新能源汽车电池大模组Busbar激光焊接工艺探究

针对新能源汽车电池大模组的生产需求,对Busbar及电芯极耳进行激光焊接试验,改变激光功率、焊接速度等工艺参数,比较搅拌激光焊和无搅拌激光焊接工艺,并考察了焊缝的组织形貌、孔隙率、抗剪强度等性能。研究发现,Busbar激光焊接优化工艺为中心功率3400 W,外环功率1800 W,焊接速度25 mm/s,离焦量+1 mm,焊接接头成形良好。比较搅拌激光焊接和无搅拌激光焊接工艺,Busbar激光搅拌焊接接头最大剪切强度为164 MPa,无搅拌激光焊接接头最大剪切强度为152 MPa,从而证明激光搅拌焊接工艺能够显著优化Busbar接头的焊接质量。

Semantic-driven method for designing 3D busbars

Traditional busbar design is inefficient, costly, and error-prone because of frequent changes of requirements. This paper proposes a semantic-driven method for designing 3D busbars to solve this problem. The design process contains two main parts, namely, semantic-driven routing design and automatic routing segmentation. Semantic-driven routing design creates a relation table between electrical semantics and 3D modeling parameters, as well as helps designers create routings efficiently using electrical parameters as input. Automatic routing segmentation can convert routings into busbar segments that also include manufacturing information. Because the design operations are associated with one another, the resulting busbars can automatically be changed in real time when requirements are changed.

Numerical simulation of busbar configuration in large aluminum electrolysis cell

Various busbar configurations were built and modeled by the custom code based on the commercial package ANSYS for the 500 kA aluminum electrolysis cell.The configuration parameters,such as side riser entry ratio,number of cathode bars connected to each riser,vertical location of side cathode busbar and short side cathode busbar,distance between rows of cells in potline,the number of neighboring cells,ratio of compensation busbar carried passing under cell and its horizontal location under cell along with large magnetohydrodynamic(MHD) computation based on the custom evaluation function were simulated and discussed.The results show that a cell with riser entry ratio of 11:9:8:9:11 and cathode busbar located at the level of aluminum solution,50% upstream cathode current passing under cell for magnetic field compensation,the distance between rows of 50 m is more stable.

Thermal Dissipation Modelling and Design of ITER PF Converter Alternating Current Busbar

Because the larger metallic surrounds are heated by the eddy current, which is generated by the AC current flowing through the AC busbar in the International Thermonuclear ExperimentM Reactor （ITER） poloidal field （PF） converter system, shielding of the AC busbar is required to decrease the temperature rise of the surrounds to satisfy the design requirement. Three special types of AC busbar with natural cooling, air cooling and water cooling busbar structure have been proposed and investigated in this paper. For each cooling scheme, a 3D finite model based on the proposed structure has been developed to perform the electromagnetic and thermal analysis to predict their operation behavior. Comparing the analysis results of the three different cooling patterns, water cooling has more advantages than the other patterns and it is selected to be the thermal dissipation pattern for the AC busbar of ITER PF converter unit. The approach to qualify the suitable cooling scheme in this paper can be provided as a reference on the thermal dissipation design of AC busbar in the converter system.

Design of Balanced Reactor Welded with Water-Cooled Aluminum Busbars

A new process of welding aluminum water-cooled busbars is proposed, It can not only reduce the weight and cost, but also improve the dynamic and thermal stability. Furthermore~ both finite element method analysis and a prototype test testify the advantages of the design which is not limited by load current and provides a new approach for water-cooled reactors.

Design of a DC Busbar for the ITER PF Converter

The DC busbar is an important component for the ITER PF converter module to connect the converter and the reactor. This paper analyzes different cross-sections and different thermodynamic properties under natural-cooling and water-cooling conditions, and simulation is carried out by the software of the finite element method （FEM）. The result of the analysis shows that the water-cooling method is the better choice for the DC busbar.

Effect of laser surface melting treatment on properties of electric copper busbar joints

Electrical conductance and temperature of electric copper busbar joints were measured under different torque moments. Experimental results show that laser surface melting can increase hardness and refine structure of the copper, and it does not deteriorate electric resistance. Meanwhile, the temperature of laser treated joints under electric current is slightly lower than that of original sample. Salt spray test shows that laser treated sample has better salt spray corrosion resistance than the original sample does. The electric resistance of both laser treated and original samples are increased with salt spray time. For the same salt spray time, the electric resistance of busbar joint is decreased with increasing torque moment.

Busbar Differential Relaying Method Based on Combined Amplitude and Phase Information of High Frequency Transient Currents

Busbar differential relaying method based on combined amplitude and phase information of high frequency transient currents is put forward in this paper for the speed and reliability problems of busbar protection based on fundamental frequency. Under the analysis of features of bus high frequency differential currents, complex wavelet analysis is used to extract the amplitude and phase features of 1/4 period high frequency differential currents, and amplitude and phase information are used to form the polar coordinates. Bus fault is identified intuitively and precisely according to polar locus differences. This polar coordinates represented busbar differential protection scheme based on high frequency transient signals can not only avoid TA saturation, realizing quick protection, lots of PSCAD/EMTDC simulations also show that this busbar differential protection scheme works well under different fault conditions.

Simulation of Space Charge Impact on Partial Discharge Inception Voltage in Power Busbars Dedicated to Future Hybrid Aircrafts

Reducing greenhouse gases, saving energy resources and mass optimization require technological changes towards increasingly electric vehicles. At the same time, performance improvement of semiconductor and dielectric materials further promotes electronic components confinement, resulting in a significant increase of embedded power densities. In the particular case of future hybrid propulsion aircrafts, electrical power that intended to supply reactors would be converted through power electronics components mounted on power busbars and insulated by solid dielectrics materials. These dielectrics materials have to respond to various electrical constraints of use (HVDC), in spite of environment change of aircraft parameters such as low pressure, temperature and thermal cycles, humidity... Unfortunately, partial discharges phenomenon is the most problem within electrical insulation system (EIS). Based on a topological model of power busbars designed for power converters dedicated to hybrid aircraft, partial discharge studies were conducted by simulation in various charging conditions of a PTFE insulator. Simulation results, which focus on electric field thresholds criteria of partial discharge inception voltage in air, reveal a net sensitivity of a space charge accumulation and distribution on dielectrics behaviour even for low space charge density, depending on their location in dielectrics. Compared to the behaviour observed with implanted homocharges, when by increasing homocharges density from 0.5 C/m3 to 2 C/m3 we observe a decrease of electric field by 450%, simulation results show a highest risk of partial discharge inception when heterocharges are accumulated inside dielectrics. Their accumulation increases the electric field in triple points beyond electric field thresholds of partial discharge inception in air. The simulated electric field reaching 22 kV/mm with only 2 C/m3 of heterocharges density accumulated in dielectric/busbars interfaces.

Sampled Value Attack Detection for Busbar Differential Protection Based on a Negative Selection Immune System

Considering a variety of sampled value(SV)attacks on busbar differential protection(BDP)which poses challenges to conventional learning algorithms,an algorithm to detect SV attacks based on the immune system of negative selection is developed in this paper.The healthy SV data of BDP are defined as self-data composed of spheres of the same size,whereas the SV attack data,i.e.,the nonself data,are preserved in the nonself space covered by spherical detectors of different sizes.To avoid the confusion between busbar faults and SV attacks,a self-shape optimization algorithm is introduced,and the improved self-data are verified through a power-frequency fault-component-based differential protection criterion to avoid false negatives.Based on the difficulty of boundary coverage in traditional negative selection algorithms,a self-data-driven detector generation algorithm is proposed to enhance the detector coverage.A testbed of differential protection for a 110 kV double busbar system is then established.Typical SV attacks of BDP such as amplitude and current phase tampering,fault replays,and the disconnection of the secondary circuits of current transformers are considered,and the delays of differential relay operation caused by detection algorithms are investigated.

基于有限时间观测器的光储系统母线电压互补滑模控制

针对光储直流微网混合储能系统易受能源间歇性输入、负载随机性扰动以及功率流向切换等干扰,会造成母线电压波动、系统功率失稳等问题,提出一种基于有限时间观测器的互补滑模控制(FTESO+CSMC)策略.首先,根据混合储能元件的高低频特性,对系统差额功率进行电流等效分配.然后,设计有限时间扩张状态观测器,对系统受到的总扰动进行观测,并将扰动观测值作为前馈项输入互补滑模控制器中,对系统扰动进行补偿,保证系统状态在有限时间内达到收敛,提高了系统的快速性和抗扰性,并根据Lyapunov理论证明了控制系统的稳定性.最后,基于MATLAB仿真平台,对多种模拟工况进行仿真,仿真结果表明,相较于传统控制策略,本文所提控制具有更快的响应速度以及更好的抗扰性能.

海上风电低频输电系统快速母线保护

海上风电低频输电系统母线故障后,换流器型电源等效电势与阻抗因控制的切换与调整过程,不再像传统电网可视为恒定。文中理论分析了母线电流差动保护适应性,明确故障控制策略对差动保护灵敏度的影响方式。利用母线区内外故障所对应的故障等效模型不同,提出基于时域全量模型识别的母线保护。该保护原理反映被保护元件自身拓扑的变化,理论上具有不受电源特性影响的优势,同样适用于其他换流器型电网。同时,所提保护在时域中实现,不存在相量提取问题,动作速度快。最后,在PSCAD/EMTDC中搭建了仿真模型,验证了所提母线保护的可靠性和快速性。

550kV气体绝缘母线大电流工况下温升特性分析

探究气体绝缘母线在超高压大电流工况下的温升特性对设备的正常运行以及监测维护意义重大。然而,在长期大电流负荷运行下,因接触异常等原因导致母线在较小封闭空间内产生大量热量,极易造成局部过热严重威胁设备安全运行。针对这一问题,本文以550kV气体绝缘母线为研究对象,构建了考虑接触电阻的3维电磁-温度-流体多场耦合模型,计算其在1.1倍额定电流(8800A)、气压0.3MPa条件下的母线温度分布,并搭建了大电流温升试验平台进行验证,试验测量结果与仿真结果吻合度高。基于验证后的可靠模型,进一步探究了通流水平、SF_(6)气压及接触状态对母线温度分布的影响规律。结果表明:母线最高温度位于盆子凹面处电接触部位顶部(约为54℃),该端触头上方SF_(6)温度比导杆上方高近15℃,凹面处触头径向温度梯度明显低于凸面处触头径向温度梯度;在非等温自然对流的情况下,母线温度整体呈径向上高下低、轴向端部高中间低的规律分布;母线温度随通流水平提高呈非线性上升、随SF_(6)气压增大呈近似线性下降,可在一定范围内提高设备绝缘气体压强以降低设备运行温度;异常电接触处温度随阻值增大近似线性增加,而电接触异常往往是母线过热的主要风险点。研究结果可为超高压大电流气体绝缘设备产品设计及状态监测提供参考。

涂层传热性能对母线散热能力影响分析

为提升电力开关柜散热性能、提高供配电稳定性,本文依据传热学基础理论对电力开关柜传热过程进行分析,采用溶液共混法成功制备了适用于电力开关柜母线散热的涂层材料,并基于电磁-热-流多物理场耦合原理构建了电力开关柜涂层-热分析模型,结合母线负载电流计算理论,从涂层热导率、发射率等方面对涂覆散热涂层前后的电力开关柜传热特性进行分析。结果表明:涂层热导率相比于涂层发射率对母线温升影响较小,母线表面涂覆涂层之后,B相母线表面发射率由0.2增大到0.846时,三相母线最大负载电流与未涂覆相比提升18.75%。

基于馈线和电流的专用轨回流牵引供电系统接地故障保护

对于专用轨回流牵引供电系统,负极回流轨对地具有良好的绝缘特性,极大地限制了正极接地故障所产生的短路电流。由于负极母线电位下降、接地电阻较大等原因,现有的正极接地保护在实际应用中暴露出选择性差、灵敏度低等问题。本文通过对专用轨回流牵引供电系统短路电流以及负荷电流的潮流分析,提出以供电区间馈线和电流作为正极接地故障判断的特征量,并设计基于该故障特征量的保护方案,基于MATLAB/Simulink仿真系统,验证了该保护方案的有效性。

并联电容器叠层母排寄生电感建模及测量方法

并联电容器母排的寄生电感是电力电子变换器换流回路总寄生电感的主要部分,寄生电感易导致电压过冲,因此需要精确提取和计算叠层母排的寄生电感。这里首先以一种5电容器并联的叠层母排为研究对象,建立了多电容器并联叠层母排的电感计算模型;在此基础上,提出一种可对母排寄生电感进行直接测量的实验方法,规避了在母排上连接电容器所产生的误差。最后,使用该方法对叠层母排寄生电感值进行实验测量,并将测量结果与有限元仿真计算结果进行对比,测量结果与仿真结果的偏差在2%以内,验证了所提方法的有效性和准确性,从而为叠层母排的低感设计提供了测量验证的基础方法。

基于磁流体稳定性提升的电解槽母线改造研究

磁场是电解槽磁流体稳定性的决定性因素,本文对铝电解槽的磁流体稳定性进行研究,通过采用自均衡网络化母线技术降低电解槽垂直磁场,改造后的垂直磁场平均降低47.5%,且四个象限磁场强度分布均匀。通过瞬态磁流体模型及流动场稳定性分析验证,500s左右后电解槽可自行恢复稳定状态,界面变形减小1.2cm,证明采用自均衡网络化母线技术后的电解槽自平衡能力及抗波动能力均得到增强,从而节省直流电耗150kWh/t-Al。

三相交错并联直流变换器母排低电感设计

由于开关器件频率的提升和电压等级的提高,功率回路中的杂散电感引起的冲击电压影响越来越受到关注。为解决在高频器件下因母排杂散电感引起的冲击电压过高的现象,将以往研究中的解析法建模和部分元等效两种方法结合起来建立能同时反映结构参数作用机理并反映各部分电感对冲击电压影响的综合电感模型。利用模型按照叠层方式设计、基础尺寸设计和器件布局设计3步设计了一款用于三相交错并联直流变换器的叠层母排。对于其中有着复杂影响效果的结构参数,将数学模型代入双层规划算法,进行了参数寻优。最终设计了一款低杂散电感、低冲击电压母排,并通过双脉冲实验验证了设计的有效性和模型的准确性。

一起500kVGIL管母支柱绝缘子故障分析

为了分析某换流站的一起500 kV GIL管母支柱绝缘子故障,对故障GIL开展解体检查、结构原理分析、重力影响分析、导体膨胀仿真计算、绝缘子浇注工艺分析、绝缘子装配工艺分析等。通过研究分析,确定了GIL故障原因为三支柱绝缘子铝质金属表面与绝缘体之间存在微小间隙缺陷,在生产、运输、安装、运行等过程中小间隙逐渐扩展、劣化,最终导致击穿放电。最后从强化生产工艺控制、提升出厂检测标准、提高运输过程管控要求、加强现场超声波带电局放测试几方面提出改进建议,为后续GIL生产、运输、运维等方面提供借鉴。

10 kV管型绝缘母线典型缺陷下的电场畸变分析

变电站管型绝缘母线接头潮气侵入和残留导电微粒是其常见缺陷,缺陷导致接头电场分布发生畸变,危及其绝缘性能,甚至发生绝缘击穿、烧毁等事故。本文采用有限元多物理场仿真技术,基于实际结构构建了绕包式管型绝缘母线接头模型,分别在金属屏蔽层与主绝缘层界面、主绝缘层与内密封层界面设置长度分别为10、30、50 mm的3种不同水膜和半径为0.5 mm的半圆形导电杂质,利用COMSOL软件进行电场仿真分析,研究不同缺陷位于不同界面对管型绝缘母线接头电场分布的影响。结果表明:水膜和导电杂质都会对绝缘带材界面电场分布产生不同程度的影响,缺陷内部场强下降,缺陷边缘场强剧增,其中绝缘界面残留导电微粒时电场畸变情况比水分侵入时更加严重,更易发生绝缘击穿事故,应加强端部密封和严防导电微粒残留。