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Talking about the Fault of High Voltage Connector Docking

1. Overview

High-voltage connectors are widely used in AC and DC eight-axis electric locomotives. They are mainly composed of supporting porcelain bottles, cap assembly, horn, bellows, top rods, cross head assembly, locking device, etc. as shown in Figure 1. Its main function is to realize the reliable connection of the high voltage circuit on the roof of section A and section B of eight-axle electric locomotive, and to realize control in the cab to avoid dangerous roof operation. In batch production, occasionally two docking high-voltage connectors can not be docked again after separation.

2. Analysis of docking failure

Although the frequency of docking failure is low, once it occurs, it is difficult to eliminate it. We can only disassemble and replace the horns of high-voltage connectors for re-verification. High-voltage connector docking failure is directly manifested as: when two high-voltage connectors are separated, the lock tongue on the horn of sheep is not opened, resulting in the next closure of the loop on the horn of sheep can not be inserted into the lock, resulting in failure. At present, the way to solve the problem is to disassemble the horns of the high-voltage connector, check each part according to the drawings, find out the defective parts, and reassemble after replacement. After several disassemblies and summaries, it is found that the deformed part is the clamp in the horn, but because the clamp and other parts in the horn constitute a complex four-axis structure, quantitative and qualitative analysis can not be carried out in the field. Locks, clamps and rings in the horns of sheep

3. Analysis of docking fault with CATIA three-dimensional model

CATIA three-dimensional modeling can simulate every part perfectly in computer, assemble parts according to the requirements of drawings, realize the quantitative control of movement displacement of each part, and synchronize the movement trajectory of related parts. Therefore, CATIA three-dimensional modeling analysis has more advantages and efficiency than traditional field analysis.

The influence of clamp deformation on high-voltage connector is analyzed by using the three-dimensional model of CAT engineering A. Three-dimensional modeling, assembly and restraint of clamp and related parts in sheep horn are carried out, as shown in Figure 3 (spring is simulated by restraint system of CAT A). From Figure 3, it can be seen that the pull spring and the cover plate are connected by axes, the clamp and the pull spring are connected by axes, the clamp and the lock tongue are connected by axes, and the cover plate and the lock tongue are connected by axes, forming a complex four-axis structure.

As long as the four-axis structure in Figure 3 rotates any axis (realized by angle constraint), the other axes rotate at the same time. The various states of the lock tongue are quantitatively analyzed by this linkage method. When the four axes are in a straight line, the force of the system is balanced and the lock tongue is still, as shown in Figure 4. The lock tongue closing state corresponds to the docking state of the high-voltage connector. Figure 4 shows that the height of the ring (27 mm) is greater than the height of the front end of the lock tongue from the cover plate (12.28 mm) in the static state. When the high-voltage connector docking, the ring will break the balance of the lock tongue upward. Close. Fig. 5 shows that the lock tongue closure will be maintained by an oblique downward force; the lock tongue opening state corresponds to the separation state of the high-pressure connector. Fig. 4 shows that the diameter of the ring (12 mm) is larger than the width of the lock tongue from the cover plate (10.23 mm) when the lock tongue is stationary. When the high-pressure connector is separated, the ring will pull the lock tongue downward to break the balance and the lock tongue will open. Fi It is maintained by an oblique upward force. The above analysis proves that the design of high voltage connector is correct.

The design of high voltage connector is correct. For the reason of docking failure, the field conclusion can be temporarily discarded and theoretical simulation can be carried out with CATIA. According to Figure 4, if the width of the lock tongue is larger than the diameter of the ring (12mm) when the lock tongue is still, the lock tongue will remain closed. Once the high-voltage connector is opened, it will not be able to close and docking failure will occur.

When the width of the lock tongue and the cover plate is equal to the diameter of the ring (12 mm), the position of the clamp and the spring connecting shaft moves up 4.83 mm compared with the normal position. At this time, the clamp and the spring connection axis, the clamp and the lock tongue connection axis, the cover plate and the lock tongue connection axis are in the same straight line to achieve balance. This is the critical point of docking failure, so when the clamp deformation makes the clamp and spring connection axially move more than 4.83 mm, docking failure will occur.


Through the three-dimensional simulation of CAT worker A, it is concluded that the butt failure will occur if the bending deformation of clamp is greater than 4.83 mm. The clamp in the horn of high-pressure connector is made of stainless steel with low hardness and easy deformation.

The bending deformations of the faulty clamps measured in situ are all greater than 4.83 mm, which validates the conclusion of CATIA three-dimensional analysis. In the follow-up production, the material of clamp is replaced by Q235A steel plate with chromium plating on the surface, which not only enhances the strength of clamp (avoids deformation), but also reduces the production cost. Therefore, the new clamp effectively reduces the occurrence of butt failure of high-voltage connector.

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