用于电力导线电磁脉冲焊接的分体式集磁器

张媛媛; 张斌; 陈洪波; 沈婷; 舒一航

doi:10.11884/HPLPB202638.250113

用于电力导线电磁脉冲焊接的分体式集磁器

doi: 10.11884/HPLPB202638.250113

张媛媛^1,,
张斌¹,
陈洪波¹,
沈婷¹,
舒一航^{2, 3, ,}

1.
国网重庆市电力公司璧山供电分公司，重庆 402760
2.
输变电装备技术全国重点实验室（重庆大学电气工程学院），重庆 400044
3.
国网重庆市电力公司永川供电分公司，重庆 402160

基金项目: 国网重庆市电力公司重点科技项目（522010240006）

详细信息

作者简介:
张媛媛，2358851884@qq.com

通讯作者:
舒一航，hang1shu@163.com。

中图分类号: TM89
计量
- 文章访问数: 33
- HTML全文浏览量: 16
- PDF下载量: 1
- 被引次数: 0
出版历程
- 收稿日期: 2025-05-07
- 修回日期: 2025-11-10
- 录用日期: 2025-11-11
- 网络出版日期: 2025-11-17

Split field shaper applied to electromagnetic pulse welding of power wires

1.
State Grid Chongqing Bishan Power Supply Company, Chongqing 402760, China
2.
State Key Laboratory of Power Transmission Equipment Technology, School of Electrical Engineering, Chongqing University, Chongqing 400044, China
3.
State Grid Chongqing Yongchuan Power Supply Company, Chongqing 402160, China

摘要

摘要: 电磁脉冲焊接技术是一种新兴固态焊接技术，将其应用于电力导线与端子的连接，可有效提升电力导线接头的可靠性。然而，电磁脉冲焊接接头存在中间未结合区域，严重制约了电磁脉冲焊接技术在电力导线连接领域的应用。提出了一种分体式集磁器结构，以进一步提升电磁脉冲焊接接头的结合性能。为证实所提出分体式集磁器结构的有效性，首先，基于对分体式集磁器和传统一体式集磁器的理论分析，进行分体式集磁器结构设计；随后，通过仿真探究了集磁器结构对接头变形区域电磁参数和运动参数的影响规律；最后，开展实验测试，对比分析使用不同集磁器结构所制备电磁脉冲焊接接头力学性能，验证分体式集磁器对接头结合性能的改善作用。实验结果表明，相较于具有相同尺寸的一体式集磁器，使用分体式集磁器制备的电磁脉冲焊接接头拉伸性能提高了22.73%，焊痕总长度增加了2.68 mm。
- 电力导线 /
- 电磁脉冲焊接 /
- 集磁器 /
- 变形行为 /
- 接头性能
Abstract: Background
Electromagnetic pulse welding (EMPW) is an emerging solid-state welding technology. Its application in connecting power conductors and terminals can effectively enhance joint reliability. However, EMPW joints exhibit unbonded intermediate zones, and their tensile performance requires improvement, which severely restricts the application of EMPW technology in power conductor connections.
Purpose
To address this, this paper proposes a split field shaper structure to further improve the bonding performance of electromagnetic pulse welded joints.
Methods
To validate the effectiveness of the proposed split field shaper structure, this paper combines equivalent circuit analysis, finite element simulation models, and mechanical property testing of experimental specimens to demonstrate the efficacy of the proposed method.
Results
Theoretical analysis of both the split and traditional field shaper provides the basis for the split field shaper structure design. Finite element simulation models reveal the influence patterns of the field shaper structure on the electromagnetic and motion parameters of the joint deformation zone. Mechanical property tests validated the split field shaper's enhancement of joint bonding performance. Experimental results demonstrate that, compared to the integrated field shaper, joints prepared using the segmented field shaper exhibit a 22.73% increase in tensile performance and a 2.68 mm extension in the total weld length.
Conclusions
The proposed split field shaper successfully enhances joint mechanical properties relative to conventional field shaper while maintaining overall dimensional consistency.
- power wires /
- electromagnetic pulse welding /
- field shaper /
- deformation behavior /
- joint performance

HTML全文

图 1 集磁器工作原理

Figure 1. Working principle of field shaper

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图 2 电磁脉冲焊接等效电路

Figure 2. Equivalent circuit of electromagnetic pulse welding

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图 3 不同集磁器电流分布

Figure 3. The current distribution of different filed shaper

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图 4 使用分体式集磁器时电磁脉冲焊接等效电路

Figure 4. Equivalent circuit of electromagnetic pulse welding with split type field shaper

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图 5 使用不同集磁器时集磁器内表面电流分布

Figure 5. Distribution of current on inner surface when using different field shaper

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图 6 使用一体式集磁器时飞管电磁参数分布

Figure 6. Distribution of tube electromagnetic parameters when using an integrated field shaper

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图 7 使用分体式集磁器时飞管电磁参数分布

Figure 7. Distribution of tube electromagnetic parameters when using a split field shaper

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图 8 使用不同集磁器时飞管位移分布

Figure 8. Distribution of tube deformation parameters when using different field shaper

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图 9 使用不同集磁器时的碰撞参数

Figure 9. Collision parameters when using different field shaper

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图 10 力学性能测试结果

Figure 10. Mechanical performance test results

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图 11 接头焊痕分布情况

Figure 11. Distribution of welding marks on joints

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