Article(id=1200394759656305153, tenantId=1146029695717560320, journalId=1189987059142926344, issueId=1200394757995360759, articleNumber=null, orderNo=null, doi=10.19457/j.1001-2095.dqcd26072, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1721404800000, receivedDateStr=2024-07-20, revisedDate=1728403200000, revisedDateStr=2024-10-09, acceptedDate=null, acceptedDateStr=null, onlineDate=1764126012958, onlineDateStr=2025-11-26, pubDate=1742400000000, pubDateStr=2025-03-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1764126012958, onlineIssueDateStr=2025-11-26, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1764126012958, creator=13701087609, updateTime=1764126012958, updator=13701087609, issue=Issue{id=1200394757995360759, tenantId=1146029695717560320, journalId=1189987059142926344, year='2025', volume='55', issue='3', pageStart='3', pageEnd='96', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1764126012562, creator=13701087609, updateTime=1764148644802, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1200489684553027930, tenantId=1146029695717560320, journalId=1189987059142926344, issueId=1200394757995360759, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1200489684553027931, tenantId=1146029695717560320, journalId=1189987059142926344, issueId=1200394757995360759, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=91, endPage=96, ext={EN=ArticleExt(id=1200394759861826056, articleId=1200394759656305153, tenantId=1146029695717560320, journalId=1189987059142926344, language=EN, title=Design and Research of Instantaneous Tripping Device for Circuit Breakers, columnId=null, journalTitle=Electric Drive, columnName=null, runingTitle=null, highlight=null, articleAbstract=

Thermal and magnetic protection circuit breakers provided short circuit protection by instantaneous tripping devices. In the magnetic field formed by the coil with current,the moving armature and stationary core overcomed the spring force and engage under the influence of electromagnetic force,thereby pushing the circuit breaker mechanism to operate and causing the product tripping. During the entire process,only when the electromagnetic force reaches a certain value could be the moving armature and stationary core reliably engage at the preset current value. In actual engineering design,in order to simplify the design and calculation process,issues such as magnetic leakage may be ignored. Therefore,the theoretical calculated magnetic attraction force,i.e. spring reaction force,will be smaller than the preset target. By analogy calculation method,it is possible to directly eliminate the influence of magnetic leakage and part manufacturing accuracy on the test results during the manufacturing process,and complete the design of the instantaneous release device once. Finally,practical application cases were used to illustrate how to accurately and quickly design an instantaneous release devices through a combination of theoretical calculations and experiments.

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热磁式断路器通过瞬时脱扣装置进行短路保护。在通电线圈形成的磁场中,动、静铁心在电磁力的作用下克服弹簧反力吸合,进而推动断路器机构动作使产品脱扣。整个过程中只有电磁力达到一定的数值,动、静铁心才能在预设定的电流值下可靠地吸合。在实际的工程设计过程中,为了简化设计及计算过程,会忽略漏磁等问题,故理论计算得出的磁吸力,即弹簧反力值会小于预设目标。通过类比计算的方法,可以直接剔除漏磁和制作工艺过程中零件制作精度对试验结果的影响,一次完成瞬时脱扣装置的设计。最后,通过实际应用案例来说明如何通过理论计算和试验结合的方式,准确快速地设计出瞬时脱扣装置脱扣电流的方法。

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耿丽恺(1984—),男,硕士,高级工程师,Email:

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耿丽恺(1984—),男,硕士,高级工程师,Email:

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耿丽恺(1984—),男,硕士,高级工程师,Email:

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figureFileBig=EMsEBBogb3tlz4NqTugb5A==, tableContent=null), ArticleFig(id=1200450375133295488, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=CN, label=图4, caption=C特性40A产品弹簧力值F=1.51 N时样机瞬时脱扣电流倍数曲线, figureFileSmall=PTC0HVP7ioYE7+6Gnh02pg==, figureFileBig=EMsEBBogb3tlz4NqTugb5A==, tableContent=null), ArticleFig(id=1200450375250736005, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=EN, label=Tab.1, caption=

Regulations of instantaneous tripping device characteristic in standard GB/T 10963.1

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试验 型式 试验
电流
起始
状态
脱扣或不脱扣
时间极限
预期
结果
d B
C
D
3In
5In
10In
冷态 t≤0.1 s 不脱扣
e B
C
D
5In
10In
20In
冷态 t<0.1 s 脱扣
), ArticleFig(id=1200450375405925259, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=CN, label=表1, caption=

GB/T 10963.1标准对瞬时脱扣特性的规定

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试验 型式 试验
电流
起始
状态
脱扣或不脱扣
时间极限
预期
结果
d B
C
D
3In
5In
10In
冷态 t≤0.1 s 不脱扣
e B
C
D
5In
10In
20In
冷态 t<0.1 s 脱扣
), ArticleFig(id=1200450375527560083, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=EN, label=Tab.2, caption=

Instantaneous tripping current multiple of prototype when spring force is F=0.68 N

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样机编号 瞬时脱扣电流倍数 样机编号 瞬时脱扣电流倍数
1 5.68 6 5.60
2 6.01 7 5.90
3 5.76 8 6.00
4 5.55 9 5.95
5 5.87 10 5.82
), ArticleFig(id=1200450375645000601, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=CN, label=表2, caption=

弹簧力值F=0.68 N时样机瞬时脱扣电流倍数

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样机编号 瞬时脱扣电流倍数 样机编号 瞬时脱扣电流倍数
1 5.68 6 5.60
2 6.01 7 5.90
3 5.76 8 6.00
4 5.55 9 5.95
5 5.87 10 5.82
), ArticleFig(id=1200450376798434210, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=EN, label=Tab.3, caption=

Instantaneous tripping current multiple of prototype when spring force is F=0.96 N

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样机编号 瞬时脱扣电流倍数 样机编号 瞬时脱扣电流倍数
1 7.10 6 7.00
2 6.81 7 7.05
3 6.79 8 6.89
4 6.77 9 7.17
5 6.92 10 7.06
), ArticleFig(id=1200450376987177895, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=CN, label=表3, caption=

弹簧力值F=0.96 N时样机瞬时脱扣电流倍数

, figureFileSmall=null, figureFileBig=null, tableContent=
样机编号 瞬时脱扣电流倍数 样机编号 瞬时脱扣电流倍数
1 7.10 6 7.00
2 6.81 7 7.05
3 6.79 8 6.89
4 6.77 9 7.17
5 6.92 10 7.06
), ArticleFig(id=1200450377104618410, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=EN, label=Tab.4, caption=

40A product of C characteristic instantaneous tripping current multiple of prototype when spring force is F=1.51 N

, figureFileSmall=null, figureFileBig=null, tableContent=
样机编号 瞬时脱扣电流倍数 样机编号 瞬时脱扣电流倍数
1 6.75 6 6.49
2 6.88 7 6.79
3 6.45 8 6.81
4 6.72 9 6.53
5 6.85 10 6.64
), ArticleFig(id=1200450377226253234, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=CN, label=表4, caption=

C特性40A产品弹簧力值F=1.51 N时样机瞬时脱扣电流倍数

, figureFileSmall=null, figureFileBig=null, tableContent=
样机编号 瞬时脱扣电流倍数 样机编号 瞬时脱扣电流倍数
1 6.75 6 6.49
2 6.88 7 6.79
3 6.45 8 6.81
4 6.72 9 6.53
5 6.85 10 6.64
), ArticleFig(id=1200450377352082357, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=EN, label=Tab.5, caption=

Comparison table between theoretical calculation and actual measurement of instantaneous tripping current

, figureFileSmall=null, figureFileBig=null, tableContent=
特性 额定
电流/A
线圈匝数 弹簧力值/N 理论瞬时
脱扣电流/A
实测瞬时
脱扣电流/A
C 32 3 0.68 6.6In (5.55~6.01)In
3 0.96 (6.59~7.14)In (6.77~7.17)In
C 40 3 1.51 (6.37~6.75)In (6.45~6.85)In
), ArticleFig(id=1200450377494688698, tenantId=1146029695717560320, journalId=1189987059142926344, articleId=1200394759656305153, language=CN, label=表5, caption=

瞬时脱扣电流理论计算与实测值对比表

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特性 额定
电流/A
线圈匝数 弹簧力值/N 理论瞬时
脱扣电流/A
实测瞬时
脱扣电流/A
C 32 3 0.68 6.6In (5.55~6.01)In
3 0.96 (6.59~7.14)In (6.77~7.17)In
C 40 3 1.51 (6.37~6.75)In (6.45~6.85)In
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断路器瞬时脱扣装置脱扣电流的设计研究
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耿丽恺 1, 2 , 侯娟 1, 2 , 张春香 1, 2 , 胡文英 1, 2 , 李文华 3 , 李翠娟 4
电气传动 | 可靠性与诊断 2025,55(3): 91-96
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电气传动 | 可靠性与诊断 2025, 55(3): 91-96
断路器瞬时脱扣装置脱扣电流的设计研究
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耿丽恺1, 2 , 侯娟1, 2, 张春香1, 2, 胡文英1, 2, 李文华3, 李翠娟4
作者信息
  • 1 天津天传电控设备检测有限公司,天津 300300
  • 2 天津电气科学研究院有限公司,天津 300180
  • 3 河北工业大学 电气工程学院,天津 300401
  • 4 青岛市生态环境局胶州分局,山东 青岛 266300
  • 耿丽恺(1984—),男,硕士,高级工程师,Email:

Design and Research of Instantaneous Tripping Device for Circuit Breakers
Likai GENG1, 2 , Juan HOU1, 2, Chunxiang ZHANG1, 2, Wenying HU1, 2, Wenhua LI3, Cuijuan LI4
Affiliations
  • 1 Tianjin Tianchuan Electric Control Equipment Test Co.,Ltd.,Tianjin 300300,China
  • 2 Tianjin Research Institute of Electric Science Co.,Ltd.,Tianjin 300180,China
  • 3 School of Electrical Engineering,Hebei University of Technology,Tianjin 300401,China
  • 4 Jiaozhou Branch of Qingdao Municipal Bureau of Ecology and Environment,Qingdao 266300,Shandong,China
出版时间: 2025-03-20 doi: 10.19457/j.1001-2095.dqcd26072
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热磁式断路器通过瞬时脱扣装置进行短路保护。在通电线圈形成的磁场中,动、静铁心在电磁力的作用下克服弹簧反力吸合,进而推动断路器机构动作使产品脱扣。整个过程中只有电磁力达到一定的数值,动、静铁心才能在预设定的电流值下可靠地吸合。在实际的工程设计过程中,为了简化设计及计算过程,会忽略漏磁等问题,故理论计算得出的磁吸力,即弹簧反力值会小于预设目标。通过类比计算的方法,可以直接剔除漏磁和制作工艺过程中零件制作精度对试验结果的影响,一次完成瞬时脱扣装置的设计。最后,通过实际应用案例来说明如何通过理论计算和试验结合的方式,准确快速地设计出瞬时脱扣装置脱扣电流的方法。

断路器  /  瞬时脱扣装置  /  脱扣电流  /  脱扣电流的检测  /  类比计算

Thermal and magnetic protection circuit breakers provided short circuit protection by instantaneous tripping devices. In the magnetic field formed by the coil with current,the moving armature and stationary core overcomed the spring force and engage under the influence of electromagnetic force,thereby pushing the circuit breaker mechanism to operate and causing the product tripping. During the entire process,only when the electromagnetic force reaches a certain value could be the moving armature and stationary core reliably engage at the preset current value. In actual engineering design,in order to simplify the design and calculation process,issues such as magnetic leakage may be ignored. Therefore,the theoretical calculated magnetic attraction force,i.e. spring reaction force,will be smaller than the preset target. By analogy calculation method,it is possible to directly eliminate the influence of magnetic leakage and part manufacturing accuracy on the test results during the manufacturing process,and complete the design of the instantaneous release device once. Finally,practical application cases were used to illustrate how to accurately and quickly design an instantaneous release devices through a combination of theoretical calculations and experiments.

circuit breaker  /  instantaneous tripping device  /  tripping current  /  detection of instantaneous tripping current  /  analogous calculation
耿丽恺, 侯娟, 张春香, 胡文英, 李文华, 李翠娟. 断路器瞬时脱扣装置脱扣电流的设计研究. 电气传动, 2025 , 55 (3) : 91 -96 . DOI: 10.19457/j.1001-2095.dqcd26072
Likai GENG, Juan HOU, Chunxiang ZHANG, Wenying HU, Wenhua LI, Cuijuan LI. Design and Research of Instantaneous Tripping Device for Circuit Breakers[J]. Electric Drive, 2025 , 55 (3) : 91 -96 . DOI: 10.19457/j.1001-2095.dqcd26072
随着社会自动化和工业化程度的提高,工厂的用电量逐步提升,同时增加了电网对输配电设备的需求。在配电层级中,断路器作为重要的保护环节,其性能的稳定至关重要。当线路发生短路或者过载故障时,断路器能够可靠地动作,实现对电网和设备的有效保护。尤其是热磁式断路器,其因机械结构稳定可靠和价格低廉,得到了广泛应用。
当线路发生短路故障时,低压断路器通过瞬时脱扣装置来进行线路和设备的短路保护。低压断路器瞬时脱扣装置的脱扣特性需满足GB/T 14048.2[1]或GB/T 10963.1[2]标准的规定。在实际设计和生产过程中,为实现对瞬时脱扣装置的脱扣电流的测算,常用的方式为反复地制作样机和不断地试验验证,最终确定瞬时脱扣电流值,耗费了大量的时间和成本。而对于研发项目来说,时间目标和成本目标往往是不可调整的。本文的目的是通过计算和试验结合的方式,一次设计完成满足符合标准要求的瞬时脱扣装置的脱扣电流值,提高一次成功率和瞬时脱扣检测的合格率,缩短设计时间和降低设计成本。
断路器的瞬时脱扣装置,是指无任何人为的时间延迟而动作和没有任何故意的延时而动作的脱扣器。瞬时脱扣装置一般由静铁心、动铁心、线圈、反力弹簧组成[3],其结构简图如图1所示。瞬时脱扣装置的工作原理:动、静铁心在通电线圈所形成的磁场中产生磁场力;当线路发生短路,电流增大到足够量值时,动、静铁心在磁场中所产生的磁场力克服弹簧反力,动、静铁心吸合,进而推动断路器机构动作使机构脱扣,实现线路的短路保护。达到足够量值时的电流值即为断路器的瞬时脱扣电流。图1中,s表示的是磁路长度,即空气隙。
在不同的应用场景中,瞬时脱扣电流值有不同的脱扣形式要求,即不同的瞬时脱扣电流范围。在设计时,不能一味地追求断路器脱扣形式要求的下限瞬时脱扣电流值,应一并考虑在其制作过程中瞬时脱扣特性的合格率和瞬时脱扣特性的稳定性。故在实际研发过程中,较多的设计采用瞬时脱扣特性中脱扣电流范围的中值做为设计的中值。
线路中的电流流过断路器,在瞬时脱扣装置的线圈中形成磁场,动、静铁心在线圈所形成的磁场中,产生磁吸力。
麦克斯韦电磁吸力公式[4]如下式所示:
$F=\frac{{B}_{}^{2}\times S}{2\times {\mu }_{0}}$
式中:F为电磁吸力;B为磁感应强度;S为磁极横截面积;µ0为磁导率,对于瞬时脱扣装置,其为真空磁导率(4π×10-7 N/A2)。
为后续分析方便区分,设磁极横截面积S=A,即
$F=\frac{{B}_{}^{2}\times A}{2\times {\mu }_{0}}$
对于断路器瞬时脱扣装置,其工作气隙甚小且磁导体也不饱和,此时漏磁所占比重甚小,为了简化计算,漏磁因素忽略不计,则磁感应强度[5]
$B={\mu }_{{0}^{}}\times H$
其中
$H=\frac{n\times i}{s}$
式中:H为磁场强度;n为线圈匝数;i为线圈中流过的电流。
将式(4)代入式(3)中得:
$B=\frac{n\times i}{s}\times {\mu }_{0}$
将式(5)代入式(2)中,得:
$F=\frac{{\mu }_{0}\times A}{2\times {s}^{2}}\times {n}^{2}\times {i}^{2}$
在出现短路电流时,瞬时脱扣装置动作瞬间的i值即为瞬时脱扣电流值。从式(6)中可以看出弹簧反力值F与线圈匝数n的平方成正比,与线圈中流过的电流i的平方成正比。
由式(6)得出瞬时脱扣电流:
$i=\sqrt{\frac{2\times F}{{\mu }_{0}\times A}}\times \frac{s}{n}$
同一结构的断路器,磁脱装置是由相同的动铁心和静铁心组成的,其磁极有效横截面积A和空气隙s为定值。同一壳架等级不同额定电流的产品变化的是线圈匝数n和反力弹簧力值F。由式(7)可见瞬时脱扣电流i与弹簧力值F平方根成正比,与线圈匝数n成反比。
假设断路器标称的额定电流为In,当配电回路中出现短路故障时,线圈中流过故障电流为i,设ix倍的额定电流即i=xIn。则将i=xIn代入式(7)中,瞬时脱扣电流倍数x
$x=\sqrt{\frac{2\times F}{{\mu }_{0}\times A}}\times \frac{s}{n}\times \frac{1}{{I}_{\mathrm{n}}}$
从式(7)可以看出,瞬时脱扣电流与弹簧反力值F、有效横截面积A、空气隙s、真空磁导率µ0和线圈匝数n有关。其中, µ0为定值,而反力弹簧力值F、有效横截面积A、空气隙s、线圈匝数n都与零件制作过程中的制作工艺精度有关,均存在尺寸公差。由此可见,零件制作的精度会直接影响瞬时脱扣电流的大小。
在实际断路器通电过程中,瞬时脱扣装置还存在漏磁等现象,漏磁等因素在实际中的分布较复杂,其理论计算也较复杂,在设计时较常见的是人工计算。所以,为了简化设计计算过程,往往不会将漏磁等问题计算进去,但是其影响是不能忽略的。
基于上述两个问题考虑,特采用类比计算的方法来设计研究瞬时脱扣电流。
同一壳架等级的断路器,假设断路器标称的额定电流为In1,线圈中流过的电流i1a倍的额定电流,即i1=a×In1;假设断路器标称的额定电流为In2,线圈中流过的电流i2b倍的额定电流,即i2=b×In2。则式(6)可列为
${F}_{1}=\frac{{\mu }_{0}\times A}{2\times {s}^{2}}\times {n}_{1}^{2}\times {i}_{1}^{2}$
${F}_{2}=\frac{{\mu }_{0}\times A}{2\times {s}^{2}}\times {n}_{2}^{2}\times {i}_{2}^{2}$
式(9)除以式(10)得:
$\frac{{F}_{1}}{{F}_{2}}=\frac{{n}_{1}^{2}\times {i}_{1}^{2}}{{n}_{2}^{2}\times {i}_{2}^{2}}=\frac{{n}_{1}^{2}\times {a}^{2}\times {I}_{\mathrm{n}1}^{2}}{{n}_{2}^{2}\times {b}^{2}\times {I}_{\mathrm{n}2}^{2}}$
式(11)整理得:
$b=a\times \frac{{I}_{\mathrm{n}1}}{{I}_{\mathrm{n}2}}\times \frac{{n}_{1}}{{n}_{2}}\times \sqrt{\frac{{F}_{2}}{{F}_{1}}}$
从式(12)中可以看出,瞬时脱扣电流倍数b与瞬时脱扣电流倍数a、电流In1In2、线圈匝数n1n2、反力弹簧力值F1F2有关。式(12)中已经不再包含反力弹簧力值F、有效横截面积A、空气隙s等参数。
通过上述分析以及式(7)、式(12)公式对比可见,式(12)中瞬时脱扣电流倍数b只与弹簧反力值、额定电流、线圈匝数和瞬时脱扣电流倍数a有关,上述所涉及的数据均是可以测量和量化的。式(12)中已经剔除了零件精度和漏磁等问题对计算结果的影响。故采用式(12)将瞬时脱扣电流转化为瞬时脱扣电流倍数来进行分析计算。
后文通过试验样机数据来验证上述理论分析的正确性和准确度。
本文以小型断路器标准GB/T 10963.1为例进行分析和验证。标准GB/T 10963.1《电气附件 家用及类似场所用过电流保护断路器 第1部分:用于交流的断路器》的规定如表1所示。
C特性断路器瞬时脱扣电流标准中要求为5~10倍的额定电流,其瞬时脱扣电流组中值为7.5倍的额定电流。在实际使用场景中,当发生瞬时短路电流时,瞬时脱扣装置较早脱扣更有利于保护线路和设备。因此在设计时,C特性断路器的瞬时脱扣电流值较多取7倍的额定电流。
在同一壳架等级断路器中,以C特性32A产品为例进行分析计算瞬时脱扣装置的脱扣电流以及倍数。定值参数磁极横截面积A=π×(5.5/2)2mm2[6],空气隙s=3 mm,真空磁导率µ0=4π×10-7 N/A2。额定电流In=32 A,取线圈匝数n=3,弹簧力值F=0.68 N。
由式(7)得出理论瞬时脱扣电流i=213.4 A。瞬时脱扣电流i=aIn,算得瞬时脱扣电流倍数a=6.6。瞬时脱扣电流6.6In在标准要求的瞬时脱扣电流5In~10In之间,且在设计瞬时脱扣电流中值7In附近。
GB/T 10963.1中对瞬时脱扣特性的试验验证在9.10.3条款中进行了定义:对于C特性断路器从冷态开始,对所有极串联通以5In的电流。断开时间应不小于0.1 s。然后再从冷态开始,分别对每一极通以10In的电流。断路器应在小于0.1 s时间内脱扣。
在对瞬时脱扣电流设计研究过程中,需要对具体的瞬时脱扣电流值和断开时间进行检测。试验过程可以采用示波器对具体瞬时脱扣电流值和断开时间进行检测[7]
根据3.1节所确定的AsnF等参数值,制作额定电流In=32 A的10台样机,对其进行瞬时脱扣电流的检测。为了方便分析对比,将检测得到的瞬时脱扣电流值转化为瞬时脱扣电流倍数进行分析,其检测结果如表2所示。
实测值的分布图如图2所示。实测瞬时脱扣电流范围为5.55In~6.01In,实测瞬时脱扣电流倍数远低于预定的C特性设计瞬时脱扣电流倍数中值7倍。不满足设计的要求,需要进行设计调整。
在断路器设计过程中,产品外形确定后,瞬时脱扣装置的空间也就确定下来了,进而铁心的横截面积A、空气隙s就为定值了。通过式(7)可以得出,通过调整线圈匝数n和弹簧力值F可以达到调整瞬时脱扣电流i的目的。从制造工艺的角度考虑,弹簧力值可调性更高,更容易实现,固优先考虑调整弹簧反力值F [8]
本文分析的样本In=32 A,则式(12)中In1= In2=32 A,n1=n2=3,式(11)可以简化为
$b=a\times \sqrt{{F}_{2}/{F}_{1}}$
则式(13)只与弹簧力值F和瞬时脱扣电流倍数a有关。aF1为已知量,如要增大b,则需增加F2值。即通过增大弹簧力值F来提高瞬时脱扣电流,提高弹簧力值FF2=0.96 N。
表2检测的实测值最小值为${i}_{1}^{\text{'}}$=5.55In,最大值为${i}_{1}^{"}$=6.01InF1=0.68 N。则式(13)中取a'=5.55,${a}_{}^{"}$=6.01。将a'F1F2代入到式(13)中,得出b'=6.59;将${a}_{}^{"}$F1F2代入到式(13)中,得出${b}_{}^{"}$=7.14。当反力弹簧更改为F2=0.96 N时,根据F1=0.68 N获得的实测值,计算出的理论瞬时脱扣电流为6.59In~7.14In
根据实测值计算调整反力弹簧力值F后得出的理论计算结果,进行新样机瞬时脱扣电流数据检测,其检测结果数据如表3所示。
实测瞬时脱扣电流倍数数据范围为6.77In~7.17In,实测脱扣电流倍数在设计瞬时脱扣电流倍数7倍中值左右,且吻合性很好。实测值的分布图如图3所示。
为更好地验证上述计算方法的普适性,以C特性40A产品为例,再次对瞬时脱扣电流及倍数进行分析和计算。直接以3.3节中C特性32A产品实测瞬时脱扣电流倍数数据6.77In~7.17In为基准,来计算40A产品的瞬时脱扣电流及倍数,并进行样机试制。
设C特性40A产品的定值参数与32A产品相同,定值参数磁极横截面积A=π×(5.5/2)2 mm2,空气隙s=3 mm,真空磁导率µ0=4π×10-7 N/A2。额定电流In=40 A,取线圈匝数n=3,弹簧力值F=1.18 N。
3.3节中瞬时脱扣电流倍数a=6.77~7.17,F1=0.96 N,n1=3,由式(12)得出40A产品的瞬时脱扣电流倍数b为5.63~5.96。
40A理论计算瞬时脱扣电流为(5.63~5.96)In,在标准要求的瞬时脱扣电流(5~10)In之间,但瞬时脱扣电流倍数远低于预定的C特性设计瞬时脱扣电流倍数中值7倍。不满足设计的要求,需要进行设计调整。
增大弹簧力值F来提高瞬时脱扣电流,提高弹簧力值FF2=1.51 N。由式(12)得出40A产品的瞬时脱扣电流为(6.37~6.75)In,在标准要求的瞬时脱扣电流(5~10)In之间,且在设计瞬时脱扣电流中值7In附近。
调整反力弹簧力值F后得出的瞬时脱扣电流理论计算结果,进行新样机瞬时脱扣电流数据检测,其检测结果数据如表4所示。
实测瞬时脱扣电流倍数数据范围为(6.45~6.85)In,实测脱扣电流倍数已在设计瞬时脱扣电流倍数7倍中值左右,吻合性很好。实测值的分布图如图4所示。
C特性40A产品其理论计算瞬时脱扣电流为(6.37~6.75)In,实测瞬时脱扣电流为(6.45~6.85)In。从上述40A产品的理论计算和实测瞬时脱扣电流数据的对比,再次验证了2.4节瞬时脱扣电流倍数类比计算方法的可实施性。
本文理论计算的数据和实测的数据整理如表5所示。
表5可见,在弹簧力值F=0.68 N时,理论瞬时脱扣电流和实际试制样机时的实测瞬时脱扣电流二者的结果存在一定的差异,此差异的产生在实际的生产过程中是正常的。根据2.4小节分析其设计过程中由于简化漏磁等因素和零件制作过程中的精度问题[9],其试验样机实测瞬时脱扣电流数值(5.55~6.01)In理应低于理论计算数值6.6In
F=0.96 N制作样机前的理论计算值采用的计算源数据是F=0.68 N时制作样机实测的数据,F=0.96 N的理论计算所得到的数据采用的是式(13)的计算结果,式(13)中已经不再包含反力弹簧力值F、有效横截面积A、空气隙s等数据,剔除了零件精度对计算结果所产生的影响,且采用类比计算,消除了F=0.68 N时理论计算忽略漏磁等因素所带来的影响[10],所以F=0.96 N时样机实测的瞬时脱扣电流数据与理论瞬时脱扣电流数据很接近,得出的结果非常准确。F=0.96 N时理论计算数据为${7}_{-0.41}^{0.14}$,实测数据为${7}_{-0.23}^{0.17}$,瞬时脱扣电流倍数理论计算值与实测值吻合度达到了97.3%。
热磁式断路器瞬时脱扣装置脱扣电流的设计,根据标准的要求预设定所需要的瞬时脱扣电流中值,然后根据空间的大小预设线圈的匝数,利用磁吸力公式计算出弹簧反力的大小。计算得出的此弹簧反力大小还需要考虑在瞬时脱扣装置既定的空间内是否可以放置此反力弹簧。
瞬时脱扣装置的空间确定后,铁心尺寸和空气隙大小均为固定值,且没有调整空间,预定的瞬时脱扣电流为按标准确定的设计中值,基本也没有可调空间。在测算过程中只有线圈匝数和弹簧力值可以调整,以使其达到预定的瞬时脱扣电流值。从制造工艺的角度考虑,弹簧力值可调性更高,更容易实现,固优先考虑调整弹簧反力值。
在实际生产过程中,大部分瞬时脱扣装置的设计都出自原有的模型,此时可以直接采用本文调整过程中所采用的式(12)或式(13)类比方法进行理论计算,从而剔除漏磁和制作工艺过程中零件制作精度对试验结果的影响。从本文计算和试验数据的对比可见,根据类比计算方法,一次得到了设计结果。
理论计算的目的是能够准确快速地实现既定的设计目标,避免反复的样机试制和试验带来的时间和成本的浪费,大大提高了一次成功率和瞬时脱扣检测的合格率,缩短了设计时间和降低了设计成本。
本文中采用的是相同额定电流下进行的样本举例分析,不同额定电流下的分析也是同样的分析步骤。
  • 天津电气科学研究院有限公司自立科研项目(JC2023ZL005)
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doi: 10.19457/j.1001-2095.dqcd26072
  • 接收时间:2024-07-20
  • 首发时间:2025-11-26
  • 出版时间:2025-03-20
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  • 收稿日期:2024-07-20
  • 修回日期:2024-10-09
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天津电气科学研究院有限公司自立科研项目(JC2023ZL005)
作者信息
    1 天津天传电控设备检测有限公司,天津 300300
    2 天津电气科学研究院有限公司,天津 300180
    3 河北工业大学 电气工程学院,天津 300401
    4 青岛市生态环境局胶州分局,山东 青岛 266300
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2种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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