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How does the large-area copper-aluminum contact design of the new copper-aluminum transition clamp ensure long-term stable operation?

Publish Time: 2025-07-21
In the high-voltage transmission system, the new copper-aluminum transition clamp is a key component connecting copper conductors and aluminum conductors. Its performance is directly related to the safety and stability of the entire transmission line. Due to the significant differences between copper and aluminum in physical properties, chemical properties and thermal expansion coefficients, the traditional copper-aluminum connection method often faces problems such as high contact resistance, easy oxidation, and insufficient structural strength, resulting in frequent faults such as heating, poor contact and even breakage at the line connection point. Therefore, the use of advanced design and manufacturing processes to improve the conductivity and structural strength of the new copper-aluminum transition clamp has become the key to ensuring the long-term stable operation of high-voltage lines.

In recent years, the manufacturing technology of the new copper-aluminum transition clamp has been continuously improved, especially in the large-area copper-aluminum contact design. Modern high-performance new copper-aluminum transition clamps usually adopt T2 copper rod cold extrusion forging process, combined with high-pressure die-cast aluminum welding one-piece molding technology, which greatly improves the mechanical strength and conductivity of the wire clamp. This design not only effectively solves the problem of fracture that may occur during the use of traditional wire clamps, but also significantly reduces the contact resistance and improves the stability and reliability of the connection.

1. T2 copper rod cold extrusion forging technology improves structural strength

T2 copper has good conductivity and mechanical strength, and is an ideal material for manufacturing high-voltage wire clamps. Through the cold extrusion forging process, the T2 copper rod is formed by a high-pressure mold at room temperature, making the internal grains of the material more dense and the density significantly improved. This process not only retains the excellent conductivity of the copper material, but also greatly enhances the overall structural strength of the wire clamp. Compared with traditional casting or hot processing processes, cold extrusion forging can effectively avoid defects such as pores and shrinkage inside the material, thereby significantly improving the tensile strength and fatigue life of the wire clamp.

In high-voltage transmission lines, wire clamps need to withstand greater mechanical stress and environmental loads. The new copper-aluminum transition clamp forged by cold extrusion has higher shear resistance and fatigue resistance, which can effectively avoid fracture problems caused by mechanical vibration, wind load and other factors, thereby ensuring the long-term stable operation of the line.

2. V-groove inner wall and high-pressure die-cast aluminum welding integrated molding technology optimizes contact performance

The contact performance between copper and aluminum is a key factor affecting the conductivity of the transition clamp. In order to increase the contact area and reduce the contact resistance, the modern new copper-aluminum transition clamp uses V-groove processing on the inner wall of the copper sleeve. This design increases the actual contact area between copper and aluminum, making the connection between the wire and the clamp tighter, and effectively reducing the resistance increase and local overheating caused by poor contact.

At the same time, the aluminum part of the clamp adopts high-pressure die-cast aluminum welding integrated molding technology to ensure seamless connection of the copper-aluminum joint. This process avoids defects such as air cavity and slag inclusion that may exist in traditional welding processes, making the copper-aluminum contact surface more uniform and dense, thereby further reducing the contact resistance and improving the conductivity efficiency. In addition, the high-pressure die-cast aluminum process can also realize the integrated molding of complex structures, improving the mechanical strength and corrosion resistance of the clamp.

3. Large-area contact design improves conductivity and thermal stability

The large-area copper-aluminum contact design not only improves the conductivity of the clamp, but also enhances its thermal stability. In high-voltage transmission lines, heat is generated when current passes through the conductor. If the contact resistance is too high, it will cause local temperature rise, which will lead to serious consequences such as oxidation, ablation and even line breakage. By increasing the copper-aluminum contact area, the current carrying capacity of the wire clamp is significantly improved, the heat distribution is more uniform, the local temperature rise is effectively reduced, and the service life of the wire clamp is extended.

In addition, the large-area contact design also improves the clamp's clamping force and anti-slip ability on the wire, ensuring that there will be no poor contact due to loose wires during long-term operation. This design performs particularly well in harsh environments such as high load, high humidity, and high salt spray, and can effectively resist the impact of environmental factors on connection performance.

4. Comprehensive performance ensures long-term safe operation of high-voltage lines

As a key connection element in the power system, the performance of the new copper-aluminum transition clamp directly affects the safety and stability of the entire transmission network. Through the application of advanced processes such as T2 copper rod cold extrusion forging, V-groove inner wall processing, and high-pressure die-cast aluminum welding integrated molding, the modern new copper-aluminum transition clamp has achieved a qualitative leap in structural strength, conductivity, thermal stability, etc. The comprehensive application of these technologies not only solves the problems of easy breakage and high contact resistance of traditional wire clamps, but also significantly improves the durability and reliability of wire clamps, providing a solid guarantee for the long-term stable operation of high-voltage transmission lines.

The large-area copper-aluminum contact design of the new copper-aluminum transition clamp effectively improves the mechanical and electrical properties of the connection through the combination of advanced materials and manufacturing processes, providing reliable technical support for the safe and efficient operation of high-voltage transmission systems.
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