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Design and Simulation of a Magnetic Flux Control System Using Gradient Permeability Ceramics for Rapid Induction Welding of Cable Conductors.

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Title: Design and Simulation of a Magnetic Flux Control System Using Gradient Permeability Ceramics for Rapid Induction Welding of Cable Conductors.
Authors: Zhao, Shuo1 (AUTHOR), Bi, Bingchang2 (AUTHOR), Bi, Jianbin1 (AUTHOR), Zhao, Xindong2 (AUTHOR) xindong_zhao@hrbust.edu.cn, Wang, Jiaqi2 (AUTHOR), Zou, Jiakun1 (AUTHOR), Zeng, Ming1 (AUTHOR), Zhang, Renfei1 (AUTHOR), Luo, Guochu1 (AUTHOR)
Source: Energies (19961073). Feb2026, Vol. 19 Issue 4, p1006. 18p.
Subject Terms: *Magnetic flux, *Ceramic materials, *Electrical conductors, *Heat engineering, *Fusion welding, *Computer simulation, *Computer simulation of heat transfer, *Electricity safety
Abstract: Efficient on-site connection of power cable conductors is critical for ensuring the safe operation of the power grid. Traditional thermite welding methods pose significant safety risks, including open flames and fumes. Meanwhile, induction heating, when applied to cable conductors, faces challenges of severe magnetic field dispersion, low heating efficiency, and a high risk of damaging adjacent insulation layers. This paper proposes a novel magnetic flux control system based on gradient permeability ceramics to address these issues. The core of this system is the synergistic utilization of a gradient permeability composite ceramic mold and a high-permeability shielding shell. A 2D axisymmetric multiphysics coupled model was established to compare the performance of the optimized system with a conventional case and single control components. Simulation results demonstrate that the optimized system increases the magnetic flux density at the weld seam to 3.7 times that of the conventional setup (0.263 T). Consequently, the weld seam of the 240 mm2 copper conductor is rapidly heated to the melting point of copper (1083 °C) within 7.78 s. Due to the high heating rate, upon completion of the welding process, the temperatures of the inner shielding and insulation layers are only 48.8 °C and 24.3 °C, respectively, well below the materials' safety thresholds. These findings suggest that the proposed magnetic flux control strategy achieves rapid and precise heating, offering a theoretical foundation for the development of high-performance on-site equipment for fabricating cable joints. [ABSTRACT FROM AUTHOR]
Database: Energy & Power Source
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Header DbId: enr
DbLabel: Energy & Power Source
An: 191973426
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Label: Title
  Group: Ti
  Data: Design and Simulation of a Magnetic Flux Control System Using Gradient Permeability Ceramics for Rapid Induction Welding of Cable Conductors.
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  Data: <searchLink fieldCode="AR" term="%22Zhao%2C+Shuo%22">Zhao, Shuo</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Bi%2C+Bingchang%22">Bi, Bingchang</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Bi%2C+Jianbin%22">Bi, Jianbin</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhao%2C+Xindong%22">Zhao, Xindong</searchLink><relatesTo>2</relatesTo> (AUTHOR)<i> xindong_zhao@hrbust.edu.cn</i><br /><searchLink fieldCode="AR" term="%22Wang%2C+Jiaqi%22">Wang, Jiaqi</searchLink><relatesTo>2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zou%2C+Jiakun%22">Zou, Jiakun</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zeng%2C+Ming%22">Zeng, Ming</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhang%2C+Renfei%22">Zhang, Renfei</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Luo%2C+Guochu%22">Luo, Guochu</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Energies+%2819961073%29%22">Energies (19961073)</searchLink>. Feb2026, Vol. 19 Issue 4, p1006. 18p.
– Name: Subject
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  Data: *<searchLink fieldCode="DE" term="%22Magnetic+flux%22">Magnetic flux</searchLink><br />*<searchLink fieldCode="DE" term="%22Ceramic+materials%22">Ceramic materials</searchLink><br />*<searchLink fieldCode="DE" term="%22Electrical+conductors%22">Electrical conductors</searchLink><br />*<searchLink fieldCode="DE" term="%22Heat+engineering%22">Heat engineering</searchLink><br />*<searchLink fieldCode="DE" term="%22Fusion+welding%22">Fusion welding</searchLink><br />*<searchLink fieldCode="DE" term="%22Computer+simulation%22">Computer simulation</searchLink><br />*<searchLink fieldCode="DE" term="%22Computer+simulation+of+heat+transfer%22">Computer simulation of heat transfer</searchLink><br />*<searchLink fieldCode="DE" term="%22Electricity+safety%22">Electricity safety</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Efficient on-site connection of power cable conductors is critical for ensuring the safe operation of the power grid. Traditional thermite welding methods pose significant safety risks, including open flames and fumes. Meanwhile, induction heating, when applied to cable conductors, faces challenges of severe magnetic field dispersion, low heating efficiency, and a high risk of damaging adjacent insulation layers. This paper proposes a novel magnetic flux control system based on gradient permeability ceramics to address these issues. The core of this system is the synergistic utilization of a gradient permeability composite ceramic mold and a high-permeability shielding shell. A 2D axisymmetric multiphysics coupled model was established to compare the performance of the optimized system with a conventional case and single control components. Simulation results demonstrate that the optimized system increases the magnetic flux density at the weld seam to 3.7 times that of the conventional setup (0.263 T). Consequently, the weld seam of the 240 mm2 copper conductor is rapidly heated to the melting point of copper (1083 °C) within 7.78 s. Due to the high heating rate, upon completion of the welding process, the temperatures of the inner shielding and insulation layers are only 48.8 °C and 24.3 °C, respectively, well below the materials' safety thresholds. These findings suggest that the proposed magnetic flux control strategy achieves rapid and precise heating, offering a theoretical foundation for the development of high-performance on-site equipment for fabricating cable joints. [ABSTRACT FROM AUTHOR]
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RecordInfo BibRecord:
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    Identifiers:
      – Type: doi
        Value: 10.3390/en19041006
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 18
        StartPage: 1006
    Subjects:
      – SubjectFull: Magnetic flux
        Type: general
      – SubjectFull: Ceramic materials
        Type: general
      – SubjectFull: Electrical conductors
        Type: general
      – SubjectFull: Heat engineering
        Type: general
      – SubjectFull: Fusion welding
        Type: general
      – SubjectFull: Computer simulation
        Type: general
      – SubjectFull: Computer simulation of heat transfer
        Type: general
      – SubjectFull: Electricity safety
        Type: general
    Titles:
      – TitleFull: Design and Simulation of a Magnetic Flux Control System Using Gradient Permeability Ceramics for Rapid Induction Welding of Cable Conductors.
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            NameFull: Zhao, Shuo
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            NameFull: Bi, Bingchang
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            NameFull: Bi, Jianbin
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            NameFull: Zhao, Xindong
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            NameFull: Wang, Jiaqi
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            NameFull: Zeng, Ming
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            NameFull: Zhang, Renfei
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            – D: 15
              M: 02
              Text: Feb2026
              Type: published
              Y: 2026
          Identifiers:
            – Type: issn-print
              Value: 19961073
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              Value: 19
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            – TitleFull: Energies (19961073)
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