Novel epoxy resin pouring tubular busbar and special processing device and processing method thereof

Abstract

The invention relates to the technical field of tubular busbar processing, and discloses a novel epoxy resin pouring tubular busbar. Comprising a tubular bus, the tubular bus is formed by combining a metal tube conductor, a conductor shielding layer, an insulating layer, an insulation shielding layer, a metal shielding layer and a closed jacket, and the insulating layer comprises 70-120 parts of bisphenol A epoxy resin, 1-2 parts of methyl tetrahydrophthalic anhydride, 3-6 parts of an active toughening agent and 1-2 parts of an accelerant. According to the invention, a layered coating process is changed into an automatic and continuous multi-layer winding new process, mechanization and automation of production are realized, effective bonding between material layers is realized in the aspects of inner and outer shielding materials and insulating materials, the effects of reducing the partial discharge level of a product and improving the electrical performance are achieved, and the production cost is reduced. Due to the adoption of a high-performance insulating material and a new multilayer co-extrusion technology and a new process, the product quality of the cable type solid insulation intelligent bus is effectively improved, and the production efficiency is greatly improved at the same time.

Description

Technical Field

[0001] The invention relates to the technical field of tubular busbar processing, in particular to a novel epoxy resin cast tubular busbar and a special processing device and method thereof. Background Art

[0002] Epoxy resin cast tubular busbars are high-voltage insulated busbars. Using an epoxy resin casting process, they form an integrated solid insulation layer on the conductor surface, resulting in high insulation, strong current-carrying capacity, and excellent environmental adaptability. They are primarily used in power systems (such as substations and nuclear power plants) to replace traditional cables or metal busbars, addressing issues such as insulation degradation and excessive capacitance and current. The existing tubular busbar processing technology is complex, with alternating insulation and shielding layers, low efficiency, and a long production cycle requiring 24 hours to produce the product. The product cannot be bent and has poor heat dissipation performance. The metal conductor layer and the resin layer are prone to cracking during hot and cold cycles, affecting the stability of electrical performance. The busbar per unit length is heavy, inconvenient to install, and is not flame retardant. In order to increase the current carrying capacity, the insulated tubular busbar must have a larger diameter. At this time, gravity can easily cause insulation eccentricity during extrusion. The extruded insulated tubular busbar is extruded first and then bent, which will cause the formed insulation to be stretched and squeezed. First, the bending radius is greatly limited, which is equivalent to applying stress on the insulation. Stretching will thin the insulation, while squeezing may cause air gaps. Second, prestressing will reduce the mechanical and performance of the material. Summary of the Invention

[0003] In response to the deficiencies in the prior art, the present invention provides a novel epoxy resin cast tubular busbar and a dedicated processing device and method thereof, which transforms the layered coating process into an automated, continuous multi-layer winding process, thereby realizing mechanized and automated production. Effective bonding between the inner and outer shielding materials and insulating materials is achieved, resulting in a reduction in the level of partial discharge and improved electrical performance of the product. The use of high-performance insulating materials and new multi-layer co-extrusion technologies and processes not only effectively improves the product quality of the cable-type solid-insulated intelligent busbar, but also significantly improves production efficiency and other advantages.

[0004] To solve the above technical problems, the present invention provides the following technical solution: a novel epoxy resin cast tubular busbar, comprising a tubular busbar, wherein the tubular busbar is composed of a metal tube conductor, a conductor shielding layer, an insulating layer, an insulating shielding layer, a metal shielding layer, and a closed jacket, wherein the insulating layer comprises 70-120 parts of bisphenol A epoxy resin, 1-2 parts of methyltetrahydrophthalic anhydride, 3-6 parts of an active toughening agent, and 1-2 parts of an accelerator.

[0005] A new type of special processing device for epoxy resin cast tubular busbars includes a base, the upper surface of the base is fixedly connected to a bracket, the inner top wall of the bracket is provided with a ribbon, the upper surface of the base is fixedly connected to a support frame, the inner top wall of the support frame is fixedly connected to a polishing seat, the front surface of the base is fixedly connected to a second motor, the output end of the second motor is movably connected to a conveyor belt through a conveyor roller, and the upper surface of the base is fixedly connected to a drying box.

[0006] Preferably, the upper surface of the conveyor belt is fixedly connected to a placement plate, the upper surface of the placement plate is slidably connected to a first support plate, the upper surface of the first support plate is fixedly connected to a first flange, the interior of the first flange is interlockingly connected to a vacuum tube, the upper surface of the placement plate is slidably connected to a second support plate, the upper surface of the second support plate is fixedly connected to a second flange, and the interior of the second flange is interlockingly connected to an injection pipe.

[0007] Preferably, the upper surface of the support frame is fixedly connected to a horizontal plate, the lower surface of the horizontal plate is slidably connected to a movable plate, the lower surface of the movable plate is fixedly connected to a first motor, and the output rear end of the first motor is fixedly connected to a driving shaft.

[0008] Preferably, the front surface of the first motor is fixedly connected to a fixing ring, the side surface of the fixing ring is fixedly connected to a connecting ring, the outer surface of the connecting ring is sleeved with a driven shaft, the outer surface of the driven shaft is connected to the driving shaft through a belt, and the side surface of the driven shaft is fixedly connected to a reeling rod.

[0009] Preferably, a slider is slidably connected to the interior of the support frame, a baffle is fixedly connected to the front surface of the slider, an inner wall of the baffle is threadedly connected to a first threaded rod, and the first threaded rod is threadedly connected to the interior of the support frame.

[0010] Preferably, the rear surface of the slider is fixedly connected to an electric push rod, and the output end of the electric push rod is fixedly connected to a third motor.

[0011] Preferably, the output end of the third motor is fixedly connected to a connecting plate, and the front surface of the connecting plate is slidably connected to a first clamping ring.

[0012] Preferably, the front surface of the connecting plate is slidably connected to a second clamping ring, and the second clamping ring is located above the first clamping ring, the internal thread of the second clamping ring is connected to a second threaded rod, and the bottom end of the second threaded rod is connected to the internal thread of the first clamping ring.

[0013] A novel method for processing epoxy resin cast tubular busbars comprises the following steps: S1. Select copper or aluminum tubes as conductors, clean and remove surface dust, polish the surface, and then apply coupling agent on the conductor surface; S2. First, seal and fix the copper tube with flanges on both sides, then wrap it with semi-conductive crepe paper. After wrapping, wrap the crepe paper again until it reaches 20mm, then heat shrink the semi-conductive heat shrink tube and prepare epoxy resin. S3. One side of the tubular busbar is flange-connected to the vacuum equipment, and the other side is flange-connected to the epoxy resin injection equipment. After the vacuuming operation is completed, epoxy resin is injected from the other side for impregnation. After the glue comes out of the vacuumed side, the glue injection is stopped and the tubular busbar is cured at high temperature in an oven to complete the processing of the tubular busbar.

[0014] Compared with the prior art, the present invention provides a novel epoxy resin cast tubular busbar and a dedicated processing device and method thereof, which have the following beneficial effects: The present invention transforms the layered coating process into an automated and continuous multi-layer winding process, thereby realizing mechanization and automation of production. In terms of inner and outer shielding materials and insulating materials, effective bonding between material layers is achieved, resulting in a reduction in the level of partial discharge of the product and an improvement in the electrical performance. Due to the use of high-performance insulating materials and new multi-layer co-extrusion technologies and processes, not only the product quality of the cable-type solid insulated intelligent busbar is effectively improved, but also the production efficiency is greatly improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 Schematic diagram of the internal structure of the tubular busbar of the present invention; Figure 2 This is a schematic diagram of the overall structure of the tubular busbar processing of the present invention; Figure 3 for Figure 2 Schematic diagram of the structure at A in the middle; Figure 4 for Figure 2 Schematic diagram of the structure at B in the middle; Figure 5 This is a bottom view of the structure of the support frame of the present invention; Figure 6 for Figure 5 Schematic diagram of the structure at C in the middle; Figure 7 This is a schematic diagram of the plate placement structure of the present invention.

[0016] Among them: 1. Metal tube conductor; 2. Conductor shielding layer; 3. Insulation layer; 4. Insulation shielding layer; 5. Metal shielding layer; 6. Enclosed jacket; 7. Placement plate; 8. Drying box; 9. Conveyor belt; 10. Support frame; 11. Streamer; 12. Bracket; 13. Second motor; 14. Electric push rod; 15. Polishing seat; 16. Slider; 17. Second support plate; 18. Second flange; 19. Injection pipe; 20. First flange; 21. Vacuum tube; 22. First support plate; 23. Third motor; 24. Connecting plate; 25. Second threaded rod; 26. Second clamping ring; 27. First clamping ring; 28. Baffle; 29. ​​First threaded rod; 30. Driving shaft; 31. Moving plate; 32. Cross plate; 33. First motor; 34. Belt; 35. Driven shaft; 36. Fixed ring; 37. Connecting ring; 38. Base; 39. Unwinding rod. DETAILED DESCRIPTION

[0017] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention. Example

[0018] See also Figure 1 The new epoxy resin cast tubular busbar includes a tubular busbar, which is composed of a metal tube conductor 1, a conductor shielding layer 2, an insulating layer 3, an insulating shielding layer 4, a metal shielding layer 5, and a closed jacket 6. The components of the insulating layer 3 are 70-120 parts of bisphenol A epoxy resin, 1-2 parts of methyltetrahydrophthalic anhydride, 3-6 parts of an active toughening agent, and 1-2 parts of an accelerator.

[0019] 70-120 parts of bisphenol A epoxy resin are used as the main material of the insulation layer, providing stable dielectric properties and high voltage resistance, reducing the risk of breakdown. The design of the conductor shielding layer 2 and the insulation shielding layer 4 effectively homogenizes the electric field, reduces local discharge, and extends the service life. The addition of 3-6 parts of active toughening agent improves the brittleness of the epoxy resin, withstands thermal cycling and mechanical stress, and reduces the risk of cracking of the insulation layer. The metal tube structure provides a high-strength skeleton, combined with the metal shielding layer 5 to resist external mechanical damage, suitable for complex installation environments. 1-2 parts of methyltetrahydrophthalic anhydride are used as a curing agent, and 1-2 parts of accelerator are used to ensure low-temperature curing efficiency and high cross-linking density, with a temperature resistance of more than 120°C. The closed jacket 6 protects against moisture, chemical corrosion and ultraviolet rays, adapting to outdoor or harsh industrial environments, improving the electrical, mechanical and environmental tolerance of the busbar, while taking into account lightweight and economic efficiency, suitable for harsh scenarios such as high-voltage power distribution and new energy power stations. Example

[0020] See also Figure 2-Figure 7 A new type of special processing device for epoxy resin cast tube busbar includes a base 38, the upper surface of the base 38 is fixedly connected to a bracket 12, the upper surface of the base 38 is fixedly connected to a drying box 8, the inner top wall of the bracket 12 is provided with a streamer 11, the upper surface of the base 38 is fixedly connected to a support frame 10, the front surface of the base 38 is fixedly connected to a second motor 13, the output end of the second motor 13 is movably connected to a conveyor belt 9 through a conveyor roller, the upper surface of the conveyor belt 9 is fixedly connected to a placing plate 7, the upper surface of the placing plate 7 is slidably connected to a first support plate 22, the upper surface of the first support plate 22 is fixedly connected to a first flange 20, the interior of the first flange 20 is engaged with a vacuum tube 21, the upper surface of the placing plate 7 is slidably connected to a second support plate 17, the upper surface of the second support plate 17 is fixedly connected to a second flange 18, and the interior of the second flange 18 is engaged with an injection pipe 19.

[0021] The second motor 13 drives the conveyor roller to drive the conveyor belt 9 to circulate. The placement plate 7 acts as a carrier and moves with the conveyor belt 9 to realize the transfer of the workpiece station. The first support plate 22 and its first flange 20 constitute a vacuum sealing station, which is vacuumed through the vacuum tube 21. The second support plate 17 and its second flange 18 constitute the injection station. The injection pipe 19 is connected to the resin delivery system. The drying box 8 provides the temperature field required for curing. The streamer 11 on the top of the bracket 12 may be used for dust removal. The tubular busbar blank is fixed to the placement plate 7 and enters the vacuum station with the conveyor belt 9. The first flange 20 and the second flange 18 can be used to seal and fix the two ends of the copper tube. The vacuum tube 21 is vacuumed to remove bubbles, and the workpiece is moved to the drying box 8 for preheating and dehumidification. After the second support plate 17 is positioned, the injection pipe 19 injects epoxy resin under pressure. The resin is filled without bubbles in a vacuum environment. The workpiece after injection completes the resin curing in the drying box 8. The conveyor belt 9 realizes the automatic flow of each station, forming a continuous production line, realizing the fully automated production process of epoxy resin tubular busbar from pretreatment, vacuum injection to curing.

[0022] The upper surface of the support frame 10 is fixedly connected to a horizontal plate 32, the lower surface of the horizontal plate 32 is slidably connected to a movable plate 31, the lower surface of the movable plate 31 is fixedly connected to a first motor 33, the output rear end of the first motor 33 is fixedly connected to the driving shaft 30, the front surface of the first motor 33 is fixedly connected to a fixing ring 36, the side surface of the fixing ring 36 is fixedly connected to a connecting ring 37, the outer surface of the connecting ring 37 is sleeved with a driven shaft 35, the outer surface of the driven shaft 35 is transmission-connected to the driving shaft 30 through a belt 34, and the side surface of the driven shaft 35 is fixedly connected to a unwinding rod 39.

[0023] The first motor 33 acts as a power source, driving the driving shaft 30 to rotate. The belt 34 connects the driving shaft 30 and the driven shaft 35 to achieve power transmission, causing the driven shaft 35 to rotate synchronously. The driven shaft 35 drives the unwinding rod 39 to rotate, realizing the unwinding of the semi-conductive crepe paper. The movable plate 31 can slide under the cross plate 32, allowing the entire motor and transmission mechanism to move laterally to accommodate rolls of different widths or adjust the unwinding position. The fixing ring 36 and the connecting ring 37 provide stable support, ensuring that the driven shaft 35 maintains stable rotation during movement. The unwinding rod 39 is used to fix the semi-conductive crepe paper. Driven by the first motor 33, the unwinding speed is uniformly unwound. By adjusting the speed of the first motor 33, the unwinding speed can be controlled to ensure that it matches the conveying speed of the conveyor belt 9 to achieve synchronous processing and realize movable unwinding. Driven by the first motor 33 and driven by the belt 34, the unwinding rod 39 rotates stably and can be adjusted in position by sliding. This is suitable for the unwinding requirements of rolls of different specifications and ensures the continuous automated production of subsequent epoxy resin tubular busbars.

[0024] The inner top wall of the support frame 10 is fixedly connected to the polishing seat 15, and the interior of the support frame 10 is slidably connected to the slider 16, the front surface of the slider 16 is fixedly connected to the baffle 28, the inner wall of the baffle 28 is threadedly connected to the first threaded rod 29, and the first threaded rod 29 is connected to the internal thread of the support frame 10, the rear surface of the slider 16 is fixedly connected to the electric push rod 14, the output end of the electric push rod 14 is fixedly connected to the third motor 23, the output end of the third motor 23 is fixedly connected to the connecting plate 24, the front surface of the connecting plate 24 is slidably connected to the first clamping ring 27, the front surface of the connecting plate 24 is slidably connected to the second clamping ring 26, and the second clamping ring 26 is located above the first clamping ring 27, the internal thread of the second clamping ring 26 is connected to the second threaded rod 25, and the bottom end of the second threaded rod 25 is connected to the internal thread of the first clamping ring 27.

[0025] The first clamping ring 27 and the second clamping ring 26 are used to clamp the tubular busbar to ensure that it remains stable during the polishing process. The second threaded rod 25 is threadedly connected to the first clamping ring 27 and the second clamping ring 26 at the same time. The distance between the two clamping rings can be adjusted during rotation to adapt to pipes of different diameters. The connecting plate 24 provides sliding support so that the clamping ring can fine-tune its position to ensure centering accuracy. The third motor 23 serves as a polishing power source to drive the connecting plate 24 and the clamping ring assembly to rotate, so that the tubular busbar rotates and rubs on the polishing seat 15 to achieve uniform polishing. The electric push rod 14 can push the slider 16 back and forth to adjust the polishing pressure or feed rate to ensure polishing. The effect is controllable. The slider 16 slides inside the support frame 10 and cooperates with the rotation of the first threaded rod 29 to adjust the position of the baffle 28, thereby controlling the lateral feed of the polishing mechanism. The baffle 28 is used to limit and ensure that the polishing mechanism moves within the set range to avoid overtravel, thereby realizing automatic polishing of the tubular busbar. The workpiece is fixed by the first clamping ring 27 and the second clamping ring 26, and the third motor 23 drives the rotation. The electric push rod 14 controls the polishing pressure. The first threaded rod 29 and the second threaded rod 25 adjust the feed amount to ensure uniform and efficient polishing. It is suitable for pipes of different diameters, improves surface finish, and meets the pretreatment requirements before epoxy resin pouring. Example

[0026] A novel method for processing epoxy resin cast tubular busbars comprises the following steps: S1. Select copper or aluminum tubes as conductors, clean and remove surface dust, polish the surface, and then apply coupling agent on the conductor surface; S2. First, seal and fix the copper tube with flanges on both sides, then wrap it with semi-conductive crepe paper. After wrapping, wrap the crepe paper again until it reaches 20mm, then heat shrink the semi-conductive heat shrink tube and prepare epoxy resin. S3. One side of the tubular busbar is flange-connected to the vacuum equipment, and the other side is flange-connected to the epoxy resin injection equipment. After the vacuuming operation is completed, epoxy resin is injected from the other side for impregnation. After the glue comes out of the vacuumed side, the glue injection is stopped and the tubular busbar is cured at high temperature in an oven to complete the processing of the tubular busbar.

[0027] When in use, the copper tube is placed on the surface of the conveyor belt 9, and the dust on the surface of the copper tube is cleaned by the streamer 11. The cleaned copper tube is placed between the first clamping ring 27 and the second clamping ring 26, and the second threaded rod 25 is screwed so that the first clamping ring 27 and the second clamping ring 26 can fix the two ends of the copper tube. The height of the copper tube can be adjusted to fit the polishing seat 15 by sliding the slider 16 and the support frame 10. The electric push rod 14 and the third motor 23 are connected to the external power supply. Starting the electric push rod 14 can push the distance between the two groups of first clamping rings 27 and the second clamping rings 26 to adjust so that copper tubes of different lengths can be clamped. Starting the third motor 23 can drive the copper tube to rotate and rub against the polishing seat 15 for polishing. After the copper tube is polished, the two ends of the copper tube are connected to the first flange 20 and the second flange 18 respectively. The first motor 33 is started to drive the driving shaft 30, and the belt 34 is used to drive the driven shaft 35 to rotate, so that the unwinding rod 39 can wrap the semi-conductive crepe paper around the surface of the copper tube. After wrapping, the heat shrink tube can be sleeved on the surface of the copper tube, the vacuum tube 21 is evacuated to remove bubbles, and the injection tube 19 is pressurized to inject epoxy resin. The resin is filled without bubbles in a vacuum environment. The workpiece after injection is cured in the drying box 8. The conveyor belt 9 realizes the automatic flow of each workstation to form a continuous production line, realizing the full process automated production of epoxy resin tubular busbar from pretreatment, vacuum injection to curing.

[0028] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A novel epoxy resin cast tubular busbar, including a tubular busbar, characterized by: The tubular busbar is formed by combining a metal tube conductor (1), a conductor shielding layer (2), an insulating layer (3), an insulating shielding layer (4), a metal shielding layer (5), and a closed jacket (6); the insulating layer (3) comprises 70-120 parts of bisphenol A epoxy resin, 1-2 parts of methyltetrahydrophthalic anhydride, 3-6 parts of an active toughening agent, and 1-2 parts of an accelerator.

2. A new type of epoxy resin casting tube busbar special processing device, including a base (38), characterized by: The upper surface of the base (38) is fixedly connected to a bracket (12), the inner top wall of the bracket (12) is provided with a streamer (11), the upper surface of the base (38) is fixedly connected to a support frame (10), the inner top wall of the support frame (10) is fixedly connected to a polishing seat (15), the front surface of the base (38) is fixedly connected to a second motor (13), the output end of the second motor (13) is movably connected to a conveyor belt (9) through a conveyor roller, and the upper surface of the base (38) is fixedly connected to a drying box (8).

3. According to the new epoxy resin casting tube-type busbar special processing device according to claim 2, the upper surface of the conveyor belt (9) is fixedly connected to a placement plate (7), the upper surface of the placement plate (7) is slidably connected to a first support plate (22), the upper surface of the first support plate (22) is fixedly connected to a first flange (20), the interior of the first flange (20) is connected in an interlocking manner to a vacuum tube (21), the upper surface of the placement plate (7) is slidably connected to a second support plate (17), the upper surface of the second support plate (17) is fixedly connected to a second flange (18), and the interior of the second flange (18) is connected in an interlocking manner to an injection pipe (19).

4. According to the new epoxy resin cast tubular busbar processing device of claim 2, the upper surface of the support frame (10) is fixedly connected to a horizontal plate (32), the lower surface of the horizontal plate (32) is slidably connected to a movable plate (31), the lower surface of the movable plate (31) is fixedly connected to a first motor (33), and the output rear end of the first motor (33) is fixedly connected to a driving shaft (30).

5. The new epoxy resin cast tube busbar processing device according to claim 4, wherein the front surface of the first motor (33) is fixedly connected to a fixing ring (36), the side surface of the fixing ring (36) is fixedly connected to a connecting ring (37), the outer surface of the connecting ring (37) is sleeved with a driven shaft (35), the outer surface of the driven shaft (35) is transmission-connected to the driving shaft (30) through a belt (34), and the side surface of the driven shaft (35) is fixedly connected to a reeling rod (39).

6. According to the new epoxy resin cast tubular busbar processing device according to claim 2, the support frame (10) is internally slidably connected to a slider (16), the front surface of the slider (16) is fixedly connected to a baffle (28), the inner wall of the baffle (28) is threadedly connected to a first threaded rod (29), and the first threaded rod (29) is threadedly connected to the inner surface of the support frame (10).

7. The new epoxy resin cast tubular busbar processing device according to claim 6, wherein the rear surface of the slider (16) is fixedly connected to an electric push rod (14), and the output end of the electric push rod (14) is fixedly connected to a third motor (23).

8. The novel epoxy resin cast tubular busbar processing device according to claim 7, wherein the output end of the third motor (23) is fixedly connected to a connecting plate (24), and the front surface of the connecting plate (24) is slidably connected to a first clamping ring (27).

9. According to the new epoxy resin cast tubular busbar processing device of claim 8, the front surface of the connecting plate (24) is slidably connected to a second clamping ring (26), and the second clamping ring (26) is located above the first clamping ring (27), the internal thread of the second clamping ring (26) is connected to a second threaded rod (25), and the bottom end of the second threaded rod (25) is connected to the internal thread of the first clamping ring (27).

10. A novel method for processing epoxy resin cast tubular busbars, characterized in that: The following steps are involved: S1. Select copper or aluminum tubes as conductors, clean and remove surface dust, polish the surface, and then apply coupling agent on the conductor surface; S2. First, seal and fix the copper tube with flanges on both sides, then wrap it with semi-conductive crepe paper. After wrapping, wrap the crepe paper again until it reaches 20mm, then heat shrink the semi-conductive heat shrink tube and prepare epoxy resin. S3. One side of the tubular busbar is flange-connected to the vacuum equipment, and the other side is flange-connected to the epoxy resin injection equipment. After the vacuuming operation is completed, epoxy resin is injected from the other side for impregnation. After the glue comes out of the vacuumed side, the glue injection is stopped and the tubular busbar is cured at high temperature in an oven to complete the processing of the tubular busbar.

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