电连接器可靠性研究述评

介绍了国外电连接器可靠性研究情况;对国内电连接器可靠性研究主要介绍了失效分析研究、可靠性试验和可靠性设计三方面的现状;重点介绍了在航天电连接器的接触失效分析,以及在温度、振动及其综合应力作用下的加速可靠性寿命试验方面的一些研究状态;最后在电连接器可靠性研究方面提出了一些建议。     

Specification, performance, testing and qualification ofextra-heavy-duty connectors for high-voltage applications

The reliability of substation connectors is a constant concern for electrical utilities and represents one of the weak links of Hydro-Quebec's 735 kV power system. This paper describes some of the early findings of current-cycling tests on 4000 kcmil aluminum cable connectors and defines the need for more stringent qualification test specifications. Use of the ANSI C119.4 light-duty (125 cycles) test specification revealed a strong dependency on basic parameters such as surface roughness, dimension, type and surface finish of hardware, surface preparation, mounting techniques, etc. The first batch of test samples failed dramatically at an early stage in the current and load cycling tests. Some recommendations are formulated     

Bolted Connectors for Stranded Aluminum Power Conductors

Sixteen different commercial bolted connectors for 50 and 240 mm stranded aluminum cable conductors have been examined in order to identify and clarify the correlations between the quality of a connector and its design characteristics, material usage, assembly procedures, bolt numbers and configurations and other relevant parameters. The quality is assessed with basis in resistance measurements after short circuit testing and during thermal cycling as specified by the IEC 61238-1 standard. The tightening torque of the bolts was measured during connector assembly, and the resulting axial compressive forces were calculated. A very strong correlation is observed between this compressive force and the connector quality; large forces give connections with low and stables resistances. The various other design parameters considered are found to have significantly less or in some cases hardly any notable influence on the electrical test results.     

Selection and Installation of Insulated Aluminum Cable

Insulated power cable with aluminum conductors has been widely applied at both low and medium voltages in industrial and commercial electric systems. The economic pressure on the cost and availability of copper assures that the use of aluminum conductors will be accelerated. Aluminum cable is available in the same sizes and with the same insulations as copper cable. Devices and methods have been designed for properly splicing and terminating aluminum cable. The successful use of aluminum cable depends primarily on good installation practice that would apply to copper cable as well. There are, however, some differences between copper and aluminum, and the object of this paper is to provide a better understanding of the significance of these differences.     

等传输容量铜、铝导体海缆技术经济性比较

针对铜资源日益紧张造成电线电缆行业原材料成本压力的问题,分析铜、铝材料性能差异,完成等传输容量下铜、铝导体截面换算,依据现有生产工艺,采用解析法,完成铜、铝导体海缆参数计算,对比分析铜、铝导体海缆的技术经济性,进一步研究铝导体连接性能。结果表明：等传输容量条件下,铜、铝导体海缆单位质量近似相等,两者损耗及短路电流特性相近,铜导体海缆材料成本为铝导体海缆的110%~180%,采用交流氩弧焊可使铝导体接头具备良好电气与机械性能,铝导体海缆经济性更优。     

特高压铝管预制式跳线接头防滑移方案研究

在特高压输电线路中,耐张段之间通常采用刚性跳线来导流,以减少跳线风偏和弧垂,压缩杆塔结构尺寸。铝管预制式跳线为刚性跳线的一种。以往设计形式的铝管接头部分由于轴向受力过大,或施工装夹不到位等原因,曾出现铝管接头滑移现象。为此,对铝管接头滑移问题进行了深入研究,提出了内接头攻丝配螺钉和铝管端部焊法兰盘2种改进方案,简要介绍了实施步骤、注意事项和试验情况,并将2种方案进行了分析比较。结果表明,2种方案都能有效地抑制铝管接头滑移,保证跳线及整个线路安全稳定运行。     

铜包铝芯电线电缆在建筑电气工程中的应用

阐述了铜包铝导体质量和主要特性参数。及其在选购和使用现场的检验方法。介绍了选择铜包铝芯线缆型号、规格和技术条件的相关技术规程。分析了铜包铝导体及铜包铝芯电线电缆的优势。解答了人们在使用铜包铝芯线缆时所关心的几个问题,对于规范铜包铝芯电缆的应用具有积极的引导作用。     

Computer-aided testing of electrical apparatus supplying nonlinearloads

A computer-aided testing program for electrical apparatus (CATEA) is designed to test the performance of single and polyphase electrical devices. It has been applied to measure the losses of single- and three-phase AC and DC electrical machines, single- and three-phase transformers with linear and nonlinear loads. On-line measurements of iron-core and copper losses of singleand three-phase transformers with rectifier load are presented and compared with the results of the open- and short-circuit tests     

Fabricated Aluminum Cage Construction in Large Induction Motors

The use of aluminum in fabricated cage windings of large induction motors has been explored, and it was found that aluminum and its alloys present a viable alternative to copper and its alloys. This paper enumerates the advantages and limitations of aluminum as a cage material, outlines the considerations necessary in the utilization of the material for this application, and summarizes the results of a testing program which demonstrated the adequacy of aluminum alloy cages in full scale machines.     

The high-frequency phenomenon of copper clad aluminum wires which are lower the alternating current resistance than copper solid wires,and the application of copper clad aluminum wires to the electrical equipment

The paper is proposed approximate formulas of the ac resistance of lead wires and coils which made by using copper clad aluminum (CCA) wires. There are the frequency range that the ac resistance of CCA wires is lower than it of cupper solid wires for lead wires and coils of an electrical equipment. It is shown that the application of CCA wires is economical as comparing with copper solid wires, if the design is due to successful calculation in the electrical equipment. The measured resistance is compared with the formula. CCA wires is an example of multiple conductors which shall be expected to apply in future.     

Copper corrosion issue and analysis on copper damascene process

As semiconductor device features shrink into deep-submicron regime, copper metallization is taking the place of aluminum (Al)-tungsten (W) metallization because of the higher electrical conductivity and electromigration resistance of copper. However, it is very difficult for copper to be etched by dry etching method, thus copper metallization is created with damascene process. In this process, chemical mechanical polishing (CMP) is the key step. The wet chemical treatment in CMP makes copper corrosion to be one of the critical issues for copper metallization. This paper has addressed the three different types of copper corrosion, namely copper chemical corrosion, copper galvanic corrosion and photo assistant copper corrosion. The failure analyses for how to differentiate them and identify their root causes have been also discussed in details.     

镀银多元合金浸锌工艺研究与应用

在高压电器产品中,为保证产品有良好的导电性能,其核心零件经常采用铝及铝合金镀银处理,但是此类零部件在镀银前需进行前期处理,还要进行特殊中间处理.该项目采用的中间处理工艺属浸锌工艺,是对普通浸锌工艺优化,采用降低主要成分的浓度来降低溶液的粘度,同时添加各种金属离子(如镍、铅、铜),使金属离子与锌离子共沉积,改变电极电位,...     

光纤连接器的应用环境条件和失效机理分析

针对国内缺乏光纤连接器失效机理研究的现状,分析了户外、水下和军事应用背景下光纤连接器的典型环境条件及其可靠性问题。对光纤连接器进行了失效模式、机理及影响分析（FMMEA）,为光纤连接器基于失效物理的可靠性设计分析相关研究奠定基础,并对光纤连接器可靠性验证相关的试验标准和预计标准进行了分析。分析结果表明,目前的标准及方法无法对光纤连接器进行准确的可靠性验证,需要进一步深入研究光纤连接器的失效规律,并建立其失效机理模型。     

The New IEEE-404 Test Specification for Joints Highlights the Importance of Connector Selection

On behalf of Hydro-Québec, IREQ undertook the evaluation of heat-shrinkable joints for 25-kV solid dielectric cable using the test schedule described in IEEE Standard 404-1986, a new specification containing higher performance requirements. Unexpectedly, the first batch of test samples failed. dramatically during the early stages of thermal heat and load cycling. Close examination of the joints followed by laboratory experiments, indicated thermal runaway of the connectors as the cause of failure, eventually attributed to faulty connector installation and compression. The experimental techniques and instrumentation used in this investigation are described in detail. The connector installation conditions were modified and the resulting satisfactory performance was demonstrated by testing samples for thermal stability under load-cycling conditions. New jointed-cable test samples were prepared and the splicing system successfully passed all the requirements of IEEE Standard 404-1986. It is now an accepted technique for the Hydro-Québec distribution system. This experience revealed that all aspects of a distribution system must be carefully considered when changes are made in the product performance requirements of any element. In fact all components of the system must be adjusted accordingly in order to provide the overall superior performance demanded by electrical utilities committed to reliable customer service.     

节能导线电晕损失及电阻损耗特征试验研究

根据国家相关标准,对高导电率钢芯硬铝绞线、铝合金芯铝绞线、中强度铝合金绞线等节能导线进行了电晕损失试验和直流电阻测试试验,分析了导线直径、导线表面状态对导线电晕损失的影响规律,得到了直流电阻值和单位长度电阻损耗,获得了220 k V线路用典型节能导线的主要电气特性,为未来导线的选型及设计提供有力数据支撑。     

电连接器微动磨损研究综述

持续的机械振动应力将引起电连接器中插针与插孔发生微动磨损,相应出现的电接触故障是导致电连接器功能失效的根本原因之一。本文概括了近年来国内外学者对此问题的研究进展,列举了对微动磨损研究可采用的试验方法;分析了镀层材料、微动幅值、接触压力、循环次数及接触表面形貌等因素对微动性能的影响;描述了微动引起接触电阻间歇变化的现象及最新的仿真分析技术。     

Field Testing of Cables: Theory and Practice

Testing cables in the field requires a specialized knowledge of dielectric behavior, electrical stress phenomena, safe and proper use of test equipment, and interpretation of test results. Theoretical and practical aspects of high-potential field testing of medium- and high-voltage extruded cables are discussed. The fundamental theory of ac and dc voltage stresses is reviewed along with the behavior of the cable insulation under dc stress. It is concluded that a dc test is preferred over an ac test for field applications. However, for a dc test the cable should be cooled to ambient temperature so that the voltage stress distribution is the same as for an ac voltage. A program for field testing is suggested along with the voltage levels to use for the test. Finally, guidance on performing the test in the field is given along with examples on interpreting the test results.     

国产耐热导线的机电性能研究

耐热铝合金导线是一种能够大幅度提高载流量的新型导线.在输电线路上推广应用普通耐热铝合金导线,具有显著的经济效益和社会效益。近年来国产普通耐热铝合金导线的大量试验数据表明,国内部分厂家生产的普通耐热铝合金导线的主要机械和电气性能,已达到或超过进口产品的水平,为我国电网大规模地采用国产耐热导线奠定了基础。     

Design Considerations for the Use of Aluminum Alloys for Integral Horsepower Motors

The design considerations on the use of aluminum alloys for the external supporting parts of integral horsepower induction motors are compared with the previously conventional use of cast iron. Covered are such factors as type of aluminum alloy selected considering service requirements and manufacturing methods planned, strength, reliability, durability (including corrosion resistance), effect on overall weight and performance. The tests made to check suitability of actual results against design plans are briefly described. In addition, the considerations and tests required to use aluminum windings alternatively with copper are discussed.     

腐蚀环境对电气设备防爆性能的影响

文章主要针对不同型式（主要涉及隔爆型、增安型）、不同隔爆结构（平面式、止口式、圆筒式、螺纹式）、不同材质（不锈钢、碳钢、铝、铜及塑料、橡胶、涂层等）的防爆电气产品,在海洋盐雾及二氧化硫腐蚀环境中进行人工模拟加速试验,得出材料耐蚀情况以及腐蚀环境对防爆结构破坏的特点和对电气防爆安全性能的影响.