EP3179485A1 - High-power coaxial cable - Google Patents
High-power coaxial cable Download PDFInfo
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- EP3179485A1 EP3179485A1 EP16002409.7A EP16002409A EP3179485A1 EP 3179485 A1 EP3179485 A1 EP 3179485A1 EP 16002409 A EP16002409 A EP 16002409A EP 3179485 A1 EP3179485 A1 EP 3179485A1
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- Prior art keywords
- coaxial cable
- bundles
- conductor
- individual wires
- bundle
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Images
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/001—Power supply cables for the electrodes of electric-welding apparatus or electric-arc furnaces
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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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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/04—Concentric cables
Definitions
- the invention relates to a coaxial cable for the transmission of high currents in the range of several hundred to several thousand amps at high frequencies, especially in the kilohertz range, with a first electrical conductor for a first current phase and a coaxially arranged second electrical conductor for a second current phase, respectively are formed by a number of annularly arranged bundles of a plurality of mutually insulated individual wires, wherein between the first and second conductor is an elastic insulating layer to prevent a flashover.
- the invention relates to a cable for transmitting high electrical power up to the megawatt range.
- Such Hoch inskoaxialrait are known and are mainly used for industrial induction heating, for example, when melting, tempering or tempering of steel, in the high currents between 1,000-15,000 amps at high frequency usually from 4 kHz to 150 kHz, in extreme cases even up to 400 kHz via the cable. This must be done with minimal power losses.
- Today's cables have both a high tendency to inductive and ohmic losses.
- the skin effect occurring at high frequencies leads to high voltage drops in the cable. An effective skin effect reduction does not exist until today.
- the generic coaxial cable such that the bundles of the first and / or second electrical conductor form a mesh.
- the bundles are thus blurred, i. regularly entwined.
- the coaxial cable's inductive losses and skin effect are reduced, resulting in better power utilization of the coaxial cable, and ultimately, more power can be transported to the consumer.
- the individual wires are preferably made of copper, since copper has a low resistivity. As a result, the ohmic losses of the coaxial cable are low.
- each bundle in the braid in its direction of extension alternately cross two other bundles and cross each other. This simplifies the production compared to a braid in which each bundle alternately only crosses and undercuts another bundle due to the plurality of bundles. Intersecting bundles can lie in a braid angle between 30 ° and 60 °.
- the isolation of the individual wires can be formed for example by a lacquer. This isolation is crucial for reducing the skin effect. Since the insulation of the individual wires is not an insulation against flashovers in the event of potential differences, the paint used can be an electrical paint commonly used in the construction of coils and transformers. A varnish for insulation forms a very thin layer, so that the diameter of the individual wires is not appreciably increased.
- each bundle is wound around the longitudinal axis of the respective bundle, as is the case with a cable.
- the bundles remain bundles during processing or braiding and the individual wires do not separate.
- the individual wires may have a diameter of 0.1 mm to 0.5 mm.
- the bundles can have a large number, for example 20 to 60 such individual wires. The smaller the diameter, the more individual wires can be used with the same conductor cross-section and the more single wires are used, the more the current can be split, and the lower the skin effect.
- the first and / or the second electrical conductor of bundles of a plurality of mutually insulated individual wires may be formed, which are arranged in two concentric circles, wherein the bundles of the two circles each form their own mesh.
- the elastic insulating layer is made of EPDM (ethylene-propylene-diene rubber).
- EPDM ethylene-propylene-diene rubber
- This material is characterized by high insulation properties, so that the thickness of the insulating layer with the same insulation performance as in the prior art, may be lower. This, in turn, causes the first and second electrical conductors to be closer together, thereby reducing inductive loss.
- the electrical conductors are hot.
- the first and second electrical conductors preferably lie in a liquid-flowable chamber.
- the insulating layer can separate a first liquid-permeable chamber from a second liquid-permeable chamber.
- FIG. 1 shows a coaxial cable 1 for transmitting high currents in the kiloampere range, in particular in the range of several hundred to several thousand amps, at high frequencies in the kilohertz range, with a first electrical conductor 4 for a first phase of current and a second coaxial to this arranged second electrical conductor 7 for a second Current phase, each formed by a number of annularly arranged bundles 4a, 7a of a plurality of individual wires, wherein between the first and second conductors 4, 7 is an elastic insulating layer 5, 6 for preventing a flashover.
- a coaxial cable is state of the art.
- Water-cooled coaxial cables are mainly used in industrial induction heating, for example in melting, tempering or tempering steel).
- a particular requirement in this area is that high currents (1,000-15,000 amperes) with very high frequency (i.d.R 4-150 kHz, in extreme cases up to 400 kHz) must be routed to the induction heater.
- household electricity has only a current of a few amperes and a frequency of 50 Hz.
- the inner spiral 2 is formed by a thick wire which extends helically around the cable axis, as shown in FIG. 5 you can see. It supports the first electrical conductor 4, hereinafter also called inner conductor 4, from.
- the inner conductor 4 consists of a plurality of circularly arranged around the inner spiral 3 bundles 4a.
- Each bundle 4a in turn consists of a plurality of individual wires made of copper, also referred to below as copper wires. Copper is used here because it has a very low resistance and is therefore a very good conductor.
- the diameter of each copper wire is 0.2mm.
- the copper wires are wound along the longitudinal extent of the respective bundle 4a, so that each bundle 4a is formed in the manner of a rope.
- the bundles 4a are therefore also referred to as Kupferseilbündel.
- the cavity 2 is not needed for electrical reasons, since it is not penetrated by the current. However, it serves as a cooling water pipe and thus ensures more efficient heat dissipation.
- the inner cavity 1 and the annular space in which the cable collars 4a of the inner conductor are located together form an inner cooling water chamber 9.
- the elastic insulating layer 5 which here comprises an inner cooling tube 5 and a radially outside of the cooling tube 5 applied layer 6.
- the cooling hose 5 surrounds the inner conductor 4 annular and limits the inner cooling water chamber 9 to the outside.
- the second conductor 7, hereinafter referred to as the outer conductor 7, which consists of a plurality of circularly arranged bundles 7a, which in turn are formed from a plurality of individual wires.
- the bundles 7a of the second conductor 7 may be formed equal to those of the first conductor 4, so that it is also possible here to speak of copper wires and copper wire bundles 7a.
- the outer conductor 7 is located in an outer cooling water chamber 10 in the form of an annular space.
- An outer cooling hose 8 bounds the outer cooling water chamber 10 radially outward. This forms the outermost layer of the coaxial cable 1. It thus isolates the cable electrically and protects against mechanical and chemical action.
- the insulating layer i. the inner cooling tube 5 together with its externally applied layer, fulfill the task of a dielectric and separate the two current phases in the second conductor 7 and the first conductor 4 from each other. In addition, they separate the two cooling water chambers 9, 10 from each other.
- Both the inner cooling water chamber 9, ie the inner cavity 2 together with the space around the inner conductor 4, as well as the outer cooling water chamber 10, ie the space around the outer conductor 7 are flowed through cooling water, due to the high current, the high frequency and the herein to be able to deduce the resulting heat from the skin effect.
- This cooling ability is also a decisive factor for the power efficiency of such a cable 1. Because the more heat can be dissipated, the more current can be passed through such a cable 1.
- FIG. 3 shows the electrical standard circuit diagram for a coaxial cable 1, in which a consumer 11, for example in the form of an induction furnace, which is electrically substantially a coil, between the inner conductor 4 and the outer conductor 7 is connected.
- the inner conductor 4 and the outer conductor 7 can each lead a current phase of a three-phase voltage network, wherein the phases 120 ° may be shifted from each other.
- the illustrated prior art involves various disadvantages:
- the cables have 1 inductive losses, which today average about 10% voltage drop (based on the usual lengths used). This is partly due to the skin effect, which is always present, ie it is only a relatively small proportion of the actual conductor cross-sections used for the passage of electricity. It is estimated that this proportion is on average only around 20% in the relevant frequency band today. Conversely, this means that almost 80% of the cable cross section is actually not used for the current flow. On the other hand, too little insulation is to blame. Because due to little high-impedance insulating fabric inserts in the cooling hoses used for the insulation 5, 8 wide distances between the inner conductor 4 and the outer conductor 7 must be selected to prevent flashovers. However, if the two conductors 4, 7 were closer together, the electromagnetic fields generated by the respective conductor 4, 7 would be more extinguished, so that less energy flows into these fields. Thus, for maximum conduction efficiency, a minimum distance would be required.
- the voltage drop due to the inductive loss is about 79 V and due to the ohmic resistance about 13V.
- the coaxial cable 1 forms the coaxial cable according to FIG. 1 Now further to the effect that the individual wires are insulated against each other and the bundles 4a, 7a of the first and second electrical conductors 4, 7 form a braid 12, which leads to advantages in various points.
- FIG. 4 shows a plan view of the braid 12, from which the second conductor 7 is formed.
- the braid 12 is of particular importance.
- This causes the electromagnetic fields around the individual bundles to weaken, which in turn contributes to the reduction of inductive losses.
- the individual bundles 4a, 7a are not covered separately. This has the advantage that they are not fixed in their cross-sectional shape. Thus, the individual wires in the cross section of the bundles 4a, 7a viewed not circularly arranged but approximately oval. That that the bundles 4a, 7a are rather flat, which is an effect of the axial train on the coaxial cable or on the respective braid 12. As a result, the bundles 4a, 7a are close to each other, so that there are no open stitches.
- the braid 12 causes a total of an absolutely dense electromagnetic field with low scattering effect, which also reduces the inductive losses of the coaxial cable 1.
- FIG. 1 make clear, if one considers that in circular bundles 4a, 7a free spaces forming gussets between two adjacent bundles 4a, 7a and the insulating layer 5, 6 lie.
- circular bundles 4a, 7a as in FIG. 1 corresponds to the radial thickness of the electrical conductors 4, 7 respectively the diameter of the bundles 4a, 7a, wherein between two adjacent bundles 4a, 7a each of the electrical conductors 4, 7 are unused gussets.
- the individual individual wires of the bundles 4a, 7a of the first and second conductors 4, 7 are each homogeneously distributed on the corresponding electrical conductors 4, 7 bearing ring in the cross section of the coaxial cable 1, so that almost fully the entire radial thickness of respective annular space is filled with the individual wires.
- This causes the radial thickness of the respective annular space with braided bundles 4a, 7a according to FIG FIG. 4 is smaller at the same conductor cross-section, as in the case of the round bundles 4a, 7a in FIG. 1 ,
- the radial distance is decisive for the height of the inductive losses, so that the inductive losses are reduced to a minimum due to the braid-related smaller conductor spacing.
- the braid 12 from bundles 4a, 7a of the first and / or second electrical conductor 4, 7 also leads to a reduction of the skin effect and consequently to an increase in the current-carrying cross-sectional area, so that the coaxial cable 1 lead more power / power to the load 11 can, as comparable cables according to the prior art.
- the distance of each bundle 4a, 7a from the axis of the coaxial cable 1 varies approximately sinusoidally in the radial direction. If a bundle 4a, 7a crosses another bundle, it lies radially further outward, if it crosses another bundle, it lies radially further inside.
- the distance of each bundle 4a, 7a of the one electrical conductor 4, 5 in the direction of extension also changes relative to the other electrical conductor 7, 4.
- each Bundle is rather the sum of individual wires, from which a current-apart from the axial end-can not flow out. This means that the current at the high frequencies can not "collect” on the surface of a bundle, but at most on the surface of a wire. Overall, the effective current used by the cross section of the electrical conductors 4, 7 is thereby increased.
- the insulating layer 5, 6 between the first electrical conductor 4 and the second electrical conductor 7 by a tube made of EPDM (ethylene-propylene-diene rubber).
- EPDM ethylene-propylene-diene rubber
- FIG. 5 shows an embodiment of a coaxial cable 1 according to the invention in a perspective view, with a partially schematic representation selected and a portion of the cable 1 is cut to recognize the internal structure, which is substantially the structure in the FIGS. 1 and 2 equivalent.
- the axial end of the coaxial cable 1 has a connection head 13 for connecting the cable 1 to a load 11 or a voltage source, for example a transformer. In the connection head, the current is fed into the individual bundles 4a, 7a of the first and second electrical conductors 4, 7.
- FIG. 5 Schematically are in FIG. 5 the layers forming the first and second electrical conductors 4, 7 are each formed by a number of annularly arranged bundles 4a, 7a of a plurality of mutually insulated individual wires.
- the layers are formed according to the invention as a braid 12.
- FIGS. 5a and 5b An enlarged and schematic representation of two exemplary braid structures is shown in FIGS. 5a and 5b shown.
- FIG. 5a shows a simple mesh structure in which each bundle 4a, 7a alternately covers and bridges a single crossing bundle 4a, 7a.
- FIG. 5b shows FIG. 4 in which each bundle 4a, 7a alternately overlaps and bridges two crossing bundles 4a, 7a.
- each bundle is represented by three individual wires, although each bundle consists of a plurality of individual wires.
- both the inner conductor 4 and the outer conductor 7 each consist of two braids 12.
- the first and the second electrical conductors 4, 7 are each formed from bundles 4a, 7a, which are arranged in two concentric circles.
- the bundles 4, 7a of the two circles each form their own braid 12. Consequently, there are two braids 12 one above the other.
- the outer conductor 7 has an inner braid 7.1 and an outer braid 7.2 and the inner conductor 4, an inner braid 4.1 and an outer braid 4.2. While a single braid, for example, leads to a cross-section of 70mm 2, the conductor cross section can be doubled by a second braid layer for example to 140mm. 2
- the coaxial cable according to the invention can be adapted to any application, so that neither an expensive over-sizing nor a risky undersizing can take place.
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Abstract
Die Erfindung betrifft ein Koaxialkabel (1) zur Übertragung von Hochströmen im Bereich von mehreren hundert bis mehreren tausend Ampere bei Hochfrequenzen, insbesondere im Kilohertzbereich, mit einem ersten elektrischen Leiter (4) für eine erste Stromphase und einem koaxial zu diesem angeordneten zweiten elektrischen Leiter (7) für eine zweite Stromphase, die jeweils durch eine Anzahl ringförmig angeordneter Bündel (4a, 7a) aus einer Vielzahl gegeneinander isolierter Einzeldrähte gebildet sind, wobei zwischen dem ersten und zweiten Leiter (4, 7) eine elastische Isolationsschicht (5, 6) zur Verhinderung eines Spannungsüberschlags liegt. Dabei ist vorgesehen, dass die Bündel (4, 7a) des ersten und/ oder zweiten elektrischen Leiters (4, 7) ein Geflecht bilden. Hierdurch werden die induktiven Verluste reduziert und der effektiv nutzbare Leiterquerschnitt erhöht.The invention relates to a coaxial cable (1) for transmitting high currents in the range of several hundred to several thousand amperes at high frequencies, in particular in the kilohertz range, with a first electrical conductor (4) for a first current phase and a second electrical conductor arranged coaxially therewith ( 7) for a second current phase, each formed by a number of annularly arranged bundles (4a, 7a) of a plurality of mutually insulated individual wires, wherein between the first and second conductors (4, 7) an elastic insulating layer (5, 6) for Prevention of voltage flashover is. It is provided that the bundles (4, 7a) of the first and / or second electrical conductor (4, 7) form a mesh. This reduces the inductive losses and increases the effectively usable conductor cross-section.
Description
Die Erfindung betrifft ein Koaxialkabel zur Übertragung von Hochströmen im Bereich von mehreren hundert bis mehreren tausend Ampere bei Hochfrequenzen, insbesondere im Kilohertzbereich, mit einem ersten elektrischen Leiter für eine erste Stromphase und einem koaxial zu diesem angeordneten zweiten elektrischen Leiter für eine zweite Stromphase, die jeweils durch eine Anzahl ringförmig angeordneter Bündel aus einer Vielzahl gegeneinander isolierter Einzeldrähte gebildet sind, wobei zwischen dem ersten und zweiten Leiter eine elastische Isolationsschicht zur Verhinderung eines Spannungsüberschlags liegt. Insbesondere betrifft die Erfindung ein Kabel zur Übertragung hoher elektrischer Leistungen bis in den Megawattbereich.The invention relates to a coaxial cable for the transmission of high currents in the range of several hundred to several thousand amps at high frequencies, especially in the kilohertz range, with a first electrical conductor for a first current phase and a coaxially arranged second electrical conductor for a second current phase, respectively are formed by a number of annularly arranged bundles of a plurality of mutually insulated individual wires, wherein between the first and second conductor is an elastic insulating layer to prevent a flashover. In particular, the invention relates to a cable for transmitting high electrical power up to the megawatt range.
Solche Hochleistungskoaxialkabel sind bekannt und werden vor allem zur industriellen induktiven Erwärmung, beispielsweise beim Schmelzen, Vergüten oder Anlassen von Stahl eingesetzt, bei der hohe Stromstärken zwischen 1.000-15.000 Ampere bei hoher Frequenz in der Regel von 4 kHz bis 150 kHz, in Extremfällen sogar bis zu 400 kHz über das Kabel geleitet werden. Dies muss unter minimalen Leistungsverlusten erfolgen. Heutige Kabel haben aber sowohl eine hohe Neigung zu induktiven als auch ohmschen Verlusten. Insbesondere der bei hohen Frequenzen auftretende Skin-Effekt führt zu hohen Spannungsabfällen im Kabel. Eine effektive Skin-Effekt-Reduzierung existiert bis heute nicht.Such Hochleistungskoaxialkabel are known and are mainly used for industrial induction heating, for example, when melting, tempering or tempering of steel, in the high currents between 1,000-15,000 amps at high frequency usually from 4 kHz to 150 kHz, in extreme cases even up to 400 kHz via the cable. This must be done with minimal power losses. Today's cables have both a high tendency to inductive and ohmic losses. In particular, the skin effect occurring at high frequencies leads to high voltage drops in the cable. An effective skin effect reduction does not exist until today.
Es ist daher Aufgabe der vorliegenden Erfindung ein Hochleistungskoaxialkabel für Industrieanwendungen bereitzustellen, das geringere induktive Verluste besitzt und ferner einen gesteigerten nutzbaren Leiterquerschnitt im relevanten Frequenzband durch Reduzierung des Skineffekts aufweist.It is therefore an object of the present invention to provide a high performance coaxial cable for industrial applications which has lower inductive losses and Furthermore, it has an increased usable conductor cross-section in the relevant frequency band by reducing the skin effect.
Diese Aufgabe wird durch ein Hochleistungskabel mit den Merkmalen des Anspruchs 1 gelöst. Vorteilhafte Weiterbildungen sind in den Unteransprüchen wiedergegeben und werden nachfolgend erläutert.This object is achieved by a high-performance cable with the features of
Erfindungsgemäß wird vorgeschlagen, das gattungsgemäße Koaxialkabel derart weiterzubilden, dass die Bündel des ersten und/ oder zweiten elektrischen Leiters ein Geflecht bilden. Die Bündel sind folglich miteinander verflogen, d.h. regelmäßig ineinander geschlungen. Durch die Verwendung eines Geflechts werden die induktiven Verluste des Koaxialkabels sowie der Skin-Effekt reduziert, so dass eine bessere Leistungsausnutzung des Koaxialkabels besteht und letztendlich mehr Leistung zum Verbraucher transportiert werden kann.According to the invention it is proposed to develop the generic coaxial cable such that the bundles of the first and / or second electrical conductor form a mesh. The bundles are thus blurred, i. regularly entwined. By using a mesh, the coaxial cable's inductive losses and skin effect are reduced, resulting in better power utilization of the coaxial cable, and ultimately, more power can be transported to the consumer.
Die Einzeldrähte sind vorzugsweise aus Kupfer, da Kupfer einen geringen spezifischen Widerstand aufweist. Hierdurch sind die ohmschen Verluste des Koaxialkabels gering.The individual wires are preferably made of copper, since copper has a low resistivity. As a result, the ohmic losses of the coaxial cable are low.
Vorzugsweise kann jedes Bündel in dem Geflecht in seiner Erstreckungsrichtung abwechselnd jeweils zwei andere Bündel überkreuzen und unterkreuzen. Dies vereinfacht aufgrund der Vielzahl an Bündeln die Herstellung im Vergleich zu einem Geflecht, bei dem jedes Bündel abwechselnd nur ein anderes Bündel überkreuzt und unterkreuzt. Sich kreuzende Bündel können in einem Flechtwinkel zwischen 30° und 60° liegen.Preferably, each bundle in the braid in its direction of extension alternately cross two other bundles and cross each other. This simplifies the production compared to a braid in which each bundle alternately only crosses and undercuts another bundle due to the plurality of bundles. Intersecting bundles can lie in a braid angle between 30 ° and 60 °.
Die Isolation der Einzeldrähte kann beispielsweise durch einen Lack gebildet sein. Diese Isolation ist von entscheidender Bedeutung für die Reduzierung des Skin-Effekts. Da die Isolation der Einzeldrähte keine Isolation gegen Überschläge bei Potenzialunterschieden ist, kann als Lack ein üblicherweise bei dem Bau von Spulen und Transformatoren verwendeter Elektrolack verwendet werden. Ein Lack zur Isolation bildet eine sehr dünne Schicht, so dass der Durchmesser der Einzeldrähte nicht merklich erhöht ist.The isolation of the individual wires can be formed for example by a lacquer. This isolation is crucial for reducing the skin effect. Since the insulation of the individual wires is not an insulation against flashovers in the event of potential differences, the paint used can be an electrical paint commonly used in the construction of coils and transformers. A varnish for insulation forms a very thin layer, so that the diameter of the individual wires is not appreciably increased.
Es ist des Weiteren von Vorteil, wenn die Einzeldrähte jedes Bündels um die Längsachse des jeweiligen Bündels gewunden sind, wie dies bei einem Seil der Fall ist. Dies führt dazu, dass die Bündel bei der Verarbeitung bzw. beim Flechten Bündel bleiben und sich die Einzeldrähte nicht vereinzeln.It is also advantageous if the individual wires of each bundle are wound around the longitudinal axis of the respective bundle, as is the case with a cable. As a result, the bundles remain bundles during processing or braiding and the individual wires do not separate.
Geeigneterweise können die Einzeldrähte einen Durchmesser von 0,1 mm bis 0,5mm aufweisen. Hierdurch können die Bündel eine Vielzahl, beispielsweise 20 bis 60 solcher Einzeldrähte aufweisen. Je kleiner der Durchmesser desto mehr Einzeldrähte können bei gleichem Leiterquerschnitt verwendet werden und je mehr Einzeldrähte verwenden werden, desto mehr kann der Strom aufgeteilt werden, und desto geringer ist der Skin-Effekt.Suitably, the individual wires may have a diameter of 0.1 mm to 0.5 mm. As a result, the bundles can have a large number, for example 20 to 60 such individual wires. The smaller the diameter, the more individual wires can be used with the same conductor cross-section and the more single wires are used, the more the current can be split, and the lower the skin effect.
Um den Leiterquerschnitt zu verdoppeln, beispielsweise von 70mm2 auf 140mm2 können beispielsweise bei jedem der beiden Leiter zwei Geflechtlagen verwendet werden, so dass, wenn sowohl der erste als auch der zweite elektrische Leiter durch ein Geflecht aus Bündeln von Einzeldrähten gebildet ist, insgesamt vier solcher Geflechte in dem Koaxialkabel vorhanden sind. So kann folglich der erste und/ oder der zweite elektrische Leiter von Bündeln aus einer Vielzahl gegeneinander isolierter Einzeldrähte gebildet sein, die in zwei konzentrischen Kreisen angeordnet sind, wobei die Bündel der beiden Kreise jeweils ein eigenes Geflecht bilden.For example, to double the conductor cross section, for example, from 70mm 2 to 140mm 2 , two mesh layers may be used in each of the two conductors so that when both the first and second electrical conductors are formed by a mesh of bundles of individual wires, there are four in total such braids are present in the coaxial cable. Thus, therefore, the first and / or the second electrical conductor of bundles of a plurality of mutually insulated individual wires may be formed, which are arranged in two concentric circles, wherein the bundles of the two circles each form their own mesh.
Vorzugsweise ist die elastische Isolationsschicht aus EPDM (Ethylen-Propylen-Dien-Kautschuk) hergestellt. Dieses Material kennzeichnet sich durch hohe Isolationseigenschaften, so dass die Dicke der Isolationsschicht bei gleicher lsolationsleistung wie im Stand der Technik, geringer sein kann. Dies führt wiederum dazu, dass der erste und zweite elektrische Leiter näher beieinander liegen können, wodurch der induktive Verlust verringert wird.Preferably, the elastic insulating layer is made of EPDM (ethylene-propylene-diene rubber). This material is characterized by high insulation properties, so that the thickness of the insulating layer with the same insulation performance as in the prior art, may be lower. This, in turn, causes the first and second electrical conductors to be closer together, thereby reducing inductive loss.
Aufgrund der Hochleistung, die das erfindungsgemäße Koaxialkabel zu übertragen vermag, werden die elektrischen Leiter heiß. Zur Kühlung deshalb vorgesehen sein, das Koaxialkabel beispielsweise mit Wasser zu kühlen. Vorzugsweise liegen hierfür der erste und zweite elektrische Leiter in einer flüssigkeitsdurchströmbaren Kammer ein. Dabei kann die Isolationsschicht eine erste flüssigkeitsdurchströmbaren Kammer von einer zweiten flüssigkeitsdurchströmbaren Kammer trennen.Due to the high performance that is able to transmit the coaxial cable according to the invention, the electrical conductors are hot. For cooling therefore be provided to cool the coaxial cable, for example, with water. For this purpose, the first and second electrical conductors preferably lie in a liquid-flowable chamber. In this case, the insulating layer can separate a first liquid-permeable chamber from a second liquid-permeable chamber.
Weitere Merkmale und Vorteile der Erfindung werden nachfolgend anhand eines Ausführungsbeispiels und der beigefügten Figuren erläutert. Es zeigen:
-
Figur 1 : den prinzipiellen Aufbau eines wassergekühlten Koaxialkabels nach dem Stand der Technik -
Figur 2 : das Koaxialkabel nach mit Skin-EffektFigur 1 -
Figur 3 : elektrisches Ersatzschaltbild eines Koaxialkabels -
Figur 4 : Darstellung des Geflechts aus Bündeln des zweiten Leiters -
Figur 5 : perspektivische Darstellung eines teilweise aufgeschnittenen Koaxialkabels gemäß der Erfindung -
Figuren 5a, 5b : Darstellung beispielhafter Geflechtstrukturen
-
FIG. 1 : the basic structure of a water-cooled coaxial cable according to the prior art -
FIG. 2 : the coaxial cable behindFIG. 1 with skin effect -
FIG. 3 : Electrical equivalent circuit of a coaxial cable -
FIG. 4 : Representation of the braid from bundles of the second conductor -
FIG. 5 : Perspective view of a partially cut coaxial cable according to the invention -
FIGS. 5a, 5b : Representation of exemplary braid structures
Wassergekühlte Koaxialkabel finden in der Hauptsache Anwendung in der industriellen induktiven Erwärmung, beispielsweise beim Schmelzen, Vergüten oder Anlassen von Stahl). Eine besondere Anforderung in diesem Bereich ist, dass hohe Stromstärken (1.000-15.000 Ampere) mit sehr hoher Frequenz (i.d.R. 4-150 kHz, in Extremfällen bis zu 400 kHz) zum Induktionserwärmer geleitet werden müssen. Im Vergleich hierzu hat Haushaltsstrom lediglich eine Stromstärke von wenigen Ampere und eine Frequenz von 50 Hz.Water-cooled coaxial cables are mainly used in industrial induction heating, for example in melting, tempering or tempering steel). A particular requirement in this area is that high currents (1,000-15,000 amperes) with very high frequency (i.d.R 4-150 kHz, in extreme cases up to 400 kHz) must be routed to the induction heater. In comparison, household electricity has only a current of a few amperes and a frequency of 50 Hz.
Wichtigste Anforderung an stromleitende Kabel in diesem Bereich ist eine möglichst leistungsverlustfreie Durchleitung. Hierbei gilt es zwei Arten des Verlustes zu unterscheiden, da man kapazitive Verluste vernachlässigen kann. Erstens ist dies der ohmsche Verlust. Dies ist der Leistungsverlust, der durch den elektrischen Widerstand eines Leiters entsteht und zur Erwärmung des Leiters führt. Der ohmsche Widerstand wird in der Hauptsache durch das Material der Leiter bestimmt. Zweitens gibt es noch bei oben beschriebenen Anwendungen den induktiven Verlust. Dieser Verlust entsteht durch die Frequenz des Stroms, insbesondere dadurch, dass sich die zwei Phasen des Stroms bei steigender Frequenz gegenseitig negativ beeinflussen ("den Strom verdrängen").The most important requirement for current-carrying cables in this area is a throughput without loss of power. Here are two types of loss to distinguish, since you can neglect capacitive losses. First, this is the ohmic loss. This is the loss of power due to the electrical resistance of a conductor and leads to heating of the conductor. The ohmic resistance is determined mainly by the material of the conductors. Second, there are still inductive losses in applications described above. This loss is due to the frequency of the current, in particular the fact that the two phases of the current mutually negatively influence ("displace the current") with increasing frequency.
Aufgrund der hohen Frequenzen, die im Bereich der induktiven Erwärmung benötigt werden, kommt diesem Effekt im Bereich der industriellen induktiven Erwärmung eine besondere Bedeutung zu. Der Grund für diese Leistungsverluste ist der sogenannte Skin-Effekt, der dafür sorgt, dass bei steigender Frequenz der Strom den Leiter weniger stark durchdringt bzw. im Querschnitt betrachtet nur an der Oberfläche des Leiters fließt. Somit wird nur noch ein geringer Teil des Leiterquerschnitts zur Stromdurchleitung verwendet. Folge ist, dass eine große Strommenge durch einen sehr kleinen Querschnitt fließt. Es kommt zu erhöhter Temperaturentwicklung bis hin zur Zerstörung der Leiter. Dies erhöht wiederum die Anforderungen an Leiter für hochfrequente Ströme.Due to the high frequencies that are needed in the field of inductive heating, this effect in the field of industrial inductive heating is of particular importance. The reason for these power losses is the so-called skin effect, which ensures that, as the frequency increases, the current flows less strongly through the conductor or, viewed in cross-section, only flows on the surface of the conductor. Thus, only a small part of the conductor cross-section is used for power transmission. The consequence is that a large amount of electricity flows through a very small cross-section. It comes to increased temperature development up to the destruction of the ladder. This in turn increases the demands on conductors for high frequency currents.
Bei dem Koaxialkabel 1 nach
Der Hohlraum 2 wird aus elektrotechnischen Gründen nicht benötigt, da er vom Strom nicht durchdrungen wird. Er dient jedoch als Kühlwasserleitung und sorgt somit für einen effizienteren Wärmeabtransport. Der innere Hohlraum 1 und der Ringraum, in dem die Seilbünde 4a des Innenleiters liegen, bilden gemeinsam eine innere Kühlwasserkammer 9.The
In der Abfolge des Schichtaufbaus weiter radial außen liegend, folgt die elastische Isolationsschicht 5, die hier einen inneren Kühlschlauch 5 und eine radial außen auf den Kühlschlauch 5 aufgebrachte Schicht 6 umfasst. Der Kühlschlauch 5 umgibt den Innenleiter 4 ringförmig und begrenzt die innere Kühlwasserkammer 9 nach außen hin. Als nächstes folgt der zweite Leiter 7, nachfolgend Außenleiter 7 genannt, der aus einer Vielzahl kreisförmig angeordneter Bündel 7a besteht, welche wiederum aus einer Vielzahl einzelner Drähte gebildet sind. Die Bündel 7a des zweiten Leiters 7 können gleich zu denjenigen des ersten Leiters 4 gebildet sein, sodass auch hier von Kupferdrähten und Kupferseilbündeln 7a gesprochen werden kann.In the sequence of the layer structure further radially outward, follows the elastic insulating
Der Außenleiter 7 liegt in einer äußeren Kühlwasserkammer 10 in Form eines Ringraums ein. Ein äußerer Kühlschlauch 8 begrenzt die äußere Kühlwasserkammer 10 radial nach außen. Dieser bildet die äußerste Schicht des Koaxialkabels 1. Er isoliert das Kabel folglich elektrisch und schützt vor mechanischer und chemischer Einwirkung. Die Isolationsschicht, d.h. der innere Kühlschlauch 5 samt seiner außen aufgebrachten Schicht, erfüllen die Aufgabe eines Dielektrikums und trennen die beiden Stromphasen im zweiten Leiter 7 und ersten Leiter 4 voneinander. Darüber hinaus trennen sie die beiden Kühlwasserkammern 9, 10 von einander.The
Sowohl die innere Kühlwasserkammer 9, d.h. der innere Hohlraum 2 samt dem Raum um den Innenleiter 4, als auch die äußere Kühlwasserkammer 10, d.h. der Raum um den Außenleiter 7 sind kühlwasserdurchströmt, um die auf Grund der hohen Stromstärke, der hohen Frequenz und dem hierin begründeten Skin-Effekt entstehende Hitze ableiten zu können. Diese Kühlfähigkeit ist auch ein entscheidender Faktor für die Leistungseffizienz eines solchen Kabels 1. Denn je mehr Hitze abgeleitet werden kann, desto mehr Strom kann durch ein solches Kabel 1 geleitet werden.Both the inner
Ein wichtiger, die Tragfähigkeit des Kabels 1 begrenzender Faktor, ist der Skin-Effekt. Er sorgt dafür, dass die beiden Leiter 4, 7 nur oberflächlich durchströmt werden und zwar wegen der elektromagnetischen Wechselwirkung zwischen den beiden Leitern 4, 7 der äußere Teil des Innenleiters 4 und der innere Teil des Außenleiters 7, was in
Beispielsweise besitzen die Kabel 1 induktive Verluste, die heute durchschnittlich bei etwa 10 % Spannungsabfall liegen (bezogen auf die üblichen eingesetzten Längen). Dies liegt zum einen am Skin-Effekt, der stets vorhanden ist, d.h. es wird nur ein relativ kleiner Anteil der tatsächlichen Leiterquerschnitte für die Durchleitung von Strom verwendet. Es wird geschätzt, dass dieser Anteil heute im relevanten Frequenzband im Durchschnitt nur bei ca. 20% liegt. Umgekehrt bedeutet dies, dass fast 80% des Kabelquerschnitts tatsächlich gar nicht für den Stromfluss verwendet wird. Zum anderen ist eine zu geringe Isolierung Schuld. Denn aufgrund von wenig hochohmig isolierenden Gewebeeinlagen in den zur Isolation genutzten Kühlschläuchen 5, 8 müssen weite Abstände zwischen dem Innenleiter 4 und dem Außenleiter 7 gewählt werden, um Überschläge zu verhindern. Würden die beiden Leiter 4, 7 aber näher zusammen liegen, würden sich die vom jeweiligen Leiter 4, 7 erzeugten elektromagnetischen Felder mehr auslöschen, so dass weniger Energie in diese Felder fließt. Für eine maximale Leitungseffizienz wäre folglich ein minimaler Abstand erforderlich.For example, the cables have 1 inductive losses, which today average about 10% voltage drop (based on the usual lengths used). This is partly due to the skin effect, which is always present, ie it is only a relatively small proportion of the actual conductor cross-sections used for the passage of electricity. It is estimated that this proportion is on average only around 20% in the relevant frequency band today. Conversely, this means that almost 80% of the cable cross section is actually not used for the current flow. On the other hand, too little insulation is to blame. Because due to little high-impedance insulating fabric inserts in the cooling hoses used for the
Bei einem Beispielkabel mit einem Durchmesser von 80 mm, einer Länge von 15 m, einer Frequenz von 5 kHz, bei 40°C, einer Eingansstromstärke von 4700 A und einer Eingangsspannung von 1.000 V beträgt der Spannungsabfall aufgrund des induktiven Verlustes ca. 79 V und der aufgrund des ohmschen Widerstandes ca. 13V.For a sample cable with a diameter of 80 mm, a length of 15 m, a frequency of 5 kHz, at 40 ° C, an input current of 4700 A and an input voltage of 1000 V, the voltage drop due to the inductive loss is about 79 V and due to the ohmic resistance about 13V.
Das erfindungsgemäße Koaxialkabel 1 bildet das Koaxialkabel gemäß
Zum einen ist eine hohe mechanische Flexibilität der elektrischen Leiter 4, 7 gegeben, da die sich regelmäßig kreuzenden Bündel 4a, 7a eines Leiters 4, 7 gegeneinander beweglich sind. Dabei ist besonders hervorzuheben, dass sie sich an jede Biegelage des Koaxialkabels 1 faltenfrei anpassen. Im Gegensatz zu herkömmlichen Koaxialkabeln 1 nach
Elektrotechnisch ist das Geflecht 12 von besonderer Bedeutung. Denn von der Gesamtheit und Gesamtzahl der Bündel 4a, 7a verlaufen die eine Hälfte der Bündel 4a, 7a schraubenförmig im Uhrzeigersinn um die Längsachse des Koaxialkabels 1, die andere Hälfte der Bündel 4a, 7a schraubenförmig gegen den Uhrzeigersinn um die Längsachse, so dass zwischen den sich kreuzenden Bündeln 4a, 7a ein Flechtwinkel liegt, der im Fall der Ausführungsvariante in
Die einzelnen Bündel 4a, 7a sind nicht gesondert ummantelt. Dies hat zum Vorteil, dass sie in ihrer Querschnittsform nicht festgelegt sind. So sind die Einzeldrähte im Querschnitt der Bündel 4a, 7a betrachtet nicht kreisrund angeordnet sondern annähernd oval. D.h. dass die Bündel 4a, 7a sind eher flach ausgebildet, was eine Wirkung des axialen Zuges am Koaxialkabel bzw. an dem jeweiligen Geflecht 12 ist. Hierdurch liegen die Bündel 4a, 7a dicht aneinander, so dass keine offenen Maschen bestehen. Das Geflecht 12 bewirkt insgesamt ein absolut dichtes elektromagnetisches Feld mit geringer Streuwirkung, was ebenfalls die induktiven Verluste des Koaxialkabels 1 reduziert.The
Schließlich ist räumlich noch zu berücksichtigen, dass die Geflechte 12 zu einem lokal höheren Füllgrad in dem jeweiligen Ringraum des Koaxialkabels 1 führen, in dem der erste bzw. zweite Leiter 4, 7 liegt, weil der Querschnitt der Bündel 4a, 7a auf den Umfang des jeweiligen Leiters 4, 7 verteilt ist. Dies kann man sich leicht anhand
Gegenüber einer solchen Anordnung sind die einzelnen Einzeldrähte der Bündel 4a, 7a des ersten und zweitens Leiters 4, 7 jeweils homogen auf den den entsprechenden elektrischen Leiter 4, 7 tragenden Ring im Querschnitt des Koaxialkabels 1 verteilt, so dass nahezu vollumfänglich die gesamte radiale Dicke des jeweiligen Ringraums mit den Einzeldrähten ausgefüllt ist. Dies bewirkt wiederum, dass die radiale Dicke des jeweiligen Ringraums mit geflochtenen Bündeln 4a, 7a gemäß
Das Geflecht 12 aus Bündeln 4a, 7a des ersten und/ oder zweiten elektrischen Leiters 4, 7 führt zudem zu einer Reduzierung des Skin-Effekts und folglich zu einer Erhöhung der stromdurchflossenen Querschnittsfläche, so dass das Koaxialkabel 1 mehr Strom/ Leistung zum Verbraucher 11 führen kann, als vergleichbare Kabel nach dem Stand der Technik. Dies lässt sich damit erklären, dass bei dem Geflecht 12 der Abstand jedes Bündels 4a, 7a von der Achse des Koaxialkabels 1 in radialer Richtung betrachtet annähernd sinusförmig variiert. Wenn ein Bündel 4a, 7a ein anderes Bündel überkreuzt, liegt es radial weiter außen, wenn es ein anderes Bündel unterkreuzt, liegt es radial weiter innen. Damit verändert sich auch der Abstand jedes Bündels 4a, 7a des einen elektrischen Leiters 4, 5 in Erstreckungsrichtung relativ gesehen zum anderen elektrischen Leiter 7, 4.The
Wie bezüglich
Wie man anhand von
Die Isolation der Einzeldrähte in den einzelnen Bündeln 4a, 7a gegeneinander erfolgt durch Elektrolack, beispielsweise Polyethylen, und hat besondere Bedeutung für die Reduzierung des Skin-Effekt. Denn durch die Isolation wirken die Einzeldrähte nicht wie ein einziger elektrischer Leiter, in dem der Strom "überall" hin kann. Jedes Bündel ist vielmehr die Summe einzelner Drähte, aus denen ein Strom -abgesehen vom Axialende- nicht herausfließen kann. Dies führt dazu, dass sich der Strom bei den hohen Frequenzen nicht an der Oberfläche eines Bündels "sammeln" kann, sondern allenfalls an der Oberfläche eines Drahtes. Insgesamt wird dadurch der effektive vom Strom genutzte Querschnitt der elektrischen Leiter 4, 7 erhöht.The isolation of the individual wires in the
Bei dem erfindungsgemäßen Koaxialkabel 1 ist die Isolationsschicht 5, 6 zwischen dem ersten elektrischen Leiter 4 und dem zweiten elektrischen Leiter 7 durch einen Schlauch aus EPDM (Ethylen-Propylen-Dien-Kautschuk) hergestellt. Dieses Material ist diffusionsdicht und elektrisch gut isolierend, sodass der radiale Abstand der beiden elektrischen Leiter 4, 7 kleiner ist als beim Stand der Technik gemäß
Schematisch sind in
Ein weiterer Unterschied der Variante in
Mit dem erfindungsgemäßen Hochleistungskoaxialkabel ist erstmals eine weiterführende Skin-Effekt-Reduzierung integriert zur Steigerung der Effizienz für industrielle Anwendungen. Dabei werden die induktiven Verluste um bis zu 50% reduziert und der nutzbare Leiterquerschnitt im relevanten Frequenzband von ca. 20% auf bis zu 35% gesteigert.With the high-performance coaxial cable according to the invention, a further skin-effect reduction is integrated for the first time for increasing the efficiency for industrial applications. The inductive losses are reduced by up to 50% and the usable conductor cross section in the relevant frequency band is increased from approx. 20% to up to 35%.
Von besonderem Vorteil ist der modulare Aufbau des Koaxialkabels 1, da es mehrere Möglichkeiten gibt, eine entsprechende Anpassung des Leiterquerschnitts an eine bestimmte Verwendung vorzunehmen. So ist der Querschnitt der elektrischen Leiter in erster Linie dadurch definiert,
- wie viele Bündel in Umfangsrichtung vorhanden sind, wodurch u.a. der Kabeldurchmesser beeinflusst wird,
- wie viele Drähte jedes Bündel hat, wodurch letztendlich der Durchmesser der einzelnen Bündel beeinflusst wird,
- welchen Durchmesser die Einzeldrähte haben, und
- wie viele Geflechtlagen übereinander liegen.
- how many bundles are present in the circumferential direction, which influences, among other things, the cable diameter,
- how many wires each bundle has, which ultimately affects the diameter of each bundle,
- which diameter the individual wires have, and
- how many layers of mesh lie on top of each other.
Durch entsprechende Wahl dieser Parameter kann das erfindungsgemäße Koaxialkabel an jede Anwendung angepasst werden, so dass weder eine teure Überdimensionierung noch eine risikobehaftete Unterdimensionierung erfolgen kann.By appropriate choice of these parameters, the coaxial cable according to the invention can be adapted to any application, so that neither an expensive over-sizing nor a risky undersizing can take place.
- 1 Koaxialkabel1 coaxial cable
- 2 Innerer Hohlraum2 Inner cavity
- 3 Innenspirale3 inner spiral
- 4 Innenleiter4 inner conductors
- 4a Seilbündel des Innenleiters4a rope bundle of the inner conductor
- 4.1 inneres Geflecht des Innenleiters4.1 inner mesh of the inner conductor
- 4.2 äußeres Geflecht des Innenleiters4.2 outer braid of the inner conductor
- 5 Innerer Kühlschlauch5 inner cooling hose
- 6 Isolationsschicht6 insulation layer
- 7 Außenleiter7 outer conductor
- 7a Seilbündel des Außenleiters7a rope bundle of the outer conductor
- 7.1 inneres Geflecht des Außenleiters7.1 Inner braid of the outer conductor
- 7.2 äußeres Geflecht des Außenleiters7.2 outer braid of the outer conductor
- 8 Äußerer Kühlschlauch8 Outer cooling hose
- 9 Innere Kühlwasserkammer9 inside cooling water chamber
- 10 Äußere Kühlwasserkammer10 Outer cooling water chamber
- 11 Spule, Verbraucher, Induktionsofen11 coil, consumer, induction furnace
- 12 Geflecht12 braid
- 13 Anschlusskopf13 connection head
Claims (9)
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