电力电缆铝芯线与铜连接管的电磁焊接条件研究

doi:10.19595/j.cnki.1000-6753.tces.211592

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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,本文通过对70mm²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成线性关系。电缆接头电阻随着充电电压的提升而减小,当充电电压为12kV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12kV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12kV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128.9m/s,理论推导计算出的碰撞速度为134.7m/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。

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	路志建
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关键词 ：电磁焊接, 焊接条件, 接头电阻, 接头强度, 波状界面

Abstract：

The cable connector is generally used to make hydraulic clamp pressure, limited by the shape of the mould, the cable joints are not crimped tightly. And it will produce the springback between the connectors and cable cores, forming a gap. It is easy to 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. In view of this, this paper conducted simulation and experimental research on electromagnetic pulse welding of 70mm² 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, and 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 in the working area of the field shaper show that the magnetic field on the central axis of the field shaper is roughly in a "bell-shaped" distribution, and 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. And the distribution law of the axial magnetic field measured by the experiment 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 is similar to the simulation and the measured velocity waveforms. The theoretically calculated collision speed and the measured value are within 10%, which has an approximate linear relationship with the charging voltages.
The resistance of the cable joints decreases with the increase of the charging voltages. When the charging voltage is 10kV, the resistance of the joint is 35.12μΩ, which has met the requirements of the national standard. When the charging voltage is greater than 12kV, the resistance of the cable joints is 25.2 μΩ, which is only 60.8% of the required value. The strength of the cable joints increases with the increase of the charging voltages. When the charging voltage is 10kV, the tensile strength of the cable joints has met the requirements of the national standard. When the charging voltage is greater than 12kV, the aluminum stranded wire body breaks, indicating that the strength of the electromagnetic welding joints is greater than the strength of the base metal. But when the charging voltage is greater than 16kV, due to the high-speed collision between the copper outer tube and the aluminum stranded wire at this time, the aluminum stranded wire is seriously damaged, so that the mechanical properties of the cable joints are sharply reduced.
The test results of the micro-interface of the cable joints show that when the charging voltage is 12kV, a continuous wave-like interface is observed on the section of the welded joints. The wave peak is about 20μm, and the wavelength is about 70μm, which has achieved the welding effect. At this time, the measured and calculated by theoretical derivation collision speed of the outer tube are 128.9m/s and 134.7m/s, and the deviations from the lower limit collision speed are 5.6% and 10.3% respectively. Therefore, the discharge energy value required for two different materials to reach the welding conditions can be well predicted, which can provide an effective reference for the design of electromagnetic welding equipments in the future.

Key words： Electromagnetic welding Welding conditions Resistance of the cable joint Tensile strength of the cable joint Wave-like interface

基金资助:

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

通讯作者: 常江男,1976年生,高级工程师,研究方向为电缆制造与检测、输配电管理。E-mail：340272347@qq.com

作者简介: 路志建男,1996年生,博士研究生,研究方向为电磁成形、电磁焊接技术以及脉冲功率技术。E-mail：luzhijian0805@stu.xjtu.edu.cn

引用本文:

路志建, 常江, 白晓斌, 陆豪赫, 杨兰均. 电力电缆铝芯线与铜连接管的电磁焊接条件研究[J]. 电工技术学报, 0, (): 76-76. Lu Zhijian, Chang Jiang, Bai Xiaobin, Lu Haohe, Yang Lanjun. Research on Electromagnetic Pulse Welding Conditions of Aluminum Core Wire and Copper Connecting Tube of Power Cable. Transactions of China Electrotechnical Society, 0, (): 76-76.

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https://dgjsxb.ces-transaction.com/CN/10.19595/j.cnki.1000-6753.tces.211592 https://dgjsxb.ces-transaction.com/CN/Y0/V/I/76

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