CN115954148A - Wind-resistant vibration-resistant low-smoke halogen-free flame-retardant low-temperature-resistant ethylene propylene insulated cable and manufacturing method thereof - Google Patents
Wind-resistant vibration-resistant low-smoke halogen-free flame-retardant low-temperature-resistant ethylene propylene insulated cable and manufacturing method thereof Download PDFInfo
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Abstract
An anti-wind anti-vibration low-smoke halogen-free flame-retardant low-temperature-resistant ethylene propylene insulated cable and a manufacturing method thereof. The manufacturing steps of the cable include: synthesizing a plurality of tinned copper wire strands into folded yarns, and performing compound twisting on the folded yarns to form a conductor; the cable core is wrapped with the semi-conducting belt, the inner screen layer, the insulating layer and the outer screen layer are jointly extruded outside the conductor wrapped with the semi-conducting belt, the semi-conducting belt is wrapped outside the cable core, the cable core is loosely wrapped with the tinned copper wire, the loosely wrapped cable core is wrapped with the low-smoke halogen-free belt, and the wrapped cable core is wrapped with the low-smoke halogen-free flame-retardant sheath material. Compared with the prior art, the cable has the characteristics of better wind resistance, vibration resistance, low temperature resistance, high flame retardance, environmental protection and the like.
Description
Technical Field
The technical scheme relates to the technical field of cables, in particular to a power cable for a high-speed railway vehicle and a preparation method thereof.
Background
In the prior art, due to the rapid development of high-speed railways, the requirements of matched parts are continuously improved. For example, a high-voltage cable used for connecting a high-speed railway pantograph and a high-voltage box inside a train body has a very special use condition, and not only needs to meet the requirements of wind blowing when the train runs at a high speed, but also needs to meet the vibration requirements of the train in the running process, and also needs to meet the environments of wind, sand, rain, snow, high and low temperature and the like of the external environment.
Because no special cable exists, other cables are mostly adopted for replacing use at present, the situations that part of performance of the replaced cable just reaches the standard and part of performance is redundant occur frequently, and the requirements of reliability (stability), economy and the like of a product are difficult to meet at the same time.
For this reason, a new cable product is needed which can be used in the above-mentioned operating conditions. Major problems encountered in the development and production of such cables include: the negative/positive influence of the structures/production processes on each other to meet the respective performance requirements; reliability, economy, production applicability and the like of the product.
Disclosure of Invention
In order to solve the problems in the prior art, the technical scheme provides the high-voltage cable which is particularly suitable for being connected between a high-speed rail pantograph and a high-voltage box inside a vehicle body, and the cable is an ethylene propylene insulated cable with wind resistance, vibration resistance, low-smoke halogen-free flame-retardant and low-temperature-resistant characteristics.
Firstly, the cable structure is designed as follows: an inner screen layer, an insulating layer, an outer screen layer, a semi-conducting belt, a metal shielding layer, an outer isolation layer and a sheath layer are sequentially wrapped outside the conductor; the outer diameter of the cable ranges from 41.0 mm to 44.5mm.
The insulating material of the insulating layer is a high-electric-property ethylene propylene insulating material, the Shore hardness of the insulating material is 75A, the sheathing material of the sheathing layer is a low-temperature-resistant environment-friendly low-smoke halogen-free flame-retardant sheathing material, and the Shore hardness of the sheathing material is 83A;
the material of the conductor is a 5 th tin-plated copper conductor which meets the IEC60228 regulation; the conductor is formed by bundling tinned copper monofilaments into folded yarns according to the pitch diameter ratio of 20-22 times, and then twisting the folded yarns repeatedly according to the pitch diameter ratio of 9-12 times; the conductor is wrapped with a layer of semi-conductive Teflon tape to form an inner isolation layer, and the wrapping covering rate is 25-35%; the outer diameter of the conductor wrapped by the inner isolation layer is 12.8-13.0 mm;
the inner screen layer, the insulating layer and the outer screen layer are formed by three layers of an inner shielding cable material, a high-electric-property ethylene propylene insulating material and an outer shielding cable material through co-extrusion, and are produced through an extrusion process; the nominal thickness of the insulating layer is 8.00mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 8.00mm multiplied by 90-0.1 mm; the thickness of the inner screen layer is not less than 0.60mm; the thickness of the outer screen layer is not less than 0.80mm;
the conductor is wrapped by an inner screen layer, an insulating layer and an outer screen layer to form a wire core;
the thickness of the semi-conductive belt is 0.10mm, and the lapping rate of the lapping belt is 20-25%;
the metal shielding layer is formed by sparsely winding tinned copper wires with the wire diameter of 0.70 mm; the pitch diameter ratio of the tinned copper wires of the sparse winding structure is not more than 12 times, and the gap between every two adjacent tinned copper wires is not more than 0.35mm;
the semi-conductive belt and the metal shielding layer are coated outside the wire core to form a cable core;
the outer isolation layer is formed by wrapping a low-smoke halogen-free tape with the thickness of 0.20mm, and the covering rate of the wrapping tape is 30-35%;
the sheath layer is formed by extruding sheath materials, the extrusion type process is used for production, the nominal thickness of the sheath layer is 3.00mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 3.00mm multiplied by 85% -0.1mm.
In order to optimize the performance of the cable, a high-electric-property ethylene propylene insulating material is designed, and the high-electric-property ethylene propylene insulating material comprises the following raw materials in parts by mass:
95-100 parts of ethylene propylene diene monomer, 0-18 parts of low-density polyethylene, 4-6 parts of vulcanizing agent, 5-7 parts of vulcanization accelerator, 70-85 parts of filler, 4-6 parts of antioxidant, 9-14 parts of softener and 9-13 parts of stabilizer.
In order to prepare the high-quality insulating material, the preparation steps of the insulating material are designed as follows:
1) Banburying the ethylene propylene diene monomer and the low-density polyethylene in an internal mixer for 10-12 min;
2) Adding a vulcanization accelerator, a filler, an antioxidant, a stabilizer and a softener into an internal mixer at one time, and mixing with the material obtained in the step 1) for 15-20 min;
3) Moving the material obtained in the step 2) out of an internal mixer, mixing on a double-roll open mill, and then adding the material into a rubber filter for rubber filtering;
4) Mixing and weighing the materials obtained in the step 3) by an open mill, adding the materials into an internal mixer for continuous internal mixing, adding a vulcanizing agent in the internal mixing process, and then continuously mixing for 5-8 min;
5) Carrying out double-roller open milling on the material obtained in the step 4), drawing the material through thin, and then carrying out three-roller page rolling and sheet discharging to obtain a mixed material;
6) Granulating and cooling the mixed material obtained in the step 5) by adopting a gear pump rubber extruder to obtain a high-pressure ethylene-propylene insulating material;
in the step 1), the banburying temperature is less than 105 ℃; the mixing temperature in the step 2) is less than 110 ℃; the temperature of the filter rubber in the step 3) is less than 140 ℃; in the step 4), the banburying temperature is less than 105 ℃.
Aiming at the production resources such as newly designed cable structures and the existing production equipment, the production process is designed as follows:
1) Manufacturing a conductor:
1.1 Composite strands from tinned copper tows: when the conductors are bundled into the folded yarns, a Nichhoff bunching machine is adopted for bundling, the bundled yarns are 37 folded in the left direction, the bunching pitch of the folded yarns is 40-45 mm, and the bunching pitch-diameter ratio is 20-22 times;
1.2 ) twisting the strands to form a conductor; when the compound twisted strands are twisted, twisting is carried out by adopting a back twist cage twisting device, and the traction speed of a traction wheel is 18m/min;
the inner layer is 1+6 folded yarn twisted layer twisting cage turning left, the rotating speed of the twisting cage is 143.5rpm, and the twisting pitch is 78-82 mm;
the middle layer is a 12-strand stranding layer stranding cage which turns to the left direction, the rotating speed of the stranding cage is 91.5rpm, and the stranding pitch is 113-118 mm;
the outermost layer is 18 strand stranding layers, the stranding cage turns to the left direction, the rotating speed of the stranding cage is 92.3rpm, and the stranding pitch is 124-128 mm;
the pitch diameter ratio of the outermost layer of the conductor is 9-12 times, and the final twisting outer diameter of the conductor is 12.8-13.0 mm;
2) Manufacturing an inner isolation layer:
wrapping the conductor with a layer of semi-conductive Teflon tape with the thickness of 0.10mm, wherein the covering rate of the wrapping tape is 25% -35%, the rotating speed of a wrapping head is 286r/min during wrapping, the width of the wrapping tape is 35mm, and the wrapping pitch is 22mm;
3) Manufacturing an inner screen layer, an insulating layer and an outer screen layer:
adopting a Telex sulfur production line to carry out three-layer co-extrusion production and extrusion type process production, wherein the steam pressure is 13.5bar, the production speed is 12m/min, and the screw rotating speed is 14r/min;
inner screen layer extrusion temperature: the charging section is 70 ℃, the plasticizing section is 90 ℃ and the homogenizing section is 95 ℃;
insulating layer extrusion temperature: the charging section is 55 ℃, the plasticizing first zone is 60 ℃, the plasticizing second zone is 70 ℃ and the homogenizing section is 80 ℃;
outer screen layer extrusion temperature: the charging section is 60 ℃, the plasticizing first zone is 75 ℃, the plasticizing second zone is 80 ℃ and the homogenizing section is 90 ℃;
head temperature: the first area of the machine head is 90 ℃, the second area of the machine head is 90 ℃ and the third area of the machine head is 90 ℃;
the water level of cooling water in the vulcanization pipe is set to be 25% of the total height of the water level;
4) Wrapping a semi-conductive belt:
wrapping a semi-conductive tape with the thickness of 0.10mm outside the wire core, wherein the covering rate of the wrapping tape is 20% -25%, the rotating speed of a wrapping head is 285r/min, the width of the wrapping tape is 40mm, and the wrapping pitch is 28mm;
5) Manufacturing a metal shielding layer:
0.70mm tinned copper wire is adopted for sparse winding outside a wire core of the wrapped semi-conductive tape, and the pitch diameter ratio of the sparse winding copper wire is not more than 12 times;
6) Manufacturing an outer isolation layer:
wrapping a layer of low-smoke halogen-free tape with the thickness of 0.20mm outside the cable core, wherein the covering rate of the wrapping tape is 30% -35%, the rotating speed of a wrapping head is 367r/min during wrapping, the width of the wrapping tape is 45mm, and the wrapping pitch is 24mm;
7) Manufacturing an outer sheath:
adopting an imported Telex sulfur production line to carry out extrusion production and extrusion process production, wherein the steam pressure is 9.5bar, the production speed is 18m/min, the screw rotating speed is 18r/min,
extrusion temperature: the charging section is 65 ℃, the plasticizing first zone is 70 ℃, the plasticizing second zone is 75 ℃ and the homogenizing section is 80 ℃;
head temperature: the first area of the machine head is 85 ℃, the second area of the machine head is 90 ℃ and the third area of the machine head is 90 ℃;
the cooling water level in the vulcanization tube was 25%.
Optimizing the conductor manufacturing process of step 1):
a) When the conductors are combined, the conductor combination pitch is 43mm, and the strand combination pitch ratio is 21;
b) When the conductor is twisted repeatedly, the inner layer: the strand stranding pitch is 80mm;
c) When the conductor is twisted repeatedly, the intermediate layer: the strand twisting pitch is 115mm;
d) When the conductor is twisted repeatedly, the outermost layer is as follows: the strand lay pitch was 126mm.
The cable has the characteristics of better wind resistance, vibration resistance, low temperature resistance, high flame retardance, environmental protection and the like. Through trial production, the method is used for manufacturing the cable, the design requirement is completely met, and meanwhile, the excellent rate of the product exceeds 99.7%.
Drawings
FIG. 1 is a schematic radial cross-sectional view of the cable of the present embodiment;
in the figure: the cable comprises a conductor 1, an inner screen layer 2, an insulating layer 3, an outer screen layer 4, a semi-conducting belt 5, a metal shielding layer 6, an outer isolation layer 7 and a sheath layer 8.
Detailed Description
The present disclosure will be further described with reference to the accompanying drawings and the following detailed description.
Referring to fig. 1, the structure of the wind-resistant, vibration-resistant, low-smoke, halogen-free, flame-retardant and low-temperature-resistant ethylene propylene insulated cable of the present embodiment is as follows: an inner screen layer 2, an insulating layer 3, an outer screen layer 4, a semi-conducting belt 5, a metal shielding layer 6, an outer isolation layer 7 and a sheath layer 8 are sequentially wrapped outside the conductor 1; the outer diameter range of the cable is 41.0-44.5 mm;
the insulating material of the insulating layer is a high-electric-property ethylene propylene insulating material, the Shore hardness of the insulating material is 75A, the sheathing material of the sheathing layer is a low-temperature-resistant environment-friendly low-smoke halogen-free flame-retardant sheathing material, and the Shore hardness of the sheathing material is 83A;
the material of the conductor is a 5 th tin-plated copper conductor which is in accordance with IEC 60228; the conductor is formed by bundling tinned copper monofilaments into folded yarns according to the pitch diameter ratio of 20-22 times, and then twisting the folded yarns repeatedly according to the pitch diameter ratio of 9-12 times; the conductor is wrapped with a layer of semi-conductive Teflon tape to form an inner isolation layer, and the wrapping covering rate is 25-35%; the outer diameter of the conductor wrapped by the inner isolation layer is 12.8-13.0 mm;
the inner screen layer 2, the insulating layer 3 and the outer screen layer 4 are formed by three layers of inner shielding cable materials, high-electric-property ethylene propylene insulating materials and outer shielding cable materials through co-extrusion, and the extrusion type production process is adopted; the nominal thickness of the insulating layer is 8.00mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 8.00mm multiplied by 90-0.1 mm; the thickness of the inner screen layer 2 is not less than 0.60mm; the thickness of the outer screen layer 4 is not less than 0.80mm;
the conductor 1 is coated with an inner screen layer 2, an insulating layer 3 and an outer screen layer 4 to form a wire core;
the thickness of the semi-conductive belt 5 is 0.10mm, and the lapping rate of the lapping belt is 20-25%;
the metal shielding layer 6 is formed by sparsely winding tinned copper wires with the wire diameter of 0.70 mm; the pitch diameter ratio of the tinned copper wires of the sparse winding structure is not more than 12 times, and the gap between every two adjacent tinned copper wires is not more than 0.35mm;
the core is coated with a semi-conductive belt 5 and a metal shielding layer 6 to form a cable core;
the outer isolation layer 7 is formed by wrapping a low-smoke halogen-free tape (which can adopt a non-woven fabric tape) with the thickness of 0.20mm, and the covering rate of the wrapping tape is 30-35%;
the sheath layer 8 is formed by extruding sheath materials, the extrusion type process is used for production, the nominal thickness of the sheath layer is 3.00mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 3.00mm multiplied by 85% -0.1mm.
The high-voltage cable for connecting the high-speed rail pantograph and the high-voltage box in the vehicle body is single in product, and the requirements on the pressure resistance and the current-carrying performance of the cable are fixed, so that the sectional area of a conductor and the thicknesses of an insulating layer and a sheath layer made of specific cable materials are single indexes.
For the specific cable used under the working conditions, the design constraint factors mainly meet the performance requirements of wind resistance, vibration resistance, low smoke, zero halogen, flame retardance, low temperature resistance and the like.
The wind resistance performance requirements are as follows: the conductor process design of the cable ensures that the conductors are very tightly twisted, improves the roundness and tightness of the conductors, adopts extrusion type production in the production processes of insulation and sheaths, ensures the tightness of the whole cable, and ensures the structural stability of the cable when being blown by wind.
The requirements for vibration resistance are as follows: the cable adopts ethylene propylene rubber insulating material and low smoke zero halogen elastomeric compound sheath material, and these two kinds of materials are rubber class materials, have excellent elastic recovery performance, after the cable receives the vibration, can be autonomic the completion structure resume. The Shore hardness of the insulating material is 75A, and the Shore hardness of the sheathing material is 83A.
The low-smoke halogen-free flame-retardant low-temperature-resistant flame-retardant coating has the following performance requirements: the cable materials in the cable structure and the like are halogen-free smokeless flame retardant and low temperature resistant cable materials.
In order to eliminate the negative influence among the processes in the production process of the cable with the new structure and manufacture the cable with high efficiency and high quality, the following manufacturing method is provided, and the steps comprise:
1) Manufacturing a conductor:
1.1 Composite yarn from tin-plated copper strands: when the conductors are bundled into the strands, a Nichhoff bunching machine is adopted for bundling, the left-hand 37 strands are bundled, the stranding pitch of the strands is 40-45 mm, and the ratio of the bundling pitch to the diameter is 20-22 times;
1.2 ) twisting the strands to form a conductor; when the compound twisted strands are twisted, twisting is carried out by adopting a back twist cage twisting device, and the traction speed of a traction wheel is 18m/min;
the inner layer is a stranding layer of 1+6 strands (namely the axis position is 1 strand, 6 strands are wound outside the strand) the stranding cage turns to the left direction, the rotation speed of the stranding cage is 143.5rpm, and the stranding pitch is 78-82 mm;
the middle layer is a stranding layer of 12 strands (namely 12 strands surround the same axis), the direction of the stranding cage is turned to the left direction, the rotating speed of the stranding cage is 91.5rpm, and the stranding pitch is 113-118 mm;
the outermost layer is a stranding layer of 18 strands (namely the 18 strands surround the same axis), the direction of the stranding cage is turned to the left direction, the rotating speed of the stranding cage is 92.3rpm, and the stranding pitch is 124-128 mm;
the pitch diameter ratio of the outermost layer of the conductor is 9-12, and the final twisting outer diameter of the conductor is 12.8-13.0 mm;
2) Manufacturing an inner isolation layer:
wrapping the conductor with a layer of semi-conductive Teflon tape with the thickness of 0.10mm, wherein the covering rate of the wrapping tape is 25% -35%, the rotating speed of a wrapping head is 286r/min during wrapping, the width of the wrapping tape is 35mm, and the wrapping pitch is 22mm;
3) Manufacturing an inner screen layer, an insulating layer and an outer screen layer:
adopting a Telex sulfur production line to carry out three-layer co-extrusion production and extrusion type process production, wherein the steam pressure is 13.5bar, the production speed is 12m/min, and the screw rotating speed is 14r/min;
inner screen layer extrusion temperature: the charging section is 70 ℃, the plasticizing section is 90 ℃ and the homogenizing section is 95 ℃;
insulating layer extrusion temperature: the charging section is 55 ℃, the plasticizing first zone is 60 ℃, the plasticizing second zone is 70 ℃ and the homogenizing section is 80 ℃;
outer screen layer extrusion temperature: the feeding section is 60 ℃, the plasticizing first zone is 75 ℃, the plasticizing second zone is 80 ℃ and the homogenizing section is 90 ℃;
head temperature: the first area of the machine head is 90 ℃, the second area of the machine head is 90 ℃ and the third area of the machine head is 90 ℃;
the water level of cooling water in the vulcanization pipe is set to be 25% of the total height of the water level;
4) Wrapping a semi-conductive belt:
wrapping a semi-conductive tape with the thickness of 0.10mm outside the wire core, wherein the covering rate of the wrapping tape is 20-25%, the rotating speed of a wrapping head is 285r/min, the width of the wrapping tape is 40mm, and the wrapping pitch is 28mm during wrapping;
5) Manufacturing a metal shielding layer:
0.70mm tinned copper wire is adopted for sparse winding outside a wire core of the wrapped semi-conductive tape, and the pitch diameter ratio of the sparse winding copper wire is not more than 12 times;
6) Manufacturing an outer isolation layer:
wrapping a layer of low-smoke halogen-free tape with the thickness of 0.20mm outside the cable core, wherein the lapping rate of the wrapping tape is 30% -35%, the rotating speed of a wrapping head is 367r/min during wrapping, the width of the wrapping tape is 45mm, and the wrapping pitch is 24mm;
7) Manufacturing an outer sheath:
adopting an imported Telex continuous sulfur production line to carry out extrusion production and extrusion process production, wherein the steam pressure is 9.5bar during production, the production speed is 18m/min, the screw rotating speed is 18r/min,
extrusion temperature: the feeding section is 65 ℃, the plasticizing first zone is 70 ℃, the plasticizing second zone is 75 ℃ and the homogenizing section is 80 ℃;
head temperature: the first area of the machine head is 85 ℃, the second area of the machine head is 90 ℃ and the third area of the machine head is 90 ℃;
the water level of cooling water in the vulcanization pipe is 25%;
the preferred process parameters of the embodiment are as follows:
in the step 1), in the process of bunching and twisting:
a) When the conductors are combined, the conductor combination pitch is 43mm, and the strand combination pitch ratio is 21;
b) When the conductor is twisted repeatedly, the inner layer: the strand lay pitch is 80mm;
c) When the conductor is twisted repeatedly, the intermediate layer: the strand lay pitch was 115mm;
d) When the conductor is twisted repeatedly, the outermost layer is as follows: the strand lay pitch was 126mm.
The conductor produced by the process enhances the compactness of the conductor, improves the flexibility, has a round shape and stable electrical property, and is beneficial to the extrusion production of the outer layer structure of the conductor, uniform thickness and the like.
In this example:
the inner shielding cable material is a low-smoke halogen-free rubber semiconductive material;
the insulating material of the insulating layer is a high-electric ethylene propylene insulating material;
the outer shielding cable material is a low-smoke halogen-free rubber semi-conductive material;
the sheath material is a low-temperature-resistant environment-friendly low-smoke halogen-free flame-retardant steam cross-linked sheath material.
In the example, the inner shielding cable material is specifically a low-smoke halogen-free rubber semiconductive material with the model of XJ-JDN;
the external shielding cable material is specifically a low-smoke halogen-free rubber semiconductive material with the model of/XJ-JDW;
the sheath material is a low-temperature-resistant environment-friendly low-smoke halogen-free flame-retardant steam cross-linked sheath material with the model number of SSKC1200, and has good low-temperature resistance, low-smoke halogen-free flame retardance and good environment-friendly performance.
In order to further improve the performance and production applicability of the cable insulating layer, the insulating material of the embodiment is a self-made insulating material, and the concrete steps are as follows:
the insulating material is a high-electric-property ethylene propylene insulating material, and comprises the following raw materials in parts by weight:
95-100 parts of ethylene propylene diene monomer (Jihua/4049)
0 to 18 portions of low-density polyethylene (Chinese petrochemical/LDPE)
Vulcanizing agent 4-6 parts (Dongying sea Jing/DCP)
5-7 shares of vulcanization accelerator, (Weifang Hengfeng/ZnO)
70-85 parts of filler (Jiangxi Guangyuan/CaCO) 3 ）
4 to 6 portions of antioxidant, (Tianjin Kemai/TMQ)
9 to 14 portions of softener (Chinese petrifaction/paraffin)
9-13 parts of a stabilizer; (Nanjing national sea/MB)
The preparation method of the insulating material comprises the following steps:
3.1 Mixing ethylene propylene diene monomer and low-density polyethylene in an internal mixer for 10-12 min;
3.2 Adding a vulcanization accelerator, a filler, an antioxidant, a stabilizer and a softener into an internal mixer at one time, and mixing with the material obtained in the step 3.1) for 15-20 min;
3.3 Moving the material obtained in the step 3.2) out of an internal mixer, placing the internal mixer on a double-roll open mill for mixing, and then adding the obtained material into a rubber filter for rubber filtration;
3.4 Mixing and weighing the material obtained in the step 3.3) by an open mill, adding the material into an internal mixer for continuous internal mixing, adding a vulcanizing agent in the internal mixing process, and then continuously internal mixing for 5-8 min;
3.5 Carrying out double-roller open milling on the material obtained in the step 3.4), drawing the material through thin penetration, and then carrying out three-roller page rolling and sheet discharging to obtain a mixed material;
3.6 And) granulating and cooling the mixed material obtained in the step 3.5) by adopting a gear pump rubber extruder to obtain the high-pressure ethylene-propylene insulating material.
In the step 3.1), the banburying temperature is less than 105 ℃; in the step 3.2), the mixing temperature is less than 110 ℃; in the step 3.3), the temperature of the filter rubber is less than 140 ℃; the banburying temperature in the step 3.4) is less than 105 ℃.
In the aspect of performance, the insulation performance of the self-made insulation material is superior to that of the existing commercially available like insulation, and meanwhile, the self-made insulation material has low temperature resistance, low smoke, zero halogen and flame retardance, excellent electrical performance and the like.
In the aspect of production and processing, the self-made insulating material is used as the middle layer of the three-layer co-extrusion structure, the self-made insulating material has good processing technology performance, the insulating extrusion smoothness is good, the control of the insulating eccentricity is improved, and the cable is guaranteed to have good electrical performance.
Through tests, the cable has better technical performance and can completely meet the following technical requirements:
1. the cable passes through vibration and impact tests and meets the requirements of IEC 61373-2010 class-I B level. According to standard IEC 61373-2010.
2. The cable passes a wind tunnel test with a wind speed of 110 m/s. And simulating the use condition of the cable to verify the reliability.
3. The tensile strength of the insulation is 12.3Mpa, and the elongation at break of the insulation is 370 percent. According to standard TB 1484.2.
4. Aging of an insulating air box: (135 ℃ C. + -1, 168 h.) according to standard TB 1484.2.
The tensile strength change rate after insulation aging is-3%, and the elongation at break change rate after insulation aging is-5%.
5. The tensile strength of the sheath is 16.5Mpa, and the elongation at break of the insulation is 240%. According to standard TB 1484.2.
6. Aging of a sheath air box: (120 ℃ C. + -1, 168 h) according to standard TB 1484.2.
The change rate of the tensile strength of the sheath after aging is 18 percent below zero, and the change rate of the elongation at break of the sheath after aging is 12 percent below zero.
7. Sheath-50 ℃ low-temperature stretching: 30 percent. According to standard TB 1484.2.
8. The mineral oil resistance of the sheath can meet the requirements (100 ℃,72 h), the tensile strength change rate after oil resistance is-9%, and the elongation at break change rate after oil resistance is-20%. According to standard TB 1484.2.
9. Salt spray resistance test of cable (70 ℃,168 h): according to standard TB 1484.2.
The change rate of the tensile strength of the insulation is-3 percent, and the change rate of the elongation at break of the insulation is-5 percent;
the change rate of the tensile strength of the sheath is-4 percent, and the change rate of the elongation at break of the sheath is-8 percent.
10. Testing the smoke density: the minimum light transmission is 82% according to standard EN 50264-3.
11. Single vertical burn test: by following the standard EN 50264-3.
12. Cable bundling flame retardant class B test: by following the standard EN 50264-3.
13. The toxicity index is not greater than 3 according to standard EN 50264-3.
14. The cable meets RoHS2.0 and REACH environmental protection requirements. According to the standard SJ/T11365.
The cable is particularly suitable for a vehicle power supply system of a high-speed railway motor train unit.
Claims (6)
1. A method for manufacturing a wind-resistant, vibration-resistant, low-smoke, halogen-free, flame-retardant and low-temperature-resistant ethylene propylene insulating cable is characterized in that the cable has the structure as follows: an inner screen layer, an insulating layer, an outer screen layer, a semi-conducting belt, a metal shielding layer, an outer isolation layer and a sheath layer are sequentially wrapped outside the conductor; the outer diameter range of the cable is 41.0-44.5 mm;
the manufacturing steps of the cable include:
1) Manufacturing a conductor:
1.1 Composite strands from tinned copper tows: when the conductors are bundled into the folded yarns, a Nichhoff bunching machine is adopted for bundling, the bundled yarns are 37 folded in the left direction, the bunching pitch of the folded yarns is 40-45 mm, and the bunching pitch-diameter ratio is 20-22 times;
1.2 ) twisting the strands to form a conductor; when the compound twisted strands are twisted, twisting is carried out by adopting a back twist cage twisting device, and the traction speed of a traction wheel is 18m/min;
the inner layer is 1+6 folded yarn twisted layer twisting cage turning left, the rotating speed of the twisting cage is 143.5rpm, and the twisting pitch is 78-82 mm;
the middle layer is a 12-strand stranded layer, the stranding cage turns to the left direction, the rotating speed of the stranding cage is 91.5rpm, and the stranding pitch is 113-118 mm;
the outermost layer is 18 strand stranding layers, the stranding cage turns to the left direction, the rotating speed of the stranding cage is 92.3rpm, and the stranding pitch is 124-128 mm;
the pitch diameter ratio of the outermost layer of the conductor is 9-12 times, and the final twisting outer diameter of the conductor is 12.8-13.0 mm;
2) Manufacturing an inner isolation layer:
a layer of semi-conductive Teflon tape with the thickness of 0.10mm is used for wrapping the conductor, the covering rate of the wrapping tape is 25% -35%, the rotating speed of a wrapping head is 286r/min during wrapping, the width of the wrapping tape is 35mm, and the wrapping pitch is 22mm;
3) Manufacturing an inner screen layer, an insulating layer and an outer screen layer:
adopting a Telex sulfur production line to carry out three-layer co-extrusion production and extrusion type process production, wherein the steam pressure is 13.5bar, the production speed is 12m/min, and the screw rotating speed is 14r/min;
inner screen layer extrusion temperature: the feeding section is 70 ℃, the plasticizing section is 90 ℃ and the homogenizing section is 95 ℃;
insulating layer extrusion temperature: the charging section is 55 ℃, the plasticizing first zone is 60 ℃, the plasticizing second zone is 70 ℃ and the homogenizing section is 80 ℃;
outer screen layer extrusion temperature: the charging section is 60 ℃, the plasticizing first zone is 75 ℃, the plasticizing second zone is 80 ℃ and the homogenizing section is 90 ℃;
head temperature: the first area of the machine head is 90 ℃, the second area of the machine head is 90 ℃ and the third area of the machine head is 90 ℃;
the water level of cooling water in the vulcanization pipe is set to be 25% of the total height of the water level;
4) Wrapping a semi-conductive belt:
wrapping a semi-conductive tape with the thickness of 0.10mm outside the wire core, wherein the covering rate of the wrapping tape is 20% -25%, the rotating speed of a wrapping head is 285r/min, the width of the wrapping tape is 40mm, and the wrapping pitch is 28mm during wrapping;
5) Manufacturing a metal shielding layer:
0.70mm tinned copper wire is adopted for sparse winding outside a wire core of the wrapped semi-conductive tape, and the pitch diameter ratio of the sparse winding copper wire is not more than 12 times;
6) Manufacturing an outer isolation layer:
wrapping a layer of low-smoke halogen-free tape with the thickness of 0.20mm outside the cable core, wherein the covering rate of the wrapping tape is 30% -35%, the rotating speed of a wrapping head is 367r/min during wrapping, the width of the wrapping tape is 45mm, and the wrapping pitch is 24mm;
7) Manufacturing an outer sheath:
adopting an imported Telex sulfur production line to carry out extrusion production and extrusion process production, wherein the steam pressure is 9.5bar, the production speed is 18m/min, the screw rotating speed is 18r/min,
extrusion temperature: the charging section is 65 ℃, the plasticizing first zone is 70 ℃, the plasticizing second zone is 75 ℃ and the homogenizing section is 80 ℃;
head temperature: the first area of the machine head is 85 ℃, the second area of the machine head is 90 ℃ and the third area of the machine head is 90 ℃;
the cooling water level in the vulcanization tube was 25%.
2. The manufacturing method of the wind-resistant vibration-resistant low-smoke halogen-free flame-retardant low-temperature-resistant ethylene propylene insulated cable according to claim 1 is characterized in that in the step 1), in the bundling and twisting process:
a) When the conductors are combined, the conductor combination pitch is 43mm, and the strand combination pitch ratio is 21;
b) When the conductor is twisted repeatedly, the inner layer: the stranding pitch of the strands is 80mm;
c) When the conductor is twisted repeatedly, the intermediate layer: the strand twisting pitch is 115mm;
d) When the conductor is twisted repeatedly, the outermost layer is as follows: the strand lay pitch was 126mm.
3. The manufacturing method of the wind-resistant, vibration-resistant, low-smoke, halogen-free, flame-retardant and low-temperature-resistant ethylene propylene insulating cable according to claim 1 or 2, characterized in that the insulating material is a high-electrical ethylene propylene insulating material, the Shore hardness of the insulating material is 75A, and the insulating material comprises the following raw materials in parts by mass:
95 to 100 parts of ethylene propylene diene monomer,
0 to 18 portions of low-density polyethylene,
4-6 parts of a vulcanizing agent,
5 to 7 portions of vulcanization accelerator,
70-85 parts of a filler,
4-6 parts of an antioxidant, namely,
9 to 14 portions of a softening agent,
9-13 parts of a stabilizer.
4. The manufacturing method of the wind-resistant vibration-resistant low-smoke halogen-free flame-retardant low-temperature-resistant ethylene propylene insulated cable according to claim 3, characterized in that the preparation step of the insulating material comprises the following steps:
1) Banburying the ethylene propylene diene monomer and the low-density polyethylene in an internal mixer for 10-12 min;
2) Adding a vulcanization accelerator, a filler, an antioxidant, a stabilizer and a softener into an internal mixer at one time, and mixing with the material obtained in the step 1) for 15-20 min;
3) Moving the material obtained in the step 2) out of an internal mixer, mixing on a double-roll open mill, and then adding the material into a rubber filter for rubber filtering;
4) Mixing and weighing the material obtained in the step 3) by an open mill, adding the material into an internal mixer for continuously internal mixing, adding a vulcanizing agent in the internal mixing process, and then continuously internal mixing for 5-8 min;
5) Carrying out double-roller open milling on the material obtained in the step 4), drawing the material through thin, and then carrying out three-roller page rolling and sheet discharging to obtain a mixed material;
6) Granulating and cooling the mixed material obtained in the step 5) by adopting a gear pump rubber extruder to obtain a high-pressure ethylene-propylene insulating material;
the banburying temperature in the step 1) is less than 105 ℃; the mixing temperature in the step 2) is less than 110 ℃; the temperature of the filter rubber in the step 3) is less than 140 ℃; the banburying temperature in the step 4) is less than 105 ℃.
5. The utility model provides a wind-resistant anti vibration low smoke zero halogen flame retardant low temperature resistant EPT insulated cable which the characterized by structure is: an inner screen layer, an insulating layer, an outer screen layer, a semi-conducting belt, a metal shielding layer, an outer isolation layer and a sheath layer are sequentially wrapped outside the conductor; the outer diameter range of the cable is 41.0-44.5 mm;
the insulating material of the insulating layer is a high-electrical-property ethylene propylene insulating material, the Shore hardness requirement of the insulating material is 75A, the sheathing material of the sheathing layer is a low-temperature-resistant environment-friendly low-smoke halogen-free flame-retardant sheathing material, and the Shore hardness requirement of the sheathing material is 83A;
the material of the conductor is a 5 th tin-plated copper conductor which meets the IEC60228 regulation; the conductor is formed by bundling tinned copper monofilaments into folded yarns according to the pitch diameter ratio of 20-22 times, and then twisting the folded yarns repeatedly according to the pitch diameter ratio of 9-12 times; the conductor is wrapped with a layer of semi-conductive Teflon tape to form an inner isolation layer, and the wrapping covering rate is 25-35%; the outer diameter of the conductor wrapped by the inner isolation layer is 12.8-13.0 mm;
the inner screen layer, the insulating layer and the outer screen layer are formed by three layers of an inner shielding cable material, a high-electric-property ethylene propylene insulating material and an outer shielding cable material through co-extrusion, and the inner screen layer, the insulating layer and the outer screen layer are produced through an extrusion type process; the nominal thickness of the insulating layer is 8.00mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 8.00mm multiplied by 90-0.1 mm; the thickness of the inner screen layer is not less than 0.60mm; the thickness of the outer screen layer is not less than 0.80mm;
the conductor is wrapped by an inner screen layer, an insulating layer and an outer screen layer to form a wire core;
the thickness of the semi-conductive belt is 0.10mm, and the lapping rate of the lapping belt is 20-25%;
the metal shielding layer is formed by sparsely winding tinned copper wires with the wire diameter of 0.70 mm; the pitch diameter ratio of the tinned copper wires of the sparse winding structure is not more than 12 times, and the gap between every two adjacent tinned copper wires is not more than 0.35mm;
the semi-conductive belt and the metal shielding layer are coated outside the wire core to form a cable core;
the outer isolation layer is formed by wrapping a low-smoke halogen-free tape with the thickness of 0.20mm, and the covering rate of the wrapping tape is 30-35%;
the sheath layer is formed by extruding sheath materials, the extrusion process is used for production, the nominal thickness of the sheath layer is 3.00mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 3.00mm multiplied by 85% -0.1mm.
6. The wind-resistant vibration-resistant low-smoke halogen-free flame-retardant low-temperature-resistant ethylene propylene insulating cable according to claim 5, characterized in that the insulating material is a high-electrical ethylene propylene insulating material, the Shore hardness of the insulating material is 75A, and the insulating material comprises the following raw materials in parts by mass:
95 to 100 parts of ethylene propylene diene monomer,
0 to 18 portions of low-density polyethylene,
4-6 parts of a vulcanizing agent,
5 to 7 portions of vulcanization accelerator,
70-85 parts of a filler,
4-6 parts of an antioxidant,
9 to 14 portions of a softening agent,
9-13 parts of a stabilizer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310104262.1A CN115954148A (en) | 2023-02-13 | 2023-02-13 | Wind-resistant vibration-resistant low-smoke halogen-free flame-retardant low-temperature-resistant ethylene propylene insulated cable and manufacturing method thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310104262.1A CN115954148A (en) | 2023-02-13 | 2023-02-13 | Wind-resistant vibration-resistant low-smoke halogen-free flame-retardant low-temperature-resistant ethylene propylene insulated cable and manufacturing method thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN115954148A true CN115954148A (en) | 2023-04-11 |
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ID=87297963
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310104262.1A Pending CN115954148A (en) | 2023-02-13 | 2023-02-13 | Wind-resistant vibration-resistant low-smoke halogen-free flame-retardant low-temperature-resistant ethylene propylene insulated cable and manufacturing method thereof |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN115954148A (en) |
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2023
- 2023-02-13 CN CN202310104262.1A patent/CN115954148A/en active Pending
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