Cable terminal test tool and manufacturing process thereof

Abstract

The invention provides a cable terminal test tool and a manufacturing process thereof, and relates to the technical field of high-voltage cable tests. The cable terminal test tool comprises an insulating cylinder, the outer side of the insulating cylinder is sleeved with an insulating sheath, a flange plate is fixedly installed at a top end interface of the insulating cylinder, a tested cable terminal is installed at the bottom end of the insulating cylinder, the center position of the top end of the tested cable terminal is connected with an internal conducting rod, and the internal conducting rod is arranged at the center position in the insulating cylinder. An aluminum alloy raw material is cut into a workpiece with the size needed by the flange through cutting equipment, preprocessing is carried out, the workpiece is punched into the shape of the flange through a punching machine, chamfering, punching and corresponding thread machining are carried out, the flange is subjected to finishing, polishing and fine machining, and it is guaranteed that the size of the flange is correct; and finally, the flange is subjected to heat treatment and surface anti-corrosion treatment, and the sealing safety and reliability of the flange structure are improved.

Description

Technical Field

[0001] The invention relates to the technical field of high-voltage cable testing, in particular to a cable terminal testing tool and a manufacturing process thereof. Background Art

[0002] As the construction of new power systems continues to advance, the form of the power grid is also undergoing profound changes. High-voltage cables and GIS equipment have increasingly replaced overhead lines and outdoor open equipment with their small footprint, high operational reliability, and easy maintenance, becoming the arteries of a strong smart grid. The cable terminals at the connection between high-voltage cables and GIS equipment have become the weak points of the overall insulation of the power grid, directly affecting the reliability of power supply. After the 110kV high-voltage cable withstand voltage test of the 110kV Sinoma lithium membrane GIS user substation, after actual application, it was proposed that the 110kV cable terminals that finally enter the cable warehouse must undergo a 128kV withstand voltage test.

[0003] The invention with the existing application number 202111309694.3 relates to an integrated test fixture for an intermediate joint of a high-voltage cable accessory and GIS. The fixture includes a support seat, a high-voltage lead-in mechanism is provided at one end of the support seat, an electric slide is provided on the upper side of the support seat, a plurality of moving blocks are provided at the moving end of the electric slide, a connecting fixture is provided on the upper side of the support seat, joint assemblies are provided at both ends of the connecting fixture, an automatic sleeve mechanism is provided on the outside of the joint assembly, the high-voltage lead-in mechanism is connected and fixed to one end of the support seat in a fixed manner, the joint bracket of the joint assembly is used to fix and control the movement of the test cable, the compression device is manually controlled to complete the connection and fixation between the cone head and the cable, and the electric slide is controlled to drive the joint bracket and the tightening frame to move horizontally, so as to complete the connection between the high-voltage lead-in mechanism and the gas tank terminal, solve the difficulty of manually installing and removing products on the cable, and can simply switch the high-voltage lead of the pressure-resistant equipment or the impact equipment, and quickly switch the test items.

[0004] However, the above-mentioned tooling still has the following problems when used: the joints of the tooling are connected by flanges. Since the test process may be subjected to harsh conditions such as high voltage and high current, the flange parts of the tooling are easily damaged. For example, the joints, clamps and other parts may become loose or break, affecting the sealing safety and reliability of the flange structure, and thus the normal progress of the test.

[0005] To this end, we have developed a new cable terminal test tooling and its manufacturing process. Summary of the invention

[0006] 1. Technical issues to be resolved In view of the deficiencies in the prior art, the present invention provides a cable terminal test tool and a manufacturing process thereof, which solves the above-mentioned problems.

[0007] (II) Technical solution To achieve the above objectives, the present invention is implemented through the following technical solutions: a cable terminal test tool, including an insulating cylinder, an insulating sheath is sleeved and installed on the outer side of the insulating cylinder, a flange is fixedly installed at the top interface of the insulating cylinder, a cable terminal to be tested is installed at the bottom of the insulating cylinder, an internal conductive rod is connected to the center position of the top of the cable terminal to be tested, the internal conductive rod is arranged at the center position in the insulating cylinder, air guide ports are arranged at both ends of the bottom of the insulating cylinder, a pressure gauge is fixedly installed at one end of the bottom of the insulating cylinder and at the opening of the air guide port on one side, and an air charging and discharging valve is fixedly installed at the other end of the bottom of the insulating cylinder and at the opening of the air guide port on the other side.

[0008] Preferably, a cable terminal test tool, including a manufacturing process of an insulating tube, comprises the following specific steps: 1) Determine the final dimensions of the cylinder wall and draw engineering drawings based on standardized processes; 2) Select appropriate glass fiber reinforced plastic material and prepare the mold required to make the cylinder to ensure that it meets the design specifications; 3) Coat the mold surface to prevent adhesion. Ensure the inner surface of the mold is flat, clean, and properly lubricated; 4) Apply the glass fiber cloth layer by layer on the mold surface, and each layer must be saturated to ensure that the glass fiber and resin are fully combined; 5) Wait for the material to solidify and harden in the mold according to the hardening time and temperature requirements. After hardening, remove the cylinder wall from the mold; 6) Trim and polish the cylinder wall, check the appearance of the cylinder wall, and inspect the appearance and size of the cylinder wall to ensure that its size is correct, the appearance is intact, and there is no bump or dirt; 7) Carry out multiple pressure tests on the cylinder wall; 8) Tensile strength performance test.

[0009] Preferably, a cable terminal test tool, including a manufacturing process of an insulating sheath, comprises the following specific steps: 1) Determine the final size of the customized insulating sheath based on the size of the barrel wall; 2) Select a structure in which large and small sheds are alternately distributed and curved downward, and draw an engineering drawing; 3) Select appropriate silicone rubber material and prepare the required molds and tools; 4) Coat the mold surface to prevent silicone rubber from adhering, ensure the inner surface of the mold is flat, clean, and properly lubricated; 5) Mix the silicone rubber mixture according to the proportion, and inject or cast the mixed silicone rubber into the prepared insulating sheath mold to ensure that the silicone rubber fills the mold and avoids bubbles and gaps; 6) Wait for the silicone rubber to solidify and harden in the mold according to the curing time and temperature requirements of the silicone rubber. Then remove the insulating sheath from the mold; 7) Trim the insulating sheath, check key properties such as size, surface quality, hardness, etc., inspect the appearance and size of the insulating sheath to ensure that its size is correct, the appearance is intact, there is no bump or dirt, and the shed structure is correct; 8) Carry out full-load withstand voltage test on the insulating sheath and monitor the partial discharge in real time.

[0010] Preferably, a cable terminal test tool, including a flange manufacturing process, comprises the following specific steps: 1) Determine the final size of the customized flange according to the standard process and draw the engineering drawing; 2) Use cutting equipment to cut the raw materials into workpieces of required size and perform pre-processing; 3) Use a punch press to punch the workpiece into the shape of a flange, and perform chamfering, drilling and corresponding thread processing; 4) The flange is trimmed and polished to ensure the flange size is correct, and the flange is heat treated and surface anti-corrosion treated; 5) Perform an appearance inspection on the processed flange, and check the appearance and size of the flange to ensure that its size is correct and the appearance is not dirty; 6) Conduct electrochemical tests; 7) Yield strength test.

[0011] (III) Beneficial effects The present invention provides a cable terminal test tool and a manufacturing process thereof, which has the following beneficial effects: 1. A cable terminal test fixture and its manufacturing process, by using cutting equipment to cut aluminum alloy raw materials into workpieces of the required size of the flange, and pre-processing, using a punch press to punch the workpiece into the shape of the flange, and chamfering, punching and corresponding thread processing, the flange is trimmed and polished to ensure the correct size of the flange, and finally the flange is heat treated and surface anti-corrosion treated, which improves the sealing safety and reliability of the flange structure.

[0012] 2. This cable terminal test fixture and its manufacturing process, by selecting appropriate glass fiber reinforced plastic materials, prepare the mold required for making the cylinder, ensure that it meets the design specifications, and apply a coating on the mold surface to prevent adhesion. Ensure that the inner surface of the mold is flat and clean, and properly lubricate, and apply the glass fiber cloth layer by layer on the mold surface, each layer must be saturated to ensure that the glass fiber and resin are fully combined, according to the hardening time and temperature requirements, wait for the material to solidify and harden in the mold, after hardening, remove the cylinder wall from the mold, trim and polish the cylinder wall, check the appearance of the cylinder wall, and improve the safety and reliability of the cylinder wall. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 This is a schematic diagram of the overall structure of a cable terminal test tooling of the present invention; In the figure: 1. Insulating cylinder; 2. Insulating sheath; 3. Flange; 4. Filling and discharging valve; 5. Pressure gauge; 6. Internal conductive rod; 7. Terminal of the cable under test. DETAILED DESCRIPTION

[0014] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. 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 creative work are within the scope of protection of the present invention. Example

[0015] like Figure 1 As shown, an embodiment of the present invention provides a cable terminal test tool, including an insulating cylinder 1, an insulating sheath 2 is sleeved and installed on the outer side of the insulating cylinder 1, a flange 3 is fixedly installed at the top interface of the insulating cylinder 1, a cable terminal 7 to be tested is installed at the bottom end of the insulating cylinder 1, an internal conductive rod 6 is connected to the center position of the top of the cable terminal 7 to be tested, the internal conductive rod 6 is arranged at the center position inside the insulating cylinder 1, air guide ports are arranged at both ends of the bottom of the insulating cylinder 1, a pressure gauge 5 is fixedly installed at one end of the bottom of the insulating cylinder 1 and at the opening of the air guide port on one side, and an air charging and discharging valve 4 is fixedly installed at the other end of the bottom of the insulating cylinder 1 and at the opening of the air guide port on the other side.

[0016] Among them, after the overall tooling is assembled, the assembled machine is subjected to a voltage resistance test, a partial discharge test and an air tightness test. It should be able to withstand a test voltage of 150kV for 2 hours, the partial discharge should be less than 6pc, and the air pressure drop within 2 hours should not exceed 5%.

[0017] The specific implementation process is as follows: (1) Inspect all components and structural parts to confirm that they meet design and quality standards.

[0018] (2) Prepare the work area, ensure it is clean, safe, and equipped with necessary tools and equipment.

[0019] (3) Assemble the various structural components in sequence according to the assembly drawings, paying attention to using the correct fasteners and tightening force to ensure that the assembled structure is firm and reliable.

[0020] (4) Conduct a voltage withstand test on the whole machine and record the voltage that the whole machine can withstand to ensure that the whole machine can withstand the test voltage of 150 kV for 2 hours.

[0021] (5) Conduct a partial discharge test on the entire machine and record the partial discharge data to ensure that the partial discharge does not exceed 6pc.

[0022] (6) Perform an airtightness test on the whole machine and fill the whole machine with SF6 gas to make the internal pressure reach 0.44MPa. Monitor the pressure change inside the whole machine within 2 hours to ensure that the pressure drop does not exceed 5%.

[0023] Among them, 8 different positions were set up on the top and bottom of the assembled test tooling for a 1-hour 128kV withstand voltage test, and 10 groups were carried out at each position. From the test results, it can be seen that the assembled whole machine can withstand a test voltage of 150kV for 2 hours and has a high insulation level. The goal has been achieved.

[0024] Among them, a 128kV test voltage was applied to the assembled test tooling for 3 hours and tested with a partial discharge detection device. From the test results, it can be seen that the partial discharge of the assembled whole machine did not exceed 6pc within 2 hours, with an average value of 3.4pc, and the goal was achieved.

[0025] Among them, the assembled whole is evacuated using a small inflation and deflation device, and then SF6 gas is injected into the test tooling through the air inlet to make the air pressure in the tooling reach 0.44MPa. Then an air tightness test is carried out, and the whole machine is left to stand for 2 hours, and the air pressure value is recorded every 20 minutes. A total of 6 groups of tests are carried out. From the test results, it can be seen that the whole machine is left to stand for 2 hours at an initial air pressure of 0.44MPa, and the air pressure drops by 0.019MPa, with a decrease percentage of 4.5%, which is less than 5%, and the goal is achieved.

[0026] In summary, after the test, the whole machine can withstand the test voltage of 150kV for 2 hours, the partial discharge does not exceed 6pc, and the air pressure drop does not exceed 5% in 2 hours. The goal is achieved.

[0027] like Figure 1 As shown, an embodiment of the present invention provides a cable terminal test tool, including a manufacturing process of an insulating tube 1, including the following specific steps: 1) Determine the final dimensions of the cylinder wall and draw engineering drawings based on standardized processes; 2) Select appropriate glass fiber reinforced plastic material and prepare the mold required to make the cylinder to ensure that it meets the design specifications; 3) Coat the mold surface to prevent adhesion. Ensure the inner surface of the mold is flat, clean, and properly lubricated; 4) Apply the glass fiber cloth layer by layer on the mold surface, and each layer must be saturated to ensure that the glass fiber and resin are fully combined; 5) Wait for the material to solidify and harden in the mold according to the hardening time and temperature requirements. After hardening, remove the cylinder wall from the mold; 6) Trim and polish the cylinder wall, check the appearance of the cylinder wall, and inspect the appearance and size of the cylinder wall to ensure that its size is correct, the appearance is intact, and there is no bump or dirt; 7) Carry out multiple pressure tests on the cylinder wall; 8) Tensile strength performance test.

[0028] like Figure 1 As shown, an embodiment of the present invention provides a cable terminal test tool, including a manufacturing process of an insulating sheath 2, including the following specific steps: 1) Determine the final size of the customized insulating sheath based on the size of the barrel wall; 2) Select a structure in which large and small sheds are alternately distributed and curved downward, and draw an engineering drawing; 3) Select appropriate silicone rubber material and prepare the required molds and tools; 4) Coat the mold surface to prevent silicone rubber from adhering, ensure the inner surface of the mold is flat, clean, and properly lubricated; 5) Mix the silicone rubber mixture according to the proportion, and inject or cast the mixed silicone rubber into the prepared insulating sheath mold to ensure that the silicone rubber fills the mold and avoids bubbles and gaps; 6) Wait for the silicone rubber to solidify and harden in the mold according to the curing time and temperature requirements of the silicone rubber. Then remove the insulating sheath from the mold; 7) Trim the insulating sheath, check key properties such as size, surface quality, hardness, etc., inspect the appearance and size of the insulating sheath to ensure that its size is correct, the appearance is intact, there is no bump or dirt, and the shed structure is correct; 8) Carry out full-load withstand voltage test on the insulating sheath and monitor the partial discharge in real time.

[0029] like Figure 1 As shown, an embodiment of the present invention provides a cable terminal test tool, including a manufacturing process of a flange 3, including the following specific steps: 1) Determine the final size of the customized flange according to the standard process and draw the engineering drawing; 2) Use cutting equipment to cut the raw materials into workpieces of required size and perform pre-processing; 3) Use a punch press to punch the workpiece into the shape of a flange, and perform chamfering, drilling and corresponding thread processing; 4) The flange is trimmed and polished to ensure the flange size is correct, and the flange is heat treated and surface anti-corrosion treated; 5) Perform an appearance inspection on the processed flange, and check the appearance and size of the flange to ensure that its size is correct and the appearance is not dirty; 6) Conduct electrochemical tests; 7) Yield strength test.

[0030] In addition, the present invention needs to illustrate that: The charging and discharging valve 4 is selected as a quick-plug self-closing charging and discharging valve; The pressure gauge 5 is selected as the selected diaphragm pressure gauge; The inner conductive rod 6 is selected to be a copper conductive rod.

[0031] Although 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 the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A cable terminal test tool, comprising an insulating tube (1), characterized in that: An insulating sheath (2) is sleeved and installed on the outside of the insulating cylinder (1), a flange (3) is fixedly installed at the top interface of the insulating cylinder (1), and a tested cable terminal (7) is installed at the bottom end of the insulating cylinder (1); The center position of the top end of the tested cable terminal (7) is connected to an internal conductive rod (6), and the internal conductive rod (6) is arranged at the center position inside the insulating tube (1); Air guide ports are provided at both ends of the bottom of the insulating tube (1); a pressure gauge (5) is fixedly mounted at one end of the bottom of the insulating tube (1) and at the opening of the air guide port on one side; and a charging and discharging valve (4) is fixedly mounted at the other end of the bottom of the insulating tube (1) and at the opening of the air guide port on the other side.

2. A cable terminal test fixture according to claim 1, comprising a manufacturing process of a flange (3), characterized in that: The specific steps include: 1) Determine the final size of the customized flange according to the standard process and draw the engineering drawing; 2) Use cutting equipment to cut the raw materials into workpieces of required size and perform pre-processing; 3) Use a punch press to punch the workpiece into the shape of a flange, and perform chamfering, drilling and corresponding thread processing; 4) The flange is trimmed and polished to ensure the flange size is correct, and the flange is heat treated and surface anti-corrosion treated; 5) Perform an appearance inspection on the processed flange, and check the appearance and size of the flange to ensure that its size is correct and the appearance is not dirty; 6) Conduct electrochemical tests; 7) Yield strength test.

3. A cable terminal test tool according to claim 1, comprising a manufacturing process of an insulating tube (1), characterized in that: The specific steps include: 1) Determine the final dimensions of the cylinder wall and draw engineering drawings based on standardized processes; 2) Select appropriate glass fiber reinforced plastic material and prepare the mold required to make the cylinder to ensure that it meets the design specifications; 3) Coat the mold surface to prevent adhesion. Ensure the inner surface of the mold is flat, clean, and properly lubricated; 4) Apply the glass fiber cloth layer by layer on the mold surface, and each layer must be saturated to ensure that the glass fiber and resin are fully combined; 5) Wait for the material to solidify and harden in the mold according to the hardening time and temperature requirements. After hardening, remove the cylinder wall from the mold; 6) Trim and polish the cylinder wall, check the appearance of the cylinder wall, and inspect the appearance and size of the cylinder wall to ensure that its size is correct, the appearance is intact, and there is no bump or dirt; 7) Carry out multiple pressure tests on the cylinder wall; 8) Tensile strength performance test.

4. A cable terminal test tool according to claim 1, comprising a manufacturing process of an insulating sheath (2), characterized in that: The specific steps include: 1) Determine the final size of the customized insulating sheath based on the size of the barrel wall; 2) Select a structure in which large and small sheds are alternately distributed and curved downward, and draw an engineering drawing; 3) Select appropriate silicone rubber material and prepare the required molds and tools; 4) Coat the mold surface to prevent silicone rubber from adhering, ensure the inner surface of the mold is flat, clean, and properly lubricated; 5) Mix the silicone rubber mixture according to the proportion, and inject or cast the mixed silicone rubber into the prepared insulating sheath mold to ensure that the silicone rubber fills the mold and avoids bubbles and gaps; 6) Wait for the silicone rubber to solidify and harden in the mold according to the curing time and temperature requirements of the silicone rubber. Then remove the insulating sheath from the mold; 7) Trim the insulating sheath, check key properties such as size, surface quality, hardness, etc., inspect the appearance and size of the insulating sheath to ensure that its size is correct, the appearance is intact, there is no bump or dirt, and the shed structure is correct; 8) Carry out full-load withstand voltage test on the insulating sheath and monitor the partial discharge in real time.

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