Injection molding and temperature control process method and system for environment-friendly insulating material of solid-sealed polar pole

Abstract

The invention relates to the technical field of electrical equipment insulating material manufacturing, and particularly provides an injection molding and temperature control process method and system for an environment-friendly insulating material of a solid-sealed polar pole. The method comprises the following steps: collecting data through a temperature sensor to control preheating; mixing an epoxy resin matrix with the modified nano aluminum oxide particles to obtain an insulating material mixture; injecting into an annular mold cavity and adjusting injection molding parameters according to the temperature data; an axial magnetic field is generated through the electromagnetic heating device to adjust curing conditions; and demolding after curing is finished. Accurate injection molding and temperature fine control of the insulating material are realized, and the insulating property and the production efficiency of the solid-sealed polar pole are improved.

Description

Technical Field

[0001] This invention relates to the field of electrical equipment insulation material manufacturing technology, and in particular to the injection molding and temperature control process and system for solid-sealed pole environmentally friendly insulation materials. Background Technology

[0002] Solid-sealed poles are key components in high-voltage electrical equipment, and their insulation performance directly affects the safety and reliability of the equipment. Traditional solid-sealed pole insulation materials mainly use epoxy resin-based composite materials, which are fixed to the pole surface through injection molding to form a protective layer with good insulation properties.

[0003] With the continuous increase in power system voltage levels and increasingly stringent environmental protection requirements, traditional solid-sealed terminal block insulation materials and their molding processes face numerous challenges. Currently, the injection molding technology for solid-sealed terminal block insulation materials mainly suffers from the following problems: Inaccurate temperature control in traditional injection molding processes leads to uneven axial temperature distribution in the terminal block, causing stress concentration within the insulation material. This results in micro-cracks after long-term operation, reducing insulation performance; the mixing uniformity of conventional epoxy resin matrix and fillers is poor, especially the dispersion effect of nano-level fillers, leading to unstable electrical properties and mechanical strength of the insulation material; existing injection molding processes lack real-time temperature monitoring and adaptive control mechanisms, making it impossible to dynamically adjust injection parameters and curing conditions according to the actual temperature state of the solid-sealed terminal block, resulting in poor product quality consistency and low energy efficiency.

[0004] These technical challenges severely restrict the development and application of high-performance, environmentally friendly solid-sealed electrodes, and there is an urgent need to develop a process method that can precisely control temperature, achieve uniform material dispersion, and possess intelligent injection molding capabilities. Summary of the Invention

[0005] The present invention provides a method and system for injection molding and temperature control of solid-sealed pole environmentally friendly insulating material, which can at least solve some of the problems existing in the prior art.

[0006] A first aspect of the present invention provides a method for injection molding and temperature control of a solid-sealed, environmentally friendly insulating material, comprising: Temperature data is collected by a temperature sensor installed on the outer wall surface of the solid-sealed electrode post. The heating wire is controlled to preheat the solid-sealed electrode post according to the temperature data. The temperature sensor is used to monitor the temperature until the solid-sealed electrode post reaches the first preset temperature. While the solidified electrode is maintained at a first preset temperature, the epoxy resin matrix is ​​conveyed to the first hopper, and the nano-alumina particles modified by the silane coupling agent are conveyed to the second hopper. The epoxy resin matrix and the nano-alumina particles are mixed by a two-component injection molding machine to obtain an insulating material mixture. The insulating material mixture is injected into the cavity of the annular mold, and the injection pressure and injection speed of the insulating material mixture are adjusted according to the collected temperature data until the injection is completed. A magnetic field is generated in the axial direction of the solidified electrode by an electromagnetic heating device. Based on the axial temperature distribution data of the solidified electrode collected by the temperature sensor, the decreasing gradient of the magnetic field strength is adjusted until the insulating material mixture is completely cured. The curing state of the insulating material mixture is determined based on the collected temperature data. After confirming that the curing is complete, the mold is opened and the material is demolded to obtain the formed solidified electrode post.

[0007] Temperature data is collected by a temperature sensor installed on the outer surface of the solid-sealed electrode post. Based on the temperature data, a heating wire is controlled to preheat the solid-sealed electrode post. The temperature is monitored by the temperature sensor until the solid-sealed electrode post reaches a first preset temperature, including: Multiple temperature sensors are arranged axially on the outer wall surface of the solid-sealed electrode. The spacing between the temperature sensors is related to the diameter change of the solid-sealed electrode. The temperature data of the temperature sensors is collected as the initial temperature data of the solid-sealed electrode. The temperature distribution curve of the outer wall surface of the solid-sealed pole is calculated based on the initial temperature data. The temperature distribution curve is divided into multiple temperature ranges. Each temperature range corresponds to a set of heating wires. The power of each set of heating wires is inversely proportional to the temperature value of its corresponding temperature range. The heating wires of each group are controlled to preheat the solid-sealed electrode, and the temperature data of the temperature sensor is continuously collected during the preheating process. The power of each heating wire is adjusted in real time according to the temperature data of the temperature sensor until the temperature of the outer wall surface of the solid-sealed electrode reaches the first preset temperature. The temperature uniformity of the outer wall surface of the solid-sealed electrode is calculated based on the temperature data of the temperature sensor to determine whether the solid-sealed electrode has reached the first preset temperature.

[0008] While the solidified electrode is maintained at a first preset temperature, the epoxy resin matrix is ​​conveyed to the first hopper, and the nano-alumina particles modified with a silane coupling agent are conveyed to the second hopper. The epoxy resin matrix and the nano-alumina particles are mixed using a two-component injection molding machine to obtain an insulating material mixture, comprising: While the solid-sealed electrode column maintains the first preset temperature, epoxy resin matrix is ​​conveyed into the first hopper and nano-alumina particles are conveyed into the second hopper. A magnetic field generator and an ultrasonic generator are installed in the mixing chamber of a two-component injection molding machine. The magnetic field strength generated by the magnetic field generator changes in a correlated manner with the sound wave frequency generated by the ultrasonic generator. The nano-alumina particles are oriented by the coupling effect of the magnetic field strength and the sound wave frequency. The orientation data of the nano-alumina particles in the mixing chamber is collected, and the coupling parameters of the magnetic field strength and the sound wave frequency are calculated based on the orientation data. The epoxy resin matrix and the nano-alumina particles are fed into the mixing chamber at a preset mass ratio through the feeding assembly of the two-component injection molding machine for mixing. The output power of the magnetic field generator and the ultrasonic generator are controlled according to the coupling parameters. During the mixing process, the arrangement direction and spacing of the nano-alumina particles are adjusted until the nano-alumina particles form a parallel arrangement structure with a preset spacing, thereby obtaining an insulating material mixture.

[0009] The nano-alumina particles are oriented and aligned through the coupling effect of the magnetic field strength and the sound wave frequency. Orientation data of the nano-alumina particles in the mixing chamber is collected, and the coupling parameters between the magnetic field strength and the sound wave frequency are calculated based on the orientation data, including: Through the coupling effect of the magnetic field strength and the sound wave frequency, the nano-alumina particles are oriented and aligned along the axial and radial directions of the mixing chamber; Multiple light sources and photodetectors are uniformly arranged circumferentially within the mixing chamber. The detection beam emitted by the light source passes through the oriented nano-alumina particles and is received by the corresponding photodetector. The scattering intensity and polarization degree of the detection beam after passing through the oriented nano-alumina particles are collected as the orientation data of the nano-alumina particles. The first spatial orientation angle of the nano-alumina particles relative to the axis of the mixing chamber is calculated based on the scattering intensity, and the second spatial orientation angle of the nano-alumina particles relative to the radial direction of the mixing chamber is calculated based on the polarization degree. The correction intensity is calculated based on the first spatial orientation angle, and the correction frequency is calculated based on the second spatial orientation angle. Based on the correction intensity and the correction frequency, the ratio of the magnetic field intensity generated by the magnetic field generator to the sound wave frequency generated by the ultrasonic generator is adjusted, and the ratio is used as a coupling parameter.

[0010] The insulating material mixture is injected into the cavity of an annular mold. The injection pressure and speed of the insulating material mixture are adjusted based on collected temperature data until injection molding is complete. This includes: A temperature sensing channel is provided between the inner and outer walls of the annular mold cavity. The temperature sensing channel is filled with a thermistor material. The resistance value of the thermistor material changes with temperature, causing strain deformation. The insulating material mixture is injected into the annular mold cavity, the first resistance change value of the thermistor material is determined, and the first strain in the temperature sensing channel is calculated based on the first resistance change value. The first opening angle of the annular mold cavity is adjusted according to the first strain, and the difference between the first opening angle and the preset reference angle is converted into the first adjustment amount of the injection pressure. The injection pressure is controlled according to the first adjustment amount. When the insulating material mixture is injected, the second resistance change value of the thermistor material is determined. The second strain in the temperature sensing channel is calculated based on the second resistance change value. The second opening angle of the annular mold cavity is adjusted according to the second strain variable. The difference between the second opening angle and the preset reference angle is converted into a second adjustment amount of the injection pressure. The injection pressure is adjusted according to the second adjustment amount until the injection is completed.

[0011] A magnetic field is generated along the axial direction of the solidified electrode using an electromagnetic heating device. Based on the axial temperature distribution data of the solidified electrode collected by the temperature sensor, the decreasing gradient of the magnetic field strength is adjusted until the insulating material mixture is completely cured, including: A first magnetic field is generated in the axial direction of the solid-sealed pole by a first magnetic field coil, and a first eddy current is generated in the solid-sealed pole. The distribution density of the first eddy current in the axial direction of the solid-sealed pole is measured, and a first preset angle is adjusted according to the distribution density. The first preset angle represents the angle between the magnetic field lines of the first magnetic field and the axial direction of the solid-sealed pole. Temperature distribution data along the axial direction of the solid-sealed electrode is collected by a temperature sensor, and the gradient value of the temperature distribution data along the axial direction of the solid-sealed electrode is calculated. A second preset angle is determined based on the gradient value and the distribution density. A second magnetic field is generated in the axial direction of the solid-sealed pole by a second magnetic field coil. The angle between the magnetic field lines of the second magnetic field and the axial direction of the solid-sealed pole is the second preset angle. The second magnetic field is used to generate a second eddy current in the solid-sealed pole post. The distribution density of the second eddy current along the axial direction of the solid-sealed pole post is measured, and the distribution density is converted into a third preset angle. A third magnetic field is generated in the axial direction of the solidified pole by a third magnetic field coil. The angle between the magnetic field lines of the third magnetic field and the axial direction of the solidified pole is the third preset angle, until the insulating material mixture is completely cured.

[0012] A first magnetic field is generated in the axial direction of the solid-sealed pole by a first magnetic field coil, causing the first magnetic field to generate a first eddy current in the solid-sealed pole. The distribution density of the first eddy current in the axial direction of the solid-sealed pole is measured, and a first preset angle is adjusted according to the distribution density, including: Multiple eddy current density sensor arrays are arranged along the circumferential and axial directions on the outer wall of the solid-sealed pole. The eddy current density sensor arrays collect the eddy current distribution density inside the solid-sealed pole, and the projection of the eddy current distribution density onto the axial plane of the solid-sealed pole determines the eddy current density field. The vector direction of the eddy current density field is determined according to the gradient change of the eddy current density field. A first magnetic field is generated in the axial direction of the solid-sealed pole by the magnetic field coil. The angle between the magnetic field lines of the first magnetic field and the axial direction of the solid-sealed pole is a first angle. The first magnetic field excites a first eddy current in the solid-sealed pole. The eddy current density sensor array collects the distribution density of the first eddy current in the axial and circumferential directions of the solid-sealed pole, and calculates the density vector field of the first eddy current based on the spatial distribution characteristics of the distribution density. The curl and divergence of the density vector field are mapped to the eddy current density field direction angle. A first preset angle is determined based on the angle between the eddy current density field direction angle and the eddy current density field vector direction. The angle between the magnetic field lines of the first magnetic field and the axis of the solid-sealed pole is adjusted to the first preset angle.

[0013] A second aspect of the present invention provides an injection molding and temperature control process system for solid-sealed pole environmentally friendly insulating materials, comprising: The first unit is used to collect temperature data through a temperature sensor set on the outer wall surface of the solid-sealed electrode, control the heating wire to preheat the solid-sealed electrode according to the temperature data, and monitor the solid-sealed electrode until it reaches a first preset temperature through the temperature sensor. The second unit is used to transport the epoxy resin matrix to the first hopper and the nano-alumina particles modified by the silane coupling agent to the second hopper while the solid-sealing electrode is maintained at the first preset temperature. The epoxy resin matrix and the nano-alumina particles are then mixed by a two-component injection molding machine to obtain an insulating material mixture. The third unit is used to inject the insulating material mixture into the annular mold cavity, and adjust the injection pressure and injection speed of the insulating material mixture according to the collected temperature data until the injection is completed; The fourth unit is used to generate a magnetic field in the axial direction of the solidified pole using an electromagnetic heating device, and adjusts the decreasing gradient of the magnetic field strength according to the axial temperature distribution data of the solidified pole collected by the temperature sensor until the insulating material mixture is completely cured. The fifth unit is used to determine the curing state of the insulating material mixture based on the collected temperature data. After confirming that the curing is complete, the mold is opened and the material is demolded to obtain the formed solidified pole.

[0014] A third aspect of the present invention provides an electronic device, comprising: processor; Memory used to store processor-executable instructions; The processor is configured to invoke instructions stored in the memory to execute the aforementioned method.

[0015] A fourth aspect of the present invention provides a computer-readable storage medium having stored thereon computer program instructions that, when executed by a processor, implement the aforementioned method.

[0016] This invention achieves precise control of the injection molding process for insulating materials by using a temperature sensor on the outer surface of the solidified electrode to monitor temperature data in real time. Based on this monitoring, the preheating of the heating wire and adjustment of injection molding parameters are controlled, effectively avoiding defects such as bubbles and cracks caused by improper temperature control in traditional processes, thus improving product quality stability. The use of nano-alumina particles modified with silane coupling agents mixed with an epoxy resin matrix to form the insulating material significantly enhances its dielectric strength and thermal conductivity, while reducing the use and emission of harmful substances, meeting the requirements of green and environmentally friendly development in modern power equipment. The innovative introduction of electromagnetic heating technology generates a controllable magnetic field in the axial direction of the solidified electrode and dynamically adjusts the magnetic field strength gradient based on temperature distribution data. This solves the internal stress problem caused by uneven temperature in traditional curing processes, extending the service life of the solidified electrode and improving the safety and reliability of power equipment. Attached Figure Description

[0017] Figure 1 This is a schematic flowchart of the injection molding and temperature control process for the solid-sealed pole environmentally friendly insulating material according to an embodiment of the present invention.

[0018] Figure 2 This is a schematic diagram of the process for determining coupling parameters according to an embodiment of the present invention. Detailed Implementation

[0019] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] The technical solution of the present invention will be described in detail below with reference to specific embodiments. These specific embodiments can be combined with each other, and the same or similar concepts or processes may not be described again in some embodiments.

[0021] Figure 1 This is a schematic flowchart illustrating the injection molding and temperature control process for the solid-sealed pole environmentally friendly insulating material according to an embodiment of the present invention. Figure 1 As shown, the method includes: Temperature data is collected by a temperature sensor installed on the outer wall surface of the solid-sealed electrode post. The heating wire is controlled to preheat the solid-sealed electrode post according to the temperature data. The temperature sensor is used to monitor the temperature until the solid-sealed electrode post reaches the first preset temperature. While the solidified electrode is maintained at a first preset temperature, the epoxy resin matrix is ​​conveyed to the first hopper, and the nano-alumina particles modified by the silane coupling agent are conveyed to the second hopper. The epoxy resin matrix and the nano-alumina particles are mixed by a two-component injection molding machine to obtain an insulating material mixture. The insulating material mixture is injected into the cavity of the annular mold, and the injection pressure and injection speed of the insulating material mixture are adjusted according to the collected temperature data until the injection is completed. A magnetic field is generated in the axial direction of the solidified electrode by an electromagnetic heating device. Based on the axial temperature distribution data of the solidified electrode collected by the temperature sensor, the decreasing gradient of the magnetic field strength is adjusted until the insulating material mixture is completely cured. The curing state of the insulating material mixture is determined based on the collected temperature data. After confirming that the curing is complete, the mold is opened and the material is demolded to obtain the formed solidified electrode post.

[0022] In one optional embodiment, temperature data is collected by a temperature sensor disposed on the outer surface of the solid-sealed electrode post, and a heating wire is controlled to preheat the solid-sealed electrode post based on the temperature data. The temperature is monitored by the temperature sensor until the solid-sealed electrode post reaches a first preset temperature, including: Multiple temperature sensors are arranged axially on the outer wall surface of the solid-sealed electrode. The spacing between the temperature sensors is related to the diameter change of the solid-sealed electrode. The temperature data of the temperature sensors is collected as the initial temperature data of the solid-sealed electrode. The temperature distribution curve of the outer wall surface of the solid-sealed pole is calculated based on the initial temperature data. The temperature distribution curve is divided into multiple temperature ranges. Each temperature range corresponds to a set of heating wires. The power of each set of heating wires is inversely proportional to the temperature value of its corresponding temperature range. The heating wires of each group are controlled to preheat the solid-sealed electrode, and the temperature data of the temperature sensor is continuously collected during the preheating process. The power of each heating wire is adjusted in real time according to the temperature data of the temperature sensor until the temperature of the outer wall surface of the solid-sealed electrode reaches the first preset temperature. The temperature uniformity of the outer wall surface of the solid-sealed electrode is calculated based on the temperature data of the temperature sensor to determine whether the solid-sealed electrode has reached the first preset temperature.

[0023] To address the potential temperature unevenness during the preheating process of solid-sealed electrodes, this invention achieves precise preheating control of the solid-sealed electrodes by incorporating multiple temperature sensors on the outer surface of the electrode and combining them with multiple sets of adjustable-power heating wires. The technical details of this embodiment will be explained below.

[0024] In this embodiment, multiple temperature sensors are first arranged axially on the outer surface of the solid-sealed electrode. Considering that the solid-sealed electrode is typically cylindrical and its diameter may vary axially, the arrangement of the temperature sensors needs to be correlated with this diameter variation. For example, for a solid-sealed electrode with a length of 1200 mm, a diameter of 180 mm at one end, and a diameter of 220 mm at the other end, eight PT100 platinum resistance temperature sensors can be evenly arranged axially. The spacing between these sensors is not simply equidistant but adjusted according to the diameter variation of the solid-sealed electrode. Specifically, in areas with larger diameters, the spacing between adjacent sensors is set to 180 mm; in areas with smaller diameters, the spacing between adjacent sensors is set to 150 mm. This arrangement ensures that the temperature distribution on the surface of the solid-sealed electrode can be comprehensively and accurately collected.

[0025] After the temperature sensors are installed, the system begins collecting temperature data from each sensor as the initial temperature data for the solid-sealed electrode. In actual operation, the system collects data from all temperature sensors once per second via the data acquisition module and calculates the initial temperature distribution curve of the outer surface of the solid-sealed electrode. For example, in one test, the initial temperature readings of the eight temperature sensors from one end to the other were 22.5℃, 23.1℃, 24.0℃, 25.2℃, 24.8℃, 24.0℃, 23.5℃, and 22.8℃, respectively.

[0026] Based on the acquired initial temperature distribution curve, the system divides the outer surface of the solid-sealed electrode into multiple temperature ranges. In this embodiment, the solid-sealed electrode is divided into four temperature ranges: range 1 (including sensors 1-2, temperature range 22.5℃-23.1℃), range 2 (including sensors 3-4, temperature range 24.0℃-25.2℃), range 3 (including sensors 5-6, temperature range 24.0℃-24.8℃), and range 4 (including sensors 7-8, temperature range 22.8℃-23.5℃).

[0027] Each temperature range corresponds to a set of independently controlled heating wires. The heating wires are made of nickel-chromium alloy, possessing excellent heating performance and high-temperature resistance. The initial power setting of each heating wire is inversely proportional to the average temperature of its corresponding temperature range. For example, when the first preset temperature target is 120℃, the system will configure heating wires of different power for each temperature range: the average temperature of range 1 is 22.8℃, configured with a 2000W heating wire; the average temperature of range 2 is 24.6℃, configured with a 1900W heating wire; the average temperature of range 3 is 24.4℃, configured with a 1920W heating wire; and the average temperature of range 4 is 23.2℃, configured with a 1980W heating wire.

[0028] After the preheating process begins, the system controls each group of heating wires to preheat the solid-sealed electrode post according to the set initial power. During the preheating process, the temperature acquisition module continuously collects real-time temperature data from all temperature sensors at a frequency of once per second. Based on this real-time temperature data, the control system calculates the current temperature distribution curve of the outer surface of the solid-sealed electrode post and calculates the temperature uniformity. Temperature uniformity is defined as the ratio of the difference between the maximum and minimum values ​​of all temperature sensor readings to the average temperature, expressed as a percentage.

[0029] The system dynamically adjusts the power of each heating element based on real-time temperature data. The adjustment strategy is as follows: if the difference between the current temperature and the target temperature in a certain temperature range decreases, the power of the heating element in that range is reduced accordingly; if the difference increases, the power is increased accordingly. The specific adjustment amount is proportional to the temperature difference. For example, after 30 minutes of preheating, the temperatures in the four ranges reach 85.2℃, 92.4℃, 90.8℃, and 84.5℃ respectively. At this point, the system will automatically adjust the power of the heating element in range 1 to 1800W, the power in range 2 to 1400W, the power in range 3 to 1500W, and the power in range 4 to 1820W.

[0030] The preheating process continues. When all temperature sensor readings reach or exceed the first preset temperature (120℃ in this example), and the temperature uniformity is less than a preset threshold (e.g., 5%), the system determines that the solid-sealed electrode has reached the first preset temperature. In actual operation, after approximately 60 minutes of preheating and multiple power adjustments, the readings of the eight temperature sensors were 119.5℃, 120.3℃, 121.2℃, 120.8℃, 120.5℃, 121.0℃, 120.2℃, and 119.8℃, respectively. The calculated temperature uniformity was 1.4%, which is less than the preset 5% threshold. Therefore, the system determines that the solid-sealed electrode has reached the preset temperature requirement.

[0031] By employing the aforementioned temperature monitoring and heating control methods, precise preheating control of the solid-sealed electrode post is achieved, ensuring the uniformity of the surface temperature and creating favorable conditions for subsequent processing. This method is particularly suitable for the preheating of large solid-sealed electrodes, effectively avoiding the problems of localized overheating or insufficient heating that may occur in traditional preheating methods.

[0032] In one optional embodiment, while the solidified electrode is maintained at a first preset temperature, an epoxy resin matrix is ​​conveyed to a first hopper, and nano-alumina particles modified with a silane coupling agent are conveyed to a second hopper. The epoxy resin matrix and the nano-alumina particles are then mixed using a two-component injection molding machine to obtain an insulating material mixture comprising: While the solid-sealed electrode column maintains the first preset temperature, epoxy resin matrix is ​​conveyed into the first hopper and nano-alumina particles are conveyed into the second hopper. A magnetic field generator and an ultrasonic generator are installed in the mixing chamber of a two-component injection molding machine. The magnetic field strength generated by the magnetic field generator changes in a correlated manner with the sound wave frequency generated by the ultrasonic generator. The nano-alumina particles are oriented by the coupling effect of the magnetic field strength and the sound wave frequency. The orientation data of the nano-alumina particles in the mixing chamber is collected, and the coupling parameters of the magnetic field strength and the sound wave frequency are calculated based on the orientation data. The epoxy resin matrix and the nano-alumina particles are fed into the mixing chamber at a preset mass ratio through the feeding assembly of the two-component injection molding machine for mixing. The output power of the magnetic field generator and the ultrasonic generator are controlled according to the coupling parameters. During the mixing process, the arrangement direction and spacing of the nano-alumina particles are adjusted until the nano-alumina particles form a parallel arrangement structure with a preset spacing, thereby obtaining an insulating material mixture.

[0033] In order to achieve the directional arrangement of nano-alumina particles in the solidified electrode to enhance insulation performance, in this embodiment, the temperature of the solidified electrode is first maintained at a first preset temperature, which can be set to 80°C, to ensure that the epoxy resin matrix maintains appropriate fluidity and does not cure prematurely.

[0034] While maintaining a stable temperature at the solid-sealed electrode, an epoxy resin matrix is ​​fed into the first hopper of the two-component injection molding machine. This epoxy resin matrix can be bisphenol A type epoxy resin with a viscosity of 10000-15000 mPa•s and an epoxy value of 0.52-0.54 eq / 100g. Nano-alumina particles modified with a silane coupling agent are then fed into the second hopper. These nano-alumina particles have a particle size controlled at 50-100 nm and have undergone surface modification treatment with KH550 silane coupling agent at 2% of the nano-alumina mass. The modification treatment temperature is 120°C, and the treatment time is 4 hours. The treated nano-alumina particles exhibit good organic phase affinity, which is beneficial for uniform mixing with the epoxy resin matrix.

[0035] In the mixing chamber of the two-component injection molding machine, a magnetic field generator and an ultrasonic generator are installed. The magnetic field generator uses an electromagnetic coil structure and can generate an adjustable magnetic field strength within the range of 0-1.5 T; the ultrasonic generator uses a piezoelectric ceramic transducer with an operating frequency range of 18-60 kHz and a maximum output power of 1200 W. The positioning design of the magnetic field generator and ultrasonic generator ensures that the generated magnetic field and ultrasonic waves form a three-dimensional orthogonal interaction region within the mixing chamber, guaranteeing omnidirectional directional control of the nano-alumina particles.

[0036] The mixing chamber houses a nanoparticle orientation sensing system, which consists of a light scattering detector and a data acquisition unit. The light scattering detector monitors the alignment and orientation of the alumina nanoparticles in real time through an observation window, while the data acquisition unit converts the detected light scattering intensity patterns into quantitative data on particle orientation. When the alumina nanoparticles begin to align under the influence of a magnetic field, the light scattering pattern exhibits significant anisotropy. The system calculates the alignment degree parameter R in real time, with a value ranging from 0 to 1, where 0 represents a completely random distribution and 1 represents a completely parallel alignment.

[0037] In actual operation, the epoxy resin matrix and nano-alumina particles are fed into the mixing chamber at a preset mass ratio of 4:1 via the feeding assembly of the two-component injection molding machine. During the mixing process, the initial magnetic field strength is set to 0.5T, the ultrasonic frequency to 25 kHz, and the output power to 600 W. The system collects orientation data of the nano-alumina particles in the mixing chamber. The initial alignment parameter R is 0.35, indicating a low degree of particle alignment.

[0038] Based on the collected orientation data, the system calculates the optimal coupling parameters between the magnetic field strength and the acoustic frequency. The calculation method is as follows: by iteratively testing different combinations of magnetic field strength and ultrasonic frequency, the alignment degree R value under each set of parameters is recorded, a three-dimensional response surface is plotted, and the parameter combination that maximizes the R value is found. In this embodiment, after multiple iterative tests, the optimal magnetic field strength was determined to be 0.8 T and the ultrasonic frequency to be 35 kHz. At this point, the coupling parameter K value is 28, and the corresponding alignment degree R value can reach above 0.85.

[0039] Based on the calculated coupling parameters, the control system automatically adjusts the output power of the magnetic field generator to 800 W, generating a magnetic field strength of 0.8 T; simultaneously, it adjusts the output power of the ultrasonic generator to 900 W, generating ultrasonic waves at 35 kHz. Under the synergistic effect of these two physical fields, the nano-alumina particles gradually form a directional alignment structure. The magnetic field provides the directional force, causing the weakly magnetic nano-alumina particles to align along the magnetic field lines; while the ultrasonic waves provide microscopic vibration energy, overcoming the viscous resistance between particles and promoting the movement of particles to the equilibrium position with the lowest energy.

[0040] After 3 minutes of processing, the orientation sensing system showed an alignment R-value of 0.92, indicating that the nano-alumina particles had formed a highly parallel alignment structure. Microscopic observation confirmed that a uniform spacing of approximately 150 nm was formed between the nano-alumina particles, which perfectly met the preset spacing requirements. At this point, the epoxy resin matrix and nano-alumina particles in the mixing chamber were fully mixed to form a homogeneous insulating material mixture, while maintaining the oriented alignment structure of the nano-alumina particles.

[0041] The resulting insulating material mixture exhibits excellent thermal conductivity (0.8 W / (m•K)) and electrical insulation properties (breakdown strength greater than 30 kV / mm), meeting the requirements for solid-sealed electrodes. By controlling the alignment and spacing of the nano-alumina particles through the coupling effect of magnetic field and ultrasound, the directional design of the insulating material's microstructure was successfully achieved, providing excellent comprehensive performance for the solid-sealed electrodes.

[0042] In one optional embodiment, the nano-alumina particles are oriented by the coupling effect of the magnetic field strength and the sound wave frequency, the orientation data of the nano-alumina particles in the mixing chamber is collected, and the coupling parameters of the magnetic field strength and the sound wave frequency are calculated based on the orientation data, including: Through the coupling effect of the magnetic field strength and the sound wave frequency, the nano-alumina particles are oriented and aligned along the axial and radial directions of the mixing chamber; Multiple light sources and photodetectors are uniformly arranged circumferentially within the mixing chamber. The detection beam emitted by the light source passes through the oriented nano-alumina particles and is received by the corresponding photodetector. The scattering intensity and polarization degree of the detection beam after passing through the oriented nano-alumina particles are collected as the orientation data of the nano-alumina particles. The first spatial orientation angle of the nano-alumina particles relative to the axis of the mixing chamber is calculated based on the scattering intensity, and the second spatial orientation angle of the nano-alumina particles relative to the radial direction of the mixing chamber is calculated based on the polarization degree. The correction intensity is calculated based on the first spatial orientation angle, and the correction frequency is calculated based on the second spatial orientation angle. Based on the correction intensity and the correction frequency, the ratio of the magnetic field intensity generated by the magnetic field generator to the sound wave frequency generated by the ultrasonic generator is adjusted, and the ratio is used as a coupling parameter.

[0043] This embodiment mainly includes three key steps: directional alignment of nano-alumina particles, acquisition of orientation data, and calculation of coupling parameters. Figure 2 This is a schematic diagram illustrating the process of determining coupling parameters according to an embodiment of the present invention. Figure 2 As shown, The mixing chamber has a cylindrical structure with an inner diameter of 120 mm and a height of 200 mm, and is made of non-magnetic polytetrafluoroethylene (PTFE). The magnetic field generator consists of six sets of electromagnetic coils, evenly distributed around the circumference of the mixing chamber. Each set of electromagnetic coils is wound with 500 turns of enameled wire with a diameter of 0.8 mm. The ultrasonic generator uses a piezoelectric ceramic transducer, operating in a frequency range of 20 kHz to 100 kHz, with a maximum output power of 500 watts.

[0044] The nano-alumina particles have an average particle size of 50 nanometers, exhibit a rod-like structure, an aspect ratio of approximately 5:1, and significant anisotropy in magnetic susceptibility. A 0.5% concentration suspension of nano-alumina particles was injected into the mixing chamber, with a total volume of 1000 ml. The magnetic field generator was initially set to produce a uniform magnetic field with an intensity of 0.2 Tesla, and the ultrasonic generator was initially set to a frequency of 40 kHz.

[0045] After the magnetic field generator and ultrasonic generator are activated, the long axis of the nano-alumina particles tends to align along the magnetic field lines under the influence of the magnetic field. Simultaneously, the ultrasonic waves form a standing wave field in the liquid, generating acoustic radiation force that affects the radial orientation of the particles. The coupling effect of these two forces causes the nano-alumina particles to align at specific angles along the axial and radial directions of the mixing chamber. Experimental observations show that when the magnetic field strength is 0.2 Tesla and the acoustic frequency is 40 kHz, the average orientation angle of the nano-alumina particles relative to the axial direction of the mixing chamber is approximately 25 degrees, and the average orientation angle relative to the radial direction is approximately 35 degrees.

[0046] Eight light sources and corresponding eight photodetectors are uniformly arranged circumferentially within the mixing chamber. The light sources are 650 nm semiconductor lasers with an output power of 5 mW and a beam diameter of 2 mm. The photodetectors are silicon photodiodes with a sensitivity of 0.5 amperes / watt and a response time of less than 10 nanoseconds. The light sources and corresponding photodetectors are installed at 45-degree intervals along the circumference at the center of the mixing chamber, forming eight detection optical paths passing through the center of the chamber.

[0047] When a light beam passes through oriented alumina nanoparticles, its scattering intensity and polarization change. The scattering intensity is mainly affected by the axial orientation of the alumina nanoparticles, while the polarization is mainly affected by their radial orientation. A high-speed data acquisition system was used to simultaneously acquire scattering intensity and polarization data from eight optical paths at a sampling frequency of 1000 Hz. Experimental data show that when the alumina nanoparticles are completely aligned along the axial direction, the scattering intensity reaches its maximum value, approximately 85% of the incident light intensity; when they are completely perpendicular to the axial direction, the scattering intensity drops to its minimum, approximately 15% of the incident light intensity.

[0048] The first spatial orientation angle of the nano-alumina particles relative to the axis of the mixing chamber was calculated based on the scattering intensity. When the scattering intensity was 50% of the incident light intensity, the calculated first spatial orientation angle was approximately 30 degrees. Similarly, the second spatial orientation angle of the nano-alumina particles relative to the radial direction of the mixing chamber was calculated based on the degree of polarization. When the degree of polarization was 0.6, the calculated second spatial orientation angle was approximately 40 degrees.

[0049] The correction intensity is calculated based on the first spatial orientation angle. When the first spatial orientation angle is 30 degrees, the magnetic field strength needs to be adjusted to 0.25 Tesla to make the nano-alumina particles closer to the expected axial orientation. The correction frequency is calculated based on the second spatial orientation angle. When the second spatial orientation angle is 40 degrees, the sound wave frequency needs to be adjusted to 45 kHz to make the nano-alumina particles closer to the expected radial orientation.

[0050] Based on the correction strength and correction frequency, the ratio of the magnetic field strength generated by the magnetic field generator to the sound wave frequency generated by the ultrasonic generator is adjusted, and this ratio is used as the coupling parameter. In this embodiment, the corrected magnetic field strength is 0.25 Tesla, the corrected sound wave frequency is 45 kHz, and the calculated coupling parameter is 0.25 / 45 = 0.0056 Tesla / kHz.

[0051] Comparative experiments verified that the optimal orientation of the nano-alumina particles was achieved when the coupling parameters were maintained at approximately 0.0056 Tesla / kHz, with the axial orientation angle remaining stable at 20°±2° and the radial orientation angle at 30°±2°. If the magnetic field strength increased to 0.3 Tesla, the corresponding acoustic frequency needed to be adjusted to 53.6 kHz to maintain the optimal coupling parameters.

[0052] The experiment also revealed that temperature variations affect the optimal value of the coupling parameters. When the temperature increases from 25°C to 40°C, the optimal coupling parameters decrease by approximately 8%, requiring adjustment to 0.0052 Tesla / KHz. Furthermore, changes in the concentration of nano-alumina particles also affect the coupling effect; when the concentration increases from 0.5% to 1%, the interparticle interactions strengthen, necessitating an increase of approximately 5% in the coupling parameters to maintain the same orientation effect.

[0053] By monitoring orientation data in real time and dynamically adjusting the magnetic field strength and sound wave frequency, precise directional arrangement of nano-alumina particles in the mixing chamber can be achieved, providing a controllable microstructure basis for subsequent material processing.

[0054] In one optional embodiment, the insulating material mixture is injected into the cavity of an annular mold, and the injection pressure and injection speed of the insulating material mixture are adjusted according to the collected temperature data until the injection molding is completed, including: A temperature sensing channel is provided between the inner and outer walls of the annular mold cavity. The temperature sensing channel is filled with a thermistor material. The resistance value of the thermistor material changes with temperature, causing strain deformation. The insulating material mixture is injected into the annular mold cavity, the first resistance change value of the thermistor material is determined, and the first strain in the temperature sensing channel is calculated based on the first resistance change value. The first opening angle of the annular mold cavity is adjusted according to the first strain, and the difference between the first opening angle and the preset reference angle is converted into the first adjustment amount of the injection pressure. The injection pressure is controlled according to the first adjustment amount. When the insulating material mixture is injected, the second resistance change value of the thermistor material is determined. The second strain in the temperature sensing channel is calculated based on the second resistance change value. The second opening angle of the annular mold cavity is adjusted according to the second strain variable. The difference between the second opening angle and the preset reference angle is converted into a second adjustment amount of the injection pressure. The injection pressure is adjusted according to the second adjustment amount until the injection is completed.

[0055] This invention utilizes a temperature sensing channel and a thermistor material to collect temperature data within the cavity of a ring-shaped mold, and dynamically adjusts injection molding parameters based on this data. Specific implementation details are as follows: A temperature sensing channel is installed between the inner and outer walls of the annular mold cavity. This temperature sensing channel can be a cylindrical channel with a diameter of 2mm, evenly distributed along the circumference of the annular mold cavity. For example, one temperature sensing channel can be installed every 45 degrees circumferentially, for a total of eight channels. The temperature sensing channel is filled with a thermistor material, which can be a manganese-copper alloy with a temperature coefficient of approximately -0.5% / ℃. That is, the resistance is 100 ohms at 20℃, and decreases to 50 ohms when the temperature rises to 120℃. The two ends of the thermistor material are connected to wires leading out of the mold and connected to a resistance measurement circuit.

[0056] Before injecting the insulating material mixture into the annular mold cavity, the mold is preheated to 85°C. At this temperature, the resistance of the thermistor material is approximately 57.5 ohms, which is used as a reference resistance value. The insulating material mixture is then preheated to 105°C and injected into the annular mold cavity with an initial pressure of 15 MPa. During the injection process, the resistance change of the thermistor material is monitored in real time.

[0057] When the insulating material mixture is first injected, the resistance of the thermistor material changes from 57.5 ohms to 54.3 ohms, a change of 3.2 ohms, which is the first resistance change. According to a pre-established correspondence between resistance change and strain, the first strain corresponding to a resistance change of 3.2 ohms is 0.056 mm. This means that the temperature sensing channel experiences a dimensional change of 0.056 mm due to thermal expansion and contraction.

[0058] The opening angle of the annular mold cavity is adjusted based on the measured first strain of 0.056 mm. The preset reference opening angle of the annular mold cavity is 5.5 degrees. According to the conversion relationship between strain and opening angle (each 0.01 mm of strain corresponds to a 0.2 degree angle change), the first opening angle is calculated to be 6.62 degrees, which is 1.12 degrees different from the preset reference angle. Based on the pre-established correspondence between the angle difference and the injection pressure adjustment (each 1 degree angle difference corresponds to a 2 MPa pressure adjustment), the first adjustment amount of the injection pressure is obtained as 2.24 MPa.

[0059] The injection pressure was adjusted based on the calculated initial adjustment value of 2.24 MPa, increasing the initial injection pressure from 15 MPa to 17.24 MPa. Simultaneously, the injection speed was maintained at 25 cm³ / s. The insulating material mixture was then injected again under the new injection parameters, and the resistance value of the thermistor material was monitored once more.

[0060] After approximately 30 seconds, the resistance of the thermistor material changed from 54.3 ohms to 52.1 ohms, a change of 2.2 ohms, which is the second resistance change. Based on the correspondence between resistance change and strain, the second strain corresponding to a resistance change of 2.2 ohms is 0.038 mm.

[0061] Based on the second strain of 0.038 mm, the opening angle of the annular mold cavity is adjusted again. Using the same conversion relationship, the second opening angle is calculated to be 6.26 degrees, which is 0.76 degrees different from the preset reference angle. According to the correspondence between the angle difference and the injection pressure adjustment amount, the second adjustment amount of the injection pressure is found to be 1.52 MPa.

[0062] The injection pressure was adjusted again based on the second adjustment amount of 1.52 MPa, reducing it from 17.24 MPa to 15.72 MPa. After adjustment, the injection process continued, and the resistance value of the thermistor material was continuously monitored. If the resistance value change was less than 0.5 ohms, it indicated that the temperature was stabilizing, and the insulating material mixture in the mold cavity had filled and was gradually solidifying. At this point, the injection pressure was kept constant until the insulating material was completely solidified.

[0063] Throughout the injection molding process, the temperature sensing channel reflects the temperature changes within the annular mold cavity in real time. By calculating the strain based on the change in the resistance of the thermistor material, the mold opening angle and injection pressure are adjusted accordingly. This dynamic adjustment mechanism ensures that the insulating material mixture uniformly fills the mold cavity during injection, preventing defects such as bubbles and shrinkage cavities.

[0064] In practical applications, the number and distribution of temperature sensing channels can be adjusted according to different models and sizes of ring molds. For ring molds with larger diameters, the number of temperature sensing channels can be increased to 12 or more; for ring molds with complex shapes, additional temperature sensing channels can be added in stress concentration areas to obtain more accurate temperature distribution data.

[0065] The above process effectively improves the molding quality of insulating rings, reduces scrap rates, and increases production efficiency. Experimental data shows that insulating rings produced using this process have a 35% higher inner diameter accuracy, a 42% higher surface finish, and an insulation performance qualification rate of 99.8%, far exceeding the 95.2% of the traditional fixed-parameter injection molding process.

[0066] In one optional embodiment, an electromagnetic heating device generates a magnetic field in the axial direction of the solidified electrode post. Based on the axial temperature distribution data of the solidified electrode post collected by the temperature sensor, the decreasing gradient of the magnetic field strength is adjusted until the insulating material mixture is completely cured, including: A first magnetic field is generated in the axial direction of the solid-sealed pole by a first magnetic field coil, and a first eddy current is generated in the solid-sealed pole. The distribution density of the first eddy current in the axial direction of the solid-sealed pole is measured, and a first preset angle is adjusted according to the distribution density. The first preset angle represents the angle between the magnetic field lines of the first magnetic field and the axial direction of the solid-sealed pole. Temperature distribution data along the axial direction of the solid-sealed electrode is collected by a temperature sensor, and the gradient value of the temperature distribution data along the axial direction of the solid-sealed electrode is calculated. A second preset angle is determined based on the gradient value and the distribution density. A second magnetic field is generated in the axial direction of the solid-sealed pole by a second magnetic field coil. The angle between the magnetic field lines of the second magnetic field and the axial direction of the solid-sealed pole is the second preset angle. The second magnetic field is used to generate a second eddy current in the solid-sealed pole post. The distribution density of the second eddy current along the axial direction of the solid-sealed pole post is measured, and the distribution density is converted into a third preset angle. A third magnetic field is generated in the axial direction of the solidified pole by a third magnetic field coil. The angle between the magnetic field lines of the third magnetic field and the axial direction of the solidified pole is the third preset angle, until the insulating material mixture is completely cured.

[0067] In this embodiment, the decreasing gradient of the magnetic field strength is adjusted based on the axial temperature distribution data of the solidified pole collected by the temperature sensor until the insulating material mixture is completely cured.

[0068] The specific implementation process involves generating a first magnetic field in the axial direction of the solid-sealed pole using a first magnetic field coil. The first magnetic field coil can be a helical wire structure that generates an alternating magnetic field around itself when an alternating current is applied. The magnetic field lines of this magnetic field form an initial angle with the axial direction of the solid-sealed pole, for example, 45 degrees. When this magnetic field acts inside the solid-sealed pole, it generates first eddy currents. These eddy currents are generated because, according to the law of electromagnetic induction, a current is induced in the conductive material when the magnetic field passes through it. The eddy current distribution density can be measured using a magnetic flux sensor array positioned around the solid-sealed pole. For example, when the axial eddy current distribution density detected inside the solid-sealed pole is 8.2 A / m² in the head region, 6.5 A / m² in the middle region, and 4.1 A / m² in the tail region, the system automatically adjusts a first preset angle based on this non-uniform distribution.

[0069] The specific adjustment method is as follows: when the eddy current distribution density is detected to be higher at the head of the solid-sealed pole and lower at the tail, the system will gradually adjust the first preset angle from the initial 45 degrees to 30 degrees, reducing the angle between the magnetic field lines and the axis of the solid-sealed pole, thereby making the magnetic field more concentrated on the area with lower eddy current density. This adjustment is achieved by changing the spatial position of the magnetic field coil through a servo motor in the control system, with an adjustment accuracy of ±0.5 degrees.

[0070] After adjusting the first preset angle, the temperature sensor begins to collect temperature distribution data along the axial direction of the sealed electrode. The temperature sensor uses a thermocouple array, with a measurement point set every 5 centimeters along the axial direction of the sealed electrode, allowing simultaneous monitoring of temperature changes at multiple points. When the insulating material mixture begins to heat up under electromagnetic heating, the system records the temperature data at each point. For example, in a certain measurement, the temperature data from the head to the tail of the sealed electrode were 85℃, 82℃, 78℃, 72℃, and 65℃, respectively. Based on these data, the system calculates the gradient value of the temperature distribution along the axial direction of the sealed electrode, i.e., the rate of temperature change between adjacent measurement points. In this example, the temperature gradient values ​​from head to tail are 0.6℃ / cm, 0.8℃ / cm, 1.2℃ / cm, and 1.4℃ / cm, respectively.

[0071] The system determines a second preset angle based on the calculated temperature gradient value and the previously measured eddy current distribution density. During this process, the system establishes a correlation between the temperature gradient and eddy current density, analyzing their correlation through a built-in algorithm. When the temperature gradient is found to be excessively large in the tail region, it indicates uneven heating in that area, requiring an increase in eddy current intensity. Based on this analysis, the system determines the second preset angle should be 25 degrees, smaller than the first preset angle, to make the magnetic field more inclined to act on the region with the larger temperature gradient.

[0072] After determining the second preset angle, the system activates the second magnetic field coil to generate a second magnetic field in the axial direction of the solid-sealed pole. The structure of the second magnetic field coil is similar to that of the first magnetic field coil, but its current intensity and phase can be independently controlled. When the magnetic field lines of the second magnetic field form a 25-degree angle with the axial direction of the solid-sealed pole, the magnetic field will generate a second eddy current within the solid-sealed pole. Due to the decrease in the angle, the magnetic field distribution is more concentrated in the tail region of the solid-sealed pole, thereby enhancing the eddy current intensity in that region.

[0073] Using the same magnetic flux sensor array, the system measures the distribution density of the second eddy current along the axial direction of the solid-sealed pole. For example, the adjusted eddy current distribution density is 7.8 A / m² in the head region, 7.2 A / m² in the middle region, and 6.5 A / m² in the tail region, showing a more uniform distribution. The system converts these distribution density data into a third preset angle, taking into account the temperature gradient trend and the uniformity of the eddy current distribution, ultimately determining the third preset angle to be 20 degrees.

[0074] A third magnetic field is generated along the axial direction of the solidified pole by a third magnetic field coil. This third magnetic field coil is the most powerful component in the entire electromagnetic heating system, providing a stronger magnetic field. When the angle between the magnetic field lines of the third magnetic field and the axial direction of the solidified pole is set to 20 degrees, the eddy current distribution generated within the pole is more uniform, minimizing the difference in eddy current density from head to tail, thus achieving uniform heating across the entire area. The system continuously monitors the temperature changes inside the solidified pole. Once the temperature stabilizes at 90±2℃ for 30 minutes, the system determines that the insulating material mixture has completely solidified, and the entire heating process ends.

[0075] By using this multi-stage magnetic field coil working in tandem, the system can precisely control the temperature distribution inside the solidified pole, ensuring that the insulating material mixture is uniformly cured throughout the entire axial range, thus improving the quality and reliability of the solidified pole.

[0076] In one optional embodiment, a first magnetic field is generated in the axial direction of the solid-sealed pole by a first magnetic field coil, causing the first magnetic field to generate a first eddy current in the solid-sealed pole. The distribution density of the first eddy current in the axial direction of the solid-sealed pole is measured, and a first preset angle is adjusted according to the distribution density, including: Multiple eddy current density sensor arrays are arranged along the circumferential and axial directions on the outer wall of the solid-sealed pole. The eddy current density sensor arrays collect the eddy current distribution density inside the solid-sealed pole, and the projection of the eddy current distribution density onto the axial plane of the solid-sealed pole determines the eddy current density field. The vector direction of the eddy current density field is determined according to the gradient change of the eddy current density field. A first magnetic field is generated in the axial direction of the solid-sealed pole by the magnetic field coil. The angle between the magnetic field lines of the first magnetic field and the axial direction of the solid-sealed pole is a first angle. The first magnetic field excites a first eddy current in the solid-sealed pole. The eddy current density sensor array collects the distribution density of the first eddy current in the axial and circumferential directions of the solid-sealed pole, and calculates the density vector field of the first eddy current based on the spatial distribution characteristics of the distribution density. The curl and divergence of the density vector field are mapped to the eddy current density field direction angle. A first preset angle is determined based on the angle between the eddy current density field direction angle and the eddy current density field vector direction. The angle between the magnetic field lines of the first magnetic field and the axis of the solid-sealed pole is adjusted to the first preset angle.

[0077] This invention generates a magnetic field in the axial direction of a solid-sealed pole by a magnetic field coil, and measures the eddy current distribution density based on an eddy current density sensor array. The implementation process is detailed below.

[0078] Multiple eddy current density sensor arrays are arranged circumferentially and axially on the outer wall of the solid-sealed electrode. Specifically, 12 measurement points are evenly arranged circumferentially on the outer wall of the solid-sealed electrode, and 8 eddy current density sensors are arranged axially at each measurement point, forming a 12×8 sensor array. Each sensor is made of Hall effect sensing element with a sensitivity of 5mV / G, a range of ±2000G, and a sampling frequency of 500Hz. The eddy current density sensor array is connected to the control system through a data acquisition module to collect eddy current distribution density data within the solid-sealed electrode in real time.

[0079] After the eddy current density sensor array acquires the eddy current distribution density within the solid-sealed electrode, the projection of this density onto the axial plane of the electrode is defined as the eddy current density field. Specifically, the eddy current density values ​​from the 96 acquired measurement points are used to generate a continuous eddy current density distribution surface using a cubic spline interpolation algorithm. This surface is then projected onto the axial plane of the solid-sealed electrode to form a two-dimensional eddy current density field. For example, with a solid-sealed electrode diameter of 120 mm and a height of 300 mm, the axial plane can be divided into a 300×120 grid, with each grid point containing an eddy current density value.

[0080] The direction of the eddy current density field vector is determined by the gradient change of the eddy current density field. The gradient vector (Gx, Gz) is obtained by calculating the density gradient at each point in the x and z directions. The direction of this gradient vector is the direction of the eddy current density field vector. In practical applications, the center point of the region with the maximum eddy current density can be selected to calculate its gradient vector. For example, if the maximum eddy current density is measured at 85 mA / cm² in the middle region of the solid-sealed pole, the gradient vector at this point is 37.5 degrees relative to the axial direction.

[0081] A first magnetic field is generated along the axial direction of the solid-sealed pole by a magnetic field coil. The magnetic field coil consists of a copper coil with an inner diameter of 140 mm and an outer diameter of 180 mm, a wire diameter of 1.2 mm, and 200 turns. By passing a DC current of 10 A through the coil, a magnetic field with an intensity of 0.5 T is generated at the location of the solid-sealed pole. The angle between the magnetic field lines of the first magnetic field and the axial direction of the solid-sealed pole is initially set to 45 degrees, and this magnetic field induces the first eddy current within the solid-sealed pole.

[0082] The eddy current density sensor array collects the axial and circumferential distribution density of the first eddy current on the solid-sealed pole. In actual measurement, the eddy current density recorded by the sensor array shows an asymmetrical distribution in the axial direction, with the maximum value occurring 175 mm from the top of the solid-sealed pole, and the density value is 95 mA / cm². In the circumferential direction, the eddy current density shows a relatively uniform distribution, with a variation range of no more than 10%.

[0083] The density vector field of the first eddy is calculated based on the spatial distribution characteristics of the density distribution. The collected eddy density data is processed into a three-dimensional vector field, with magnitude and direction information for each spatial point. For example, in the central region of the solidified pole, the direction of the eddy density vector is approximately 42 degrees relative to the axis, while the direction in the edge region is approximately 32 degrees.

[0084] The curl and divergence of the density vector field are mapped to the eddy density field direction angle. By calculating the curl and divergence of the density vector field, the directional characteristics of the eddy flow are obtained. In this example, the calculated eddy density field direction angle is 35 degrees, indicating that the main flow direction of the eddy is at a 35-degree angle to the axis.

[0085] The first preset angle is determined based on the angle between the eddy current density field direction angle and the eddy current density field vector direction. In the actual measurement, the eddy current density field direction angle is 35 degrees, while the eddy current density field vector direction is 37.5 degrees, and the angle between the two is 2.5 degrees. According to an empirical formula, when the angle between the two is less than 5 degrees, the average value is taken as the optimal magnetic field angle; when the angle is greater than 5 degrees, a weighted average value is taken. In this example, the first preset angle is determined to be 36.25 degrees.

[0086] Finally, adjust the angle between the magnetic field lines of the first magnetic field and the axis of the solidified pole to a first preset angle. By adjusting the installation angle of the magnetic field coil or using an auxiliary magnetic field coil combination to generate a magnetic field in a specific direction, the direction of the magnetic field lines is adjusted from the initial 45 degrees to 36.25 degrees. After adjustment, the eddy current distribution is measured again, confirming that the angle between the eddy current density field direction angle and the eddy current density field vector direction has decreased to within 0.8 degrees, indicating that the adjustment is effective.

[0087] The solid-sealed pole environmentally friendly insulation material injection molding and temperature control process system of this invention includes: The first unit is used to collect temperature data through a temperature sensor set on the outer wall surface of the solid-sealed electrode, control the heating wire to preheat the solid-sealed electrode according to the temperature data, and monitor the solid-sealed electrode until it reaches a first preset temperature through the temperature sensor. The second unit is used to transport the epoxy resin matrix to the first hopper and the nano-alumina particles modified by the silane coupling agent to the second hopper while the solid-sealing electrode is maintained at the first preset temperature. The epoxy resin matrix and the nano-alumina particles are then mixed by a two-component injection molding machine to obtain an insulating material mixture. The third unit is used to inject the insulating material mixture into the annular mold cavity, and adjust the injection pressure and injection speed of the insulating material mixture according to the collected temperature data until the injection is completed; The fourth unit is used to generate a magnetic field in the axial direction of the solidified pole using an electromagnetic heating device, and adjusts the decreasing gradient of the magnetic field strength according to the axial temperature distribution data of the solidified pole collected by the temperature sensor until the insulating material mixture is completely cured. The fifth unit is used to determine the curing state of the insulating material mixture based on the collected temperature data. After confirming that the curing is complete, the mold is opened and the material is demolded to obtain the formed solidified pole.

[0088] A third aspect of the present invention provides an electronic device, comprising: a processor; Memory used to store processor-executable instructions; The processor is configured to invoke instructions stored in the memory to execute the aforementioned method.

[0089] A fourth aspect of the present invention provides a computer-readable storage medium having stored thereon computer program instructions that, when executed by a processor, implement the aforementioned method.

[0090] This invention can be a method, apparatus, system, and / or computer program product. The computer program product may include a computer-readable storage medium having computer-readable program instructions loaded thereon for performing various aspects of the invention.

[0091] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for injection molding and temperature control of environmentally friendly insulating materials for solid-sealed poles, characterized in that, include: Temperature data is collected by a temperature sensor installed on the outer wall surface of the solid-sealed electrode post. The heating wire is controlled to preheat the solid-sealed electrode post according to the temperature data. The temperature sensor is used to monitor the temperature until the solid-sealed electrode post reaches the first preset temperature. While the solidified electrode is maintained at a first preset temperature, the epoxy resin matrix is ​​conveyed to the first hopper, and the nano-alumina particles modified by the silane coupling agent are conveyed to the second hopper. The epoxy resin matrix and the nano-alumina particles are mixed by a two-component injection molding machine to obtain an insulating material mixture. The insulating material mixture is injected into the cavity of the annular mold, and the injection pressure and injection speed of the insulating material mixture are adjusted according to the collected temperature data until the injection is completed. A magnetic field is generated in the axial direction of the solidified electrode by an electromagnetic heating device. Based on the axial temperature distribution data of the solidified electrode collected by the temperature sensor, the decreasing gradient of the magnetic field strength is adjusted until the insulating material mixture is completely cured. The curing state of the insulating material mixture is determined based on the collected temperature data. After confirming that the curing is complete, the mold is opened and the material is demolded to obtain the formed solidified electrode post.

2. The method according to claim 1, characterized in that, Temperature data is collected by a temperature sensor installed on the outer surface of the solid-sealed electrode post. Based on the temperature data, a heating wire is controlled to preheat the solid-sealed electrode post. The temperature is monitored by the temperature sensor until the solid-sealed electrode post reaches a first preset temperature, including: Multiple temperature sensors are arranged axially on the outer wall surface of the solid-sealed electrode. The spacing between the temperature sensors is related to the diameter change of the solid-sealed electrode. The temperature data of the temperature sensors is collected as the initial temperature data of the solid-sealed electrode. The temperature distribution curve of the outer wall surface of the solid-sealed pole is calculated based on the initial temperature data. The temperature distribution curve is divided into multiple temperature ranges. Each temperature range corresponds to a set of heating wires. The power of each set of heating wires is inversely proportional to the temperature value of its corresponding temperature range. The heating wires of each group are controlled to preheat the solid-sealed electrode, and the temperature data of the temperature sensor is continuously collected during the preheating process. The power of each heating wire is adjusted in real time according to the temperature data of the temperature sensor until the temperature of the outer wall surface of the solid-sealed electrode reaches the first preset temperature. The temperature uniformity of the outer wall surface of the solid-sealed electrode is calculated based on the temperature data of the temperature sensor to determine whether the solid-sealed electrode has reached the first preset temperature.

3. The method according to claim 1, characterized in that, While the solidified electrode is maintained at a first preset temperature, the epoxy resin matrix is ​​conveyed to the first hopper, and the nano-alumina particles modified with a silane coupling agent are conveyed to the second hopper. The epoxy resin matrix and the nano-alumina particles are mixed using a two-component injection molding machine to obtain an insulating material mixture, comprising: While the solid-sealed electrode column maintains the first preset temperature, epoxy resin matrix is ​​conveyed into the first hopper and nano-alumina particles are conveyed into the second hopper. A magnetic field generator and an ultrasonic generator are installed in the mixing chamber of a two-component injection molding machine. The magnetic field strength generated by the magnetic field generator changes in a correlated manner with the sound wave frequency generated by the ultrasonic generator. The nano-alumina particles are oriented by the coupling effect of the magnetic field strength and the sound wave frequency. The orientation data of the nano-alumina particles in the mixing chamber is collected, and the coupling parameters of the magnetic field strength and the sound wave frequency are calculated based on the orientation data. The epoxy resin matrix and the nano-alumina particles are fed into the mixing chamber at a preset mass ratio through the feeding assembly of the two-component injection molding machine for mixing. The output power of the magnetic field generator and the ultrasonic generator are controlled according to the coupling parameters. During the mixing process, the arrangement direction and spacing of the nano-alumina particles are adjusted until the nano-alumina particles form a parallel arrangement structure with a preset spacing, thereby obtaining an insulating material mixture.

4. The method according to claim 3, characterized in that, The nano-alumina particles are oriented and aligned through the coupling effect of the magnetic field strength and the sound wave frequency. Orientation data of the nano-alumina particles in the mixing chamber is collected, and the coupling parameters between the magnetic field strength and the sound wave frequency are calculated based on the orientation data, including: Through the coupling effect of the magnetic field strength and the sound wave frequency, the nano-alumina particles are oriented and aligned along the axial and radial directions of the mixing chamber; Multiple light sources and photodetectors are uniformly arranged circumferentially within the mixing chamber. The detection beam emitted by the light source passes through the oriented nano-alumina particles and is received by the corresponding photodetector. The scattering intensity and polarization degree of the detection beam after passing through the oriented nano-alumina particles are collected as the orientation data of the nano-alumina particles. The first spatial orientation angle of the nano-alumina particles relative to the axis of the mixing chamber is calculated based on the scattering intensity, and the second spatial orientation angle of the nano-alumina particles relative to the radial direction of the mixing chamber is calculated based on the polarization degree. The correction intensity is calculated based on the first spatial orientation angle, and the correction frequency is calculated based on the second spatial orientation angle. Based on the correction intensity and the correction frequency, the ratio of the magnetic field intensity generated by the magnetic field generator to the sound wave frequency generated by the ultrasonic generator is adjusted, and the ratio is used as a coupling parameter.

5. The method according to claim 1, characterized in that, The insulating material mixture is injected into the cavity of an annular mold. The injection pressure and speed of the insulating material mixture are adjusted based on collected temperature data until injection molding is complete. This includes: A temperature sensing channel is provided between the inner and outer walls of the annular mold cavity. The temperature sensing channel is filled with a thermistor material. The resistance value of the thermistor material changes with temperature, causing strain deformation. The insulating material mixture is injected into the annular mold cavity, the first resistance change value of the thermistor material is determined, and the first strain in the temperature sensing channel is calculated based on the first resistance change value. The first opening angle of the annular mold cavity is adjusted according to the first strain, and the difference between the first opening angle and the preset reference angle is converted into the first adjustment amount of the injection pressure. The injection pressure is controlled according to the first adjustment amount. When the insulating material mixture is injected, the second resistance change value of the thermistor material is determined. The second strain in the temperature sensing channel is calculated based on the second resistance change value. The second opening angle of the annular mold cavity is adjusted according to the second strain variable. The difference between the second opening angle and the preset reference angle is converted into a second adjustment amount of the injection pressure. The injection pressure is adjusted according to the second adjustment amount until the injection is completed.

6. The method according to claim 1, characterized in that, A magnetic field is generated along the axial direction of the solidified electrode using an electromagnetic heating device. Based on the axial temperature distribution data of the solidified electrode collected by the temperature sensor, the decreasing gradient of the magnetic field strength is adjusted until the insulating material mixture is completely cured, including: A first magnetic field is generated in the axial direction of the solid-sealed pole by a first magnetic field coil, and a first eddy current is generated in the solid-sealed pole. The distribution density of the first eddy current in the axial direction of the solid-sealed pole is measured, and a first preset angle is adjusted according to the distribution density. The first preset angle represents the angle between the magnetic field lines of the first magnetic field and the axial direction of the solid-sealed pole. Temperature distribution data along the axial direction of the solid-sealed electrode is collected by a temperature sensor, and the gradient value of the temperature distribution data along the axial direction of the solid-sealed electrode is calculated. A second preset angle is determined based on the gradient value and the distribution density. A second magnetic field is generated in the axial direction of the solid-sealed pole by a second magnetic field coil. The angle between the magnetic field lines of the second magnetic field and the axial direction of the solid-sealed pole is the second preset angle. The second magnetic field is used to generate a second eddy current in the solid-sealed pole post. The distribution density of the second eddy current along the axial direction of the solid-sealed pole post is measured, and the distribution density is converted into a third preset angle. A third magnetic field is generated in the axial direction of the solidified pole by a third magnetic field coil. The angle between the magnetic field lines of the third magnetic field and the axial direction of the solidified pole is the third preset angle, until the insulating material mixture is completely cured.

7. The method according to claim 6, characterized in that, A first magnetic field is generated in the axial direction of the solid-sealed pole by a first magnetic field coil, causing the first magnetic field to generate a first eddy current in the solid-sealed pole. The distribution density of the first eddy current in the axial direction of the solid-sealed pole is measured, and a first preset angle is adjusted according to the distribution density, including: Multiple eddy current density sensor arrays are arranged along the circumferential and axial directions on the outer wall of the solid-sealed pole. The eddy current density sensor arrays collect the eddy current distribution density inside the solid-sealed pole, and the projection of the eddy current distribution density onto the axial plane of the solid-sealed pole determines the eddy current density field. The vector direction of the eddy current density field is determined according to the gradient change of the eddy current density field. A first magnetic field is generated in the axial direction of the solid-sealed pole by the magnetic field coil. The angle between the magnetic field lines of the first magnetic field and the axial direction of the solid-sealed pole is a first angle. The first magnetic field excites a first eddy current in the solid-sealed pole. The eddy current density sensor array collects the distribution density of the first eddy current in the axial and circumferential directions of the solid-sealed pole, and calculates the density vector field of the first eddy current based on the spatial distribution characteristics of the distribution density. The curl and divergence of the density vector field are mapped to the eddy current density field direction angle. A first preset angle is determined based on the angle between the eddy current density field direction angle and the eddy current density field vector direction. The angle between the magnetic field lines of the first magnetic field and the axis of the solid-sealed pole is adjusted to the first preset angle.

8. A solid-sealed pole environmentally friendly insulating material injection molding and temperature control process system, used to implement the method as described in any one of claims 1-7, characterized in that, include: The first unit is used to collect temperature data through a temperature sensor set on the outer wall surface of the solid-sealed electrode, control the heating wire to preheat the solid-sealed electrode according to the temperature data, and monitor the solid-sealed electrode until it reaches a first preset temperature through the temperature sensor. The second unit is used to transport the epoxy resin matrix to the first hopper and the nano-alumina particles modified by the silane coupling agent to the second hopper while the solid-sealing electrode is maintained at the first preset temperature. The epoxy resin matrix and the nano-alumina particles are then mixed by a two-component injection molding machine to obtain an insulating material mixture. The third unit is used to inject the insulating material mixture into the annular mold cavity, and adjust the injection pressure and injection speed of the insulating material mixture according to the collected temperature data until the injection is completed; The fourth unit is used to generate a magnetic field in the axial direction of the solidified pole using an electromagnetic heating device, and adjusts the decreasing gradient of the magnetic field strength according to the axial temperature distribution data of the solidified pole collected by the temperature sensor until the insulating material mixture is completely cured. The fifth unit is used to determine the curing state of the insulating material mixture based on the collected temperature data. After confirming that the curing is complete, the mold is opened and the material is demolded to obtain the formed solidified pole.

9. An electronic device, characterized in that, include: processor; Memory used to store processor-executable instructions; The processor is configured to invoke instructions stored in the memory to execute the method according to any one of claims 1 to 7.

10. A computer-readable storage medium having computer program instructions stored thereon, characterized in that, When the computer program instructions are executed by the processor, they implement the method described in any one of claims 1 to 7.

Images