基于IPS的二次电缆柔性线束运动仿真和试验对比

Motion Simulation and Test Comparison of Secondary Cable Flexible Wiring Harness Based on IPS

针对继电保护小室内的二次电缆线束因设计排布及装配不合理导致线束故障频发的问题,提出了一种新的基于IPS的继电保护小室二次电缆柔性线束运动仿真分析及优化设计方法。该方法以继电保护小室柜内的多组二次电缆柔性线束为研究对象,首先通过获取线束的材料参数及空间结构,基于IPS软件建立继电保护小室与二次电缆线束的力学约束和运动模型;然后对柔性长线束进行动态仿真分析,通过提取线束运动过程的几何变形、间隙、应力应变、弯曲扭曲等变量,准确定位线束故障发生的位置和时刻并进行定量分析,基于IPS实现优化设计,实现了线束虚拟装配、风险动态分析及评估、线束疲劳分析及寿命预测等;最后通过现场实物验证对仿真结果进行了验证。验证结果表明,通过仿真分析能有效地定位故障位置,仿真分析结果与实物测量结果一致,满足对标要求,该方法能够有效发现和消除线束的故障隐患,提高线束设计和安装的可靠性。

To address the frequent failure of the secondary cable harness in relay cabinets due to unreasonable design arrangement and assembly,a new IPS-based method for motion simulation analysis and optimization design of flexible cable harnesses was proposed.This method focuses on multiple sets of secondary cable flexible wiring harnesses in a relay cabinet as the research object.Initially,by obtaining the material parameters and spatial structure of the wiring harnesses,mechanical constraints and motion models of the relay cabinets and secondary cable harnesses are established using IPS software.Subsequently,dynamic simulation analysis is conducted for the flexible long wire harness,accurately locating faults in terms of geometric deformation,clearance,stress strain,bending,and distortion during movement.The optimal design based on IPS includes virtual assembly of wire harnesses,dynamic analysis and risk evaluation,fatigue analysis of wire harnesses,and life prediction.Finally,simulation results are verified through physical field verification which demonstrates that the simulation effectively locates fault locations consistent with actual measurements while meeting standard requirements,thus effectively identifying hidden issues within wiring designs to improve reliability.