扁形换位导线结构参数模型设计

    Modeling of Structural Parameters for Flat Transposed Conductor

    • 摘要: 为改善扁形换位导线结构参数理论计算依据缺失的现状,对扁形换位导线的产品结构进行解析,采用3D实物模拟和数学推导相结合的方式,研究各结构要素之间的数量关系,提炼适用于扁形换位导线结构计算的参数模型设计方案,并结合应用示例,对比参数模型计算结果与实物测量结果之间的差异。结果表明,参数模型的理论计算结果与扁形换位导线在绞合换位制程节点的半成品形态(扁形换位绞线)的实物测量结果较吻合;将参数模型应用于工装设计,不仅满足了扁形换位导线的绞合换位工艺要求,还解决了膜包金属单线形态向扁形换位绞线形态转变的制造技术难题。该参数模型为工艺研究、工装设计和制程开发等提供了切实可行的解决方案,对电磁线设计制造行业具有实用价值,可为相关行业的技术发展创新提供有力支撑。

       

      Abstract: To address current absence of theoretical calculation basis for structural parameters of flat transposed conductors, product structure of flat transposed conductors was analyzed. A combination of 3D physical simulation and mathematical derivation was employed to study the quantitative relationships between various structural elements. Consequently, a parametric model design scheme suitable for the structural calculation of flat transposed conductors was extracted. Furthermore, application examples were utilized to compare the differences between calculation results of parametric model and actual measurement results. Results demonstrated close agreement between theoretical computations from the parametric model and empirical measurements of flat transposed strand, a semi-finished state during the combined stranding and transposition process. The utilization of parametric model in the design of jigs not only fulfilled process specifications for the stranding and transposition of flat transposed conductor, but also addressed the manufacturing technical challenge associated with morphological transition from film-coated metal monofilament to flat transposed strand configuration. The parametric model of flat transposed conductor structure was developed to provide a viable solution for process research, tooling design and process development, which could hold significant practical value for electromagnetic wire design and manufacturing industry. It was anticipated that the application of the model would provide strong support for technological development and innovation in related industries.

       

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