Study on remaining life of the contact terminal of high⁃speed circuit breakers in a subway vehicles

DANG Haitao; ZHAI Haojing; YANG Dazhang; XIANG Nan; AO Ni

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Study on remaining life of the contact terminal of high⁃speed circuit breakers in a subway vehicles

更新时间：2025-04-07

- Study on remaining life of the contact terminal of high⁃speed circuit breakers in a subway vehicles
- Journal of Mechanical Strength Pages: 1-10(2025)
- 作者机构：
  
  1.成都中车四方轨道车辆有限公司，成都 610041
  2.西南交通大学轨道交通运载系统全国重点实验室，成都 610031
- 作者简介：
  
  AO Ni, E-mail: aoni@swjtu.edu.cn
- 基金信息：
- DOI：
  CLC： U279.5
- Received：04 February 2024，
  
  Revised：15 May 2024，
  
  Published Online：07 April 2025，
- 稿件说明：
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党海涛，翟好璟，杨大章等.某型地铁车辆高速断路器接触头剩余寿命研究［J］.机械强度，DOI：10.16579/j.issn.1001.9669.XXXX.XX.001.

DANG Haitao，ZHAI Haojing，YANG Dazhang，et al.Study on remaining life of the contact terminal of high⁃speed circuit breakers in a subway vehicles［J］.Journal of Mechanical Strength，DOI：10.16579/j.issn.1001.9669.XXXX.XX.001.
党海涛，翟好璟，杨大章等.某型地铁车辆高速断路器接触头剩余寿命研究［J］.机械强度，DOI：10.16579/j.issn.1001.9669.XXXX.XX.001. DOI：

DANG Haitao，ZHAI Haojing，YANG Dazhang，et al.Study on remaining life of the contact terminal of high⁃speed circuit breakers in a subway vehicles［J］.Journal of Mechanical Strength，DOI：10.16579/j.issn.1001.9669.XXXX.XX.001. DOI：

摘要

目的

地铁车辆高速断路器是保障列车电气线路安全的重要装置，断路器通过开闭动、静触头进而控制电路的接通与断开。接触头的剩余寿命是制定断路器运维策略的重要依据，然而当前尚无系统性的研究报道。因此，搭建了符合断路器运维条件的试验场景，并基于试验数据建立了断路器的剩余寿命模型。

方法

以成都地铁某线路的UM712V型高速断路器接触头为研究对象，采用有限元模拟与试验研究相结合的方法，开展了其在日常服役条件下剩余寿命演化规律的研究，即接触头镀银层厚度磨损量随使用次数变化的规律。

结果

数值仿真结果表明，动、静触头的各类应力小于材料的疲劳极限，通过安全寿命评估可认为两类接触头的疲劳服役周期均属于无限寿命水平；试验结果表明，动触头镀层厚度随着试验次数的增加不断降低，其主要原因是打磨工艺造成了磨损，而且存在偏磨现象。基于线性模型开展了动触头镀层的磨损剩余寿命预测，计算发现动触头镀层从初始厚度3.003 mm磨耗到1.5 mm限度时，断路器接触头的使用次数为19 313次，折合自然年约为36.2年，约为设计使用寿命的2.4倍。该预测值经假设检验验证，计算结果在预测区间内。研究结果可为接触头镀层的检修间隔以及保养策略的制定提供相关参考。

Abstract

Objective

The high-speed circuit breaker is an important device to ensure the safety of train circuits

which controls the connection and disconnection of the circuit via opening or closing the moving and static contact terminal. It is an important basis to study the remaining life of the contact terminal for the operation and maintenance of circuit breakers. However

there is no systematic work being reported yet. Therefore

test scenarios were built that matched the operation and maintenance conditions of circuit breakers

and established a residual life model of circuit breakers based on test data.

Methods

The contact terminal of high-speed circuit breakers in Chengdu Metro subway vehicles was taken as the research target

and then its evolution law of the remaining life in daily service conditions was studied by using a combination approach that comprises finite element simulation and test investigation

which was to study the variation rule of the thickness of the silver-plated layer thickness of the contact terminal with the number of uses.

Results

The numerical simulation results show that the stresses in moving and static contact terminals are less than the material fatigue limit

and the fatigue service life of both types of contact terminals is considered to be an infinite life level in the safety life assessment. Moreover

the test results show that the coating thickness of the moving contact terminal decreases with the increase of test cycles

yet the reducing thickness is mainly due to the wear caused by the grinding process such as bias grinding. Based on the linear prediction model

the remaining life of the moving contact terminal was evaluated

and the calculation results show that when the coating thickness of the moving contact terminal reduced from the initial 3.003 mm to the limit of 1.5 mm

the circuit breaker contact can be used for 19 313 cycles

corresponding to the natural year about 36.2

which is about 2.4 times of design service life. The predicted value has been verified by hypothesis testing

and the calculated result is within the predicted interval. The above research results are expected to provide relevant support for the development of maintenance intervals and maintenance strategies for contact terminals.

关键词

Keywords

references

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