CN117116532A - High-current-carrying flame-retardant flexible cable with combined conductor structure for equipment and manufacturing method - Google Patents
High-current-carrying flame-retardant flexible cable with combined conductor structure for equipment and manufacturing method Download PDFInfo
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- CN117116532A CN117116532A CN202311163463.5A CN202311163463A CN117116532A CN 117116532 A CN117116532 A CN 117116532A CN 202311163463 A CN202311163463 A CN 202311163463A CN 117116532 A CN117116532 A CN 117116532A
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- 239000003063 flame retardant Substances 0.000 title claims abstract description 43
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
-
- 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
- H01B13/008—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing extensible conductors or cables
-
- 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
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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
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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
- H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
- H01B13/2606—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by braiding
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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
- H01B7/0045—Cable-harnesses
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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
- H01B7/0208—Cables with several layers of insulating material
- H01B7/0216—Two layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
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- H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
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- H—ELECTRICITY
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- 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
-
- 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
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
- H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
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- 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
- H01B7/30—Insulated conductors or cables characterised by their form with arrangements for reducing conductor losses when carrying alternating current, e.g. due to skin effect
- H01B7/303—Conductors comprising interwire insulation
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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
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Insulated Conductors (AREA)
Abstract
The invention relates to a high-current-carrying flame-retardant flexible cable with a combined conductor structure for equipment and a manufacturing method thereof. The cable adopts a creative application mode of a special structure of a combined conductor and an insulating layer coated outside a single conductor, so that the transmission of instantaneous oversized impact current of the cable is ensured, the instantaneous safe application current-carrying capacity of the cable is improved by tens of times under the condition that the section of the conductor is not increased, and the application safety of the cable is ensured. The cable combined conductor is formed by layering forward and reverse stranding of a plurality of insulating wire cores, each insulating wire core comprises a wire core conductor and an insulating layer wrapped outside the wire core conductor, and each wire core conductor is formed by stranding a plurality of wire bundles. The invention can effectively reduce the eddy current effect, ensures the transmission and application safety of the cable subjected to the instantaneous oversized impact current, is not easy to deform during bending, and has good structural stability.
Description
Technical Field
The invention relates to the technical field of cables, in particular to a high-current-carrying flame-retardant flexible cable with a combined conductor structure for equipment and a manufacturing method thereof.
Background
With the rapid development of modern equipment, some high-power test instruments and test equipment require special-performance cables for instantaneously transmitting ultra-large impact current, and the instantaneous transmission function of carrying high-power charges is met. The existing cable does not have the above properties due to the conductor structure, insulating materials, product properties and the like, and the cable can be ablated to damage instruments or equipment during application, so that the operation of the equipment is affected.
The product of the prior art scheme has the following defects:
(1) The conductor structure of the polyolefin insulated cable for the prior test is formed by twisting a plurality of bare copper wires or tinned copper wires according to a certain rule and an arrangement structure, and once the conductor is transmitted by a large alternating current, a large vortex induction current (vortex induction current is called vortex current for short hereinafter) can be generated in the conductor, and the thermal effect of the vortex current can lead the temperature of the conductor to be raised to be high instantly, thereby running faults such as the burnout of a cable insulating layer or the fusing of the conductor occur.
(2) The conventional cable insulation material is made of polyvinyl chloride, crosslinked polyethylene, halogen-free low-smoke polyolefin, rubber and other materials, and the thermal effect application generated by large current impact is not satisfied due to the factors of working temperature, material performance and the like.
(3) The overload high-temperature application of the existing cable is easy to lead the cable insulation sheath to generate thermal deformation, the deformation belongs to plastic deformation, the deformation is difficult to recover after cooling, the repeated bending stress easily leads the cable insulation layer and the sheath layer to be easily damaged and cracked, the equipment is caused, and the potential safety hazard is generated.
Therefore, the invention discloses a high-current-carrying flame-retardant flexible cable with an equipment combined conductor structure and a manufacturing method thereof, so as to overcome the defects of the prior art.
Disclosure of Invention
The invention aims to provide a high-current-carrying flame-retardant flexible cable with a combined conductor structure for equipment and a manufacturing method thereof, which can effectively reduce the eddy current effect, ensure the transmission and application safety of the cable subjected to instantaneous ultra-large impact current, are not easy to deform during bending, and have good structural stability.
The above object of the present invention can be achieved by the following technical solutions:
the invention provides a high-current-carrying flame-retardant flexible cable with a combined conductor structure for equipment, which comprises a cable combined conductor, and an inner isolation layer, a braiding layer, an outer isolation layer and a sheath layer which are wrapped outside the cable combined conductor and are sequentially arranged from inside to outside; the cable combined conductor is formed by layering forward and reverse stranding of a plurality of insulating wire cores, each insulating wire core comprises a wire core conductor and an insulating layer wrapped outside the wire core conductor, each wire core conductor is formed by stranding a plurality of wire bundles, each wire bundle is formed by combining a plurality of wire bundles, and the combination direction of the plurality of wires is the same as the stranding direction of the plurality of wire bundles.
In a preferred embodiment of the invention, the diameter of the individual wires is less than or equal to 0.08mm.
In a preferred embodiment of the present invention, each core conductor is layered stranded by 7 strands in a 1+6 arrangement.
In a preferred embodiment of the invention, the pitch diameter ratio of the wire bundle is 20-25; the core conductor has a pitch diameter ratio of 14-16 in the inner layer and 10-12 in the outer layer.
In a preferred embodiment of the invention, the insulating layer is a modified polyether ether ketone layer, and the thickness of the insulating layer is 0.1-0.5mm.
In a preferred embodiment of the invention, the insulating layer is formed by extrusion production through a semi-extrusion die, the semi-extrusion die adopts a plurality of die sleeves, at least one notch is arranged at the discharge hole of each die sleeve, and the number of the notches on each die sleeve is different, so that at least one raised mark strip is formed on the outer surface of the insulating wire core.
In a preferred embodiment of the invention, a plurality of insulated wire cores are twisted in forward and reverse directions according to an arrangement structure of 1+6+12+ … +6n, wherein n is more than or equal to 1 and less than or equal to 10, and n is a positive integer; the semi-extrusion die adopts three die sleeves, a discharge hole of each of the three die sleeves is provided with a notch, two notches and three notches, the outer surfaces of a plurality of insulating wire cores obtained by extrusion production of insulating layers by using the extrusion die are provided with a mark strip, two mark strips or three mark strips, and the mark strips, the two mark strip cores and the three mark strip cores are respectively marked as a mark strip wire core; the plurality of insulating wire cores are respectively marked as a central layer, a first layer and an nth layer from each layer from the center to the outside, and the 6n insulating wire cores contained in the nth layer are sequentially arranged according to one marking wire core, two marking wire cores and three marking wire cores and are repeatedly arranged for 2n times in a total cycle.
In a preferred embodiment of the present invention, the pitch ratio of each layer of twist in the cable assembly conductor is 10-16, and the inner layer pitch is less than or equal to the outer layer pitch.
In a preferred embodiment of the invention, the inner isolation layer and the outer isolation layer are formed by wrapping a polyester tape, the thickness of the polyester tape is 0.02-0.05mm, the width of the polyester tape is less than or equal to 1.5-2.5 times of the wrapping diameter, and the wrapping overlapping rate of the polyester tape is 25-40%.
In a preferred embodiment of the invention, the braiding layer is an aramid fiber layer, and the braiding density of the braiding layer is 80-90%.
In a preferred embodiment of the present invention, the sheath layer is an insulating silicone rubber layer.
The invention also provides a manufacturing method of the high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment, which comprises the following steps:
bundling a plurality of wires to form a wire bundle;
twisting a plurality of wire bundles to form a wire core conductor; wherein, the binding direction of the plurality of wires is the same as the twisting direction of the multi-strand wire bundle;
wrapping an insulating layer outside each wire core conductor to form an insulating wire core;
layering and forward and reverse twisting a plurality of insulated wire cores to form a cable combination conductor;
wrapping an inner isolation layer outside the cable assembly conductor;
wrapping the braiding layer outside the inner isolation layer;
wrapping an outer isolation layer outside the braiding layer;
and wrapping a sheath layer outside the outer isolation layer to form the high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment.
In a preferred embodiment of the invention, the insulating layer is produced by extruding a modified polyether-ether-ketone material through a semi-extrusion die, and after the modified polyether-ether-ketone material is extruded and wrapped on the wire core conductor, the wire core conductor is cooled step by adopting an air precooling mode, then hot water soaking mode and then a cold water soaking mode; wherein, the balance coefficient of the mold core and the mold sleeve in the semi-extrusion mold is 1.00-1.01, and the stretching ratio is 1.4-1.8.
In a preferred embodiment of the present invention, the high current-carrying and flame-retardant flexible cable with a combined conductor structure for equipment manufactured by the manufacturing method is the high current-carrying and flame-retardant flexible cable with a combined conductor structure for equipment.
According to the high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment and the manufacturing method, the whole cable combined conductor is designed and divided into a plurality of insulated wire cores with small sections, the wire core conductors in each insulated wire core are uniformly arranged and layered and secondarily twisted, and the eddy current effect generated by alternating transmission of large current of a single conductor is solved. The plurality of insulating wire cores are arranged in a forward and reverse regular mode and layered and multi-time stranded mode, so that the structural stability is higher. Four layers are arranged outside the cable combined conductor, and two layers of isolation layers mainly play a role in electrical isolation; the braiding layers are arranged between the two isolation layers, so that the cable is softer when the two isolation layers are deformed and bent when the cable is stretched and deformed; the outer sleeve layer mainly plays a role in flame retardation and protection; and the cable combined conductor is better protected, secondary insulation protection is formed, and the flame-retardant effect is better. The whole flexible cable can meet the function of carrying high-power charges and instantaneously transmitting ultra-large impulse current, and can be used for some high-power test instruments and test equipment.
Drawings
The following drawings are only for purposes of illustration and explanation of the present invention and are not intended to limit the scope of the invention.
Wherein:
fig. 1: the invention provides a schematic cross section of a high current-carrying flame-retardant flexible cable with a combined conductor structure for equipment.
Fig. 2: the invention provides a schematic cross-section of one of the wire core conductors.
Reference numerals illustrate:
1. a cable assembly conductor; 11. a core conductor; 12. an insulating layer;
2. an inner isolation layer; 3. a braiding layer; 4. an outer isolation layer; 5. and a sheath layer.
Detailed Description
For a clearer understanding of technical features, objects, and effects of the present invention, a specific embodiment of the present invention will be described with reference to the accompanying drawings.
As shown in fig. 1 and 2, the present embodiment provides a high-current-carrying flame-retardant flexible cable with a combined conductor structure for equipment, which comprises a cable combined conductor 1, and an inner isolation layer 2, a braiding layer 3, an outer isolation layer 4 and a sheath layer 5 which are wrapped outside the cable combined conductor 1 and are sequentially arranged from inside to outside; the cable combined conductor 1 is formed by layering forward and reverse stranding of a plurality of insulated wire cores, each insulated wire core comprises a wire core conductor 11 and an insulating layer 12 wrapped outside the wire core conductor 11, each wire core conductor 11 is formed by stranding a plurality of wire bundles, each wire bundle is formed by stranding a plurality of wire bundles, and the stranding direction of the plurality of wires is the same as the stranding direction of the plurality of wire bundles.
Therefore, the high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment of the embodiment divides the whole cable combined conductor 1 into a plurality of insulated wire cores with small sections, and the wire core conductors 11 in each insulated wire core are uniformly and regularly arranged and layered and secondarily stranded, so that the eddy current effect generated by alternating transmission of large current of a single conductor is solved. The plurality of insulating wire cores are arranged in a forward and reverse regular mode and layered and multi-time stranded mode, so that the structural stability is higher. Four layers are arranged outside the cable combination conductor 1, and two layers of isolation layers mainly play a role in electrical isolation; the braiding layer 3 is arranged between the two isolation layers, so that the cable is softer when the two isolation layers are deformed and bent when the cable is stretched and deformed; the sheath layer 5 mainly plays a role in flame retardation protection; and further, the cable combined conductor 1 is better protected, secondary insulation protection is formed, and the flame-retardant effect is better. The whole flexible cable can meet the function of carrying high-power charges and instantaneously transmitting ultra-large impulse current (namely high current carrying), and can be used for some high-power test instruments and test equipment.
In a specific implementation mode, the diameter of the single wire is less than or equal to 0.08mm. The wires can be made of copper wires, for example, because the diameter of a single wire is smaller, and eddy current generated by current change of a conductor can be effectively reduced by twisting a plurality of thin wires together.
Referring to fig. 2, each core conductor 11 is layered and twisted by 7 strands according to a 1+6 arrangement structure, which can satisfy the requirements of cross-sectional area and resistance and simplify the process.
Firstly, a plurality of conductor bundles are combined into a stranded wire, and then the stranded wire is stranded into a wire core conductor 11 with a small section in the same direction according to a 1+6 arrangement structure, and because the stranded wire is stranded again, the original stranded wire part is bound in a fixed area (refer to figure 2), and the stranded wire is not easy to deform due to larger displacement during bending; the pitch diameter ratio of the strands (namely, the pitch diameter ratio of the wire bundles) is controlled to be 20-25, the pitch diameter ratio of the strands (the pitch diameter ratio of the wire core conductor 11) is controlled to be 14-16 in the inner layer and to be 10-12 in the outer layer, and the pitch of the strands is properly reduced in the secondary twisting due to the fact that the strand direction and the strand twisting direction adopt the secondary twisting in the same direction, and the strand twisting structure is similar to a primary twisting structure. The wire core conductor 11 twisted into a small section is visually inspected to be similar to a conductor, is placed on a guide wheel with the diameter of 10 times of the conductor, and is subjected to 3000 bending tests, wherein no single wire protrudes out and no wire broken end is exposed. The problem of conductor core breakage is solved, and the damage to the insulating layer 12 caused by conductor bending wire breakage or protrusion affects the product performance.
The multi-strand annealed and bundled flexible conductor is stranded into a cable core conductor 11 with a small section according to a 1 strand+6 strand arrangement structure. In a specific embodiment, 91-core small section core conductor 11 is stranded 95mm 2 95mm of cable assembly conductor 1 2 The cable combination conductor 1 of the utility model requires that the direct current resistance is not more than 0.206 ohm/km at 20 ℃, the wire core conductor 11 which is divided into small sections is reserved with 5 percent of production process stretching allowance, the direct current resistance of each core is controlled to be not more than 17.8 ohm/km, single wires with the diameter not less than 0.07mm are adopted for calculation, each strand is not less than 36 wires, the wires are twisted together, the wires and the stranded wires are twisted in the same direction, the outer diameters of the conductor and the wire core can be reduced, and the wire core is softer.
The insulating layer 12 is preferably a modified polyether ether ketone layer.
When the insulating layer 12 is produced, the semi-extrusion die is adopted for extrusion production, the balance coefficient K value of the die core and the die sleeve is controlled between 1.00 and 1.01, the stretching ratio S value is controlled between 1.4 and 1.8, the extrusion is tight and easy to strip, the production speed is ensured, and the extrusion appearance quality of the insulating layer 12 is also ensured.
In the extrusion coating process of the modified polyether-ether-ketone insulating layer, the wire core diameter is small, the production line speed is high, the surface printing is difficult, the laser marking affects the production efficiency, and the color storage types and the number of raw materials can be increased due to the special price of the material performance, such as color separation production, so that the production and operation cost is greatly increased. In this embodiment, the insulating layer 12 is formed by extrusion production with a semi-extrusion die, the semi-extrusion die adopts a plurality of die sleeves, at least one notch is formed at the discharge port of each die sleeve, and the number of the notches on each die sleeve is different, so that at least one raised mark strip is formed on the outer surface of the insulating wire core.
The length direction of the opening is axially arranged along the discharge hole, and when a plurality of openings are formed, the plurality of openings are circumferentially uniformly arranged at intervals. The existence of the notch during extrusion can enable the obtained insulating layer 12 to form a bulge at the position, so that the outer surface of the formed insulating wire core is produced to form a bulge mark strip, and the length direction of the mark strip extends along the axial direction of the insulating wire core; the number of the specific die sleeves is determined according to the needs, for example, three die sleeves are adopted in the embodiment, a gap, two gaps and three gaps are respectively arranged at the discharge holes of the three die sleeves, and one sign strip, two sign strips and three sign strips are respectively arranged on the outer surface of the insulating wire core formed by production, so that the use needs are met and the process is simplified. Therefore, three die sleeves are adopted in the extrusion coating process, one opening is filed out by a file at the discharge hole of one die sleeve, two openings are filed out by the other die sleeve, three openings are filed out by the other die sleeve, a raised mark strip is formed at the opening of the die sleeve during extrusion, the surface mark is not printed without changing the color of the material, and the insulation wire core can be identified and distinguished only by the number of the raised mark lines on the surface of the insulation wire core.
The high-temperature-resistant anti-vortex high-current-impact-resistant insulating layer 12 formed by heating, plasticizing and extruding the modified polyether-ether-ketone insulating material and tightly wrapping the outside of the small-section wire core conductor 11, wherein the thickness of the insulating layer 12 is controlled within the range of 0.10-0.50mm, and the section of the conductor is 1mm 2 The thickness of the insulating layer 12 is preferably designed to be about 0.20-0.30 mm, the process of the insulating layer 12 is too thin to control, the spark test is easy to break down, and the outer diameter of a product with too thick insulating layer 12 is larger, so that the bending radius of the product is influenced. In the high-temperature heating plasticizing extrusion process of the insulating layer 12 by adopting a high-temperature extruder, air precooling is firstly adopted, so that the production line speed is not too high, reheat water is soaked, and then cooling is carried out stepwise in a segmented and gradual manner by using a cold water soaking mode, so that the insulating layer 12 of the modified polyether ether ketone (PEEK) material is prevented from generating brittle stress at a higher cooling speed, and the insulating layer 12 is prevented from cracking, so that the product performance requirement is not met.
The insulating layer 12 adopts a thermoplastic flame-retardant high polymer material modified polyether ether ketone (PEEK) with high mechanical strength, high temperature resistance, corrosion resistance, hydrolysis resistance, impact resistance and fatigue resistance and good electrical insulation performance as an extrusion coating material, and the thermal deformation temperature of the modified polyether ether ketone insulating material is high (up to 316 ℃). When the transmission current is overlarge, the cable conductor continuously and stably works at the temperature of 300 ℃, the hidden danger that the insulating layer 12 is easy to burn and erode due to high-temperature deformation is solved, the product of the embodiment is not ablated and damaged due to instant current-carrying capacity mutation, and the normal operation of equipment can be ensured.
In an alternative embodiment, the insulating layer 12 may also be made of silicone rubber, thermoplastic Polyimide (TPI), or other materials, where the extrusion high temperature resistance is generally close to and the polyimide high temperature resistance is relatively good.
When the cable is practically applied, the polyether-ether-ketone insulating layer 12 is stripped at the end of the cable by adopting the special wire stripper, the polyether-ether-ketone insulating layer is about 1-2 cm, the wire stripper is in grouping and press connection with the wiring terminal, and then the wire stripper is connected to a wiring board to form the one-phase cable composite conductor 1, the short-time transmission current is not less than 1000A within 30s, the instantaneous transmission current of the cable is not less than 5000A, and the problems of eddy current effect generated by transmission of ultra-large alternating current and thermal deformation of the cable are solved. The cable has high working temperature, large instantaneous current-carrying capacity and strong impact resistance, can meet the instantaneous electric energy transmission and grounding conduction protection functions of high-power test instruments and test equipment, and also has the performance requirements of flame retardance, wear resistance, corrosion resistance, soft bending and the like.
Further, the plurality of insulating wire cores are twisted in the forward and reverse directions according to the arrangement structure of 1+6+12+ … +6n, wherein n is more than or equal to 1 and less than or equal to 10, and n is a positive integer. The outer surfaces of a plurality of insulating wire cores obtained by utilizing the extrusion die with the three die sleeves for extrusion production of the insulating layers are provided with one mark strip, two mark strips or three mark strips, and the mark strips are respectively marked as one mark strip wire core, two mark strip wire cores and three mark strip wire cores; the plurality of insulating wire cores are respectively marked as a central layer, a first layer and an nth layer from each layer from the center to the outside, and the 6n insulating wire cores contained in the nth layer are sequentially arranged according to one marking wire core, two marking wire cores and three marking wire cores and are repeatedly arranged for 2n times in a total cycle.
Specifically, on the arrangement of the insulated wire cores, the central layer is any insulated wire core with a marking strip. The first layer 6 insulating wire cores are arranged by one marking strip wire core, two marking strip wire cores and three marking strip wire cores, and are circularly arranged once (namely, are circularly and reciprocally arranged twice in a total); the second layer 12 insulating wire cores are arranged by one marking strip wire core, two marking strip wire cores and three marking strip wire cores, and are arranged in a reciprocating manner four times in a total circle; the third layer 18 wire cores are arranged by one marking strip wire core, two marking strip wire cores and three marking strip wire cores, and are arranged for six times in a circulating and reciprocating way; when the push-up … … is applied to products, one marking strip wire core, two marking strip wire cores and three marking strip wire cores are connected separately and are respectively connected to corresponding grouping wire positions; the split combination is connected to different positions, and the current can be distributed uniformly to each small wire core for transmission. The pitch diameter ratio of each layer of twisting in the cable combined conductor 1 is 10-16, the twisting is tight, the pitch of the inner layer is not larger than that of the outer layer, the smaller pitch diameter ratio of layering twisting and the pitch of the inner and outer layers are strictly controlled, the bending softness performance of the product and the bending deformation recovery function are ensured, and the structural stability of the twisted wire in multiple bending use is better.
Further, the inner isolation layer 2 and the outer isolation layer 4 are formed by wrapping polyester tapes, the thickness of the polyester tapes is 0.02-0.05mm, the width of the polyester tapes is less than or equal to 1.5-2.5 times of the wrapping diameter, and the wrapping overlapping rate of the polyester tapes is 25-40%.
The inner isolation layer 2 and the outer isolation layer 4 are formed by wrapping a polyester tape with a specific thin width, for example, in the embodiment, the polyester tape with the thickness of 0.03mm and the width of 40mm is used, and the wrapping isolation with the overlapping rate of about 33% is adopted, so that the wrapping bending displacement sliding performance is improved, the original state can be quickly recovered after the polyester tape is straightened, the electrical isolation insulation performance is realized, and the product softness performance is ensured.
The braiding layer 3 is an aramid fiber layer, and the braiding density of the braiding layer 3 is 80-90%.
An aramid fiber woven layer 3 is arranged between the inner isolation layer 2 and the outer isolation layer 4. The aramid fiber is adopted for knitting protection, the knitting density is about 85%, and the high-density knitting increases the protection function of deformation in stretching application.
The sheath layer 5 is an insulating silicon rubber layer.
The high-temperature-resistant insulating-grade silicon rubber cable sheath material is extruded and tightly coated outside the outer isolation layer 4 to form a bending-resistant, wear-resistant, corrosion-resistant and soft flame-retardant sheath layer 5, and after molding, the sheath layer is baked, vulcanized and shaped in a step temperature groove with the temperature below 200 ℃ for a set time, and then is led into a water tank for cooling. The sheath layer 5 after extrusion and vulcanization is easy to peel and not adhered to the outer isolation layer 4, the working temperature of the cable is high, the instantaneous current-carrying capacity is high, the impact resistance is high, and the cable can meet the performance requirements of instantaneous electric energy transmission and grounding conduction protection of high-power test instruments and test equipment, flame retardance, abrasion resistance, corrosion resistance, soft bending and the like.
The outer surface of the cable combination conductor 1 is overlapped, wrapped and isolated by adopting a polyester tape with the thickness of 0.02-0.05mm and the width of not exceeding 1.5-2.5 times of the wrapping diameter, and the wrapping overlapping rate is controlled within the range of 25% -40%; the outside is woven by adopting aramid fiber, and the weaving density is controlled between 80% and 90%; the braided layer 3 is wrapped with the polyester tape again for effective isolation, and finally the flame-retardant sheath layer 5 is wrapped, so that effective protection of the cable combination conductor 1 is realized.
Further, the embodiment also provides a manufacturing method of the high-current-carrying flame-retardant flexible cable for equipment, which comprises the following steps:
bundling a plurality of wires to form a wire bundle;
twisting the multi-strand wire bundles to form a wire core conductor 11; wherein, the binding direction of the plurality of wires is the same as the twisting direction of the multi-strand wire bundle;
wrapping an insulating layer 12 outside each wire core conductor 11 to form an insulating wire core;
layering and forward and reverse twisting a plurality of insulated wire cores to form a cable combination conductor 1;
wrapping an inner isolation layer 2 outside the cable combination conductor 1;
wrapping the braiding layer 3 outside the inner isolation layer 2;
wrapping an outer isolation layer 4 outside the braiding layer 3;
and the outer isolation layer 4 is wrapped with a sheath layer 5 to form the high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment.
Further, the insulating layer 12 is produced by extruding a modified polyether-ether-ketone material through a semi-extrusion die, and after the modified polyether-ether-ketone material is extruded and wrapped on the wire core conductor 11, air precooling is adopted, then hot water soaking is adopted, and then a cold water soaking mode is adopted for cooling step by step; wherein, the balance coefficient of the mold core and the mold sleeve in the semi-extrusion mold is 1.00-1.01, and the stretching ratio is 1.4-1.8.
The high current-carrying flame-retardant flexible cable with the combined conductor structure for equipment obtained by the manufacturing method is the high current-carrying flame-retardant flexible cable with the combined conductor structure for equipment shown in the above-mentioned fig. 1 and 2, and specific principles and effects are described in detail in the foregoing, and are not repeated here.
In summary, the high current-carrying flame-retardant flexible cable with the combined conductor structure for equipment and the manufacturing method thereof belong to modern high-power testing instruments, cables for testing equipment and manufacturing methods. When the product is applied, one marking strip wire core, two marking strip wire cores and three marking strip wire cores are connected separately and are respectively connected to corresponding grouping line positions; are separately combined and connected to different positions, and can uniformly distribute the current to eachAnd transmitting on the strip small wire cores. The whole flexible cable adopts a creative application mode of a special structure of a combined conductor and a high-temperature-resistant material insulating layer coated outside a single conductor, and ensures that the cable can bear instantaneous ultra-large impact current (the section of the cable conductor is 1 mm) 2 The current exceeding 10A can be born in the cable), under the condition of not increasing the section of the conductor, the instantaneous safe application current-carrying capacity of the cable is improved by tens of times, the short-time transmission current of the cable is not less than 1000A in 30s, the instantaneous transmission current of the cable is not less than 5000A, and the problems of eddy current effect and thermal deformation of the cable caused by the transmission of the ultra-large alternating current are solved. The ultra-high power electromagnetic conversion device can particularly meet the technical category of ultra-high current instantaneous transmission application, can provide transmission performance for current ultra-high power electromagnetic conversion, and can provide energy-saving protection requirements for high-power equipment operation electric energy transmission wiring. Has the following advantages:
(1) The cable conductor adopts a plurality of copper wire bundles to be combined firstly, and then is stranded in the same direction according to the 1+6 arrangement structure, and the pitches of some bundle wire strands can be removed during the same-direction stranding, so that the cable conductor is similar to a one-time bundling structure, the product has small outer diameter, is softer and has high production efficiency. The plurality of wire core conductors 11 are twisted forward and backward according to the arrangement structure of 1+6+12+18+24+30+ …, and the twisted wire structure is better in stability when the wire is bent for multiple times. The whole cable combined conductor 1 is designed to be formed by twisting a plurality of wire core conductors 11 with small sections provided with insulating layers 12, and when in use, the insulating layers 12 are stripped and then pressed together by connecting terminals, so that the eddy current effect generated by the large-current alternating transmission of a single conductor formed by twisting a plurality of metal wires is solved;
(2) The insulating layer 12 is made of a thermoplastic flame-retardant high polymer material polyether-ether-ketone with high mechanical strength, high temperature resistance, corrosion resistance, hydrolysis resistance, impact resistance, fatigue resistance and good electrical insulation performance, and the thermal deformation temperature of the material can reach more than 316 ℃. The problem of high-temperature deformation of the insulating layer 12 under the condition that the temperature of the conductor of the ultra-large current cable is up to 300 ℃ is solved, and the product of the invention is not ablated and damaged due to instantaneous current-carrying capacity mutation, so that the normal operation of equipment can be ensured.
(3) The standard stranding test of the wire core conductor 11 requires that no single wire protrudes from the wire core conductor 11 and no broken end of the wire is exposed. The problem of conductor core breakage is solved, and the damage to the insulating layer 12 caused by conductor bending wire breakage or protrusion affects the product performance. The extrusion design parameters are controlled in an important way, the extrusion is tight and easy to peel, the thickness of the insulating layer 12 is controlled in a thinner range, and the outer diameter of the cable combination conductor 1 is ensured not to be too large; the small pitch diameter ratio is twisted and the polyester tape is lapped and wrapped, so that the performance requirement that the cable needs to be soft due to bending movement and is restored to the original state after deformation is solved, and the high-density braiding is performed by adopting the aramid fiber, so that the protection function of applying deformation is increased. The flame-retardant flexible cable prepared by adopting the modified polyether-ether-ketone insulating silicon rubber material sheath and the special process structure has high working temperature and strong shock resistance, and can meet the performance requirements of instantaneous electric energy transmission, grounding conduction protection and the like of high-power equipment.
The foregoing is illustrative of the present invention and is not to be construed as limiting the scope of the invention. Any equivalent changes and modifications can be made by those skilled in the art without departing from the spirit and principles of this invention, and are intended to be within the scope of this invention.
Claims (14)
1. The high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment is characterized by comprising a cable combined conductor, and an inner isolation layer, a braiding layer, an outer isolation layer and a sheath layer which are wrapped outside the cable combined conductor and are sequentially arranged from inside to outside;
the cable combination conductor is formed by layering forward and reverse stranding of a plurality of insulating wire cores, each insulating wire core comprises a wire core conductor and an insulating layer wrapping the outer portion of the wire core conductor, each wire core conductor is formed by stranding a plurality of wire bundles, each wire bundle is formed by combining a plurality of wire bundles, and the combining direction of the plurality of wires is the same as the stranding direction of the plurality of wire bundles.
2. The composite conductor structure for equipment high current-carrying flame-retardant flexible cable according to claim 1, wherein,
the diameter of each wire is less than or equal to 0.08mm.
3. The composite conductor structure for equipment high current-carrying flame-retardant flexible cable according to claim 1, wherein,
each wire core conductor is layered and stranded by 7 wire bundles according to a 1+6 arrangement structure.
4. The composite conductor structure for equipment, as set forth in claim 3, wherein,
the pitch diameter ratio of the wire bundle is 20-25; the core conductor has a pitch diameter ratio of 14-16 in the inner layer and 10-12 in the outer layer.
5. The composite conductor structure for equipment high current-carrying flame-retardant flexible cable according to claim 1, wherein,
the insulating layer is a modified polyether-ether-ketone layer, and the thickness of the insulating layer is 0.1-0.5mm.
6. The composite conductor structure for equipment high current-carrying flame-retardant flexible cable according to claim 5, wherein,
the insulating layer adopts half extrusion formula mould extrusion production to form, half extrusion formula mould adopts a plurality of die sleeves, every the discharge gate department of die sleeve all is equipped with an at least opening, and each the quantity of opening on the die sleeve is different, so that the surface of insulating sinle silk forms an at least bellied marking strip.
7. The composite conductor structure for equipment high current-carrying flame-retardant flexible cable according to claim 6, wherein,
the plurality of insulated wire cores are twisted in forward and reverse directions according to an arrangement structure of 1+6+12+ … +6n, wherein n is more than or equal to 1 and less than or equal to 10, and n is a positive integer;
the semi-extrusion die adopts three die sleeves, a discharge hole of each of the three die sleeves is provided with a notch, two notches and three notches, the outer surfaces of a plurality of insulating wire cores obtained by extrusion production of the insulating layer by using the extrusion die are provided with a marking strip, two marking strips or three marking strips, and the marking strips are respectively marked as a marking strip wire core, two marking strip wire cores and three marking strip wire cores; the plurality of insulating wire cores are respectively marked as a central layer, a first layer and an nth layer from each layer from the center to the outside, and the 6n insulating wire cores contained in the nth layer are sequentially arranged according to one marking wire core, two marking wire cores and three marking wire cores and are arranged in a total cycle in a reciprocating manner for 2n times.
8. The composite conductor structure for equipment high current-carrying flame-retardant flexible cable according to claim 7, wherein,
the pitch diameter ratio of each layer of twisting in the cable combination conductor is 10-16, and the pitch of the inner layer is smaller than or equal to the pitch of the outer layer.
9. The composite conductor structure for equipment high current-carrying flame-retardant flexible cable according to claim 1, wherein,
the inner isolation layer and the outer isolation layer are formed by wrapping polyester belts, the thickness of the polyester belts is 0.02-0.05mm, the width of the polyester belts is less than or equal to 1.5-2.5 times of the wrapping diameter, and the wrapping overlapping rate of the polyester belts is 25-40%.
10. The composite conductor structure for equipment high current-carrying flame-retardant flexible cable according to claim 1, wherein,
the braiding layer is an aramid fiber layer, and the braiding density of the braiding layer is 80-90%.
11. The composite conductor structure for equipment high current-carrying flame-retardant flexible cable according to claim 1, wherein,
the sheath layer is an insulating silicon rubber layer.
12. The manufacturing method of the high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment is characterized by comprising the following steps of:
bundling a plurality of wires to form a wire bundle;
twisting a plurality of wire bundles to form a wire core conductor; the wire bundle combination direction of the plurality of wires is the same as the twisting direction of the plurality of wire bundles;
wrapping an insulating layer outside each wire core conductor to form an insulating wire core;
layering, forward and reverse twisting a plurality of insulated wire cores to form a cable combination conductor;
wrapping an inner isolation layer outside the cable assembly conductor;
wrapping a braiding layer outside the inner isolation layer;
wrapping an outer isolation layer outside the braiding layer;
and wrapping a sheath layer outside the outer isolation layer to form the high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment.
13. The method for manufacturing the high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment according to claim 12, wherein,
the insulation layer is produced by extruding a modified polyether-ether-ketone material through a semi-extrusion die, and after the modified polyether-ether-ketone material is extruded on the wire core conductor, the wire core conductor is cooled stepwise by adopting air precooling, then hot water soaking and then a cold water soaking mode.
14. The method for manufacturing the high-current-carrying flame-retardant flexible cable with the combined conductor structure for equipment according to claim 12, wherein,
the high current-carrying flame-retardant flexible cable with the combined conductor structure for equipment is the high current-carrying flame-retardant flexible cable with the combined conductor structure for equipment according to any one of claims 1 to 11.
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| CN117637258A (en) * | 2023-11-29 | 2024-03-01 | 迈特诺（马鞍山）特种电缆有限公司 | Processing method of wear-resistant cable for urban rail |
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| CN117637258A (en) * | 2023-11-29 | 2024-03-01 | 迈特诺（马鞍山）特种电缆有限公司 | Processing method of wear-resistant cable for urban rail |
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