A method of welding a stator bar electrical joint

Abstract

A kind of stator bar electric joint welding method, the method includes setting up air cooling device and water cooling device on the outside of stator bar, temperature measuring device is opened during welding, and the real-time temperature around weld during welding is monitored, air cooling is carried out by air cooling device during welding, when the temperature around welding point exceeds 100°C, water cooling is started immediately and stator bar is cooled by water cooling, and drying and slow cooling treatment are carried out by air cooling device after welding is completed;The working mode of the present application adopts air cooling plus liquid cooling double cooling, improves the cooling effect of stator bar during welding, while ensuring that electric bar insulating layer is not damaged, also greatly improves welding efficiency.

Description

Technical Field

[0001] This invention belongs to the field of welding technology for hydropower generation equipment, and specifically relates to a welding method for stator bar electrical joints. Background Technology

[0002] During the welding process of stator bar electrical joints in hydro-generator sets, a large amount of heat is generated, which can easily cause irreversible damage to the insulation layer at the bar ends. Current solutions often involve soaking a towel in water and wrapping it tightly around the insulation surface at the stator bar ends to achieve evaporative heat absorption.

[0003] However, since the conductive material of the stator bars is usually soft copper, the cooling effect of the above method is not good due to the extremely fast conduction of the welded body during the welding process. It is also impossible to monitor the temperature of the electrical joint in real time during the welding process. Therefore, this welding work not only requires a high level of welding skill from the welder, but also affects the welding efficiency. Summary of the Invention

[0004] In view of the technical problems existing in the background art, the present invention provides a stator bar electrical connector welding method. This method adopts a dual cooling mode of air cooling and liquid cooling, which improves the cooling effect of the stator bar during the welding process, and greatly improves the welding efficiency while ensuring that the insulation layer of the electrical bar is not damaged.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0006] A method for welding stator bar electrical connectors, the method comprising the following steps:

[0007] Step 1: Install an air-cooling device on the outside of the stator bars, install a water-cooling device below the air-cooling device, and install a temperature measuring device above the air-cooling device.

[0008] Step 2: Weld electrical connectors to the upper end of the stator bars. During the welding process, start the air cooling device and cool the area around the welding point of the stator bars.

[0009] Step 3: Turn on the temperature measuring device and connect the temperature measuring device and the water cooling device via wired or wireless connection.

[0010] Step 4: Point the temperature measuring device at the insulation layer at the end of the stator bar and monitor the real-time temperature at that point during the welding process.

[0011] Step 5: When the temperature near the insulation layer of the stator bar exceeds 100°C, the temperature measuring device immediately sends a signal to the water cooling device and starts the water cooling device. The water cooling device immediately cools down the stator bar.

[0012] Step 6: After the stator bars and electrical connectors are welded together, weld the adjacent electrical connectors together. During the welding process, use the same cooling method as in steps 1 to 5.

[0013] Step 7: After the adjacent electrical connectors are welded, remove the water cooling device and dry and slow-heat the device using the air cooling device.

[0014] Step 8: Once the welding points are completely dry and the weld quality meets the requirements, remove the air-cooling device, and the welding work is finished.

[0015] In a preferred embodiment, the water-cooling device includes an adjustable bracket, a cooling clip, and an air inlet pipe; the side of the adjustable bracket is connected to the cooling clip, and the back of the adjustable bracket is connected to the air inlet pipe.

[0016] In a preferred embodiment, the adjustable bracket includes a bracket housing, which has an internal hollow structure and is connected to an air inlet pipe. A slider is provided inside the bracket housing, one side of which is connected to the bracket housing via a spiral air pipe, and the other side of which is connected to a cooling clip.

[0017] The upper end face of the bracket housing has a strip-shaped hole. The screw passes through the strip-shaped hole and is vertically connected to the slider. The screw is equipped with a locking nut to fix the position of the slider.

[0018] The cooling clamp has a hollow structure and is connected to the slider. The side of the cooling clamp has a toothed groove that clamps the outer wall of the electrical connector. An air vent is provided in the toothed groove and is connected to the cooling clamp.

[0019] In a preferred embodiment, the water cooling device includes a water tank, a sponge block, and a water inlet pipe; the top of the water tank is provided with a strip, and the bottom of the adjustable bracket is provided with a slot; the water tank and the bracket housing are detachably connected by the strip and the slot; the two sides of the water tank are connected to the sponge block, and the bottom of the water tank is connected to the water inlet pipe.

[0020] In a preferred embodiment, multiple water supply branch pipes are connected to both sides of the water tank. The ends of the water supply branch pipes are provided with water outlets, and the sponge block is provided with corresponding insertion holes that are connected to the water supply branch pipes.

[0021] In a preferred embodiment, the temperature measuring device includes an infrared thermometer and an electronic water valve. The infrared thermometer is mounted on top of an adjustable bracket, and the electronic water valve is mounted on the water inlet pipe. The electronic water valve and the infrared thermometer are connected by wired or wireless means.

[0022] This patent can achieve the following beneficial effects:

[0023] 1. This method uses air cooling and water cooling to replace the traditional wet towel cooling method, which can effectively improve the cooling effect during the welding process of the wire rod and ensure that the insulation layer on the outer layer of the wire rod is not damaged by high temperature.

[0024] 2. This method can automatically clamp the outside of the wire bar during the welding process. Its adjustable bracket (2) device can be adapted to be installed on the outside of wire bars of different thicknesses, which greatly shortens the preparation work before welding, thereby improving the welding efficiency and ensuring the final welding quality. Attached Figure Description

[0025] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0026] Figure 1 This is a schematic diagram of the overall structure of the cooling device of the present invention;

[0027] Figure 2 This is an enlarged schematic diagram of the air-cooling device structure of the present invention;

[0028] Figure 3 This is a schematic diagram of the overall structure of the cooling device of the present invention. Figure 2 ;

[0029] Figure 4 This is an enlarged schematic diagram of the connection structure between the air-cooling device and the water-cooling device of the present invention;

[0030] Figure 5 This is a schematic diagram of the water cooling device of the present invention.

[0031] In the diagram: 1. Electrical connector; 2. Adjustable bracket; 201. Bracket housing; 202. Strip hole; 203. Slider; 204. Spiral air pipe; 205. Screw; 206. Locking nut; 207. Slot; 3. Cooling clip; 301. Gear; 4. Water tank; 401. Insert; 5. Sponge block; 501. Insertion hole; 6. Stator rod; 7. Water inlet pipe; 701. Electronic water valve; 8. Air inlet pipe; 9. Water supply branch pipe; 10. Infrared thermometer. Detailed Implementation

[0032] like Figure 1 As shown, a stator bar welding cooling device includes an adjustable bracket 2, a cooling clamp 3, and a sponge block 5. The side of the adjustable bracket 2 is connected to the cooling clamp 3. The cooling clamp 3 is fixed to the non-welding parts on both sides of the electrical connector 1. The lower end of the adjustable bracket 2 is movably connected to a water tank 4. The adjustable bracket 2 is connected to an air inlet pipe 8. The lower end of the water tank 4 is connected to a water inlet pipe 7. The two sides of the water tank 4 are connected to the sponge block 5.

[0033] During operation, the tops of the stator bars 6 are welded together via electrical connectors 1. The adjustable bracket 2 is fixed to the outside of the electrical connectors 1 and cooled by air cooling via cooling clamps 3. The lower part of the adjustable bracket 2 is connected to a water tank 4 and a sponge block to form a water cooling system. When the surface temperature of the welding material is higher than 100°C, the water cooling system below is immediately activated to cool the welding material. The heat has already been cooled by the time it reaches the insulating end of the stator bars 6, ensuring that the insulation layer at the end of the stator bars 6 is not damaged by high temperature.

[0034] Preferred solutions include Figure 2 As shown, the adjustable bracket 2 includes a bracket housing 201, which has a hollow structure and is connected to the air inlet pipe 8. A slider 203 is provided inside the bracket housing 201. One side of the slider 203 is connected to the bracket housing 201 through a spiral air pipe 204, and the other side of the slider 203 is connected to the cooling clip 3. A strip-shaped hole 202 is opened on the upper end face of the bracket housing 201. A screw 205 passes through the strip-shaped hole 202 and is perpendicularly connected to the slider 203. A locking nut 206 is provided on the screw 205 to fix the position of the slider 203.

[0035] Before welding, slide the slider 203 through the screw 205 to adjust the spacing of the cooling clamp 3, so that the device can be used for stator bars 6 of different widths. After the cooling clamp 3 clamps the two sides of the electrical connector 1, tighten the locking nut 206 downwards. At this time, the positions of the screw 205 and the slider 203 are fixed and the preliminary adjustment work is completed.

[0036] Preferred solutions include Figure 2 and Figure 3 As shown, the cooling clamp 3 has a hollow structure and is connected to the slider 203. The side of the cooling clamp 3 has a toothed groove 301 that clamps the outer wall of the electrical connector 1. An air vent is provided in the toothed groove 301 and is connected to the cooling clamp 3.

[0037] The cooling clip 3 is made of metal and has high temperature resistance. When the device is working, the cooling gas is input into the bracket housing 201 through the air inlet pipe 8, and then transported to the slider 203 through the spiral air pipe 204. Finally, it is transferred to the cooling clip 3 through the slider 203 and blown out from the air hole in the tooth groove 301 to achieve the effect of air cooling of the electrical connector 1.

[0038] Preferred solutions include Figure 4 As shown, the top of the water tank 4 is provided with a strip 401, and the bottom of the bracket housing 201 is provided with a slot 207. The water tank 4 and the bracket housing 201 are detachably connected by the strip 401 and the slot 207. This structure allows for quick assembly and disassembly of the water tank 4 and other water cooling devices, facilitating their maintenance and upkeep. In addition, water cooling equipment can be selectively installed. When the welding temperature is low, only the upper air cooling device can be installed, increasing the versatility of cooling operations.

[0039] Preferred solutions include Figure 5 As shown, multiple water supply branch pipes 9 are connected to both sides of the water tank 4. The end of each water supply branch pipe 9 is provided with a water outlet. The sponge block 5 is provided with a corresponding insertion hole 501 and is inserted into the water supply branch pipe 9. An infrared thermometer 10 is installed on the adjustable bracket 2, and an electronic water valve 701 is installed on the water inlet pipe 7. The electronic water valve 701 is connected to the infrared thermometer 10 via a signal.

[0040] During the welding process, the infrared thermometer 10 can monitor the surface temperature of the electrical connector 1 at any time. When the surface temperature of the electrical connector 1 is higher than 100°C, the infrared thermometer 10 immediately sends a signal to the electronic water valve 701. The electronic water valve 701 opens and the water inlet pipe 7 fills the water tank 4 with water. The cooling water in the water tank 4 is then sprayed out by the water supply branch pipe 9 and wets the external sponge block 5. The sponge block 5 is made of a high-temperature resistant and highly absorbent material. The wet sponge block 5 adheres to the surface of the electrical connector 1 to evaporate and dissipate heat, so that the device achieves the effect of water cooling and improves the welding quality of the electrical connector 1.

[0041] Example 1

[0042] A method for welding stator bar electrical connectors, the method comprising the following steps:

[0043] Step 1: Install an air-cooling device on the outside of the stator bar 6. First, slide the slider 203 through the screw 205 to adjust the spacing of the cooling clamp 3 so that the device can be used for stator bars 6 of different widths. After the cooling clamp 3 clamps the electrical connector 1 on both sides, tighten the locking nut 206 downwards.

[0044] A water cooling device is installed below the air cooling device. The insert 401 at the top of the water tank 4 is inserted into the slot 207 at the bottom of the bracket housing 201. An infrared thermometer 10 is installed on the bracket housing 201.

[0045] The second step is to weld the electrical connector 1 at the upper end of the stator bar 6. During the welding process, the cooling gas is input into the bracket housing 201 through the air inlet pipe 8, and then transported to the slider 203 through the spiral air pipe 204. Finally, it is transferred to the cooling clamp 3 through the slider 203 and blown out from the air hole in the tooth groove 301 to achieve the effect of air cooling of the electrical connector 1.

[0046] Third step: Turn on the temperature measuring device and connect the infrared thermometer 10 and the electronic water valve 701 wirelessly.

[0047] Step 4: Point the temperature measuring device at the insulation layer at the end of stator bar 6 and monitor the real-time temperature at that point during the welding process;

[0048] Step 5: When the temperature near the insulation layer of the stator bar 6 exceeds 100°C, the infrared thermometer 10 immediately sends a signal to the electronic water valve 701. The electronic water valve 701 opens and the water inlet pipe 7 fills the water tank 4 with water. The cooling water in the water tank 4 is then sprayed out by the water supply branch pipe 9 and wets the external sponge block 5. The wet sponge block 5 adheres to the surface of the electrical connector 1 for evaporative heat dissipation.

[0049] Step 6: After the stator bar 6 is welded to the electrical connector 1, the adjacent electrical connector 1 is welded. During the welding process, the same cooling method as in steps 1 to 5 is used.

[0050] Step 7: After the adjacent electrical connectors 1 are welded, the water tank 4 device is removed and hot air is injected into the cooling clamp 3 through the air inlet pipe 8. The hot air is finally blown out through the toothed air hole in 301 and dries the wet stator bar 6. At the same time, the weld is heat exchanged.

[0051] Step 8: Once the welding points are completely dry and the weld quality meets the requirements, remove the air-cooling device, and the welding work is complete.

[0052] The above embodiments are merely preferred technical solutions of the present invention and should not be considered as limitations on the present invention. The scope of protection of the present invention should be limited to the technical solutions described in the claims, including equivalent substitutions of the technical features described in the claims. That is, equivalent substitutions and improvements within this scope are also within the scope of protection of the present invention.

Claims

1. A method for welding stator bar electrical connectors, characterized in that, The method includes the following steps: Step 1: Install an air-cooling device on the outside of the stator bar (6), install a water-cooling device below the air-cooling device, and set up a temperature measuring device above the air-cooling device. Step 2: Weld electrical connector (1) to the upper end of stator bar (6). During the welding process, start the air cooling device and cool the area around the welding point of stator bar (6). Step 3: Turn on the temperature measuring device and connect the temperature measuring device and the water cooling device via wired or wireless connection. Step 4: Point the temperature measuring device at the insulation layer at the end of the stator bar (6) and monitor the real-time temperature at that point during the welding process. Step 5: When the temperature near the insulation layer of the stator bar (6) exceeds 100°C, the temperature measuring device immediately sends a signal to the water cooling device and starts the water cooling device. The water cooling device immediately cools down the stator bar (6) with water. Step 6: After the stator bar (6) and the electrical connector (1) are welded, the adjacent electrical connector (1) is welded. During the welding process, the same cooling method as in Step 1 to Step 5 is used. Step 7: After the adjacent electrical connectors (1) are welded, remove the water cooling device and dry and slow heat treatment through the air cooling device. Step 8: Once the welding points are completely dry and the weld quality meets the requirements, remove the air-cooling device, and the welding work is completed. The water cooling device includes an adjustable bracket (2), a cooling clip (3) and an air inlet pipe (8); the side of the adjustable bracket (2) is connected to the cooling clip (3), and the back of the adjustable bracket (2) is connected to the air inlet pipe (8). The water cooling device includes a water tank (4), a sponge block (5), and a water inlet pipe (7); the top of the water tank (4) is provided with a strip (401), and the bottom of the adjustable bracket (2) is provided with a slot (207). The water tank (4) and the bracket housing (201) are detachably connected through the strip (401) and the slot (207); the two sides of the water tank (4) are connected to the sponge block (5), and the bottom of the water tank (4) is connected to the water inlet pipe (7). The adjustable bracket (2) includes a bracket housing (201), which has an internal hollow structure and is connected to the air inlet pipe (8). A slider (203) is provided inside the bracket housing (201). One side of the slider (203) is connected to the bracket housing (201) through a spiral air pipe (204), and the other side of the slider (203) is connected to the cooling clip (3). The upper end face of the bracket housing (201) is provided with a strip hole (202). The screw (205) passes through the strip hole (202) and is vertically connected to the slider (203). The screw (205) is provided with a locking nut (206) to fix the position of the slider (203). The cooling clamp (3) is a hollow structure and is connected to the slider (203). The side of the cooling clamp (3) is provided with a toothed groove (301) and clamps the outer wall of the electrical connector (1). An air outlet is provided in the toothed groove (301) and is connected to the cooling clamp (3).

2. The stator bar electrical connector welding method according to claim 1, characterized in that: The water tank (4) has multiple water supply branch pipes (9) connected to both sides. The end of the water supply branch pipe (9) is provided with a water outlet. The sponge block (5) is provided with a corresponding insertion hole (501) and is inserted into the water supply branch pipe (9).

3. The stator bar electrical connector welding method according to claim 1, characterized in that: The temperature measuring device includes an infrared thermometer (10) and an electronic water valve (701). The infrared thermometer (10) is installed above the adjustable bracket (2), and the electronic water valve (701) is installed on the water inlet pipe (7). The electronic water valve (701) and the infrared thermometer (10) are connected by wired or wireless means.

Images