CN113871058B - Manufacturing method of special cable for car dumper and cable - Google Patents
Manufacturing method of special cable for car dumper and cable Download PDFInfo
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- CN113871058B CN113871058B CN202110998151.0A CN202110998151A CN113871058B CN 113871058 B CN113871058 B CN 113871058B CN 202110998151 A CN202110998151 A CN 202110998151A CN 113871058 B CN113871058 B CN 113871058B
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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
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
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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
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/28—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances natural or synthetic rubbers
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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
- H01B7/02—Disposition of insulation
- H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
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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
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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
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/1875—Multi-layer sheaths
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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
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/22—Metal wires or tapes, e.g. made of steel
- H01B7/221—Longitudinally placed metal wires or tapes
- H01B7/223—Longitudinally placed metal wires or tapes forming part of a high tensile strength core
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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
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/22—Metal wires or tapes, e.g. made of steel
- H01B7/228—Metal braid
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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
- H01B7/282—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable
- H01B7/2825—Preventing penetration of fluid, e.g. water or humidity, into conductor or cable using a water impermeable sheath
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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
- H01B7/292—Protection against damage caused by extremes of temperature or by flame using material resistant to heat
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Ropes Or Cables (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
Abstract
A manufacturing method of a special cable for a car dumper comprises the following steps: 1) Manufacturing a cable conductor; 2) Extruding a conductor insulating layer and a steel wire rope outer protective layer; 3) The wire core, the anti-pulling rope and the filling rope form a cable wrapping; 4) Braiding a tinned copper wire shielding layer; 5) Extruding a fluoroplastic inner sheath; 6) And extruding a nylon outer sheath. The cable manufactured by the manufacturing method is a wire core formed by extruding an insulating layer outside a tinned conductor; the tensile rope consists of a steel wire rope and an outer extrusion steel wire rope protective layer; the cable core is formed by twisting a plurality of cable cores, a tensile rope and a filling rope together, and the polyester belt, the shielding layer, the inner sheath and the outer sheath are sequentially wrapped outside the cable core. The cable manufactured by the cable manufacturing method can well meet the use requirements of outdoor high-strength car dumper equipment cables, and achieves the performances of radial water resistance, excellent tensile strength, wear resistance, high and low temperature resistance, ultraviolet resistance, shielding, interference resistance and the like.
Description
Technical Field
The invention relates to a novel special cable for equipment and a cable manufacturing method, in particular to a special cable with excellent performances of tensile resistance, wear resistance, high and low temperature resistance, ultraviolet resistance, radial water resistance, shielding interference resistance and the like for an outdoor high-strength car dumper, and belongs to the technical field of cables.
Background
The cable for equipment is special in use environment, and particularly has higher requirements on the performances of tensile resistance, wear resistance, high and low temperature resistance, ultraviolet resistance, radial water resistance, shielding, interference resistance and the like of the cable, and the conventional cable for equipment cannot meet the requirements, so that potential safety hazards are avoided in the high-strength use process of the equipment, and the special cable is matched to solve the problem.
Disclosure of Invention
In order to solve the technical problems, the invention provides a manufacturing method of a special cable for a car dumper, which can realize the manufacturing of the special cable product through the specific structural design of the cable, the material use and the control of the production process.
A manufacturing method of a special cable for a car dumper comprises the following steps:
1) Manufacturing a cable conductor 2;
2) Extruding a conductor insulating layer 3 and a steel wire rope outer protective layer 9;
3) The wire core, the anti-pulling rope and the filling rope 4 are cabled and wrapped;
4) Braiding a tinned copper wire shielding layer 5;
5) Extruding a fluoroplastic inner sheath 6;
6) A nylon outer sheath 7 is extruded and wrapped,
the step 1) comprises the following steps:
1.1 Preformed monofilaments:
and (3) wiredrawing: drawing the copper rod into filaments by adopting a corresponding wire drawing die respectively;
and (3) wiredrawing process: the copper rod sequentially penetrates into a plurality of wire drawing dies according to the pass, the arc surface of the monofilament corresponds to the arc groove of the die hole, the copper wire is ensured to be stressed stably, and the section of the monofilament has no deviation;
1.2 Tinned copper monofilament is prepared by tinning a layer outside the bare copper monofilament, and the thickness of the tin layer is controlled to be 0.7-0.9 mu m.
1.3 Taking tin-plated copper monofilaments to twist to form a conductor according to the requirement;
the step 2) comprises the following steps: extruding silicon rubber insulating materials outside the conductor and the steel wire rope to respectively manufacture a wire core and a tensile rope;
the temperature zone of the rubber extruder for extruding the silicon rubber insulating material is controlled as follows: one region 140-160 ℃, two regions 150-190 ℃, three regions 190-200 ℃, four regions 200-220 ℃ and five regions 220-230 ℃; the first region is a feeding section, the second region and the third region are plasticizing sections, and the fourth region and the fifth region are homogenizing sections; setting the temperature of a machine head: 250 ℃;
preheating the conductor before entering the rubber extruder, wherein the preheating temperature is 100+/-10 ℃;
the extrusion mode of the silicon rubber insulating material is extrusion type, in the extrusion process, the steam pressure is 14-16 bar during production, the production speed is 7-9 m/min, and the screw speed of an extruder is 20-30 r/min;
water-cooling in a cold water tank for 20min; the water temperature of the cold water tank is controlled to be 8-15 ℃;
the step 3) comprises the following steps:
3.1 Cabling and stranding a plurality of wire cores, 1 anti-pulling rope and a plurality of filling ropes on a cabling machine to prepare a cable core; the pull-resistant rope is positioned at the axis;
the anti-pulling rope consists of a steel wire rope and a steel wire rope protective layer, wherein the steel wire rope is formed by twisting 49 steel wires with the nominal diameter of 0.17mm, the twisting pitch diameter ratio is 20-25 times, the nominal thickness of the steel wire rope protective layer is 0.7mm, and the calculated outer diameter of the anti-pulling rope is 3.1mm; the difference between the outer diameter of the tensile rope and the outer diameter of the wire core should not exceed 1.0mm, and the tensile strength of the steel wire rope in the tensile rope is obviously superior to that of the copper core in the wire core, which is as high as 14KN/mm 2 。
The cabling direction is left, and the cabling pitch diameter ratio is controlled to be 12-14 times; the tension of each wire core is uniformly adjusted before cabling;
the rotating speed of a stranding cage of the cabling machine is 66-78 r/min, and the traction speed of the cabling machine is 20-30 m/min;
when the cable is formed, the anti-pulling rope is placed at the central axis position instead of the outer layer, so that the problems of unstable structure and uneven appearance caused by incomplete consistency of the outer diameter of the anti-pulling rope and the wire core can be avoided, the tensile strength of a cable finished product is obviously improved, and the cable is prevented from breaking under the high-strength operation of the car dumper.
3.2 Overlapping and wrapping a polyester belt outside the cable core;
during wrapping, the traction speed is 40-60 m/min, and the wrapping pitch is 30mm;
the step 4) comprises the following steps: a braiding machine is used for braiding shielding outside the cable core by adopting tinned copper wires to prepare a shielding layer; the knitting density is not less than 80%; the weaving pitch is 46mm;
the step 5) comprises the following steps: extruding fluoroplastic (preferably poly perfluoroethylene propylene) outside the shielding layer to obtain an inner sheath, wherein the extrusion mode is extrusion pipe type;
the temperature zone of the extruder for extruding fluoroplastic is controlled as follows: 130-180 ℃ in the first region, 180-200 ℃ in the second region, 200-230 ℃ in the third region, 225-245 ℃ in the fourth region and 240-260 ℃ in the fifth region; the first region is a feeding section, the second region and the third region are plasticizing sections, and the fourth region and the fifth region are homogenizing sections; setting the temperature of a machine head: 280 ℃;
the semi-finished product after the fluoroplastic is extruded is cooled by sections: the temperature of the first section of water tank is 50-70 ℃, and the temperature of the second section of water tank is room temperature;
when the fluoroplastic is extruded, the cable head is lifted off the water surface;
the step 6) comprises the following steps: extruding nylon sheath material on the outermost layer to obtain an outer sheath, wherein the extrusion mode is extrusion pipe type;
6.1 Preheating the cable prepared in the step 5);
6.2 Drying the nylon sheath material;
6.3 The temperature zone of the extruder for extruding nylon sheath material is controlled as follows: first region 201 ℃, second region 212 ℃, third region 232 ℃, fourth region 230 ℃, fifth region 233 ℃ and sixth region 235 ℃; the first area and the second area are feeding sections, the third area and the fourth area are plasticizing sections, and the fifth area and the sixth area are homogenizing sections; the temperature of the machine neck is 241 ℃, the first area of the machine head is 241, and the second area of the machine head is 244 ℃;
6.4 The nylon sheath adopts sectional water cooling, the water temperature of the first section of water tank is (50-70) DEG C, and the water temperature of the second section of water tank is normal temperature.
In the step 1.1), the diameter range of the tinned copper monofilament is 0.32 mm-0.85 mm; in the step 1.3), the diameter of the conductor ranges from 1.6mm to 2.5mm; the twisting direction of the tinned copper monofilament is left, and the twisting pitch diameter ratio is 18-25 times.
The nominal thickness range of the insulating layer and the steel wire rope protective layer is 0.6-0.8 mm, and the thickness of the thinnest point is more than or equal to 90-0.1 mm of the nominal value.
In the step 3.1), the number of the wire cores is 3-16, and the sectional area of the conductor of the wire cores is 1.5mm 2 ～4mm 2 ；
The filling rope is twisted by high-temperature resistant polypropylene net-shaped tearing films;
in step 3.2), the nominal thickness of the polyester tape is 0.04mm, and the lapping overlap width is not less than 5mm.
In the step 4), the nominal diameter range of the tinned copper wire is 0.15-0.20 mm.
In the step 5), the nominal thickness of the inner sheath is 0.8-1.0 mm, and the thickness of the thinnest point is more than or equal to 80% of the nominal value.
In the step 6), the nominal thickness range of the outer sheath is 1.0-1.2 mm, and the thickness of the thinnest point is more than or equal to 85-0.1 mm of the nominal value.
Advantageous effects
After the technical scheme is adopted, the invention has the following beneficial effects:
in order to meet the special application environment of the cable for the outdoor high-strength car dumper, the performance requirements of tensile strength, wear resistance, high and low temperature resistance, ultraviolet resistance, radial water resistance, shielding, interference resistance and the like of the cable are required to be met.
(1) The silicon rubber material, the fluoroplastic material and the nylon outer sheath material have good high and low temperature resistance, are respectively used as an insulating layer, an inner sheath and an outer sheath of the cable, the tinned conductor can prevent the copper wire from being oxidized and blackened when being wet at high temperature, the reliability of the conductor is improved, the silicon rubber also has good electrical performance, and the material combination has excellent electrical performance and can meet the high and low temperature resistance requirement of the use environment.
(2) The anti-pulling rope consists of a steel wire rope and a silicon rubber protective layer, so that the tensile property of the cable can be greatly improved.
(3) The tin-plated copper braided wire has waterproof performance and can play a good role in shielding and resisting interference on the cable.
(4) The nylon outer sheath is extruded through a special process, so that the nylon material has good fatigue resistance stability, impact resistance, wear resistance and ultraviolet resistance while playing a role in radial water resistance.
The cable disclosed by the invention is based on a newly designed cable shape structure, and simultaneously uses specific structural parameters, material combinations and processing technology to achieve the effects of tensile resistance, wear resistance, high and low temperature resistance, ultraviolet resistance, radial water resistance, shielding, interference resistance and the like of the cable, and can be well applied to normal operation of an outdoor high-strength car dumper.
Drawings
FIG. 1 is a schematic view of the radial structure of a cable according to the present invention;
in the figure: tin-plated conductor 1, insulating layer 2, filling rope 3, polyester area 4, shielding layer 5, inner sheath 6, outer sheath 7, wire rope 8, wire rope sheath 9.
Detailed Description
The following further describes the technical scheme with reference to the accompanying drawings and specific embodiments:
referring to fig. 1, the cable manufacturing method of this example produces a cable structure of: a wire core formed by extruding an insulating layer 2 outside a tinned conductor 1; the tensile rope consists of a steel wire rope 8 and an outer extrusion steel wire rope protective layer 9; the cable core is formed by twisting a plurality of cable cores, an anti-pulling rope and a filling rope 3 together, and the polyester belt 4, the shielding layer 5, the inner sheath 6 and the outer sheath 7 are sequentially wrapped outside the cable core.
In the example, the tinned conductor is formed by twisting tinned copper monofilaments, and the diameter range of the tinned copper monofilaments is 0.32-0.85 mm; the diameter range of the conductor is 1.6 mm-2.5 mm; the twisting direction of the tinned copper monofilament is left, and the twisting pitch diameter ratio is 18-25 times. The tinned conductor can prevent the copper wire from oxidation and blackening when being wet at high temperature and improve the reliability of the conductor.
The insulating layer is made of silicon rubber insulating material, the nominal thickness range of the insulating layer is 0.6-0.8 mm, and the thickness of the thinnest point is more than or equal to 90% -0.1mm of the nominal value. The filling rope is a high-temperature-resistant polypropylene reticular tearing film, is tightly filled in the middle of the cable core in the cable forming process, and plays roles of improving the roundness of the cable and enhancing the waterproof performance.
The nominal thickness of the polyester belt is 0.04mm, and the lapping overlapping width is not less than 5mm; the shielding layer is formed by weaving metal braiding wires; the nominal diameter range of the braided wire is 0.15-0.20 mm; the knitting density is not less than 80%; the metal braided wires are tinned copper wires. The inner sheath is composed of fluoroplastic sheath material, the nominal thickness of the inner sheath is 0.8-1.0 mm, and the thickness of the thinnest point is more than or equal to 80% of the nominal value. The outer sheath is made of nylon sheath material, the nominal thickness range of the outer sheath is 1.0-1.2 mm, and the thickness of the thinnest point is more than or equal to 85% -0.1mm of the nominal value.
The cable can well solve the use requirement of outdoor high-strength car dumper equipment cables, and achieves the performances of radial water resistance, excellent tensile strength, wear resistance, high and low temperature resistance, ultraviolet resistance, shielding, interference resistance and the like.
The insulating material can be silicon rubber insulating material XJ-80A, and the manufacturer is Suzhou Fu Australian cable materials Co.
In this example, fluoroplastic_f46 was used for the inner sheath, and the manufacturer was oslo plastic products limited in the city of Tianchang.
In this example, nylon 12 sheath material_l25w40x is used for the outer sheath, and the manufacturer is switzerland EMS (china) trade company.
The cable manufacturing method comprises the following steps: 1) Manufacturing a cable conductor; 2) Extruding a conductor insulating layer and a steel wire rope outer protective layer; 3) The wire core, the anti-pulling rope and the filling rope form a cable wrapping; 4) Braiding a tinned copper wire shielding layer; 5) Extruding a fluoroplastic inner sheath; 6) An extruded nylon outer sheath is characterized in that
The step 1) comprises the following steps:
1.1 Preformed monofilaments:
and (3) wiredrawing: drawing the copper rod into filaments by adopting a corresponding wire drawing die respectively;
and (3) wiredrawing process: sequentially penetrating the copper rod into 11 wire drawing dies according to the pass, and enabling the arc surface of the monofilament to correspond to the arc groove of the die hole, so that the copper wire is ensured to be stressed stably, and the section of the monofilament is free from deviation;
1.2 Tinning the bare copper monofilament with tin layer thickness of 0.7-0.9 microns.
1.3 And (3) stranding the tinned copper monofilament prepared in the step 1.2) to form a conductor.
The step 2) comprises the following steps: extruding silicon rubber materials outside the conductor and the steel wire rope to form a wire core and a tensile rope, wherein the temperature zone of an extruding rubber extruder for extruding silicon rubber is controlled as follows: one region 140-160 ℃, two regions 150-190 ℃, three regions 190-200 ℃, four regions 200-220 ℃ and five regions 220-230 ℃; the first region is a feeding section, the second region and the third region are plasticizing sections, and the fourth region and the fifth region are homogenizing sections; setting the temperature of a machine head: 250 ℃; because of the adoption of the silicon rubber material, the application temperature range is larger, and besides the excellent insulating property, the production adaptability is also better.
The temperature of the machine head part needs to be precisely controlled, and meanwhile, the conductor needs to be preheated, and the preheating temperature is 100+/-10 ℃; the insulating material is tightly wrapped by the measure, and the defects such as bubbles and the like are not easy to generate in the insulating material.
The extrusion mode of the silicone rubber is extrusion type, during the extrusion process, the steam pressure is 14-16 bar during production, the production speed is 7-9 m/min, and the screw speed of the rubber extruder is 20-30 r/min;
water-cooling in a cold water tank for 20min; the water temperature of the cold water tank is controlled to be 8-15 ℃; after the conductor wrapped with the insulating material is fully cooled at low temperature, the insulating material has good molecular structure stability, and the wire core is prevented from deforming and the insulating thickness is uneven when the conductor is wound on a wire coil for standby.
The step 3) comprises the following steps: cable stranding is carried out on the cable core, the anti-pulling rope and the filling rope in cable former equipment, the cable forming direction is left, and the cable forming pitch diameter ratio is controlled to be 12-14 times; the tension of each wire core should be uniformly adjusted before cabling. The cable core after cabling should be round, compact, stable in structure, accurate in twisting direction, uniform in pitch, continuous, complete and clear in number. The defects of creek jump, greasy dirt scratch and the like are overcome. The outer layer of the cable core is overlapped and wrapped by a layer of polyester tape with the nominal thickness of 0.04mm, and the overlapping width of the wrapping is not less than 5mm; the tension of the belt should be regulated uniformly during wrapping, and the wrapping should be continuous, complete, flat and tight, and the cover is even.
The step 4) comprises the following steps: the cable core is braided and shielded by adopting tinned copper wires, the doubling and paying-off tension of the tinned copper wires is uniformly adjusted, and the winding displacement is compact and free from the phenomena of crossing, wire pressing, wire piling and wire disorder;
the braiding layer does not allow integral connection, and burrs caused by root breakage and strand breakage must be repaired to the root. The wire ingot was allowed to be replaced 1 time every 1 meter. When the knitting yarn breaks during the knitting process, the splicing treatment is needed, and the exposed monofilaments are repaired and flattened. Two repairs are not allowed to occur at the same location, each repair should be at least 1 meter apart; the knitting density is not less than 80%.
The step 5) comprises extruding a fluoroplastic inner sheath outside the shielding layer, wherein the extruding mode is pipe extruding, and the temperature area of an extruding machine for extruding the fluoroplastic is controlled as follows: 130-180 ℃ in the first region, 180-200 ℃ in the second region, 200-230 ℃ in the third region, 225-245 ℃ in the fourth region and 240-260 ℃ in the fifth region; the first region is a feeding section, the second region and the third region are plasticizing sections, and the fourth region and the fifth region are homogenizing sections; setting the temperature of a machine head: 280 ℃; the semi-finished product after the fluoroplastic is extruded is cooled by sections: the temperature of the first section water tank is 50-70 ℃, and the temperature of the second section water tank is normal temperature. The cable head should be lifted off the water surface during extrusion molding, and the axial water inlet is not allowed. Preferably, the fluorinated ethylene propylene is selected, the processing temperature range of the fluorinated plastic is larger, and the fluorinated plastic is easy to be imported and produced. When cooling, the fluoroplastic is cooled by temperature division to avoid the influence of uneven solidification and shrinkage of the fluoroplastic on the precision of the subsequent process.
Step 6) comprises extruding a nylon outer sheath on the outermost layer in a tube extrusion mode, wherein the reference temperature and the attention points of nylon extrusion are shown in table 1;
TABLE 1
In order to optimize the cable performance, nylon sheathing materials as above are used. The sheath material has high requirement on the precision of the processing temperature and accurate temperature control. In order to allow repeated bonding of inner and outer jacket materials of a large difference in properties, the cable is preheated prior to manufacture of the outer jacket. Since the inner sheath is heated during extrusion, the cooling requirements of the fluoroplastic are taken into account during cooling.
Destructive anatomic test detection: the outer diameter control deviation of the cable conductor is +/-0.1 mm, the outer diameter control deviation of the cable insulation core is +/-0.2 mm, and the outer diameter control deviation of finished cables with the same specification is +/-0.5 mm, so that the cables can be perforated and laid in equipment. Softness control: the hardness of the material is controlled, wherein the hardness of the insulating material is less than or equal to 60A. Through detection, the electrical performance, mechanical performance and special performance of the cable are all required to be detected in table 2, and in the detection items in table 2, the results are all qualified:
TABLE 2
| Sequence number | Project name | Data |
| 1 | Electrical performance of a Cable | |
| 1.1 | Conductor DC resistance test | 11.2Ω/km |
| 1.2 | AC voltage test | 2.5kV/5min, no breakdown |
| 1.3 | Insulation resistance test at maximum rated temperature | 35MΩ·km |
| 2 | Cable construction dimensions | |
| 2.1 | Insulation thickness (average thickness) | 0.7mm |
| 2.2 | Nominal diameter of braided copper wire | 0.20mm |
| 2.3 | Sheath thickness (average thickness) | 1.0mm |
| 2.4 | Outer diameter of cable | 14.5mm |
| 2.5 | Cable roundness | 0.8mm |
| 3 | Physical properties of insulating machinery | |
| 3.1 | Test of original mechanical Properties of insulation | 17.2Mpa; elongation at break 350% |
| 3.2 | Mechanical property test of insulation aging (high temperature resistance) | 18.5Mpa; elongation at break 300% |
| 3.3 | Insulation ozone resistance test | Sample does not crack |
| 4 | Wear test of sheath | YJB125/150 round trip 236 times |
| 5 | Ultraviolet protection test for sheath | Satisfy the following requirements |
| 6 | Ozone resistance test of sheath | Sample does not crack |
| 7 | Sheath low temperature tensile test | Elongation at break 320% |
| 8 | Single cable flame retardant test | Satisfy the following requirements |
| 9 | Test of the shielding inhibition factor | Mask inhibition coefficient 0.02 |
The experimental conditions of the tensile property, the high and low temperature resistance, the shielding property, the ultraviolet resistance and the wear resistance of the cable are shown in the following table 3:
TABLE 3 Table 3
Claims (9)
1. The manufacturing method of the special cable for the car dumper is characterized by comprising the following steps:
1) Manufacturing a cable conductor;
2) Extruding a conductor insulating layer and a steel wire rope outer protective layer;
3) The wire core, the anti-pulling rope and the filling rope form a cable wrapping;
4) Braiding a tinned copper wire shielding layer;
5) Extruding a fluoroplastic inner sheath;
6) The nylon outer sheath is extruded and wrapped,
the step 1) comprises the following steps:
1.1 Preformed monofilaments:
and (3) wiredrawing: drawing the copper rod into filaments by adopting a corresponding wire drawing die respectively;
and (3) wiredrawing process: the copper rod sequentially penetrates into a plurality of wire drawing dies according to the pass, the arc surface of the monofilament corresponds to the arc groove of the die hole, the copper wire is ensured to be stressed stably, and the section of the monofilament has no deviation;
1.2 Tin plating copper monofilament is prepared by tinning a layer outside the bare copper monofilament, and the thickness of the tin layer is controlled to be 0.7-0.9 mu m;
1.3 Taking tin-plated copper monofilaments to twist to form a conductor according to the requirement;
the step 2) comprises the following steps: extruding silicon rubber insulating materials outside the conductor and the steel wire rope to respectively manufacture a wire core and a tensile rope;
the temperature zone of the rubber extruder for extruding the silicon rubber insulating material is controlled as follows: one region 140-160 ℃, two regions 150-190 ℃, three regions 190-200 ℃, four regions 200-220 ℃ and five regions 220-230 ℃; the first region is a feeding section, the second region and the third region are plasticizing sections, and the fourth region and the fifth region are homogenizing sections; setting the temperature of a machine head: 250 ℃;
preheating the conductor before entering the rubber extruder, wherein the preheating temperature is 100+/-10 ℃;
the extrusion mode of the silicon rubber insulating material is extrusion type, in the extrusion process, the steam pressure is 14-16 bar during production, the production speed is 7-9 m/min, and the screw speed of an extruder is 20-30 r/min;
water-cooling in a cold water tank for 20min; the water temperature of the cold water tank is controlled to be 8-15 ℃;
the step 3) comprises the following steps:
3.1 Cabling and stranding a plurality of wire cores, 1 anti-pulling rope and a plurality of filling ropes on a cabling machine to prepare a cable core; the pull-resistant rope is positioned at the axis;
the cabling direction is left, and the cabling pitch diameter ratio is controlled to be 12-14 times; the tension of each wire core is uniformly adjusted before cabling;
the rotating speed of a stranding cage of the cabling machine is 66-78 r/min, and the traction speed of the cabling machine is 20-30 m/min;
3.2 Overlapping and wrapping a polyester belt outside the cable core;
during wrapping, the traction speed is 40-60 m/min, and the wrapping pitch is 30mm;
the step 4) comprises the following steps: a braiding machine is used for braiding shielding outside the cable core by adopting tinned copper wires to prepare a shielding layer; the knitting density is not less than 80%;
the step 5) comprises the following steps: extruding fluoroplastic outside the shielding layer to obtain an inner sheath, wherein the extrusion mode is extrusion pipe type;
the temperature zone of the extruder for extruding fluoroplastic is controlled as follows: 130-180 ℃ in the first region, 180-200 ℃ in the second region, 200-230 ℃ in the third region, 225-245 ℃ in the fourth region and 240-260 ℃ in the fifth region; the first region is a feeding section, the second region and the third region are plasticizing sections, and the fourth region and the fifth region are homogenizing sections; setting the temperature of a machine head: 280 ℃;
the semi-finished product after the fluoroplastic is extruded is cooled by sections: the temperature of the first section of water tank is 50-70 ℃, and the temperature of the second section of water tank is room temperature;
when the fluoroplastic is extruded, the cable head is lifted off the water surface;
the step 6) comprises the following steps: extruding nylon sheath material on the outermost layer to obtain an outer sheath, wherein the extrusion mode is extrusion pipe type;
6.1 Preheating the cable prepared in the step 5);
6.2 Drying the nylon sheath material;
6.3 The temperature zone of the extruder for extruding nylon sheath material is controlled as follows: first region 201 ℃, second region 212 ℃, third region 232 ℃, fourth region 230 ℃, fifth region 233 ℃ and sixth region 235 ℃; the first area and the second area are feeding sections, the third area and the fourth area are plasticizing sections, and the fifth area and the sixth area are homogenizing sections; the temperature of the machine neck is 241 ℃, the first area of the machine head is 241, and the second area of the machine head is 244 ℃;
6.4 The nylon sheath adopts sectional water cooling, the water temperature of the first section of water tank is 50-70 ℃, and the water temperature of the second section of water tank is normal temperature.
2. The method for manufacturing a special cable for a car dumper according to claim 1, wherein in the step 1.1), the diameter of the tinned copper monofilament is in the range of 0.32mm to 0.85mm; in the step 1.3), the diameter of the conductor ranges from 1.6mm to 2.5mm; the twisting direction of the tinned copper monofilament is left, and the twisting pitch diameter ratio is 18-25 times.
3. The method for manufacturing the special cable for the car dumper, which is disclosed in claim 1, is characterized in that the nominal thickness range of the insulating layer and the steel wire rope protective layer is 0.6-0.8 mm, and the thickness of the thinnest point is more than or equal to 90% -0.1mm of the nominal value.
4. The method of manufacturing a special cable for a car dumper according to claim 1, wherein in the step 3.1), the number of the wire cores is 3-16, and the sectional area of the conductor of the wire cores is 1.5mm 2 ～4mm 2 ；
The filling rope is twisted by high-temperature resistant polypropylene net-shaped tearing films;
in step 3.2), the nominal thickness of the polyester tape is 0.04mm, the lapping overlap width is not less than 5mm, and the lapping pitch is 30mm.
5. The method for manufacturing a special cable for a car dumper according to claim 1, wherein in the step 3.1), the tensile rope is formed by wrapping a steel wire rope sheath with the steel wire rope; the steel wire rope is formed by twisting 49 steel wires with the nominal diameter of 0.17mm, and the twisting pitch diameter ratio is 20-25 times; the nominal thickness of the steel wire rope sheath is 0.7mm, the outer diameter of the tensile rope is 3.1mm, the difference between the outer diameter of the tensile rope and the outer diameter of the wire core is not more than 1.0mm, and the tensile strength of the steel wire rope is 14KN/mm 2 。
6. The method for manufacturing a special cable for a car dumper according to claim 1, wherein in the step 4), the nominal diameter of the tinned copper wire is in the range of 0.15-0.20 mm; the braiding pitch was 46mm.
7. The method of manufacturing a special cable for a car dumper according to claim 1, wherein in the step 5), the nominal thickness of the inner sheath is 0.8-1.0 mm, and the thickness of the thinnest point is more than or equal to 80% of the nominal value.
8. The method of manufacturing a special cable for a car dumper according to claim 1, wherein in the step 6), the nominal thickness of the outer jacket is 1.0-1.2 mm, and the thickness of the thinnest point is more than or equal to 85% -0.1mm of the nominal value.
9. A cable produced by the production method according to any one of claims 1 to 8, characterized in that a wire core composed of a tin-plated conductor externally extruded with an insulating layer; the tensile rope consists of a steel wire rope and an outer extrusion steel wire rope protective layer; the cable core is formed by twisting a plurality of cable cores, a tensile rope and a filling rope together, and the polyester belt, the shielding layer, the inner sheath and the outer sheath are sequentially wrapped outside the cable core;
the tinned conductor is formed by twisting tinned copper monofilaments, and the diameter range of the tinned copper monofilaments is 0.32-0.85 mm; the diameter range of the conductor is 1.6 mm-2.5 mm; the twisting direction of the tinned copper monofilament is left, and the twisting pitch diameter ratio is 18-25 times;
the insulating layer is made of silicon rubber insulating material, the nominal thickness range of the insulating layer is 0.6-0.8 mm, and the thickness of the thinnest point is more than or equal to 90% -0.1mm of the nominal value;
the filling rope is a high-temperature-resistant polypropylene reticular tearing film;
the nominal thickness of the polyester belt is 0.04mm, and the lapping overlapping width is not less than 5mm;
the shielding layer is formed by weaving metal braiding wires; the nominal diameter range of the knitting yarn is 0.15-0.20 mm, and the knitting density is not less than 80%; the metal braided wires are tinned copper wires;
the inner sheath is made of fluoroplastic sheath material, the nominal thickness of the inner sheath is 0.8-1.0 mm, and the thickness of the thinnest point is more than or equal to 80% of the nominal value;
the outer sheath is made of nylon sheath material, the nominal thickness range of the outer sheath is 1.0-1.2 mm, and the thickness of the thinnest point is more than or equal to 85-0.1 mm of the nominal value.
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