CN110724364B - 一种300~900℃多变色不可逆示温材料及其制备方法与应用 - Google Patents
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Abstract
本发明公开了一种300~900℃多变色不可逆示温材料及其制备方法与应用,所述示温材料以质量百分数计,由以下组分组成:有色颜料:24~28.6%,填料1:7.5~8.5%,填料2:14.5~18.7%,树脂基料:47~50%,制备方法如下:步骤一、配料:按配比量称取各种组分,首先加入有色颜料,将固体颗粒研磨粉碎,然后加入填料1和填料2混合均匀,最后加入树脂基料搅拌制成色浆;步骤二、制备示温材料:将色浆转入高速球磨机中进行研磨分散,球磨至细度30µm即可。本发明的多变色示温材料在300~900℃区间有7种颜色变化,检修人员可以通过观察电力系统各部分材料的颜色,快速地判断故障类型及故障发生位置。
Description
技术领域
本发明涉及一种宽温度范围内多变色不可逆示温材料及其制备方法与其在电力系统中各种关键部位测温及故障检测应用。
背景技术
现今,高新技术的蓬勃发展持续推动着社会智能化转变进程,而智能化转变的核心便是万物互联,功能传感材料则是实现万物互联互通的关键,目前亦已成为高新技术的发展热点。在温度智能测控传感方面,原有的红外传感由于硬件较大、使用要求高和设备昂贵等原因,已无法满足物联网大范围多点实时测控的要求。示温材料作为一种新型温度传感材料,为此应运而生。它可通过所呈现的颜色变化直观地指示物体表面的温度分布及变化,且具有成本低廉、感应灵敏、变色明显、不受涂覆物体表面形状影响等优点,未来将在众多领域的温度检测中有望得到广泛应用。
近年来,随着智能电网的快速发展,如何保障电力系统的安全稳定运行已成为一项重大课题。现实中,发生故障后每晚一分钟恢复供电,都会造成巨大的社会财富损失,对于医院中重症病人而言,可能还意味着付出生命代价。目前电力系统架空输电线路实际故障中由雷击等引起的过热故障约占30%,温度分布在高温区800℃以上,因此对电力系统以雷击为主过热故障监测十分重要。目前电网系统中常用的测温方法是人工巡检,不仅费时费力,而且存在安全问题,并且效率低。尽管目前提出了无人机红外巡检方案,但红外测温由于受测量距离、粉尘和水气等外界因素的影响,其测量精度不高,同时存在设备昂贵、使用要求较高的缺点,故无法满足未来智能电网的需求。为了实现对电网各部分温度的监测和过热故障点的快速排查,同时利用数据库及人工智能对故障类型进行判断,我们需要开发出一种简单有效、价格低廉的测温系统,该系统需具有高准确度及稳定性,以实现收集数据和稳定运行的要求。示温材料作为一种以颜色变化来指示物体表面温度变化及分布功能性材料,使用方便,示温现象明显,很适合用于长时间连续工作器件和复杂结构元件的表面测温,已在航空航天领域示温检测中得到应用,现今在电网故障检测上也已引起重视。目前国内外对此已文献报导,美国专利局公开了MC 165-2、MC 104-2、KN-4和KN-11共四种市售单变色示温材料适用于电网过热故障检测;国内谷山强等人最早地研究并制备了用于电网过热故障监测的单变色不可逆示温材料。然而无论国内还是国外,对于电网故障监测中研究与应用的多为单变色低温示温材料,即随着温度变化只能发生一种颜色改变,而且变色温度基本在200℃以下,因此无法通过温度对故障类型进行区分,且无法收集到有参考价值的故障温度数据。
智能电网的发展对温度监测传感系统提出更高的要求,单变色低温示温材料不再能够满足大温度区间内故障类型检测及故障部位温度测定的需求。
发明内容
本发明针对单变色低温示温材料存在的上述问题,提供了一种300~900℃多变色不可逆示温材料及其制备方法与应用。该材料在300~900℃区间内有7种颜色变化,且响应时间在7s以内,变色明显,稳定性好。在此基础上,研究建立了该材料所示颜色与所处温度的数据库,构建出温-色标准曲线数学模型,通过该模型,即可快速判断故障类型并实现对电力系统各部分温度的实时监测。
本发明的目的是通过以下技术方案实现的:
一种300~900℃多变色不可逆示温材料,以质量百分数计,由以下组分组成:有色颜料:24~28.6%,填料1:7.5~8.5%,填料2:14.5~18.7%,树脂基料:47~50%,其中:
所述有色颜料为有机化合物结晶紫、七水硫酸钴CoSO4·7H2O、氧化铋Bi2O3的混合物,有机化合物结晶紫、七水硫酸钴CoSO4·7H2O、氧化铋Bi2O3的质量比为0.1~0.13:0.1~0.13:2.3~2.7,硫酸钴颜料在高温下分解转化为氧化钴,氧化钴与氧化铋、结晶紫等颜料之间可生成多元氧化物,导致颜色的变化;
所述填料1为氧化铝和氧化钛的混合物,氧化铝和氧化钛的质量比为1.1~1.3:0.6~0.7;
所述填料2为滑石粉和高岭土的混合物,滑石粉和高岭土的质量比为8.5~10.5:6.5~8.5;
所述树脂基料为环氧树脂或有机硅树脂中的一种。
上述300~900℃多变色不可逆示温材料的制备方法,包括如下步骤:
步骤一、配料:按配比量称取各种组分,首先加入有色颜料,将固体颗粒研磨粉碎,然后加入填料1和填料2混合均匀,最后加入树脂基料搅拌制成色浆;
步骤二、制备示温材料:将色浆转入高速球磨机中进行研磨分散,球磨至细度30 µm即可,所得材料可应用于电网系统的过热故障检测及各种关键部位温度的实时监测。
本发明所制备的材料利用涂刷法涂覆于蝶形片及尺寸为30mm×20mm的马口铁板上,采用可调式涂膜器控制涂膜厚度为30µm。使用酒精喷灯作为加热设备,将蝶形片最窄处对准火焰中心,恒温时间5s,测试涂层变色后等温线数目及分布情况;马口铁板材料膜实干后在200℃下固化2h,然后分别将试片放入升至300℃、400℃、500℃、600℃、700℃、800℃、900℃的马弗炉中恒温5s取出冷却至室温,作为标准比色试片。蝶形片测试结果如图1所示,标准比色试片测试结果如图2所示。
本发明300~900℃多变色不可逆示温材料的技术指标如表1所示:
表1
按照《漆膜颜色标准》(GB/T3181-1995),涂层的变色采用色度坐标值来表示,涂层的变色点所对应的温度如表2所示:
表2
收集本发明示温材料不同温度下的颜色值RGB值,如表3所示:
表3
本发明为对故障进行自动化判读且对其温度进行准确搜集,建立了一个温-色标准曲线数学模型:首先收集材料不同温度下的颜色R、G、B值,然后利用Matlab建立色温空间曲线,其中X、Y、Z轴分别对应R、G、B三个颜色值。色温空间曲线如图3所示。
计算某位置A的温度时,首先利用图像系统采集并分析颜色A,获得其RGB值(RA,GA,BA),在色温空间中确定A点位置,若A点位于色温曲线Tb-Tc段(Tb<Tc),利用差值法计算A点温度,计算公式为:
式中,T a 和T b 分别代表a、b点的温度,ab和bc代表两点间的线段长度。
若A点位于曲线外A*位置时,利用三维最小二乘法进行空间最短距离运算,找到曲线上距A*点最近的点A,利用差值法计算A点温度。对目标点、色温曲线进行空间最短距离评价所依据的三维最小二乘法的数学模型为:
式中,R a 和R a* 、G a 和G a* 、B a 和B a* 分别代表色温空间曲线图中A点和曲线外A*的颜色值,其中:R代表Red (红),G代表Green(绿),B代表Blue(蓝)。
收集不同故障对应的温度数据,构建起各种故障类型对应的温度数据库,为智能电网自主检测提供支撑。
相比于现有技术,本发明具有如下优点:
1、本发明的多变色示温材料在300~900℃区间有7种颜色变化,检修人员可以通过观察电力系统各部分材料的颜色,快速地判断故障类型及故障发生位置。
2、本发明在实验中整理出材料的颜色值与对应温度之间的数据库,构建起颜色值与温度之间的数学模型。在实际生活中,本发明将极大地推动电网智能化进程,如利用图像摄取与处理系统,通过对图像中材料颜色的分析,对照数学模型进行计算,将可以实现对电网各部分温度的实时监测,并能够准确地判断出故障点的位置及故障类型,若结合计算机,还可实现自动读取数据和智能故障报警等功能。
附图说明
图1为蝶形片测试结果;
图2为标准比色试片测试结果;
图3为色温空间曲线。
具体实施方式
下面结合实施例对本发明的技术方案作进一步的说明,但并不局限于此,凡是对本发明技术方案进行修改或者等同替换,而不脱离本发明技术方案的精神和范围,均应涵盖在本发明的保护范围中。
实施例1
本实施例中,多变色示温材料的配方为:七水硫酸钴0.05 g,结晶紫0.05 g,氧化铋1.2 g,氧化铝0.2 g,氧化钛0.2 g,滑石粉0.4 g,高岭土0.4 g,环氧树脂2.4 g。具体制备方法如下:
步骤一、预混合:按配方称量各种组份,首先将颜料、填料用研钵预先研磨,然后依次加入颜料、填料、树脂、二甲苯(2 ml),边加料边搅拌,制成色浆。
步骤二、研磨分散:将已制得的色浆送入球磨机,研磨分散,用刮板细度计控制细度至25~30µm即可。
步骤三、调和:把研磨分散后的色浆用溶剂调至合适的稠度,室温搅拌1h,备用。
步骤四、底材处理:将马口铁板用砂纸打磨至完全去除保护层,清除表面油污,用二甲苯擦拭干净,备用。
步骤五、涂层制备:将制备的材料按《漆膜一般制备法》的规定,在 200×200mm的马口铁板上使用可调式涂膜器制备漆膜,控制涂层样品厚度为30~35µm之间,漆膜实干后室温下晾干即得用于实验测定的涂层样片。
步骤六、测试记录:晾干后测试涂片的变色性能,用照相机、色差仪记录涂片在设定温度下煅烧冷却后的颜色和色度参数RGB值,并计算煅烧前后涂片的色差。
实施例2
本实施例中,多变色示温材料的配方为:七水硫酸钴0.06g,结晶紫0.05g,氧化铋1.3g,氧化铝0.25g,氧化钛0.15g,滑石粉0.4g,高岭土0.4g,环氧树脂2.5g。具体制备方法如下:
步骤一、预混合:按配方称量各种组份,首先将颜料、填料用研钵预先研磨,然后依次加入颜料、填料、树脂、二甲苯(2 ml),边加料边搅拌,制成色浆。
步骤二、研磨分散:将已制得的色浆送入球磨机,研磨分散,用刮板细度计控制细度至25~30µm即可。
步骤三、调和:把研磨分散后的色浆用溶剂调至合适的稠度,室温搅拌1h,备用。
步骤四、底材处理:将马口铁板用砂纸打磨至完全去除保护层,清除表面油污,用二甲苯擦拭干净,备用。
步骤五、涂层制备:将制备的材料按《漆膜一般制备法》的规定,在 200×200mm的马口铁板上使用可调式涂膜器制备漆膜,控制涂层样品厚度为30~35µm之间,漆膜实干后室温下晾干即得用于实验测定的涂层样片。
步骤六、测试记录:晾干后测试涂片的变色性能,用照相机、色差仪记录涂片在设定温度下煅烧冷却后的颜色和色度参数RGB值,并计算煅烧前后涂片的色差。
实施例3
本实施例中,多变色示温材料的配方为:水硫酸钴0.05g,结晶紫0.05g,氧化铋1.2g,氧化铝0.2g,氧化钛0.15,滑石粉0.4g,高岭土0.4g,有机硅树脂2.4g。具体制备方法如下:
步骤一、预混合:按配方称量各种组份,首先将颜料、填料用研钵预先研磨,然后依次加入颜料、填料、树脂、二甲苯(2 ml),边加料边搅拌,制成色浆。
步骤二、研磨分散:将已制得的色浆送入球磨机,研磨分散,用刮板细度计控制细度至25~30µm即可。
步骤三、调和:把研磨分散后的色浆用溶剂调至合适的稠度,室温搅拌1h,备用。
步骤四、底材处理:将马口铁板用砂纸打磨至完全去除保护层,清除表面油污,用二甲苯擦拭干净,备用。
步骤五、涂层制备:将制备的材料按《漆膜一般制备法》的规定,在 200×200mm的马口铁板上使用可调式涂膜器制备漆膜,控制涂层样品厚度为30~35µm之间,漆膜实干后室温下晾干即得用于实验测定的涂层样片。
步骤六、测试记录:晾干后测试涂片的变色性能,用照相机、色差仪记录涂片在设定温度下煅烧冷却后的颜色和色度参数RGB值,并计算煅烧前后涂片的色差。
Claims (9)
1.一种300~900℃多变色不可逆示温材料,其特征在于所述多变色不可逆示温材料以质量百分数计,由以下组分组成:有色颜料:24~28.6%,填料1:7.5~8.5%,填料2:14.5~18.7%,树脂基料:47~50%,其中:所述有色颜料为有机化合物结晶紫、七水硫酸钴CoSO4·7H2O、氧化铋Bi2O3的混合物;所述填料1为氧化铝和氧化钛的混合物;所述填料2为滑石粉和高岭土的混合物。
2.根据权利要求1所述的300~900℃多变色不可逆示温材料,其特征在于所述有机化合物结晶紫、七水硫酸钴CoSO4·7H2O、氧化铋Bi2O3的质量比为0.1~0.13:0.1~0.13:2.3~2.7。
3.根据权利要求1所述的300~900℃多变色不可逆示温材料,其特征在于所述氧化铝和氧化钛的质量比为1.1~1.3:0.6~0.7。
4.根据权利要求1所述的300~900℃多变色不可逆示温材料,其特征在于所述滑石粉和高岭土的质量比为8.5~10.5:6.5~8.5。
5.根据权利要求1所述的300~900℃多变色不可逆示温材料,其特征在于所述树脂基料为环氧树脂或有机硅树脂中的一种。
6.一种权利要求1-5任一项所述300~900℃多变色不可逆示温材料的制备方法,其特征在于所述方法包括如下步骤:
步骤一、配料:按配比量称取各种组分,首先加入有色颜料,将固体颗粒研磨粉碎,然后加入填料1和填料2混合均匀,最后加入树脂基料搅拌制成色浆;
步骤二、制备示温材料:将色浆转入高速球磨机中进行研磨分散,球磨至细度30 µm即可。
7.一种权利要求1-5任一项所述300~900℃多变色不可逆示温材料在电网系统的过热故障检测及各种关键部位温度的实时监测中的应用。
8.根据权利要求7所述的300~900℃多变色不可逆示温材料在电网系统的过热故障检测及各种关键部位温度的实时监测中的应用,其特征在于通过构建温-色标准曲线数学模型,检测电网系统的过热故障、实时监测各种关键部位的温度。
9.根据权利要求8所述的300~900℃多变色不可逆示温材料在电网系统的过热故障检测及各种关键部位温度的实时监测中的应用,其特征在于所述温-色标准曲线数学模型的构建方法如下:首先收集示温材料不同温度下的颜色R、G、B值,然后利用Matlab建立色温空间曲线,其中X、Y、Z轴分别对应R、G、B三个颜色值。
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