Optimization Design And Study Of Formability On Self-elastic Contact Finger Used In The High Voltage Isolating Switch

Contact fingers are the most core components of high voltage isolating switch. Whether isolating switch connects or not depends on assembly structure of contact finger/contact. The service life of contact finger determines the life of high voltage switch, and determines the safe operation of the high voltage power grid. The tradition contact finger is made of copper plate which thickness is up to 5mm, and the contact pressure between the contact finger and the contact is afforded by spring. So the tradition contact finger with the spring not only wastes plenty of copper, but can easily result in contact overheat or a major power accident. The self-elastic contact finger without the support of the spring has a small quantity usage of copper which consumedly save copper, and prevent overheat happening which may be caused by the spring. So the self-elastic contact finger is an important goal that designers go after in recent years. In this paper, combining with high voltage isolating switch service condition, using the optimized design method, a new kind of self-elastic contact finger used in high voltage isolating switch was designed, and the new assembly structure of self-elastic contact finger/contact was analyzed. Then, the forming process of the new self-elastic contact finger was studied by numerical analysis.1. According to the strength and rigidity theoretical analysis of self-elastic contact finger, Using ANSYS Workbench, The self-elastic contact finger was analyzed, and the cross-section shapes of self-elastic contact finger were optimized. Get conclusions as follows:(1) In the case of certain materials, the cross-section shape of self-elastic contact finger is one of the main factors which influence its own strength and rigidity. To improve its strength and rigidity, self-elastic contact finger with"W"shape section was put forward in this research.(2) After the optimization, Section parameter of self-elastic contact finger with "W"shape section were thickness h = 3 mm, fillet radius r = 2.32 mm, middle groove width w = 2.73 mm; thickness of self-elastic contact finger with rectangular section is h = 3.33 mm.(3) Compared with the self-elastic contact finger with rectangular section, the maximum deformation of the optimized self-elastic contact finger with"W"shape section was reduced 1.43 mm, rigidity was increased observably.(4) Compared with the traditional copper contact finger, section thickness of self-elastic contact finger with"W"shape section was reduced 1.82 mm, mass reduced 47 g, materials saved by 38.7%.2. Assembly structure parametric model of self-elastic contact-finger/contact was created using SolidWorks software, parameter names of contact diameter D and contact displacement S were set. The model and input parameters were imported into ANSYS Workbench software, in which the relationship between input parameters and response parameters were researched and input parameter D and S were optimized based on goal-driven optimization technique. Optimized input parameters are D = 63.39 mm, S = 15.42 mm.3. This paper analyzed forming characteristics of self-elastic contact finger, established bending and swaging compound + bending and punching compound new process to form self-elastic contact finger with"W"shape section. Using Deform - 3D software, bending and swaging compound forming performance of self-elastic contact finger with"W"shape section was researched. Get conclusions as follows:(1) Severe plastic deformations were occurred around the filleted corner of"W"shape section region of the self-elastic contact finger and the maximum equivalent stress and maximum equivalent strain were on the filleted corner. On the filleted corner region the damage coefficient was highest.(2) Based on the optimal design for self-elastic contact finger and the study on forming numerical simulation, put forward that the round angle-radius r of self-elastic contact finger with"W"shape section was revised to 2.7 mm.(3) According to the forming process of new self-elastic contact finger, bending and swaging compound and bending and punching compound forming die both were designed for self-elastic contact finger with"W"shape section.