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.

A mathematical model of rough surface contact characterization in spot welding

Based on the elastic-plastic mechanics and the contact mechanics, an asperity contact model for the resistance spot welding of the rough surface is presented. The numerical results indicate that the real contact area is only a small section of the nominal contact area. The value of the real contact area is randomly fluctuating within 20%. The real contact area’s distribution and each point’s deformation can also be obtained from this model, which is primary in the calculation of the contact resistance and the temperature field of the spot welding.

The Asymmetric Laplace Law for distribution of aluminum contact resistance in spot welding

This paper investigates the distribution of contact resistance of the aluminum alloy in the squeeze stage. A new method of measuring path＇ s resistance is proposed firstly. Contact resistances are calculated accurately by the systems of 5 linear equations and solutions show that three contact resistances are different. The probability density functions of contact resistance in workpiece/workpiece（ W/W） and upper electrode/workpiece（ E/W） show that the curve shape has steeper peak and heavier tail than that of the normal distribution. Non-parameter hypothesis test is performed and the result shows that R2 , R4 reject the normal distribution using chi-square and kolmogoroo statistic D method. Therefore, the Asymmetric Laplace distribution is fitted to empirical distributions and is applied to quantify the influence of random contact resistance. The result illustrates that AL distribution is very close to contact resistance of W/W and upper E/W and normal distribution has some deviation. The paper is helpful to research the initial nugget conditions, weldability and the transient multi-coupling field.

汽车变速器齿轮修形对齿轮疲劳寿命的影响研究

新能源卡车变速器齿轮受壳体变形影响易出现疲劳点蚀失效。针对壳体变形问题引入齿轮螺旋线补偿修形,利用Romax Designer对齿轮进行修形优化,改善齿轮的接触斑点,降低齿轮的最大接触应力。修形优化后的齿轮通过变速器疲劳耐久试验,对齿轮寿命提升约一倍。

基于MASTA的大速比减速器齿轮综合修形优化设计

为了优化某大速比减速器斜齿圆柱齿轮传动系统的振动噪声水平,通过MASTA对其一、二级齿轮传动进行啮合及振动噪声仿真分析,发现存在偏载、应力集中、振动噪声较大等问题,存在较大的传递误差。以减小传递误差与齿面接触应力为目标,进行齿面修形优化设计,建立齿面修形优化模型并求解,采用MASTA对修形后模型进行分析,并对其样机进行噪声试验,验证齿面修形的有效性。结果显示:MASTA分析结果符合理论分析,仿真方法准确,修形后齿轮的接触应力和传递误差均明显减小,接触斑点分布均匀,振动噪声明显降低,且一级齿轮传动比二级齿轮传动效果更明显。可见此优化设计方案对减速器减振降噪具有较好的效果,为此类减速器齿轮设计提供理论参考。

弓网接触状态光纤传感监测技术研究

在弓网检测的应用场景中,传统的测力传感器和加速度传感器依赖电源供电,且必须安装在高电压的受电弓上,从而增加额外的设备和复杂性。文章研究采用无源光纤布拉格光栅(FBG)光传感器,这种传感器无需额外安装供电电源和充电控制系统等设备。通过介绍光纤传感器的基本原理,并分析其应用场景,提出在弓网状态监测的高电压环境中,光纤传感器具有独特优势:不仅无需供电,减少额外设备,还能实现信号传输的高低压隔离,有效抵抗电磁干扰。针对受电弓检测的特殊需求,开发基于光纤传感技术的接触力和加速度传感器,其便于在受电弓上安装且对受电弓结构无影响。在列车受电弓上的实际安装测试中,成功实现对弓网接触力、硬点等参数的高精度检测。该弓网状态监测系统能够适用于专用检测车和运营动车组,大幅扩展弓网监测的应用范围。

Formation Process of Intermittent Molten Bridge Between Au-Plated Contacts at Super Low Breaking Velocity

This paper presents the molten bridge behaviors of Au-plated material at super low breaking velocity conditions by introducing our new designed test rig. The typical waveforms of the contact voltage and contact force during breaking are investigated under the load of 5- 25 V/0.2-1 A and velocity of 25-150 nm/s. It is shown that the intermittent molten bridge is formed from the competition of multitude contact a-spots for current distribution and the solid- liquid mixing characteristics of a molten bridge. Also, it is proved that the bridge is not composed by the completed melted metal by using FEM thermal simulation and the voltage-temperature relation. The observed surface morphology reveals that the scattered and stacked melted regions are attributed to the intermittent bridge. Finally, the effects of breaking velocity and electrical load on bridge length and duration are also analyzed.

Influence of Surface Condition on Expulsion in Spot Welding AZ31B Magnesium Alloy

Experiments were carried out to study the influence of surface condition on expulsion during the spot welding of AZ31B Mg alloy. A general electrical contact resistance theory for conductive rough surfaces and the relation between maximum temperature Tm in the contact and voltage-drop V across interface of two surfaces were employed to understand the reason of expulsion in Mg alloy spot welding. The main reason of expulsion is that the high electrical contact resistance induced by large roughness of the surface and oxide film covered on the surface leads to local melting of metal in the interface of two surfaces, and liquid metal of the local area ejected from the specimen under electrode force forms expulsion.

Measurement of dynamic resistance in resistance spot welding

The conventional methods of determining the dynamic resistance were mostly done by measuring the voltage and current at secondary side of transformer in resistance welding machines, in which the measuring set-up normally interferes with the movement of electrode, and the measuring precision is influenced by inductive noise caused by the high welding current. In this study, the dynamic resistance is determined by measuring the voltage at primary side and current at secondary side. This increases the accuracy of measurement because of higher signal-noise ratio, and allows to apply to in-process system without any wires connected to electrodes.

Formation of a 40 A DC Current Arc During the Opening of Silver Contacts

The erosion of silver contacts due to break arcs with length proportional to time and of variable duration has been measured by weighing the contacts following 5000 openings at a constant current equal to 40 A.The experimental results show that,for arc durations shorter than 60 μs,the transfer of metal from the anode to the cathode occurs,but after passing this stage,when the two electrodes are separated by greater distances,each will display erosion.This is the result of the diffusion of material outside the space between the two electrodes.In order to interpret these results,we have applied a classical model of the physical phenomena occurring at the root of the arc.Analysis of the experimental results shows that for an arc duration of less than15 μs,no distinct cathode root is seen to exist,but beyond this,several spots appear gradually on the cathode for arc duration up to 50 μs,after which they merge into a single spot.The comparison between experiment results and theoretical interpretation is reasonable up to 60 μs.

Numerical Simulation on Nugget Formation and Evolution in Spot Welding of Aluminum Alloy

With the squeeze of electrode tips, the oxide film on aluminum (Al) alloy surface is broken and numbers of micro-gaps are formed randomly. The micro-gaps act as conducting spots at the beginning of welding, so the contact resistance is extremely high and unstable in spot welding of Al alloy. In this paper, a new contact resistance model is adopted to simulate the nugget forming process. This model describes the random distribution characteristic of conducting spots. The simulation results indicate that, within the first 5 ms of welding current (AC, 50 Hz), the temperature distribution at the workpieces interface is seriously irregular. In addition, the nugget does not nucleate from the weld center and grow continuously, however, it nucleates randomly from several points almost instantaneously and then merges into an entity quickly. Experimental results agreed with the numerical simulation.

基于通道拉伸和改进MSR的蜗轮副接触斑点图像增强算法

在蜗轮副接触斑点视觉检测中,摄像头所采集到的图像整体亮度较低、对比度低,导致图像检测结果不够理想,所以需使用图像增强技术,对图像的亮度、对比度等信息进行增强。为此,提出了一种基于通道拉伸和改进多尺度Retinex(MSR)的图像增强算法。首先,在低光照环境下,对图片进行了通道拉伸,增强了其饱和度和对比度,避免了图像增强过程中出现图像细节颜色失真的情况;然后,为了进一步增加图像细节的对比度,采用改进MSR算法对拉伸后的图像进行了处理,利用自适应权重双边滤波、tanh函数分别替换了传统MSR中的高斯中心环绕函数和对数函数,以减少细节信息的丢失;最后,采用自适应伽马变换对图像亮度做了进一步改善,使图像的质量更高,便于图像的后续处理。实验结果表明:与MSR、基于双边滤波改进的MSR增强算法相比,基于通道拉伸和改进多尺度Retinex的蜗轮副接触斑点图像增强算法的图像增强效果更好;进行图像增强后,图片的均值、标准差、信息熵、对比度相比于原图分别提高了48.3%、61.6%、7.1%、91.3%。研究结果表明:采用该图像增强算法之后,图像的质量和特征信息更好,有利于图像的检测和处理。

考虑阴极斑点动态特性的真空灭弧室触头磁场计算方法研究

真空断路器广泛应用于中压电力系统中,利用触头线圈产生的磁场调控真空电弧是提高真空断路器开断能力的重要手段,然而目前的设计方法没有综合考虑阴极斑点动态运动与触头线圈磁场的耦合效应,影响其设计准确性和精度。本文建立了考虑阴极斑点与磁场耦合关系的触头磁场计算模型,根据阴极斑点分布计算触头间隙控制电弧的磁场,并由磁场推进阴极斑点运动。在四分之一匝线圈式触头下,分析了阴极斑点分布对触头磁场的影响,对比了考虑耦合关系对触头磁场计算结果造成的差异。仿真结果表明,在阴极斑点的初始扩散阶段,纵磁变化不明显,而横磁随阴极斑点扩散而变化;稳定燃弧时,考虑耦合关系与否的纵磁最大差值可达纵磁最大值的24.1%。本文所建立的模型以及计算方法为真空灭弧室触头提供了一种新的设计思路与方法。

基于齿轮微观修形的行星减速器减振降噪研究

为改善某工厂的全自动攻丝机用行星齿轮减速器的振动噪声问题,并提升攻丝机的攻丝精度和使用寿命,对全自动攻丝机用减速器进行传动接触斑点试验,并利用Romax软件对减速器进行仿真,试验与仿真分析结果显示啮合齿轮副存在明显偏载问题。针对上述分析,提出基于遗传算法的齿向修形、渐开线修形及齿廓修形等复合齿轮微观修形优化方案;对修形优化后减速器重新建模仿真,并搭建行星齿轮减速器振动、噪声检测试验台,对修形前后减速器样机进行试验测试。结果表明:修形后减速器啮合时的偏载问题得到明显改善,齿面峰值载荷降低11.75%,最大接触应力降低29.62%,传动误差降低35.71%,减速器整体的振动噪声显著降低。

变速器振动噪声分析及轮齿修形优化

变速器是影响整车噪声振动舒适性(Noise Vibration&Harshness,NVH)的重要因素,如何降低变速器运行过程中的呼啸噪声是研究焦点。面向工程中应用的变速器,建立了综合考虑壳体刚度、轴承接触变形等因素的变速器壳体有限元模型,分析了齿轮传递误差及接触斑点,对比了接触斑点的测试与仿真结果,验证了有限元模型的可靠性。根据频谱分布确定了噪声激励源为输出齿轮副,给出了变速器齿轮修形的技术方案。优化后,变速器系统齿轮动态啮合过程的传动误差下降了69%、噪声下降了4 dB。

太阳能光热发电追光系统中蜗杆副选型及应力分析

针对目前太阳能光热发电定日镜追光系统中蜗杆副精度寿命短、侧隙难调整等不足,探讨了蜗杆副的选型,通过建立传动副三维模型和有限元模型,分析了完整工作周期载荷下的齿面应力,试制传动副样件并进行了齿面精度检测和接触斑点试验。分析结果表明:在工作周期的主要工作载荷和极限载荷下,齿面有限元模拟分析的最大Von-Mises应力均满足设计要求;传动副齿面应力分布规律与接触斑点和图形学显示结果吻合;蜗杆齿面螺旋线误差、齿形误差以及蜗轮齿面全齿齿距累积误差、单齿距偏差和径向跳动检测结果显示,该双导程蜗杆为6级精度,蜗轮为7级精度,满足追光系统设计要求。研究结果可为后续太阳能追光系统中蜗杆副的选型和实际应用奠定理论支撑和试验参照。

铁道电气化接触网产生硬点的原因分析与改进对策

铁道电气化接触网硬点问题是铁道电气化建设的常见问题之一,此类问题容易产生电弧伤害以及机械损伤问题。解决此问题,一直都将是铁道接触网的关键性工作。下面将以铁道电气化接触网硬点问题为研究对象,主要探讨电气化接触网、接触网硬点问题和危害、接触网硬点产生原因以及硬点改进对策,结合我国铁道接触网建设实际情况,从理论和实践两个方面总结铁道电气化接触网硬点改进对策,旨在推动我国铁道电气化接触网发展。

电驱齿轮齿向复合修形设计与仿真分析

齿轮副啮合时产生螺旋线偏啮主要由设计因素偏啮分量f_(de)和制造因素偏啮分量f_(ma)引起,单纯应用某一种修形不能完全适应齿轮传动系统复杂的运行工况。根据螺旋线偏啮的时变性和随机性,文中推荐的齿向复合修形方案为:应用齿端修缘消除边缘接触效应和棱边接触,减小偏啮量;应用螺旋线修形对f_(de)进行抵消,以消除或减小f_(de)引起的偏啮量;应用鼓形修形对f_(ma)及f_(de)的变动量进行纠偏,确保齿轮副啮合时各工况下的最大接触载荷始终位于齿宽设定范围内并保持相切接触。将理论分析与工程设计和生产实践相结合,给出了修形参数的数值计算方法,同时结合专业的传动系统仿真分析软件Romax对齿轮修形前和修形后的接触斑和关键性能指标进行对比,以验证文中所推荐的复合修形方案具有良好的适应性和可行性。

基于加速度测量接触网平顺性研究

接触线的平顺性直接影响弓网受流质量和弓网运行安全性。为了维持弓网之间有效的高速滑动摩擦,必须保证接触线的高度平顺性。基于受电弓滑板加速度的检测方法是检测接触线短波不平顺存在的有效方法。通过接触网短波不平顺的种类、特征、产生原因分析,研究接触线不平顺检测方法和管理评价标准,以保证接触线的平顺性,提升弓网受流性能及延长弓网使用寿命。通过现场检测试验数据案例分析,论证接触网的短波不平顺判断依据—可基于一段时间内接触线垂向振动的幅值、标准差、振动过程的加速度最大值等统计特性;分析加速度测量波形图可得出缺陷为局部不平顺还是接触线张力不均的结论。

压裂泵组合式人字齿结构轮齿修形研究

组合式人字齿轮的变形及误差会降低齿轮传动啮合性能,针对这一问题,以某型号压裂泵动力传动系统组合式人字齿轮副为例,对组合式人字齿的传动啮合特性进行了理论强度计算、误差分析、仿真修形及实验研究。首先,分析了该齿轮副的结构形式,计算了该传动系统人字齿轮副的接触及弯曲疲劳强度,并分析了影响齿轮接触及弯曲疲劳强度的因素;然后,对该齿轮结构的误差形式及补偿措施进行了分析讨论,并对齿轮轴的变形及齿部修形特性进行了理论分析;最后,基于KISS soft软件计算出了齿廓的修形量,通过对比不同修形量对齿轮副的传动误差、接触应力及啮合斑点的影响,得出了最优的修形参量,并进行了实验验证。研究结果表明:轮齿修形补偿了变形及误差对齿轮传动特性的影响,同时其传动误差峰值降低了38%,齿面线载荷降低了41.3%,齿面接触区沿齿向分布均匀化,传动啮合性能得到了较大的改善。