Device for testing electrical insulation performance of copper-clad aluminum composite bus based on multi-parameter coupling

Abstract

The invention discloses a copper-clad aluminum composite bus electrical insulation performance test device based on multi-parameter coupling, and relates to the technical field of copper-clad aluminum bus electrical insulation performance test.The copper-clad aluminum composite bus electrical insulation performance test device comprises a detection table, a first detection chamber is arranged on one side of the upper surface of the detection table, and a second detection chamber is arranged on the other side of the upper surface of the detection table; a control device is arranged on one side, close to the first detection chamber and the second detection chamber, of the upper surface of the detection table, measurement supporting plates are symmetrically arranged in the detection table, temperature and humidity adjusting devices are arranged in the first detection chamber and the second detection chamber, and a multi-axis detection device is arranged in the second detection chamber; the rapid switching function in the scheme allows simulation of various extreme environment combinations in a single test, the insulation performance degradation path is comprehensively evaluated, and the independently sealed rapid switching chamber can isolate external interference and maintain steady-state control of the test environment.

Description

Technical Field

[0001] The invention relates to the technical field of copper-clad aluminum busbar electrical insulation performance testing, in particular to a copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling. Background Art

[0002] Copper clad aluminum composite busbar, also known as copper clad aluminum busbar or copper-aluminum composite busbar, is a bimetallic composite conductor made by closely combining copper and aluminum using a specific process. The copper clad aluminum composite busbar uses aluminum as the matrix and is covered with copper on the outer layer. Through a specific process, the interfaces of the two metals, copper and aluminum, are fused or diffused to form a close metallurgical bond. The copper clad aluminum composite busbar combines the high-quality and stable conductive properties of copper with the low cost of aluminum. Although its conductivity is slightly lower than that of pure copper busbar, under the same specifications, by appropriately increasing the cross-sectional area, it can achieve the same current carrying capacity as pure copper.

[0003] However, most of the existing copper-clad aluminum detection equipment is a single functional module, lacking the ability to collect composite parameters simultaneously, so it can only perform a single measurement during electrical measurement. Since the DC resistance of copper-clad aluminum conductors is higher than that of pure copper, if only the resistance is measured without combining temperature rise or heat dissipation conditions, it may cause the conductor to heat up more in actual applications, accelerate the oxidation of the aluminum core, and even cause loose connection points or fire hazards. Especially in high temperature or high current scenarios, single parameter measurement cannot warn of thermal stability problems of the material.

[0004] In addition, the existing copper-clad aluminum usually uses a mechanical clamp to fix the busbar before measurement. The extrusion of the mechanical clamp will cause damage to the busbar surface. After the surface copper layer is damaged, the aluminum core is exposed and in contact with the air, resulting in the formation of an oxide film and increased contact resistance. In the DC resistance test, the increase in local resistance in the damaged area will mask the true conductive performance of the material.

[0005] Therefore, a copper-clad aluminum composite busbar electrical insulation performance test device based on multi-parameter coupling is proposed to solve the above problems. Summary of the invention

[0006] In view of this, the technical problem to be solved by the present invention is to propose a copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling to solve the problems of single measurement of copper-clad aluminum and easy damage during measurement and fixation in the prior art.

[0007] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a copper-clad aluminum composite busbar electrical insulation performance test device based on multi-parameter coupling, comprising a test platform, a first test chamber is arranged on one side of the upper surface of the test platform, a second test chamber is arranged on the other side of the upper surface of the test platform, a control device is arranged on the upper surface of the test platform close to the first test chamber and the second test chamber, a measuring support plate is symmetrically arranged in the test platform, a temperature and humidity regulating device is arranged in the first test chamber and the second test chamber, a multi-axis detection device is arranged in the second test chamber, and the copper-clad aluminum composite busbar electrical insulation performance test device based on multi-parameter coupling also includes a multi-scene switching mechanism, a base vibration monitoring mechanism and a resistance and mechanical testing mechanism; The multi-scene switching mechanism is arranged in the detection platform, and the multi-scene switching mechanism is used for dynamic detection switching of the copper-clad aluminum busbar; The base vibration monitoring mechanism is arranged on the measuring support plate, and the base vibration monitoring mechanism is used for vibration fixing of the copper-clad aluminum busbar; The resistance and mechanical testing mechanism is arranged above the measuring support plate, and is used for measuring the insulation resistance and mechanical stress of the copper-clad aluminum busbar.

[0008] Preferably, the multi-scene switching mechanism includes a transmission disk, which is symmetrically rotatably connected in the detection table, and the outer surface of the transmission disk is transmission-connected to a transmission belt, the outer surface of one side of the transmission belt is fixedly connected to a first push plate, and the outer surface of the other side of the transmission belt is fixedly connected to a second push plate, and the first push plate and the second push plate are both slidably connected to the inner walls on both sides of the detection table close to the measuring support plate, and a first U-shaped guide groove is opened on the inner wall of the detection table close to the second push plate, and a second U-shaped guide groove is opened on the inner wall of the detection table close to the first push plate.

[0009] Preferably, a composite slider is slidably connected in the second U-shaped guide groove and the first U-shaped guide groove, and the composite slider consists of a square slider and a cylinder, the square slider is slidably connected in the first U-shaped guide groove and the second U-shaped guide groove respectively, a second V-shaped groove is provided on the first push plate, and a first V-shaped groove is provided on the second push plate, the outer surface of the cylinder is slidably connected in the first V-shaped groove and the second V-shaped groove respectively, and one end of the cylinder away from the square slider is fixedly connected to the bottom of the measuring support plates on both sides of the middle of the testing platform.

[0010] Preferably, the base vibration monitoring mechanism includes an amplitude disk, which is rotatably connected to the middle part of the measuring pallet, and amplitude blocks are evenly arranged on the upper surface of the amplitude disk. A support is arranged above the amplitude blocks, and protrusions are arranged at both ends of the lower surface of the support. The middle part of the support is fixedly connected to the middle part of the measuring pallet, and a servo motor is installed in the middle part of the upper surface of the support. A gear is fixedly connected to the servo motor drive shaft, and Z-shaped rack plates are meshed with tooth surfaces on both sides of the gear, and a first clamp is movably connected to the end of the Z-shaped rack plate away from the gear.

[0011] Preferably, a multifunctional placement rack is fixedly connected to the upper surfaces of both ends of the support, the middle part of the first jaw is rotatably connected to the multifunctional placement rack, the first jaw is provided with sliding teeth, the tooth surface of the first jaw is meshed with a second jaw, the middle part of the second jaw is rotatably connected to the multifunctional placement rack, and a pressure sensor and a mechanical strain sensor are respectively installed on the upper surface of the multifunctional placement rack.

[0012] Preferably, the resistance and mechanical testing mechanism includes an electric telescopic rod, one end of which is installed on the multi-axis detection device, and the other end of the electric telescopic rod is fixedly connected to a fixed block, a sliding groove is opened in the middle of the fixed block, and a compression spring is fixedly connected in the sliding groove, and the compression spring is fixedly connected to a T-shaped slider at one end away from the sliding groove, and the outer surface of the T-shaped slider is slidably connected in the sliding groove opened in the fixed block.

[0013] Preferably, a measuring probe is fixedly connected to the middle part of the lower surface of the T-shaped slider, auxiliary plates are rotatably connected to the two sides of the T-shaped slider close to the measuring probe, the auxiliary plate is rotatably connected to a clamping plate at one end away from the T-shaped slider, a support plate is rotatably connected to the middle part of the clamping plate, and the support plate is rotatably connected to the bottom of the fixed block at one end away from the clamping plate.

[0014] Compared with the prior art, the present invention provides a copper-clad aluminum composite busbar electrical insulation performance test device based on multi-parameter coupling, which has the following beneficial effects: 1. The rotation of the transmission disk can synchronously drive the measuring pallets located on both sides of the test bench to start moving toward the middle of the test bench. The mutual squeezing effect of the first V-shaped groove and the second V-shaped groove and the second U-shaped guide groove can enable the measuring pallet to complete the dynamic switching of the measuring environment in the first test chamber and the second test chamber. The fast switching function in this solution allows the simulation of multiple extreme environment combinations in a single test, and comprehensively evaluates the insulation performance degradation path. At the same time, the independently sealed fast switching chamber can isolate external interference and maintain steady-state control of the test environment.

[0015] 2. Mechanical vibration can be generated on the surface of the platform by the collision between the amplitude block at the upper end of the amplitude disk and the protrusion set at the bottom of the platform. The vibration frequency of the platform can be controlled by controlling the rotation speed of the servo drive motor, so that the data of copper-clad aluminum at different vibration frequencies can be quickly measured. This design is crucial for in-depth research on the electrical properties of copper-clad aluminum materials at different vibration frequencies. In the field of materials science and electrical engineering, such tests are of great significance for understanding the dynamic response of materials, optimizing equipment design, and ensuring product reliability.

[0016] 3. In this scheme, the copper-clad aluminum busbar can be quickly and flexibly clamped. Compared with the traditional rigid clamping, the flexible clamping method in this scheme can better avoid scratches or indentations on the busbar, effectively protect the surface quality of the busbar, and extend its service life; 4. Further, the present solution installs strain sensors on the surface of the multifunctional placement rack to detect the measurement results of copper-clad aluminum under different mechanical stresses. By installing strain sensors on the surface of the multifunctional placement rack, real-time monitoring of copper-clad aluminum materials during stress can be achieved. This real-time monitoring capability helps to timely discover possible abnormalities or damage to the material during stress, providing strong support for timely measures.

[0017] 5. This scheme symmetrically installs a multi-axis detection device in the first detection room. Not only can the measuring probe quickly contact the surface of the copper-clad aluminum busbar and generate a certain pressure through the three-axis adjustment action of the multi-axis detection device, but the clamping plate can be driven to clamp the two sides of the copper-clad aluminum while the measuring probe is pressed. Not only can the insulation resistance of the copper-clad aluminum be quickly detected, but also when the multi-axis detection device applies a certain mechanical pressure to the surface of the copper-clad aluminum, the data of the copper-clad aluminum under different stresses can be measured and stored through the synchronous measurement of the mechanical strain sensor under the copper-clad aluminum. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention; Figure 2 It is an auxiliary schematic diagram of the three-dimensional structure of the present invention; Figure 3 A schematic diagram of the structural connection relationship of the multi-scene switching mechanism of the present invention; Figure 4 A longitudinal cross-sectional schematic diagram of the structural connection relationship of the multi-scene switching mechanism of the present invention; Figure 5 A vertical cross-sectional schematic diagram of the structural connection relationship of the multi-scene switching mechanism of the present invention; Figure 6 It is a vertical section auxiliary schematic diagram of the structural connection relationship of the multi-scene switching mechanism of the present invention; Figure 7 It is a schematic diagram of the structural connection relationship between the base vibration monitoring mechanism and the resistance and mechanical testing mechanism of the present invention; Figure 8 It is a schematic diagram of the connection relationship between the base vibration monitoring mechanism and the resistance and mechanical testing mechanism structure parts in the cutaway state of the present invention; Fig. 9 For the present invention Figure 8 Enlarged view of point A in the middle; Fig.10 For the present invention Figure 8 Enlarged view of point B in the middle.

[0019] In the figure: 1. Testing platform; 11. First testing room; 12. Second testing room; 13. Control device; 14. Measuring support plate; 15. Temperature and humidity adjustment device; 16. Multi-axis testing device; 2. Multi-scene switching mechanism; 21. Transmission disc; 22. Transmission belt; 23. First push plate; 24. Second push plate; 25. First U-shaped guide groove; 26. First V-shaped groove; 27. Second V-shaped groove; 28. Second U-shaped guide groove; 3. Base vibration monitoring mechanism; 31. Amplitude plate; 32. Amplitude block; 33. Support platform; 34. Gear; 35. Z-shaped rack plate; 36. First clamping jaw; 37. Second clamping jaw; 38. Multifunctional placement rack; 4. Resistance and mechanical testing mechanism; 41. Electric telescopic rod; 42. Compression spring; 43. Fixed block; 44. T-shaped slider; 45. Measuring probe; 46. Auxiliary plate; 47. Clamp; 48. Support plate. DETAILED DESCRIPTION

[0020] 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.

[0021] The present invention is further described in detail below based on the accompanying drawings and embodiments.

[0022] For the first embodiment, please refer to Figures 1 to 10 As shown: In order to solve the problems mentioned in the technical solution, the embodiment of the present application provides a copper-clad aluminum composite busbar electrical insulation performance test device based on multi-parameter coupling, including a test platform 1, a first test chamber 11 is provided on one side of the upper surface of the test platform 1, a second test chamber 12 is provided on the other side of the upper surface of the test platform 1, a control device 13 is provided on the upper surface of the test platform 1 close to the first test chamber 11 and the second test chamber 12, a measuring support plate 14 is symmetrically provided in the test platform 1, a temperature and humidity adjustment device 15 is provided in the first test chamber 11 and the second test chamber 12, and a multi-axis detection device 16 is symmetrically provided in the first test chamber 11. The copper-clad aluminum composite busbar electrical insulation performance test device based on multi-parameter coupling also includes a multi-scene switching mechanism 2, a base vibration monitoring mechanism 3 and a resistance and mechanical testing mechanism 4; The multi-scene switching mechanism 2 is arranged in the detection platform 1, and the multi-scene switching mechanism 2 is used for dynamic detection switching of the copper-clad aluminum busbar; The base vibration monitoring mechanism 3 is arranged on the measuring support plate 14, and the base vibration monitoring mechanism 3 is used for vibration fixing of the copper-clad aluminum busbar; The resistance and mechanical testing mechanism 4 is arranged above the measuring support plate 14 , and is used for measuring the insulation resistance and mechanical stress of the copper-clad aluminum busbar.

[0023] Specifically, Figures 3 to 6 As shown, the transmission disk 21 is symmetrically rotatably connected in the detection platform 1, and the outer surface of the transmission disk 21 is transmission-connected with a transmission belt 22, and the outer surface of one side of the transmission belt 22 is fixedly connected with a first push plate 23, and the outer surface of the other side of the transmission belt 22 is fixedly connected with a second push plate 24, and the first push plate 23 and the second push plate 24 are both slidably connected to the inner walls of the detection platform 1 on both sides close to the measuring support plate 14, and a first U-shaped guide groove 25 is opened on the inner wall of the detection platform 1 on the side close to the second push plate 24, and a second U-shaped guide groove 28 is opened on the inner wall of the detection platform 1 on the side close to the first push plate 23.

[0024] Among them, the middle part of a transmission disk 21 on one side of the testing platform 1 is fixedly connected to the motor drive shaft, and the motor is installed in the testing platform 1. A measuring hole that is interconnected with the first testing chamber 11 and the second testing chamber 12 is opened at the bottom, and the measuring hole is adapted to the size of the measuring support plate 14. Sealing gaskets are evenly installed on the outer periphery of the measuring support plate 14 for sealing with the first testing chamber 11 and the second testing chamber 12 when the measuring support plate 14 switches with each other.

[0025] A composite slider is slidably connected in the second U-shaped guide groove 28 and the first U-shaped guide groove 25, and the composite slider is composed of a square slider and a cylinder. The square slider is slidably connected in the first U-shaped guide groove 25 and the second U-shaped guide groove 28 respectively. A second V-shaped groove 27 is provided on the first push plate 23, and a first V-shaped groove 26 is provided on the second push plate 24. The outer surface of the cylinder is slidably connected in the first V-shaped groove 26 and the second V-shaped groove 27 respectively, and the end of the cylinder away from the square slider is fixedly connected to the bottom of the measuring support plates 14 on both sides of the middle of the detection platform 1.

[0026] The square slider in the composite slider can control the measuring support plate 14 to remain horizontal when sliding, and the opening height of the first U-shaped guide groove 25 and the first V-shaped groove 26 in the detection platform 1 is greater than the opening height of the second V-shaped groove 27 and the second U-shaped guide groove 28.

[0027] The rotation of the transmission disk 21 can synchronously drive the measuring pallets 14 located on both sides of the test platform 1 to start moving toward the middle of the test platform 1. The mutual squeezing action of the first V-shaped groove 26 and the second V-shaped groove 27 and the second U-shaped guide groove 28 can enable the measuring pallet 14 to complete the dynamic switching of the measuring environment in the first test chamber 11 and the second test chamber 12. The fast switching function in this scheme allows simulating multiple extreme environment combinations in a single test, such as salt spray corrosion and then immediately switching to wet heat cycle, to comprehensively evaluate the insulation performance degradation path. At the same time, the independently sealed fast switching chamber can isolate external interference such as laboratory temperature and humidity fluctuations, and maintain steady-state control of the test environment such as ±0.5°C accuracy.

[0028] Specifically, Figure 8 and Fig. 9 As shown, the amplitude disk 31 is rotatably connected to the middle part of the measuring support plate 14, the upper surface of the amplitude disk 31 is evenly provided with amplitude blocks 32, a support platform 33 is provided above the amplitude blocks 32, and protrusions are provided at both ends of the lower surface of the support platform 33. The middle part of the support platform 33 is fixedly connected to the middle part of the measuring support plate 14, and a servo motor is installed in the middle part of the upper surface of the support platform 33. A gear 34 is fixedly connected to the servo motor drive shaft, and Z-shaped rack plates 35 are meshed with tooth surfaces on both sides of the gear 34, and a first clamping jaw 36 is movably connected to the end of the Z-shaped rack plate 35 away from the gear 34.

[0029] Among them, a servo drive motor is installed in the middle of the measuring support plate 14, and the drive shaft of the servo drive motor is connected to the amplitude block 32 through transmission. The rotation of the servo drive motor can synchronously drive the amplitude disk 31 to rotate, and the collision between the amplitude block 32 at the upper end of the amplitude disk 31 and the protrusion set at the bottom of the support 33 can cause mechanical vibration on the surface of the support 33, and the speed of the vibration frequency of the support 33 can be controlled by controlling the rotation speed of the servo drive motor, so that the data of copper-clad aluminum at different vibration frequencies can be quickly measured. Through this design, it is very important to deeply study the electrical properties of copper-clad aluminum materials at different vibration frequencies. In the fields of materials science and electrical engineering, such tests are of great significance for understanding the dynamic response of materials, optimizing equipment design and ensuring product reliability.

[0030] Furthermore, a multifunctional placement rack 38 is fixedly connected to the upper surface of both ends of the support 33, the middle part of the first clamping jaw 36 is rotatably connected to the multifunctional placement rack 38, the first clamping jaw 36 is provided with sliding teeth, the tooth surface of the first clamping jaw 36 is meshed with the second clamping jaw 37, the middle part of the second clamping jaw 37 is rotatably connected to the multifunctional placement rack 38, and the upper surface of the multifunctional placement rack 38 is respectively installed with a pressure sensor and a mechanical strain sensor.

[0031] The inner side of the upper bevel of the second clamping jaw 37 is wrapped with a flexible material.

[0032] In this solution, the copper-clad aluminum busbar can be quickly and flexibly clamped by setting. Compared with the traditional rigid clamping, the flexible clamping method in this solution can better avoid scratches or indentations on the busbar, effectively protect the surface quality of the busbar, and extend its service life; Furthermore, the present solution installs strain sensors on the upper surface of the multifunctional placement rack 38 to detect the measurement results of copper-clad aluminum under different mechanical stresses. By installing strain sensors on the upper surface of the multifunctional placement rack 38, real-time monitoring of the copper-clad aluminum material during the stress process can be achieved. This real-time monitoring capability helps to timely discover possible abnormalities or damage to the material during the stress process, providing strong support for timely measures.

[0033] Specifically, Fig.10As shown, one end of the electric telescopic rod 41 is installed on the multi-axis detection device 16, and the other end of the electric telescopic rod 41 is fixedly connected to a fixed block 43. A sliding groove is opened in the middle of the fixed block 43, and a compression spring 42 is fixedly connected in the sliding groove. The compression spring 42 is fixedly connected to a T-shaped slider 44 at one end away from the sliding groove. The outer surface of the T-shaped slider 44 is slidably connected in the sliding groove opened in the fixed block 43. A measuring probe 45 is fixedly connected to the middle of the lower surface of the T-shaped slider 44. The T-shaped slider 44 is rotatably connected to auxiliary plates 46 on both sides of the measuring probe 45. The auxiliary plate 46 is rotatably connected to a clamping plate 47 at one end away from the T-shaped slider 44. A support plate 48 is rotatably connected to the middle of the clamping plate 47, and the support plate 48 is rotatably connected to the bottom of the fixed block 43 at one end away from the clamping plate 47.

[0034] This solution symmetrically installs a multi-axis detection device 16 in the first detection chamber 11, which not only allows the measuring probe 45 to quickly contact the surface of the copper-clad aluminum busbar and generate a certain pressure under the three-axis adjustment action of the multi-axis detection device 16, but also drives the clamping plate 47 to clamp the two sides of the copper-clad aluminum when the measuring probe 45 is pressed, which not only allows the rapid detection of the insulation resistance of the copper-clad aluminum, but also, when the multi-axis detection device 16 applies a certain mechanical pressure to the surface of the copper-clad aluminum, the synchronous measurement of the mechanical strain sensor under the copper-clad aluminum can measure and store the data under different stresses of the copper-clad aluminum.

[0035] Second embodiment What is different from the first embodiment is that the test bench 1 is also provided with a dynamic environment simulation module: the copper-clad aluminum composite busbar is subjected to controllable temperature, humidity and mechanical vibration conditions; Multi-parameter coupling acquisition module: sensors are arranged in a distributed array in the first detection chamber 11 and the second detection chamber 12, and are used to collect electrical parameters and environmental parameters of the busbar in real time; Intelligent analysis module: It is configured to output the insulation performance evaluation results based on the collected multi-parameter data through the coupling relationship model and predict the insulation failure threshold; among which, the coupling relationship model is a numerical simulation model based on multi-physical field coupling, and the input parameters include electric field strength, thermal stress, and mechanical vibration spectrum, and the output is the equivalent aging coefficient of the insulation layer.

[0036] Adaptive control module: connected to the dynamic environment simulation unit, and adjusts environmental parameters in real time according to the feedback from the intelligent analysis unit.

[0037] Among them, the dynamic environment simulation module is used to integrate the temperature control, humidity adjustment, and vibration simulation functions of the multi-scene switching mechanism 2, the base vibration monitoring mechanism 3, the resistance and mechanical testing mechanism 4, the temperature and humidity adjustment device 15, and the multi-axis detection device 16, and dynamically adjust the insulation failure threshold by combining historical data and real-time parameters to improve the warning accuracy and cover the complex working condition testing needs.

[0038] The specific implementation steps of the above embodiment are as follows: First, preliminary material preparation was carried out for the insulation performance test of copper-clad aluminum composite busbar in high temperature and high humidity environment; Material sample specifications: copper clad aluminum composite busbar (model CAB-1000), cross-sectional size 50mm×10mm, insulation layer is double-layer silicone rubber (thickness 2mm).

[0039] Secondly, adjust the modules and units as follows; Dynamic environment simulation module: Temperature control unit: The temperature and humidity adjustment device 15 uses a semiconductor refrigeration chip (TEC-12706) with an infrared heating film, with a temperature adjustment range of -40°C to 200°C and an accuracy of ±0.5°C; Humidity adjustment unit: ultrasonic atomizer + silica gel dehumidification wheel, humidity range 10%~95%RH, fluctuation ±3%.

[0040] The steps for testing the insulation performance of copper-clad aluminum busbar are as follows: Step 1: Install the sample.

[0041] First, place the busbar sample on the multifunctional placement rack 38, ensure that the contact surface of the clamp is coated with thermal conductive silicone grease to reduce thermal resistance, and at the same time, start clamping the busbar through the control device 13; The specific operation is as follows: since the servo drive motor fixedly connected to the gear 34 is electrically connected to the control device 13, the rotation of the servo drive motor can be controlled by the control of the control device 13. When the servo motor rotates, the gear 34 will be driven to start synchronous rotation. That is, when the servo motor rotates counterclockwise, the gear 34 is meshed with the Z-shaped rack plate 35, which will drive the Z-shaped rack plate 35 to start pulling the first clamp 36. Fig. 9 As shown in the marking, at this time, the first jaw 36 is pulled by the Z-shaped rack plate 35, which will drive the first jaw 36 to start rotating counterclockwise. Since the first jaw 36 and the second jaw 37 are meshed with each other, the counterclockwise rotation of the second jaw 37 will drive the second jaw 37 to rotate clockwise, thereby clamping the two sides of the copper-clad aluminum. Since the inner side of the second jaw 37 is made of flexible material and the outer surface is coated with thermal conductive silicone grease, it can not only reduce thermal resistance but also reduce damage to the busbar surface.

[0042] Step 2: Adjust the contact between the insulation measurement terminal and the busbar.

[0043] like Figure 8 and Fig.10As shown, first, the multi-axis detection device 16 is started. The three-axis control of the multi-axis detection device 16 can be used to control the electric telescopic rod 41 to be adjusted at different positions. When it is adjusted to be perpendicular to the two ends of the busbar, the electric telescopic rod 41 is started to extend. When the electric telescopic rod 41 is extended, the measuring probe 45 contacts and squeezes the two ends of the busbar. At this time, the squeezing of the measuring probe 45 will drive the T-shaped slider 44 to start sliding upward along the sliding groove of the fixed block 43. At this time, the upward sliding of the T-shaped slider 44 will drive the clamping plate 47 to start centering the two sides of the busbar to prevent the busbar from deflecting.

[0044] Step 3: Multi-parameter synchronous acquisition and model calibration.

[0045] First, a test voltage of 6kV was applied to the copper-clad aluminum busbar, and baseline data was collected for 5 minutes. The busbar material parameters, copper thermal conductivity 401W / m·K, and silicone rubber dielectric constant 3.2, were input into the COMSOL model. The measured data such as electric field distribution and temperature rise curve were compared with the simulation results, and the calibration model error was adjusted to an error of <5%.

[0046] Step 4: Conduct dynamic environment simulation.

[0047] First, by starting the dynamic environment simulation system, the multi-axis detection device 16 will start to stop measuring in the first detection chamber 11. At this time, the transmission disk 21 at the bottom of the detection table 1 starts to rotate. The rotation of the transmission disk 21 will drive the Figures 3 to 6 The transmission belt 22 shown in FIG. 1 starts synchronous transmission. At this time, since the first push plate 23 and the second push plate 24 are both fixed on the transmission belt 22, when the transmission belt 22 rotates, the first push plate 23 and the second push plate 24 will be driven to rotate in the opposite direction. Figure 5 and Figure 6As shown, since the second U-shaped guide groove 28 and the first U-shaped guide groove 25 are both slidably connected with a composite slider, and the composite slider is composed of a square slider and a cylinder, the square slider is slidably connected in the first U-shaped guide groove 25 and the second U-shaped guide groove 28 respectively, the first push plate 23 is provided with a second V-shaped groove 27, and the second push plate 24 is provided with a first V-shaped groove 26, the outer surface of the cylinder is slidably connected in the first V-shaped groove 26 and the second V-shaped groove 27 respectively, and the end of the cylinder away from the square slider is fixedly connected to the bottom of the measuring support plates 14 on both sides of the middle of the detection platform 1, wherein the square slider in the composite slider can control the measuring support plate 14 to remain horizontal when sliding, and the opening height of the first U-shaped guide groove 25 and the first V-shaped groove 26 in the detection platform 1 is greater than that of the first U-shaped guide groove 25 and the first V-shaped groove 26. The opening height of the second V-groove 27 and the second U-shaped guide groove 28 can synchronously drive the measuring pallet 14 located on both sides of the test platform 1 to start moving toward the middle of the test platform 1 through the rotation of the transmission plate 21. The mutual squeezing effect of the first V-groove 26, the second V-groove 27 and the second U-shaped guide groove 28 can enable the measuring pallet 14 to complete the dynamic switching of the measurement environment in the first test chamber 11 and the second test chamber 12. The fast switching function in this scheme allows simulating multiple extreme environment combinations in a single test, such as salt spray corrosion and then immediately switching to wet heat cycle, to comprehensively evaluate the insulation performance degradation path. At the same time, the independently sealed fast switching chamber can isolate external interference (such as laboratory temperature and humidity fluctuations) and maintain steady-state control of the test environment (such as ±0.5℃ accuracy).

[0048] At this time, the test parameters are constantly changed according to the test status, and the insulation performance of copper-clad aluminum under different parameters is tested respectively. The specific steps are as follows; Temperature: 25℃→120℃ (heating rate 10℃ / min); humidity: 50%RH→85%RH (adjustment rate 5%RH / min); vibration: apply 0.5Hz~50Hz random vibration spectrum (acceleration 5g).

[0049] Real-time data collection: Electric field intensity fluctuation range: 4.2kV / mm~8.7kV / mm; Maximum strain on the insulating layer surface: 0.15%; Interface temperature rise: ΔT=62℃ (peak value).

[0050] Intelligent analysis module output: the equivalent aging coefficient increased from 0.12 (initial) to 0.68 (after 2 hours); predicted insulation failure threshold: when the aging coefficient is ≥0.75, the breakdown risk is >90%.

[0051] Step 5: Adaptive feedback control.

[0052] When the aging coefficient reaches 0.6, the adaptive control module triggers the following adjustments: temperature: drops to 100°C (20°C drop); vibration frequency: limited to 0.5Hz~30Hz (reduce high-frequency mechanical stress); humidity: maintain 85%RH unchanged. After the adjustment, the aging coefficient growth rate is reduced by 50%, verifying the effectiveness of closed-loop control.

[0053] Step 6: When the preset termination condition (aging coefficient 0.75 or 6 hours) is reached, the test is stopped and a report is generated.

[0054] Insulation performance degradation curve; hot spot distribution map (marking the location of maximum electric field distortion); prediction of remaining life based on historical data regression analysis.

[0055] Please refer to the above working process Figures 1 to 10 .

[0056] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0057] 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 copper-clad aluminum composite busbar electrical insulation performance test device based on multi-parameter coupling, characterized in that: The invention comprises a testing platform (1), wherein a first testing chamber (11) is arranged on one side of the upper surface of the testing platform (1), a second testing chamber (12) is arranged on the other side of the upper surface of the testing platform (1), a control device (13) is arranged on one side of the upper surface of the testing platform (1) close to the first testing chamber (11) and the second testing chamber (12), a measuring support plate (14) is symmetrically arranged in the testing platform (1), a temperature and humidity regulating device (15) is arranged in both the first testing chamber (11) and the second testing chamber (12), and a multi-axis testing device (16) is symmetrically arranged in the first testing chamber (11). The copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling further comprises a multi-scene switching mechanism (2), a base vibration monitoring mechanism (3) and a resistance and mechanical testing mechanism (4); The multi-scene switching mechanism (2) is arranged in the detection platform (1), and the multi-scene switching mechanism (2) is used for dynamic detection switching of the copper-clad aluminum busbar; The base vibration monitoring mechanism (3) is arranged on a measuring support plate (14), and the base vibration monitoring mechanism (3) is used for vibration fixing of a copper-clad aluminum busbar; The resistance and mechanical testing mechanism (4) is arranged above the measuring support plate (14), and the resistance and mechanical testing mechanism (4) is used for measuring the insulation resistance and mechanical stress of the copper-clad aluminum busbar.

2. The copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling according to claim 1 is characterized in that: The multi-scene switching mechanism (2) comprises a transmission disc (21), the transmission disc (21) being symmetrically rotatably connected in the detection platform (1), the outer surface of the transmission disc (21) being transmission-connected to a transmission belt (22), the outer surface of one side of the transmission belt (22) being fixedly connected to a first push plate (23), and the outer surface of the other side of the transmission belt (22) being fixedly connected to a second push plate (24).

3. The copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling according to claim 2 is characterized in that: The first push plate (23) and the second push plate (24) are both slidably connected to the inner walls of the detection platform (1) on both sides close to the measuring support plate (14); the inner wall of the detection platform (1) on the side close to the second push plate (24) is provided with a first U-shaped guide groove (25); and the inner wall of the detection platform (1) on the side close to the first push plate (23) is provided with a second U-shaped guide groove (28).

4. The copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling according to claim 3 is characterized in that: The second U-shaped guide groove (28) and the first U-shaped guide groove (25) are both slidably connected with a composite slider, and the composite slider is composed of a square slider and a cylinder. The square slider is slidably connected to the first U-shaped guide groove (25) and the second U-shaped guide groove (28), respectively. The first push plate (23) is provided with a second V-shaped groove (27), and the second push plate (24) is provided with a first V-shaped groove (26). The outer surface of the cylinder is slidably connected to the first V-shaped groove (26) and the second V-shaped groove (27), respectively. The end of the cylinder away from the square slider is fixedly connected to the bottom of the measuring support plates (14) on both sides of the middle of the detection platform (1).

5. The copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling according to claim 1 is characterized in that: The base vibration monitoring mechanism (3) comprises an amplitude disk (31), the amplitude disk (31) is rotatably connected to the middle of the measuring support plate (14), the upper surface of the amplitude disk (31) is evenly provided with amplitude blocks (32), a support platform (33) is provided above the amplitude blocks (32), and protrusions are provided at both ends of the lower surface of the support platform (33).

6. The copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling according to claim 5 is characterized in that: The middle part of the support platform (33) is fixedly connected to the middle part of the measuring support plate (14); a servo motor is installed in the middle part of the upper surface of the support platform (33); a gear (34) is fixedly connected to the servo motor drive shaft; the gear (34) is meshed with Z-shaped rack plates (35) on the tooth surfaces on both sides; and the Z-shaped rack plate (35) is movably connected to a first clamping claw (36) at one end away from the gear (34).

7. The copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling according to claim 6 is characterized in that: The upper surfaces of both ends of the support platform (33) are fixedly connected to a multifunctional placement frame (38); the middle part of the first clamping jaw (36) is rotatably connected to the multifunctional placement frame (38); the first clamping jaw (36) is provided with sliding teeth; the tooth surface of the first clamping jaw (36) is meshed with a second clamping jaw (37); the middle part of the second clamping jaw (37) is rotatably connected to the multifunctional placement frame (38); and a pressure sensor and a mechanical strain sensor are respectively installed on the upper surface of the multifunctional placement frame (38).

8. The copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling according to claim 1 is characterized in that: The resistance and mechanical testing mechanism (4) comprises an electric telescopic rod (41), one end of the electric telescopic rod (41) being mounted on the multi-axis detection device (16), the other end of the electric telescopic rod (41) being fixedly connected to a fixed block (43), a sliding groove being provided in the middle of the fixed block (43), and a compression spring (42) being fixedly connected in the sliding groove, the compression spring (42) being fixedly connected to a T-shaped slider (44) at one end away from the sliding groove, and the outer surface of the T-shaped slider (44) being slidably connected in the sliding groove provided in the fixed block (43).

9. The copper-clad aluminum composite busbar electrical insulation performance testing device based on multi-parameter coupling according to claim 8, characterized in that: A measuring probe (45) is fixedly connected to the middle of the lower surface of the T-shaped slider (44); auxiliary plates (46) are rotatably connected to the two sides of the T-shaped slider (44) close to the measuring probe (45); one end of the auxiliary plate (46) away from the T-shaped slider (44) is rotatably connected to a clamping plate (47); a support plate (48) is rotatably connected to the middle of the clamping plate (47); and one end of the support plate (48) away from the clamping plate (47) is rotatably connected to the bottom of the fixed block (43).

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