CN118549733A - Method and system for detecting manufacturing defects of dry type air-core reactor technology - Google Patents
Method and system for detecting manufacturing defects of dry type air-core reactor technology Download PDFInfo
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Abstract
本发明公开了一种干式空心电抗器工艺制造缺陷检测方法及系统，属于电抗器制造缺陷检测技术领域。解决了现有技术中传统的故障检测方法难以针对干式空心电抗器工艺制造缺陷进行检测的问题；本发明通过测量干式空心电抗器两端的电压和流经干式空心电抗器的电流，利用谐波分析法计算得到干式空心电抗器总功率因数；根据电抗器结构设计参数计算得到干式空心电抗器的涡流损耗，得到干式空心电抗器涡流损耗对应功率因数；根据不同的频率值，构造干式空心电抗器电阻损耗对应功率因数与频率的关系特性曲线，判断干式空心电抗器是否存在工艺制造缺陷。本发明有效实现了对干式空心电抗器工艺制造缺陷的检测，可以应用于干式空心电抗器相关故障检测试验。
The present invention discloses a method and system for detecting manufacturing defects of dry-type air-core reactors, and belongs to the technical field of manufacturing defect detection of reactors. The present invention solves the problem that the traditional fault detection method in the prior art is difficult to detect manufacturing defects of dry-type air-core reactors; the present invention measures the voltage at both ends of the dry-type air-core reactor and the current flowing through the dry-type air-core reactor, and calculates the total power factor of the dry-type air-core reactor by using the harmonic analysis method; the eddy current loss of the dry-type air-core reactor is calculated according to the structural design parameters of the reactor, and the power factor corresponding to the eddy current loss of the dry-type air-core reactor is obtained; according to different frequency values, a characteristic curve of the relationship between the power factor corresponding to the resistance loss of the dry-type air-core reactor and the frequency is constructed to determine whether the dry-type air-core reactor has manufacturing defects. The present invention effectively realizes the detection of manufacturing defects of dry-type air-core reactors, and can be applied to related fault detection tests of dry-type air-core reactors.
Description
技术领域Technical Field
本发明涉及一种干式空心电抗器工艺制造缺陷检测方法及系统，属于电抗器制造缺陷检测技术领域。The invention relates to a method and a system for detecting manufacturing defects of a dry-type air-core reactor, belonging to the technical field of manufacturing defect detection of reactors.
背景技术Background Art
干式空心电抗器具有结构简单、重量轻、体积小、线性好、损耗低、维护方便等优点，干式空心电抗器可以补偿无功功率、抑制工频过电压、限制短路过电流及滤除高次谐波，其在电力系统中广泛应用。Dry-type air-core reactors have the advantages of simple structure, light weight, small size, good linearity, low loss and easy maintenance. Dry-type air-core reactors can compensate for reactive power, suppress power frequency overvoltage, limit short-circuit overcurrent and filter out high-order harmonics. They are widely used in power systems.
干式空心电抗器由多包封、多层线圈同轴并联绕制，在绕制过程中不可避免的会出现线圈匝间、高度、半径等工艺制造缺陷，上述工艺制造缺陷会导致干式空心电抗器内部形成环流，使包封局部温度升高，会加速绝缘老化，减少电抗器的使用寿命，也会加剧热应力对包封绝缘的破坏，使电抗器包封开裂，更容易造成匝间短路故障，影响电网稳态运行。The dry-type air-core reactor is composed of multiple encapsulations and multiple layers of coils that are coaxially wound in parallel. During the winding process, process defects such as coil turn spacing, height, and radius are inevitable. The above-mentioned process defects will cause a circulating current to form inside the dry-type air-core reactor, causing the local temperature of the encapsulation to rise, which will accelerate insulation aging and reduce the service life of the reactor. It will also aggravate the damage of thermal stress to the encapsulation insulation, causing the reactor encapsulation to crack, which is more likely to cause turn-to-turn short-circuit failures and affect the steady-state operation of the power grid.
目前，现有技术中直流电阻法和工频损耗法都无法有效反映干式空心电抗器工艺缺陷，因此，亟需提出一种针对干式空心电抗器工艺制造缺陷进行检测的方法及系统。At present, neither the DC resistance method nor the power frequency loss method in the existing technology can effectively reflect the process defects of dry-type air-core reactors. Therefore, it is urgent to propose a method and system for detecting the process defects of dry-type air-core reactors.
发明内容Summary of the invention
在下文中给出了关于本发明的简要概述，以便提供关于本发明的某些方面的基本理解。应当理解，这个概述并不是关于本发明的穷举性概述。它并不是意图确定本发明的关键或重要部分，也不是意图限定本发明的范围。其目的仅仅是以简化的形式给出某些概念，以此作为稍后论述的更详细描述的前序。A brief overview of the present invention is provided below in order to provide a basic understanding of certain aspects of the present invention. It should be understood that this overview is not an exhaustive overview of the present invention. It is not intended to identify key or important parts of the present invention, nor is it intended to limit the scope of the present invention. Its purpose is merely to present certain concepts in a simplified form as a prelude to a more detailed description discussed later.
鉴于此，为解决现有技术传统的故障检测方法难以针对干式空心电抗器工艺制造缺陷进行检测的问题，本发明提供一种干式空心电抗器工艺制造缺陷检测方法及系统。In view of this, in order to solve the problem that the conventional fault detection method in the prior art is difficult to detect the manufacturing defects of the dry-type air-core reactor, the present invention provides a method and system for detecting the manufacturing defects of the dry-type air-core reactor.
技术方案一如下：一种干式空心电抗器工艺制造缺陷检测方法，包括以下步骤：Technical solution 1 is as follows: A method for detecting manufacturing defects of a dry-type air-core reactor comprises the following steps:
S1.根据电抗器电压有效值、电抗器电流有效值和总体有功损耗，初步得到干式空心电抗器功率因数，将总体有功损耗分解为电阻损耗和涡流损耗，进而初步得到干式空心电抗器电阻损耗对应功率因数；S1. According to the effective value of the reactor voltage, the effective value of the reactor current and the overall active power loss, the power factor of the dry-type air-core reactor is preliminarily obtained, and the overall active power loss is decomposed into resistance loss and eddy current loss, and then the power factor corresponding to the resistance loss of the dry-type air-core reactor is preliminarily obtained;
S2.通过测量干式空心电抗器两端的电压和流经干式空心电抗器的电流，利用谐波分析法计算得到干式空心电抗器总功率因数；S2. By measuring the voltage across the dry-type air-core reactor and the current flowing through the dry-type air-core reactor, the total power factor of the dry-type air-core reactor is calculated using the harmonic analysis method;
S3.根据电抗器结构设计参数计算得到干式空心电抗器的涡流损耗，结合干式空心电抗器功率因数，得到干式空心电抗器涡流损耗对应功率因数；S3. The eddy current loss of the dry-type air-core reactor is calculated according to the design parameters of the reactor structure, and the power factor corresponding to the eddy current loss of the dry-type air-core reactor is obtained in combination with the power factor of the dry-type air-core reactor;
S4.根据不同的频率值，构造干式空心电抗器电阻损耗对应功率因数与频率的关系特性曲线，对干式空心电抗器电阻损耗对应功率因数与频率同时取对数，根据取对数后得到的函数关系拟合结果判断干式空心电抗器是否存在工艺制造缺陷。S4. According to different frequency values, construct a characteristic curve of the relationship between the power factor and frequency corresponding to the resistance loss of the dry-type air-core reactor, take the logarithm of the power factor and frequency corresponding to the resistance loss of the dry-type air-core reactor at the same time, and judge whether there is a process manufacturing defect in the dry-type air-core reactor based on the function relationship fitting result obtained after taking the logarithm.
进一步地，所述S1中，干式空心电抗器功率因数表示为：Furthermore, in S1, the power factor of the dry-type air-core reactor is It is expressed as:
其中，P为总体有功损耗，U为电抗器电压有效值，I为电抗器电流有效值，PR为电阻损耗，Pe为涡流损耗；Wherein, P is the overall active power loss, U is the effective value of the reactor voltage, I is the effective value of the reactor current, PR is the resistance loss, and Pe is the eddy current loss;
干式空心电抗器电阻损耗对应功率因数表示为：Power factor corresponding to resistance loss of dry-type air-core reactor It is expressed as:
进一步地，所述S2中，包括以下步骤：Furthermore, the step S2 includes the following steps:
S21.通过Fourier级数展开得到干式空心电抗器上检测信号的电压U(t)和干式空心电抗器上检测信号的电流I(t)；S21. The voltage U(t) of the detection signal on the dry-type air-core reactor and the current I(t) of the detection signal on the dry-type air-core reactor are obtained by Fourier series expansion;
S22.根据干式空心电抗器上检测信号的电压和干式空心电抗器上检测信号的电流，得到在一个周期内的基波电压信号和基波电流信号的实部与虚部，进而得到基波电压信号和基波电流信号的幅值与初相位，最终得到干式空心电抗器功率因数；S22. According to the voltage of the detection signal on the dry-type air-core reactor and the current of the detection signal on the dry-type air-core reactor, the real and imaginary parts of the fundamental voltage signal and the fundamental current signal within one cycle are obtained, and then the amplitude and initial phase of the fundamental voltage signal and the fundamental current signal are obtained, and finally the power factor of the dry-type air-core reactor is obtained;
所述S21中，干式空心电抗器上检测信号的电压U(t)表示为：In S21, the voltage U(t) of the detection signal on the dry-type air-core reactor is expressed as:
其中，f为频率，Auk为k次电压谐波的幅值，auk为k次电压谐波分量的实部，buk为k次电压谐波分量的虚部，为k次电压谐波的初相位；Where, f is the frequency, A uk is the amplitude of the kth voltage harmonic, a uk is the real part of the kth voltage harmonic component, b uk is the imaginary part of the kth voltage harmonic component, is the initial phase of the kth voltage harmonic;
干式空心电抗器上检测信号的电流I(t)表示为：The current I(t) of the detection signal on the dry-type air-core reactor is expressed as:
其中，Aik为k次电流谐波的幅值，aik为k次电流谐波分量的实部，bik为k次电流谐波分量的虚部，为k次电流谐波的初相位；Among them, Aik is the amplitude of the kth current harmonic, aik is the real part of the kth current harmonic component, bik is the imaginary part of the kth current harmonic component, is the initial phase of the kth current harmonic;
所述S22中，在一个周期内，基波电压信号的实部au1表示为：In S22, within one cycle, the real part a u1 of the fundamental voltage signal is expressed as:
在一个周期内，基波电压信号的虚部bu1表示为：In one cycle, the imaginary part of the fundamental voltage signal b u1 is expressed as:
在一个周期内，基波电流信号的实部ai1表示为：In one cycle, the real part of the fundamental current signal a i1 is expressed as:
在一个周期内，基波电流信号的虚部bi1表示为：In one cycle, the imaginary part of the fundamental current signal bi1 is expressed as:
基波电流信号的幅值Um表示为：The amplitude Um of the fundamental current signal is expressed as:
基波电流信号幅值Im表示为：The fundamental current signal amplitude Im is expressed as:
基波电压信号初相位表示为：Fundamental voltage signal initial phase It is expressed as:
基波电流信号初相位分别为：Fundamental current signal initial phase They are:
干式空心电抗器功率因数表示为：Dry-type air-core reactor power factor It is expressed as:
进一步地，所述S3中，根据电抗器结构设计参数计算得到干式空心电抗器的涡流损耗；涡流损耗Pe表示为：Furthermore, in S3, the eddy current loss of the dry-type air-core reactor is calculated according to the reactor structure design parameters; the eddy current loss Pe is expressed as:
其中，i为层数，k为匝数，ω为角频率，Di为线圈直径，di为导线直径，ρ为导线电阻率，Brik为径向磁通密度，Bzik为轴向磁通密度，ni为单位高度匝数，hi为高度；Where i is the number of layers, k is the number of turns, ω is the angular frequency, D i is the coil diameter, d i is the wire diameter, ρ is the wire resistivity, B rik is the radial flux density, B zik is the axial flux density, n i is the number of turns per unit height, and h i is the height;
径向磁通密度Brik表示为：The radial magnetic flux density B rik is expressed as:
其中，ri为第i层线圈半径，rj为第j层线圈半径，nj为第j层单位高度匝数，xl为第l层第k匝线圈，xk为第i层第k匝线圈，hj为第j层线圈高度，Ij为第j层线圈通电电流，μ0为真空中磁导率，cosθ为第i层第k匝线圈任一点与第j层第l匝线圈任一点处径向方向夹角的余弦值；Wherein, ri is the radius of the i-th coil, rj is the radius of the j-th coil, nj is the number of turns per unit height of the j-th coil, xl is the k-th coil of the l-th coil, xk is the k-th coil of the i-th coil, hj is the height of the j-th coil, Ij is the current of the j-th coil, μ0 is the magnetic permeability in vacuum, and cosθ is the cosine of the radial angle between any point of the k-th coil of the i-th coil and any point of the l-th coil of the j-th coil;
轴向磁通密度Bzik表示为：The axial magnetic flux density B zik is expressed as:
整合上述公式，干式空心电抗器电阻损耗对应功率因数表示为：Integrating the above formula, the power factor corresponding to the resistance loss of the dry-type air-core reactor is It is expressed as:
进一步地，所述S4中，在任一频率f下，对干式空心电抗器施加不同频率的电压，测量得到不同频率下的电流值，计算得到不同频率下干式空心电抗器功率因数依据干式空心电抗器结构设计参数，计算得到不同频率下干式空心电抗器的涡流损耗Pe，进而计算得到不同频率下干式空心电抗器电阻损耗对应功率因数并得到干式空心电抗器电阻损耗对应功率因数与频率f的关系特性曲线；Furthermore, in S4, at any frequency f, voltages of different frequencies are applied to the dry-type air-core reactor, current values at different frequencies are measured, and power factors of the dry-type air-core reactor at different frequencies are calculated. According to the structural design parameters of the dry-type air-core reactor, the eddy current loss P e of the dry-type air-core reactor at different frequencies is calculated, and then the power factor corresponding to the resistance loss of the dry-type air-core reactor at different frequencies is calculated. And get the power factor corresponding to the resistance loss of the dry air-core reactor Characteristic curve of relationship with frequency f;
当干式空心电抗器不存在工艺制造缺陷时，在双对数坐标下干式空心电抗器电阻损耗对应功率因数与频率f的关系特性曲线呈线性关系变化，当干式空心电抗器存在工艺制造缺陷时，在双对数坐标下干式空心电抗器电阻损耗对应功率因数与频率f的关系特性曲线呈非线性关系变化；When there is no manufacturing defect in the dry-type air-core reactor, the power factor corresponding to the resistance loss of the dry-type air-core reactor in the double logarithmic coordinates The characteristic curve of the relationship with frequency f changes linearly. When there are manufacturing defects in the dry-type air-core reactor, the power factor corresponding to the resistance loss of the dry-type air-core reactor in the double logarithmic coordinates is The characteristic curve with respect to frequency f changes in a nonlinear relationship;
对干式空心电抗器电阻损耗对应功率因数与频率f同时取对数，进一步得到干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的关系特性曲线，采用最小二乘法对干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的进行数据拟合，其函数关系满足多项式函数，得到干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的函数关系拟合结果；Power factor corresponding to resistance loss of dry-type air-core reactor Take the logarithm of the frequency f at the same time, and further obtain the logarithm of the power factor corresponding to the resistance loss of the dry-type air-core reactor The characteristic curve of the relationship between the logarithm of the frequency and the lgf is calculated by the least square method to calculate the logarithm of the power factor corresponding to the resistance loss of the dry-type air-core reactor. The data is fitted with the logarithm of the frequency lgf, and its functional relationship satisfies the polynomial function, and the logarithm of the power factor corresponding to the resistance loss of the dry-type air-core reactor is obtained. The fitting result of the functional relationship with the logarithm of frequency lgf;
干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的函数关系拟合结果表示为：Logarithm of power factor corresponding to resistance loss of dry-type air-core reactor The fitting result of the functional relationship with the logarithm of the frequency lgf is expressed as:
其中，a2为对数lgf的二次项系数，a1为对数lgf的一次项系数，a0为常数项系数；Among them, a 2 is the coefficient of the quadratic term of logarithm lgf, a 1 is the coefficient of the linear term of logarithm lgf, and a 0 is the coefficient of the constant term;
将对数lgf的二次项系数a2的绝对值与对数lgf的一次项系数a1的绝对值之比定义为非线性系数β；The ratio of the absolute value of the coefficient a 2 of the quadratic term of logarithm lgf to the absolute value of the coefficient a 1 of the linear term of logarithm lgf is defined as the nonlinear coefficient β;
非线性系数β表示为：The nonlinear coefficient β is expressed as:
干式空心电抗器工艺制造缺陷越严重干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf函数关系拟合结果所表现的非线性程度越大，非线性系数β越大，当β>0.16时，干式空心电抗器温升超过标准规定，判定干式空心电抗器存在工艺制造缺陷。The more serious the manufacturing defects of dry-type air-core reactors, the logarithm of the power factor corresponding to the resistance loss of dry-type air-core reactors The greater the degree of nonlinearity shown in the fitting result of the logarithmic lgf function relationship with the frequency, the larger the nonlinear coefficient β. When β>0.16, the temperature rise of the dry-type air-core reactor exceeds the standard requirements, and it is determined that the dry-type air-core reactor has a manufacturing defect.
技术方案二：一种干式空心电抗器工艺制造缺陷检测系统，用于实现技术方案一所述的一种干式空心电抗器工艺制造缺陷检测方法，所述系统包括变频电源、第一电阻分压器、第二电阻分压器、电流信号采样电阻、功率因数测量装置和上位机；Technical Solution 2: A dry-type air-core reactor manufacturing defect detection system, used to implement a dry-type air-core reactor manufacturing defect detection method described in Technical Solution 1, the system includes a variable frequency power supply, a first resistor divider, a second resistor divider, a current signal sampling resistor, a power factor measurement device and a host computer;
所述变频电源与第一电阻分压器、第二电阻分压器、电流信号采样电阻和功率因数测量装置分别连接，且变频电源接地；The variable frequency power supply is connected to the first resistor divider, the second resistor divider, the current signal sampling resistor and the power factor measurement device respectively, and the variable frequency power supply is grounded;
所述功率因数测量装置与第一电阻分压器、第二电阻分压器和电流信号采样电阻分别连接；The power factor measuring device is connected to the first resistor voltage divider, the second resistor voltage divider and the current signal sampling resistor respectively;
所述第一电阻分压器、第二电阻分压器和电流信号采样电阻依次连接；The first resistor voltage divider, the second resistor voltage divider and the current signal sampling resistor are connected in sequence;
所述上位机与功率因数测量装置连接。The host computer is connected to the power factor measuring device.
进一步地，所述功率因数测量装置包括A/D转换器、嵌入式计算机和光电转换器；Further, the power factor measuring device includes an A/D converter, an embedded computer and a photoelectric converter;
所述A/D转换器、嵌入式计算机、光电转换器和上位机依次连接；The A/D converter, embedded computer, photoelectric converter and host computer are connected in sequence;
所述上位机包括数据接收模块、数据计算模块、数据显示模块和数据存储模块；The host computer includes a data receiving module, a data calculation module, a data display module and a data storage module;
所述数据接收模块、数据计算模块、数据显示模块和数据存储模块依次连接。The data receiving module, the data calculating module, the data display module and the data storage module are connected in sequence.
本发明的有益效果如下：本发明通过在不同频率下测量干式空心电抗器总功率因数及计算涡流损耗，进一步计算电阻损耗所对应的功率因数，建立干式空心电抗器电阻损耗所对应的功率因数与频率的特性关系，采用数据拟合的方法求解干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的关系特性曲线，并定义非线性系数，提出了利用非线性系数检测干式空心电抗器工艺制造缺陷的检测方法，以解决现有技术中干式空心电抗器工艺制造缺陷无法检测的技术问题，保证了干式空心电抗器生产质量。The beneficial effects of the present invention are as follows: the present invention measures the total power factor of the dry-type air-core reactor and calculates the eddy current loss at different frequencies, further calculates the power factor corresponding to the resistance loss, establishes the characteristic relationship between the power factor corresponding to the resistance loss of the dry-type air-core reactor and the frequency, and uses the data fitting method to solve the logarithm of the power factor corresponding to the resistance loss of the dry-type air-core reactor. A characteristic curve of the relationship between the frequency and the logarithm lgf is drawn, and a nonlinear coefficient is defined. A detection method for detecting process defects of dry-type air-core reactors using the nonlinear coefficient is proposed to solve the technical problem that process defects of dry-type air-core reactors cannot be detected in the prior art, thereby ensuring the production quality of dry-type air-core reactors.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
此处所说明的附图用来提供对本发明的进一步理解，构成本发明的一部分，本发明的示意性实施例及其说明用于解释本发明，并不构成对本发明的不当限定。在附图中：The drawings described herein are used to provide a further understanding of the present invention and constitute a part of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:
图1为一种干式空心电抗器工艺制造缺陷检测方法流程示意图；FIG1 is a schematic flow chart of a method for detecting manufacturing defects of a dry-type air-core reactor;
图2为同轴薄壁螺线管简化模型示意图；FIG2 is a schematic diagram of a simplified model of a coaxial thin-walled solenoid;
图3为干式空心电抗器电阻损耗对应功率因数与频率f的关系特性曲线示意图；Figure 3 shows the power factor corresponding to the resistance loss of the dry-type air-core reactor Schematic diagram of the characteristic curve of the relationship with frequency f;
图4为干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的关系特性曲线示意图；Figure 4 shows the logarithm of the power factor corresponding to the resistance loss of the dry-type air-core reactor Schematic diagram of the characteristic curve of the relationship with the logarithm of the frequency lgf;
图5为一种干式空心电抗器工艺制造缺陷检测系统示意图；FIG5 is a schematic diagram of a dry-type air-core reactor manufacturing defect detection system;
图6为功率因数测量装置应用流程示意图；FIG6 is a schematic diagram of the application process of the power factor measurement device;
图7为上位机结构示意图；Figure 7 is a schematic diagram of the upper computer structure;
图8为涡流损耗计算流程示意图。FIG8 is a schematic diagram of the eddy current loss calculation process.
附图说明：1.干式空心电抗器；11.电阻；12.电感；2.变频电源；3.第一电阻分压器；4.第二电阻分压器；5.电流信号采样电阻；6.功率因数测量装置；7.上位机。Description of the drawings: 1. Dry-type air-core reactor; 11. Resistor; 12. Inductor; 2. Variable frequency power supply; 3. First resistor voltage divider; 4. Second resistor voltage divider; 5. Current signal sampling resistor; 6. Power factor measurement device; 7. Host computer.
具体实施方式DETAILED DESCRIPTION
为了使本发明实施例中的技术方案及优点更加清楚明白，以下结合附图对本发明的示例性实施例进行进一步详细的说明，显然，所描述的实施例仅是本发明的一部分实施例，而不是所有实施例的穷举。需要说明的是，在不冲突的情况下，本发明中的实施例及实施例中的特征可以相互组合。In order to make the technical solutions and advantages of the embodiments of the present invention more clearly understood, the exemplary embodiments of the present invention are further described in detail below in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than an exhaustive list of all the embodiments. It should be noted that the embodiments of the present invention and the features in the embodiments can be combined with each other without conflict.
实施例1：参考图1-图8详细说明本实施例，一种干式空心电抗器工艺制造缺陷检测方法，包括以下步骤：Embodiment 1: This embodiment is described in detail with reference to FIGS. 1 to 8 , a method for detecting manufacturing defects of a dry-type air-core reactor, comprising the following steps:
S1.根据电抗器电压有效值、电抗器电流有效值和总体有功损耗，初步得到干式空心电抗器功率因数，将总体有功损耗分解为电阻损耗和涡流损耗，进而初步得到干式空心电抗器电阻损耗对应功率因数；S1. According to the effective value of the reactor voltage, the effective value of the reactor current and the overall active power loss, the power factor of the dry-type air-core reactor is preliminarily obtained, and the overall active power loss is decomposed into resistance loss and eddy current loss, and then the power factor corresponding to the resistance loss of the dry-type air-core reactor is preliminarily obtained;
S2.通过测量干式空心电抗器两端的电压和流经干式空心电抗器的电流，利用谐波分析法计算得到干式空心电抗器总功率因数；S2. By measuring the voltage across the dry-type air-core reactor and the current flowing through the dry-type air-core reactor, the total power factor of the dry-type air-core reactor is calculated using the harmonic analysis method;
S3.根据电抗器结构设计参数计算得到干式空心电抗器的涡流损耗，结合干式空心电抗器功率因数，得到干式空心电抗器涡流损耗对应功率因数；S3. The eddy current loss of the dry-type air-core reactor is calculated according to the design parameters of the reactor structure, and the power factor corresponding to the eddy current loss of the dry-type air-core reactor is obtained in combination with the power factor of the dry-type air-core reactor;
S4.根据不同的频率值，构造干式空心电抗器电阻损耗对应功率因数与频率的关系特性曲线，对干式空心电抗器电阻损耗对应功率因数与频率同时取对数，根据取对数后得到的函数关系拟合结果判断干式空心电抗器是否存在工艺制造缺陷。S4. According to different frequency values, construct a characteristic curve of the relationship between the power factor and frequency corresponding to the resistance loss of the dry-type air-core reactor, take the logarithm of the power factor and frequency corresponding to the resistance loss of the dry-type air-core reactor at the same time, and judge whether there is a process manufacturing defect in the dry-type air-core reactor based on the function relationship fitting result obtained after taking the logarithm.
进一步地，所述S1中，干式空心电抗器功率因数表示为：Furthermore, in S1, the power factor of the dry-type air-core reactor is It is expressed as:
其中，P为总体有功损耗，U为电抗器电压有效值，I为电抗器电流有效值，PR为电阻损耗，Pe为涡流损耗；Wherein, P is the overall active power loss, U is the effective value of the reactor voltage, I is the effective value of the reactor current, PR is the resistance loss, and Pe is the eddy current loss;
干式空心电抗器电阻损耗对应功率因数表示为：Power factor corresponding to resistance loss of dry-type air-core reactor It is expressed as:
具体的，对于干式空心电抗器总体有功损耗P由两部分组成，一部分由电阻损耗PR提供，另一部分由涡流损耗Pe提供。Specifically, for the dry air-core reactor, the overall active power loss P consists of two parts, one part is provided by the resistance loss PR , and the other part is provided by the eddy current loss Pe .
进一步地，所述S2中，包括以下步骤：Furthermore, the step S2 includes the following steps:
S21.通过Fourier级数展开得到干式空心电抗器上检测信号的电压U(t)和干式空心电抗器上检测信号的电流I(t)；S21. The voltage U(t) of the detection signal on the dry-type air-core reactor and the current I(t) of the detection signal on the dry-type air-core reactor are obtained by Fourier series expansion;
S22.根据干式空心电抗器上检测信号的电压和干式空心电抗器上检测信号的电流，得到在一个周期内的基波电压信号和基波电流信号的实部与虚部，进而得到基波电压信号和基波电流信号的幅值与初相位，最终得到干式空心电抗器功率因数；S22. According to the voltage of the detection signal on the dry-type air-core reactor and the current of the detection signal on the dry-type air-core reactor, the real and imaginary parts of the fundamental voltage signal and the fundamental current signal within one cycle are obtained, and then the amplitude and initial phase of the fundamental voltage signal and the fundamental current signal are obtained, and finally the power factor of the dry-type air-core reactor is obtained;
所述S21中，干式空心电抗器上检测信号的电压U(t)表示为：In S21, the voltage U(t) of the detection signal on the dry-type air-core reactor is expressed as:
其中，f为频率，Auk为k次电压谐波的幅值，auk为k次电压谐波分量的实部，buk为k次电压谐波分量的虚部，为k次电压谐波的初相位；Where, f is the frequency, A uk is the amplitude of the kth voltage harmonic, a uk is the real part of the kth voltage harmonic component, b uk is the imaginary part of the kth voltage harmonic component, is the initial phase of the kth voltage harmonic;
干式空心电抗器上检测信号的电流I(t)表示为：The current I(t) of the detection signal on the dry-type air-core reactor is expressed as:
其中，Aik为k次电流谐波的幅值，aik为k次电流谐波分量的实部，bik为k次电流谐波分量的虚部，为k次电流谐波的初相位；Among them, Aik is the amplitude of the kth current harmonic, aik is the real part of the kth current harmonic component, bik is the imaginary part of the kth current harmonic component, is the initial phase of the kth current harmonic;
所述S22中，在一个周期内，基波电压信号的实部au1表示为：In S22, within one cycle, the real part a u1 of the fundamental voltage signal is expressed as:
在一个周期内，基波电压信号的虚部bu1表示为：In one cycle, the imaginary part of the fundamental voltage signal b u1 is expressed as:
在一个周期内，基波电流信号的实部ai1表示为：In one cycle, the real part of the fundamental current signal a i1 is expressed as:
在一个周期内，基波电流信号的虚部bi1表示为：In one cycle, the imaginary part of the fundamental current signal bi1 is expressed as:
基波电流信号的幅值Um表示为：The amplitude Um of the fundamental current signal is expressed as:
基波电流信号幅值Im表示为：The fundamental current signal amplitude Im is expressed as:
基波电压信号初相位表示为：Fundamental voltage signal initial phase It is expressed as:
基波电流信号初相位分别为：Fundamental current signal initial phase They are:
干式空心电抗器功率因数表示为：Dry-type air-core reactor power factor It is expressed as:
进一步地，所述S3中，根据电抗器结构设计参数计算得到干式空心电抗器的涡流损耗；Further, in said S3, the eddy current loss of the dry-type air-core reactor is calculated according to the design parameters of the reactor structure;
涡流损耗Pe表示为：The eddy current loss Pe is expressed as:
其中，i为层数，k为匝数，ω为角频率，Di为线圈直径，di为导线直径，ρ为导线电阻率，Brik为径向磁通密度，Bzik为轴向磁通密度，ni为单位高度匝数，hi为高度；Where i is the number of layers, k is the number of turns, ω is the angular frequency, D i is the coil diameter, d i is the wire diameter, ρ is the wire resistivity, B rik is the radial flux density, B zik is the axial flux density, n i is the number of turns per unit height, and h i is the height;
径向磁通密度Brik表示为：The radial magnetic flux density B rik is expressed as:
其中，ri为第i层线圈半径，rj为第j层线圈半径，nj为第j层单位高度匝数，xl为第l层第k匝线圈，xk为第i层第k匝线圈，hj为第j层线圈高度，Ij为第j层线圈通电电流，μ0为真空中磁导率，cosθ为第i层第k匝线圈任一点与第j层第l匝线圈任一点处径向方向夹角的余弦值；Wherein, ri is the radius of the i-th coil, rj is the radius of the j-th coil, nj is the number of turns per unit height of the j-th coil, xl is the k-th coil of the l-th coil, xk is the k-th coil of the i-th coil, hj is the height of the j-th coil, Ij is the current of the j-th coil, μ0 is the magnetic permeability in vacuum, and cosθ is the cosine of the radial angle between any point of the k-th coil of the i-th coil and any point of the l-th coil of the j-th coil;
轴向磁通密度Bzik表示为：The axial magnetic flux density B zik is expressed as:
整合上述公式，干式空心电抗器电阻损耗对应功率因数表示为：Integrating the above formula, the power factor corresponding to the resistance loss of the dry-type air-core reactor is It is expressed as:
具体的，参考图2，干式空心电抗器由多根同轴绕制的铝导线并联而成，每一根线圈都可以看作成一个薄壁螺线管；Specifically, referring to FIG2 , the dry-type air-core reactor is formed by connecting a plurality of coaxially wound aluminum wires in parallel, and each coil can be regarded as a thin-walled solenoid;
参考图8，输入各支路尺寸参数，即频率f、线圈层数m、单位高度匝数n、直径D、高度h、电流I和绕组导线直径d，读取各支路参数，计算电抗器第j层绕组上第l匝线圈在第i层绕组上第k匝线圈处的磁场，i、k、j和l的初始值均取1，判断l是否小于或等于njhj，如果是，则l＝l+1，如果否，判断j是否小于或等于m，如果是，则l＝1，j＝j+1，如果否，进行径向磁通密度Brik、轴向磁通密度Bzik和损耗Peik的计算，判断k是否小于或等于nihi，如果是，l＝1，j＝1，k＝k+1，如果否，判断i是否小于或等于m，如果是，l＝1，j＝1，k＝k，i＝i+1，如果否，计算得到最终的涡流损耗Pe。Referring to Figure 8, input the size parameters of each branch, namely, frequency f, number of coil layers m, number of turns per unit height n, diameter D, height h, current I and winding wire diameter d, read the parameters of each branch, calculate the magnetic field at the kth turn of the lth turn on the jth layer winding of the reactor at the ith layer winding, the initial values of i, k, j and l are all 1, judge whether l is less than or equal to njhj , if yes, then l=l+1, if not, judge whether j is less than or equal to m, if yes, then l=1, j=j+1, if not, calculate the radial magnetic flux density Brik , axial magnetic flux density Bzik and loss Peik , judge whether k is less than or equal to nij , if yes, l=1, j=1, k=k+1, if not, judge whether i is less than or equal to m, if yes , l=1, j=1, k=k+1, if not, calculate whether i is less than or equal to m, if yes, l=1, j=1, k=k, i=i+1, if not, calculate and obtain the final eddy current loss Pe .
进一步地，所述S4中，在任一频率f下，对干式空心电抗器施加不同频率的电压，测量得到不同频率下的电流值，计算得到不同频率下干式空心电抗器功率因数依据干式空心电抗器结构设计参数，计算得到不同频率下干式空心电抗器的涡流损耗Pe，进而计算得到不同频率下干式空心电抗器电阻损耗对应功率因数并得到干式空心电抗器电阻损耗对应功率因数与频率f的关系特性曲线；Furthermore, in S4, at any frequency f, voltages of different frequencies are applied to the dry-type air-core reactor, current values at different frequencies are measured, and power factors of the dry-type air-core reactor at different frequencies are calculated. According to the structural design parameters of the dry-type air-core reactor, the eddy current loss P e of the dry-type air-core reactor at different frequencies is calculated, and then the power factor corresponding to the resistance loss of the dry-type air-core reactor at different frequencies is calculated. And get the power factor corresponding to the resistance loss of the dry air-core reactor Characteristic curve of relationship with frequency f;
当干式空心电抗器不存在工艺制造缺陷时，在双对数坐标下干式空心电抗器电阻损耗对应功率因数与频率f的关系特性曲线呈线性关系变化，当干式空心电抗器存在工艺制造缺陷时，在双对数坐标下干式空心电抗器电阻损耗对应功率因数与频率f的关系特性曲线呈非线性关系变化；When there is no manufacturing defect in the dry-type air-core reactor, the power factor corresponding to the resistance loss of the dry-type air-core reactor in the double logarithmic coordinates The characteristic curve of the relationship with frequency f changes linearly. When there are manufacturing defects in the dry-type air-core reactor, the power factor corresponding to the resistance loss of the dry-type air-core reactor in the double logarithmic coordinates is The characteristic curve with respect to frequency f changes in a nonlinear relationship;
对干式空心电抗器电阻损耗对应功率因数与频率f同时取对数，进一步得到干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的关系特性曲线，采用最小二乘法对干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的进行数据拟合，其函数关系满足多项式函数，得到干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的函数关系拟合结果；Power factor corresponding to resistance loss of dry-type air-core reactor Take the logarithm of the frequency f at the same time, and further obtain the logarithm of the power factor corresponding to the resistance loss of the dry-type air-core reactor The characteristic curve of the relationship between the logarithm of the frequency and the lgf is calculated by the least square method to calculate the logarithm of the power factor corresponding to the resistance loss of the dry-type air-core reactor. The data is fitted with the logarithm of the frequency lgf, and its functional relationship satisfies the polynomial function, and the logarithm of the power factor corresponding to the resistance loss of the dry-type air-core reactor is obtained. The fitting result of the functional relationship with the logarithm of frequency lgf;
干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的函数关系拟合结果表示为：Logarithm of power factor corresponding to resistance loss of dry-type air-core reactor The fitting result of the functional relationship with the logarithm of the frequency lgf is expressed as:
其中，a2为对数lgf的二次项系数，a1为对数lgf的一次项系数，a0为常数项系数；Among them, a 2 is the coefficient of the quadratic term of logarithm lgf, a 1 is the coefficient of the linear term of logarithm lgf, and a 0 is the coefficient of the constant term;
将对数lgf的二次项系数a2的绝对值与对数lgf的一次项系数a1的绝对值之比定义为非线性系数β；The ratio of the absolute value of the coefficient a 2 of the quadratic term of logarithm lgf to the absolute value of the coefficient a 1 of the linear term of logarithm lgf is defined as the nonlinear coefficient β;
非线性系数β表示为：The nonlinear coefficient β is expressed as:
干式空心电抗器工艺制造缺陷越严重干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf函数关系拟合结果所表现的非线性程度越大，非线性系数β越大，当β>0.16时，干式空心电抗器温升超过标准规定，判定干式空心电抗器存在工艺制造缺陷即制造的干式空心电抗器为不合格产品；The more serious the manufacturing defects of dry-type air-core reactors, the logarithm of the power factor corresponding to the resistance loss of dry-type air-core reactors The greater the nonlinearity of the fitting result of the logarithmic lgf function relationship with the frequency, the greater the nonlinear coefficient β. When β>0.16, the temperature rise of the dry-type air-core reactor exceeds the standard requirements, and it is determined that the dry-type air-core reactor has a process manufacturing defect, that is, the manufactured dry-type air-core reactor is an unqualified product.
具体的，参考图3，任一频率f的取值包括但不限于1Hz、10Hz、50Hz、100Hz、500Hz、1kHz、5kHz、10kHz和50kHz，Hz为频率单位，％为干式空心电抗器电阻损耗对应功率因数的单位；Specifically, referring to FIG3 , the value of any frequency f includes but is not limited to 1 Hz, 10 Hz, 50 Hz, 100 Hz, 500 Hz, 1 kHz, 5 kHz, 10 kHz and 50 kHz, Hz is the frequency unit, and % is the power factor corresponding to the resistance loss of the dry-type air-core reactor. Units;
参考图4，存在缺陷的干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的函数关系拟合结果表示为：Refer to Figure 4, the logarithm of the power factor corresponding to the resistance loss of the defective dry-type air-core reactor The fitting result of the functional relationship with the logarithm of the frequency lgf is expressed as:
对于存在缺陷的干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的函数关系，拟合优度R2取值为0.98；Logarithm of power factor corresponding to resistance loss of defective dry-type air-core reactor The functional relationship with the logarithm of the frequency lgf, the goodness of fit R 2 value is 0.98;
不存在缺陷的干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的函数关系拟合结果表示为：Logarithm of power factor corresponding to resistance loss of dry-type air-core reactor without defects The fitting result of the functional relationship with the logarithm of the frequency lgf is expressed as:
对于不存在缺陷的干式空心电抗器电阻损耗对应功率因数的对数与频率的对数lgf的函数关系，拟合优度R2取值1。Logarithm of power factor corresponding to resistance loss of dry-type air-core reactor without defects The functional relationship with the logarithm of the frequency lgf, the goodness of fit R2 takes the value of 1.
实施例2：参考图5-图7详细说明本实施例，一种干式空心电抗器工艺制造缺陷检测系统，用于实施例1所述的一种干式空心电抗器工艺制造缺陷检测方法，所述系统包括变频电源2、第一电阻分压器3、第二电阻分压器4、电流信号采样电阻5、功率因数测量装置6和上位机7；Embodiment 2: This embodiment is described in detail with reference to FIGS. 5 to 7 , a dry-type air-core reactor manufacturing defect detection system, which is used for a dry-type air-core reactor manufacturing defect detection method described in Embodiment 1, wherein the system comprises a variable frequency power supply 2, a first resistor divider 3, a second resistor divider 4, a current signal sampling resistor 5, a power factor measurement device 6 and a host computer 7;
所述变频电源2与第一电阻分压器3、第二电阻分压器4、电流信号采样电阻5和功率因数测量装置6分别连接，且变频电源2接地；The variable frequency power supply 2 is connected to the first resistor divider 3, the second resistor divider 4, the current signal sampling resistor 5 and the power factor measurement device 6 respectively, and the variable frequency power supply 2 is grounded;
所述功率因数测量装置6与第一电阻分压器3、第二电阻分压器4和电流信号采样电阻5分别连接；The power factor measuring device 6 is connected to the first resistor voltage divider 3, the second resistor voltage divider 4 and the current signal sampling resistor 5 respectively;
所述第一电阻分压器3、第二电阻分压器4和电流信号采样电阻5依次连接；The first resistor voltage divider 3, the second resistor voltage divider 4 and the current signal sampling resistor 5 are connected in sequence;
所述上位机7与功率因数测量装置6连接。The host computer 7 is connected to the power factor measuring device 6 .
进一步地，所述功率因数测量装置6包括A/D转换器、嵌入式计算机和光电转换器；Further, the power factor measuring device 6 includes an A/D converter, an embedded computer and a photoelectric converter;
所述A/D转换器、嵌入式计算机、光电转换器和上位机7依次连接；The A/D converter, embedded computer, photoelectric converter and host computer 7 are connected in sequence;
所述上位机7包括数据接收模块、数据计算模块、数据显示模块和数据存储模块；The host computer 7 includes a data receiving module, a data calculation module, a data display module and a data storage module;
所述数据接收模块、数据计算模块、数据显示模块和数据存储模块依次连接；The data receiving module, the data calculating module, the data display module and the data storage module are connected in sequence;
具体的，参考图5，干式空心电抗器1包括电阻11和电感12，进行干式空心电抗器工艺制造缺陷检测时，将干式空心电抗器1与第一电阻分压器3和第二电阻分压器4并联；Specifically, referring to FIG5 , the dry-type air-core reactor 1 includes a resistor 11 and an inductor 12 . When performing manufacturing defect detection of the dry-type air-core reactor, the dry-type air-core reactor 1 is connected in parallel with a first resistor divider 3 and a second resistor divider 4 .
参考图6，功率因数测量装置6内置滤波放大调理电路，第一电阻分压器3和第二电阻分压器4上的电压UL以及电流信号采样电阻5上的电压UI分别经滤波放大调理电路进行滤波放大后，通过A/D转换器把模拟量转化为数字量，再通过嵌入式计算机利用谐波分析法计算得到干式空心电抗器的基波电压信号和基波电流信号的幅值与初相位，随后进行光耦隔离，并通过光电转换器以光纤通信的方式上传至上位机便于进行进一步运算、显示、存储等处理；Referring to FIG6 , the power factor measuring device 6 has a built-in filter amplifying and conditioning circuit. The voltage U L on the first resistor divider 3 and the second resistor divider 4 and the voltage U I on the current signal sampling resistor 5 are filtered and amplified by the filter amplifying and conditioning circuit respectively, and then the analog quantity is converted into a digital quantity by an A/D converter, and then the amplitude and initial phase of the fundamental voltage signal and the fundamental current signal of the dry-type air-core reactor are calculated by the embedded computer using the harmonic analysis method, and then optical coupling isolation is performed, and the optical-to-electrical converter is used to upload the signal to the host computer in the form of optical fiber communication for further calculation, display, storage and other processing;
参考图7，数据计算模块用于进行干式空心电抗器的总功率因数计算、干式空心电抗器的涡流损耗计算和干式空心电抗器电阻损耗对应功率因数计算。Referring to Figure 7, the data calculation module is used to calculate the total power factor of the dry-type air-core reactor, the eddy current loss of the dry-type air-core reactor, and the power factor corresponding to the resistance loss of the dry-type air-core reactor. calculate.
尽管根据有限数量的实施例描述了本发明，但是受益于上面的描述，本技术领域内的技术人员明白，在由此描述的本发明的范围内，可以设想其它实施例。此外，应当注意，本说明书中使用的语言主要是为了可读性和教导的目的而选择的，而不是为了解释或者限定本发明的主题而选择的。因此，在不偏离所附权利要求书的范围和精神的情况下，对于本技术领域的普通技术人员来说许多修改和变更都是显而易见的。对于本发明的范围，对本发明所做的公开是说明性的，而非限制性的，本发明的范围由所附权利要求书限定。Although the present invention has been described according to a limited number of embodiments, it will be apparent to those skilled in the art, with the benefit of the above description, that other embodiments may be envisioned within the scope of the invention thus described. In addition, it should be noted that the language used in this specification is selected primarily for readability and didactic purposes, rather than for explaining or defining the subject matter of the present invention. Therefore, many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the appended claims. The disclosure of the present invention is illustrative, not restrictive, with respect to the scope of the present invention, which is defined by the appended claims.
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