电力电缆铝芯线与铜连接管的电磁焊接条件研究  

Research on Electromagnetic Pulse Welding Conditions of Aluminum Core Wire and Copper Connecting Tube of Power Cable

作　　者：路志建 常江 白晓斌 陆豪赫 杨兰均[1] Lu Zhijian;Chang Jiang;Bai Xiaobin;Lu Haohe;Yang Lanjun(State Key Laboratory of Electrical Insulation and Power Equipment,Xi’an Jiaotong University Xi’an 710000 China;State Grid Shaanxi Electric Power Co.Ltd Baoji Power Supply Company,Baoji 721000 China)

机构地区：[1]电力设备电气绝缘国家重点实验室(西安交通大学),西安710000 [2]国网陕西省电力有限公司宝鸡供电公司,宝鸡721000

出　　处：《电工技术学报》2023年第20期5620-5633,共14页Transactions of China Electrotechnical Society

基　　金：陕西省高校联合项目重点项目(2021GXLH-Z-007);国家电网陕西省科技项目(SGSNBJ00FZJS2201765)资助。

摘　　要：目前,电磁焊接技术在电缆接头制作中的可行性和优越性已经得到国内外诸多学者的证实,然而关于电缆接头电磁焊接的焊接条件却鲜有研究。鉴于此,该文通过对70 mm^(2)铝绞线铜中间连接管电磁焊接进行了仿真模拟和实验研究。研究结果表明,集磁器中轴线上磁场大致呈“钟型”分布,工作区位置磁场最大,远离工作区的位置,磁场迅速减小,集磁器工作区径向不同位置,磁场分布较为均匀。对外管的形变过程进行了仿真、测量及理论推导,理论推导所得外管加速阶段速度曲线与仿真以及实测速度波形相近,理论计算碰撞速度与实测值偏差在10%以内,并且外管的碰撞速度与充电电压近似呈线性关系。电缆接头电阻随着充电电压的提升而减小,当充电电压为12 kV时,接头电阻为25.2μΩ,仅为要求值的60.8%;电缆接头强度随着充电电压的提升而提高,当充电电压大于12 kV时,铝绞线本体发生断裂,说明电磁焊接接头强度大于母材的强度。当充电电压为12 kV时,焊接接头切面观察到连续的波状界面,波峰约20μm,波长约70μm,已经达到焊接效果,此时实测碰撞速度为128.9 m/s,理论推导计算出的碰撞速度为134.7 m/s,与下限碰撞速度之间的偏差分别为5.6%和10.3%,因此可以较好地预测两种材料达到焊接条件所需的能量值,为今后的电磁焊接装置设计提供有效的参考。The cable connector is generally used to make hydraulic clamp pressure.Limited by the shape of the mold,the cable joints are not crimped tightly.It will produce the spring between the connectors and cable cores,forming a gap.It can cause problems such as excessive contact resistance of the cable joints,partial discharge damage to insulation,and easy pull-off.Electromagnetic welding technology can replace the traditional hydraulic clamp technique and transition clamp,lifting the mechanical properties of the cable joints,electrical performance,and reliability.Therefore,this paper conducted simulation and experimental research on electromagnetic pulse welding of 70 mm^(2) aluminum stranded and copper connecting tubes.Firstly,the magnetic field distribution in the working area of the field shaper was measured by the magneto-optical effect method and compared with the simulation results.Secondly,the deformation process of the outer tube was analyzed by simulation,high-speed photography,and theoretical derivation.The electromagnetic welding conditions of the cable joints were obtained.Finally,the contact resistance,tensile force,and micro-interface were tested for the electromagnetic welding joints of the cable.The magnetic field measurement results show that the magnetic field on the central axis of the field shaper is roughly in a“bell-shaped”distribution,the magnetic field is the largest at the working area,and the magnetic field decreases rapidly at the position far from the working area.The distribution is relatively even at different radial positions of the field shaper working area.The distribution of the measured axial magnetic field is similar to the simulation,and the measured magnetic field in the center of the working area is about 3.9%smaller than the simulation.The deformation process of the outer tube is simulated,measured,and theoretically deduced.The acceleration stage velocity curves of the outer tube obtained from the theoretical deduction are similar to the simulation and the measured velocity w

关 键 词：电磁焊接 焊接条件 接头电阻 接头强度 波状界面 

分 类 号：TM246[一般工业技术—材料科学与工程]