高压隔离开关自力型触指结构优化设计及其成形技术研究
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摘要
触指零件是高压隔离开关最核心的部件,高压隔离开关的接通和断开要依靠触指/触头配合结构来实现,触指零件的服役寿命决定了高压隔离开关的寿命,进而决定着高压输变电网的安全运行。传统触指一般采用紫铜制作,为保证触指具有一定的强度和刚度,通常制作触指的紫铜板厚度较大,浪费铜材;传统触指一般采用弹簧提供触指和触头之间的接触压力,弹簧的存在使触指/触头的配合结构较为复杂,触指自洁能力差,同时长期使用后弹簧失去弹性,致使接触压力不足,接触电阻增大,造成导电回路过热等故障。自力型触指依靠自身刚性提供接触压力,该类型触指不但使零件厚度减薄,节省铜材,而且简化了触指/触头配合结构,自洁能力强,接触压力稳定,且避免了因弹簧存在引起的导电回路过热等故障。本文基于新型Cu-Cr合金材料在自力型触指上的应用及高压隔离开关服役工况的要求,对自力型触指和自力型触指/触头配合结构进行了研究。采用优化设计方法设计了一种高压隔离开关用新型自力型触指,同时对新型自力型触指/触头配合结构参数进行了优化分析,并通过数值分析研究了新型自力型触指的成形工艺。
1.借助ANSYS Workbench软件,根据自力型触指强度和刚度理论分析,对自力型触指受力情况进行了数值分析,同时对自力型触指截面形状进行了优化设计。得到如下结论:
(1)在触指材料一定的情况下,自力型触指截面形状是影响其自身强度和刚度的主要因素。为提高自力型触指的强度和刚度,本文提出了“W”形截面自力型触指结构。
(2)经优化后,“W”形截面自力型触指的截面参数为厚度h = 3.18mm,圆角半径r = 2.32mm,中间槽宽w = 2.73mm;矩形截面自力型触指截面厚度为h = 3.33mm。
(3)优化后的“W”形截面自力型触指与矩形截面自力型触指相比,最大变形减小了1.43mm,触指零件刚度显著提高;在触指材料相同的条件下,质量减小了4.22g。
(4)与传统紫铜触指相比,“W”形截面自力型触指厚度由5mm减小到3.18mm,质量减轻47g,节材38.7%。
2.利用SolidWorks软件建立了“W”形截面自力型触指/触头配合结构有限元分析模型。按照ANSYS Workbench软件参数化语言要求设置了优化参数,并通过无缝数据接口成功将模型及优化参数导入ANSYS Workbench软件。研究了触头直径D和触头位移S对自力型触指等效应力和变形的影响,采用目标驱动优化技术对触头直径D和触头位移S进行了优化。优化结果表明,“W”形自力型触指/触头配合结构最佳结构参数为:D = 63.39mm,S = 15.42mm。
3.分析了自力型触指成形特点,制定了弯曲、压筋复合+压弯、冲孔复合成形“W”形截面自力型触指新工艺。采用Deform-3D软件研究了“W”形截面自力型触指弯曲、压筋复合成形性能。主要研究结果如下:
(1)触指成形过程中,“W”形截面区域发生剧烈变形,过渡圆角处应力、应变最大,且破坏系数最高。
(2)基于对自力型触指的优化设计和成形数值模拟的研究,提出将“W”形截面自力型触指圆角半径修正为2.7mm。
(3)根据新型自力型触指成形工艺,设计了“W”形截面自力型触指弯曲、压筋复合和压弯、冲孔复合成形模具。
Contact fingers are the most core components of high voltage isolating switch. Whether isolating switch connects or not depends on assembly structure of contact finger/contact. The service life of contact finger determines the life of high voltage switch, and determines the safe operation of the high voltage power grid. The tradition contact finger is made of copper plate which thickness is up to 5mm, and the contact pressure between the contact finger and the contact is afforded by spring. So the tradition contact finger with the spring not only wastes plenty of copper, but can easily result in contact overheat or a major power accident. The self-elastic contact finger without the support of the spring has a small quantity usage of copper which consumedly save copper, and prevent overheat happening which may be caused by the spring. So the self-elastic contact finger is an important goal that designers go after in recent years. In this paper, combining with high voltage isolating switch service condition, using the optimized design method, a new kind of self-elastic contact finger used in high voltage isolating switch was designed, and the new assembly structure of self-elastic contact finger/contact was analyzed. Then, the forming process of the new self-elastic contact finger was studied by numerical analysis.
1. According to the strength and rigidity theoretical analysis of self-elastic contact finger, Using ANSYS Workbench, The self-elastic contact finger was analyzed, and the cross-section shapes of self-elastic contact finger were optimized. Get conclusions as follows:
(1) In the case of certain materials, the cross-section shape of self-elastic contact finger is one of the main factors which influence its own strength and rigidity. To improve its strength and rigidity, self-elastic contact finger with“W”shape section was put forward in this research.
(2) After the optimization, Section parameter of self-elastic contact finger with
“W”shape section were thickness h = 3 mm, fillet radius r = 2.32 mm, middle groove width w = 2.73 mm; thickness of self-elastic contact finger with rectangular section is h = 3.33 mm.
(3) Compared with the self-elastic contact finger with rectangular section, the maximum deformation of the optimized self-elastic contact finger with“W”shape section was reduced 1.43 mm, rigidity was increased observably.
(4) Compared with the traditional copper contact finger, section thickness of self-elastic contact finger with“W”shape section was reduced 1.82 mm, mass reduced 47 g, materials saved by 38.7%.
2. Assembly structure parametric model of self-elastic contact-finger/contact was created using SolidWorks software, parameter names of contact diameter D and contact displacement S were set. The model and input parameters were imported into ANSYS Workbench software, in which the relationship between input parameters and response parameters were researched and input parameter D and S were optimized based on goal-driven optimization technique. Optimized input parameters are D = 63.39 mm, S = 15.42 mm.
3. This paper analyzed forming characteristics of self-elastic contact finger, established bending and swaging compound + bending and punching compound new process to form self-elastic contact finger with“W”shape section. Using Deform - 3D software, bending and swaging compound forming performance of self-elastic contact finger with“W”shape section was researched. Get conclusions as follows:
(1) Severe plastic deformations were occurred around the filleted corner of“W”shape section region of the self-elastic contact finger and the maximum equivalent stress and maximum equivalent strain were on the filleted corner. On the filleted corner region the damage coefficient was highest.
(2) Based on the optimal design for self-elastic contact finger and the study on forming numerical simulation, put forward that the round angle-radius r of self-elastic contact finger with“W”shape section was revised to 2.7 mm.
(3) According to the forming process of new self-elastic contact finger, bending and swaging compound and bending and punching compound forming die both were designed for self-elastic contact finger with“W”shape section.
1.借助ANSYS Workbench软件,根据自力型触指强度和刚度理论分析,对自力型触指受力情况进行了数值分析,同时对自力型触指截面形状进行了优化设计。得到如下结论:
(1)在触指材料一定的情况下,自力型触指截面形状是影响其自身强度和刚度的主要因素。为提高自力型触指的强度和刚度,本文提出了“W”形截面自力型触指结构。
(2)经优化后,“W”形截面自力型触指的截面参数为厚度h = 3.18mm,圆角半径r = 2.32mm,中间槽宽w = 2.73mm;矩形截面自力型触指截面厚度为h = 3.33mm。
(3)优化后的“W”形截面自力型触指与矩形截面自力型触指相比,最大变形减小了1.43mm,触指零件刚度显著提高;在触指材料相同的条件下,质量减小了4.22g。
(4)与传统紫铜触指相比,“W”形截面自力型触指厚度由5mm减小到3.18mm,质量减轻47g,节材38.7%。
2.利用SolidWorks软件建立了“W”形截面自力型触指/触头配合结构有限元分析模型。按照ANSYS Workbench软件参数化语言要求设置了优化参数,并通过无缝数据接口成功将模型及优化参数导入ANSYS Workbench软件。研究了触头直径D和触头位移S对自力型触指等效应力和变形的影响,采用目标驱动优化技术对触头直径D和触头位移S进行了优化。优化结果表明,“W”形自力型触指/触头配合结构最佳结构参数为:D = 63.39mm,S = 15.42mm。
3.分析了自力型触指成形特点,制定了弯曲、压筋复合+压弯、冲孔复合成形“W”形截面自力型触指新工艺。采用Deform-3D软件研究了“W”形截面自力型触指弯曲、压筋复合成形性能。主要研究结果如下:
(1)触指成形过程中,“W”形截面区域发生剧烈变形,过渡圆角处应力、应变最大,且破坏系数最高。
(2)基于对自力型触指的优化设计和成形数值模拟的研究,提出将“W”形截面自力型触指圆角半径修正为2.7mm。
(3)根据新型自力型触指成形工艺,设计了“W”形截面自力型触指弯曲、压筋复合和压弯、冲孔复合成形模具。
Contact fingers are the most core components of high voltage isolating switch. Whether isolating switch connects or not depends on assembly structure of contact finger/contact. The service life of contact finger determines the life of high voltage switch, and determines the safe operation of the high voltage power grid. The tradition contact finger is made of copper plate which thickness is up to 5mm, and the contact pressure between the contact finger and the contact is afforded by spring. So the tradition contact finger with the spring not only wastes plenty of copper, but can easily result in contact overheat or a major power accident. The self-elastic contact finger without the support of the spring has a small quantity usage of copper which consumedly save copper, and prevent overheat happening which may be caused by the spring. So the self-elastic contact finger is an important goal that designers go after in recent years. In this paper, combining with high voltage isolating switch service condition, using the optimized design method, a new kind of self-elastic contact finger used in high voltage isolating switch was designed, and the new assembly structure of self-elastic contact finger/contact was analyzed. Then, the forming process of the new self-elastic contact finger was studied by numerical analysis.
1. According to the strength and rigidity theoretical analysis of self-elastic contact finger, Using ANSYS Workbench, The self-elastic contact finger was analyzed, and the cross-section shapes of self-elastic contact finger were optimized. Get conclusions as follows:
(1) In the case of certain materials, the cross-section shape of self-elastic contact finger is one of the main factors which influence its own strength and rigidity. To improve its strength and rigidity, self-elastic contact finger with“W”shape section was put forward in this research.
(2) After the optimization, Section parameter of self-elastic contact finger with
“W”shape section were thickness h = 3 mm, fillet radius r = 2.32 mm, middle groove width w = 2.73 mm; thickness of self-elastic contact finger with rectangular section is h = 3.33 mm.
(3) Compared with the self-elastic contact finger with rectangular section, the maximum deformation of the optimized self-elastic contact finger with“W”shape section was reduced 1.43 mm, rigidity was increased observably.
(4) Compared with the traditional copper contact finger, section thickness of self-elastic contact finger with“W”shape section was reduced 1.82 mm, mass reduced 47 g, materials saved by 38.7%.
2. Assembly structure parametric model of self-elastic contact-finger/contact was created using SolidWorks software, parameter names of contact diameter D and contact displacement S were set. The model and input parameters were imported into ANSYS Workbench software, in which the relationship between input parameters and response parameters were researched and input parameter D and S were optimized based on goal-driven optimization technique. Optimized input parameters are D = 63.39 mm, S = 15.42 mm.
3. This paper analyzed forming characteristics of self-elastic contact finger, established bending and swaging compound + bending and punching compound new process to form self-elastic contact finger with“W”shape section. Using Deform - 3D software, bending and swaging compound forming performance of self-elastic contact finger with“W”shape section was researched. Get conclusions as follows:
(1) Severe plastic deformations were occurred around the filleted corner of“W”shape section region of the self-elastic contact finger and the maximum equivalent stress and maximum equivalent strain were on the filleted corner. On the filleted corner region the damage coefficient was highest.
(2) Based on the optimal design for self-elastic contact finger and the study on forming numerical simulation, put forward that the round angle-radius r of self-elastic contact finger with“W”shape section was revised to 2.7 mm.
(3) According to the forming process of new self-elastic contact finger, bending and swaging compound and bending and punching compound forming die both were designed for self-elastic contact finger with“W”shape section.
引文
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