HXD1 series locomotive high-voltage insulator residual life periodic performance research method based on C6 repair

Abstract

The invention relates to a C6 repair-based HXD1 series locomotive high-voltage insulator residual life periodic performance research method, which comprises the following steps of: performing state grading, accelerated aging test and data fitting on a high-voltage insulator, establishing a thermal life model based on an Arrhenius equation, and accurately predicting the residual life of the insulator. The method has the advantages of being small in sample demand, easy and convenient to implement, high in prediction precision and the like, and is suitable for service life evaluation and maintenance decision making of the HXD1 series electric locomotive high-voltage insulator.

Description

Technical Field

[0001] This invention relates to the field of high-voltage electrical equipment life prediction technology, and in particular to a method for studying the remaining life cycle performance of high-voltage insulators of HXD1 series locomotives based on C6 maintenance. Background Technology

[0002] Insulators are electrical devices that provide insulation and mechanical fixation. They are mainly used to support high-voltage conductors, isolate live conductors from grounding conductors, and ensure the insulation performance of electrical systems under complex operating conditions.

[0003] When overhauling the C6 section of the HXD1 series locomotive, the high-voltage insulators had been in operation for approximately 12 years. By analyzing the parts of the insulators that had experienced lifespan degradation, the degradation patterns were identified, and the remaining lifespan of the insulators was assessed. This provided a theoretical basis for the reliable and safe use, maintenance, and repair of insulators for Harmony-type locomotives.

[0004] Existing methods for predicting insulator life rely on statistical data analysis based on the insulator's age and current condition, using algorithms to predict its remaining life. While this method can predict the remaining life of a group of insulators, it requires a large sample collection. To achieve accurate prediction of remaining life, this method requires eigenvalue measurements of insulators of different ages. After obtaining the data, curve fitting training is performed to obtain the relationship between the insulator's overall score and its equivalent operating time, which is then used to predict the remaining life. This method requires a large sample collection and is time-consuming, making it unsuitable for the study of the remaining life of high-voltage insulators used in the C6 overhaul of the HXD1 series electric locomotive. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a method for studying the remaining life cycle performance of high-voltage insulators of HXD1 series locomotives based on C6 maintenance. By classifying the state of the insulators, conducting accelerated aging tests and fitting the thermal life equation, a scientific assessment of the remaining life of high-voltage insulators of HXD1 series locomotives under C6 maintenance can be achieved.

[0006] To solve the above-mentioned technical problems, the technical solution of the present invention is: a method for studying the remaining life cycle performance of high-voltage insulators of HXD1 series locomotives based on C6 repair, comprising the following steps:

[0007] Condition monitoring and classification of HXD1 series C6 high-voltage insulators;

[0008] Insulators with the highest proportion of condition levels were selected as the research object;

[0009] Dumbbell-shaped specimens were prepared according to GB / T528-2009 standard;

[0010] Exploratory tests were conducted to determine the maximum temperature for aging tests;

[0011] The elongation at break and tensile strength of samples aged at different temperatures and times were measured.

[0012] Using 50% of the initial elongation at break as the end point of the aging life, the relationship curve between temperature and aging time was fitted based on the Arrhenius thermal life equation.

[0013] Based on the ambient operating temperature and the fitted curve, the remaining life of the high-voltage insulator is predicted.

[0014] As an improvement, the status classification includes four levels: good, normal, warning, and exit, which are determined based on appearance, insulation resistance, and leakage current indicators.

[0015] As an improvement, the aging test shall have no fewer than four temperature points, with an interval of no less than 10°C between adjacent temperatures, and the aging times shall be 600h, 800h, 1000h, and 1200h respectively.

[0016] As an improvement, the thermal life equation is: lgτ=a+b / T, where τ is the expected thermal aging life, a is a constant related to the specified failure, T is the aging temperature K, and b is a constant related to the activation energy.

[0017] As an improvement, the method requires no fewer than 16 insulator samples.

[0018] The specific steps of this invention are as follows:

[0019] Step 1: Determine the selection range of C6 insulator samples based on the actual situation. To ensure the reliability of the data analysis results, samples with a production year difference of less than one year should be selected.

[0020] Step 2: Clean the collected insulators, check the surface condition of the sheds and record it;

[0021] Step 3: Perform withstand voltage insulation leakage current testing on the insulators and record the data results;

[0022] Step 4: Classify the condition of the insulator according to the classification indicators, and distinguish them into four status levels: good, normal, warning, and exit.

[0023] Step 5: Select the insulators with the largest proportion of condition levels among all C6 insulators as the research object. To meet the test requirements, the number of insulators should not be less than 16.

[0024] Step 6: Cut off the high-voltage insulator skirts, prepare the sample strips according to GB / T528-2009, and then cut the sample strips into 5 dumbbell-shaped samples;

[0025] Step 7: Tense the test sample according to the requirements of GB / T528-2009, and determine the initial tensile strength and elongation at break of the sample.

[0026] Step 8: Conduct a 24-hour exploratory test according to the umbrella skirt material and the recommended temperature in GJB92.1. After the test, test the elongation at break and tensile strength. It is required that the elongation at break at the highest temperature aging and the first point should not be less than 80% of the elongation at break before aging, and the elongation at break at the first point after aging at the lowest temperature should not be higher than 80% of the elongation at break before aging. Determine the highest temperature for the aging test based on this requirement.

[0027] Step 9: Determine four temperature points for the aging test based on the highest temperature, with an interval of no less than 10℃ between adjacent temperatures. The aging times are arranged in descending order of aging temperature as 600h, 800h, 1000h, and 1200h.

[0028] Step 10: Place the prepared test sample into an oven that has been heated to the specified temperature, and start calculating the aging time. The number of intermediate sample checks at each temperature should not be less than 10, and 5 samples should be measured each time. Calculate the average value of the elongation at break and tensile strength after aging as the test result, and record the aging time, elongation at break and tensile strength after aging at each sample check.

[0029] Step 11: Obtain the aging time and aging temperature of the C6-repaired silicone rubber insulator material through aging tests, plot the relationship curve between aging temperature and aging time, and plot the logarithm of aging time and the reciprocal of aging temperature using the least squares method. Then, fit the Arrhenius thermal life equation in GB / T20028-2005 to derive the thermal life equation for the high-voltage insulator under C6 repair, which is finally transformed into: lgτ=a+b / T, where τ is the expected thermal aging life, a is a constant related to the specified failure, T is the aging temperature K, and b is a constant related to the activation energy. Fit the data of each detected temperature point, and calculate the remaining life of the high-voltage insulator based on C6 repair under the condition of an insulator operating temperature of 40°C using the thermal life equation.

[0030] The beneficial effects of this invention compared to the prior art are:

[0031] By classifying the condition of high-voltage insulators, conducting accelerated aging tests, and fitting data, a thermal life model based on the Arrhenius equation is established to accurately predict the remaining life of the insulators. This invention has the advantages of small sample requirements, simple implementation, and high prediction accuracy, and is applicable to the life assessment and maintenance decision-making of high-voltage insulators in HXD1 series electric locomotives. Attached Figure Description

[0032] Figure 1 A flowchart for the study of the remaining life of high-voltage insulators.

[0033] Figure 2 To determine the life end point curves at various test temperatures for insulation.

[0034] Figure 3 This is a graph showing the insulation temperature index. Detailed Implementation

[0035] The present invention will now be further described with reference to the accompanying drawings.

[0036] A method for studying the remaining life cycle performance of high-voltage insulators in HXD1 series locomotives based on C6 repair, such as... Figure 1 As shown, the specific steps include the following:

[0037] Step 1: Determine the selection range of C6 insulator samples based on the actual situation. To ensure the reliability of the data analysis results, samples with a production year difference of less than one year should be selected.

[0038] Step 2: Clean the collected insulators, check the surface condition of the sheds and record it;

[0039] Step 3: Perform withstand voltage insulation leakage current testing on the insulators and record the data results;

[0040] Step 4: Classify the insulator's condition according to the grading indicators, distinguishing it into four levels: Good, Average, Warning, and Out of Service; details are as follows:

[0041]

[0042] Step 5: Select the insulators with the largest proportion of condition levels among all C6 insulators as the research object. To meet the test requirements, the number of insulators should not be less than 16.

[0043] Step 6: Cut off the high-voltage insulator skirts, prepare the sample strips according to GB / T528-2009, and then cut the sample strips into 5 dumbbell-shaped samples;

[0044] Step 7: Tense the test sample according to the requirements of GB / T528-2009, and determine the initial tensile strength and elongation at break of the sample.

[0045] Step 8: As Figure 2 As shown, a 24-hour exploratory test was conducted according to the umbrella skirt material and the temperature recommended in GJB92.1. After the test, the elongation at break and tensile strength were tested. It was required that the elongation at break at the highest temperature aging and the first point should not be less than 80% of the elongation at break before aging, and the elongation at break at the first point after aging at the lowest temperature should not be more than 80% of the elongation at break before aging. Based on this requirement, the highest temperature for the aging test was determined.

[0046] Step 9: Determine four temperature points for the aging test based on the highest temperature, with an interval of no less than 10℃ between adjacent temperatures. The aging times are arranged in descending order of aging temperature as 600h, 800h, 1000h, and 1200h.

[0047] Step 10: Place the prepared test sample into an oven that has been heated to the specified temperature, and start calculating the aging time. The number of intermediate sample checks at each temperature should not be less than 10, and 5 samples should be measured each time. Calculate the average value of the elongation at break and tensile strength after aging as the test result, and record the aging time, elongation at break and tensile strength after aging at each sample check.

[0048] Step 11: As Figure 3 As shown, the aging time and aging temperature of the C6-repaired silicone rubber insulator material were obtained through aging tests. A curve showing the relationship between aging temperature and aging time was plotted. Using the least squares method, a curve showing the relationship between the logarithm of aging time and the reciprocal of aging temperature was also plotted. Then, using the Arrhenius thermal life equation in GB / T 20028-2005, a thermal life equation for the high-voltage insulator based on the C6 repair was fitted, ultimately transforming into: lgτ=a+b / T, where τ is the expected thermal aging life, a is a constant related to specified failure, T is the aging temperature K, and b is a constant related to activation energy. The detected temperature data were fitted, and combined with the insulator's ambient operating temperature of 40°C, the remaining life of the high-voltage insulator based on the C6 repair was calculated using the thermal life equation.

Claims

1. A method for studying the remaining life cycle performance of high-voltage insulators in HXD1 series locomotives based on C6 maintenance, characterized in that, Includes the following steps: Condition monitoring and classification of HXD1 series C6 high-voltage insulators; Insulators with the highest proportion of condition levels were selected as the research object; Dumbbell-shaped specimens were prepared according to GB / T528-2009 standard; Exploratory tests were conducted to determine the maximum temperature for aging tests; The elongation at break and tensile strength of samples aged at different temperatures and times were measured. Using 50% of the initial elongation at break as the end point of the aging life, the relationship curve between temperature and aging time was fitted based on the Arrhenius thermal life equation. Based on the ambient operating temperature and the fitted curve, the remaining life of the high-voltage insulator is predicted.

2. The method for studying the remaining life cycle performance of high-voltage insulators of HXD1 series locomotives based on C6 repair, as described in claim 1, is characterized in that: The status classification includes four levels: good, normal, warning, and exit, which are determined based on appearance, insulation resistance, and leakage current indicators.

3. The method for studying the remaining life cycle performance of high-voltage insulators of HXD1 series locomotives based on C6 repair, as described in claim 1, is characterized in that: The aging test shall have no fewer than four temperature points, with an interval of no less than 10°C between adjacent temperatures, and the aging times shall be 600h, 800h, 1000h, and 1200h respectively.

4. The method for studying the remaining life cycle performance of high-voltage insulators of HXD1 series locomotives based on C6 repair, as described in claim 1, is characterized in that: The thermal lifetime equation is: lgτ=a+b / T In the formula, τ is the expected life of thermal aging, a is a constant related to the specified failure, T is the aging temperature K, and b is a constant related to the activation energy.

5. The method for studying the remaining life cycle performance of HXD1 series locomotive high-voltage insulators based on C6 repair, as described in claim 1, is characterized in that: The method requires no fewer than 16 insulator samples.

6. The method for studying the remaining life cycle performance of high-voltage insulators of HXD1 series locomotives based on C6 repair, as described in claim 1, is characterized in that: The specific steps are as follows: Step 1: Determine the selection range of C6 insulator samples based on the actual situation. To ensure the reliability of the data analysis results, samples with a production year difference of less than one year should be selected. Step 2: Clean the collected insulators, check the surface condition of the sheds and record it; Step 3: Perform withstand voltage insulation leakage current testing on the insulators and record the data results; Step 4: Classify the condition of the insulator according to the classification indicators, and distinguish them into four status levels: good, normal, warning, and exit. Step 5: Select the insulators with the largest proportion of condition levels among all C6 insulators as the research object. To meet the test requirements, the number of insulators should not be less than 16. Step 6: Cut off the high-voltage insulator skirts, prepare the sample strips according to GB / T528-2009, and then cut the sample strips into 5 dumbbell-shaped samples; Step 7: Tense the test sample according to the requirements of GB / T528-2009, and determine the initial tensile strength and elongation at break of the sample. Step 8: Conduct a 24-hour exploratory test according to the umbrella skirt material and the recommended temperature in GJB92.

1. After the test, test the elongation at break and tensile strength. It is required that the elongation at break at the highest temperature aging and the first point should not be less than 80% of the elongation at break before aging, and the elongation at break at the first point after aging at the lowest temperature should not be higher than 80% of the elongation at break before aging. Determine the highest temperature for the aging test based on this requirement. Step 9: Determine four temperature points for the aging test based on the highest temperature, with an interval of no less than 10℃ between adjacent temperatures. The aging times are arranged in descending order of aging temperature as 600h, 800h, 1000h, and 1200h. Step 10: Place the prepared test sample into an oven that has been heated to the specified temperature, and start calculating the aging time. The number of intermediate sample checks at each temperature should not be less than 10, and 5 samples should be measured each time. Calculate the average value of the elongation at break and tensile strength after aging as the test result, and record the aging time, elongation at break and tensile strength after aging at each sample check. Step 11: Obtain the aging time and aging temperature of the C6-repaired silicone rubber insulator material through aging tests, plot the relationship curve between aging temperature and aging time, and plot the logarithm of aging time and the reciprocal of aging temperature using the least squares method. Then, fit the Arrhenius thermal life equation in GB / T20028-2005 to derive the thermal life equation of the high-voltage insulator under C6 repair, which is finally transformed into: lgτ=a+b / T, where τ is the expected thermal aging life, a is a constant related to the specified failure, T is the aging temperature K, and b is a constant related to the activation energy. The data from each detected temperature point were fitted, and combined with the insulator's ambient operating temperature of 40°C, the remaining life of the high-voltage insulator based on C6 repair was calculated using the thermal life equation.

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