Insulated torsion bar spline

Abstract

This application discloses an insulated torsion bar spline, comprising a straight section, a recessed section, a tapered section, and a bottom section arranged sequentially from top to bottom. The maximum diameter of the recessed section, tapered section, and bottom section is less than or equal to the diameter of the straight section. The total height of the insulated torsion bar spline is defined as L, the height of the straight section as L1, the height of the recessed section as L2, the height of the tapered section as L3, and the height of the bottom section as L4, satisfying the following conditions: 10%L≤L1≤15%L, 38%L≤L2≤43%L, 45%L≤L3≤49%L, and L4≤1%L. The diameter of the straight section is defined as D, and the maximum depth of the recessed section is 2%~4%D. The insulated torsion bar spline is made of metal, and the straight section, recessed section, tapered section, and bottom section are connected as a single structure. This application's insulated torsion bar spline, through optimization of its shape and dimensions, effectively improves the torque of the insulated torsion bar.

Description

Technical Field

[0001] This application relates to the field of insulator testing tooling technology, and in particular to an insulating torsion bar spline. Background Technology

[0002] Insulating torsion bars are commonly used to connect high-voltage conductors and insulators, serving a supporting and fixing function. In power systems, the magnitude of the torsion force of the insulating torsion bar directly affects the safe operation of the system. Summary of the Invention

[0003] To solve the above-mentioned technical problems, this application proposes an insulated torsion bar spline, which can effectively increase the torque of the insulated torsion bar.

[0004] The insulated torsion bar spline according to an embodiment of this application includes: The structure consists of a straight segment, a recessed segment, a converging segment, and a bottom segment arranged sequentially from top to bottom. The maximum diameter of the recessed segment, the converging segment, and the bottom segment is less than or equal to the diameter of the straight segment. Let L be the total height of the insulated torsion bar spline, L1 be the height of the straight section, L2 be the height of the recessed section, L3 be the height of the converging section, and L4 be the height of the ground section. Then, the following conditions must be met: 10%L≤L1≤15%L, 38%L≤L2≤43%L, 45%L≤L3≤49%L, and L4≤1%L. The diameter of the straight line segment is defined as D, and the maximum depth of the concave segment is 2% to 4%D; The insulated torsion bar spline is made of metal, and the straight section, the recessed section, the tapered section and the bottom section are connected as a single structure.

[0005] The insulating torsion bar spline according to the embodiments of this application has at least the following beneficial effects: By optimizing the shape and size of the spline of the insulating torsion bar, the torque of the insulating torsion bar was effectively improved.

[0006] In some embodiments of this application, the recessed segment includes a first arc segment, a middle segment, and a second arc segment. The middle segment transitions to the straight segment through the first arc segment, and the middle segment transitions to the converging segment through the second arc segment. The two ends of the first arc segment are tangent to the straight line segment and the middle segment, respectively, and the two ends of the first arc segment are tangent to the middle segment and the converging segment, respectively.

[0007] In some embodiments of this application, the height of the first arc segment is defined as L. 21 The height of the middle section is L. 22 The height of the second arc segment is L. 23 Then the following condition is met: L21 <L 23 <L 22 35%L2≤L 21 +L 23 ≤40%L2.

[0008] In some embodiments of this application, the radius of the first arc segment is defined as R1, the radius of the middle segment as R2, and the radius of the second arc segment as R3, then the following conditions are met: R2 > R1, R1 = R3.

[0009] In some embodiments of this application, the center of the insulating torsion bar spline is provided with a connecting hole, the connecting hole includes a first hole segment and a second hole segment, the diameter of the first hole segment is smaller than the diameter of the second hole segment, and the sidewall of the first hole segment is provided with a radially protruding spline structure.

[0010] In some embodiments of this application, the depth of the connecting hole is defined as N, then 60%L≤N≤65%L.

[0011] In some embodiments of this application, the height of the first hole segment is defined as N1 and the height of the second hole segment is defined as N2, then 80%N≤N1≤90%N, 10%N≤N2≤20%N.

[0012] In some embodiments of this application, the diameter of the first hole segment is defined as R6 and the diameter of the second hole segment is defined as R7, then the following condition is met: 64%R7≤R6≤70%R7.

[0013] In some embodiments of this application, the diameter of the converging section decreases sequentially from top to bottom.

[0014] In some embodiments of this application, the projection of the insulating torsion bar spline onto the horizontal plane is a circle, and its projection onto the vertical plane is a symmetrical shape.

[0015] Additional aspects and advantages of this application will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of this application. Attached Figure Description

[0016] The present application will be further described below with reference to the accompanying drawings and embodiments, wherein: Figure 1 This is a schematic diagram of the axonal structure of an embodiment of this application; Figure 2 This is a front view of an embodiment of this application; Figure 3 This is a cross-sectional view of an embodiment of this application; Figure 4 This is a cross-sectional view of the insulating torsion bar spline mounted on the insulating post according to an embodiment of this application; Figure 5 Test and inspection reports for existing insulated torsion bars; Figure 6 This is a test report for the insulating torsion bar spline using the insulating torsion bar spline of this embodiment; Figure 7 This is a simulation diagram of the insulating torsion bar using the insulating torsion bar spline of this embodiment; Figure 8 This is a comparative report of torsion tests between existing insulated torsion bars and insulated torsion bars using the insulated torsion bar spline of this embodiment.

[0017] Icon labels: Straight segment 100; Concave segment 200, first arc segment 210, middle segment 220, second arc segment 230; Converging section 300; Bottom section 400; Connecting hole 500, first hole section 510, second hole section 520. Detailed Implementation

[0018] The embodiments of this application are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this application, and should not be construed as limiting this application.

[0019] In the description of this application, it should be understood that the orientation descriptions, such as up, down, etc., are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0020] In the description of this application, "multiple" refers to two or more. The use of "first" and "second" is for the purpose of distinguishing technical features only and should not be construed as indicating or implying relative importance, or implicitly indicating the number of technical features indicated, or the order in which the technical features are indicated.

[0021] In the description of this application, unless otherwise expressly defined, terms such as "setup," "installation," and "connection" should be interpreted broadly, and those skilled in the art can reasonably determine the specific meaning of the above terms in this application in conjunction with the specific content of the technical solution.

[0022] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application. The embodiments of this application may omit unnecessary detailed descriptions. For example, detailed descriptions of well-known matters and repeated descriptions of actually identical structures may be omitted. This is to avoid making the following description unnecessarily lengthy and to facilitate understanding by those skilled in the art.

[0023] In this application, the technical features described in an open-ended manner include both closed technical solutions consisting of the listed features and open technical solutions that include the listed features.

[0024] Reference Figures 1 to 8 This application discloses an insulating torsion bar spline for high-voltage electrical equipment. The spline structure includes four components arranged from top to bottom: a straight section 100, a recessed section 200, a tapered section 300, and a bottom section 400. The maximum diameter of the recessed section 200, the tapered section 300, and the bottom section 400 does not exceed the diameter of the straight section 100, ensuring the overall structural coordination and dimensional consistency.

[0025] Reference Figure 2 As shown, the total height of the insulated torsion bar spline is defined as L, the height of the straight segment 100 is L1, the height of the recessed segment 200 is L2, the height of the tapered segment 300 is L3, and the height of the bottom segment 400 is L4. These heights satisfy the following proportional relationships: 10%L≤L1≤15%L, 38%L≤L2≤43%L, 45%L≤L3≤49%L, and L4≤1%L. The diameter of the straight segment 100 is defined as D, and the maximum depth of the recessed segment 200 is defined as 2%~4%D, ensuring that the depth of the recessed segment 200 is within a reasonable range. The insulated torsion bar spline is made of metal, such as aluminum alloy; the straight segment 100, recessed segment 200, tapered segment 300, and bottom segment 400 are connected as a single structure, enhancing the overall strength and stability.

[0026] The insulating torsion bar spline of this application embodiment effectively improves the torque of the insulating torsion bar by optimizing the shape and size of the insulating torsion bar spline, thereby improving the performance and reliability of the equipment.

[0027] In some embodiments of this application, reference is made to Figure 1 , Figure 2As shown, the concave segment 200 includes a first arc segment 210, a middle segment 220, and a second arc segment 230. The middle segment 220 transitions to the straight segment 100 through the first arc segment 210, and the middle segment 220 transitions to the converging segment 300 through the second arc segment 230. The two ends of the first arc segment 210 are tangent to the straight segment 100 and the middle segment 220, respectively, and the two ends of the second arc segment 230 are tangent to the middle segment 220 and the converging segment 300, respectively, to ensure a smooth transition and reduce stress concentration.

[0028] In some embodiments of this application, reference is made to Figure 2 As shown, the height of the first arc segment 210 is defined as L. 21 The height of the middle section 220 is L. 22 The height of the second arc segment 230 is L. 23 Then it satisfies: L 21 <L 23 <L 22 35%L2≤L21+L 23 ≤40%L2, these proportional relationships optimize the shape and function of the recessed segment 200.

[0029] In some embodiments of this application, reference is made to Figure 2 As shown, the radius of the first arc segment 210 is defined as R1, the radius of the middle segment 220 is defined as R2, and the radius of the second arc segment 230 is defined as R3. Then, the following conditions are met: R2 > R1, R1 = R3. These radius relationships further refine the geometric characteristics of the structure.

[0030] In some embodiments of this application, reference is made to Figure 3 As shown, the insulated torsion bar spline has a connecting hole 500 at its center, which includes a first hole section 510 and a second hole section 520. The diameter of the first hole section 510 is smaller than the diameter of the second hole section 520, and the sidewall of the first hole section 510 has a radially protruding spline structure, which enhances the connection function and mechanical stability.

[0031] In some embodiments of this application, reference is made to Figure 3 As shown, the depth of the connecting hole 500 is defined as N. This depth satisfies the following relationship: 60%L≤N≤65%L, ensuring a reasonable ratio between the depth of the connecting hole 500 and the total height.

[0032] In some embodiments of this application, reference is made to Figure 3 As shown, the height of the first hole segment 510 is defined as N1, and the height of the second hole segment 520 is defined as N2. At this time, these heights satisfy the following relationship: 80%N≤N1≤90%N, and 10%N≤N2≤20%N, thus optimizing the height distribution of the hole segments.

[0033] In some embodiments of this application, reference is made to Figure 3 As shown, the diameter of the first aperture segment 510 is defined as R6, and the diameter of the second aperture segment 520 is defined as R7. At this point, these diameters satisfy the following relationship: 64%R7≤R6≤70%R7, ensuring the reasonableness of the aperture ratio.

[0034] In some embodiments of this application, the diameter of the tapering section 300 decreases sequentially from top to bottom, a design that contributes to stress distribution and overall structural compactness.

[0035] In some embodiments of this application, the projection of the insulating torsion bar spline onto the horizontal plane is circular, and its projection onto the vertical plane is a symmetrical shape. It should be understood that, referring to... Figure 4 As shown, in this embodiment of the application, the insulating torsion bar spline is installed on the insulating post to form an insulating torsion bar. The insulating torsion bar spline is installed at both ends of the insulating post. The insulating post is usually cast from an epoxy resin mixture.

[0036] Specific reference Figure 1 As shown, the outer periphery of the insulated torsion bar spline is generally rounded and symmetrically designed. Specifically, it offers the following advantages: 1. Ensures uniform electric field distribution in the circumferential direction, eliminating the risk of partial discharge; uniform electric field line distribution: the electric field generated by the high-voltage conductor is uniform and consistent in the circumferential direction, avoiding local strong spikes; controllable field strength at the edge of the spline surface: the maximum field strength on the insert surface is concentrated at the rounded corner edge, and the symmetrical design makes this maximum value evenly distributed in the 360° direction, avoiding concentration on one side; simplified insulation design: only radial and axial parameters need to be optimized, without having to consider circumferential non-uniformity, which can greatly reduce design complexity.

[0037] 2. Achieve balanced mechanical load and avoid interface failure; uniform stress transmission: the stress at the interface between the metal spline and epoxy resin is evenly distributed along the circumference, which can avoid local peeling or micro-cracks; coordinated thermal expansion and contraction: the thermal expansion coefficients of aluminum alloy spline and epoxy resin are very different, and the symmetrical structure can make the circumferential thermal stress cancel each other out; vibration resistance: mechanical vibration will be generated during the operation of GIS switch, and the symmetrical structure can avoid fatigue damage caused by eccentric torque.

[0038] 3. Simplified manufacturing process and quality control; Precision machining: Symmetrical splines can be machined in one step on a CNC lathe, ensuring key parameters such as fillet radius and surface roughness; Defect-free casting: During epoxy resin casting, the symmetrical structure ensures uniform resin flow and avoids defects such as air bubbles and insufficient filling; Non-destructive testing: Ultrasonic testing and X-ray inspection can be carried out at any angle without the need for rotation positioning.

[0039] By optimizing the spline design of the insulating torsion bar, its performance and reliability were significantly improved, as was its overall torque-carrying capacity. For details, please refer to [reference needed]. Figure 5 and Figure 6 Compare and analyze the results reports shown: Figure 5 The demonstration shows the performance of existing insulated torsion bars in destructive testing. Their splined sections typically have a traditional cylindrical structure, and the test results show that the ultimate torque is 664.85 N·m. Figure 6 The image shows the test results of the insulated torsion bar spline structure used in this embodiment under the same test conditions. Its destructive test limit torque reached 720.55 N·m. However, it should be noted that this value is limited by the strength limit of the current test fixture itself; the fixture was damaged during the test, therefore the actual limit torque of the insulated torsion bar should be higher than 720.55 N·m. To accurately measure its true limit value, further upgrades and reinforcements to the test fixture are needed. Nevertheless, a direct comparison of existing data clearly shows that the insulated spline torsion bar structure proposed in this embodiment is significantly superior to existing conventional structures in terms of limit torque, achieving a substantial performance improvement.

[0040] In addition, combined Figure 7 The simulation analysis results of the insulated spline torsion bar in this embodiment, and Figure 8 The detailed reports on the existing insulated torsion bar and the insulated torsion bar of this embodiment recorded in the torsion test can more comprehensively show that the new insulated spline not only has better mechanical properties in theory, but also shows excellent torque bearing capacity in actual tests, which fully proves the rationality and advancement of its design.

[0041] Throughout this specification, references to "implementation method," "partial implementation method," "one implementation method," "another method," "specific method," or "partial method" mean that at least one implementation method or embodiment in this application includes the specific features, structures, materials, or characteristics described in that implementation method or embodiment.

[0042] In this application, numerical ranges are involved. Unless otherwise specified, the numerical ranges mentioned above are considered continuous and include the minimum and maximum values ​​of the range, as well as every value between the minimum and maximum values. Any lower limit can be combined with any upper limit to form an unspecified range; and any lower limit can be combined with other lower limits to form an unspecified range, just as any upper limit can be combined with any other upper limit to form an unspecified range. Furthermore, each individually disclosed point or single value can itself serve as a lower or upper limit and be combined with any other point or single value or with other lower or upper limits to form an unspecified range.

[0043] Although illustrative embodiments have been demonstrated and described, those skilled in the art should understand that the above embodiments should not be construed as limiting the present application, and that changes, substitutions and modifications can be made to the embodiments without departing from the spirit, principles and scope of the present application.

Claims

1. An insulated torsion bar spline, characterized in that, include: The structure consists of a straight segment, a recessed segment, a converging segment, and a bottom segment arranged sequentially from top to bottom. The maximum diameter of the recessed segment, the converging segment, and the bottom segment is less than or equal to the diameter of the straight segment. Let L be the total height of the insulated torsion bar spline, L1 be the height of the straight section, L2 be the height of the recessed section, L3 be the height of the converging section, and L4 be the height of the ground section. Then, the following conditions must be met: 10%L≤L1≤15%L, 38%L≤L2≤43%L, 45%L≤L3≤49%L, and L4≤1%L. The diameter of the straight line segment is defined as D, and the maximum depth of the concave segment is 2% to 4%D; The insulated torsion bar spline is made of metal, and the straight section, the recessed section, the tapered section and the bottom section are connected as a single structure.

2. The insulated torsion bar spline according to claim 1, characterized in that, The concave segment includes a first arc segment, a middle segment, and a second arc segment. The middle segment and the straight segment transition through the first arc segment, and the middle segment and the converging segment transition through the second arc segment. The two ends of the first arc segment are tangent to the straight line segment and the middle segment, respectively, and the two ends of the first arc segment are tangent to the middle segment and the converging segment, respectively.

3. The insulated torsion bar spline according to claim 2, characterized in that, Define the height of the first arc segment as L. 21 The height of the middle section is L. 22 The height of the second arc segment is L. 23 Then the following condition is met: L 21 9L 23 9L 22 ;35%L2≤L 21 +L 23 ≤40%L2.

4. The insulated torsion bar spline according to claim 2, characterized in that, Let the radius of the first arc segment be R1, the radius of the middle segment be R2, and the radius of the second arc segment be R3, then the following conditions are met: R2 > R1, R1 = R3.

5. The insulated torsion bar spline according to claim 1, characterized in that, The insulating torsion bar spline has a connecting hole at its center. The connecting hole includes a first hole segment and a second hole segment. The diameter of the first hole segment is smaller than the diameter of the second hole segment. The sidewall of the first hole segment has a radially protruding spline structure.

6. The insulated torsion bar spline according to claim 5, characterized in that, If the depth of the connecting hole is defined as N, then 60%L≤N≤65%L.

7. The insulated torsion bar spline according to claim 5, characterized in that, Define the height of the first hole segment as N1 and the height of the second hole segment as N2, then 80%N≤N1≤90%N, 10%N≤N2≤20%N.

8. The insulated torsion bar spline according to claim 5, characterized in that, If the diameter of the first hole segment is defined as R6 and the diameter of the second hole segment is defined as R7, then the following condition is met: 64%R7≤R6≤70%R7.

9. The insulated torsion bar spline according to claim 1, characterized in that, The diameter of the converging section decreases from top to bottom.

10. The insulated torsion bar spline according to claim 1, characterized in that, The projection of the insulated torsion bar spline onto the horizontal plane is a circle, and its projection onto the vertical plane is a symmetrical figure.

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