As aerospace, electrified railway, weapon equipment manufacturing, and other fields have leapt forward, the operating environment of current-carrying friction pairs is becoming increasingly severe, and research on the current-carrying friction and wear theory and its vital technologies are progressively in demand. This study summarizes the relevant research on the current-carrying friction and wear. In this study, the essential characteristics and classification of current-carrying friction and wear are summarized, the effect of working parameters on current-carrying friction and wear performance is clarified, and the generation mechanism, failure mechanism, and factors of current-carrying friction and wear are emphatically investigated. Moreover, the mechanism of arc generation and the effect of environmental conditions and surface facial masks on the friction and wear process are summarized. This paper also introduces the preparation technology of a conductive wear-resistant self-lubricating material, the main factors affecting the conductive wear-resistant property of the coating, and the action mechanism. The simulation and prediction results of the current-carrying friction and wear temperature field and the wear amount are presented. Finally, the problems in the current-carrying friction and wear research are classified, and future research directions in this field are proposed. The future’s critical development and improvement directions are also proposed from the aspects of developing coating quality evaluation equipment, optimizing the coating quality, and studying the coating self-lubricating mechanisms.
An accurate extraction of vibration signal characteristics of an on-load tap changer (OLTC) during contact switching can effectively help detect its abnormal state. Therefore, an improved fuzzy C-means clustering method for abnormal state detection of the OLTC contact is proposed. First, the wavelet packet and singular spectrum analysis are used to denoise the vibration signal generated by the moving and static contacts of the OLTC. Then, the Hilbert-Huang transform that is optimized by the ensemble empirical mode decomposition (EEMD) is used to decompose the vibration signal and extract the boundary spectrum features. Finally, the gray wolf algorithm-based fuzzy C-means clustering is used to denoise the signal and determine the abnormal states of the OLTC contact. An analysis of the experimental data shows that the proposed secondary denoising method has a better denoising effect compared to the single denoising method. The EEMD can improve the modal aliasing effect, and the improved fuzzy C-means clustering can effectively identify the abnormal state of the OLTC contacts. The analysis results of field measured data further verify the effectiveness of the proposed method and provide a reference for the abnormal state detection of the OLTC.
This paper analyzes the effect of sliding speed on the electrical conductivity and friction properties of the contact pair of an on-load tap changer (OLTC). Reciprocating current-carrying tribological tests were carried out on a rod–plate–copper–tin–copper contact galvanic couple at different sliding speeds in air and insulating oil media. The results show that as the sliding speed increases from 24 mm/s to 119 mm/s, the average contact resistance in air increases from 0.2 Ω to 0.276 Ω, and the average contact resistance in insulating oil also increases from 0.2 Ω to 0.267 Ω. At 119 mm/s, the maximum contact resistance in insulating oil reaches 0.3 Ω. The micro-topography images obtained by scanning electron microscopy show that with the increase in sliding speed, the wear mechanisms in the air are mainly abrasive wear and adhesive wear, and the wear mechanisms in oil are mainly layered wear and erosion craters; high sliding speed and arcing promote contact surface fatigue and crack generation. X-ray photoelectron spectroscopy was used to analyze the surface. The copper oxide in the air and the cuprous sulfide in the insulating oil cause the surface film resistance, and the total contact resistance increases accordingly. In addition, the test shows that 119 mm/s in air and 95 mm/s in insulating oil are the speed thresholds. Below these speed thresholds, the increase in contact resistance is mainly caused by mechanical wear. Above these thresholds, the increase in contact resistance is mainly caused by arc erosion and chemical oxidation processes. Non-mechanical factors exacerbate the deterioration of the contact surface and become the main factor for the increase in contact resistance.
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