CuCr25 W1 Ni2 contact material of vacuum interrupter

CuCr25W1Ni2 alloy was prepared by means of vacuum induction melting (VIM). A series of Cu/Cr alloys with different compositions (mass fraction, 25%～75%) and Cr grain sizes (up to 150 μm) were investigated for their differences in physical properties and breakdown voltage. The influence of alloy elements and microstructure on the performance of CuCr25W1Ni2 alloy was also discussed. Experimental results show that the chromium phase is strengthened and its size is minimized by the addition of tungsten powder. After electrical breakdown, very fine tungsten particles in the melt layer form the external nuclei in the solidification process. The microstructure of surface melt layer of CuCr25W1Ni2 alloy is much flatter. It can notably improve the dielectric strength. On the other hand, the nickel can enhance the mutual solubility of copper and chromium, and the whole alloy is strengthened. [

Investigation of cathode spot characteristics in vacuum under transverse magnetic field (TMF) contacts

With the continuous improvement of current levels in power systems, the demands on the breaking capacity requirements of vacuum circuit breakers are getting higher and higher. The breaking capacity of vacuum breakers is determined by cathode spots, which provide electrons and metal vapor to maintain the arc. In this paper, experiments were carried out on two kinds of transverse magnetic field（TMF） contacts in a demountable vacuum chamber, the behavior of the cathode spots was recorded by a high-speed charge-coupled device（CCD） video camera, and the characteristics of the cathode spots were analyzed through the image processing method. The phenomenon of cathode spot groups and the star-shaped pattern of the spots were both discovered in the experiment. The experimental results show that with the condition of TMF contacts the initial expansion speed of cathode spots is influenced by some parameters, such as the tested current, contact gap, the structure of the contact, the contact diameter, the number of slots, etc. In addition, the influence of the magnetic field on the formation of the cathode spot groups, the distribution, and the dynamic characteristics of the cathode spots were analyzed. It is concluded that the characteristics of the cathode spots are due to the effect of the magnetic field on the near-cathode plasma. The study of the characteristics of cathode spots in this paper would be helpful in the exploration of the physical process of vacuum arcs, and would be of guiding significance in optimizing the design of vacuum circuit breakers.

Preparation of CuCr25 alloys through vacuum arc smelting and their properties

CuCr alloys are important contact materials, but all conventional preparing methods have disadvantages and mismatch the requirements for mass production and high properties. The CuCr25 alloys were prepared by means of arc smelting in vacuum, and their microstructures, physical properties as well as dielectric strength were investigated. The experimental results show that vacuum arc smelting is an ideal method to produce CuCr25 contact alloys with fine microstructure, low gas content, high density and dielectric strength. Meanwhile, with the high productivity and low cost, CuCr25 contact materials can be produced with mass production through vacuum arc smelting method.

Effect of Electrical Current on the Tribological Behavior of the Cu-WS_2-G Composites in Air and Vacuum

As the traditional graphite-based composites cannot meet the requirement of rapid developing modern industry, novel sliding electrical contact materials with high self-lubricating performance in multiple environments are eagerly required. Herein a copper-based composite with WS2 and graphite as solid lubricant are fabricated by powder metallurgy hot-pressed method. The friction and wear behaviors of the composites with and without current are investigated under the condition with sliding velocity of 10 m/s and normal load of 2.5N/cm 2 in both air and vacuum. Morphologies of the worn surfaces are observed by optical microscope and compositions of the lubricating films are analyzed by XPS. Surface profile curves and roughness of the worn surfaces are obtained by 2205 surface profiler. The results of wear tests show that the friction coefficient and wear volume loss of the composites with current are greater than that without current in both air and vacuum due to the adverse effects of electrical current which damaged the lubricating film partially and roughed the worn surfaces. XPS results demonstrate that the lubricating film formed in air is composed of oxides of Cu, WS2 , elemental S and graphite, while the lubricating film formed in vacuum is composed of Cu, WS2 and graphite. Because of the synergetic lubricating action of oxides of Cu, WS2 and graphite, the composites show low friction coefficient and wear volume loss in air condition. Owing to the fact that graphite loses its lubricity which makes WS2 become the only lubricant, severe adhesive and abrasive wear occur and result in a high value of wear rate in vacuum condition. The formation of the lubricating film on the contact interface between the brush and ring is one of the factors which can greatly affect the wear performance of the brushes. The low contact voltage drop of the composites in vacuum condition is attributed to the high content of Cu in the surface film. This study fabricated a kind of new sliding electrical contact self-lubricating composite with dual-lubricant which can work well in both air and vacuum environments and provides a comprehensive analysis on the lubrication mechanisms of the composite.

Investigation on X-Radiation for 126 kV Vacuum Interrupters

When subjected to high voltages between opened contacts, vacuum interrupters may emit X-rays. In order to ensure that these are of an acceptable level, vacuum interrupters should comply with the limits for X-ray emission and the test procedures to be carried out to verify this based on relevant standards and specifications. In this paper, a comprehensive experimental study has been performed for 126 kV vacuum interrupters used in a transmission system to understand the X-radiation level and its influence by three main parameters, namely applied power-frequency voltage, contact gap and power=frequency voltage conditioning. The radiation instrument is an FJ347 radiometer and the X-radiation dose was measured at the power-frequency test voltage. These tests demonstrated that the X-radiation emission level for a 126 kV vacuum interrupter did not exceed the following： 5 μSv per hour at a rated voltage of 126 kV and 150 μSv per hour at a power-frequency voltage of 230 kV at 1 m distance. The X-radiation dose increased with the applied power-frequency voltage increasing and decreased with the contact gap increasing. The X- radiation dose for 126 kV vacuum interrupters decreased by 57% after the conditioning procedure with a certain power-frequency voltage. During the conditioning procedure, the average value of the X-radiation dose was 4.49 mSv, which means if a professional conditions 180 interrupters per year, it will be safe at the 6.4 m distance.

Arc characteristics during the instability stage on transverse magnetic field contacts

The arcing process greatly affects the breaking ability after current zero.The instability stage is the transition stage from the ignition to the movement stage,which affects the arc movement characteristics.In this paper,the arc characteristics during the instability stage on spiral-type contacts were investigated using a high-speed video camera.A multi-column parallel instability mode and a single-column instability mode were found during the instability stage.The arc appearance and constriction degree changed rapidly.The arc voltage usually increased accompanied by fluctuations.In addition,it was found that the current significantly influenced the arc mode and duration in the instability stage.With increased peak current,the probability of a single-column instability mode increased,and the fluctuation range and average time decreased.

铁心式双极纵磁触头纵向磁场测量及磁场饱和特性研究

铁心式双极纵磁触头是高压真空灭弧室中常用的触头类型之一。为探究铁心式双极纵磁触头真空灭弧室燃弧过程中真空电弧不可控模式出现的成因,对铁心式双极纵磁触头的纵向磁场特性进行了实验与仿真研究。采用霍尔效应传感器阵列搭建了触头磁场测量平台,对1~15 kA下铁心式双极纵磁触头的纵向磁场分布进行了测量,基于实测结果验证了铁心式双极纵磁触头磁场仿真模型的准确性,并利用该仿真模型进一步仿真分析了1~40 kA电流下的触头磁场饱和特性及40 kA电流等级下燃弧过程中触头间纵向磁场的动态变化规律。结果显示,铁心式双极纵磁触头的纵向磁场在电流大于10 kA后开始呈现出显著的饱和趋势,由于磁场饱和现象的存在,大电流燃弧过程中触头磁场随时间的变化曲线在电流峰值附近将出现数毫秒的畸变。铁心式双极纵磁触头的纵向磁场饱和现象及纵向磁场随触头开距增大的衰减共同导致了该触头大电流燃弧过程中电流峰值附近真空电弧不可控模式的出现。文中的研究加深了对铁心式双极纵磁触头控弧过程的理解,并对该触头的设计具有指导价值。

集成电路微组装用环氧粘接胶树脂析出及控制研究

环氧粘接胶常用作集成电路粘接材料。在其固化过程中,经常观察到树脂析出现象。树脂析出物会沾污键合区,带来键合可靠性问题。本文利用接触角的方法研究了树脂析出的机理,讨论了基板粗糙度和树脂析出的关系,初步得出真空烘培对于树脂析出有较大影响,而基板粗糙度和树脂析出的严重程度无必然关联。

平板触头小开距高电流密度下真空电弧特性的实验研究

平板触头被广泛应用于真空触发开关和真空有载分接开关中,为研究其在高电流密度下的真空电弧特性及阳极模式的转变,该文针对直径15、20mm的平板触头,在3、6mm开距下进行触发燃弧实验,并依次对电弧电压特性、电弧能量特性、电弧形貌、触头烧蚀情况进行分析研究。结果表明:峰值电流一定时,随着触头直径与开距的比值的增大,电弧电压和电弧能量减小。触头直径与开距的比值越小,电弧出现阳极模式的阈值电流越小,且触头烧蚀越严重。在开距6mm时,直径15mm触头电弧电压在大部分时间比较稳定,阳极羽流在电弧快熄灭之前出现,而直径20mm触头电弧电压在整个燃弧期间频繁波动,电弧模式不断变化,阳极羽流在整个燃弧期间都有出现。研究结果对于大电流真空开断具有理论指导意义。

带铁心横磁-纵磁触头结构的优化设计

触头作为真空灭弧室的核心元件,其灭弧能力会直接影响直流开断过程。该文通过有限元仿真软件建立了三种触头模型,计算了高频电流下触头产生的磁场分布。电流峰值时的触头间隙中心可产生约为21 mT的纵向磁场,横向磁感应强度约为71 mT,纵向磁场分布不均匀。为了进一步提高触头间隙磁场强度以及分布均匀度,在触头模型中增加铁心及改变铁心结构来提升触头产生的磁场强度,基于BP神经网络与智能优化算法联合的方法对触头模型进行优化设计。优化结果显示:当触头的结构参数外触头非径向开槽夹角α为31.8°、外触头内外半径差值Δ为8.3 mm、内触头片半径r为15.2 mm、外触头杯斜槽高度h为16.1 mm、铁心结构开槽宽度d为1.1 mm时,触头间隙中心产生了74.99 mT的横向磁场;电流峰值时刻的触头间隙中心可产生44.02 mT的纵向磁场,不均匀度从优化前的7.44减小到4.67,均匀度得到了较大提升,提高了磁场对真空电弧的调控能力。

基于多目标灰狼优化算法与RBF神经网络的真空灭弧室触头结构优化设计

在真空灭弧室触头开断过程中,合适的磁场分布有利于提高其开断性能;在合闸过程中,动、静触头间存在的电动斥力会导致触头出现弹跳现象。针对以上问题,首先建立了带铁芯式杯状纵磁触头的三维模型,进行了磁场分布与电动力的计算;为了进一步提高触头的性能,然后构建了以触头片开槽长度、开槽宽度、径向偏转角度、杯座斜槽高度及单个斜槽上下旋转角度为输入,电流峰值时刻触头间隙中心平面纵向磁场强度最大值、过零时刻中心点处磁滞时间、合闸时动静触头间的电动斥力分别为输出的RBF神经网络模型;最后结合RBF神经网络模型与多目标灰狼优化算法(MOGWO)对触头结构进行了优化。结果表明:与初始结构参数相比,当触头片开槽长度为19.74mm、宽度为3.94mm、径向偏转角为19.9°、杯座斜槽高度为18.0mm、斜槽上下旋转角为119.2°时,触头具有更好的磁场分布特性,且动、静触头间的电动斥力明显减小,有利于提高触头的工作性能。

大电流真空电弧中阳极熔化过程的实验与仿真研究

大电流真空开断过程中,阳极触头在电弧作用下的熔化过程极大地影响着开断结果。目前对阳极熔化的研究集中于铜及铜基合金,所涉及的材料热特性参数较为局限。为了在更大物性参数范围下剖析阳极熔化机理,该文对W、Mo、Cr、Fe四种材料开展了阳极熔化实验研究,同时建立电弧磁流体动力学模型及阳极传热模型对熔化过程进行仿真模拟。结果表明,在固定阴极为Cu的大电流燃弧实验中,四种阳极材料的临界熔化电流分别为14.0、11.9、8.6、7.5 kA;在阳极热过程模拟中,确定了阳极输入能流密度的空间与时间分布,并得到了阳极表面温度。四种材料的阳极最高温度均出现在燃弧时刻7.0 ms附近,临界电流下计算得到的阳极最高温度与相应材料熔点误差小于150 K。

磁控触头旋转开断过程中直流真空电弧形态与电压特性

为探索直流断路器磁控触头开断产生的真空电弧形态演变规律及其电压特性,提出了一种在触头直拉基础上附加阴极旋转运动的开断方式“旋转—直拉开断”。由于磁控触头开断电流自生磁场会影响真空电弧发展过程,文章对阴极旋转开断产生的磁场进行了仿真分析。同时搭建了可拆卸真空灭弧实验平台,对万字型横磁触头和杯状纵磁触头在不同开断方式下的真空电弧的形态演化规律以及电弧电压特性进行了对比分析研究。仿真与实验结果表明:真空电弧在旋转开断方式下受到触头磁场和旋转离心力的共同作用,燃弧时间更短、由限制型电弧向扩散态的转变更快、熄弧效率更高。“旋转—直拉开断”使得在阴极表面的亮斑运动加速,使得电弧能量逸散更快有效提高熄弧能力。

CuCr55电极触头真空电弧燃弧与烧蚀特性

铜铬合金材料作为电接触领域最重要的触头材料之一,在真空灭弧室中得到了广泛的应用。采用电弧熔炼方法制备了CuCr55触头材料,对比了熔铸CuCr25、熔渗CuCr50和电弧熔炼CuCr55材料的微观结构,并着重分析了电弧熔炼CuCr55触头的真空电弧燃弧与烧蚀特性。利用高速摄影机拍摄短路电流燃弧特性,得到了产生阳极斑点的临界电流。利用电子显微镜观察烧蚀过后的触头表面微观形貌,触头表面未出现材料断裂、细微裂痕或显著隆起。研究结果表明,电弧熔炼CuCr55触头具有铬颗粒细小均匀、显微组织球化弥散分布的微观结构,以及良好的均匀烧蚀特性。

真空断路器铜铬金属蒸气等离子体非局部热力学平衡态物性参数分析

真空断路器在大电流故障开断过程中,以真空为介质条件的灭弧系统内所产生的金属蒸气电弧等离子体组氛与电极材料特性密切相关。为了研究开断过程中金属蒸气等离子体物性参数的变化,以真空断路器CuCr25~CuCr75触头电极材料为研究对象,建立非局部热力学平衡模型,研究铜铬合金不同配比下金属蒸气等离子体粒子组氛分布。采用统计热力学方法求得等离子体热力学参数,分析不同合金配比下比焓和比定压热容分布;利用Chapman-Enskog法计算等离子体输运参数,探究铜铬合金材料配比对电导率的影响。

真空灭弧室CuCr触头抗电弧烧蚀和抗熔焊研究与改进

CuCr触头材料的抗烧蚀和抗熔焊性是影响真空灭弧室寿命的重要因素。文中以CuCr触头材料在真空电弧下的烧蚀为立足点,对烧蚀过程和机理进行叙述,并从CuCr触头的微观组织以及真空灭弧室的磁场类型论述影响CuCr触头烧蚀的相关机理。同时指出抗熔焊性能与触头材料的抗拉以及热导率等因素有关。最后从表面改性和合金化角度总结了提高触头抗烧蚀的研究进展,并总结改进触头抗烧蚀性能的研究方向。

电流频率对真空断路器开断能力影响的仿真分析

随着风电等新能源以及直流电网的发展,断路器开断电流的频率呈现出多样化,要求断路器可以开断高于或者低于50 Hz的电流。针对此问题,文中试图从燃弧过程、磁场调控以及弧后过程3个方面去研究电流频率对真空断路器开断能力的影响。文中首先研究了不同频率下的电弧微观参数分布,发现随着频率的增加,电弧形态越呈现出集聚的现象,触头呈现出局部烧蚀严重的现象,但是由于燃弧时间变短,触头总的烧蚀变小。频率越低,燃弧时间越长,触头则呈现出严重的烧蚀。然后研究了不同频率下常用杯状纵磁触头的磁场分布,发现随着频率的增加,磁场分布越不均匀,对电弧等离子体的扩散作用变小,并且由于燃弧时间的缩短,等离子体更不易扩散。最后通过频率对弧后鞘层生长过程的影响分析发现,频率越大,弧后鞘层生长到满开距越慢,从而降低开断能力。文中得出:低频下的断路器触头整体烧蚀严重,电弧熄弧的时候将产生大量的金属蒸气,金属蒸气的衰减过程将主导断路器的弧后绝缘恢复过程,而高频下的断路器的弧后绝缘恢复过程则由鞘层生长过程主导。

配用CuCr合金电极的真空介质开关电弧阳极热过程分析

真空介质开关电弧的主要成分源于故障电流开断过程中触头电极在极间产生的金属蒸气,且真空电弧的微观动力学行为直接影响开关的开断能力。文章通过建立真空介质电弧双温磁流体动力学模型,研究配用不同配比CuCr合金触头电极材料的真空介质开关在故障电流开断下阳极热过程的变化情况,得到阳极触头表面温度和熔池范围沿径向和轴向的分布。仿真结果表明,开断故障电流的增大及电极合金材料中Cu含量的增大均会导致输入阳极的能流密度增大。在200 A电弧电流作用下,阳极表面温度未达到CuCr合金的熔点,未发生熔化;而在6 kA电弧电流作用下,阳极温度先后达到Cu和Cr的熔点,电极熔化程度随合金中Cr含量的增大而减弱。

横磁触头真空电弧起始运动的临界触头开距实验研究

起始桥柱状真空电弧运动的临界开距是对应于横磁触头大电流真空电弧运动模式演变的标志性物理量,对横磁触头真空断路器大电流开断性能具有重要影响。本文的研究目标是实验研究横磁触头开槽方式、燃弧时间和电弧电流等因素对横磁触头起始桥柱状真空电弧运动临界开距的影响规律。研究结果显示在燃弧时间0 ms~10 ms、电流有效值5 kA~31.5 kA的实验条件下,3种结构的横磁触头的起始桥柱状电弧有越靠近电流峰值起弧,停滞时间越长的趋势。直角槽型卐字形横磁触头(CuCr40)、螺旋槽型横磁触头(CuCr25)和曲线槽型卐字形横磁触头(CuCr50)的电弧运动临界开距分别在0.96,1.1 mm和1.7 mm有概率最大值点。相关研究结果对横磁触头大电流真空电弧的发展和演变特性的理解提供基础。

快速真空开关合闸触头弹跳暂态过程研究

以电磁斥力驱动器作为操动机构的快速真空开关具有分闸速度快,分合闸时间短和分合闸时间分散性小的优势,目前已广泛应用于多种电力设备中。目前对于快速真空开关的分闸过程已有众多研究,但合闸过程的相关问题尚属空白。文中研究了快速真空开关合闸过程中触头弹跳问题。建立了多物理场耦合仿真模型,完整描述了快速真空开关的合闸过程。得到了快速真空开关的v1与Dmax的关系,其中v1为合闸过程中动静触头首次接触的瞬时速度,Dmax为动触头的最大弹跳距离。根据这一关系式,确定了合闸过程中无触头弹跳情况下的临界瞬时合闸速度vcri。根据vcri限制,设计了一种新型的油阻尼器来调节快速真空开关的合闸行程曲线,实现无触头弹跳合闸。研制了装备新型油缓冲器的快速真空开关,搭建了机械特性测试平台,对其合闸特性进行了测试。测试结果表明:测量结果与仿真结果之间的误差不超过10%,且实现了无触头弹跳合闸。