Simulation and Experimental Study of Arc Column Expansion After Ignition in Low-Voltage Circuit Breakers

The dynamic process of arc pressure and corresponding arc column expansion, which is the main feature after arc ignition and has a significant effect on the breaking behaviour of low -voltage circuit breakers, is studied. By constructing a three dimensional mathematical model of air arc plasma and adopting the Control Volume Method, the parameters of arc plasma including temperature and pressure are obtained. The variations of pressure field and temperature field with time are simulated. The result indicates that there are six stages for the process of arc column expansion according to the variation of pressure in arc chamber. In the first stage, the maximal pressure locates in the region close to cathode, and in the second stage the maximal pressure shifts to the region close to the anode. In the third stage, the pressure difference between the middle of arc column and the ambient gas is very large, so the arc column begins to expand apparently. In the fourth stage, the pressure wave propagates towards both ends and the maximal pressure appears at the two ends when the pressure wave reaches both sidewalls. In the fifth stage, the pressure wave is reflected and collides in the middle of the arc chamber. In the last stage, the propagation and reflection of pressure wave will repeat several times until a steady burning state is reached. In addition, the experimental results of arc column expansion, corresponding to the arc pressure variation, are presented to verify the simulation results.

Comparison of Reynolds average Navier-Stokes turbulence models in numerical simulations of the DC arc plasma torch

Five turbulence models of Reynolds average Navier-Stokes(RANS),including the standard k-ω model,the RNG k-e model taking into account the low Reynolds number effect,the realizable k-ω model,the SST k-ω model,and the Reynolds stress model(RSM),are employed in the numerical simulations of direct current(DC)arc plasma torches in the range of arc current from 80 A to 240 A and air gas flow rate from 10 m^3 h^-1 to 50 m^3 h^-1.The calculated voltage,electric field intensity,and the heat loss in the arc chamber are compared with the experiments.The results indicate that the arc voltage,the electric field,and the heat loss in the arc chamber calculated by using the standard k-ω model,the RNG k-ωmodel taking into account the low Reynolds number effect,and the realizable k-ω model are much larger than those in the experiments.The RSM predicts relatively close results to the experiments,but fails in the trend of heat loss varying with the gas flow rate.The calculated results of the SST k-ω model are in the best agreement with the experiments,which may be attributed to the reasonable predictions of the turbulence as well as its distribution.

Numerical Study on Arc Plasma Behavior During Arc Commutation Process in Direct Current Circuit Breaker

This paper focuses on the numerical investigation of arc plasma behavior during arc commutation process in a medium-voltage direct current circuit breaker （DCCB） contact system. A three-dimensional magneto-hydrodynamic （MHD） model of air arc plasma in the contact system of a DCCB is developed, based on commercial software FLUENT. Coupled electromagnetic and gas dynamic interactions are considered as usual, and a thin layer of nonlinear electrical resistance elements is used to represent the voltage drop of plasma sheath and the formation of new arc root. The distributions of pressure, temperature, gas flow and current density of arc plasma in arc region are calculated. The simulation results indicate that the pressure distribution related to the contact system has a strong effect on the arc commutation process, arising from the change of electrical conductivity in the arc root region. In DCCB contact system, the pressure of arc root region will be concentrated and higher if the space above the moving contact is enclosed, which is not good for arc root commutation. However, when the region is opened, the pressure distribution would be lower and more evenly, which is favorable for the arc root commutation.

3D Numerical Analysis of the Arc Plasma Behavior in a Submerged DC Electric Arc Furnace for the Production of Fused MgO

A three dimensional steady-state magnetohydrodynamic model is developed for the arc plasma in a DC submerged electric arc furnace for the production of fused MgO. The arc is generated in a small semi-enclosed space formed by the graphite electrode, the molten bath and unmelted raw materials. The model is first used to solve a similar problem in a steel making furnace, and the calculated results are found to be in good agreement with the published measurements. The behavior of arcs with different arc lengths is also studied in the furnace for MgO production. From the distribution of the arc pressure on the bath surface it is shown that the arc plasma impingement is large enough to cause a crater-like depression on the surface of the MgO bath. The circulation of the high temperature air under the electrode may enhance the arc efficiency, especially for a shorter arc.

Numerical Analysis of the Arc Plasma in a Simplified Low-voltage Circuit Breaker Chamber with Ferromagnetic Materials

This paper is devoted to the simulation of the arc plasma in a simplified low-voltage circuit breaker chamber. Based on a group of coupled governing equations, a three-dimensional （3-D） arc plasma model is built and solved by a modified commercial code. Firstly, this paper presents a solution of the stationary state of the arc plasma and discusses the distribution of some parameters throughout the chamber. Secondly, with the ferromagnetic materials included, the balance of the stationary state is broken and a transient course is calculated. In light of the simulation results, the temperature distribution sequence, the arc motion and the plasma jet are then described and analyzed in detail.

Three-dimensional non-equilibrium modeling of a DC multi-cathode arc plasma torch

In this paper,a three-dimensional non-equilibrium steady arc model is used to investigate the temperature,velocity and electromagnetic field in multi-cathode arc torch,and the formation mechanism of a large-area,uniform and diffused arc plasma is analyzed.The numerical simulation results show that a large volume plasma region can be formed in the central region of the generator during discharge.During this process,the maximum electron temperature appears near the cathode and in the central convergence region,while the maximum heavy particle temperature only appears in the central convergence region.This phenomenon is consistent with the experimental arc images.Near the cathode tip,the arc column is in a contraction state.In the area slightly away from the cathode,the six arc columns begin to join together.In the plasma generator,there is a large-scale current distribution in all directions of X,Y and Z,forming a stable arc plasma with a wide range of diffusion.The calculated electron temperature distribution is in good agreement with the measured electron temperature.The results suggest that the largearea diffused arc plasma in the multi-cathode arc torch is the combined effect of current distribution,convection heat transfer and heat conduction.

Numerical simulation and analysis of lithium plasma during low-pressure DC arc discharge

Alkali metal DC arc discharge has the characteristics of easy ionization,low power consumption,high plasma temperature and ionization degree,etc,which can be applied in aerospace vehicles in various ways.In this paper,we calculate the physical property parameters of lithium vapor,one of the major alkali metals,and analyze the discharge characteristics of lithium plasma with the magnetohydrodynamic(MHD)model.The discharge effects between constant current and voltage sources are also compared.It is shown that the lithium plasma of DC arc discharge has relatively high temperature and current density.The peak temperature can reach tens of thousands of K,and the current density reaches 6 x 107 A m 2.Under the same rated power,the plasma parameters of the constant voltage source discharge are much higher than those of the constant current source discharge,which can be used as the preferred discharge mode for aerospace applications.

Numerical simulation of temperature field in plasma-arc flexible forming of laminated-composite metal sheets

Flexible forming of laminated-composite metal sheets (LCMS) using plasma arc is a latest technique, which produces LCMS components by thermal stress without mould and external force. Considering that the controllable temperature field is the key during the forming process, a three-layer FEM model, based on the characteristics along LCMS thickness direction, was developed to study the variation rules of temperature field, which was verified robustness by experimental validation. Besides, the influences of process parameters such as plasma arc power, scanning speed and plasma arc diameter on LCMS temperature field were performed. The comparisons of LCMS with single layer metal sheet (SLMS) show the temperature difference of LCMS along thickness direction is smaller than that of SLMS, but the heat-affected zone of LCMS along X axis is wider than that of SLMS under the same process parameters.

Simulation of the Process of Arc Energy-Effect in High Voltage Auto-Expansion SF_6 Circuit Breaker

A new magnetic hydro-dynamics （MHD） model of arc in H.V. auto-expansion SF6 circuit breaker that takes into consideration nozzle ablation due to both radiation and thermal conduction is presented in this paper. The effect of PTFE （polytetrafluorethylene） vapor is considered in the mass, momentum and energy conservation equations of the constructed model. Then, the gas flow fields with and without conduction considered are simulated. By comparing the aforementioned two results, it is indicated that the arc＇s maximal temperature with conduction considered is 90 percent of that without considering conduction.

Numerical Simulation of the Eddy Current Effects on the Arc Splitting Process

This paper focuses on a numerical simulation of the arc plasma behavior in the arc splitting process, considering the eddy currents in the electrodes and the splitter plate. Based on three-dimensional （3D） magneto-hydrodynamic （MHD） theory, a thin layer of nonlinear electrical resistance elements is used in the model to represent the voltage drop of plasma sheath and the formation of new arc root in order to include the arc splitting process in the simulation. In the arcing process, eddy currents in metal parts are generated by a time-varying magnetic field. The arc model is calculated with the time-varying magnetic field term, so that the eddy current effects can be considered. The effect of nonlinear permeability of a ferromagnetic material is also involved in the calculation. Using the simulation results for the temperature, velocity and current density distribution, the arc splitting process is analyzed in detail. The calculated results are compared with the simulation neglecting eddy currents.

Influence of Copper Vapor on Low-Voltage Circuit Breaker Arcs During Stationary and Moving States

The influence of copper vapor on the low-voltage circuit breaker arcs is studied. A three-dimensional （3-D） magnetohydrodynamics（MHD） model of arc motion under the effect of external magnetic field is built up. By adopting the commercial computational fluid dynamics （CFD） package FLUENT based on control-volume method, the above MHD model is solved. For the mediums of air-1% Cu and air-10% Cu, the distributions of stationary temperature, pressure, electrical potential and the arc motion processes are compared with those of a pure air arc. The copper vapor diffusion process in the arc chamber and the distribution of copper vapor mass concentration are also simulated. The results shows that the copper vapor has a cooling effect on the arc plasma and can decrease the stationary voltage as well. Moreover, the presence of copper vapor can decelerate the arc motion in the quenching chambers. The maximal copper vapor concentration locates behind the arc root because of the existence of a ＂double vortex＂ near the electrodes.

大电流真空电弧开断过程瞬态特性仿真分析

针对开断过程中传统稳态模型无法表征真空电弧动态特性问题,以工频电流下开断峰值为10 kA大电流真空电弧为研究对象,搭建等离子体弧柱区二维物理模型,在已有双温磁流体动力学稳态模型中引入密度、温度、压力及速度等流场参数时变项,同时利用动网格技术控制弧柱区变化速率,模拟触头分闸过程,综合考虑电流及开距变化情况下等离子体各物理场参数变化,以获取开断时电弧微观流场瞬态特性,探究开断过程中电弧形态及能量变化。分析结果可知:离子压力、温度、电子温度和阳极表面能流密度均随动、静触头分离而减小;离子速度无明显变化;等离子体不断向外扩散,由于电流减小,金属蒸汽源也逐渐减少,极间等离子体密度降低,阳极尚未达到活跃程度,最终电弧熄灭。

直流电弧等离子体炬数值模拟与诊断

直流电弧等离子体炬内部物理过程复杂且具动态性,较难对其进行准确描述与深入研究,且其工作温度较高,其状态参数难以使用常规方式测量。针对直流电弧等离子体炬,建立流动、传热和电磁相互耦合的数值模型,基于Fluent软件对直流电弧等离子体炬进行三维数值模拟和特性分析,设计并搭建了一套热焓探针实验系统,完成对直流电弧等离子体炬射流参数的测量分析。结果表明:建立的数值模型模拟结果与实验测量结果吻合较好,误差在10%以内;炬内温度与速度最大值与工作气流量呈正相关,均出现在靠近阴极区域,且沿轴线逐渐降低;等离子体炬内高温区与高电流密度区重合。

单头部模型燃烧室滑动弧等离子体点火数值仿真研究

针对航空发动机燃烧室内滑动弧等离子体点火的特性,采用数值模拟的方法对航空发动机单头部模型燃烧室进行滑动弧等离子体点火研究,将滑动弧等离子体简化为动态热源,并将滑动弧等离子体点火与电火花点火对比,归纳2种点火方式下燃烧室点火过程中温度分布与火焰演化的规律,总结滑动弧等离子体点火的特性。计算结果表明,电火花点火和滑动弧等离子体点火2种点火方式所能达到的平均温度峰值基本相同。在滑动弧等离子体点火过程中,放电功率为200 W、空气流量为25 m^(3)/h条件下,余气系数为1时,着火延迟时间为224.6 ms;余气系数为2时,着火延迟时间为324.9 ms;余气系数为4时,着火延迟时间为878.7 ms。另外,在放电功率为200 W、余气系数为1的条件下,当空气流量为15 m^(3)/h时,着火延迟时间为194.8 ms;空气流量为35 m^(3)/h时,着火延迟时间为298.9 ms。结果表明着火延迟时间随着余气系数、空气流量的增大而增长。

Study of Variation Patterns of Shock Wave Control by Different Plasma Aerodynamic Actuations

Demonstrative experiments on the variation patterns of the position, angle, and intensity of shock wave are presented. Different means of aerodynamic actuation, such as variations of the distance between discharge channels, the number of discharge channels, the DC discharge voltage, the angle of ramp, and the application of magnetic field, in a supersonic flow of M = 2.2 are employed. Results of both the schlieren and pressure test indicated that when the plasma aerodynamic actuation is applied, the starting point of the shock wave was shifted 1 mm to 8 mm upstream on average, the shock wave angle was reduced 470 to 8% on average, and the shock wave intensity was decreased by 8% to 26%. The local plasma aerodynamic actuation could generate an extrusive plasma layer with high temperature and pressure. This plasma layer caused an upstream-shift of the separating point of the boundary layer. which changed the structure of the original shock wave. Moreover, in a simulation study, the plasma aerodynamic actuation was simplified as a thermal source term added to the Navier-Stokes equations, after all, the results obtained showed consistency with the experimental results.

钛管高速双枪TIG焊电弧和熔池动态行为的数值模拟

采用高速双枪TIG焊制造钛焊管。建立双钨极、双电弧和熔池耦合数学模型,研究温度场分布、电弧等离子体和熔池液态金属流动以及双枪TIG焊系统能量传输行为。电弧极性相同,在电磁力作用下,前后电极下方的电弧等离子体相向流动。熔池Marangoni力远高于电弧剪切力,是熔池上表面液态金属后向流动的主要驱动力。计算的双钨极电弧热效率为79.8%。高速双枪TIG焊可以提高钛焊管的制造效率和质量。

厚板铝合金变极性等离子弧焊电弧物理特性

为克服厚板铝合金穿孔焊接熔池极易失稳的难题,该研究从厚板焊接时电弧温度场出发,旨在探究厚板穿孔焊接熔池稳定性的机理。通过建立三维数值模型,研究了焊接母材厚度分别为5 mm和16 mm下变极性等离子电弧的温度场、流场和电流密度分布。结果表明,随着板厚的增加,变极性等离子电弧温度场分布发生改变,5 mm板厚电弧温度的衰减情况为线性,而16 mm厚板焊接的电弧温度衰减情况为二次型,使得温度变化更加复杂。变极性等离子弧焊接5 mm厚度铝合金时,整个小孔熔池的电流密度呈1.0×10^(6) A/m^(2)以上,但是在焊接16 mm厚板铝合金时,相同电流密度仅达到小孔深度的12 mm处。该研究有望对实现大厚度铝合金稳定焊接,拓宽变极性等离子弧焊接应用范围提供理论指导。

0.2 mm不锈钢薄板焊接工艺研究及仿真分析

分别采用激光焊和微束等离子弧焊开展0.2 mm奥氏体不锈钢薄板的对焊加工,并选用圆锥体热源模型对2种焊接工艺进行模拟研究。结果表明:激光焊和微束等离子弧焊均可实现0.2 mm厚的不锈钢薄板对焊加工;采用圆锥体热源能准确勾勒出不锈钢薄板在2种焊接工艺下焊缝截面的熔池轮廓;选取相同的仿真参数,激光焊和微束等离子弧焊出现类似的变形场和应力场,微束等离子弧焊的总体变形和整体应力略大于激光焊的。

等离子弧焊接熔池和小孔形成过程数值分析

目的研究等离子弧焊接穿孔过程中熔池内部的金属流动情况和小孔动态变化过程。方法通过“传热-熔池流动-小孔”之间的相互耦合关系,建立了等离子弧焊接穿孔过程的数值分析模型,通过VOF方法追踪了小孔界面,采用FLOW-3D软件模拟了等离子弧焊接熔池和小孔的形成过程,定量计算了等离子弧焊接温度场、熔池流场及小孔形状;分析了等离子弧焊接熔池和小孔行为;并通过等离子弧焊接实验数据验证了模拟结果。结果当焊接时间为0~1.0 s时,小孔深度曲线与熔深曲线几乎相同,小孔底部紧贴熔池底部;在2.8s以后,小孔深度曲线与熔深曲线有一定距离,小孔深度曲线在一定范围内波动,等离子弧焊接电弧挖掘作用到达极限,电弧压力与其他力达到平衡状态。模拟的焊缝熔深为8.04mm、熔宽为13.20mm,实验测得的焊缝熔深为8.00 mm、熔宽为13.42 mm。结论构建的随小孔动态变化的曲面热源模型和电弧压力模型可以描述等离子弧焊接过程中的电弧热-力分布;模拟出了等离子弧焊接熔池和小孔动态演变过程;模拟得到的等离子弧焊接焊缝形貌与实验测得的焊缝形貌基本吻合。

六相交流放电再入飞行器热环境地面模拟研究

再入飞行器高速飞行过程中,其表面受到强烈的气动加热作用,所产生的复杂高温气体环境会破坏飞行器材料,影响飞行器结构的可靠性.因此,基于地面装置实现高速飞行器再入过程中表面热环境的模拟,对于再入飞行器的热防护测试具有十分重要的意义.文章基于数值模拟,分析了工作气压的变化对等离子体中非平衡能量输运过程以及等离子体气体温度等参数的影响规律,提出了通过改变工作气压来调节等离子体冲击壁面的热流密度的方法.基于此,首先以表面热流密度和加热时间与真实飞行条件下一致为原则,基于六相交流电弧放电等离子体实验平台,产生了大体积、高气体温度,且壁面热流密度可调的等离子体电弧射流.然后,对采用酚醛浸渍基碳热防护材料的烧蚀体进行了地面烧蚀实验,在壁面热流密度为1.07~3.95 MW/m2范围内获得了与文献报道吻合较好的实验结果,初步验证了该方法的可行性.对高速再入飞行器典型部件进行了烧蚀实验,在壁面最高热流密度为5 MW/m2的实验条件下,获得了与空间飞行实验吻合良好的地面模拟实验结果.这表明在不采用高成本风洞的前提下,本论文所提出的地面模拟实验方法可在一定程度上模拟飞行器再入过程中的表面热环境.