Testing Device for Electrical Insulation Performance of Copper-Clad Aluminum Composite Busbar Based on Multi-Parameter Coupling

Abstract

The present invention discloses an electrical insulation performance testing device for copper-clad aluminum composite busbars based on multi-parameter coupling, which relates to the technical field of electrical insulation performance testing of copper-clad aluminum busbars. It includes a detection table. On one side of the upper surface of the detection table, there is a first detection chamber. On the other side of the upper surface of the detection table, there is a second detection chamber. On the side of the upper surface of the detection table close to the first detection chamber and the second detection chamber, there is a control device. Measuring pallets are symmetrically arranged in the detection table. Temperature and humidity adjustment devices are arranged in both the first detection chamber and the second detection chamber. A multi-axis detection device is arranged in the second detection chamber. The fast-switching function in this solution allows multiple extreme environment combinations to be simulated in a single test to comprehensively evaluate the insulation performance degradation path. At the same time, the independently sealed fast-switching chamber can isolate external interference and maintain the steady-state control of the test environment.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical insulation performance testing of copper-clad aluminum busbars, and specifically to a testing device for the electrical insulation performance of copper-clad aluminum composite busbars based on multi-parameter coupling. Background Art

[0002] The copper-clad aluminum composite busbar, also known as copper-clad aluminum row or copper-aluminum composite row, is a bimetallic composite conductor formed by tightly combining copper and aluminum through a specific process. The copper-clad aluminum composite busbar uses aluminum as the base body, with a copper coating on the outer layer. Through a specific process, the interfaces between the two metals of copper and aluminum are fused or diffused with each other to form a tight metallurgical bond. The copper-clad aluminum composite busbar combines the high-quality and stable electrical conductivity of copper with the low cost of aluminum. Although its conductivity is slightly lower than that of a pure copper busbar, under the same specifications, by appropriately increasing the cross-sectional area, the same current-carrying capacity as that of pure copper can be achieved.

[0003] However, most of the existing copper-clad aluminum detection devices are single-functional modules and lack the ability to synchronously collect composite parameters. Therefore, only single measurements can be carried out during electrical measurement. Since the DC resistance of the copper-clad aluminum conductor is higher than that of pure copper, if only the resistance is measured without considering the temperature rise or heat dissipation conditions, it may lead to increased heating of the conductor in actual applications, accelerate the oxidation of the aluminum core, and even cause loosening of the connection points or fire hazards. Especially in high-temperature or high-current scenarios, single-parameter measurement cannot warn of the thermal stability problems of the material.

[0004] In addition, before measurement, the existing copper-clad aluminum usually uses mechanical clamps to fix the busbar. However, due to the extrusion of mechanical clamping, the surface of the busbar will be damaged. After the surface copper layer is damaged, the aluminum core is exposed and contacts with air, resulting in the formation of an oxide film and an increase in contact resistance. In the DC resistance test, the local resistance increase in the damaged area will cover up the true electrical conductivity of the material.

[0005] Therefore, a testing device for the electrical insulation performance of copper-clad aluminum composite busbars 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 provide a testing device for the electrical insulation performance of copper-clad aluminum composite busbars based on multi-parameter coupling to solve the problems of single measurement of copper-clad aluminum and easy damage during fixation in the prior art.

[0007] To achieve the above object, the present invention provides the following technical solutions: A test device for the electrical insulation performance of copper-clad aluminum composite busbars based on multi-parameter coupling, including a detection table, on one side of the upper surface of the detection table, there is a first detection chamber, on the other side of the upper surface of the detection table, there is a second detection chamber, on the upper surface of the detection table, near one side of the first detection chamber and the second detection chamber, there is a control device, symmetrically arranged in the detection table are measurement pallets, in both the first detection chamber and the second detection chamber, there are temperature and humidity adjustment devices, in the second detection chamber, there is a multi-axis detection device. The test device for the electrical insulation performance of copper-clad aluminum composite busbars based on multi-parameter coupling further includes a multi-scene switching mechanism, a base vibration monitoring mechanism, and a resistance and mechanical test mechanism;

[0008] The multi-scene switching mechanism is arranged in the detection table, and the multi-scene switching mechanism is used for the dynamic detection switching of copper-clad aluminum busbars;

[0009] The base vibration monitoring mechanism is arranged on the measurement pallet, and the base vibration monitoring mechanism is used for the vibration fixation of copper-clad aluminum busbars;

[0010] The resistance and mechanical test mechanism is arranged above the measurement pallet, and the resistance and mechanical test mechanism is used for the measurement of the insulation resistance and mechanical stress of copper-clad aluminum busbars.

[0011] Preferably, the multi-scene switching mechanism includes a transmission disc, the transmission disc is symmetrically and rotatably connected in the detection table, the outer surface of the transmission disc is drivingly connected with a transmission belt, on one outer surface of the transmission belt, there is a first push plate fixedly connected, on the other outer surface of the transmission belt, there is a second push plate fixedly connected, both the first push plate and the second push plate are slidably connected to the inner walls on both sides of the detection table near the measurement pallet, on the inner wall of the detection table near the second push plate, there is a first U-shaped guiding groove, and on the inner wall of the detection table near the first push plate, there is a second U-shaped guiding groove.

[0012] Preferably, in both the second U-shaped guiding groove and the first U-shaped guiding groove, there is a composite slider slidably connected, and the composite slider is composed of a square slider and a cylinder. The square slider is slidably connected in the first U-shaped guiding groove and the second U-shaped guiding groove respectively. On the first push plate, there is a second V-shaped groove, on the second push plate, there is a first V-shaped groove. The outer surface of the cylinder is slidably connected in the first V-shaped groove and the second V-shaped groove respectively, and the ends of the cylinder away from the square slider are fixedly connected to the bottoms of the measurement pallets on both sides of the middle of the detection table respectively.

[0013] Preferably, the base vibration monitoring mechanism includes an amplitude disk rotatably connected to the middle of the measuring support plate. The upper surface of the amplitude disk is evenly provided with amplitude blocks. Above the amplitude blocks is a support table. At both ends of the lower surface of the support table are convex blocks. The middle of the support table is fixedly connected to the middle of the measuring support plate. In the middle of the upper surface of the support table is installed a servo motor. A gear is fixedly connected to the driving shaft of the servo motor. The two tooth surfaces of the gear are engaged with Z-shaped rack plates. One end of the Z-shaped rack plate away from the gear is movably connected to a first clamping jaw.

[0014] Preferably, on the upper surfaces of both ends of the support table are fixedly connected with multi-functional placement racks. The middle of the first clamping jaw is rotatably connected to the multi-functional placement rack. The first clamping jaw is provided with sliding teeth. The tooth surface of the first clamping jaw is engaged with a second clamping jaw. The middle of the second clamping jaw is rotatably connected to the multi-functional placement rack. On the upper surface of the multi-functional placement rack are respectively installed a pressure sensor and a mechanical strain sensor.

[0015] Preferably, the resistance and mechanical testing mechanism includes an electric telescopic rod. One end of the electric telescopic rod is installed on the multi-axis detection device. The other end of the electric telescopic rod is fixedly connected with a fixed block. A chute is opened in the middle of the fixed block, and a compression spring is fixedly connected in the chute. One end of the compression spring away from the chute is fixedly connected with a T-shaped slider. The outer surface of the T-shaped slider is slidably connected in the chute opened in the fixed block.

[0016] Preferably, in the middle of the lower surface of the T-shaped slider is fixedly connected with a measuring probe rod. On both sides of the T-shaped slider close to the measuring probe rod are rotatably connected with auxiliary plates. One end of the auxiliary plate away from the T-shaped slider is rotatably connected with a clamping plate. The middle of the clamping plate is rotatably connected with a support plate. One end of the support plate away from the clamping plate is rotatably connected to the bottom of the fixed block.

[0017] Compared with the prior art, the present invention provides a copper-clad aluminum composite bus electrical insulation performance testing device based on multi-parameter coupling, having the following beneficial effects:

[0018] 1. By the rotation of the transmission disk, the measuring support plates located on both sides of the detection table can be synchronously driven to move towards the middle of the detection table. Through the mutual extrusion of the first V-shaped groove, the second V-shaped groove and the second U-shaped guiding groove, the measuring support plate can complete the dynamic switching of the measurement environment in the first detection chamber and the second detection chamber. The fast switching function in this scheme allows simulating various extreme environment combinations in a single test, comprehensively evaluating the insulation performance degradation path. At the same time, the independently sealed fast switching chamber can isolate external interference and maintain the steady-state control of the test environment.

[0019] 2. The mechanical vibration can be generated on the surface of the turntable by the collision between the amplitude block at the upper end of the amplitude disc and the convex block set at the bottom of the turntable. By controlling the rotation speed of the servo drive motor, the vibration frequency of the turntable can be controlled, so as to quickly measure the data of copper-clad aluminum at different vibration frequencies. Through the design of this solution, it is crucial for the in-depth study of 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.

[0020] 3. In this solution, the copper-clad aluminum busbar can be quickly and flexibly clamped. Compared with the traditional rigid clamping, the flexible clamping method in this solution can avoid scratching or indentation on the busbar more effectively, protect the surface quality of the busbar, and extend its service life.

[0021] 4. Further, by installing a strain sensor on the upper surface of the multi-functional placement rack in this solution, the measurement results of copper-clad aluminum under different mechanical stresses can be detected and collected. By installing a strain sensor on the upper surface of the multi-functional placement rack, real-time monitoring of the copper-clad aluminum material during the stress process can be realized. This real-time monitoring ability helps to timely detect possible abnormalities or damages during the stress process of the material, providing strong support for taking timely measures.

[0022] 5. In this solution, by symmetrically installing a multi-axis detection device in the first detection chamber, not only can the measuring probe quickly contact the surface of the copper-clad aluminum busbar and generate a certain pressure under the three-axis adjustment of the multi-axis detection device, but also when the measuring probe is pressed, the clamping plate can be driven to clamp both sides of the copper-clad aluminum. It can not only quickly detect the insulation resistance of the copper-clad aluminum, but also measure and store the data of the copper-clad aluminum under different stress actions through the synchronous measurement of the mechanical strain sensor under the copper-clad aluminum when a certain mechanical pressure is applied to the surface of the copper-clad aluminum by the multi-axis detection device. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 is a three-dimensional structure schematic diagram of the present invention;

[0024] Figure 2 is an auxiliary three-dimensional structure schematic diagram of the present invention;

[0025] Figure 3 is a schematic diagram of the structural connection relationship of the multi-scene switching mechanism of the present invention;

[0026] Figure 4 is a longitudinal sectional view of the structural connection relationship of the multi-scene switching mechanism of the present invention;

[0027] Figure 5 is a vertical sectional view of the structural connection relationship of the multi-scene switching mechanism of the present invention;

[0028] Figure 6 This is a vertical sectional auxiliary schematic diagram of the structural connection relationship of the multi-scene switching mechanism of the present invention;

[0029] Figure 7 This is a schematic diagram of the structural connection relationship of the base vibration monitoring mechanism, resistance and mechanical testing mechanism of the present invention;

[0030] Figure 8 This is a schematic diagram of the structural connection relationship in the partially cut state of the base vibration monitoring mechanism, resistance and mechanical testing mechanism of the present invention;

[0031] Figure 9 For the present invention Figure 8 The enlarged view at position A;

[0032] Figure 10 For the present invention Figure 8 The enlarged view at position B.

[0033] In the figure:

[0034] 1. Detection table; 11. First detection chamber; 12. Second detection chamber; 13. Control device; 14. Measuring support plate; 15. Temperature and humidity adjustment device; 16. Multi-axis detection device;

[0035] 2. Multi-scene switching mechanism; 21. Driving 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;

[0036] 3. Base vibration monitoring mechanism; 31. Amplitude disc; 32. Amplitude block; 33. Support table; 34. Gear; 35. Z-shaped rack plate; 36. First clamping jaw; 37. Second clamping jaw; 38. Multi-functional placement rack;

[0037] 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. Clamping plate; 48. Support plate. Detailed implementation manners

[0038] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0039] Next, the present invention will be further described in detail according to the drawings and embodiments.

[0040] For the first embodiment, please refer to Figures 1 to 10 As shown:

[0041] 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;

[0042] 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;

[0043] 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;

[0044] 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.

[0045] 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.

[0046] 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.

[0047] A composite slider is slidably connected to both the second U-shaped guide groove 28 and the first U-shaped guide groove 25. 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. A second V-shaped groove 27 is formed in the first push plate 23, and a first V-shaped groove 26 is formed in the second push plate 24. The outer surface of the cylinder is slidably connected to the first V-shaped groove 26 and the second V-shaped groove 27 respectively, and the ends of the cylinder away from the square slider are fixedly connected to the bottoms of the two measuring brackets 14 on both sides of the middle of the test bench 1.

[0048] The square slider in the composite slider can control the measuring bracket 14 to remain horizontal during sliding. The opening height of the first U-shaped guide groove 25 and the first V-shaped groove 26 in the test bench 1 is greater than the opening height of the second V-shaped groove 27 and the second U-shaped guide groove 28.

[0049] By rotating the transmission disc 21, the measuring brackets 14 located on both sides of the test bench 1 can be synchronously driven to move towards the middle of the test bench 1. Through the mutual extrusion of the first V-shaped groove 26, the second V-shaped groove 27 and the second U-shaped guide groove 28, the measuring brackets 14 can 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 solution allows multiple extreme environment combinations to be simulated in a single test, such as immediately switching to a damp heat cycle after salt spray corrosion, comprehensively evaluating the degradation path of the insulation performance. At the same time, the independently sealed fast switching chamber can isolate external interferences such as laboratory temperature and humidity fluctuations, and maintain the steady-state control of the test environment, such as an accuracy of ±0.5°C.

[0050] Specifically, as Figure 8 and Figure 9 shown, the amplitude disc 31 is rotatably connected to the middle of the measuring bracket 14. Amplitude blocks 32 are evenly arranged on the upper surface of the amplitude disc 31. A support platform 33 is arranged above the amplitude blocks 32. Protrusions are arranged at both ends of the lower surface of the support platform 33. The middle of the support platform 33 is fixedly connected to the middle of the measuring bracket 14. A servo motor is installed in the middle of the upper surface of the support platform 33. A gear 34 is fixedly connected to the driving shaft of the servo motor. The two side tooth surfaces of the gear 34 are engaged with a Z-shaped rack plate 35. One end of the Z-shaped rack plate 35 away from the gear 34 is movably connected to a first jaw 36.

[0051] 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.

[0052] 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.

[0053] The inner side of the upper bevel of the second clamping jaw 37 is wrapped with a flexible material.

[0054] 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;

[0055] 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.

[0056] Specifically, Figure 10As shown in the figure, one end of the electric telescopic rod 41 is installed on the multi-axis detection device 16. The other end of the electric telescopic rod 41 is fixedly connected with a fixed block 43. A chute is provided in the middle of the fixed block 43, and a compression spring 42 is fixedly connected in the chute. One end of the compression spring 42 away from the chute is fixedly connected with a T-shaped slider 44. The outer surface of the T-shaped slider 44 is slidably connected in the chute provided in the fixed block 43. The middle of the lower surface of the T-shaped slider 44 is fixedly connected with a measuring probe 45. On both sides of the T-shaped slider 44 close to the measuring probe 45, auxiliary plates 46 are rotatably connected. One end of the auxiliary plate 46 away from the T-shaped slider 44 is rotatably connected with a clamping plate 47. The middle of the clamping plate 47 is rotatably connected with a support plate 48. One end of the support plate 48 away from the clamping plate 47 is rotatably connected to the bottom of the fixed block 43.

[0057] In this solution, by symmetrically installing the multi-axis detection device 16 in the first detection chamber 11, not only can the measuring probe 45 quickly contact the surface of the copper-clad aluminum busbar and generate a certain pressure under the three-axis adjustment of the multi-axis detection device 16, but also when the measuring probe 45 is pressed, it can drive the clamping plate 47 to clamp both sides of the copper-clad aluminum. It can not only quickly detect the insulation resistance of the copper-clad aluminum, but also, under the condition that the multi-axis detection device 16 applies a certain mechanical pressure to the surface of the copper-clad aluminum, through the synchronous measurement of the mechanical strain sensor under the copper-clad aluminum, the data under different stress actions of the copper-clad aluminum can be measured and stored.

[0058] Second Embodiment

[0059] What is different from the first embodiment is that a dynamic environment simulation module is further provided in the detection table 1: controllable temperature, humidity and mechanical vibration conditions are applied to the copper-clad aluminum composite busbar;

[0060] Multi-parameter coupling acquisition module: The sensors are arranged in a distributed array in the first detection chamber 11 and the second detection chamber 12, and are used to collect the electrical parameters and environmental parameters of the busbar in real time;

[0061] Intelligent analysis module: Configured to output the insulation performance evaluation result and predict the insulation failure threshold based on the collected multi-parameter data through the coupling relationship model; among them, 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 insulating layer.

[0062] Adaptive control module: Connected to the dynamic environment simulation unit, and adjusts the environmental parameters in real time according to the feedback of the intelligent analysis unit.

[0063] Among them, the dynamic environment simulation module is used to integrate the temperature control, humidity adjustment, and vibration simulation functions for 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. Combining historical data and real-time parameters, it dynamically adjusts the insulation failure threshold, improves the early warning accuracy, and covers the test requirements under complex working conditions.

[0064] The specific implementation steps of the above embodiments are as follows:

[0065] First, conduct preliminary material preparation for the insulation performance test of the copper-clad aluminum composite busbar in a high-temperature and high-humidity environment;

[0066] Material sample specifications: Copper-clad aluminum composite busbar (model CAB-1000), cross-sectional size 50mm×10mm, and the insulation layer is double-layer silicone rubber (thickness 2mm).

[0067] Secondly, adjust the module and unit as follows;

[0068] Dynamic environment simulation module: Temperature control unit: Among them, the temperature and humidity adjustment device 15 uses a thermoelectric cooler (TEC-12706) in combination with an infrared heating film, with a temperature adjustment range of -40°C to 200°C and an accuracy of ±0.5°C;

[0069] Humidity adjustment unit: Ultrasonic atomizer + silica gel dehumidification wheel, humidity range 10% to 95%RH, fluctuation ±3%.

[0070] The steps for testing the insulation performance of the copper-clad aluminum busbar are as follows:

[0071] Step 1: Install the sample.

[0072] First, place the busbar sample on the multi-functional placement rack 38, ensure that the contact surface of the fixture is coated with thermal conductive silicone grease to reduce thermal resistance, and at the same time control the start of clamping the busbar through the control device 13;

[0073] 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 through the control of the control device 13. When the servo motor rotates, it will drive the gear 34 to start rotating synchronously. That is, when the servo motor rotates counterclockwise, at this time, through the engagement of the gear 34 with the Z-shaped rack plate 35, the Z-shaped rack plate 35 will be driven to pull the first jaw 36, as Figure 9As shown in the annotation, at this time, when the first jaw 36 is pulled by the Z-shaped rack plate 35, the first jaw 36 will start to rotate counterclockwise. Since the first jaw 36 meshes with the second jaw 37, the counterclockwise rotation of the second jaw 37 will drive the second jaw 37 to rotate clockwise, so as to realize the clamping of both 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 the thermal resistance but also reduce the damage to the surface of the bus bar.

[0074] Step 2: Adjust the contact between the insulation measurement terminal and the bus bar.

[0075] As Figure 8 and Figure 10 shown, first start the multi-axis detection device 16. Through the three-axis control of the multi-axis detection device 16, the electric telescopic rod 41 can be adjusted at different positions. When it is adjusted to be perpendicular to both ends of the bus bar, at this time, start the electric telescopic rod 41 to extend. When the electric telescopic rod 41 extends and the measurement probe 45 contacts and presses against both ends of the bus bar, at this time, the T-shaped slider 44 will start to slide upward along the chute of the fixed block 43 under the extrusion of the measurement probe 45. At this time, the upward sliding of the T-shaped slider 44 will drive the clamping plate 47 to start centering and fixing both sides of the bus bar to prevent the bus bar from deflecting.

[0076] Step 3: Synchronously collect multi-parameters and calibrate the model.

[0077] First, apply a test voltage of 6 kV to the copper-clad aluminum bus bar and collect the baseline data for 5 minutes; input the bus bar material parameters of copper thermal conductivity of 401 W / m·K and silicone rubber dielectric constant of 3.2 into the COMSOL model; compare the measured data such as the electric field distribution and the temperature rise curve with the simulation results, and calibrate the model error to be adjusted to an error <5%.

[0078] Step 4: Conduct dynamic environment simulation.

[0079] 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, start the rotation of the transmission disk 21 at the bottom of the detection table 1. The rotation of the transmission disk 21 will drive the transmission belt 22 as Figures 3 to 6 shown to start synchronous transmission. At this time, since both the first push plate 23 and the second push plate 24 are fixed on the transmission belt 22, when the transmission belt 22 rotates, it will drive the first push plate 23 and the second push plate 24 to rotate in opposite directions. Through as Figure 5 and Figure 6As shown in the figure, since composite sliders are slidably connected in both 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 formed on the first push plate 23, and a first V-shaped groove 26 is formed on the second push plate 24. The outer surfaces of the cylinders are slidably connected in the first V-shaped groove 26 and the second V-shaped groove 27 respectively, and the ends of the cylinders away from the square sliders are fixedly connected to the bottoms of the two measuring supports 14 on both sides of the middle of the test bench 1. The square slider in the composite slider can control the measuring support 14 to remain horizontal during sliding, and the opening height of the first U-shaped guide groove 25 and the first V-shaped groove 26 in the test bench 1 is greater than the opening height of the second V-shaped groove 27 and the second U-shaped guide groove 28. By rotating the transmission disk 21, the measuring supports 14 on both sides of the test bench 1 can be synchronously driven to move towards the middle of the test bench 1. Through the mutual extrusion of the first V-shaped groove 26, the second V-shaped groove 27 and the second U-shaped guide groove 28, the measuring support 14 can complete the dynamic switching of the measurement environment in the first detection chamber 11 and the second detection chamber 12. The fast switching function in this solution allows simulating multiple extreme environment combinations in a single test, such as immediately switching to damp heat cycling after salt spray corrosion, comprehensively evaluating the degradation path of insulation performance. At the same time, the independently sealed fast switching chamber can isolate external interference (such as laboratory temperature and humidity fluctuations) and maintain the steady-state control of the test environment (such as ±0.5°C accuracy).

[0080] At this time, the test parameters are continuously changed according to the test status, and the copper-clad aluminum insulation performance under different parameters is detected respectively. The specific steps are as follows;

[0081] Temperature: 25°C → 120°C (heating rate 10°C / min); Humidity: 50%RH → 85%RH (adjustment rate 5%RH / min); Vibration: Apply a random vibration spectrum of 0.5Hz - 50Hz (acceleration 5g).

[0082] Real-time data acquisition: Electric field strength fluctuation range: 4.2kV / mm - 8.7kV / mm; Maximum strain on the surface of the insulation layer: 0.15%; Interface temperature rise: ΔT = 62°C (peak).

[0083] Output of the intelligent analysis module: The equivalent aging coefficient rises from 0.12 (initial) to 0.68 (after 2 hours of continuous operation); Predicted insulation failure threshold: When the aging coefficient ≥ 0.75, the breakdown risk > 90%.

[0084] Step Five: Adaptive feedback control.

[0085] When the aging coefficient reaches 0.6, the adaptive control module triggers the following adjustments: Temperature: Drop to 100°C (a decrease of 20°C); Vibration frequency: Limit to 0.5 Hz - 30 Hz (reduce high-frequency mechanical stress); Humidity: Maintain at 85% RH unchanged. After the adjustment, the growth rate of the aging coefficient decreases by 50%, verifying the effectiveness of the closed-loop control.

[0086] Step Six: Stop the test and generate a report when the preset termination condition (aging coefficient 0.75 or continuous for 6 hours) is reached.

[0087] Insulation performance degradation curve; Hot spot distribution map (mark the position of the maximum electric field distortion); Predict the remaining life based on historical data regression analysis.

[0088] Please refer to the above working process Figures 1 to 10 。

[0089] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "comprising a..." does not exclude the presence of additional identical elements in the process, method, article or device comprising the element.

[0090] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. 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 multi-scene switching mechanism (2) comprises a transmission disc (21), the transmission disc (21) is symmetrically rotatably connected in the detection platform (1), the outer surface of the transmission disc (21) is transmission-connected to a transmission belt (22), the outer surface of one side of the transmission belt (22) is fixedly connected to a first push plate (23), and the outer surface of the other side of the transmission belt (22) is fixedly connected to a second push plate (24); 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); 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), the first push plate (23) is provided with a second V-shaped groove (27), 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), 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); 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 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).

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 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).

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 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).

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 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).

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: 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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