CN114068104A - Novel high-performance long-service-life electric automobile alternating-current charging pile cable machining method - Google Patents
Novel high-performance long-service-life electric automobile alternating-current charging pile cable machining method Download PDFInfo
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- CN114068104A CN114068104A CN202111345390.2A CN202111345390A CN114068104A CN 114068104 A CN114068104 A CN 114068104A CN 202111345390 A CN202111345390 A CN 202111345390A CN 114068104 A CN114068104 A CN 114068104A
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- charging pile
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- pile cable
- cable
- current charging
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- 238000000034 method Methods 0.000 title claims abstract description 17
- 238000003754 machining Methods 0.000 title description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 29
- 238000004519 manufacturing process Methods 0.000 claims abstract description 23
- 229910052802 copper Inorganic materials 0.000 claims abstract description 19
- 239000010949 copper Substances 0.000 claims abstract description 19
- 239000004020 conductor Substances 0.000 claims abstract description 15
- 230000005540 biological transmission Effects 0.000 claims abstract description 13
- 238000003672 processing method Methods 0.000 claims abstract 5
- 239000000463 material Substances 0.000 claims description 21
- 239000004433 Thermoplastic polyurethane Substances 0.000 claims description 8
- 229920002803 thermoplastic polyurethane Polymers 0.000 claims description 8
- 229920002799 BoPET Polymers 0.000 claims description 7
- 239000005041 Mylar™ Substances 0.000 claims description 7
- 239000004721 Polyphenylene oxide Substances 0.000 claims description 7
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- 239000011888 foil Substances 0.000 claims description 7
- 229920000570 polyether Polymers 0.000 claims description 7
- 238000004804 winding Methods 0.000 claims description 6
- 239000000945 filler Substances 0.000 claims description 5
- 229920001169 thermoplastic Polymers 0.000 claims description 5
- 239000004416 thermosoftening plastic Substances 0.000 claims description 5
- 238000004132 cross linking Methods 0.000 claims description 4
- 229920001971 elastomer Polymers 0.000 claims description 4
- 239000000806 elastomer Substances 0.000 claims description 4
- 229920000098 polyolefin Polymers 0.000 claims description 4
- 229920001187 thermosetting polymer Polymers 0.000 claims description 4
- 239000004745 nonwoven fabric Substances 0.000 claims description 3
- 238000009954 braiding Methods 0.000 claims 1
- 239000011248 coating agent Substances 0.000 claims 1
- 238000000576 coating method Methods 0.000 claims 1
- 238000005452 bending Methods 0.000 abstract description 7
- 241001391944 Commicarpus scandens Species 0.000 abstract description 2
- 230000002035 prolonged effect Effects 0.000 abstract description 2
- 229920002725 thermoplastic elastomer Polymers 0.000 description 8
- 238000009941 weaving Methods 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 238000010586 diagram Methods 0.000 description 2
- 101100280138 Mus musculus Evi2a gene Proteins 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910000039 hydrogen halide Inorganic materials 0.000 description 1
- 239000012433 hydrogen halide Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 238000000053 physical method Methods 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000007790 scraping Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Images
Classifications
-
- 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
- H01B13/02—Stranding-up
- H01B13/0207—Details; Auxiliary devices
-
- 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
-
- 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
- H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
- H01B13/2613—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by longitudinal lapping
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Insulated Conductors (AREA)
- Charge And Discharge Circuits For Batteries Or The Like (AREA)
- Electric Propulsion And Braking For Vehicles (AREA)
Abstract
The invention discloses a novel high-performance long-service-life electric automobile alternating-current charging pile cable processing method, which comprises the following steps of: s1) manufacturing a power transmission wire core; s2) manufacturing a signal wire; s3) manufacturing a charging pile cable; the conductor body is made of six types of thin bare copper wires IEC60228, so that the flexibility of the whole cable can be effectively improved, the thin copper wires are more resistant to bending and are not easy to break in the using process, and the bending breaking resistance of the whole cable can be greatly improved; meanwhile, the conductor body adopts a wire bundling process of twisting bare copper wires and bulletproof wires together, the risk that the cable conductor is broken due to bending, dragging, twisting and other factors in the use process of the charging wire is prevented, and the service life of the whole device is prolonged.
Description
Technical Field
The invention relates to the technical field of cable processing, in particular to a novel method for processing a cable of a high-performance and long-service-life alternating-current charging pile of an electric automobile.
Background
The electric automobile alternating-current charging stake cable on the existing market adopts the copper conductor insulating sheath material to generally be TPE (thermoplastic elastomer)'s cable, and this kind of cable insulating sheath material exists that density is big, the electrical property is poor, temperature resistant grade is not enough, uses the TPE material to glue the hand for a long time and easily is stained with the ash. The cable has the problems of poor resistance to hot water, acid, alkali, oil and chemical solvents, poor resistance to humidity and heat, poor resistance to cyclic bending, easy breakage of a signal wire and the like. And the whole wire is thick, heavy and not wear-resistant. Therefore, the comfort level test in the using process of a customer is poor, the service life of the cable is short, the equipment cost of the charging station is high, and the safety coefficient of cable transmission electric energy is low.
Disclosure of Invention
The invention aims to provide a novel method for processing a cable of an electric automobile alternating-current charging pile with high performance and long service life, and aims to solve the problems in the background technology.
In order to achieve the purpose, the invention provides the following technical scheme:
a novel high-performance and long-service-life electric automobile alternating-current charging pile cable machining method comprises the following steps:
s1) manufacturing a power transmission wire core: firstly, selecting six types of I EC60228 thin bare copper wires, then twisting the bare copper wires together with the bulletproof wires to manufacture a conductor body, and finally thermoplastic wrapping an insulating layer on the outer side of the conductor body to manufacture a power transmission wire core; wherein the insulating layer is an environment-friendly halogen-free irradiation crosslinking polyolefin thermosetting elastomer at 125 ℃;
s2) signal line production: selecting two signal wire cores, pulling and sleeving an aluminum foil mylar on the outer sides of the two signal wire cores together, winding and sleeving a copper wire woven layer on the outer side of the aluminum foil mylar, and finally winding and sleeving a middle layer on the outer side of the copper wire woven layer to manufacture a signal wire;
s3) manufacturing a charging pile cable: twisting a signal wire and five power transmission wire cores together, wrapping a wrapping layer on the outer side of the signal wire and five power transmission wire cores together, and finally, thermoplastic wrapping a sheath layer on the outer side of the wrapping layer, and filling fillers in the wrapping layer to manufacture a charging pile cable; the wrapping layer is formed by wrapping high-temperature-resistant tear-resistant non-woven fabrics; the sheath layer is made of polyether type thermoplastic polyurethane sheath materials.
In a further embodiment, the copper wire weaving layer is formed by weaving 6 strands of copper wires with the diameter of 0.10mm, and then weaving 24 strands of copper wires in an interweaving manner; the middle tegument layer is made of polyether type thermoplastic polyurethane sheathing material.
Compared with the prior art, the invention has the beneficial effects that: the conductor body is made of six types of thinner bare copper wires I EC60228, so that the flexibility of the whole cable can be effectively improved, the thin copper wires are more resistant to bending and are not easy to break in the using process, and the bending resistance of the whole cable can be greatly improved; meanwhile, the conductor body adopts a wire bundling process of twisting bare copper wires and bulletproof wires together, the risk that the cable conductor is broken due to bending, dragging, twisting and other factors in the use process of the charging wire is prevented, and the service life of the whole device is prolonged.
Drawings
FIG. 1 is a schematic diagram of a processing technology of a novel method for processing a high-performance long-life electric automobile alternating-current charging pile cable;
fig. 2 is a schematic structural diagram of a novel high-performance long-life electric vehicle alternating-current charging pile cable.
In the figure: the cable comprises a conductor body 1, an insulating layer 2, an aluminum foil Mylar 3, a copper wire braided layer 4, a filler 5, a wrapping layer 6, a middle tegument 7 and a sheath layer 8.
Detailed Description
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on those shown in the drawings, and are used only for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first", "second", etc. are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first," "second," etc. may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified.
In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art through specific situations.
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1-2, a method for processing a cable of a novel high-performance and long-life alternating-current charging pile for an electric vehicle includes the following steps:
s1) manufacturing a power transmission wire core: firstly, selecting six types of I EC60228 thin bare copper wires, then twisting the bare copper wires together with the bulletproof wires to manufacture a conductor body 1, and finally thermoplastic wrapping an insulating layer 2 on the outer side of the conductor body 1 to manufacture a power transmission wire core;
the insulating layer 2 is made of 125 ℃ environment-friendly halogen-free irradiation crosslinking polyolefin thermosetting elastomer, the hardness is 85 +/-5A, and the flexibility of the cable is ensured. And the density of the material is 1.02g/cm3, which is nearly 1/5 less than that of TPE material used in the market, namely 1.2g/cm3, so that the weight of the cable is reduced to a great extent, and the cable is lighter for customers in the using process. In addition, the material adopts an electronic irradiation physical method technology, so that the linear polymer is changed into a polymer technology with a three-dimensional space network structure, the irradiated cable has excellent flame retardance, high heat resistance and excellent physical and mechanical properties, the rated temperature of the cable is-50-125 ℃, and the cable is far higher than that of a TPE material used in the market, the rated temperature of the TPE material is-40-105 ℃, and potential safety hazards caused by conductor heating when the cable charges an electric automobile are prevented. The charring property of the polymer can be improved through irradiation crosslinking reaction, and the flame retardance of the polymer can be further improved. And the material does not contain halogen, and does not release hydrogen halide gas harmful to human bodies in the case of extreme fire. The material has higher electrical performance, the volume resistivity at 20 ℃ can reach 1016 omega cm, the volume resistivity at 20 ℃ is two orders of magnitude higher than 1014 omega cm of the common TPE, the dielectric strength reaches 35KV/mm, and the dielectric strength is 25KV/mm higher than 1/3 of the common TPE. Namely, the radiation cross-linked polyolefin thermosetting elastomer can adopt a thin-wall structure under the condition of reaching the same rated voltage, so that the overall outer diameter of the cable is thinner, the weight is lighter, and the use comfort of a customer is greatly improved. The material has excellent oil resistance, corrosion resistance, liquid resistance and flexibility. The use safety of the cable in a complex environment is ensured. The material performance is far higher than the EVI-2 performance requirement of EN50620:2017/I EC62893-3:2017 standard insulating material;
s2) signal line production: selecting two signal wire cores, then pulling and sleeving an aluminum foil mylar 3 on the outer sides of the two signal wire cores together, then winding and sleeving a copper wire braided layer 4 on the outer side of the aluminum foil mylar 3, and finally winding and sleeving a middle layer 7 on the outer side of the copper wire braided layer 4 to manufacture a signal wire;
the copper wire weaving layer 4 is formed by weaving 6 strands of copper wires with the diameter of 0.10mm in a combining mode and then interweaving 24 strands of copper wires; the middle tegument layer 7 is made of polyether type thermoplastic polyurethane sheathing material;
s3) manufacturing a charging pile cable: twisting a signal wire and five power transmission wire cores together, wrapping a wrapping layer 6 on the outer side of the signal wire and five power transmission wire cores together, and finally, thermoplastic wrapping a sheath layer 8 on the outer side of the wrapping layer 6, and filling fillers 5 in the wrapping layer 6 to manufacture a charging pile cable;
the wrapping layer 6 is formed by wrapping high-temperature-resistant tear-resistant non-woven fabrics; the sheath layer 8 is made of a polyether type thermoplastic polyurethane sheath material, and the filler 5 is made of a high-strength PP net;
the polyether type thermoplastic polyurethane sheath material has the performances of high mechanical property, high temperature resistance level, wear resistance, oil resistance, weather resistance, hot water resistance, cold resistance, tear resistance and the like. The tear strength is more than 40N/mm, and the risk of cracking in outdoor severe environment is effectively prevented. The scraping and grinding test frequency is more than ten thousand, so that the problem that the cable is easy to wear due to friction and back-and-forth dragging during the use process is well solved. The cable has excellent water resistance and rated temperature of-50-90 ℃, and the safety of the cable in severe environments such as rainy and snowy days in winter and summer is ensured. And adopt TPU sheath material to compare in other sheath materials can reduce 0.8 ~ 2.0 mm's thickness for the less weight of external diameter of whole cable is lighter, has increased the comfortable experience degree of user when charging electric automobile.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Furthermore, it should be understood that although the present description refers to embodiments, not every embodiment may contain only a single embodiment, and such description is for clarity only, and those skilled in the art should integrate the description, and the embodiments may be combined as appropriate to form other embodiments understood by those skilled in the art.
Claims (5)
1. The novel method for processing the high-performance and long-service-life electric automobile alternating-current charging pile cable is characterized by comprising the following steps of:
s1) manufacturing a power transmission wire core: firstly, selecting six types of thin bare copper wires IEC60228, then twisting the bare copper wires together with the bulletproof wires to manufacture a conductor body (1), and finally thermoplastic wrapping an insulating layer (2) on the outer side of the conductor body (1) to manufacture a power transmission wire core;
s2) signal line production: selecting two signal wire cores, then pulling and sleeving an aluminum foil mylar (3) on the outer sides of the two signal wire cores together, then winding and sleeving a copper wire braided layer (4) on the outer side of the aluminum foil mylar (3), and finally winding and sleeving a middle tegument layer (7) on the outer side of the copper wire braided layer (4) to manufacture a signal wire;
s3) manufacturing a charging pile cable: a signal line and five transmission line sinle silks are twisted together to wrap around covering (6) around the package jointly in the outside, wrap up in the outside of covering (6) and cover restrictive coating (8) at last thermoplastically, and pack the filler in wrapping the package, in order to make into and fill the electric pile cable.
2. The novel high-performance long-life electric vehicle alternating-current charging pile cable processing method according to claim 1, characterized in that the insulating layer (2) is an environment-friendly halogen-free irradiation crosslinking polyolefin thermosetting elastomer at 125 ℃.
3. The novel high-performance long-service-life electric vehicle alternating-current charging pile cable processing method according to claim 1, characterized in that the copper wire braided layer (4) is formed by braiding 6 strands of copper wires with the diameter of 0.10mm and then interweaving 24 strands of copper wires with one another.
4. The novel high-performance long-life electric vehicle alternating-current charging pile cable processing method according to claim 1, characterized in that the middle layer (7) is made of a polyether thermoplastic polyurethane sheathing material.
5. The novel high-performance long-service-life electric vehicle alternating-current charging pile cable processing method according to claim 1, characterized in that the wrapping layer (6) is formed by wrapping high-temperature-resistant tear-resistant non-woven fabrics; the sheath layer (8) is made of a polyether type thermoplastic polyurethane sheath material.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111345390.2A CN114068104A (en) | 2021-11-12 | 2021-11-12 | Novel high-performance long-service-life electric automobile alternating-current charging pile cable machining method |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202111345390.2A CN114068104A (en) | 2021-11-12 | 2021-11-12 | Novel high-performance long-service-life electric automobile alternating-current charging pile cable machining method |
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| Publication Number | Publication Date |
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| CN114068104A true CN114068104A (en) | 2022-02-18 |
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| CN202111345390.2A Pending CN114068104A (en) | 2021-11-12 | 2021-11-12 | Novel high-performance long-service-life electric automobile alternating-current charging pile cable machining method |
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Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2004341266A (en) * | 2003-05-16 | 2004-12-02 | Du Pont Toray Co Ltd | Tensile material for cable and its manufacturing method |
| CN101842432A (en) * | 2007-10-22 | 2010-09-22 | 巴塞尔聚烯烃意大利有限责任公司 | Crosslinkable thermoplastic olefin elastomers and crosslinked thermoset olefin elastomers obtained therefrom |
| CN106229047A (en) * | 2016-09-28 | 2016-12-14 | 上海卡迪夫电缆有限公司 | A kind of high temperature resistant anti tear silicone rubber flexible cable and preparation method thereof |
| CN106601346A (en) * | 2016-12-23 | 2017-04-26 | 金杯电工衡阳电缆有限公司 | 1500V and lower high voltage cables for electric vehicle |
| CN112542264A (en) * | 2020-12-09 | 2021-03-23 | 安徽康泰电气有限公司 | Power cable for ultra-flexible high-reliability welding robot and preparation method |
| CN214505033U (en) * | 2021-04-23 | 2021-10-26 | 红旗电缆电器仪表集团有限公司 | Novel lightweight exchanges and fills cable |
-
2021
- 2021-11-12 CN CN202111345390.2A patent/CN114068104A/en active Pending
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2004341266A (en) * | 2003-05-16 | 2004-12-02 | Du Pont Toray Co Ltd | Tensile material for cable and its manufacturing method |
| CN101842432A (en) * | 2007-10-22 | 2010-09-22 | 巴塞尔聚烯烃意大利有限责任公司 | Crosslinkable thermoplastic olefin elastomers and crosslinked thermoset olefin elastomers obtained therefrom |
| CN106229047A (en) * | 2016-09-28 | 2016-12-14 | 上海卡迪夫电缆有限公司 | A kind of high temperature resistant anti tear silicone rubber flexible cable and preparation method thereof |
| CN106601346A (en) * | 2016-12-23 | 2017-04-26 | 金杯电工衡阳电缆有限公司 | 1500V and lower high voltage cables for electric vehicle |
| CN112542264A (en) * | 2020-12-09 | 2021-03-23 | 安徽康泰电气有限公司 | Power cable for ultra-flexible high-reliability welding robot and preparation method |
| CN214505033U (en) * | 2021-04-23 | 2021-10-26 | 红旗电缆电器仪表集团有限公司 | Novel lightweight exchanges and fills cable |
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