CN108645452B - Multi-field coupling insulation aging test device for cable of airplane power supply system - Google Patents
Multi-field coupling insulation aging test device for cable of airplane power supply system Download PDFInfo
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Abstract
A multi-field coupling insulation aging test device for cables of an aircraft power supply system belongs to the technical field of insulation aging life testing of cables of an airborne power supply system. The test device consists of a cable bending stress loader, a thermal stress loading program-controlled high-low temperature alternating test box, a test cable variable clamp, a tensile stress loading device, an insulation resistance measuring instrument, a force sensor, an electric controller and an upper computer PC. The thermal stress loading program-controlled high-low temperature alternating test box is connected with the base bottom plate, the test cable position-changeable clamp is connected with the tensile stress loading device, the cable bending stress loader is tensioned in the thermal stress loading program-controlled high-low temperature alternating test box through the test cable, the insulation resistance measuring instrument is connected with the tensile stress loading device mounting plate, and the test cable position-changeable clamp is respectively connected with the tensile stress loading device mounting plate and the base bottom plate. The method is used for evaluating the insulation life of the wires and cables of the domestic aviation equipment, and further ensures the reliable operation of the airborne power supply system.
Description
Technical Field
The invention relates to a multi-field coupling insulation aging test device for cables of an airplane power supply system, which is used for evaluating the insulation life of wires and cables of domestic aviation equipment so as to ensure the reliable operation of an airborne power supply system and belongs to the technical field of cable insulation aging life test of the airborne power supply system.
Background
With the rapid development of the technical level of modern aviation technology, the whole electrical automation level of the airplane is obviously improved, and various advanced airborne devices are introduced. At present, most advanced airborne equipment adopts an electric energy working mode, and various transmission cables mainly undertake the transmission and control of electric energy among different electric equipment in a power distribution network. As a highly integrated aircraft, various distribution cables with different wire diameters and different lengths are arranged in a narrow space of an aircraft body of the aircraft, and the distribution cables comprise an alternating current power line, a direct current power line, a three-phase power line, a single power line and the like. Because the aviation cable is generally sealed in a narrow fuselage, the working environment is much worse than that of ground industrial equipment, and because the surrounding climatic conditions of the aircraft are very complex and the temperature changes violently in the flying, using and parking processes, the oxidation process of the cable insulation layer is accelerated, and further the expansion of fine cracks of the insulation layer is accelerated under the action of an electric field. On the other hand, due to structural limitations of the aircraft and space limitations of wiring, most of the cables are bundled to form a bundle to pass between the metal framework and the skin in a bending mode, and alternating mechanical stress is applied to the cables due to long-time vibration of the aircraft during flight, so that aging and even breakage of the cable insulation layer are accelerated. The Letromec company engineers have tested one out-of-service Boeing 747, A300, L-1011 and two DC-9 installed cables and the test results show that: l-1011 insulation aging cracks were 13 per 1000m cable, with 1.6 insulation aging cracks in a 1000m cable for a DC-9 aircraft. The L-1011 whole machine has about 240km of cables, and the total number of cracks exceeds 3000. The United states transport safety Commission (NTSB) concluded in 1996 that a major cause of 800 crash accidents in the world Wide Web airlines was the explosion of the fuel tanks in their central wings due to short-circuit sparks from the wires. The American military carries out all-around inspection on the P-3C anti-submarine aircraft cable in service, and finds that the cable has serious aging phenomenon and serious potential danger. According to the statistical data of China, cable faults occur in 10A 320 airplanes which are used for handling in the southern aviation Shenzhen maintenance factory in 2002 for many times, and therefore, the airplane is arranged to be stopped for maintenance and replaced for tens of times, and normal flight operation is influenced. Therefore, the gradual aging and even damage of the insulation material of the cable is a great risk threatening the flight safety of the airplane.
The evaluation of an aviation cable service life model and the research of a service life prediction method need to be based on aging failure data, a domestic wire and cable applied to an existing aircraft power supply system lacks of an effective service life prediction means, even a small number of test devices are mainly limited to cable aging tests under a single influence factor, and the aging process of the wire and cable in a power distribution network of the aircraft power supply system under an actual working condition environment cannot be objectively and comprehensively reflected. The aviation cable insulation aging process is not a single effect of a certain influence factor but a result under the influence of multiple factors, but the influence factors are not equal, wherein the key factor plays a leading role in the service life of the aviation cable, and other factors play synergistic roles. Therefore, based on the similarity principle, the experimental environment matched with the actual aging process of the cable is established, the reasonable representation of the aging life of the aviation wire and cable is realized, and the method is an important research task.
Aiming at the aging test requirements under the multi-field coupling synergistic effect of the wires and the cables of the airplane power supply system, the invention establishes an aging test environment simulating the multi-physical field coupling of heat, machinery and an electric field under the assumed condition according with engineering practice, thereby reducing the deviation of single factor to the aging life evaluation, leading the evaluation result of the insulation aging test to be closer to the actual aging life of the cables and ensuring the reliability of the actual work of the wires and the cables of the airborne power supply system.
Disclosure of Invention
The invention aims to provide a reliable test means for cable service life prediction so as to ensure the working reliability of wires and cables of domestic aviation equipment in a complex coupling stress field, and provides a multi-field coupling insulation aging test device for cables of an aircraft power supply system.
The purpose of the invention is realized by the following technical scheme:
a multi-field coupling insulation aging test device for cables of an aircraft power supply system mainly comprises a cable bending stress loader, a thermal stress loading program-controlled high-low temperature alternating test box, a test cable position-changeable clamp, a tensile stress loading device, an insulation resistance measuring instrument, a force sensor, an electric controller and an upper computer PC.
The test cable is a tested piece of the test device;
the cable bending stress loader comprises: the device comprises a lock nut, an end rubber plug, a cable hole rubber plug and a simulated airplane skin metal tube;
a simulated aircraft skin metal tube in the cable bending stress loader is a hollow cylinder, a group of through holes with a certain interval are formed along a central symmetry plane, and the interval of the through holes is determined according to the minimum bending radius of a test cable; the end rubber plug is of a stepped shaft type structure, a through hole is formed in the position along the axis, the size of the through hole is determined according to the line diameter of the test cable, and the diameter of the through hole is slightly larger than that of the test cable in principle; the size of a small end journal of the end rubber plug is matched with the inner hole of the simulated airplane skin metal tube, and the size of a large end journal is consistent with the outer diameter of the simulated airplane skin metal tube; processing threads at two ends of a simulated airplane skin metal pipe;
the test cable variable position clamp comprises: the tension end sliding lower pressing plate mounting block, the upper pressing plate, the sliding lower pressing plate and the fixed end sliding lower pressing plate mounting block;
the tensile stress loading device comprises: the device comprises a stepping motor, an installation transfer block, a first bearing seat, a second bearing seat, a trapezoidal lead screw nut pair, a guide circular guide rail, a linear bearing, an installation plate, a force sensor support, a fixed end support and a base bottom plate;
the first bearing seat and the second bearing seat have the same functions and play a supporting role, but have different internal structures, the first bearing seat is an angular contact ball bearing, and the second bearing seat is a deep groove ball bearing;
the test cable position-changeable clamp is of a standard modular structure from top to bottom, the test cable position-changeable clamp corresponds to two groups of the force measuring end and the fixed end, and the two groups of corresponding upper pressing plates and the sliding lower pressing plate are consistent; the force measuring end groups in the two groups of test cable position-variable clamps are tension end sliding lower pressure plate mounting blocks which are fixedly connected with the force measuring ends of the force sensors; the fixed end group is formed by fixedly connecting a fixed end sliding lower pressure plate mounting block with a base bottom plate through a fixed end bracket; the tension end sliding lower press plate mounting block and the fixed end sliding lower press plate mounting block are both of rectangular groove structures, and two threaded holes are machined in the side surface of one end close to the test cable along the length direction; the upper pressing plate is a rectangular cube, a group of semicircular through holes are uniformly distributed in the length direction, the semicircular through holes penetrate through the upper pressing plate along the width direction, the lower boundary of each semicircular through hole is overlapped with the ground of the upper pressing plate, the radius of each group of semicircular through holes is slightly smaller than the diameter of a test cable specification line, and countersunk holes are symmetrically machined in two sides of each semicircular through hole; the sliding lower pressing plate is a rectangular cube with an inverted T-shaped cross section, the length of the sliding lower pressing plate is consistent with that of the upper pressing plate, the width of the upper end of the sliding lower pressing plate is consistent with that of the upper pressing plate, and the width of the lower end of the sliding lower pressing plate is in a certain proportional relation with that of the upper pressing plate and is larger than that of the upper pressing plate;
the connection relation of all modules in the multi-field coupling insulation aging test device for the cable of the airplane power supply system is as follows:
the thermal stress loading program-controlled high-low temperature alternating test box is connected with the base bottom plate, the test cable position-changeable clamp is connected with the tensile stress loading device, the cable bending stress loader is tensioned in the thermal stress loading program-controlled high-low temperature alternating test box through the test cable, the insulation resistance measuring instrument is connected with the tensile stress loading device mounting plate, the tensile end of the test cable position-changeable clamp is connected with the tensile stress loading device mounting plate through the tensile end sliding lower pressing plate mounting block, and the fixed end of the test cable position-changeable clamp is connected with the base bottom plate through the fixed end sliding lower pressing plate mounting block.
The connection relation of each module in the cable bending stress loader is as follows: the cable hole rubber plug is connected with the test cable, the end rubber plug is connected with the simulated airplane skin metal tube, the simulated airplane skin metal tube is connected with the lock nut, and the lock nut is connected with the end rubber plug;
the connection relationship of each module in the test cable displaceable clamp is as follows: the sliding lower pressing plate is connected with the upper pressing plate, and the test cable is respectively connected with the upper pressing plate and the sliding lower pressing plate; the upper pressing plate and the positioning holes at the two sides of the sliding lower pressing plate are respectively connected with the pulling force end sliding lower pressing plate mounting block and the fixed end sliding lower pressing plate mounting block;
the connection mode of each module in the tensile stress loading device is as follows: the mounting plate is connected with the trapezoidal screw nut pair and the linear bearing; the force sensor is connected with the force sensor bracket and the mounting plate; the output end of the stepping motor is connected with the trapezoidal screw nut pair; the guide round guide rail is connected with the base bottom plate; the linear bearing is movably connected with the guide circular guide rail.
The installation and the working process of the cable bending stress loader are as follows:
cable hole rubber plugs are fixedly arranged at a group of through holes which are arranged along the central symmetry plane at certain intervals in the cable bending stress loader, so that the test cable is prevented from being mechanically abraded at the bending part of the through holes under the action of tensile stress; the test cable penetrates from the inside of one side of the hollow cylinder, penetrates out from one side of the first through hole, penetrates through one side of the second through hole and penetrates out from the other side of the hollow cylinder, and the process is repeated until the test cable penetrates from one side of the last through hole and then penetrates out from the inside of the hollow cylinder; the size of a small end journal of the end rubber plug is matched with the inner hole of the simulated airplane skin metal tube, and the size of a large end journal is consistent with the outer diameter of the simulated airplane skin metal tube; threads processed at two ends of the simulated aircraft skin metal pipe are connected with a lock nut, a test cable penetrates out of a central through hole of the lock nut, and the size of the central through hole is slightly larger than that of the test cable; along with the gradual tightening of the lock nut, the lock nut extrudes the end rubber plug, the central through hole of the end rubber plug is compressed along the radial direction to deform and shrink, the test cable is clamped and positioned, and the effect of fixing the wire harness of the test cable in the airplane skin is simulated.
The test cable displaceable clamp is installed as follows:
the upper end of the sliding lower pressing plate is matched with the upper pressing plate, a threaded hole matched with the upper pressing plate is processed corresponding to the position of the countersunk hole of the upper pressing plate, and semicircular through holes with consistent size in the processing direction are processed corresponding to the position of the semicircular through hole of the upper pressing plate; the test cable passes through the semicircular through hole of the sliding lower pressing plate with the corresponding size, the contact position of the test cable and the semicircular through hole of the sliding lower pressing plate is sleeved with a heat-shrinkable tube with the corresponding size for protection, the upper pressing plate and the sliding lower pressing plate are connected and fastened through threads, and the upper pressing plate and the sliding lower pressing plate clamp and fix two ends of the test cable; the center of a through hole formed by matching the upper pressing plate and the sliding lower pressing plate is consistent with the force measuring axis of the force sensor and the axis of the test cable; positioning holes are symmetrically processed on the side surface of the lower end of the sliding lower pressing plate close to the test cable corresponding to the two sides of the semicircular through hole; the tension end sliding lower pressing plate mounting block and the fixed end sliding lower pressing plate mounting block are both of rectangular groove structures, two threaded holes are machined in the side face of one end, close to the test cable, of the test cable along the length direction, and the lower end of the sliding lower pressing plate can slide in the rectangular groove; and determining the integral positioning position of the combined upper pressing plate and the combined sliding lower pressing plate according to the diameter of the test cable, coinciding the positioning holes on two sides of the center of the through hole formed by matching the upper pressing plate and the sliding lower pressing plate with the threaded holes of the mounting block of the sliding lower pressing plate at the pulling end and the mounting block of the sliding lower pressing plate at the fixed end, and then positioning and fixing the positioning holes through the set screws.
The installation process of the tensile stress loading device is as follows: the mounting plate is fixedly connected with the lead screw nut and the linear bearing so as to realize the movement along the guide direction of the linear bearing under the traction of the trapezoidal lead screw nut pair; the force sensor is fixedly installed on the mounting plate through the force sensor support, the upper computer PC outputs a control command to the electric controller according to the tensile stress required by the insulation aging test, a stepping motor driver in the electric controller controls the stepping motor to rotate, a stepping motor output shaft drives the screw nut pair through a coupler, the mounting plate moves along the tensile stress direction of the test cable under the traction of the trapezoid screw nut pair, the force sensor measures the axial tension force applied to the test cable and feeds the axial tension force back to the upper computer PC, when the specified test force value is reached, the stepping motor stops rotating, and the trapezoid screw nut pair realizes positioning and holding by means of the self-locking characteristic.
The multi-field coupling insulation aging test device for the cable of the airplane power supply system can provide stress environments of three coupling fields of mechanical stress, thermal stress and electric field at the same time; the mechanical stress comprises tensile stress and bending stress, the tensile stress is generated by a tensile stress loading device, and the bending stress is generated by a cable bending stress loader; the thermal stress is generated by a thermal stress loading program-controlled high-low temperature alternating test box; the electric field is generated by a high-voltage power supply inside the insulation resistance measuring instrument;
one end of the test cable is fixed on the fixed end support through the test cable variable position clamp, the other end of the test cable penetrates through the cable bending stress loader, the cable bending stress loader penetrates into a silicon corundum heating tube inside the thermal stress loading program-controlled high-low temperature alternating test box to be heated, the insulation aging test temperature is the direct measurement quantity of a temperature measurement sensor inside the thermal stress loading program-controlled high-low temperature alternating test box, and the temperature rise process of the thermal stress loading program-controlled high-low temperature alternating test box is directly controlled and real-time temperature is collected through an upper computer PC. One end of the test cable output heating pipe is fixed at the force measuring end of the force sensor through a test cable variable position clamp, and the tensile stress borne by the test cable in the insulation aging test process is measured; the insulation resistance measuring instrument is internally provided with a high-voltage power supply, a positive electrode test wire is connected to a metal conductor inside a test cable at one end of the test cable near the force sensor, and a negative electrode test wire is connected to an insulation surface skin at the fixed end of the test cable; the test voltage output of the insulation resistance measuring instrument is controlled by an upper computer PC, and the insulation resistance value between the conductor and the insulation surface skin of the measured test cable in the coupling stress environment is collected in real time; when the insulation resistance value is reduced to a certain value, the aging failure of the test cable is indicated.
The function of each module of the test device is as follows:
the cable bending stress loader has the function of simulating the working condition environment that the test cable is paved in the airplane skin; the test cable position-variable clamp has the functions of being compatible with the positioning and clamping requirements of test cables with different wire diameters and expanding the applicability of the test device; the force sensor is used for measuring the axial tension borne by the test cable and feeding the axial tension back to the PC (personal computer), when the specified test force value is reached, the stepping motor is controlled by the electric controller to stop rotating, and the lead screw nut pair realizes positioning and holding by means of self-locking property; the electric controller is used for controlling the stepping motor to rotate through a stepping motor driver inside the electric controller; the PC of the upper computer has the function of collecting and storing the data of the whole-life insulation aging test of the test cable in the coupling stress environment.
Advantageous effects
The utility model provides an insulating aging test device of aircraft power supply system cable multi-field coupling, compares with current insulating aging test device, has following beneficial effect:
1. aiming at the defect that the existing domestic aviation equipment wire and cable lack effective service life prediction test means, the invention establishes an insulation aging test device with thermal, mechanical, electric field and other physical coupling based on the similarity principle so as to reduce the deviation of single factors to aging life evaluation in the existing aging test process and enable the evaluation result of the insulation aging test to be closer to the actual aging life of the cable;
2. according to the cable bending stress loader disclosed by the invention, the influence of bending stress on the insulation aging of the test cable is introduced, the effects of paving the test cable in an airplane skin and fixing a wire harness are simulated, and the accuracy of an insulation aging test result is improved;
3. the test cable position-changeable clamp can meet the requirement of insulation aging tests of test cables with various wire diameters in one-time installation, and meanwhile, the clamp structure ensures that the axis of the test cable is unified with the reference of the force measuring axis of the force sensor.
Drawings
FIG. 1 is a schematic structural diagram of a multi-field coupling insulation aging test device for cables of an aircraft power supply system according to the present invention;
FIG. 2 is a schematic structural diagram of a test cable variable position clamp in the multi-field coupling insulation aging test device for cables of an aircraft power supply system according to the present invention;
FIG. 3 is a test cable harness bending stress loader of the test cable transposable clamp of the present invention;
wherein, 1, a stepping motor; 2, installing a transfer block; 3-a first bearing block; 4-trapezoidal screw nut pair; 5, guiding a round guide rail; 6-linear bearing; 7, mounting a plate; 8-force sensor support; 9-a force sensor; 10, sliding a lower pressure plate mounting block at a tension end; 11-an upper platen; 12-sliding the lower platen; 13 — a second bearing block; 14-test cable; 15-fixed end sliding lower press plate mounting block; 16-fixed end bracket; 17-base floor; 18-thermal stress loading program control type high and low temperature alternating test box; 19-insulation resistance measuring instrument; 20-a lock nut; 21-end rubber plug; 22-cable hole rubber plug; 23-simulating an aircraft skin metal pipe; 24-an electrical controller; 25-upper computer PC.
Detailed Description
The invention is further illustrated with reference to the following figures and examples.
Example 1
The embodiment illustrates a specific implementation of the multi-field coupling insulation aging test device for the cable of the aircraft power supply system.
FIG. 1 is a schematic structural diagram of a multi-field coupling insulation aging test device for cables of an aircraft power supply system according to the present invention;
as can be seen from figure 1, the multi-field coupling insulation aging test device for the cable of the aircraft power supply system mainly comprises a lock nut (20), an end rubber plug (21), a cable hole rubber plug (22), a simulated aircraft skin metal tube (23), a thermal stress loading program-controlled high-low temperature alternating test box (18), a tension end sliding lower pressing plate mounting block (10), an upper pressing plate (11), a sliding lower pressing plate (12), a fixed end sliding lower pressing plate mounting block (15), a stepping motor (1), a mounting adapter block (2) and a first bearing seat (3), the device comprises a second bearing seat (13), a trapezoidal screw nut pair (4), a guide circular guide rail (5), a linear bearing (6), a mounting plate (7), a force sensor support (8), a fixed end support (16), a base bottom plate (17), an insulation resistance measuring instrument (19), a force sensor (9), an electric controller (24) and an upper computer PC (25).
FIG. 2 is a schematic structural diagram of a test cable variable position clamp in the multi-field coupling insulation aging test device for cables of an aircraft power supply system according to the present invention;
as can be seen from figure 2, the test cable displaceable clamp mainly comprises a tension end sliding lower pressure plate mounting block (10), an upper pressure plate (11), a sliding lower pressure plate (12), a fixed end sliding lower pressure plate mounting block (15), a force sensor (9) and a test cable (14);
FIG. 3 is a test cable harness bending stress loader of the test cable transposable clamp of the present invention;
as can be seen from fig. 3, the bending stress loader for the test cable harness consists of a test cable (14), a lock nut (20), an end rubber plug (21), a cable hole rubber plug (22) and a simulated airplane skin metal tube (23);
the cable bending stress loader mainly simulates a working condition environment that a test cable is paved in an airplane skin, wherein a metal pipe for simulating the airplane skin is a hollow cylinder, a group of through holes with a certain interval are formed along a central symmetry plane, and the interval of the through holes is determined according to the minimum bending radius of the test cable. The through hole is fixedly provided with a cable hole rubber plug to avoid mechanical abrasion of the test cable at the bending part of the through hole under the action of tensile stress. The test cable penetrates from the inside of one side of the hollow cylinder, penetrates out from one side of the first through hole, penetrates through from one side of the second through hole and penetrates out from the other side of the hollow cylinder, and the process is repeated until the test cable penetrates from one side of the last through hole and then penetrates out from the inside of the hollow cylinder. The end rubber plug is of a stepped shaft type structure, a through hole is formed in the position along the axis, the size of the through hole is determined according to the diameter of the test cable, the outer diameter of the test cable is 5mm, the diameter of the through hole is slightly larger than that of the test cable in principle, therefore, the diameter of the through hole is determined to be 5.5mm, the size of a small-end journal of the end rubber plug is matched with the inner hole of the aircraft skin metal pipe, and the size of a large-end journal is consistent with the outer diameter of the. The threads are machined at two ends of the aircraft skin metal pipe and connected with the lock nut, the test cable penetrates out of a center through hole of the lock nut, and the size of the center through hole is 7 mm. Along with the gradual tightening of the lock nut, the lock nut extrudes the end rubber plug, the central through hole of the end rubber plug is compressed along the radial direction to deform and shrink, the test cable is tightened and positioned, and the effect of fixing the wire harness of the test cable in the airplane skin is simulated.
The test cable position-variable clamp is of a top-down standard modular structure, is mainly compatible with the positioning and clamping requirements of test cables with different wire diameters, and enlarges the applicability of the test device. The test cable position-changeable clamp corresponds the dynamometry end and the stiff end two sets ofly, only is different from among the two sets of test cable position-changeable clamps pulling force end slip holding down plate installation piece and force transducer dynamometry end fixed connection, stiff end slip holding down plate installation piece through stiff end support and base bottom plate fixed connection, corresponds the top board and slides the holding down plate and all unanimous. The top board is rectangular shape cube, a set of semicircle through-hole of length direction equipartition, and the aperture is 2.8mm, 4.8mm, 6.8mm, 9.8mm respectively, and the semicircle through-hole runs through along width direction, and semicircle through-hole lower boundary and top board ground coincidence, semicircle through-hole bilateral symmetry processing counter sink. The sliding lower pressing plate is a rectangular cube with an inverted T-shaped cross section, the length of the sliding lower pressing plate is consistent with that of the upper pressing plate, the width of the upper end of the sliding lower pressing plate is consistent with that of the upper pressing plate, and the width of the lower end of the sliding lower pressing plate is in a certain proportional relation with that of the upper pressing plate and is larger than that of the upper pressing plate. The upper end of the sliding lower pressing plate is matched with the upper pressing plate, a threaded hole matched with the upper pressing plate is processed corresponding to the position of the countersunk hole of the upper pressing plate, and semicircular through holes with consistent size in the processing direction are processed corresponding to the position of the semicircular through hole of the upper pressing plate. The test cable passes through the semicircular through hole of the sliding lower pressing plate with the corresponding size, the contact position of the test cable and the semicircular through hole of the sliding lower pressing plate is sleeved with the heat-shrinkable tube with the corresponding size for protection, the upper pressing plate and the sliding lower pressing plate are fastened through threaded connection, and the upper pressing plate and the sliding lower pressing plate clamp and fix two ends of the test cable. The center of a through hole (the corresponding hole diameter of the embodiment is 4.8mm) formed by matching the upper pressing plate and the sliding lower pressing plate is consistent with the force measuring axis of the force sensor and the axis of the test cable. Positioning holes are symmetrically processed on the side surface of the lower end of the sliding lower pressing plate close to the test cable corresponding to the two sides of the semicircular through hole. The tension end sliding lower pressing plate mounting block and the fixed end sliding lower pressing plate mounting block are both of rectangular groove structures, two threaded holes are machined in the side face of one end of the near-test cable along the length direction, and the lower end of the sliding lower pressing plate can slide in the rectangular groove. And determining the integral positioning position of the combined upper pressing plate and the combined sliding lower pressing plate according to the diameter of the test cable, coinciding the positioning holes on two sides of the center of the through hole formed by matching the upper pressing plate and the sliding lower pressing plate with the threaded holes of the mounting block of the sliding lower pressing plate at the pulling end and the mounting block of the sliding lower pressing plate at the fixed end, and then positioning and fixing the positioning holes through the set screws.
The mounting plate in the tensile stress loading device is fixedly connected with the lead screw nut and the linear bearing so as to move along the guide direction of the linear bearing under the traction of the trapezoidal lead screw nut pair. The force sensor is fixedly installed on the mounting plate through the force sensor support, the upper computer PC outputs a control command to the electric controller according to the tensile stress required by the insulation aging test, a stepping motor driver in the electric controller controls the stepping motor to rotate, a stepping motor output shaft drives the screw nut pair through a coupler, the mounting plate moves along the tensile stress direction of the test cable under the traction of the trapezoid screw nut pair, the force sensor measures the axial tension force applied to the test cable and feeds the axial tension force back to the upper computer PC, when the specified test force value is reached, the stepping motor stops rotating, and the trapezoid screw nut pair realizes positioning and holding by means of the self-locking characteristic.
The multi-field coupling insulation aging test device for the cable of the airplane power supply system can provide stress environments of three coupling fields of mechanical stress, thermal stress and electric field at the same time, wherein the mechanical stress comprises tensile stress and bending stress, the tensile stress is generated by a tensile stress loading device, and the bending stress is generated by a cable bending stress loading device; the thermal stress is generated by a thermal stress loading program-controlled high-low temperature alternating test box; the electric field is generated by a high-voltage power supply inside the insulation resistance measuring instrument. One end of the test cable is fixed on the fixed end support through the test cable variable position clamp, the other end of the test cable penetrates through the cable bending stress loader, the cable bending stress loader penetrates into a silicon corundum heating tube inside the thermal stress loading program-controlled high-low temperature alternating test box to be heated, the insulation aging test temperature is the direct measurement quantity of a temperature measurement sensor inside the thermal stress loading program-controlled high-low temperature alternating test box, and the temperature rise process of the thermal stress loading program-controlled high-low temperature alternating test box is directly controlled and real-time temperature is collected through an upper computer PC. One end of the test cable output heating pipe is fixed at the force measuring end of the force sensor through the test cable position-variable clamp, and the tensile stress borne by the test cable in the insulation aging test process is measured. The insulation resistance measuring instrument is internally provided with a high-voltage power supply, a positive electrode testing wire is connected to a metal conductor inside a testing cable at one end of the testing cable near the force sensor, and a negative electrode testing wire is connected to an insulation surface skin at the fixed end of the testing cable. The test voltage output of the insulation resistance measuring instrument is controlled by an upper computer PC, and the insulation resistance value between the conductor and the insulation surface skin of the measured test cable in the coupling stress environment is collected in real time. When the insulation resistance value is reduced to a certain resistance value, the aging failure of the test cable is indicated, and the upper computer PC collects and stores the insulation aging test data of the test cable in the coupling stress environment. The measurement and control precision of the coupling stress field is shown in the table 1, and the insulation aging test data is shown in the table 2.
TABLE 1 measurement and control accuracy of coupled stress field
TABLE 2 test data for cable insulation aging test
The insulation aging test device is based on the similarity principle, and is characterized in that the insulation aging test device is established through coupling of multiple physical properties such as heat, machinery and electric fields, so that the deviation of single factors to aging life evaluation in the existing aging test process is reduced, and the aging test result shows that the test device reliably and accurately simulates the actual working condition environment of the test cable in the aviation equipment, so that the evaluation result of the insulation aging test is closer to the actual aging life of the cable.
While the foregoing is directed to the preferred embodiment of the present invention, it is not intended that the invention be limited to the embodiment and the drawings disclosed herein. Equivalents and modifications may be made without departing from the spirit of the disclosure, which is to be considered as within the scope of the invention.
Claims (7)
1. The utility model provides an insulating aging test device of aircraft power supply system cable multi-field coupling which characterized in that: the test device mainly comprises a cable bending stress loader, a thermal stress loading program-controlled high-low temperature alternating test box, a test cable variable clamp, a tensile stress loading device, an insulation resistance measuring instrument, a force sensor, an electric controller and an upper computer PC;
the test cable is a tested piece of the test device;
a simulated aircraft skin metal tube in the cable bending stress loader is a hollow cylinder, a group of through holes with a certain interval are formed along a central symmetry plane, and the interval of the through holes is determined according to the minimum bending radius of a test cable; the end rubber plug is of a stepped shaft type structure, a through hole is formed in the position along the axis, the size of the through hole is determined according to the line diameter of the test cable, and the diameter of the through hole is slightly larger than that of the test cable; the size of a small end journal of the end rubber plug is matched with the inner hole of the simulated airplane skin metal tube, and the size of a large end journal is consistent with the outer diameter of the simulated airplane skin metal tube; processing threads at two ends of a simulated airplane skin metal pipe;
the tensile stress loading device comprises: the device comprises a stepping motor, an installation transfer block, a first bearing seat, a second bearing seat, a trapezoidal lead screw nut pair, a guide circular guide rail, a linear bearing, an installation plate, a force sensor support, a fixed end support and a base bottom plate;
the first bearing seat and the second bearing seat have the same functions and play a supporting role, but have different internal structures, the first bearing seat is an angular contact ball bearing, and the second bearing seat is a deep groove ball bearing;
the test cable position-changeable clamp is of a standard modular structure from top to bottom, the test cable position-changeable clamp corresponds to two groups of the force measuring end and the fixed end, and the two groups of corresponding upper pressing plates and the sliding lower pressing plate are consistent; the force measuring end groups in the two groups of test cable position-variable clamps are tension end sliding lower pressure plate mounting blocks which are fixedly connected with the force measuring ends of the force sensors; the fixed end group is formed by fixedly connecting a fixed end sliding lower pressure plate mounting block with a base bottom plate through a fixed end bracket; the tension end sliding lower press plate mounting block and the fixed end sliding lower press plate mounting block are both of rectangular groove structures, and two threaded holes are machined in the side surface of one end close to the test cable along the length direction; the upper pressing plate is a rectangular cube, a group of semicircular through holes are uniformly distributed in the length direction, the semicircular through holes penetrate through the upper pressing plate along the width direction, the lower boundary of each semicircular through hole is overlapped with the ground of the upper pressing plate, the radius of each group of semicircular through holes is slightly smaller than the diameter of a test cable specification line, and countersunk holes are symmetrically machined in two sides of each semicircular through hole; the sliding lower pressing plate is a rectangular cube with an inverted T-shaped cross section, the length of the sliding lower pressing plate is consistent with that of the upper pressing plate, the width of the upper end of the sliding lower pressing plate is consistent with that of the upper pressing plate, and the width of the lower end of the sliding lower pressing plate is in a certain proportional relation with that of the upper pressing plate and is larger than that of the upper pressing plate;
the connection relation of all modules in the multi-field coupling insulation aging test device for the cable of the airplane power supply system is as follows:
the thermal stress loading program-controlled high-low temperature alternating test box is connected with a base bottom plate, the test cable variable position clamp is connected with a tensile stress loading device, the cable bending stress loader is tensioned in the thermal stress loading program-controlled high-low temperature alternating test box by a test cable, the insulation resistance measuring instrument is connected with a tensile stress loading device mounting plate, the tensile end of the test cable variable position clamp slides the lower pressing plate mounting block through the tensile end to be connected with the tensile stress loading device mounting plate, and the fixed end of the test cable variable position clamp slides the lower pressing plate mounting block through the fixed end to be connected with the base bottom plate;
the connection relation of each module in the cable bending stress loader is as follows: the cable hole rubber plug is connected with the test cable, the end rubber plug is connected with the simulated airplane skin metal tube, the simulated airplane skin metal tube is connected with the lock nut, and the lock nut is connected with the end rubber plug;
the connection relationship of each module in the test cable displaceable clamp is as follows: the sliding lower pressing plate is connected with the upper pressing plate, and the test cable is respectively connected with the upper pressing plate and the sliding lower pressing plate; the upper pressing plate and the positioning holes at the two sides of the sliding lower pressing plate are respectively connected with the pulling force end sliding lower pressing plate mounting block and the fixed end sliding lower pressing plate mounting block;
the connection mode of each module in the tensile stress loading device is as follows: the mounting plate is connected with the trapezoidal screw nut pair and the linear bearing; the force sensor is connected with the force sensor bracket and the mounting plate; the output end of the stepping motor is connected with the trapezoidal screw nut pair; the guide round guide rail is connected with the base bottom plate; the linear bearing is movably connected with the guide circular guide rail;
the function of each module of the test device is as follows:
the cable bending stress loader has the function of simulating the working condition environment that the test cable is paved in the airplane skin; the test cable position-variable clamp has the functions of being compatible with the positioning and clamping requirements of test cables with different wire diameters and expanding the applicability of the test device; the force sensor is used for measuring the axial tension borne by the test cable and feeding the axial tension back to the PC (personal computer), when the specified test force value is reached, the stepping motor is controlled by the electric controller to stop rotating, and the lead screw nut pair realizes positioning and holding by means of self-locking property; the electric controller is used for controlling the stepping motor to rotate through a stepping motor driver inside the electric controller; the PC of the upper computer has the function of collecting and storing the data of the whole-life insulation aging test of the test cable in the coupling stress environment.
2. The aircraft power supply system cable multi-field coupling insulation aging test device of claim 1, characterized in that: the cable bending stress loader comprises: lock nut, tip rubber buffer, cable hole rubber buffer and simulation aircraft skin metal tube.
3. The aircraft power supply system cable multi-field coupling insulation aging test device of claim 1, characterized in that: the test cable variable position clamp comprises: the tension end sliding lower press plate mounting block, the upper press plate, the sliding lower press plate and the fixed end sliding lower press plate mounting block.
4. The aircraft power supply system cable multi-field coupling insulation aging test device of claim 1, characterized in that: the multi-field coupling insulation aging test device for the cable of the airplane power supply system can provide stress environments of three coupling fields of mechanical stress, thermal stress and electric field at the same time; the mechanical stress comprises tensile stress and bending stress, the tensile stress is generated by a tensile stress loading device, and the bending stress is generated by a cable bending stress loader; the thermal stress is generated by a thermal stress loading program-controlled high-low temperature alternating test box; the electric field is generated by a high-voltage power supply inside the insulation resistance measuring instrument;
one end of a test cable is fixed on the fixed end support through a test cable variable position clamp, the other end of the test cable penetrates through a cable bending stress loader, the cable bending stress loader penetrates through a silicon corundum heating tube inside a thermal stress loading program-controlled high-low temperature alternating test box to be heated, the insulation aging test temperature is the direct measurement quantity of a temperature measurement sensor inside the thermal stress loading program-controlled high-low temperature alternating test box, and the temperature rise process of the thermal stress loading program-controlled high-low temperature alternating test box is directly controlled and real-time temperature is collected through an upper computer PC; one end of the test cable output heating pipe is fixed at the force measuring end of the force sensor through a test cable variable position clamp, and the tensile stress borne by the test cable in the insulation aging test process is measured; the insulation resistance measuring instrument is internally provided with a high-voltage power supply, a positive electrode test wire is connected to a metal conductor inside a test cable at one end of the test cable near the force sensor, and a negative electrode test wire is connected to an insulation surface skin at the fixed end of the test cable; the test voltage output of the insulation resistance measuring instrument is controlled by an upper computer PC, and the insulation resistance value between the conductor and the insulation surface skin of the measured test cable in the coupling stress environment is collected in real time; when the insulation resistance value is reduced to a certain value, the aging failure of the test cable is indicated.
5. The aircraft power supply system cable multi-field coupling insulation aging test device of claim 1, characterized in that: the installation and the working process of the cable bending stress loader are as follows: cable hole rubber plugs are fixedly arranged at a group of through holes which are arranged along the central symmetry plane at certain intervals in the cable bending stress loader, so that the test cable is prevented from being mechanically abraded at the bending part of the through holes under the action of tensile stress; the test cable penetrates from the inside of one side of the hollow cylinder, penetrates out from one side of the first through hole, penetrates through one side of the second through hole and penetrates out from the other side of the hollow cylinder, and the process is repeated until the test cable penetrates from one side of the last through hole and then penetrates out from the inside of the hollow cylinder; the size of a small end journal of the end rubber plug is matched with the inner hole of the simulated airplane skin metal tube, and the size of a large end journal is consistent with the outer diameter of the simulated airplane skin metal tube; threads processed at two ends of the simulated aircraft skin metal pipe are connected with a lock nut, a test cable penetrates out of a central through hole of the lock nut, and the size of the central through hole is slightly larger than that of the test cable; along with the gradual tightening of the lock nut, the lock nut extrudes the end rubber plug, the central through hole of the end rubber plug is compressed along the radial direction to deform and shrink, the test cable is clamped and positioned, and the effect of fixing the wire harness of the test cable in the airplane skin is simulated.
6. The aircraft power supply system cable multi-field coupling insulation aging test device of claim 1, characterized in that: the test cable displaceable clamp is installed as follows:
the upper end of the sliding lower pressing plate is matched with the upper pressing plate, a threaded hole matched with the upper pressing plate is processed corresponding to the position of the countersunk hole of the upper pressing plate, and semicircular through holes with consistent size in the processing direction are processed corresponding to the position of the semicircular through hole of the upper pressing plate; the test cable passes through the semicircular through hole of the sliding lower pressing plate with the corresponding size, the contact position of the test cable and the semicircular through hole of the sliding lower pressing plate is sleeved with a heat-shrinkable tube with the corresponding size for protection, the upper pressing plate and the sliding lower pressing plate are connected and fastened through threads, and the upper pressing plate and the sliding lower pressing plate clamp and fix two ends of the test cable; the center of a through hole formed by matching the upper pressing plate and the sliding lower pressing plate is consistent with the force measuring axis of the force sensor and the axis of the test cable; positioning holes are symmetrically processed on the side surface of the lower end of the sliding lower pressing plate close to the test cable corresponding to the two sides of the semicircular through hole; the tension end sliding lower pressing plate mounting block and the fixed end sliding lower pressing plate mounting block are both of rectangular groove structures, two threaded holes are machined in the side face of one end, close to the test cable, of the test cable along the length direction, and the lower end of the sliding lower pressing plate can slide in the rectangular groove; and determining the integral positioning position of the combined upper pressing plate and the combined sliding lower pressing plate according to the diameter of the test cable, coinciding the positioning holes on two sides of the center of the through hole formed by matching the upper pressing plate and the sliding lower pressing plate with the threaded holes of the mounting block of the sliding lower pressing plate at the pulling end and the mounting block of the sliding lower pressing plate at the fixed end, and then positioning and fixing the positioning holes through the set screws.
7. The aircraft power supply system cable multi-field coupling insulation aging test device of claim 1, characterized in that: the installation process of the tensile stress loading device is as follows: the mounting plate is fixedly connected with the trapezoidal screw nut pair and the linear bearing so as to realize the movement along the guide direction of the linear bearing under the traction of the trapezoidal screw nut pair; the force sensor is fixedly installed on the mounting plate through the force sensor support, the upper computer PC outputs a control command to the electric controller according to the tensile stress required by the insulation aging test, a stepping motor driver in the electric controller controls the stepping motor to rotate, a stepping motor output shaft drives the screw nut pair through a coupler, the mounting plate moves along the tensile stress direction of the test cable under the traction of the trapezoid screw nut pair, the force sensor measures the axial tension force applied to the test cable and feeds the axial tension force back to the upper computer PC, when the specified test force value is reached, the stepping motor stops rotating, and the trapezoid screw nut pair realizes positioning and holding by means of the self-locking characteristic.
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| CN109557286B (en) * | 2018-11-14 | 2021-09-21 | 中国直升机设计研究所 | Durability test and service life evaluation method for electric heating windshield transparent part for helicopter |
| CN109902396B (en) * | 2019-03-04 | 2021-10-12 | 中国石油化工股份有限公司 | Cable analysis method and device |
| CN110414087B (en) * | 2019-07-10 | 2023-01-24 | 北京华安中泰检测技术有限公司 | Electronic product service life evaluation method under multi-stress coupling effect |
| CN110530734B (en) * | 2019-09-04 | 2021-11-23 | 安徽上造智能设备科技有限公司 | Power cable thermal aging detection device |
| CN117849562B (en) * | 2024-03-08 | 2024-05-17 | 常州艾博格电器有限公司 | Wire harness sheath insulating properties check out test set |
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| CN2591628Y (en) * | 2002-12-06 | 2003-12-10 | 湖南远能电力发展有限公司 | Insulating property on-line detector for electrical equipment |
| CN1244819C (en) * | 2004-03-22 | 2006-03-08 | 西安交通大学 | On-line detector for insulation of cross-linked polythylene power cable sheath |
| CN101464235B (en) * | 2009-01-12 | 2011-06-08 | 重庆大学 | Test method and apparatus for polymer power cable insulation accelerated electric tree aging |
| CN102735977A (en) * | 2012-07-12 | 2012-10-17 | 四川大学 | Electrical-thermal aging device of cable accessories under high voltage and high current and test method thereof |
| CN103439611B (en) * | 2013-08-31 | 2016-03-09 | 安徽省电力科学研究院 | A kind of electric wire conductivity and tension and aging comprehensive test device |
| CN205749757U (en) * | 2016-05-20 | 2016-11-30 | 贵州电网有限责任公司毕节供电局 | Cable aging diagnosis system |
| CN106885975A (en) * | 2017-04-10 | 2017-06-23 | 华北电力大学（保定） | A kind of high-tension cable ageing testing method and device based on impulse response |
| CN107192928B (en) * | 2017-05-29 | 2019-07-12 | 西南交通大学 | The experimental provision for the vehicle-carrying cable insulation aging that operating ambient temperature frequently changes |
| CN107576897A (en) * | 2017-08-30 | 2018-01-12 | 广西电网有限责任公司电力科学研究院 | A kind of high-voltage cable insulating burn in test circuit and its method of testing |
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