents over 500 kA, with room to spare. The solution confirmed the design's reliability for a 30-year lifespan and demonstrated how Comsol simulation harmonizes with physical testing for robust product development.

ABB