A New Method for Measuring Contact Resistance

Min LIU Beijing Orient Institute of Measurement & Test Chinese Academy of Space Technology PO Box 8722 Beijing CHINA Post Code 100080, Email: [email protected]

ABSTRACT The contact resistance was often applied in quality testing of switches, relays and PCB pads and testing of the shield assembly for EMC. The method of measuring contact resistance has been summed up in this article, and the factors that induce measurement uncertainty have been discussed. A new method of indirect measuring contact resistance has been put forward in this article creatively, and the indirect calculation formula has been given out. This method can be used in measuring contact resistance that includes in loop circuit. This method can also been applied to calibration loop resistor standard. KEY WORDS contact resistance, measurement, loop resistance

1. Introduction
Contact resistance measurement and his application domain are fairly extensive. At the electric, the connection of circuit have various ways and means, such as connected by welding, by pressing, by plug in and blot tightly and so on. If you want to know the quality of a connector and its conduction characteristic, you just need to measure its contact resistance. The contact resistance was often applied in quality testing of switches, relays and PCB pads. At the aspect of the machinery assembly, the contact resistance of metals contact surface can be used in estimating the reliability and tightness of the machinery assembly. The contact resistance is associated with the conduction characteristic of contact surface. The larger area and the less impurity of the pair metals surface is, the better conductivity and the lower resistance are, and vice versa. By the ways of measuring contact resistance we can qualitatively analyze the reliability and tightness of the machinery assembly. This technique has been already applied in quality test of the shield assembly for EMC. Measurement methods for different application are not the same. For example, in the case of measuring contact resistance of high-power switches and relays, high current should be used, (approximately 100A)[1]. The high current can melt the oxide film and dust between pairs of contact, things just like the condition what is actually happening in working status. In the case of a dry circuit connector, the test current should be low to prevent the joint to be melted by heat, (the current less than 100mA)[2]. In the case of testing the machinery assembly quality, the different test circuits should be selected according to the different structures. There are two kinds of structure, the loop structure is close, and the non-loop structure is open. Their measurement methods are different completely. How to measure the resistance which includes in a loop circuit, but no changing the circuit? A new method will solve it. This method is very useful for measuring contact resistance in complicated machinery assembles. The contact resistance is defined as the ratio the voltage across the contact to the current flowed through a closed pair of contacts. [2][3] It accorded with Ohms law. In Fig.1, there is an interface between the metal 1 an metal 2. The current, I, which coming from the current source flows through this interface, can be read from a current meter. And then the voltage drop across the interface can be read from a voltage meter as, U. Then the contact resistance value, RX, can be calculated by (1).

RX =
V

U I
V - U + I R2 A

(1)

I metal 1 interface metal 2 R1 A RX

current source

current source

Fig.1.The definition of contact resistance (RX)

2. The measurement uncertainty

There are 4 kinds of reason to induces the measurement uncertainty: 1) The definition of contact resistance is not perfect. The voltage drop across the contact includes the voltage drop of the bulk, inevitably. So the voltage-measuring terminals should be connected as closely as possible to the contact area under test. This will help to prevent the voltage drop, which is caused by the test leads and bulk resistance, from being added into the measurement. 2) 3) 4) The oxide film and dust between pairs of contact have been changing with heat. The conductivity of contact has The stress on the contact could influence the area of contact, then influence the value of contact resistance. The Some measurement uncertainties of contact resistance have been also caused by measurement instrument. been changing with the temperature uncertainly. stress changed with temperature, air pressure humidity and time along.

3. Eliminating thermal EMFs

Each test connection point can cause thermally induced electromagnetic fields (EMF) that need to be eliminated so that the measurements will be accurate. There are three means that can be used to compensate for thermal voltages. 1) 2) To use an AC current source and AC voltage and AC current meters, as show in Fig.1. Although the result of U/I Set the DC source current direction to be in forward and reverse. The contact resistance value, RX, can be expresses its impedance, at low frequency, it will be near the actual value of contact resistance. calculated by (2). [3]

RX =
3)

U forward + U reverse 2I

(2)

To make one voltage measurement with the source current off, make a second measurement with the source

current on, and then subtract the first measurement from the second. The contact resistance value, RX, can be calculated by (3). [3][4]
RX = U1 U 0 I

(3)

4. The methods for measuring contact resistance

The Four-terminal is typical normal measurement technique, which is always applied in measuring low-lever resistance and contact resistance to prevent the lead resistance from being added into the measurement. [1][2][3][4]

1) The direct method for non-loop circuit and structure The non-loop structure means there are no others contact point but the place under measuring. The circuit is open. DMM or micro-Ohm meter can read out the contact resistance value directly, as show in Fig.2.
The contact under measuring Metal 1 Metal 2 Metal 1 Test probe Metal 2

IH

PH

PL

IL
a

lead b

IH

PH

PL

IL

Micro-Ohm meter

Micro-Ohm meter

Fig. 2. Direct measure with resistance meter contact resistance 1 2

1 R12 R31 R23

1 R1 R3 R2

3 (a)

3
(b) Fig.3. The indirect method for measuring contact resistance

(c)

2) The indirect method for loop circuit and structure The simple loop structures are show in Fig.3(a). We can choose three points on the loop structure, the point 1 and 2 are close to the contact, point 3 is at discretion. The resistance R12 across point 1 and 2 is just the contact resistance. The measurement procedure has three steps. a. Measure the resistance R12 at the point 1 and 2, the value recorded as A; b. Measure the resistance R23 at the point 2 and 3, the value recorded as B; c. Measure the resistance R31 at the point 3 and 1, the value recorded as C. The equivalent circuit is show in Fig. 3(b). According to series-parallel circuit, the values A, B, C can be expressed as the coupled equations (4)
R12 ( R31 + R23 ) =A R12 + ( R31 + R23 ) R23 ( R12 + R31 ) =B R23 + ( R12 + R31 )
R31 ( R23 + R12 ) =C R31 + ( R23 + R12 )

(4)

The solutions of the coupled equations expressed as the coupled equations

(4) are the final result. The transformation of Y-

resistance networks will

help us to solve the problems. The transformation circuit is show in Fig.3(c). And the transformation formulas are (5). [5]

R12 = R1 + R2 + R23 = R2 + R3 + R31 = R3 + R1 +

R1 R2 R3 R2 R3 R1 R3 R1 R2

(5)

According to the Y-form resistance network, in Fig.3(c), the values should be measured as A=R1+R2; B=R2+R3; C=R3+R1 .The expressions of R1,R2, R3:
R1 = A+ B +C B 2 A+ B +C R2 = C 2 A+ B +C R3 = A 2

(6)

Combine the (6) into (5), we can get the final result as (7):
R12 = A + 1 A2 ( B C ) 2 2 A+ B+C 1 B 2 (C A) 2 R23 = B + A B+C 2 1 C 2 ( A B) 2 R31 = C + A+ B C 2

(7)

If there is too much difference of the values between A, B and C, the errors caused by instrument resolution and calculation precision would badly affect the result, so much as the result value would be negative.

5. Conclusion
Because the contact resistance changes with environment and the current pass through, the condition for measurement should be close as the condition in use. The four-terminal measurement technique and eliminating thermally EMFs technique must be used in accurate measurement. This indirect measurement method can be applied in measuring contact resistance or loop resistance. It needs three test points, three steps and three formulas. This method had been approved correct, and can also be used in calibrating the loop- resistor standard.

References
[1] STANDARD of Electric Power Industry of China DL/T596-1996 power facility. [2] China National STANDARD electrical contact materials [3] Mary Anne Tupta, Hone your contact-resistance measurements, Quality Magazine October 1995. (www.qualitymag.com). [4] EIA STANDARD TP-06B, Contact Resistance Test Procedure for Electrical Connector, EIA-364-06B MAY 2000. [5] Kongzhang Zhou, Circuit Theory (volume 1), p85, The China education book concern. 1983.10 GB/T15248-1994 Measuring method for contact resistance of precious metal The preventability test procedure for electric