Article(id=1222482831335482265, tenantId=1146029695717560320, journalId=1149653034449285133, issueId=1222482826851771163, articleNumber=null, orderNo=null, doi=10.16790/j.cnki.1009-9239.im.2021.02.012, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1597939200000, receivedDateStr=2020-08-21, revisedDate=1600012800000, revisedDateStr=2020-09-14, acceptedDate=null, acceptedDateStr=null, onlineDate=1769392219623, onlineDateStr=2026-01-26, pubDate=1613750400000, pubDateStr=2021-02-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1769392219623, onlineIssueDateStr=2026-01-26, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1769392219623, creator=13041195026, updateTime=1769392219623, updator=13041195026, issue=Issue{id=1222482826851771163, tenantId=1146029695717560320, journalId=1149653034449285133, year='2021', volume='54', issue='2', pageStart='1', pageEnd='106', issueExtLink='null', onlineDate='null', pubDate='1613750400000', pubDateStr='2021-02-20', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1769392218554, creator='13041195026', updateTime=1770971669597, updator='13701087609', preIssue=null, nextIssue=null, articleTotal=null, ext={EN=IssueExt(id=1229107524746670183, tenantId=1146029695717560320, journalId=1149653034449285133, issueId=1222482826851771163, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1229107524750864488, tenantId=1146029695717560320, journalId=1149653034449285133, issueId=1222482826851771163, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null, downloadFileDto=null}, startPage=68, endPage=74, ext={EN=ArticleExt(id=1222482831687803824, articleId=1222482831335482265, tenantId=1146029695717560320, journalId=1149653034449285133, language=EN, title=Analysis on Ampacity and Temperature Distribution of Electric Vehicle Cable with High Thermal Conductivity, columnId=1222482827711603484, journalTitle=Insulating Materials, columnName=Special Issue on Thermal Conductive Insulating, runingTitle=null, highlight=null, articleAbstract=

In order to expand the new energy vehicle market and improve the power transmission efficiency of new energy vehicles, it is necessary to improve the current-carrying capacity of its internal cables. But at the same time, with the increase of load current, the heat dissipation problem of vehicle cable has become prominent. In this study, a finite element simulation model of vehicle cable considering electric field and thermal field was established by COMSOL software, the ampacity was solved by the Nelder-Mead method, and then the effectiveness of Nelder-Mead method was verified by the analytical methods. The improvement effect of the increase of insulation material thermal conductivity on the current-carrying capacity and heat dissipation of the vehicle cable was simulated analyzed. The results show that when a silicone rubber/boron nitride nanosheets (20%) composites with 0.833 W/(m·K) of thermal conductivity was used in vehicle cable, the ampacity of vehicle cable obtained by simulation increases by 5.12%, which can promote heat dissipation more significantly at overload, but it would increase the critical radius of insulation, resulting in a slight increase of conductor temperature when the insulation thickness decreases within the critical radius of insulation.

, authors=null, authorsList=Jin LI, Yifang WANG, Xiaoxiao KONG, Boxue DU, Jing XU, Chuanbin WANG, Chongjun TIAN, authorCompany=null, correspAuthors=null, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1222482837580800262, articleId=1222482831335482265, tenantId=1146029695717560320, journalId=1149653034449285133, language=CN, title=电动汽车用高导热车载线温度场分布与载流量分析, columnId=1222482827858404128, journalTitle=绝缘材料, columnName=导热绝缘专题, runingTitle=null, highlight=null, articleAbstract=

为了扩大新能源汽车市场,提升新能源汽车动力传输的效率,需要提高其内部车载线的载流能力,但同时随着负载电流的增加,车载线的散热困难问题凸显。本研究应用COMSOL软件建立车载线电热耦合的有限元仿真模型,应用Nelder-Mead方法求解出载流量,并对比解析方法,验证Nelder-Mead方法的有效性。仿真分析绝缘材料热导率的提升对车载线载流量和散热的改善效果。结果表明:应用热导率为0.833 W/(m·K)的硅橡胶/氮化硼纳米片(20%)高导热复合材料,仿真得到车载线的载流量提升了5.12%,在过载时能更好地促进散热,但也增加了绝缘临界半径,导致绝缘厚度在绝缘临界半径以内减薄时,导体温度有轻微升高。

, authors=

李进(1988-),男(汉族),河北唐山人,副教授,博士,主要从事大容量电缆与气体绝缘输电管道绝缘设计与缺陷检测的研究。

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李进(1988-),男(汉族),河北唐山人,副教授,博士,主要从事大容量电缆与气体绝缘输电管道绝缘设计与缺陷检测的研究。

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李进(1988-),男(汉族),河北唐山人,副教授,博士,主要从事大容量电缆与气体绝缘输电管道绝缘设计与缺陷检测的研究。

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The critical radius of insulation in thermal radiation environment.[J]. 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tableContent=null), ArticleFig(id=1222974147441971630, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1222482831335482265, language=CN, label=图8, caption=径向温度分布, figureFileSmall=tpkRPj6tlDyssmwWLPocjw==, figureFileBig=bWPUvhtT07CLGnfYR3m1og==, tableContent=null), ArticleFig(id=1222974147509080497, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1222482831335482265, language=EN, label=Tab.1, caption=Size and material parameters, figureFileSmall=null, figureFileBig=null, tableContent=
结构材料

外半径

/mm

导热系数

/(W/(m·K))

恒压热容

/(J/(kg·K))

密度

/(kg/m3)

导体层第6种软铜导体5.254003858700
绝缘层硅橡胶6.100.215001000
屏蔽层铜丝编织加铝塑复合带6.804003857400
外护层硅橡胶7.900.215001000
), ArticleFig(id=1222974147576189363, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1222482831335482265, language=CN, label=表1, caption=

尺寸参数及材料参数

, figureFileSmall=null, figureFileBig=null, tableContent=
结构材料

外半径

/mm

导热系数

/(W/(m·K))

恒压热容

/(J/(kg·K))

密度

/(kg/m3)

导体层第6种软铜导体5.254003858700
绝缘层硅橡胶6.100.215001000
屏蔽层铜丝编织加铝塑复合带6.804003857400
外护层硅橡胶7.900.215001000
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环境温度/℃热导率/(W/(m·K))载流量/AΔk/%
200.24690
0.34792.13
0.44853.41
0.54884.05
0.64904.48
0.74924.90
0.84935.12
0.94945.33
1.04955.54
1.14965.76
1.24965.76
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不同热导率下的载流量

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环境温度/℃热导率/(W/(m·K))载流量/AΔk/%
200.24690
0.34792.13
0.44853.41
0.54884.05
0.64904.48
0.74924.90
0.84935.12
0.94945.33
1.04955.54
1.14965.76
1.24965.76
), ArticleFig(id=1222974147785904569, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1222482831335482265, language=EN, label=Tab.3, caption=Ampacity of high thermal conductivity vehicle cables and ordinary vehicle cables, figureFileSmall=null, figureFileBig=null, tableContent=
电缆类型普通车载线高导热车载线Δk/%
载流量/A4694935.12
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高导热车载线和普通车载线的载流量

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电缆类型普通车载线高导热车载线Δk/%
载流量/A4694935.12
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尺寸类型绝缘层厚度/mm外护层厚度/mm外半径/mm
0.851.107.90
0.801.057.80
0.751.007.70
), ArticleFig(id=1222974148029174207, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1222482831335482265, language=CN, label=表4, caption=

不同绝缘厚度的尺寸参数

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尺寸类型绝缘层厚度/mm外护层厚度/mm外半径/mm
0.851.107.90
0.801.057.80
0.751.007.70
), ArticleFig(id=1222974148134031809, tenantId=1146029695717560320, journalId=1149653034449285133, articleId=1222482831335482265, language=EN, label=Tab.5, caption=Conductor temperature of different insulation thickness, figureFileSmall=null, figureFileBig=null, tableContent=
尺寸类型导体温度/℃
普通车载线高导热车载线
126.06115.58
126.82116.75
127.54117.92
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不同绝缘厚底下的导体温度

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尺寸类型导体温度/℃
普通车载线高导热车载线
126.06115.58
126.82116.75
127.54117.92
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电动汽车用高导热车载线温度场分布与载流量分析
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李进 1, 2 , 王义方 1 , 孔晓晓 1 , 杜伯学 1 , 徐静 2 , 汪传斌 2 , 田崇军 2
绝缘材料 | 导热绝缘专题 2021,54(2): 68-74
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绝缘材料 |导热绝缘专题 2021 , 54 (2) : 68 -74
电动汽车用高导热车载线温度场分布与载流量分析
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李进(1988-),男(汉族),河北唐山人,副教授,博士,主要从事大容量电缆与气体绝缘输电管道绝缘设计与缺陷检测的研究。

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李进(1988-),男(汉族),河北唐山人,副教授,博士,主要从事大容量电缆与气体绝缘输电管道绝缘设计与缺陷检测的研究。

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李进1, 2, 王义方1, 孔晓晓1, 杜伯学1, 徐静2, 汪传斌2, 田崇军2
作者信息
  • 1天津大学 电气自动化与信息工程学院 智能电网教育部重点实验室,天津 300072
  • 2远东电缆公司,江苏 无锡 214257
Analysis on Ampacity and Temperature Distribution of Electric Vehicle Cable with High Thermal Conductivity
Jin LI1, 2, Yifang WANG1, Xiaoxiao KONG1, Boxue DU1, Jing XU2, Chuanbin WANG2, Chongjun TIAN2
Affiliations
  • 1Key Lab of Smart Grid of Ministry of Education, School of Electrical and Information Engineering, Tianjin University, Tianjin 300072, China
  • 2Yuandong Cable Co., Ltd., Wuxi 214257, China
出版时间: 2021-02-20 doi: 10.16790/j.cnki.1009-9239.im.2021.02.012
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为了扩大新能源汽车市场,提升新能源汽车动力传输的效率,需要提高其内部车载线的载流能力,但同时随着负载电流的增加,车载线的散热困难问题凸显。本研究应用COMSOL软件建立车载线电热耦合的有限元仿真模型,应用Nelder-Mead方法求解出载流量,并对比解析方法,验证Nelder-Mead方法的有效性。仿真分析绝缘材料热导率的提升对车载线载流量和散热的改善效果。结果表明:应用热导率为0.833 W/(m·K)的硅橡胶/氮化硼纳米片(20%)高导热复合材料,仿真得到车载线的载流量提升了5.12%,在过载时能更好地促进散热,但也增加了绝缘临界半径,导致绝缘厚度在绝缘临界半径以内减薄时,导体温度有轻微升高。

电动汽车车载线  /  有限元仿真  /  Nelder-Mead法  /  载流量  /  温度分布

In order to expand the new energy vehicle market and improve the power transmission efficiency of new energy vehicles, it is necessary to improve the current-carrying capacity of its internal cables. But at the same time, with the increase of load current, the heat dissipation problem of vehicle cable has become prominent. In this study, a finite element simulation model of vehicle cable considering electric field and thermal field was established by COMSOL software, the ampacity was solved by the Nelder-Mead method, and then the effectiveness of Nelder-Mead method was verified by the analytical methods. The improvement effect of the increase of insulation material thermal conductivity on the current-carrying capacity and heat dissipation of the vehicle cable was simulated analyzed. The results show that when a silicone rubber/boron nitride nanosheets (20%) composites with 0.833 W/(m·K) of thermal conductivity was used in vehicle cable, the ampacity of vehicle cable obtained by simulation increases by 5.12%, which can promote heat dissipation more significantly at overload, but it would increase the critical radius of insulation, resulting in a slight increase of conductor temperature when the insulation thickness decreases within the critical radius of insulation.

electrical vehicle cable  /  finite element simulation  /  Nelder-Mead method  /  ampacity  /  temperature distribution
李进, 王义方, 孔晓晓, 杜伯学, 徐静, 汪传斌, 田崇军. 电动汽车用高导热车载线温度场分布与载流量分析. 绝缘材料, 2021 , 54 (2) : 68 -74 . DOI: 10.16790/j.cnki.1009-9239.im.2021.02.012
Jin LI, Yifang WANG, Xiaoxiao KONG, Boxue DU, Jing XU, Chuanbin WANG, Chongjun TIAN. Analysis on Ampacity and Temperature Distribution of Electric Vehicle Cable with High Thermal Conductivity[J]. Insulating Materials, 2021 , 54 (2) : 68 -74 . DOI: 10.16790/j.cnki.1009-9239.im.2021.02.012
车载线是指电动汽车内部的高压屏蔽电缆,用于连接电池包、高压配电单元、电机等高压电力部件,为帮助电动汽车高效地输送电能发挥了重要的作用[1-2]。近年来,随着电动汽车的不断推广,人们越来越关注电动汽车的动力传输性能。为了提升电能输送效率,缩短输电时间,车载线载流能力需要进一步提升,但更大的电流导致敷设在电动汽车内部狭小空间里的车载线出现散热困难的问题[3-4]。因此,车载线需要增大载流量来满足载流需求,同时提升散热能力。
众所周知,电缆各层绝缘材料的热阻与载流量大小互相影响,而且导热量和材料的热导率成正比关系[5-7]。然而,目前电缆各层所用的常规绝缘材料均为热的不良导体,热阻大,热导率小,导致电缆载流量低,散热性能较差,绝缘层出现较大温度梯度[8]。已有研究在保证材料电气与力学性能的前提下,分别针对HVDC电缆和充电电缆采用高导热材料对绝缘层进行改性,提升了导热性能和载流能力,同时发现载流量随着热导率的提升出现增长放缓的现象[9-11]。但是,不同类型电缆的结构和敷设方式不同,目前没有针对电动汽车用车载线来研究绝缘材料热导率对载流量的影响,也没有针对高导热车载线的载流量提升效果和散热改善效果进行综合分析。
本研究应用COMSOL软件建立车载线电热耦合的有限元仿真模型,应用Nelder-Mead方法求解出载流量,并对比解析方法,验证Nelder-Mead方法的有效性。其次,仿真计算不同热导率绝缘材料的载流量提升效果,选出适合车载线的高导热绝缘材料。最后研究高导热车载线在负载电流、绝缘层厚度影响下对散热改善的效果。
选择额定直流电压为1 000 kV的单芯屏蔽车载线模型,外部环境为汽车内自然对流的空气,车载线在车内的分布如图1所示。导体标称横截面积选定为50 mm2,从内到外依次是导体层、绝缘层、屏蔽层、外护层,车载线结构如图2所示[12-13]
车载线结构参数和材料参数如表1所示。为了保证耐热性,选择硅橡胶作为绝缘层和外护层的材料,耐热等级达到E级,导体允许的最高运行温度为175℃,尺寸参数均在标准规定的范围内[14-16]。在第4节中将硅橡胶材料替换成高导热硅橡胶复合材料,对散热问题进行研究。
本研究应用COMSOL软件中的电流场和传热场建立三维车载线电热耦合模型[17-18]。仿真模型的尺寸和材料参数同表1,厚度为1 mm,模型周围设置为空气自然对流条件。本研究建立的仿真模型适用于空气敷设下任意电缆的载流量计算,对于直埋电缆和管道敷设电缆的载流量计算则需额外在电缆外部添加相应介质。本仿真的前提假设如下:①忽略车载线与汽车内部环境的热辐射,仅考虑车载线表皮的对流换热;②忽略温度梯度和电场强度对绝缘层和外护层材料电导率的影响;③在仿真模型中进行迭代求解载流量时忽略车载线电压下降带来的影响;④忽略敷设环境内其他电缆作为热源存在,仅考虑单一车载线下的温度分布;⑤单一车载线的热源仅考虑导体损耗,忽略极化损耗生热。
按照前提假设建立几何模型,并分别针对两个耦合的物理场进行边界条件的设置。仿真几何模型和边界条件如图3所示。首先是电流场中要模拟施加在导体中的电流、电压,屏蔽层需要接地。其次,传热场模拟外表皮与自然空气之间的对流换热,在车载线侧面表皮施加第3类边界条件。因为本研究将电流场和传热场耦合后进行多物理场仿真,所以负载电流产生的热量将会自动计算得出。但需注意导体的电导率是一个随温度变化的函数,如式(1)所示。因此需要对导体材料的电导率进行修改。
f(θc)=1ρc1+α20(θc-20)
式(1)中:ρc是铜在20℃下的电阻率,其值为1.724×10-8 Ω·m;α20是在20℃下每开尔文的质量温度系数,其值为3.93×10-3
车载线有限元仿真计算的主要原理是一种数值计算。导体温度无限接近于最高允许温度时的电流值即为稳态载流量。只有已知流经车载线导体的电流值才能获得车载线的温度分布,进而得知导体温度,但是求解载流量需要先使导体温度达到最高允许的运行温度。因此,载流量的计算存在一定难度。本研究使用Nelder-Mead方法,通过迭代求解车载线的载流量[19]。Nelder-Mead方法的优点是不用求导,而是从小到大依次将目标函数值进行排序来取得最值;缺点是迭代次数和迭代时间受到计算区间和初始值的影响[20]
当应用Nelder-Mead法来求解目标函数的最小值时,通过反射、扩张、收缩和压缩4种方式来增大或缩小求解区间,将区间内的目标函数值按照从小到大的顺序排列好之后,再进行下一次迭代计算[21]。当计算导体温度和最高允许温度差值的绝对值最小时,求出此时对应的电流值。本研究预设迭代计算的电流区间是400~500 A,从400 A开始进行初始计算。式(2)表示导体温度和最高允许温度差值的绝对值达到最小时终止迭代,其中,θc为导体温度,θ为导体最高允许工作温度,ε表示容差,取0.01。终止迭代的另一种原因是迭代次数达到阈值,表示在给定计算区间内找不到最小值,本研究选取迭代次数的阈值为1 000。
|θc-θ|ε
最终得出在20℃的环境温度下,普通车载线的载流量为469.09 A,取整数为469 A,此时的温度分布如图4所示,导体温度十分趋近于175℃,表明载流量计算正确。
Nelder-Mead法的迭代过程如图5所示。从图5可以看出,在469 A附近存在|θc|的最小值,印证了载流量的计算准确。从图5还可以看出,本研究迭代次数为44次,从电流400 A时开始计算,随着迭代次数的增加,电流区间逐渐缩小,迭代30次之后,电流区间就在载流量附近很小的范围内变化,直至求出|θc|最小时的电流值,即载流量。
等值热路模型是基于固体传热理论的模型,将电缆各层等效为多层同心圆筒模型,描述从电缆芯至电缆外表皮沿半径方向的传热过程[22-24]。高压直流车载线的等效热路模型如图6所示。图6Wc代表导体损耗,单位为W/m。导体损耗是指电流流经线芯导体产生的焦耳热,导体损耗与温度有关,随温度不断变化。导体损耗是车载线生热的来源,即热源。T1T3T4分别代表绝缘层热阻、外护层热阻和环境热阻,单位为K·m/W。θcθiθsθa分别代表导体温度、绝缘层表面温度、外护层表面温度和环境温度,单位为℃。
电缆稳态载流量解析计算的主要依据是IEC 60287标准[5-6]。本研究车载线的额定直流电压为1 000 V,因此采用IEC 60287规定的5 kV以下直流电缆载流量计算公式,简化后的公式如式(3)所示[12]
I=ΔθR'T0,5
式(3)中:Δθ是导体最高允许工作温度θ与环境温度θa的差值,单位为℃;R′是在最高温度下导体每单位长度的直流电阻,单位为Ω/m;T是每单位长度的传热总热阻值,即热阻T1T3T4之和,单位为K·m/W。
绝缘层热阻T1的计算公式如式(4)所示。
T1=ρT2πln1+2t1dc
式(4)中:ρT表示绝缘层材料的热阻率,单位为 K·m/W;t1表示绝缘层的厚度,单位为mm;dc为导体的直径,单位为mm。外护层热阻T3和环境热阻T4的计算公式均参考IEC标准,在此不再展开叙述。
为了验证本研究有限元仿真计算的载流量是否准确,将传统解析法的结果和有限元仿真的结果进行对比。
在20℃的环境温度下,解析法的计算结果为472 A,有限元仿真的计算结果为469 A,两个方法的载流量差值为3 A,误差为0.6%。V K RAO[13]计算出50 mm2的电动汽车高压车载线在室温下载流量为470 A。因此本研究提出的方法是行之有效的。
绝缘材料的热导率影响着电缆的载流量,而且随着热导率的提升,电缆载流量的增长变得缓慢[9-11]。同时绝缘复合材料热导率的提升也需要提高导热填料的含量。为了保证车载线载流量提升的经济性,不能过度掺杂高导热填料。因此,车载线绝缘材料热导率的合理选择至关重要。不同热导率下电缆的载流量如表2所示,载流量取整数。从表2可以看出,在20℃的环境温度下,随着热导率的增加,载流量逐渐增长,而提升比例Δk(见式(5))也在逐渐放缓。当热导率为0.8~1.2 W/(m·K)时,载流量提升比例均在5%以上,但很难超过6%,而且热导率从1.1 W/(m·K)提升至1.2 W/(m·K)时,两个载流量整数值相同,意味着载流量增量已不足1 A。
Δk=Iλ-I0.2I0.2
因此对于高导热车载线来说,绝缘材料的热导率达到0.8 W/(m·K)已足够,本研究选择掺杂20%氮化硼纳米片的硅橡胶纳米复合材料作为绝缘层和外护层材料,其中采用的生胶是沈阳金帝贸易有限公司生产的分子量为55万、乙烯基摩尔分数为0.12%的聚二甲基乙烯基硅橡胶;采用的填料是北京德科岛金科技有限公司生产的平均厚度小于100 nm、片径为1~3 μm、比表面积为30 m2/g的氮化硼纳米片。制得的硅橡胶/氮化硼纳米复合材料热导率为0.833 W/(m·K),替换普通硅橡胶,最终制成高导热车载线。高导热车载线和普通车载线的载流量对比如表3所示。
为了验证载流量提升放缓的原因,本研究画出导体温度随绝缘材料热导率变化的曲线图,如图7所示。
图7可以看出,在400 A电流和20℃的环境温度下,随着绝缘材料热导率的增加,导体温度的下降也逐渐放缓,和载流量的情况相同,验证了导体温度是载流量提升放缓的原因[9]。此外,随着环境温度的升高,导体温度也逐渐升高,而且在不同环境温度下,导体温度随绝缘材料热导率的变化趋势相同,表明提升绝缘材料热导率对散热的改善趋势不受环境温度的干扰。
对于车载线散热的问题,可以从温度行为进行研究。引起散热变化的原因有很多,外因包括环境温度、流经线芯的负载电流,内因有绝缘材料的热导率、厚度等。下面从负载电流和绝缘材料的厚度的角度来分析高导热车载线对散热的改善效果。
在通常条件下,电缆负载电流增加,导体温度升高、绝缘层温度梯度扩大,导致绝缘材料的寿命缩短[15]。高导热绝缘材料的应用可以降低电缆导体温度和绝缘层的温度梯度[9-11]。因此,本研究在不同负载电流下(轻载和过载)计算高导热车载线的径向温度,验证高导热车载线对散热的改善效果。
图8为车载线径向温度分布曲线,“A”表示普通车载线,“B”代表高导热车载线,因为在20℃的环境温度下,普通车载线载流量为469 A,高导热车载线载流量为493 A,因此“400 A”代表车载线轻载状态,“500 A”代表车载线过载状态,曲线1、2、3、4分别代表在环境温度为20℃下普通车载线轻载时、高导热车载线轻载时、普通车载线过载时和高导热车载线过载时的径向温度分布情况。
对比图8中曲线1和曲线2,在轻载条件下,相比普通车载线,高导热车载线绝缘层和外护层温度梯度更小,导体温度降低了11℃,绝缘层温差缩小了76.7%,表明高导热材料有利于降低电缆的导体温度和绝缘层温度梯度,维持绝缘材料的使用寿命。而过载时,如曲线3和曲线4所示,高导热绝缘层和外护层温度梯度减小更为明显,绝缘层温差缩小了77.2%,导体温度降低了22℃,表明负载电流越大,高导热材料对散热的促进效果越突出。另外,从曲线1到曲线3,导体温度升高了76℃;从曲线2到曲线4,导体温度升高了65℃。这表明在相同负载电流增量下,高导热车载线升温更低,促进了散热。在电动汽车加速、减速和充电等过程中发生负载电流变化时,高导热车载线可以有效缓解导体升温,促进散热。
为了验证高导热车载线绝缘层厚度对车载线散热的影响,本研究在标准规定的合理范围内进行绝缘层和外护层厚度的减薄,共设置了3种尺寸类型,尺寸参数如表4所示。
在20℃的环境温度下绝缘层厚度减薄后400 A电流下的导体温度变化如表5所示。
表5可以看出,随着车载线绝缘层厚度的减薄,普通和高导热车载线的导体温度均出现轻微升高,但是,高导热车载线导体温度的增量更大。一般认为,减薄绝缘层厚度可以减小绝缘层热阻,进而促进散热。但是由于车载线外表皮存在对流换热,绝缘层减薄缩小了外表皮面积,根据牛顿冷却定律可知,减小流体接触面积会降低热流量,进而降低散热速率,两种作用结果是相反的。因此,从传热学角度,车载线存在着绝缘临界半径[25]。即当电缆外半径在临界半径以内时,绝缘层减薄不利于散热;当电缆外半径在临界半径以外时,绝缘层减薄促进散热。对于高导热车载线来说,热导率提升是增加了绝缘临界半径。在仅考虑外部环境对流换热的条件下,绝缘临界半径的计算公式如式(6)所示。
r=kh
式(6)中:k表示绝缘材料热导率,单位为W/(m·K);h表示对流换热系数或换热系数,单位为W/(m2·K)。
空气自然对流下的换热系数为5~10 W/(m2·K),因此普通车载线的绝缘临界半径在20~40 mm,高导热车载线的绝缘临界半径在83~167 mm。标准规定下车载线最大的外半径均在绝缘临界半径以内,绝缘层减薄导致导体温度轻微升高。因此,从散热角度不建议对高导热车载线进行绝缘层减薄。
(1)应用Nelder-Mead法可以准确求解车载线载流量,但应注意迭代计算的初始值和计算区间会影响迭代次数和计算时间。
(2)针对车载线结构,绝缘材料热导率在0.8~1.2 W/(m·K)时,载流量提升比例在5%以上,很难超过6%。应用热导率为0.833 W/(m·K)的硅橡胶/氮化硼纳米片(20%)纳米复合材料作为车载线绝缘层和外护层材料,载流量提升了5.12%,有效提高了车载线的载流能力。
(3)环境温度升高不利于车载线的散热,导致导体温度升高,但提升绝缘材料热导率对散热的改善趋势不受环境温度的干扰。
(4)高导热车载线在轻载和过载下均能有效降低导体温度,缩小绝缘层温差,但过载时高导热车载线对散热的提升效果更好。相同的负载电流下,高导热车载线导体温度的温升更低,促进了散热。
(5)在标准规定的范围内对车载线进行绝缘减薄导致导体温度提高,原因在于绝缘临界半径大于车载线最大外半径。车载线热导率的提高增大了绝缘临界半径,因此高导热绝缘减薄导致导体温升量更多。从散热角度,不建议对车载线进行绝缘层减薄。
  • 国家自然科学基金资助项目(51807136)
  • 国家自然科学基金资助项目(51537008)
  • 江苏省博士后科研资助计划(2020Z092)
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doi: 10.16790/j.cnki.1009-9239.im.2021.02.012
  • 接收时间:2020-08-21
  • 首发时间:2026-01-26
  • 出版时间:2021-02-20
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  • 收稿日期:2020-08-21
  • 修回日期:2020-09-14
基金
国家自然科学基金资助项目(51807136)
国家自然科学基金资助项目(51537008)
江苏省博士后科研资助计划(2020Z092)
作者信息
    1天津大学 电气自动化与信息工程学院 智能电网教育部重点实验室,天津 300072
    2远东电缆公司,江苏 无锡 214257
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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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