Device and method for testing high voltage insulated equipment
By designing a grounding plane device with elastic compressible conductive fibers, the flexibility and cost issues of existing high-voltage equipment insulation testing devices are solved, enabling efficient testing of equipment with different shapes and making it suitable for large-scale production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- APTIV TECHNOLOGIES AG
- Filing Date
- 2022-08-15
- Publication Date
- 2026-07-10
AI Technical Summary
Existing high-voltage equipment insulation testing devices suffer from problems such as high manufacturing costs, inflexibility, non-reusability, and unsuitability for large-scale production.
An apparatus and method employing elastic compressible conductive fibers are used to design a device comprising first and second grounding planes, each grounding plane having elastic compressible conductive fibers, for testing insulation of high-voltage equipment.
It enables flexible testing that adapts to devices of different shapes, reduces manufacturing costs, improves test repeatability, and is suitable for mass production.
Smart Images
Figure CN115704850B_ABST
Abstract
Description
[0001] Cross-references of related applications
[0002] This application claims priority to U.S. Patent Application No. 17 / 402,770, filed August 16, 2021, the entire disclosure of which is incorporated herein by reference. Technical Field
[0003] This patent application relates to apparatus and methods for testing equipment used in high-voltage applications (e.g., exceeding 200 volts), and more particularly to apparatus and methods for testing the insulation integrity of high-voltage equipment. Background Technology
[0004] High-voltage electrical equipment (such as busbars, wiring harnesses, or combinations thereof) is preferably tested when energized with a high voltage in contact with a ground plane to verify the integrity and adequacy of the electrical insulation on the equipment and to ensure that no arcing occurs due to insulation defects.
[0005] Existing apparatuses for performing such tests encompass a variety of devices and methods. A first example test apparatus includes a machined metal plate used as a ground plane surrounding the device under test (DUT). The metal plate has a specific shape to conform to the specific geometry of the DUT. Because these metal plates are custom-made for each device, a disadvantage of the first example test apparatus is the need for separate ground planes, which are specifically configured for each unique DUT configuration, the manufacturing cost and time of producing each ground plane, and the variations in ground planes driven by engineering changes during the DUT's design cycle. A second example test apparatus includes a chamber containing a chain of metal balls connected to the ground, positioned above and below the DUT. Because the metal ball chain below the device is incompressible, this second example test apparatus is less suitable for inflexible devices (such as busbars). A third example test apparatus is a metal vacuum chamber in which the DUT is placed. The vacuum in the chamber increases the arc distance. A disadvantage of this third example test apparatus is the need for a sealed interface to test the device. The pneumatic characteristics of the third example test apparatus result in higher costs in terms of design, integration, and maintenance. Furthermore, some DUTs cannot withstand the required differential pressure. The fourth example test apparatus is a wand or cuff, which replaces the ambient air around the device under test with an inert gas. This fourth example test apparatus is designed for manual use and has low test repeatability, therefore it is not suitable for routine mass production use. Summary of the Invention
[0006] According to one or more aspects of this disclosure, an apparatus for testing an insulating high-voltage device includes: a first ground plane connected to a reference voltage potential, the first ground plane having a first plurality of resiliently compressible conductive fibers extending therefrom; and a second ground plane connected to the reference voltage potential, the second ground plane having a second plurality of resiliently compressible conductive fibers extending therefrom. The first and second ground planes are arranged between them to receive the insulating high-voltage device under test connected to a voltage potential greater than or less than the reference voltage potential, and are configured such that at least a portion of the first and second plurality of resiliently compressible conductive fibers makes compressive contact with the insulating high-voltage device under test.
[0007] In one or more embodiments of the device according to the foregoing paragraph, the first and second plurality of elastic compressible conductive fibers are formed from a carbon-loaded, wound-up polymer foam material.
[0008] In one or more embodiments of the device according to any of the preceding paragraphs, the first and second plurality of elastic compressible conductive fibers are formed of metallic material.
[0009] In one or more embodiments of the device according to any of the preceding paragraphs, the first and second plurality of elastic compressible conductive fibers are formed in a helical shape.
[0010] In one or more embodiments of the device according to any of the preceding paragraphs, the first and second plurality of elastic compressible conductive fibers are formed of coarse stainless steel wool, copper wool, or brass wool material.
[0011] In one or more embodiments of the apparatus according to any of the preceding paragraphs, the first ground plane is connected to the second ground plane by a hinged hinge.
[0012] In one or more embodiments of the apparatus according to any of the preceding paragraphs, the reference voltage potential is the ground potential, and wherein the voltage potential of the measured insulating high-voltage device is at least 200 volts greater than the ground potential.
[0013] In one or more embodiments of the apparatus according to any of the preceding paragraphs, the apparatus further includes an electrical connector that electrically attaches the high-voltage insulated device under test to a voltage potential disposed within an insulating enclosure.
[0014] In one or more embodiments of the apparatus according to any of the preceding paragraphs, the electrical connector is configured to receive the uninsulated portion of the high-voltage device under test within an insulating cover.
[0015] In one or more embodiments of the apparatus according to any of the preceding paragraphs, the electrical connector is a first electrical connector, and the apparatus further includes a second electrical connector that electrically attaches the high-voltage device under test to the voltage potential at different locations on the high-voltage device under test.
[0016] According to one or more aspects of this disclosure, a method for testing an insulating high-voltage device includes the steps of: providing a first ground plane having a first plurality of elastically compressible conductive fibers extending therefrom and a second ground plane having a second plurality of elastically compressible conductive fibers extending therefrom; connecting the first and second ground planes to a reference voltage potential; and connecting the insulating high-voltage device under test to a voltage potential greater than or less than the reference voltage potential.
[0017] In one or more embodiments of the method according to the foregoing paragraph, the method further includes the step of forming first and second plurality of elastic compressible conductive fibers from a polymer foam material unwound from a carbon-loaded coil.
[0018] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the step of forming first and second plurality of elastic compressible conductive fibers from a metallic material.
[0019] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the step of forming the first and second plurality of elastic compressible conductive fibers into a helical shape.
[0020] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the step of forming first and second plurality of elastic compressible conductive fibers from coarse stainless steel wool, copper wool, or brass wool material.
[0021] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the step of connecting the first ground plane to the second ground plane via a hinged hinge.
[0022] In one or more embodiments of the method according to any of the preceding paragraphs, the reference voltage potential is the ground potential, and the voltage potential of the measured insulating high-voltage device is at least 200 volts greater than the ground potential.
[0023] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the steps of providing an electrical connector within an insulating enclosure, and electrically attaching the high-voltage device under test to a voltage potential via the electrical connector.
[0024] In one or more embodiments of the method according to any of the preceding paragraphs, the electrical connector is configured to receive the uninsulated portion of the high-voltage device under test within an insulating cover.
[0025] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the steps of: providing a second electrical connector, and electrically attaching the high-voltage device under test to different locations on the high-voltage device under test via the second electrical connector. Attached Figure Description
[0026] The invention will now be described by way of example with reference to the accompanying drawings, in which:
[0027] Figure 1 This is a perspective view of an apparatus for testing high-voltage devices according to some embodiments;
[0028] Figure 2A Based on some embodiments Figure 1 A side view of the high-voltage device within the apparatus relative to the device before compression;
[0029] Figure 2B Based on some embodiments Figure 1 A side view of the high-voltage device within the apparatus after compression of the apparatus;
[0030] Figure 3 It is disposed within an insulating cover according to some embodiments. Figure 1 Electrical connectors for the device; and
[0031] Figure 4 This is a flowchart of a method for testing high-voltage devices according to some embodiments. Detailed Implementation
[0032] This paper presents a test apparatus and test method that overcomes the shortcomings of previous devices used for high-voltage insulation testing.
[0033] Figure 1The test apparatus 10 shown has a first ground plane, hereinafter referred to as the upper ground plane 12, which is connected to a reference voltage potential 14, for example, a ground potential. The upper ground plane 12 has a first plurality of resilient compressible conductive fibers 16 extending from an upper ground plane 18. The test apparatus 10 also has a second ground plane, hereinafter referred to as the lower ground plane 20, which is also connected to the same reference voltage potential 14. The lower ground plane 20 has a second plurality of resilient compressible conductive fibers 22 extending from a lower ground plane 24. The upper ground plane 12 and the lower ground plane 20 are arranged to receive the high-voltage insulated device 2 under test, such as an insulated busbar, an insulated cable, or an insulated bundle between them. The device under test 2 is connected to a test voltage potential 26, which is greater than or less than the reference voltage potential 14. The difference between the test voltage potential 26 and the reference voltage potential 14 can be at least 200 volts. The reference voltage potential 14 is preferably at a ground potential, and the test voltage potential 26 is greater than the ground potential. The upper floor 18 can have a flat configuration, while the lower floor 24 can have a frame configuration.
[0034] like Figure 2A and Figure 2B As shown, the upper ground plane 12 and the lower ground plane 20 are configured such that at least a portion of the first and second plurality of elastic compressible conductive fibers 16, 22 are in contact with... Figure 2B The device under test 2 shown in the figure is in compression contact.
[0035] like Figures 1-2B As shown, the first and second plurality of elastic compressible conductive fibers 16, 22 are formed of a metallic material, such as coarse metal mesh or coarse stainless steel wool, copper wool, or brass wool. The first and second plurality of elastic compressible conductive fibers 16, 22 can be formed on a carbon-loaded convoluted expanded polymer foam material, such as the convoluted foam absorber MF32-0002-00 manufactured by MAST Technologies of San Diego, California, USA. In the example shown, the first and second plurality of elastic compressible conductive fibers 16, 22 are formed into a helical spring shape, such as... Figure 2A , Figure 2BAs best shown in the diagram. These helical, spring-shaped fibers are then arranged into a spherical shape and electrically and mechanically attached to the upper ground plane 18 and the lower ground plane 24. When these helical fibers are arranged into a spherical shape, it has been found that they provide a large number of electrical contacts between the upper and lower ground planes 12, 20 and the device under test 2, and provide flexibility for successfully testing devices with different shapes. This is advantageous because it allows the test setup 10 to accommodate devices under test 2 with different designs (e.g., busbars and cables) or devices under test with different shapes (e.g., two flexible wire harnesses with the same configuration but different shapes). The upper ground plane 18 and the lower ground plane 24 are formed of sheets of conductive metal (such as copper, aluminum, or stainless steel).
[0036] exist Figure 1 In the illustrated example, the upper ground plane 12 is connected to the lower ground plane 20 via a hinge 28. This hinge 28 allows the device under test 2 to be placed on the lower ground plane 20, thereby... Figure 2A The device under test 2 is positioned to contact the lower ground plane 20, and then the upper ground plane 12 is allowed to be moved to a position where the upper ground plane 12 also contacts the device under test 2, as shown. Figure 2B The first and second plurality of elastic compressible conductive fibers 16, 22 are shown in the figure.
[0037] The device further includes Figure 3 The first electrical connector 30 shown is disposed within an insulating cover 32, which electrically attaches the device under test 2 to the test voltage potential 26. The device may further include a second electrical connector 30 of the same design, which attaches the device under test 2 to the test voltage potential 26 at different locations, for example, as shown in the diagram. Figure 1 The opposite ends of the device under test are shown. First and second electrical connectors 30 are configured to receive the uninsulated portion of the device 2 under test within an insulating cover 32. The apparatus also includes an additional electrical connector (not shown) that attaches the upper and lower ground planes to a reference potential.
[0038] Figure 4 A flowchart is shown of a method 100 for testing insulation high-voltage equipment that can be applied to the test apparatus 10 described above. Method 100 includes the following steps:
[0039] Step 102, providing a first ground plane having a first plurality of elastic compressible conductive fibers extending therefrom and a second ground plane having a second plurality of elastic compressible conductive fibers extending therefrom, includes: providing first and second ground planes 12, 20, each ground plane having a plurality of elastic compressible conductive fibers 16, 22 extending therefrom;
[0040] Step 104, connecting the first and second ground planes to the reference voltage potential, including connecting the first and second ground planes 12 and 20 to the reference voltage potential 14;
[0041] Step 106: Connect the high-voltage device under test to a voltage potential greater than or less than a reference voltage potential, including connecting the high-voltage device under test 2 to a test voltage potential 26 greater than or less than the reference voltage potential 14. The reference voltage potential 14 may be a ground potential, and the test voltage potential 26 may be at least 200 volts greater than the ground potential.
[0042] Step 108, forming first and second plurality of elastic compressible conductive fibers from a metallic material, including forming first and second plurality of elastic compressible conductive fibers 16, 22 from a metallic material;
[0043] Step 110, forming the first and second plurality of elastic compressible conductive fibers into a spiral shape, including forming the first and second plurality of elastic compressible conductive fibers 16, 22 into a spiral shape;
[0044] Step 112, forming the first and second plurality of elastic compressible conductive fibers from coarse metal mesh or coarse stainless steel wool, copper wool or brass wool material, including forming the first and second plurality of elastic compressible conductive fibers 16, 22 from coarse metal mesh or coarse stainless steel wool, copper wool or brass wool material;
[0045] Step 114, providing an electrical connector within an insulating cover, including providing an electrical connector 30 disposed within an insulating cover 32;
[0046] Step 116, electrically attaching the high-voltage device under test to a voltage potential via an electrical connector, including electrically attaching the device under test 2 to a test voltage potential 26 via electrical connector 30. Electrical connector 30 may be a first electrical connector, and the method may further include the steps of: providing a second electrical connector, and electrically attaching the device under test 2 to the test voltage potential 26 at different locations on the device under test 2 via the second electrical connector; and
[0047] Method 100 may further include the step of connecting the first ground plane 12 to the second ground plane 20 via a hinged hinge 28.
[0048] While the invention has been described with reference to one or more exemplary embodiments, those skilled in the art will understand that various changes can be made and equivalents can be substituted for elements therein without departing from the scope of the invention. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of the invention without departing from its essential scope. Therefore, the invention is not limited to the disclosed one or more embodiments, but will include all embodiments falling within the scope of the appended claims.
[0049] As used herein, “one or more” includes functions performed by a single element, functions performed by more than one element, such as in a distributed manner, several functions performed by a single element, several functions performed by several elements, or any combination of the foregoing.
[0050] It will be understood that while the terms first, second, etc., are used in some instances to describe various elements herein, these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact, without departing from the scope of the various described embodiments. Both the first contact and the second contact are contacts, but they are not the same contact.
[0051] The terminology used in the description of the various embodiments described herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context otherwise clearly indicates otherwise. It will also be understood that the term “and / or,” as used herein, refers to and covers any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprising,” “including,” “containing,” and / or “comprising” as used in this specification indicate the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.
[0052] As used herein, depending on the context, the term "if" may optionally be interpreted as "when," "after," "in response to determination," or "in response to detection." Similarly, depending on the context, the phrase "if determined" or "if detected [the stated condition or event]" may optionally be interpreted as "after determining," "in response to determination," "after detecting [the stated condition or event]," or "in response to detecting [the stated condition or event]."
[0053] Additionally, although the terms of law or orientation may be used herein, these elements should not be limited by such terms. Unless otherwise stated, all terms of law or orientation are for the purpose of distinguishing one element from another and, unless otherwise stated, do not indicate any particular order, sequence of operations, direction, or orientation.
Claims
1. An apparatus (10) for testing insulation high-voltage equipment (2), comprising: A first ground plane (12) connected to a reference voltage potential, the first ground plane (12) having a first plurality of helical-shaped elastic compressible conductive fibers (16) extending therefrom; and A second ground plane (20) connected to the reference voltage potential, the second ground plane (20) having a second plurality of helical elastic compressible conductive fibers (22) extending therefrom, wherein the first and second ground planes (12, 20) are arranged between them to receive a tested insulating high-voltage device connected to a voltage potential greater than or less than the reference voltage potential, and are configured such that at least a portion of the first and second plurality of elastic compressible conductive fibers (16, 22) is in compressive contact with the tested insulating high-voltage device (2).
2. The device (10) according to claim 1, characterized in that, The first and second plurality of elastic compressible conductive fibers (16, 22) are formed from a carbon-loaded, wound polymer foam material.
3. The apparatus (10) according to claim 1, characterized in that, The first and second plurality of elastic compressible conductive fibers (16, 22) are formed of metallic material.
4. The apparatus (10) according to claim 1, characterized in that, The first and second plurality of elastic compressible conductive fibers (16, 22) are formed of coarse stainless steel wool, copper wool or brass wool material.
5. The apparatus (10) according to claim 1, characterized in that, The first ground plane (12) is connected to the second ground plane (20) by a hinge (28).
6. The apparatus (10) according to claim 1, characterized in that, The reference voltage potential is the ground potential, and the voltage potential of the measured high-voltage insulated device (2) is at least 200 volts greater than the ground potential.
7. The apparatus (10) according to claim 1, characterized in that, The device (10) further includes an electrical connector (30) that electrically attaches the tested high-voltage insulated device (2) to the voltage potential disposed within an insulating cover (32).
8. The apparatus according to claim 7, characterized in that, The electrical connector (30) is configured to receive the uninsulated portion (26) of the tested high-voltage insulated device within the insulating cover (32).
9. The apparatus according to claim 7, characterized in that, The electrical connector (30) is a first electrical connector, and the device (10) further includes a second electrical connector that electrically attaches the tested high-voltage device (2) to the voltage potential at different locations on the tested high-voltage device (2).
10. A method (100) for testing the insulation of a high-voltage device (2), comprising: Provide (102) a first ground plane (12) and a second ground plane (20), the first ground plane (12) having a first plurality of elastically compressible conductive fibers (16) extending therefrom, and the second ground plane (20) having a second plurality of elastically compressible conductive fibers (22) extending therefrom; The first and second plurality of elastic compressible conductive fibers (16, 22) are formed (110) into a spiral shape; Connect the first and second ground planes (12, 20) (104) to the reference voltage potential; and Connect (106) the high-voltage device under test (2), the high-voltage device under test (2) being connected to a voltage potential greater than or less than the reference voltage potential.
11. The method (100) according to claim 10, characterized in that, The first and second plurality of elastic compressible conductive fibers (16, 22) are further formed from a polymer foam material wound from a carbon-loaded substrate.
12. The method (100) according to claim 10, characterized in that, Further comprising the first and second plurality of elastic compressible conductive fibers (16, 22) formed from a metallic material (108).
13. The method (100) according to claim 10, characterized in that, Further comprising (112) the first and second plurality of elastic compressible conductive fibers (16, 22) formed from coarse stainless steel wool, copper wool or brass wool material.
14. The method (100) according to claim 10, characterized in that, It further includes connecting the first ground plane (12) to the second ground plane (20) via a hinged hinge (28).
15. The method (100) according to claim 10, characterized in that, The reference voltage potential is the ground potential, and the voltage potential of the measured insulated high-voltage device is at least 200 volts greater than the ground potential.
16. The method (100) according to claim 10, characterized in that, Also includes: Provides an electrical connector (30) within an insulating cover (32); and The tested high-voltage insulated device (2) is electrically attached (116) to the voltage potential via the electrical connector (30).
17. The method (100) according to claim 16, characterized in that, The electrical connector (30) is configured to receive the uninsulated portion of the tested high-voltage device (2) within the insulating cover (32).
18. The method (100) according to claim 16, characterized in that, The electrical connector (30) is a first electrical connector, and the method further includes: Provide a second electrical connector; and The tested high-voltage device (2) is electrically attached (116) to the voltage potential at different locations on the tested high-voltage device (2) via the second electrical connector (30).