CN107731416B - Manufacturing method of special polyvinyl chloride insulated electronic wire and electronic wire - Google Patents
Manufacturing method of special polyvinyl chloride insulated electronic wire and electronic wire Download PDFInfo
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- CN107731416B CN107731416B CN201710906725.0A CN201710906725A CN107731416B CN 107731416 B CN107731416 B CN 107731416B CN 201710906725 A CN201710906725 A CN 201710906725A CN 107731416 B CN107731416 B CN 107731416B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/0009—Details relating to the conductive cores
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
- H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
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Abstract
A manufacturing method of a special polyvinyl chloride insulated electronic wire and the electronic wire are provided, wherein the outer diameter range of the electronic wire is 8.2-9.2 mm; the structure of the electron beam is as follows: bundling tin-plated copper monofilaments to form a conductor; the conductor is wrapped with an insulating layer to form an insulating wire core; two insulated wire cores are twisted to form a twisted pair wire core; a first isolating layer formed by wrapping a polyester tape is arranged outside the twisted pair wire core; a plurality of twisted pair wire cores wrapping the first isolation layer are twisted to form a cable core, and gaps in the cable core are filled with filling ropes; a layer of aluminum-plastic composite tape is wrapped outside the cable core to form a second isolation layer; a shielding layer formed by weaving and knotting tinned copper wires is arranged outside the second isolation layer; the shielding layer is externally wrapped with an outer sheath. The manufacturing method of the electronic wire comprises the following steps: 1) manufacturing a conductor; 2) extruding and wrapping an insulating material to form a wire core; 3) producing twisted pair wire cores; 4) producing a cable core; 5) producing a woven layer; 6) extruding sheath materials to form cables. The cable has excellent technical performance and is particularly suitable for a control system in a low-temperature resistant occasion.
Description
Technical Field
The technical scheme relates to the technical field of cables, in particular to a special polyvinyl chloride insulated electronic wire with strong anti-interference capability.
Background
The electronic wire is a short for internal cable of electrical equipment, the electric property mainly is weak current, and the concept is different from that of a cable in a strong current category.
At present, large-scale mechanical equipment is in a special operating environment, and requires that an electronic wire has high anti-interference performance and a cable has good flexibility. For example, the cable used in northern areas has strong low temperature resistance requirement, and the environment can reach-40 ℃ when the cable is used. And the cable has oil resistance and flame retardant property.
Although it may be easier to achieve a single requirement for cable design and production, the superposition of these special requirements and the functional requirements of the cable itself is very high for cable design and production and is difficult to achieve by only using common technical means.
Disclosure of Invention
Analysis of technical problems:
since the cable diameter of the electronic wire is several millimeters to approximately 4 centimeters, it is very thin compared to a general cable. The use requirement is that a plurality of wires are penetrated in the same cable as much as possible to realize multi-signal transmission (although the serial communication technology is mature, the stability of serial communication is difficult to guarantee in the scene of natural environment or severe electromagnetic environment, so different wires still need to be used according to the signal types to adopt a parallel communication mode), which brings higher difficulty to the cable internal structure design and production of the electronic wire.
In the structural design, the requirements of mechanical properties and electrical properties (including anti-interference properties) of the cable are met under the requirement of limited structural size, and for the introduction of oil-resistant, flame-retardant, low-temperature-resistant and other functional/performance cable materials, the problem that how to consider good mechanical properties and electrical properties in the structural design is difficult to solve is solved. In addition, because there are many functional wires in the thinner cable, and the wire diameter of these wires is also very small, the thickness of the cable material layer is thinner, and the introduction of the anti-electromagnetic interference layer of the cable brings new problems to the manufacture of the cable, if the manufacturing idea of the cable is adopted or continued, it is unable to guarantee higher product quality and production continuity.
The cable with small overall diameter and complex internal structure is extremely difficult to realize when high product yield is ensured in production.
In order to solve the problems in the prior art, the technical scheme provides a manufacturing method of a special polyvinyl chloride insulated electronic wire and the electronic wire,
a manufacturing method of a special polyvinyl chloride insulated electronic wire is disclosed, wherein the outer diameter range of the electronic wire is 8.2-9.2 mm;
A. the structure of the electron beam is as follows:
bundling tin-plated copper monofilaments to form a conductor; the conductor is wrapped with an insulating layer to form an insulating wire core;
two insulated wire cores are twisted to form a twisted pair wire core; a first isolating layer formed by wrapping a polyester tape is arranged outside the twisted pair wire core;
a plurality of twisted pair wire cores wrapping the first isolation layer are twisted to form a cable core, and gaps in the cable core are filled with filling ropes;
a layer of aluminum-plastic composite tape is wrapped outside the cable core to form a second isolation layer;
a shielding layer formed by weaving and knotting tinned copper wires is arranged outside the second isolation layer;
the outer sheath is wrapped outside the shielding layer;
B. the manufacturing method of the electronic wire comprises the following steps:
1) manufacturing a conductor: preparing a conductor by a tinned copper monofilament through a wire bundling machine;
in the binding process, the variation range of the take-up tension is 8-10N in the process that the wire binding machine is from the bottom of a wire coil to the full wire coil; the binding pitch-diameter ratio is 20-25;
2) extruding and wrapping insulating materials to form wire cores: on a plastic extruding machine, extruding an insulating material outside a conductor to form a wire core;
the insulating material is a flame-retardant polyvinyl chloride insulating material resistant to low temperature of-40 ℃;
the temperature zone control requirement and the cooling control requirement of the plastic extruding machine are respectively as follows:
a feeding section: 130-140 ℃; a plasticizing section: 150-160 ℃; a homogenizing section: 160-170 ℃; a die head connecting section: 160-170 ℃; a machine head: 170-175 ℃, die orifice: 175-180 ℃;
and segmented cooling is adopted during cooling: according to the advancing direction of cable production, the temperature of cooling water in a first section of cooling water tank is 50-70 ℃, and the temperature of cooling water in a second section of cooling water tank is normal temperature;
drying the wire core by blowing, and rewinding on a wire coil by a rewinder;
in the extrusion process, the linear speed range of the wire core production is 80-100 m/min;
3) producing a twisted pair wire core: on a first cable former, twisting two wire cores obtained in the step 2) in pairs, simultaneously wrapping an aluminum-plastic composite tape outside the twisted wire cores, and then winding the twisted wire cores wrapped with the first isolation layer on a take-up reel by a traction device and a take-up device of the cable former; the traction device is used for drawing the twisted wire core wrapped with the first isolation layer to do linear motion and controlling the linear velocity of the twisted wire core;
controlling the rotating speed of a stranding cage of the cabling machine and the linear speed of the twisted wire cores to enable the twisting pitch of the twisted wire cores to be 80-110 mm;
the wrapping tension of the polyester tape is controlled to be 11-13N by a brake on a tape clamp of a wrapping device of the cabling machine; controlling the lapping rotation speed to ensure that the width of the lapping cover is not less than 5 mm;
4) producing cable cores: stranding a plurality of twisted pair wire cores wrapped with the first isolating layer and the filling ropes obtained in the step 3) on a second cable former to prepare cable cores; meanwhile, an aluminum-plastic composite tape is wrapped outside the cable core;
the pair-twisted wire core wrapped with the second isolation layer is drawn by a drawing device of the cabling machine to do linear motion, and the linear velocity of the pair-twisted wire core is controlled;
controlling the rotating speed and the linear speed of a stranding cage of the cabling machine to enable the stranding pitch of the cable core to be 116-120 mm;
the wrapping tension of the aluminum-plastic composite tape is controlled to be 14-17N by a brake on a tape clamp of a wrapping device of the cabling machine;
controlling the lapping rotation speed to ensure that the width of the lapping cover is not less than 5 mm;
the aluminum surface of the aluminum-plastic composite belt faces outwards during wrapping;
5) producing a woven layer: on a spindle of the weaving machine, weaving a copper wire braid layer outside the cable core coated with the second isolation layer obtained in the step 4), wherein the process requirement is as follows: the knitting angle is 55-70 degrees; the one-way coverage rate is 0.55-0.70; the weaving pitch is 58-64 mm;
6) extruding sheath materials to form cables: on a plastic extruding machine, extruding sheath materials to the outside of the braided layer to obtain a finished product of the electronic wire;
the sheath material is an oil-resistant flame-retardant sheath material which can resist the low temperature of-40 ℃;
the temperature zone control requirement and the cooling control requirement of the rubber extruding machine are respectively as follows:
a feeding section: 140-150 ℃; a plasticizing section: 150-160 ℃; a homogenizing section: 160-170 ℃; a die head connecting section: 160-170 ℃; a machine head: 170-180 ℃, die orifice: 180-185 ℃;
and segmented cooling is adopted during cooling: according to the advancing direction of cable production, the temperature of cooling water in a first section of cooling water tank is 50-70 ℃, and the temperature of cooling water in a second section of cooling water tank is normal temperature;
drying the electronic wire, and rewinding on a wire coil by a rewinder;
in the extrusion process, the linear speed range of the electron wire is 14-17 m/min;
and 4) the steps 4) to 6) are continuous production, and the midway semi-finished product is not wound on a wire coil any more.
The structure of the electron beam is as follows:
the conductor is formed by stranding tin-plated copper monofilaments;
an insulating layer is arranged outside the conductor to form an insulating wire core; the insulating layer is formed by extruding and wrapping low-temperature-resistant (-40 ℃) flame-retardant polyvinyl chloride insulating material outside the conductor;
the two insulated wire cores are twisted in a pair twisting mode to form a pair twisted wire core; a first isolating layer formed by wrapping a polyester tape is arranged outside the twisted pair wire core;
the three twisted pair wire cores coated with the isolating layers are twisted to form a cable core;
the outside of the cable core is wrapped with a wrapped aluminum-plastic composite tape; the aluminum-plastic belt is woven by tinned copper wires, and the outer sheath material is a low-temperature-resistant (-40 ℃) oil-resistant flame-retardant polyvinyl chloride sheath material.
Furthermore, the material of the conductor is a 5 th tin-plated copper conductor which conforms to the GB/T3956; the conductor is formed by bundling tin-plated copper monofilaments according to the pitch diameter ratio of 20-25.
Further, the nominal thickness of the insulating layer is 0.76mm, the average thickness is not less than the nominal thickness, and the thickness at the thinnest part is not less than 0.69 mm.
Furthermore, in the first isolation layer, the thickness range of the polyester belt is 0.04mm, and the lapping width is not less than 5 mm.
Furthermore, in the second isolation layer, the thickness range of the aluminum-plastic belt is 0.05mm, and the width of the lap cover is not less than 5 mm.
Further, the material of weaving layer is the tinned copper wire, weaves the angle: 55-70 degrees; unidirectional coverage rate: 0.55 to 0.70.
Further, the outer sheath is formed by extruded low temperature resistant (-40 ℃) oil resistant flame retardant polyvinyl chloride sheath materials.
The outer sheath is formed by extruded low-temperature-resistant (-40 ℃) oil-resistant flame-retardant polyvinyl chloride sheath materials. In the prior art, the low temperature resistant (-40 ℃) oil-resistant flame-retardant polyvinyl chloride sheath material has the advantages of good low temperature resistance, ultraviolet ray resistance, mineral oil and fuel oil resistance, high flame-retardant property and the like.
The insulating layer is made of flame-retardant polyvinyl chloride insulating material, has good electrical performance, and has low temperature resistance and flame retardance.
Compared with the prior art, the cable has better technical performance and can completely meet the following technical requirements:
1. the maximum long-term allowable operating temperature of the cable conductor is 105 ℃.
2. When the cable is laid, the environmental temperature is not lower than-15 ℃; when the cable is used, the ambient temperature is not lower than-40 ℃.
3. The maximum temperature of the cable at short circuit (maximum duration not exceeding 5s) is 200 ℃.
4. The allowable bend radius of the cable is 6D (D-cable diameter).
Drawings
Fig. 1 is a schematic radial cross-sectional view of the cable of the present embodiment.
In the figure: conductor 1, insulating layer 2, first isolation layer 3, fill 4, second isolation layer 5, weaving layer 6, oversheath 7.
Detailed Description
The technical scheme is further explained by combining the drawings and the detailed implementation mode as follows:
a manufacturing method of a special polyvinyl chloride insulated electronic wire is disclosed, wherein the outer diameter range of the electronic wire is 8.2-9.2 mm;
A. the structure of the electron beam is as follows:
bundling tin-plated copper monofilaments to form a conductor; the conductor is wrapped with an insulating layer to form an insulating wire core;
two insulated wire cores are twisted to form a twisted pair wire core; a first isolating layer formed by wrapping a polyester tape is arranged outside the twisted pair wire core;
a plurality of twisted pair wire cores wrapping the first isolation layer are twisted to form a cable core, and gaps in the cable core are filled with filling ropes;
a layer of aluminum-plastic composite tape is wrapped outside the cable core to form a second isolation layer;
a shielding layer formed by weaving and knotting tinned copper wires is arranged outside the second isolation layer;
the outer sheath is wrapped outside the shielding layer;
B. the manufacturing method of the electronic wire comprises the following steps:
1) manufacturing a conductor: preparing a conductor by a tinned copper monofilament through a wire bundling machine;
in the binding process, the variation range of the take-up tension is 8-10N in the process that the wire binding machine is from the bottom of a wire coil to the full wire coil; the binding pitch-diameter ratio is 20-25;
2) extruding and wrapping insulating materials to form wire cores: on a plastic extruding machine, extruding an insulating material outside a conductor to form a wire core;
the insulating material is a flame-retardant polyvinyl chloride insulating material resistant to low temperature of-40 ℃;
the temperature zone control requirement and the cooling control requirement of the plastic extruding machine are respectively as follows:
a feeding section: 130-140 ℃; a plasticizing section: 150-160 ℃; a homogenizing section: 160-170 ℃; a die head connecting section: 160-170 ℃; a machine head: 170-175 ℃, die orifice: 175-180 ℃;
and segmented cooling is adopted during cooling: according to the advancing direction of cable production, the temperature of cooling water in a first section of cooling water tank is 50-70 ℃, and the temperature of cooling water in a second section of cooling water tank is normal temperature;
drying the wire core by blowing, and rewinding on a wire coil by a rewinder;
in the extrusion process, the linear speed range of the wire core production is 80-100 m/min;
3) producing a twisted pair wire core: on a first cable former, twisting two wire cores obtained in the step 2) in pairs, simultaneously wrapping an aluminum-plastic composite tape outside the twisted wire cores, and then winding the twisted wire cores wrapped with the first isolation layer on a take-up reel by a traction device and a take-up device of the cable former; the traction device is used for drawing the twisted wire core wrapped with the first isolation layer to do linear motion and controlling the linear velocity of the twisted wire core;
controlling the rotating speed of a stranding cage of the cabling machine and the linear speed of the twisted wire cores to enable the twisting pitch of the twisted wire cores to be 80-110 mm;
the wrapping tension of the polyester tape is controlled to be 11-13N by a brake on a tape clamp of a wrapping device of the cabling machine; controlling the lapping rotation speed to ensure that the width of the lapping cover is not less than 5 mm;
4) producing cable cores: stranding a plurality of twisted pair wire cores wrapped with the first isolating layer and the filling ropes obtained in the step 3) on a second cable former to prepare cable cores; meanwhile, an aluminum-plastic composite tape is wrapped outside the cable core;
the pair-twisted wire core wrapped with the second isolation layer is drawn by a drawing device of the cabling machine to do linear motion, and the linear velocity of the pair-twisted wire core is controlled;
controlling the rotating speed and the linear speed of a stranding cage of the cabling machine to enable the stranding pitch of the cable core to be 116-120 mm;
the wrapping tension of the aluminum-plastic composite tape is controlled to be 14-17N by a brake on a tape clamp of a wrapping device of the cabling machine;
controlling the lapping rotation speed to ensure that the width of the lapping cover is not less than 5 mm;
the aluminum surface of the aluminum-plastic composite belt faces outwards during wrapping;
5) producing a woven layer: on a spindle of the weaving machine, weaving a copper wire braid layer outside the cable core coated with the second isolation layer obtained in the step 4), wherein the process requirement is as follows: the knitting angle is 55-70 degrees; the one-way coverage rate is 0.55-0.70; the weaving pitch is 58-64 mm;
6) extruding sheath materials to form cables: on a plastic extruding machine, extruding sheath materials to the outside of the braided layer to obtain a finished product of the electronic wire;
the sheath material is an oil-resistant flame-retardant sheath material which can resist the low temperature of-40 ℃;
the temperature zone control requirement and the cooling control requirement of the rubber extruding machine are respectively as follows:
a feeding section: 140-150 ℃; a plasticizing section: 150-160 ℃; a homogenizing section: 160-170 ℃; a die head connecting section: 160-170 ℃; a machine head: 170-180 ℃, die orifice: 180-185 ℃;
and segmented cooling is adopted during cooling: according to the advancing direction of cable production, the temperature of cooling water in a first section of cooling water tank is 50-70 ℃, and the temperature of cooling water in a second section of cooling water tank is normal temperature;
drying the electronic wire, and rewinding on a wire coil by a rewinder;
in the extrusion process, the linear speed range of the electron wire is 14-17 m/min;
and 4) the steps 4) to 6) are continuous production, and the midway semi-finished product is not wound on a wire coil any more.
In the present embodiment:
in the step 1), in the binding process, the process from the bottom of the wire coil to the full-wire coil of the wire binding machine is as follows:
example 1, the take-up tension was 8N; the binding pitch-diameter ratio is 25;
example 2, the take-up tension was 9N; the binding pitch-diameter ratio is 23;
example 3, the take-up tension was 10N; the binding pitch-to-diameter ratio is 21.
In the step 2), the temperature zone control requirement and the cooling control requirement of the extruding machine and the linear speed requirement of the wire core production are as follows:
example 1, feeding section: 130 ℃;
a plasticizing section: 155 ℃;
a homogenizing section: 165 ℃;
a die head connecting section: 165 ℃;
a machine head: at the temperature of 170 ℃, the temperature of the mixture is adjusted,
die opening: 175 ℃;
the temperature of cooling water in the first-stage cooling water tank is 65 ℃;
the linear velocity of the wire core is 82 m/min;
example 2, feeding section: 135 deg.C;
a plasticizing section: 150 ℃;
a homogenizing section: 170 ℃;
a die head connecting section: 170 ℃;
a machine head: at a temperature of 175 c,
die opening: 178 ℃;
the temperature of cooling water in the first-stage cooling water tank is 70 ℃;
the linear velocity of the wire core is 95 m/min;
example 3, feeding section: 140 ℃;
a plasticizing section: 160 ℃;
a homogenizing section: 160 ℃;
a die head connecting section: 160 ℃;
a machine head: at a temperature of 175 c,
die opening: 180 ℃;
the temperature of cooling water in the first-stage cooling water tank is 50 ℃;
the linear velocity of the wire core was 100 m/min.
In the step 3), the stranding pitch of the twisted wire core is 80mm (example 1), 95mm (example 2) or 110mm (example 3); and controlling the wrapping tension of the polyester tape to be 12N.
In examples 1 to 3, in the step 4), the stranding pitch of the cable core is 118 mm; and controlling the lapping tension of the aluminum-plastic composite tape to be 15N.
In examples 1 to 3, the weaving pitch in the step 5) was 60 mm.
In examples 1 to 3, in the step 6), the linear velocity of the electron beam was 15 m/min;
the temperature zone control requirement and the cooling control requirement of the rubber extruding machine are respectively as follows:
example 1, feeding section: 140 ℃;
a plasticizing section: 155 ℃;
a homogenizing section: 160 ℃;
a die head connecting section: 165 ℃;
a machine head: at the temperature of 180 ℃, the temperature of the mixture is controlled,
die opening: 185 ℃ of temperature;
the temperature of cooling water in the first-stage cooling water tank is 70 ℃;
example 2, feeding section: 145 ℃;
a plasticizing section: 150 ℃;
a homogenizing section: 165 ℃;
a die head connecting section: 170 ℃;
a machine head: at the temperature of 176 c,
die opening: 183 ℃;
the temperature of cooling water in the first-stage cooling water tank is 64 ℃;
example 3, feeding section: 150 ℃;
a plasticizing section: 160 ℃;
a homogenizing section: 170 ℃;
a die head connecting section: 160 ℃;
a machine head: at the temperature of 170 ℃, the temperature of the mixture is adjusted,
die opening: 180 ℃;
the cooling water temperature in the first stage cooling water tank was 50 ℃.
In examples 1 to 3, in the step 2), the grade of the insulating material is J-105 VOD; in the step 6), the sheath material brand is H-105 VOD.
Through inspection, the yield of the product is 99.4% by adopting the process parameters of example 1; the technological parameters of example 2 are adopted, and the yield of the product is 99.8%; by adopting the process parameters of example 3, the yield of the product is 99.7%.
Referring to fig. 1, the special polyvinyl chloride insulated electronic wire manufactured by the method has the structure that: the conductors are formed by twisting tinned copper wires; the conductor is extruded with an insulating layer; twisting the insulated wire cores; a layer of polyester tape is adopted outside the twisted wire core for isolation; winding the core of the isolation belt and cabling after twisting; the cable core is wrapped with a layer of aluminum-plastic composite tape for isolation; the aluminum-plastic composite belt is braided and shielded by tinned copper wires; the outermost layer adopts a low temperature resistant (-40 ℃) oil-resistant flame-retardant polyvinyl chloride sheath;
among the conductors, the conductor is a 5 th tin-plated copper conductor specified in GB/T3956; when the conductor is in an irregular twisting mode, the combined pitch diameter ratio of the tinned copper wire bundle is 20-25;
the first layer of isolation belt is made of a polyester belt with the nominal thickness of 0.04 mm; the cover width of the polyester tape is not less than 5 mm.
The second layer of isolation belt is made of an aluminum-plastic conforming belt with the nominal thickness of 0.05 mm; the aluminum plastic is in accordance with the overlapping width of the belt and is not less than 5 mm.
The nominal thickness of the insulating layer is 0.76mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 0.69 mm.
And filling by adopting a PP rope during cabling.
The material of weaving layer is the tinned copper wire, weaves the angle: 55-70 degrees; single-phase coverage rate: 0.55 to 0.70.
The outer sheath is formed by extruded low-temperature-resistant (-40 ℃) oil-resistant flame-retardant polyvinyl chloride sheath materials. In the prior art, the low temperature resistant (-40 ℃) oil-resistant flame-retardant polyvinyl chloride sheath material has the advantages of good low temperature resistance, ultraviolet ray resistance, mineral oil and fuel oil resistance, high flame-retardant property and the like.
The insulating layer is made of flame-retardant polyvinyl chloride insulating material, has good electrical performance, and has low temperature resistance and flame retardance.
The cable has excellent technical performance and is particularly suitable for a control system in a low-temperature resistant occasion.
Through inspection, the main technical indexes of the cable are as follows:
1. the insulation tensile strength is 17.2Mpa, and the insulation elongation at break is 230%.
2. Aging of an insulating UL air box: (136 ℃ C. + -. 1, 168h)
The retention rate of tensile strength after insulation aging is 90%, and the retention rate of elongation at break after insulation aging is 83%.
3. And (3) winding the insulated wire core-40 at a low temperature: no cracking.
4. Insulating thermal deformation: (121 ℃ C. + -. 1, 120min)
The insulation deformation rate was 35%.
6. The tensile strength of the sheath is more than or equal to 16.5Mpa, and the elongation at break of the sheath is more than or equal to 210 percent.
7. Sheath UL air box aging: (136 ℃ +/-1, 168h) the retention rate of the tensile strength of the aged sheath is more than or equal to 92%, and the retention rate of the elongation at break of the aged sheath is more than or equal to 85%.
8. The sheath is stretched at the low temperature of-40 ℃ by 25 percent.
9. The flame retardant property of the cable is as follows: the cable passed the VW-1, FT1 flame retardant test.
Claims (2)
1. A method for manufacturing a special polyvinyl chloride insulated electronic wire is characterized in that
The outer diameter range of the electron beam is 8.2-9.2 mm; the structure of the electron beam is as follows:
bundling tin-plated copper monofilaments to form a conductor; the conductor is wrapped with an insulating layer to form an insulating wire core;
two insulated wire cores are twisted to form a twisted pair wire core; a first isolating layer formed by wrapping a polyester tape is arranged outside the twisted pair wire core;
a plurality of twisted pair wire cores wrapping the first isolation layer are twisted to form a cable core, and gaps in the cable core are filled with filling ropes;
a layer of aluminum-plastic composite tape is wrapped outside the cable core to form a second isolation layer;
a shielding layer formed by weaving tinned copper wires is arranged outside the second isolation layer;
the outer sheath is wrapped outside the shielding layer;
wherein:
the material of the conductor is a 5 th tin-plated copper conductor which conforms to the GB/T3956; the binding pitch-diameter ratio is 23;
the nominal thickness of the insulating layer is 0.76mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 0.69 mm;
the thickness of the polyester tape of the first isolation layer is 0.04mm, and the width of the lapping cover is not less than 5 mm;
the width of an aluminum-plastic composite tape wrapped outside the cable core is 15-25 mm, the thickness of the aluminum-plastic composite tape is 0.05mm, the width of a covering of the wrapping is not less than 5mm, and the aluminum surface faces outwards during wrapping;
the material of weaving layer is the tinned copper wire, and the monofilament diameter is 0.15mm, weaves the angle: 55-70 degrees; unidirectional coverage rate: 0.55 to 0.70;
the outer sheath is made of extruded polyvinyl chloride sheath materials which can resist low temperature of-40 ℃, oil and flame; the thickness of the outer sheath is 0.85 mm;
the manufacturing method of the electronic wire comprises the following steps:
1) manufacturing a conductor: preparing a conductor by a tinned copper monofilament through a wire bundling machine;
in the binding process, the take-up tension is 9N in the process from the bottom of the wire coil to the full wire coil of the wire binding machine; the binding pitch-diameter ratio is 23;
2) extruding and wrapping insulating materials to form wire cores: on a plastic extruding machine, extruding an insulating material outside a conductor to form a wire core;
the insulating material is a flame-retardant polyvinyl chloride insulating material resistant to low temperature of-40 ℃, and the trademark of the insulating material is J-105 VOD;
the temperature zone control requirement and the cooling control requirement of the plastic extruding machine are respectively as follows:
a feeding section: 135 deg.C; a plasticizing section: 150 ℃; a homogenizing section: 170 ℃; a die head connecting section: 170 ℃; a machine head: 175 ℃; die opening: 178 ℃;
and segmented cooling is adopted during cooling: according to the advancing direction of cable production, the temperature of cooling water in the first section of cooling water tank is 70 ℃, and the temperature of cooling water in the second section of cooling water tank is normal temperature;
drying the wire core by blowing, and rewinding on a wire coil by a rewinder;
in the extrusion process, the linear speed of the wire core produced by the wire core is 95 m/min;
3) producing a twisted pair wire core: on a first cable former, twisting two wire cores obtained in the step 2) in pairs, simultaneously wrapping a polyester tape outside the twisted wire cores, and then winding the twisted wire cores wrapped with the first isolation layer on a take-up reel by a traction device and a take-up device of the cable former; the traction device is used for drawing the twisted wire core wrapped with the first isolation layer to do linear motion and controlling the linear velocity of the twisted wire core;
controlling the rotating speed of a stranding cage of the cabling machine and the linear speed of the twisted wire cores to enable the twisting pitch of the twisted wire cores to be 95 mm;
the wrapping tension of the polyester tape is controlled to be 12N by a brake on a tape clamp of a wrapping device of the cabling machine; controlling the lapping rotation speed to ensure that the width of the lapping cover is not less than 5 mm;
4) producing cable cores: stranding a plurality of twisted pair wire cores wrapped with the first isolating layer and the filling ropes obtained in the step 3) on a second cable former to prepare cable cores; meanwhile, an aluminum-plastic composite belt is wound outside the cable core;
the pair-twisted wire core wrapped with the second isolation layer is drawn by a drawing device of the cabling machine to do linear motion, and the linear velocity of the pair-twisted wire core is controlled;
controlling the linear speed of the cabling machine and the rotating speed of the stranding cage to enable the stranding pitch of the cable core to be 118 mm;
the lapping tension of the aluminum-plastic composite belt is controlled to be 15N by a brake on a belt clamp of a lapping device of the cabling machine;
controlling the lapping rotation speed to ensure that the width of the lapping cover is not less than 5 mm;
the thickness of the aluminum-plastic composite tape wrapped outside the cable core is 0.05mm, the cover width of the wrapping is not less than 5mm, and the aluminum surface of the aluminum-plastic composite tape faces outwards during wrapping;
5) producing a shielding layer: on a spindle of the knitting machine, a tinned copper wire braided shielding layer is braided outside the cable core coated with the second isolation layer obtained in the step 4), and the process requirements are as follows: the knitting angle is 55-70 degrees; the one-way coverage rate is 0.55-0.70; the weaving pitch is 60 mm;
6) extruding sheath materials to form cables: on a plastic extruding machine, extruding sheath materials to the outside of the shielding layer to obtain a finished product of the electronic wire;
the sheath material is an oil-resistant flame-retardant sheath material resistant to low temperature of-40 ℃, and the grade of the sheath material is H-105 VOD;
the temperature zone control requirement and the cooling control requirement of the rubber extruding machine are respectively as follows:
a feeding section: 145 ℃; a plasticizing section: 150 ℃; a homogenizing section: 165 ℃; a die head connecting section: 170 ℃; a machine head: 176 ℃; die opening: 183 ℃;
and segmented cooling is adopted during cooling: according to the advancing direction of cable production, the temperature of cooling water in the first section of cooling water tank is 64 ℃, and the temperature of cooling water in the second section of cooling water tank is normal temperature;
drying the electronic wire, and rewinding on a wire coil by a rewinder;
in the extrusion process, the linear velocity of the electronic wire is 15 m/min;
and 4) the steps 4) to 6) are continuous production, and the midway semi-finished product is not wound on a wire coil any more.
2. An electron beam made by the method of claim 1, wherein said electron beam has an outer diameter in the range of 8.2 to 9.2 mm; the structure of the electron beam is as follows:
bundling tin-plated copper monofilaments to form a conductor; the conductor is wrapped with an insulating layer to form an insulating wire core;
two insulated wire cores are twisted to form a twisted pair wire core; a first isolating layer formed by wrapping a polyester tape is arranged outside the twisted pair wire core;
a plurality of twisted pair wire cores wrapping the first isolation layer are twisted to form a cable core, and gaps in the cable core are filled with filling ropes;
a layer of aluminum-plastic composite tape is wrapped outside the cable core to form a second isolation layer;
a shielding layer formed by weaving tinned copper wires is arranged outside the second isolation layer;
the outer sheath is wrapped outside the shielding layer;
wherein:
the material of the conductor is a 5 th tin-plated copper conductor which conforms to the GB/T3956; the binding pitch-diameter ratio is 23;
the nominal thickness of the insulating layer is 0.76mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 0.69 mm;
the thickness of the polyester tape of the first isolation layer is 0.04mm, and the width of the lapping cover is not less than 5 mm;
the width of an aluminum-plastic composite tape wrapped outside the cable core is 15-25 mm, the thickness of the aluminum-plastic composite tape is 0.05mm, the width of a covering of the wrapping is not less than 5mm, and the aluminum surface faces outwards during wrapping;
the material of shielding layer is the tinned copper wire, and the monofilament diameter is 0.15mm, weaves the angle: 55-70 degrees; unidirectional coverage rate: 0.55 to 0.70;
the outer sheath is made of extruded polyvinyl chloride sheath materials which can resist low temperature of-40 ℃, oil and flame; the thickness of the outer sheath is 0.85 mm.
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| CN109411129A (en) * | 2018-10-26 | 2019-03-01 | 李露青 | A kind of electron helix and its processing method |
| CN109448925A (en) * | 2018-12-11 | 2019-03-08 | 江苏上上电缆集团有限公司 | A kind of high-efficient cable manufacturing method and cable |
| CN109448892A (en) * | 2018-12-19 | 2019-03-08 | 江苏上上电缆集团有限公司 | A kind of hollow cable manufacturing method and cable |
| CN110289534B (en) * | 2019-07-02 | 2020-10-09 | 无锡振特电子有限公司 | Production process of electric automobile wire harness |
| CN110364294B (en) * | 2019-07-16 | 2021-01-19 | 安徽徽宁电器仪表集团有限公司 | Flame-retardant high-temperature-resistant computer cable and preparation process thereof |
| CN113096889A (en) * | 2021-03-27 | 2021-07-09 | 江苏上上电缆集团有限公司 | Method for manufacturing low-temperature-resistant long-service-life thin plastic insulated cable for motor train unit |
| CN113903531B (en) * | 2021-09-16 | 2023-08-22 | 江苏上上电缆集团有限公司 | Manufacturing method of ethylene-propylene insulating low-smoke halogen-free torsion-resistant medium-voltage wind energy cable and cable |
| CN114512273A (en) * | 2022-03-07 | 2022-05-17 | 安徽光神航天电子技术有限公司 | Preparation method of novel high-temperature-resistant waterproof branch cable assembly |
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| JP5914149B2 (en) * | 2012-05-08 | 2016-05-11 | 矢崎エナジーシステム株式会社 | Power cable and manufacturing method thereof |
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| CN105023645A (en) * | 2015-07-22 | 2015-11-04 | 安徽华星电缆集团有限公司 | Special cable used for industrial robot and making method of special cable |
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| JPH10283848A (en) * | 1997-04-02 | 1998-10-23 | R Peterson Edwin | Multi-core electric cable |
| JP5914149B2 (en) * | 2012-05-08 | 2016-05-11 | 矢崎エナジーシステム株式会社 | Power cable and manufacturing method thereof |
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