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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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

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	Lu Zhijian
	Chang Jiang
	Bai Xiaobin
	Lu Haohe
	Yang Lanjun

Cite this article:

Lu Zhijian,Chang Jiang,Bai Xiaobin等. Research on Electromagnetic Pulse Welding Conditions of Aluminum Core Wire and Copper Connecting Tube of Power Cable[J]. Transactions of China Electrotechnical Society, 0, (): 76-76.

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

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