Aluminum bus electrified welding construction method

Abstract

The invention relates to the technical field of electrolytic aluminum construction engineering, in particular to an aluminum bus electrified welding construction method. The method comprises the steps of bus material inspection, installation foundation axis elevation connection, aluminum bus counting and carrying, installation in place, welding and inspection acceptance and power-on debugging. During welding, a laser welding technology is adopted, before construction, the surface of the bus is ensured to be clean, a groove is manufactured, a welding area is cleaned, after assembling and fixing, the welding quality is ensured through bottoming, filling and cosmetic welding, and a welding seam is ground and polished after welding; in a new green power project, a plurality of outdoor aluminum buses are connected through an aluminum plate with the thickness of 10 mm and are connected with a power source main bus through an aluminum soft belt with the thickness of 1 mm, and laser welding is adopted at the joint; the characteristic that laser welding is not affected by the electromagnetic environment is utilized, a shielding device is not needed, construction can be conducted in the electrified state, the advantages of being high in universality, safe to operate, high in construction efficiency and good in economic benefit are achieved, and the aluminum bus electrified welding problem is effectively solved.

Description

Technical Field

[0001] The invention relates to the technical field of aluminum busbar welding, in particular to a construction method for live welding of an aluminum busbar. Background Art

[0002] With the development of my country's electrolytic aluminum industry, emerging green power projects have become a product of the times. Typically, a green power project is added near or between two existing aluminum power projects to optimize efficiency. When the green power industry is completed and the power is finally connected, the aluminum busbars of the new project need to be connected to the main busbars of the power plant. A power outage can prevent the main power source from supplying other operating equipment and branches, causing power outages and production halts throughout the industrial park, resulting in significant economic losses for the company. Therefore, how to weld and connect these local busbars while maintaining the overall system operation has become a challenging issue.

[0003] Because new green power plants are typically built around main aluminum power plants, the magnetic field is relatively strong. This can affect argon arc welding machines, causing them to fail to arc or experience arc deviation, making welding impossible. Furthermore, the main busbar current and voltage are too high, making welding impossible. Repairs typically require shutting down the entire industrial park. Once the current field dissipates and the magnetic field strength is reduced to a minimum, welding and patch welding can be performed. After completion, power is restored to the industrial park and operation is restored. Alternatively, measures to isolate the magnetic field, such as adding transition aluminum welding blocks for localized thermite welding, can be employed to perform live welding to complete the repair. Electromagnetic shielding devices are often limited by operating space and lack universal applicability. Thermite welding, on the other hand, is a complex process requiring a casting chamber and solution, requiring high spatial requirements for the welding location. Specialized thermite containers have a short lifespan, are expensive, and pose operational challenges. Summary of the Invention

[0004] The present invention aims to solve the above problems and thus provides a construction method for live welding of aluminum busbars.

[0005] The present invention solves the above problems by adopting the following technical solutions: A construction method for hot welding an aluminum busbar, comprising the following steps: S1. Busbar material inspection: Before installing the aluminum busbar, visually inspect the busbar to see if there is any damage, cracking, deformation, or scratches. If any problems are found, address them promptly. S2. Handover of installation foundation axis elevation: Before installing the aluminum busbar, hand it over to the civil foundation, check the installation elevation and main installation data dimensions of the axis to ensure that they meet the requirements of the drawings; S3. Check and transport the aluminum busbars: Check the aluminum busbars to ensure that their specifications and models meet the design requirements, and pay attention to the protection of the finished products during the lifting and transportation process; S4. Install the aluminum busbar in place: first install the bracket accurately in place, then hoist the aluminum busbar on the support frame in order. During the size adjustment process, clean the busbar simultaneously, using alcohol, cotton cloth, and a vacuum cleaner to clean the busbar surface; S5. Welding: Take safety precautions and use laser welding to weld the aluminum busbar live to ensure welding quality; S6. Inspection, acceptance and power-on debugging: After welding is completed, inspection and acceptance are carried out. DC switches are set at certain intervals on the busbar. All switches are closed before power is applied. When power is applied, the switches are opened one by one from the source, and the temperature and voltage data of each connection are measured. After confirmation, production is resumed.

[0006] Furthermore, the general principle of the busbar welding project is to install it in place according to the busbar assembly drawing, adjust the size, and finally connect the fracture.

[0007] Furthermore, before connecting the aluminum busbar to the equipment, measure the elevation of the high-voltage transformer to verify whether it is consistent with the general assembly drawing of the aluminum busbar after arrival. If it is inconsistent, deal with it in time; measure the foundation and elevation of the aluminum busbar foundation frame, and check whether the foundation frame and elevation dimensions meet the requirements of the design drawings according to the general assembly drawing of the aluminum busbar.

[0008] Furthermore, when the bracket is installed, the welding position of the support frame or hanger is determined according to the general assembly drawing or section assembly drawing of the aluminum busbar, the support frame and the channel steel or angle steel beam are welded, and their elevation is adjusted so that the error does not exceed ±5mm to ensure that the welding is firm; the aluminum busbar is installed in place at the wall penetration point, and the wall penetration partition frame is spot welded to the foundation embedded parts; if there is no wall penetration partition, the owner or the installation unit shall use asbestos mud to seal the opening; Furthermore, when welding aluminum busbars, ensure the surface of the busbars to be welded is clean and free of oil and dirt. A 45° groove is made according to specific needs. Dirt, oil, moisture, and aluminum oxide film impurities on and around the groove are thoroughly cleaned using chemical or mechanical methods. The busbars are assembled and fixed, and a laser welder is used to perform a base weld, a filler weld, and a cap weld to ensure seamless welds and a smooth, beautiful weld surface with a metallic luster. The outgoing aluminum busbars of the new green power project are connected to the main power source busbar within a certain distance. Multiple busbars are welded together using 10mm thick aluminum plates. The connection between the outgoing busbars and the main power source busbar is connected using 1mm thick aluminum soft strips. The connection is made using automatic laser welding, and the medium solder is aluminum. Furthermore, after welding is completed, the weld is ground and polished with a grinding wheel to avoid uneven weld surfaces that may cause excessively high temperatures at the joint after power is applied. Furthermore, safety precautions include setting up scaffolding on site and putting it into use after inspection by the owner and supervisor, setting up insulating springboards on the scaffolding, and laying insulating rubber on the live busbars; Furthermore, the overall inspection and acceptance includes checking whether the elevation and center line are correct; checking whether the busbar phase sequence is consistent; and checking whether the foundation support grounding is firm, reliable, and conductive.

[0009] Compared with the prior art, the present invention adopting the above technical solution has the following outstanding features: When laser passes through an electromagnetic field, the light beam will not deviate. Laser welding is not affected by the electromagnetic environment, so no shielding device is required for welding, it is less restricted by space, and has strong versatility; live welding has little impact on the overall project, which improves economic benefits; laser welding can weld inaccessible areas and perform non-contact long-distance welding, which has great flexibility, so it has few restrictions, simple operation, and ensures construction safety; laser welding has high speed, large depth, and small deformation, which can improve construction efficiency and thus save costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 This is a schematic diagram of the construction framework of an embodiment of the present invention; Figure 2 This is a schematic diagram of the aluminum busbar welding structure according to an embodiment of the present invention; The markings in the figure are: new aluminum busbar 1, aluminum plate connecting piece at the corner 2, laser welding connection part 3, aluminum soft busbar 4, and power source main busbar section 5. DETAILED DESCRIPTION

[0011] The present invention will be further described below with reference to the embodiments, the purpose of which is only to provide a better understanding of the content of the present invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0012] See also Figure 1-Figure 2 A method for hot welding an aluminum busbar comprises the following steps: S1. Busbar material inspection: Before installing the aluminum busbar, visually inspect the busbar to see if there is any damage, cracking, deformation, or scratches. If any problems are found, address them promptly. S2. Handover of installation foundation axis elevation: Before installing the aluminum busbar, hand it over to the civil foundation, check the installation elevation and main installation data dimensions of the axis to ensure that they meet the requirements of the drawings; S3. Check and transport the aluminum busbars: Check the aluminum busbars to ensure that their specifications and models meet the design requirements, and pay attention to the protection of the finished products during the lifting and transportation process; S4. Install the aluminum busbar in place: first install the bracket accurately in place, then hoist the aluminum busbar on the support frame in order. During the size adjustment process, clean the busbar simultaneously, using alcohol, cotton cloth, and a vacuum cleaner to clean the busbar surface; S5. Welding: Take safety precautions and use laser welding to weld the aluminum busbar live to ensure welding quality; S6. Inspection, acceptance and power-on debugging: After welding is completed, inspection and acceptance are carried out. DC switches are set at certain intervals on the busbar. All switches are closed before power is applied. When power is applied, the switches are opened one by one from the source, and the temperature and voltage data of each connection are measured. After confirmation, production is resumed. The general principle of busbar welding project is to install indoors first and then outdoors, and indoors first and then outside. Install it in place according to the busbar general assembly drawing, adjust the size, and finally connect at the fracture. Before connecting the aluminum busbar to the equipment, measure the elevation of the high-voltage transformer and verify whether it is consistent with the general assembly drawing of the aluminum busbar after arrival. If it is inconsistent, deal with it in time; measure the foundation and elevation of the aluminum busbar foundation frame, and check whether the foundation frame and elevation dimensions meet the requirements of the design drawings according to the general assembly drawing of the aluminum busbar. When installing the bracket, determine the welding position of the support frame or hanger according to the general assembly drawing or section assembly drawing of the aluminum busbar, weld the support frame and the channel steel or angle steel beam, and adjust their elevation so that the error does not exceed ±5mm to ensure a firm weld. Install the aluminum busbar to the wall penetration point and spot weld the wall penetration partition frame to the embedded foundation parts. If there is no wall penetration partition, the owner or the installation company shall use asbestos mud to seal the hole. When welding aluminum busbars, ensure the surface of the aluminum busbar to be welded is clean and free of oil and dirt. Create a 45° groove according to specific needs. Thoroughly clean the groove and the area around it using chemical or mechanical methods to remove dirt, oil, moisture, and aluminum oxide film impurities. Assemble and secure the aluminum busbars, then use a laser welder to perform a base weld, a filler weld, and a cap weld to ensure seamless welds and a smooth, aesthetically pleasing weld surface with a metallic sheen. The outgoing aluminum busbar 1 of the New Green Power Project is connected to the power source busbar within a cross-section distance of 5. Multiple busbars are welded together using 10mm-thick aluminum plates 2. The connection between the outgoing busbar 1 and the power source busbar cross-section 5 is made with 1mm-thick aluminum soft busbar 4. The connection 3 is made using automatic laser welding, with aluminum as the medium solder. After welding is completed, use a grinding wheel to grind and polish the weld to avoid uneven weld surface which may cause the temperature of the joint to be too high after power is applied; Safety protection measures include setting up scaffolding on site and putting it into use after inspection by the owner and supervisor, setting up insulating springboards on the scaffolding, and laying insulating rubber on the live busbars; The overall inspection and acceptance include checking whether the elevation and center line are correct; checking whether the busbar phase sequence is consistent; and checking whether the foundation support grounding is firm, reliable and has good conductivity.

[0013] When laser passes through an electromagnetic field, the light beam will not deviate. Laser welding is not affected by the electromagnetic environment, so no shielding device is required for welding, it is less restricted by space, and has strong versatility; live welding has little impact on the overall project, which improves economic benefits; laser welding can weld inaccessible areas and perform non-contact long-distance welding, which has great flexibility, so it has few restrictions, simple operation, and ensures construction safety; laser welding has high speed, large depth, and small deformation, which can improve construction efficiency and thus save costs.

[0014] The above description is only a preferred embodiment of the present invention and does not limit the scope of the present invention. Any equivalent changes made using the contents of the present invention specification and its drawings are included in the scope of the present invention.

Claims

1. A construction method for hot welding of aluminum busbars, characterized in that: The following steps are involved: S1. Busbar material inspection: Before installing the aluminum busbar, visually inspect the busbar to see if there is any damage, cracking, deformation, or scratches. If any problems are found, address them promptly. S2. Handover of installation foundation axis elevation: Before installing the aluminum busbar, hand it over to the civil foundation, check the installation elevation and main installation data dimensions of the axis to ensure that they meet the requirements of the drawings; S3. Check and transport the aluminum busbars: Check the aluminum busbars to ensure that their specifications and models meet the design requirements, and pay attention to the protection of the finished products during the lifting and transportation process; S4. Install the aluminum busbar in place: first install the bracket accurately in place, then hoist the aluminum busbar on the support frame in order. During the size adjustment process, clean the busbar simultaneously, using alcohol, cotton cloth, and a vacuum cleaner to clean the busbar surface; S5. Welding: Take safety precautions and use laser welding to weld the aluminum busbar live to ensure welding quality; S6. Inspection, acceptance and power-on debugging: After welding is completed, inspection and acceptance are carried out. DC switches are set at certain intervals on the busbar. All switches are closed before power is applied. When power is applied, the switches are opened one by one from the source, and the temperature and voltage data of each connection are measured. After confirmation, production is resumed.

2. The method for hot welding an aluminum busbar according to claim 1, wherein: The general principle of busbar welding project is to install indoors first and then outdoors, and indoors first and then outside. Install it in place according to the busbar general assembly drawing, adjust the size, and finally connect at the fracture.

3. The method for hot welding an aluminum busbar according to claim 1, wherein: Before connecting the aluminum busbar to the equipment, measure the elevation of the high-voltage transformer and verify whether it is consistent with the general assembly drawing of the aluminum busbar after arrival. If it is inconsistent, deal with it in time; measure the foundation and elevation of the aluminum busbar foundation frame, and check whether the foundation frame and elevation dimensions meet the requirements of the design drawings according to the general assembly drawing of the aluminum busbar.

4. The method for hot welding an aluminum busbar according to claim 1, wherein: When the bracket is installed in place, determine the welding position of the support frame or hanger according to the general assembly drawing or section assembly drawing of the aluminum busbar, weld the support frame and the channel steel or angle steel beam, and adjust its elevation so that the error does not exceed ±5mm to ensure that the welding is firm; install the aluminum busbar in place at the wall penetration point, and spot weld the wall penetration partition frame to the foundation embedded parts; if there is no wall penetration partition, the owner or installation unit shall use asbestos mud to seal the hole.

5. The method for hot welding an aluminum busbar according to claim 1, wherein: When welding aluminum busbars, ensure that the surface of the aluminum busbar to be welded is clean and free of oil and dirt; make a 45° groove according to specific needs; use chemical or mechanical methods to thoroughly clean the dirt, oil, moisture and aluminum oxide film impurities in the groove and on both sides of the groove; assemble and fix the aluminum busbars, and use a laser welder to perform a base weld, a filler weld, and a cover weld to ensure that there are no welds, the weld surface is flat and beautiful, and the metallic luster is exposed; the new green power project's household aluminum busbar is connected to the power source busbar within the distance, and multiple busbars are connected by welding with 10mm thick aluminum plates. The connection between the household busbar and the power source busbar is connected with a 1mm thick aluminum soft strip. The connection is made by automatic laser welding, and the medium solder is aluminum.

6. The method for hot welding an aluminum busbar according to claim 5, characterized in that: After welding is completed, use a grinding wheel to grind and polish the weld to avoid uneven weld surface causing the connection temperature to be too high after power is turned on.

7. The method for hot welding an aluminum busbar according to claim 1, wherein: Safety protection measures include setting up scaffolding on site and putting it into use after inspection by the owner and supervisor, setting up insulating springboards on the scaffolding, and laying insulating rubber on the live busbars.

8. The method for hot welding an aluminum busbar according to claim 1, wherein: The overall inspection and acceptance include checking whether the elevation and center line are correct; checking whether the busbar phase sequence is consistent; and checking whether the foundation support grounding is firm, reliable and has good conductivity.

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