Research on new intelligent flyer-type electronic detonator

To address the accidental explosion risks caused by sensitive primary explosives in industrial electronic detonators, as well as the safety and environmental issues associated with traditional no-primary detonators, a new intelligent flyer-type electronic detonator design was proposed to enhance the safety and environmental performance through flyer initiation technology. To achieve reliable initiation without sensitive primary explosives, a multi-dimensional approach combining experimental and numerical simulation methods is employed for the design and performance optimization of the new intelligent flyer-type electronic detonator. First, critical parameters for slapper initiation were determined through theoretical modeling of shock wave propagation and energy transfer. A finite element model of the flyer acceleration process was established to simulate the effects of different charge structures (e.g., confinement diameter, thickness) on flyer velocity, comprehensively considering material deformation, detonation wave interactions, and flyer fragmentation effects. Second, a high-speed camera (500 kHz) was used to synchronously record the detonation process, capturing the actual velocity, flight attitude, and deformation behavior of the flyer upon target impact. This data was used to validate the numerical model and optimize the structural design of the flyer generator. Third, the axial initiation capability was evaluated through standardized lead plate (5 mm thickness) penetration tests. The penetration depth and crater morphology were comparatively analyzed to quantify performance differences with traditional no-primary detonators. Fourth, an underwater explosion test system was utilized, with an array of pressure sensors measuring shock wave overpressure and bubble pulse energy to assess detonation stability and energy output efficiency. Fifth, donor/acceptor detonator arrays were set up at 10–50 mm intervals, and high-speed cameras were used to monitor sympathetic detonation phenomena, verifying compliance with the industrial safety standard of 40 mm minimum separation distance. Sixth, charge parameters were optimized through iterative testing: primary charge (400 mg, compaction density 1.56 g/cm³), secondary charge (200 mg, compaction density 1.41 g/cm³), tertiary charge (320 mg, loosely packed),the fourth charge layer was eliminated to simplify the production process while maintaining performance. This multi-scale methodology system provides systematic validation support for the reliability, safety, and environmental friendliness of the flyer initiation technology. The results were acquired as follows. Optimized main charge configuration (primary charge: 400 mg-1.56 g/cm³, secondary charge: 200 mg-1.41 g/cm³, tertiary charge: 320 mg-loosely packed) achieved stable detonation, achieve synergistic improvement of detonation performance and safety. When the slapper generator's necking diameter was 5.6−5.7 mm, the flyer velocity reached the reliable initiation threshold. Lead plate tests demonstrated superior axial initiation capability compared to traditional no-primary detonators. Underwater explosion tests confirmed stable detonation performance, with an air-gap sympathetic detonation distance larger than 30 mm, meeting the 40 mm safety requirement for production processes. The innovative elimination of the fourth charge simplified the production process while maintaining high safety and environmental friendliness. The technical bottlenecks of traditional no-primary detonators has been broken. The results show that the new intelligent flyer-type electronic detonator completely avoids the use of sensitive primary explosives through flyer initiation technology. It significantly outperforms traditional designs in initiation reliability, safety distance, and environmental performance, aligning with the industry's trend toward safer and greener detonators. This study provides an innovative solution for the field.