CN115255706B - Welding method of copper conductor and aluminum conductor for high-voltage submarine power cable flexible joint - Google Patents
Welding method of copper conductor and aluminum conductor for high-voltage submarine power cable flexible joint Download PDFInfo
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- CN115255706B CN115255706B CN202210902162.9A CN202210902162A CN115255706B CN 115255706 B CN115255706 B CN 115255706B CN 202210902162 A CN202210902162 A CN 202210902162A CN 115255706 B CN115255706 B CN 115255706B
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- aluminum
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- welding
- transition joint
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- 239000004020 conductor Substances 0.000 title claims abstract description 220
- 238000003466 welding Methods 0.000 title claims abstract description 165
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 130
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 130
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 title claims abstract description 117
- 229910052802 copper Inorganic materials 0.000 title claims abstract description 116
- 239000010949 copper Substances 0.000 title claims abstract description 116
- 238000000034 method Methods 0.000 title claims abstract description 29
- WPPDFTBPZNZZRP-UHFFFAOYSA-N aluminum copper Chemical compound [Al].[Cu] WPPDFTBPZNZZRP-UHFFFAOYSA-N 0.000 claims abstract description 83
- 230000007704 transition Effects 0.000 claims abstract description 83
- 239000007787 solid Substances 0.000 claims abstract description 27
- 238000004140 cleaning Methods 0.000 claims abstract description 17
- 239000000463 material Substances 0.000 claims abstract description 17
- 239000010953 base metal Substances 0.000 claims abstract description 10
- 229910052751 metal Inorganic materials 0.000 claims abstract description 9
- 239000002184 metal Substances 0.000 claims abstract description 9
- FEEABVAOCDUXPH-UHFFFAOYSA-N [Ag].[P].[Cu] Chemical compound [Ag].[P].[Cu] FEEABVAOCDUXPH-UHFFFAOYSA-N 0.000 claims abstract description 8
- SNAAJJQQZSMGQD-UHFFFAOYSA-N aluminum magnesium Chemical compound [Mg].[Al] SNAAJJQQZSMGQD-UHFFFAOYSA-N 0.000 claims abstract description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 27
- 238000001816 cooling Methods 0.000 claims description 25
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 12
- 239000007789 gas Substances 0.000 claims description 9
- 229910052786 argon Inorganic materials 0.000 claims description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 5
- 239000001307 helium Substances 0.000 claims description 4
- 229910052734 helium Inorganic materials 0.000 claims description 4
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 claims description 4
- 238000009413 insulation Methods 0.000 claims description 4
- 238000005498 polishing Methods 0.000 claims description 4
- 229920000742 Cotton Polymers 0.000 claims description 3
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 3
- 238000004873 anchoring Methods 0.000 claims description 3
- 230000007423 decrease Effects 0.000 claims description 3
- 229910052709 silver Inorganic materials 0.000 claims description 3
- 239000004332 silver Substances 0.000 claims description 3
- 230000000903 blocking effect Effects 0.000 claims 1
- 238000009529 body temperature measurement Methods 0.000 claims 1
- 230000007306 turnover Effects 0.000 claims 1
- 210000001503 joint Anatomy 0.000 description 5
- 238000005452 bending Methods 0.000 description 4
- 239000000498 cooling water Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 235000019441 ethanol Nutrition 0.000 description 3
- 230000001681 protective effect Effects 0.000 description 3
- 241000321520 Leptomitales Species 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 244000137852 Petrea volubilis Species 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 150000001879 copper Chemical class 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 230000036314 physical performance Effects 0.000 description 1
- 238000009991 scouring Methods 0.000 description 1
- 230000008054 signal transmission Effects 0.000 description 1
- 238000005476 soldering Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K33/00—Specially-profiled edge portions of workpieces for making soldering or welding connections; Filling the seams formed thereby
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
- B23K31/02—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to soldering or welding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables
Abstract
The invention discloses a welding method of a copper conductor and an aluminum conductor for a high-voltage submarine power cable flexible joint, which comprises the following steps: s1, prefabricating an aluminum-copper transition joint; welding the solid aluminum column and the solid copper column to form an aluminum-copper transition joint; s2, fixing a base metal, namely fixing a copper conductor, an aluminum conductor and an aluminum-copper transition joint which need to be welded, and S3, forming the base metal; s4, cleaning a base material; s5, recovering a base material, S6, chamfering, namely chamfering a copper conductor, an aluminum conductor end and an aluminum-copper transition joint respectively to form a pencil stub shape; s7, cleaning the groove; s8, centering the parent metal; s9, selecting a welding wire, wherein an aluminum-magnesium welding wire is adopted to weld the aluminum-copper transition joint and the aluminum conductor, and a silver-copper-phosphorus welding wire is adopted to weld the aluminum-copper transition joint and the aluminum conductor; s10, starting welding; and during welding, alternately welding the two ends at the joint. The welding method provided by the invention is simple to operate, high in welding speed and high in strength of the welding position.
Description
Technical Field
The invention relates to the technical field of cable welding, in particular to a method for welding a copper conductor and an aluminum conductor for a high-voltage submarine power cable soft joint.
Background
Submarine cables are tools which are laid on the seabed and are mainly used for electric energy transmission, and are widely applied to land and islands, offshore oil platforms and land, offshore wind farms and the like and used for electric energy and signal transmission.
The submarine cable comprises a submarine section arranged on the seabed and a landing section arranged on land, and although a copper conductor is superior to an aluminum conductor in terms of physical performance and electrical performance, the aluminum is obviously advantageous in view of the fact that the cost of aluminum in the market is far lower than that of copper, the aluminum is lighter in weight, the conductive performance of the aluminum is further improved due to the fact that the temperature of the ocean environment is lower, the conductor in the submarine cable is also made of aluminum, the temperature of the landing section environment is relatively higher, and the copper conductor is a better choice for the electrical performance. Therefore, the submarine section adopts an aluminum conductor and the landing section adopts a submarine cable conductor structure of a copper conductor, so that the submarine cable has higher cost performance and certain practicability.
For the submarine cable structure, when the submarine section is connected with the landing section, an aluminum conductor and a copper conductor are required to be connected, and the welding between the twisted copper conductor and the aluminum conductor is not clear in the prior art, so that how to ensure the welding strength between the copper conductor and the aluminum conductor becomes a technical problem to be solved urgently.
Disclosure of Invention
Aiming at the defects and defects of the prior art, the welding method of the copper conductor and the aluminum conductor for the soft joint of the high-voltage submarine power cable is simple to operate, high in welding speed and high in strength of the welding position.
In order to achieve the above object, the present invention provides the following technical solutions.
A welding method of a copper conductor and an aluminum conductor for a high-voltage submarine power cable flexible joint comprises the following steps:
s1, prefabricating an aluminum-copper transition joint; welding the solid aluminum column and the solid copper column to form an aluminum-copper transition joint;
s2, fixing a base metal, namely fixing a copper conductor and an aluminum conductor which need to be welded and a prefabricated aluminum-copper transition joint, wherein the aluminum-copper transition joint is positioned between the copper conductor and the aluminum conductor, one end of an aluminum column of the aluminum-copper transition joint is arranged close to the aluminum conductor, and one end of a copper column of the aluminum-copper transition joint is arranged close to the copper conductor;
s3, forming a base material, and respectively processing one end of the copper conductor to be welded and one end of the aluminum conductor to be welded to expose the copper conductor and the aluminum conductor, wherein the nominal diameter range of the copper conductor and the aluminum conductor is 6mm-50mm;
s4, cleaning a base material, and cleaning water-blocking materials between the copper conductor and the aluminum conductor;
s5, recovering the parent metal, recovering the monofilaments after the copper conductor and the aluminum conductor are cleaned, and simultaneously fastening by anchoring;
s6, chamfering, namely chamfering one end of the copper conductor, one end of the aluminum conductor and two ends of the aluminum-copper transition joint, which are needed to be welded, respectively to form a pencil stub shape;
s7, cleaning the groove, and ensuring that the groove is clean;
s8, centering a base metal, wherein the axes of the aluminum-copper transition joint, the copper conductor and the aluminum conductor are collinear, so that dislocation welding is avoided, the copper conductor, the aluminum-copper transition joint and the aluminum conductor are attached to each other at the groove, the groove is X-shaped after centering the copper conductor and the aluminum-copper transition joint, and the groove is X-shaped after centering the aluminum-copper transition joint and the aluminum conductor;
s9, selecting a welding wire, wherein an aluminum-magnesium welding wire is adopted to weld the aluminum-copper transition joint and the aluminum conductor, and a silver-copper-phosphorus welding wire is adopted to weld the aluminum-copper transition joint and the aluminum conductor;
s10, starting welding; and (3) adopting a multi-layer and multi-channel welding mode to weld, and alternately welding two ends at the joint when welding, and sequentially welding the cut surfaces of the X-shaped grooves from the center to the outside, wherein after the upper side of the X-shaped groove is welded completely, one welding is performed at the corresponding position of the lower side of the X-shaped groove, and sequentially welding is performed until the welding at the X-shaped groove is completed.
The beneficial effects of the invention are as follows: according to the welding method, the aluminum-copper transition joint is manufactured in advance, so that the welding strength can be ensured, the bending capacity of the copper conductor and the aluminum conductor is not influenced, meanwhile, the bevel shapes of the copper conductor, the aluminum conductor and the aluminum-copper transition joint are arranged to form a pencil stub shape, after the steel wire and the copper wire are centered, the two bevel shapes are X-shaped, and the two bevel shapes are required to be alternately welded at two ends due to the fact that the outer diameters of the copper conductor, the aluminum conductor and the aluminum-copper transition joint are large, the X-shaped bevel shapes are adopted, the two sides are alternately welded, the fact that the other side of the welded side is influenced due to factors such as temperature after one side is welded is prevented, the fact that the welded side is not misplaced is ensured, the welding strength is ensured, the aluminum-magnesium welding wire is adopted to weld the aluminum-copper transition joint and the aluminum conductor, the welding strength is ensured to be high, and the silver-copper-phosphorus welding wire is adopted to weld the aluminum-copper transition joint and the copper conductor, and the conductivity of a welding part is ensured to be good. And the mode of alternately welding during welding can achieve the minimization of welding deformation and ensure the performance of the welding part.
As an improvement of the present invention, in step S1, the solid aluminum pillar has a length of 55mm and the solid copper pillar has a length of 50mm, and the solid aluminum pillar and the solid copper pillar are welded by friction welding.
As an improvement of the present invention: in the step S4, the monofilaments in the aluminum conductor and the copper conductor are turned over layer by layer, the turning-over angle of the outermost layer is not more than 45 degrees, the deformation of the monofilaments of the aluminum conductor and the copper conductor is ensured to be as small as possible, alcohol cleaning cotton is used for wiping the surfaces of the monofilaments, water-blocking materials between the aluminum conductor and the copper conductor are cleaned, and no other components are contained in the water-blocking materials during welding.
As an improvement of the present invention, after the cleaning of the monofilaments in the aluminum conductor and the copper conductor is completed in step S5, the monofilaments are recovered while being anchored and fastened.
As an improvement of the invention, in the step S6, the single-side angle of the bevel on the aluminum conductor, the copper conductor and the aluminum-copper transition joint is 30-35 degrees.
As an improvement of the invention, in the step S9, the silver content in the silver-copper-phosphorus welding wire is more than or equal to 15 percent.
As an improvement of the invention, in the step S10, an inversion AC/DC argon arc welding machine is adopted for welding, one side of aluminum is welded first, and the corresponding position of a lower groove is welded after the welding of an X-shaped upper groove is finished during the welding.
As an improvement of the invention, after the copper conductor, the aluminum-copper transition joint and the aluminum conductor are centered, cooling devices are respectively arranged on the copper conductor, the aluminum-copper transition joint and the aluminum conductor.
As an improvement of the invention, after the copper conductor, the aluminum-copper transition joint and the aluminum conductor are centered, cooling devices are respectively arranged on the copper conductor, the aluminum-copper transition joint and the aluminum conductor; the cooling device is provided with a through hole matched with the diameters of the copper conductor, the aluminum-copper transition joint and the aluminum conductor, and the cooling device is also provided with a water cooling channel positioned at the periphery of the through hole, and a side water inlet and a side water outlet which are communicated with the water cooling channel.
As an improvement of the invention, during welding, two ends are alternately welded at the joint, firstly, a layer of continuous welding is carried out from the center to two sides on the cut surface of the X-shaped groove, then filling is carried out on the cut surface welded with the layer, and after the welding of the X-shaped upper groove is finished, the corresponding position of the groove is welded.
As an improvement of the invention, the welding between the aluminum-copper transition joint and the aluminum conductor adopts alternating current with the frequency of 80-100Hz, the welding between the copper conductor and the aluminum-copper transition joint adopts direct current, and the current ranges are 60A-200A and increase along with the increase of the outer diameter of the conductor.
As an improvement of the invention, in the step S10, the protective gas during welding is a mixed gas of 80% argon and 20% helium, and the purity of the mixed gas is more than or equal to 99.999%.
As an improvement of the present invention, the method further comprises the steps of:
s11, polishing the welding spots at the welding joints to be smooth, and controlling the outer diameter of the welding joints to be consistent with that of the body.
Drawings
FIG. 1 is a schematic illustration of an aluminum conductor, aluminum copper transition joint and copper conductor of the present invention in alignment.
Fig. 2 is a schematic view of the aluminum conductor, aluminum copper transition joint and copper conductor of the present invention at the time of soldering.
Fig. 3 is a schematic view of the cooling device of the present invention.
Fig. 4 is a schematic view of the welding sequence and welding direction at the time of welding according to the present invention.
In the figure, 1, an aluminum copper transition joint; 2. an aluminum conductor; 3. a copper conductor; 4. groove; 5. a welding layer; 6. a cooling device; 6.1, a side inlet; 6.2, a side water outlet; 6.3, through holes.
Detailed Description
The invention is further explained in connection with the drawings.
Referring to fig. 1 to 3, a method for welding a copper conductor 3 and an aluminum conductor 2 for a flexible joint of a high-voltage submarine power cable, comprises the steps of:
s1, prefabricating an aluminum copper transition joint 1; welding a solid aluminum column and a solid copper column to form an aluminum-copper transition joint 1; the length of the solid aluminum column is 55mm, the length of the solid copper column is 50mm, the outer diameters of the solid aluminum column and the solid copper column are 45mm, the solid aluminum column and the solid copper column are welded in a friction welding mode, so that the welding effect is good, the tensile bending and stretching effect is good, the lengths of the solid aluminum column and the solid copper column not only keep the welding strength, but also do not influence the bending capacity of a conductor too much, and in consideration that aluminum is easier to compress, the length of the solid aluminum column is set longer.
S2, fixing a base metal, namely fixing a copper conductor 3 and an aluminum conductor 2 which need to be welded and a prefabricated aluminum-copper transition joint 1, wherein the aluminum-copper transition joint 1 is positioned between the copper conductor 3 and the aluminum conductor 2, one end of an aluminum column of the aluminum-copper transition joint 1 is arranged close to the aluminum conductor 2, and one end of a copper column of the aluminum-copper transition joint 1 is arranged close to the copper conductor 3.
S3, forming a base material, respectively processing one end to be welded on the copper conductor 3 and one end to be welded on the aluminum conductor 2, cutting the insulating layer into a pencil stub shape by using tools such as a hooking knife, a glass knife and the like, so that the conductor part is exposed, the exposed part is about 20cm, the surface is smooth, no inner screen material remains, the sufficient distance between the two ends of the subsequent welding is ensured, and the diameters of the aluminum conductor 2 and the aluminum conductor 2 are 44.7mm.
S4, cleaning a base material, cleaning water-blocking materials between the aluminum conductor 2 and the copper conductor 3, turning over monofilaments in the aluminum conductor 2 and the copper conductor 3 layer by layer, enabling the turning-over angle of the outermost layer to be not more than 45 degrees, ensuring that the deformations of the monofilaments of the aluminum conductor 2 and the copper conductor 3 are as small as possible, wiping the surfaces of the monofilaments by alcohol cleaning cotton, cleaning the water-blocking materials between the aluminum conductor 2 and the copper conductor 3, and avoiding slag inclusion of other components during welding.
S5, recovering the parent metal, recovering the monofilaments after the aluminum conductor 2 and the copper conductor 3 are cleaned, and simultaneously fastening by anchoring, wherein the recovered conductors are consistent with the outer diameter of the body, so that the outer diameter of the welded conductors is prevented from becoming large, the conductor resistance is ensured to be qualified, and the quality of the joint is not influenced.
S6, chamfering 4 is carried out on one end to be welded on the copper conductor 3, one end to be welded on the aluminum conductor 2 and two ends of the aluminum-copper transition joint 1 respectively, so that pencil stub shapes are formed, the unilateral angle of the chamfer 4 on the aluminum conductor 2, the copper conductor 3 and the aluminum-copper transition joint 1 is 30-35 degrees, good weld joint forming is facilitated by slag removal, the proportion of filler in weld joint metal is increased, cladding thickness is increased, and weld joint strength is ensured.
S7, cleaning the groove 4, ensuring that the groove 4 is clean, wiping a base metal by using a scouring pad, dipping absolute ethyl alcohol by using a special alcohol cleaning pad, wiping the aluminum conductor 2 and the copper conductor 3, and ensuring that the ends of the aluminum conductor 2 and the copper conductor 3 are smooth, clean, free of greasy dirt, free of macroscopic fibers, free of metal burrs and other substances within a 20mm range.
S8, centering a base metal, wherein the axes of an aluminum-copper transition joint 1, a copper conductor 3 and an aluminum conductor 2 are collinear, the copper conductor 3, the aluminum-copper transition joint 1 and a groove 4 of the aluminum conductor 2 are attached, after centering the copper conductor 3 and the aluminum-copper transition joint 1, the groove 4 is X-shaped, after centering the aluminum-copper transition joint 1 and the aluminum conductor 2, the groove 4 is X-shaped, the angle of the X-shaped groove 4 is 60-70 degrees, and the clearance between the copper conductor 3, the aluminum conductor 2 and the aluminum-copper transition joint 1 is less than or equal to 0.2mm. The cooling device 6 is additionally arranged at the positions of 5cm at the two ends of the welding point and the friction welding point, the cooling device 6 is formed by splicing two water molds, through holes 6.3 matched with the diameters of the copper conductor 3, the aluminum-copper transition joint 1 and the aluminum conductor 2 are formed after the two water molds are spliced, and each water mold is further provided with a water cooling channel positioned at the periphery of the through hole 6.3, and a side water inlet 6.1 and a side water outlet 6.2 communicated with the water cooling channel. The side water inlet 6.1 of one water mould is communicated with the side water outlet 6.2 of the other water mould through an external pipeline. Through injecting cooling water into the side water inlet 6.1, the cooling water can cool the conductor in the through hole 6.3 in a water cooling channel, finally, the conductor is discharged from the side water outlet 6.2 and then enters another water mold through an external pipeline to be cooled, and water can be simultaneously fed into the side water inlets 6.1 of the plurality of cooling devices 6 through the same water inlet device. The temperature of the cooling water is 20 ℃, so that the excessive welding heat is prevented, the strength of the base metal is ensured, and the heat affected zone is reduced. Because the metal melting temperature of the welding part reaches 1000 ℃, if the metal is not cooled in time, the insulation performance of two ends is easily affected, the metal is oxidized and softened, and the like, so that the final tensile strength is insufficient and the resistance is unqualified, and the cooling device 6 is arranged to reduce the temperature.
S9, selecting a welding wire, wherein an ER5183 aluminum-magnesium welding wire is adopted between the aluminum-copper transition joint 1 and the aluminum conductor 2 for welding, the diameter of the aluminum-magnesium welding wire is 2.5mm, and the welding wire which is made of the same material as the conductor is adopted for the larger welding seam area, so that the strength of the aluminum-copper transition joint 1 can reach the optimal strength, and a BCu80AgP silver-copper-phosphorus welding wire is adopted between the aluminum-copper transition joint 1 and the aluminum conductor 2 for welding; the silver content of the silver copper phosphorus welding wire is more than or equal to 15 percent, and the diameter is 2.0mm; the conductive effect of the welding part is ensured.
S10, starting welding; adopting a multi-layer and multi-channel welding mode, wherein the welding layer 5 comprises a bottoming layer, a filling layer and a cover layer; and during welding, firstly welding one side of the butt joint of the aluminum conductor 2 and the aluminum-copper transition joint 1, and then welding one side of the butt joint of the copper conductor 3 and the aluminum-copper transition joint 1. The protective gas for argon arc welding is a mixed gas of 80% of argon and 20% of helium, and the purity of the protective gas is more than or equal to 99.999%. The welding speed is high, and compared with pure argon, helium can obtain larger penetration, melting efficiency and higher weld quality.
Referring to fig. 4, during welding, two ends are welded alternately at the joint, and the cut surfaces of the X-shaped grooves 4 are welded sequentially from the center to the outside, which helps to avoid that a single wire in a conductor is retracted during welding, poor welding phenomenon affects tension data, then filling is performed on the cut surface welded with one layer, after the upper side of the X-shaped groove 4 is welded, the lower side of the X-shaped groove 4 is welded with one corresponding position, and then the outer sides are welded sequentially until the welding of the X-shaped groove 4 is completed. Because the stress is concentrated during welding, the two sides are alternately welded to minimize welding deformation, and the process is repeated until the upper side and the lower side of the X-shaped groove 4 are welded. The welding between the aluminum conductor 2 and the aluminum copper transition joint 1 adopts alternating current with the frequency of 100Hz, the welding between the copper conductor 3 and the aluminum copper transition joint 1 adopts direct current, when the copper conductor 3 and the aluminum copper transition joint 1 are welded, the central bottoming layer current is 180A, the current gradually decreases from the center to the outer layer, the cover layer current is 150A, the current slightly decreases when the joint is welded from the center to the outer layer, and the central temperature is influenced by water cooling devices at two ends of the welding point, so the welding current at the center is larger. During welding, after one layer is welded, the welding line needs to be cooled for a period of time, so that the welding line and the strength of the original formed welding line are not damaged during the next layer of welding, the cooling time is related to the cooling speed of the cooling device 6, the insulation part at the side of the cooling device 6 needs to continuously measure the temperature, and after the temperature reaches 80 ℃, the welding is stopped and cooled to 30 ℃, and then the welding is performed. And the insulation damage caused by too high temperature is avoided.
S11, polishing the welding spots, polishing conductors at the welding joints smoothly, and controlling the outer diameter of the cable to be consistent with that of the body. A hand-held grinding wheel is adopted to polish the conductor at the welding seam smoothly, the outer diameter of the control cable is consistent with that of the body, and meanwhile, the body monofilament cannot be damaged; the surface of the conductor is polished smooth by sand paper, smoothness and no burrs are ensured, and point discharge after the burrs are electrified is avoided, so that the joint fails and is broken down under pressure.
As a result of the test, the tensile strength was 84.8MPa and the breaking force was 118.7 kN. The breaking point is on the aluminum conductor 2 and not at the weld. Resistance data at 20 ℃ after welding: 0.0175 Ω/km.
According to the welding method, the aluminum-copper transition joint 1 is manufactured in advance, so that the welding strength can be ensured, the bending capacity of the copper conductor 3 and the aluminum conductor 2 is not influenced, the shapes of the grooves 4 of the copper conductor 3, the aluminum conductor 2 and the aluminum-copper transition joint 1 are arranged to form a pencil stub shape, after centering of a steel wire and a copper wire, the two grooves 4 are X-shaped, and the two ends are required to be alternately welded due to the fact that the outer diameters of the copper conductor 3, the aluminum conductor 2 and the aluminum-copper transition joint 1 are large, the X-shaped grooves 4 are adopted for alternately welding the two sides, the fact that the influence of temperature and other side influences the welded side after one side is finished is avoided, the fact that the welding is influenced is avoided, the dislocation is ensured, the welding strength is ensured, the aluminum-magnesium welding wire is adopted for welding between the aluminum-copper transition joint 1 and the aluminum conductor 2, the welding strength is high, and the electric conductivity of a welding position is ensured to be good. And the mode of alternately welding during welding can achieve the minimization of welding deformation and ensure the performance of the welding part.
The foregoing description is only of the preferred embodiments of the invention, and all changes and modifications that come within the meaning and range of equivalency of the structures, features and principles of the invention are therefore intended to be embraced therein.
Claims (8)
1. A welding method of a copper conductor and an aluminum conductor for a high-voltage submarine power cable flexible joint is characterized by comprising the following steps: the method comprises the following steps:
s1, prefabricating an aluminum-copper transition joint, and welding a solid aluminum column and a solid copper column to form the aluminum-copper transition joint, wherein the outer diameters of the solid aluminum column and the solid copper column are 45mm;
s2, fixing a base metal, namely fixing a copper conductor and an aluminum conductor which need to be welded and a prefabricated aluminum-copper transition joint, wherein the aluminum-copper transition joint is positioned between the copper conductor and the aluminum conductor, one end of an aluminum column of the aluminum-copper transition joint is arranged close to the aluminum conductor, and one end of a copper column of the aluminum-copper transition joint is arranged close to the copper conductor;
s3, forming a base material, and respectively processing one end of the copper conductor to be welded and one end of the aluminum conductor to be welded to expose the copper conductor and the aluminum conductor, wherein the nominal diameter range of the copper conductor and the aluminum conductor is 6mm-50mm;
s4, cleaning a base material, and cleaning water-blocking materials between the copper conductor and the aluminum conductor;
s5, recovering the parent metal, recovering the monofilaments after the copper conductor and the aluminum conductor are cleaned, and simultaneously fastening by anchoring;
s6, chamfering, namely chamfering one end of the copper conductor, one end of the aluminum conductor and two ends of the aluminum-copper transition joint, which are needed to be welded, respectively to form a pencil stub shape;
s7, cleaning the groove, and ensuring that the groove is clean;
s8, centering a base metal, wherein the axes of the aluminum-copper transition joint, the copper conductor and the aluminum conductor are collinear, and the grooves of the copper conductor, the aluminum-copper transition joint and the aluminum conductor are attached to each other, the grooves are X-shaped after centering the copper conductor and the aluminum-copper transition joint, and the grooves are X-shaped after centering the aluminum-copper transition joint and the aluminum conductor;
s9, selecting a welding wire, wherein an aluminum-magnesium welding wire is adopted to weld the aluminum-copper transition joint and the aluminum conductor, and a silver-copper-phosphorus welding wire is adopted to weld the aluminum-copper transition joint and the copper conductor;
s10, starting welding; adopting a multi-layer and multi-channel welding mode to weld; when in welding, two ends are alternately welded at the joint, the cut-off surfaces of the X-shaped grooves are sequentially welded from the center to the outside, after the upper side of the X-shaped groove is welded, one welding is performed at the corresponding position of the lower side of the X-shaped groove, and the welding is sequentially performed until the welding at the X-shaped groove is completed; the welding between the aluminum conductor and the aluminum copper transition joint adopts alternating current with the frequency of 100Hz, the welding between the copper conductor and the aluminum copper transition joint adopts direct current, when the copper conductor and the aluminum copper transition joint are welded, the current of the central base layer is 180A, the current gradually decreases from the center to the outer layer, and the current of the cover layer is 150A; after the copper conductor, the aluminum-copper transition joint and the aluminum conductor are centered, cooling devices are respectively arranged on the copper conductor, the aluminum-copper transition joint and the aluminum conductor; the cooling device is provided with a through hole matched with the diameters of the copper conductor, the aluminum-copper transition joint and the aluminum conductor, and is also provided with a water cooling channel positioned at the periphery of the through hole, a side water inlet and a side water outlet communicated with the water cooling channel; the insulation part beside the cooling device is subjected to continuous temperature measurement, and after the temperature reaches 80 ℃, welding is stopped, and the temperature is cooled to 30 ℃ and then welding is performed.
2. The welding method of the copper conductor and the aluminum conductor for the soft joint of the high-voltage submarine power cable according to claim 1, wherein the welding method comprises the following steps: in step S1, the length of the solid aluminum pillar was 55mm, the length of the solid copper pillar was 50mm, and the solid aluminum pillar and the solid copper pillar were welded by friction welding.
3. The welding method of the copper conductor and the aluminum conductor for the soft joint of the high-voltage submarine power cable according to claim 1, wherein the welding method comprises the following steps: in the step S4, the monofilaments in the aluminum conductor and the copper conductor are turned over layer by layer, the turn-over angle of the outermost layer is not more than 45 degrees, alcohol cleaning cotton is used for wiping the surfaces of the monofilaments, and water blocking materials between the aluminum conductor and the copper conductor are cleaned.
4. The welding method of the copper conductor and the aluminum conductor for the soft joint of the high-voltage submarine power cable according to claim 1, wherein the welding method comprises the following steps: in the step S6, the single-side angle of the bevel on the aluminum conductor, the copper conductor and the aluminum-copper transition joint is 30-35 degrees.
5. The welding method of the copper conductor and the aluminum conductor for the soft joint of the high-voltage submarine power cable according to claim 1, wherein the welding method comprises the following steps: in the step S9, the silver content in the silver-copper-phosphorus welding wire is more than or equal to 15 percent.
6. The welding method of the copper conductor and the aluminum conductor for the soft joint of the high-voltage submarine power cable according to claim 1, wherein the welding method comprises the following steps: the welding between the aluminum-copper transition joint and the aluminum conductor adopts alternating current with the frequency of 80-100Hz, the welding between the copper conductor and the aluminum-copper transition joint adopts direct current, and the current ranges from 60A to 200A.
7. The welding method of the copper conductor and the aluminum conductor for the soft joint of the high-voltage submarine power cable according to claim 1, wherein the welding method comprises the following steps: in the step S10, the shielding gas during welding is a mixed gas of 80% of argon and 20% of helium, and the purity of the mixed gas is more than or equal to 99.999%.
8. The welding method of the copper conductor and the aluminum conductor for the soft joint of the high-voltage submarine power cable according to claim 1, wherein the welding method comprises the following steps: the method also comprises the following steps:
s11, polishing the welding spots at the welding joints to be smooth, and controlling the outer diameter of the welding joints to be consistent with that of the body.
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