AU2019101819A4 - Z-shaped sealed cable conductor of high-voltage direct-current submarine cable and design method thereof - Google Patents
Z-shaped sealed cable conductor of high-voltage direct-current submarine cable and design method thereof Download PDFInfo
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/08—Several wires or the like stranded in the form of a rope
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/0009—Details relating to the conductive cores
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/14—Submarine cables
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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
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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
- H01B9/006—Constructional features relating to the conductors
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Abstract
A Z-shaped sealed cable conductor of a high-voltage direct-current submarine cable and a
design method thereof. The cable conductor comprises a center wire and a plurality of
single wires, the plurality of single wires are stranded on an outer wall of the center wire
in a layer-by-layer overlapping manner, the single wires are Z-shaped single wires, every
two adjacent Z-shaped single wires are mutually stacked and matched end to end, the
plurality of Z-shaped single wires are spirally and tightly wound together by means of a
stranding process, and chamfers are provided at corners of the Z-shaped single wires. The
Z-shaped sealed cable conductor of the high-voltage direct-current submarine cable uses
a Z-shaped single-wire circular pressing structure, the problem of high pressing difficulty
of a frame stranding machine is effectively solved, a conductor pressing coefficient is
higher than that of a circular single-wire circular pressing structure, and the requirement
for the water blocking performance of the conductor during high-sea laying of the
high-voltage direct-current submarine cable can be satisfied.
23
1/5
FIG. 1
FIG.2
Description
1/5
FIG. 1
FIG.2
[0001] The disclosure relates to the field of power cables, and more particularly to a Z-shaped sealed conductor of a high voltage direct current (HVDC) submarine cable and a design method thereof.
[0002] With the increasing depletion of offshore wind power resources, the rapid development of open-sea wind power and global energy interconnection, HVC submarine cables are widely studied by large submarine cable manufacturers at home and abroad because of their advantages such as high transmission power, low loss and long transmission distance in the process of AC power transmission regardless of the skin effect and ortho-effect on conductors.
[0003] Around compacted structure of round single conductors is usually adopted in the design of the conductor for HVDC submarine cables. However, a too large designed cross section of the conductor will cause a too large diameter of each round single conductor due to the limitations imposed by a frame strander, resulting in poor compaction effect or great difficulty in the drawing process of the frame strander.
[0004] At present, the cross section of the round compacted submarine cable conductor with the round single conductors is at most 1800 mm 2 in various projects. If the designed cross section of the conductor is larger, the round compacted structure of the round single conductors no longer meets the design requirements using existing equipment and also hardly meets the water-proof requirements of conductors laid in deeper sea areas.
[0005] One objective of the disclosure is to provide a Z-shaped sealed conductor of an HVDC submarine cable and a design method thereof, aiming to solve the problem that it is very difficult for a frame strander to compact conductors in the related art.
[0006] The disclosure provides a Z-shaped sealed conductor of an HVDC submarine cable, comprising a central conductor and a plurality of single conductors stranded on an outer wall of the central conductor in a layer-by-layer overlapping manner;
[0007] the plurality of single conductors is Z-shaped single conductors, and every two adjacent Z-shaped single conductors are overlapped and fitted to each other end to end so that several ones are spirally and closely stranded together by a stranding process; and
[0008] chamfers are provided at corners of each Z-shaped single conductor.
[0009] In a class of this embodiment, a type of the central conductor comprises a round compacted structure and a solid copper bar.
[0010] A design method of the Z-shaped sealed conductor of the HVDC submarine cable comprises:
[0011] 1) calculating an outer diameter DA of the conductor;
[0012] 2) calculating a correction angle 6;
[0013] 3) calculating a central angle Oo between extension lines on both sides of the Z-shaped single conductor;
[0014] 4) calculating a filling factor t of the Z-shaped single conductor;
[0015] 5) making a design for drawing the Z-shaped single conductor; and
[0016] 6) optimizing the Z-shaped single conductor.
[0017] Ina class of this embodiment, the outer diameter DA of the conductor in 1) is calculated by a formula (1),
DA-= [4xS
(1);
[0018] where S is a cross-sectional area of the conductor and i is a filling factor of the conductor. The filling factor i is designed according to the previous production experience.
[0019] Ina class of this embodiment, the correction angle 6 in 2) is calculated by a formula (2),
tan o = 7c*Dn L (2);
[0020] where Dn is an outer diameter of each layer and L is a pitch of each layer.
[0021] In a class of this embodiment, in 3), the central angleOo between the extension lines on both sides of the Z-shaped single conductor is calculated by substituting the correction angle 6 calculated in 2) into a formula (3),
00 = 360-6 +01 n (3);
[0022] where n is the actual number of the Z-shaped single conductor in each layer, 01 is an overlap angle on one side of the Z-shaped single conductor, which is an angle between overlapped portions of the adjacent Z-shaped single conductors.
[0023] In a class of this embodiment, in 4), a lower half of the Z-shaped single conductor rotates to left by 01 around a center of an outer arc R1 so that the Z-shaped single conductor forms a sector, an angle k and an angle p are calculated by formulas (4) and (5) and then converted into radians a and P by formulas (6) and (7),
r tanL= R1+r (4)
r tanp= R 2 -r (5);
a X/180°*z (6);
S, p/180°* (7);
[0024] where R1 is a radius of the outer arc, R 2 is a radius of an inner arc, r is a radius of the chamfer, , is an angle between a left side at a lower end of the Z-shaped single conductor and a line connecting a center of the chamfer r at a lower left end to the center of the outer arc R1, p is an angle between a left side at an upper end of the Z-shaped single conductor and a line connecting the center of the chamfer r at an upper left end to a center of the outer arc R2, andX and p are both approximate values.
[0025] In a class of this embodiment, in 4), the actual filling factor t of the Z-shaped single conductor is calculated by substituting the radians a and P into a formula (8), (flR2 - aR')-r(R, -R,) r 2(2+a-/3-7)
(R, )T ( -R) n n (8);
[0026] when t > l, the Z-shaped sealed conductor designed by this method meets the water-proof requirements of the conductor, while when t < 1, the Z-shaped sealed conductor designed by this method fails to meet the water-proof requirements of the conductor.
[0027] In a class of this embodiment, a round bar for drawing the Z-shaped single conductor is designed in 5), and main characteristic dimensions of the Z-shaped single conductor comprises the angle Oo corresponding to the Z-shaped single conductor, a straight line length W corresponding to the outer arc of a smallest sector holding the Z-shaped single conductor, a diagonal length V of a cross section of the Z-shaped single conductor, the radius difference H between inner and outer circles R1 and R2 where sectional rings of the Z-shaped single conductor are located, the cross-sectional area S of the Z-shaped single conductor, an overlap value d of the adjacent Z-shaped single conductors and the chamfer r of the Z-shaped single conductor, where Oo is determined by the number of frames of the frame strander on each layer, the angle 01 is equal to the angle 02 and ranges from 1/4 Ooto 1/6 Oo, the overlap value d is an arc length of the angle 01 on a central circle R 3 which is an arc radius of the central circle of the Z-shaped single conductor, where R 3 = R 1+H/2; the diameter D of a copper bar for drawing is the diameter of the smallest round single conductor holding the cross section of the Z-shaped copper single conductor and is determined according to values W and V; when W/V > 1, D = W; when W/V < 1, D = V.
[0028] In a class of this embodiment, the designed Z-shaped single conductor is optimized in 6), and the sizes of the four chamfers r connected to the arc R 3 are adjusted to R, where R = H/2, and an angle corresponding to the outer arc of the Z-shaped single conductor is 03.
[0029] The following advantages are associated with the Z-shaped sealed conductor of an HVDC submarine cable of the disclosure. The Z-shaped sealed conductor of the HVDC submarine cable of the disclosure adopts a round compacted structure of Z-shaped single conductors, which effectively solves the problem that it is very difficult for a frame strander to compact conductors. Moreover, the compaction factor of the conductor is higher than that of the conductor with the round compacted structure of the round single conductors, which can meet the water-proof requirements of the conductor when the HVDC submarine cable is laid in open seas.
[0030] FIG. 1 is a sectional view of a Z-shaped sealed conductor of an HVDC submarine cable comprising a round compacted structure of 6-layer Z-shaped copper conductors as a central conductor according to one embodiment of the disclosure;
[0031] FIG. 2 is a sectional view of a Z-shaped sealed conductor of an HVDC submarine cable comprising a round copper bar structure of 7-layer Z-shaped copper conductors as a central conductor according to one embodiment of the disclosure;
[0032] FIG. 3 is a sectional view of Z-shaped copper single conductors of a Z-shaped sealed conductor of an HVDC submarine cable according to one embodiment of the disclosure;
[0033] FIG. 4 is a schematic diagram of positions of an angle k and an angle p of a plurality of Z-shaped copper single conductors of a Z-shaped sealed conductor of an HVDC submarine cable according to one embodiment of the disclosure;
[0034] FIG. 5 is a schematic diagram showing the effect of an inclination angle 6 on a cross section of a Z-shaped single conductor in a Z-shaped sealed conductor of a HVDC submarine cable according to one embodiment of the disclosure;
[0035] FIG. 6 is a sectional view of an optimized conductor of around copper bar structure comprising 7-layer Z-shaped single conductors of a Z-shaped sealed conductor of an HVDC submarine cable according to one embodiment of the disclosure; and
[0036] FIG. 7 is a sectional view of optimized Z-shaped copper single conductors of a Z-shaped sealed conductor of an HVDC submarine cable according to one embodiment of the disclosure.
[0037] To further illustrate, embodiments detailing a Z-shaped sealed conductor of an HVDC submarine cable are described below. It should be noted that the following embodiments are intended to describe and not to limit the disclosure.
[0038] Referring to FIGS. I to 7, a Z-shaped sealed conductor of an HVDC submarine cable is provided, comprising a central conductor, and a plurality of single conductors which are stranded on the outer wall of the central conductor in a layer-by-layer overlapping manner. The single conductors are Z-shaped single conductors, and every two adjacent Z-shaped single conductors are overlapped and fitted to each other end to end so that several ones are spirally and closely stranded together by a stranding process. A round compacted structure of the Z-shaped single conductors is adopted, which effectively solves the problem that it is very difficult for a frame strander to compact conductors. Moreover, the compaction factor of the conductor is higher than that of the conductor with the round compacted structure of round single conductors, which can effectively meet the longitudinal water-proof requirements of the conductors when the HVDC submarine cable is laid in open seas.
[0039] If a solid copper bar (a diameter of 63.5 mm) with a large cross section is adopted, a drawing machine no longer meets the drawing and annealing requirements or produces such a large conductor. A solid copper bar of this thickness is not easy to bend, but the cables are inevitably required to be bent in the process of production, transportation and laying, so the conductor formed by stranding a plurality of copper single conductors (copper conductors) is easier to bend, and the cables with this conductor are easy to be produced, transported and laid because of a small bending radius.
[0040] Chamfers allowing a closer connection between the two connected Z-shaped single conductors are provided at corners of each Z-shaped single conductor.
[0041] A design method of the Z-shaped sealed conductor of the HVDC submarine cable comprises the following steps 1) to 6).
[0042] In 1), an outer diameter DA of the conductor is calculated by a formula (1),
DA 4:x[:S (1);
[0043] where S which is 3000 mm2 is a cross-sectional area of the conductor, and i is a filling factor of the conductor. The value of i is designed to be 0.96 according to the previous production experience. It is calculated that DA = 63.08, which is 63.5 mm after correction.
[0044] In 2), a correction angle 6 is calculated by a formula (2),
tano = 7c*Dn L (2);
[0045] where Dn is an outer diameter of each layer and L is the pitch of each layer.
[0046] In 3), a central angle Oo between extension lines on both sides of the Z-shaped single conductor is calculated. The central angle Oo between the extension lines on both sides of the Z-shaped single conductor is calculated by substituting the correction angle 6 calculated in 2) into a formula (3),
00 = 360- 1 n (3);
[0047] where n is the actual number of the Z-shaped single conductor in each layer, 01 is an overlap angle on one side of the Z-shaped single conductor, which is an angle between overlapped portions of the adjacent Z-shaped single conductors.
[0048] In 4), the filling factor of the Z-shaped single conductor is calculated. A lower half of the Z-shaped single conductor rotates to left by 01 around a center of an outer arc Ri so that the Z-shaped single conductor forms a sector, an angle X and an angle p are calculated by formulas (4) and (5) and then converted into radians a and P by formulas (6) and (7),
tan= R 1 +r (4);
r tanp= R2 -r (5);
a = /180°*z (6);
fp = /180°*z (7)
[0049] where R 1 is a radius of the outer arc, R 2 is a radius of an inner arc, r is a radius of the chamfer, k is an angle between a left side at a lower end of the Z-shaped single conductor and a line connecting a center of the chamfer r at a lower left end to the center of the outer arc R1, p is an angle between a left side at an upper end of the Z-shaped single conductor and a line connecting the center of the chamfer r at an upper left end to a center of the outer arc R2, and k and p are both approximate values.
[0050] The actual filling factor t of the Z-shaped single conductor is calculated by substituting the radians a and P into a formula (8), (8R -aR )-r(R, - R,) r 2(2+a -6-r) (R2 - R)I -(R2 - R 2)r nn (8);
[0051] when t > i, the Z-shaped sealed conductor designed by this method meets the water-proof requirements of the conductor, while when t < i, the Z-shaped sealed conductor designed by this method fails to meet the water-proof requirements of the conductor.
[0052] In 5), a design is made for drawing the Z-shaped single conductor. Main characteristic dimensions of the Z-shaped single conductor comprises the angleOo corresponding to the Z-shaped single conductor, a straight line length W corresponding to the outer arc of a smallest sector holding the Z-shaped single conductor, a diagonal length V of a cross section of the Z-shaped single conductor, the radius difference H between inner and outer circles R1 and R 2 where sectional rings of the Z-shaped single conductor are located, the cross-sectional area S of the Z-shaped single conductor, an overlap value d of the adjacent Z-shaped single conductors and the chamfer r of the Z-shaped single conductor, where Oois determined by the number of frames of the frame strander on each layer, the angle 01 is equal to the angle 02 and ranges from 1/4Oo to 1/6Oo, the overlap value d is the arc length of the angle 01 on a central circle R3 which is an arc radius of the central circle of the Z-shaped single conductor, where R3 = RI+H/2, the diameter D of a copper bar for drawing is the diameter of the smallest round single conductor holding the cross section of the Z-shaped copper single conductor and is determined according to values W and V. When W/V > 1, D = W. When W/V < 1, D = V.
[0053] In 6), the structure of the Z-shaped single conductor is optimized, and the sizes of the four chamfers connected to the arc R 3 are adjusted to R, where R = H/2, and an angle corresponding to the outer arc of the Z-shaped single conductor is 03.
[0054] There are two types of the central conductors, i.e., a round compacted structure and a solid copper bar. 6-layer round compacted conductor structure is designed depending on whether the central conductor is the round compacted structure or the solid copper bar. The Z-shaped copper single conductor taking the round compacted structure as the central conductor is formed by stranding one layer of the round compacted structure and five layers of the Z-shaped single conductors, and the Z-shaped copper single conductor taking the solid copper bar as the central conductor is formed by stranding one layer of the solid copper bar and five layers of the Z-shaped single conductors.
[0055] Round compacted conductor structure with 6-layer Z-shaped conductors
[0056] Design scheme of the Z-shaped copper conductors using a 91-frame strander
[0057] There are two design schemes a and b depending on the diameters of the solid copper bar used as the central conductor, and three design schemes c, d and e depending on the sizes of the round compacted structure used as the central conductor.
[0058] As at most 1, 6, 12, 18, 24 and 30 frames can be provided on each layer by the 91-frame strander, there may be 1, 6, 12, 18, 24 and 30 frames actually used, in order to minimize the cross-sectional area of each Z-shaped single conductor.
[0059] As can be seen from Table 1, the Z-shaped single conductor has a fixed angle, and the cross-sectional areas of all Z-shaped single conductors on each layer are controlled to be basically the same by adjusting the height of each Z-shaped single conductor, so as to minimize the diameter D of each layer.
[0060] In the schemes a to e, with the increase in the diameter of the central conductor, the diameter D in 24 and 30 frames is basically unchanged, but the outer diameter of the Z-shaped single conductor in 6 and 12 frames increases. Although there is a little difference between the cross-sectional areas of the Z-shaped single conductors, the diameter D of the required copper bar increases, which makes it more difficult for continuous drawing and annealing equipment to produce the Z-shaped single conductors, and the width-to-depth ratio W/H of the Z-shaped single conductor increases, which makes it more difficult to strand the Z-shaped single conductors.
[0061] By comparing the design schemes of taking the solid copper bar and the round compact structure as the central conductor of the Z-shaped single conductors, as the central conductor which is the solid copper bar is small in size, the Z-shaped single conductors are more evenly and reasonably distributed on each layer in areas, and the diameter D of the smallest round single conductor holding the cross section of the Z-shaped single conductor is smaller, which is easier to produce the Z-shaped single conductors in 6 frames. Therefore, the optimal design scheme is to take the solid copper bar with a diameter of 6mm as the central conductor of the Z-shaped copper conductors, and the stranded conductors can be produced at one time with a higher production efficiency.
Table 1 Design Scheme of Round Compacted Conductor Structure with 6-layer Z-Shaped Conductors Using 91-Frame Strander
Schemes 00/0 01/0 S/mm 2 H/mm W/mm V/mm D/mm / / 28.27 3.00 / /
/ 80.0 20.0 35.38 5.75 11.25 8.34 11.25 a.06 mm solid copper bar 40.0 10.0 35.00 5.75 9.92 9.21 9.92 25.0 5.0 34.87 5.75 8.77 8.99 8.99 18.0 3.0 34.81 5.75 8.14 8.80 8.80 14.4 2.4 34.77 5.75 7.96 8.82 8.82 / / 50.24 4.00 / /
/ 80.0 20.0 35.46 5.15 11.76 8.92 11.76 b.08 mm solid copper bar 40.0 10.0 35.43 5.65 10.12 9.36 10.12 25.0 5.0 34.76 5.65 8.85 9.01 9.01 18.0 3.0 34.43 5.65 8.17 8.77 8.77 14.4 2.4 34.23 5.65 7.96 8.76 8.76 / / 50.00 4.20 / /
/ / / 36.54 5.15 12.02 9.16 12.02 c.50 mm 2 80.0 20.0 35.63 5.60 10.23 9.44 10.23 40.0 10.0 34.70 5.60 8.90 9.03 9.03 25.0 5.0 34.23 5.60 8.18 8.76 8.76 18.0 3.0 33.95 5.60 7.96 8.74 8.74 / / 70.00 5.00 / /
/ / / 36.68 4.75 12.53 9.76 12.53 d.70 mm 2 80.0 20.0 36.00 5.50 10.43 9.59 10.43 40.0 10.0 34.56 5.50 8.98 9.06 9.06 25.0 5.0 33.84 5.50 8.21 8.74 8.74 18.0 3.0 33.41 5.50 7.96 8.69 8.69 / / 95.00 5.90 / / / / / 37.86 4.45 13.31 10.59 13.31 e.95 mm 2 80.0 20.0 36.49 5.35 10.74 9.83 10.74 40.0 10.0 34.32 5.35 9.11 9.12 9.12 25.0 5.0 33.23 5.35 8.26 8.71 8.71 18.0 3.0 32.58 5.35 7.96 8.62 8.62
[0062] Design scheme of the Z-shaped copper conductors using a 127-frame strander
[0063] As at most 1, 6, 12, 18, 24, 30 and 36 frames can be provided on each layer by the 127-frame strander, there may be 1, 6, 12, 18, 24, 30 and 36 frames actually used, in order to compare with those in the 91-frame strander.
[0064] In the case of designing the same height of each layer, more usable frames can be provided by the 127-frame strander than by the 91-frame strander. By comparing the schemes a, b, c, d and e in Table 1 and those in Table 2, in Table 2, when the corresponding angle 0 decreases, the cross-sectional area, the diameter D, the width W and the diagonal length S of each Z-shaped single conductor decrease accordingly, and the width-to-height ratio of the Z-shaped single conductor ranges from 1.3 to 1.7, which is more reasonable, indicating that the production scheme using the 127-frame strander is better.
[0065] By comparing the five schemes a, b, c, d and e in Table 2, there is a little difference between the area distribution of the Z-shaped single conductors taking the solid copper bar and the round compact structure as the central conductor. In both cases, the diameter D of the Z-shaped copper conductor is less than 8 mm, but the scheme of taking the solid copper bar as the central conductor has high production efficiency and is more suitable for factory production.
Table 2 Design Scheme of Round Compacted Conductor Structure with 6-layer Z-Shaped Conductors Using 127-Frame Strander Schemes 00/0 01/0 SK/mm H/mm W/mm V/mm D/mm / / 28.26 3.00 / /
/ 40.00 10.00 17.69 5.75 5.99 6.33 6.33 a.06 mm solid 26.67 6.67 23.33 5.75 6.69 7.35 7.35 copper bar 18.75 3.75 26.16 5.75 6.60 7.61 7.61 14.40 2.40 27.85 5.75 6.52 7.73 7.73 12.00 2.00 28.98 5.75 6.64 7.92 7.92 / / 50.24 4.00 / / /
40.00 10.00 17.73 5.15 6.26 6.21 6.26 b.08 mm solid 26.67 6.67 23.62 5.65 6.83 7.39 7.39 copper bar 18.75 3.75 26.07 5.65 6.66 7.60 7.60 14.40 2.40 27.54 5.65 6.54 7.69 7.69 12.00 2.00 28.52 5.65 6.64 7.85 7.85 / / 50.00 4.20 / / /
40.00 10.00 18.27 5.15 6.40 6.30 6.40 2 26.67 6.67 23.75 5.60 6.90 7.42 7.42 c.50mm 18.75 3.75 26.02 5.60 6.70 7.60 7.60 14.40 2.40 27.39 5.60 6.55 7.67 7.67 12.00 2.00 28.30 5.60 6.64 7.82 7.82 / / 70.00 5.00 / / /
40.00 10.00 18.34 4.75 6.67 6.34 6.34 2 26.67 6.67 24.00 5.50 7.03 7.47 7.47 d.70mm 18.75 3.75 25.92 5.50 6.76 7.59 7.59 14.40 2.40 27.07 5.50 6.58 7.63 7.63 12.00 2.00 27.84 5.50 6.64 7.77 7.77 e.95 mm 2 / / 95.00 5.90 / / /
40.00 10.00 18.93 4.45 7.08 6.55 7.08 26.67 6.67 24.32 5.35 7.24 7.55 7.55 18.75 3.75 25.74 5.35 6.86 7.58 7.58 14.40 2.40 26.58 5.35 6.62 7.57 7.57 12.00 2.00 27.15 5.35 6.64 7.68 7.68
[0066] Round compacted conductor structure with 7-layer Z-shaped conductors
[0067] In the round compacted conductor structure with 7-layer Z-shaped conductors using the 127-frame strander, there are 1, 6, 12, 18, 24, 30 and 36 frames actually used, and the dimensions of the conductor structure are shown in Table 3.
[0068] By comparing the five schemes a, b, c, d and e in Table 3, the cross-sectional area and the diameter D of the Z-shaped single conductor in 6 frames gradually increase, while the cross-sectional areas of the Z-shaped single conductor in other frames differ little, but the maximum diameter D also gradually increases, which makes it more difficult to produce the Z-shaped single conductors.
[0069] By comparing Table 3 and Table 2, the maximum diameter D of the schemes b, c, d and e in Table 3 is greater than that of the schemes in Table 2, and only the maximum diameter D of the scheme a in Table 3 is less than that of the scheme a in Table 2, so the scheme a in Table 3 is superior to the schemes b, c, d and e in Table 2.
[0070] At present, the diameter of the copper bar of the Z-shaped single conductor produced by a continuous drawing and annealing process is at most 8 mm, and that produced by an extrusion process is 12.9 mm or more, but the extrusion process has low production efficiency and thus hardly meets the production requirements of conductors with a large length. The continuous drawing and annealing process has high production efficiency and thus is suitable for the production of conductors with a large length. In addition, the central conductor which is the solid copper bar with the diameter of 6 mm facilitates one-time conductor stranding, so the optimal design scheme in which the Z-shaped copper conductor is designed with the solid copper bar with the diameter of 6 mm as the central conductor and the 7-layer structure.
Table 3 Design Scheme of Round Compacted Conductor Structure with 7-Layer Z-Shaped Conductors Using 127-Frame Strander
Schemes 00/0 01/0 S/mm2 H/mm W/mm V/mm D/mm / / 28.27 3.00 / /
/ 72.00 12.00 15.41 3.20 7.29 5.60 7.29 36.00 6.00 22.48 4.95 6.89 6.73 6.89 a.06 mm 25.00 5.00 24.67 5.15 7.06 7.38 7.38 copperbar 18.75 3.75 25.45 5.15 6.99 7.58 7.58 14.40 2.40 25.91 5.15 6.67 7.50 7.50 12.00 2.00 26.22 5.15 6.64 7.56 7.56 / / 28.26 4.00 / /
/ 72.00 12.00 20.29 3.40 8.70 6.84 8.70 36.00 6.00 23.05 4.55 7.39 6.98 7.39 b.08 mm 25.00 5.00 24.92 4.95 7.03 7.50 7.50 copper1bar 8.75 3.75 25.11 4.95 6.84 7.58 7.58 14.40 2.40 25.22 4.95 6.72 7.43 7.43 12.00 2.00 25.29 4.95 6.64 7.45 7.45 / / 50.00 4.20 / /
/ 72.00 12.00 21.81 3.50 9.05 7.15 9.05 36.00 6.00 21.86 4.25 7.39 6.89 7.39 c.50 mm2 25.00 5.00 24.92 4.95 7.32 7.50 7.50 18.75 3.75 25.11 4.95 7.12 7.58 7.58 14.40 2.40 25.22 4.95 6.72 7.43 7.43 12.00 2.00 25.29 4.95 6.64 7.45 7.45 / / 70.00 5.00 / / /
72.00 12.00 27.46 3.80 10.35 8.27 10.35 36.00 6.00 22.29 3.95 7.88 7.25 7.88 d.70 mm2 25.00 5.00 25.08 4.75 7.58 7.62 7.62 18.75 3.75 24.72 4.75 7.25 7.59 7.59 14.40 2.40 24.50 4.75 6.77 7.37 7.37 12.00 2.00 24.35 4.75 6.64 7.35 7.35 / / 95.00 5.80 / / /
72.00 12.00 30.27 4.10 10.70 8.53 10.70 36.00 6.00 24.98 4.25 8.25 7.63 8.25 e.95 mm2 25.00 5.00 25.13 4.60 7.77 7.73 7.77 18.75 3.75 24.39 4.60 7.35 7.61 7.61 14.40 2.40 23.94 4.60 6.81 7.32 7.32 12.00 2.00 23.64 4.60 6.64 7.27 7.27 / / 185.0 8.10 / / /
72.00 12.00 36.10 3.50 13.64 11.52 13.64 f.185 mm2 36.00 6.00 24.86 3.55 9.36 8.52 9.36 25.00 5.00 24.95 4.15 8.36 8.09 8.36 18.75 3.75 23.22 4.15 7.64 7.68 7.68
14.40 2.40 22.19 4.15 6.92 7.21 7.21 12.00 2.00 21.49 4.15 6.64 7.05 7.05
[0071] Taking the design scheme of taking the solid copper bar with the diameter of 6 mm as the central conductor and adopting the 7-layer Z-shaped single conductor structure of the 127-frame strander as an example, the designs schemes in Table 4 have different overlap angles 01. It can be seen that the smaller the overlap angle 01, the smaller the diameter D, the more favorable it is to produce Z-shaped single conductors by the continuous drawing and annealing process, and the more reasonable the width-to-height ratio of the Z-shaped single conductors in 6 frames is, but the smaller the overlap length d is, and the too small overlap length d makes against the mutual dependence between the adjacent Z-shaped single conductors.
[0072] The larger the overlap angle 01, the larger the diameter D, the more unreasonable the width-to-height ratio of the Z-shaped single conductors in 6 frames, and the larger the overlap length d, which is favorable to the mutual dependence of the adjacent Z-shaped single conductors. However, too large diameter D will obviously increase the production difficulty, so the lap angle 01 ranges from 1/4 Oo to 1/6 Oo, and an intermediate value of 1/50o can be adopted in this design scheme.
Table 4 Design Scheme of Conductor Structure Taking Solid Copper Bar with Diameter of 6 mm as Central Conductor
Schemes 0/0 01/0 H/mm S/mm 2 W/mm d/mm W/H / / 3.00 28.27 / / /
80.00 20.00 3.20 15.41 7.97 1.60 2.50 40.00 10.00 4.95 22.48 7.63 1.51 1.54 a 26.67 6.67 5.15 24.67 7.52 1.60 1.46 20.00 5.00 5.15 25.45 7.45 1.42 1.45 16.00 4.00 5.15 25.91 7.40 1.50 1.44 13.33 3.33 5.15 26.22 7.37 1.55 1.43 / / 3.00 28.27 / / /
75.00 15.00 3.20 15.41 7.55 1.20 2.36 37.50 7.50 4.95 22.48 7.17 1.14 1.45 b 25.00 5.00 5.15 24.67 7.06 1.20 1.37 18.75 3.75 5.15 25.45 6.99 1.07 1.36 15.00 3.00 5.15 25.91 6.94 1.12 1.35 12.50 2.50 5.15 26.22 6.91 1.16 1.34
/ / 3.00 28.27 / /
/ 72.00 12.00 3.20 15.41 7.29 0.96 2.28 36.00 6.00 4.95 22.48 6.89 0.91 1.39 c 24.00 4.00 5.15 24.67 6.78 0.96 1.32 18.00 3.00 5.15 25.45 6.71 0.85 1.30 14.40 2.40 5.15 25.91 6.67 0.90 1.29 12.00 2.00 5.15 26.22 6.64 0.93 1.29
[0073] Considering the effect of the process pitch on the size of the Z-shaped single conductor and taking the design scheme of taking the solid copper bar with the diameter of 6 mm as the central conductor and adopting the 7-layer Z-shaped single conductor structure of the 127-frame strander as an example, the effect of the pitch on the inclination angle 6 of the single conductor is shown in Table 5.
Table 5 Effect of Pitch on Inclination Angle 6 of Single Conductor
First layer Sayend Third layer Foyh Fifth layer Sixth layer L/mm 240 350 420 715 870 940 R2/mm 6.2 11.15 16.3 21.45 26.6 31.75 6/0 4.64 5.78 6.99 5.40 5.49 6.06 00/0 74.22 37.02 24.61 18.53 14.82 12.33
[0074] The Z-shaped single conductor needs to be chamfered in the actual drawing and stranding production processes, which meets the actual production needs. However, the existence of the chamfer will cause gaps in the Z-shaped single conductor structure in the design scheme and reduce the longitudinal water-proof capability of the conductor, so it is necessary to chamfer properly, which can meet the water-proof requirements of the conductor and also meet the needs of mold machining and actual production.
[0075] Taking the design scheme of taking the solid copper bar with the diameter of 6 mm as the central conductor and adopting the 7-layer Z-shaped single conductor structure of the 127-frame strander as an example, the chamfer radius of the Z-shaped single conductor is 0.3 mm, which meets the requirements of mold machining capacity and actual production, and the filling factor t calculated in 4) is greater than 0.96, which meets the water-proof requirements of the conductor.
[0076] Since there is some difficulty in machining the chamfer on an inner side of the central conductor, the Z-shaped single conductor structure can be further optimized. After optimization, the main characteristic values of the Z-shaped single conductor are the angle 03 corresponding to the outer arc, the chamfer R with a radius of H/2, and the chamfer r. This structure can reduce the cross-sectional area of the Z-shaped single conductor and also improve the production efficiency of the round compacted conductor.
[0077] Therefore, in the design scheme of taking the solid copper bar with the diameter of 6 mm as the central conductor and adopting the 7-layer Z-shaped single conductor structure of the 127-frame strander, the structure dimensions are optimized as shown in Table 6.
Table 6 Structure Dimensions of the Design Scheme of 7-layer Z-shaped Single Conductors Using 127-Frame Strander after Optimization 2 r/m 03/0 Ri/mm R2/mm H/mm S/mm R/m / / / 3.00 28.27 /
/ 59.23 3.00 6.20 3.20 15.32 1.60 0.3 29.52 6.20 11.15 4.95 22.40 2.48 0.3 19.61 11.15 16.30 5.15 24.59 2.58 0.3 14.78 16.30 21.45 5.15 25.37 2.58 0.3 11.82 21.45 26.60 5.15 25.83 2.58 0.3 9.83 26.60 31.75 5.15 26.14 2.58 0.3
[0078] To reduce the cross-sectional area of each Z-shaped single conductor, it is necessary to keep the cross-sectional areas of all Z-shaped single conductors basically the same, so there is a little difference in the height of each layer. Fewer Z-shaped single conductors are arranged on the layer when moving further in, so the corresponding angle of circumference is large, and the appearance becomes more distorted.
[0079] Compared with the related art, the Z-shaped sealed conductor of the HVDC submarine cable of the disclosure adopts a round compacted structure of the Z-shaped single conductors, which effectively solves the problem that it is very difficult for the frame strander to compact conductors. Moreover, the compaction factor of the conductor is higher than that of the conductor with the round compacted structure of the round single conductors, which can meet the water-proof requirements of the conductors when the HVDC submarine cable is laid in open seas.
[0080] In the description of the disclosure, the orientation or position relationship indicated by the term "up", "down", "left", "right", "inside" and "outside" is based on the orientation or position relation shown in the attached drawings, or the orientation or position relation which is usually placed when the product of the disclosure is used, only for the convenience of describing the disclosure and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific direction, and therefore cannot be understood as a limitation of the disclosure.
[0081] It will be obvious to those skilled in the art that changes and modifications may be made, and therefore, the aim in the appended claims is to cover all such changes and modifications.
Claims (10)
1. A Z-shaped sealed conductor of an HVDC submarine cable, the Z-shaped sealed
conductor comprising a central conductor and a plurality of single conductors
stranded on an outer wall of the central conductor in a layer-by-layer overlapping
manner; wherein
the plurality of single conductors is Z-shaped single conductors, and every two adjacent Z-shaped single conductors are overlapped and fitted to each other end to end so that several ones are spirally and closely stranded together by a stranding process; and
chamfers are provided at corners of each Z-shaped single conductor.
2. The Z-shaped sealed conductor of claim 1, wherein a type of the central conductor
comprises a round compacted structure and a solid copper bar.
3. A method for designing a Z-shaped sealed conductor of an HVDC submarine
cable, the method comprising:
1) calculating an outer diameter DA of the conductor;
2) calculating a correction angle 6;
3) calculating a central angle Oo between extension lines on both sides of a Z-shaped single conductor;
4) calculating a filling factor t of the Z-shaped single conductor;
5) making a design for drawing the Z-shaped single conductor; and
6) optimizing the Z-shaped single conductor.
4. The method of claim 3, wherein the outer diameter DA of the conductor in 1) is calculated by a formula (1):
D= 4 xS
(1);
where S is a cross-sectional area of the conductor and i is a filling factor of the conductor; and the filling factor i is designed according to a previous production experience.
5. The method of claim 3, wherein the correction angle 6 in 2) is calculated by a
formula (2),
tan6 = 7c*Dn L (2);
where Dn is an outer diameter of each layer and L is a pitch of each layer.
6. The method of claim 5, wherein in 3), the central angleOo between the extension
lines on both sides of the Z-shaped single conductor is calculated by substituting
the correction angle 6 calculated in 2) into a formula (3),
00 = 360- 1 n (3);
where n is an actual number of the Z-shaped single conductor in each layer, and 01 is an overlap angle on one side of the Z-shaped single conductor, which is an angle between overlapped portions of adjacent Z-shaped single conductors.
7. The method of claim 3, wherein in 4), a lower half of the Z-shaped single
conductor rotates to left by 01 around a center of an outer arc R1 so that the
Z-shaped single conductor forms a sector, an angle k and an angle p are calculated
by formulas (4) and (5) and then converted into radians a and P by formulas (6) and (7), tanA=r R 1 +r (4); r tanp= R 2 -r (5); a = A/180°*7 (6);
§ =pU/180°*z (7)
where Ri is a radius of the outer arc, R2 is a radius of an inner arc, r is a radius of the chamfer, k is an angle between a left side at a lower end of the Z-shaped single conductor and a line connecting a center of the chamfer r at a lower left end to the center of the outer arc Ri, p is an angle between a left side at an upper end of the Z-shaped single conductor and a line connecting the center of the chamfer r at an upper left end to a center of the outer arc R2, and k and p are both approximate values.
8. The method of claim 7, wherein in 4), an actual filling factor t of the Z-shaped
single conductor is calculated by substituting the radians a and P into a formula
(8),
(flR - 2R) -r(R, - R,) r 2(2 + a - fl- 7r) t~-
(R, - R, )z I - R2) nn (8);
when t > l, the Z-shaped sealed conductor designed by this method meets the water-proof requirements of the conductor, while when t <j, the Z-shaped sealed conductor designed by this method fails to meet the water-proof requirements of the conductor.
9. The method of claim 3, wherein a round bar for drawing the Z-shaped single
conductor is designed in 5), and main characteristic dimensions of the Z-shaped single conductor comprises the angle Oo corresponding to the Z-shaped single conductor, a straight line length W corresponding to the outer arc of a smallest sector holding the Z-shaped single conductor, a diagonal length V of a cross section of the Z-shaped single conductor, a radius difference H between inner and outer circles R 1 and R 2 where sectional rings of the Z-shaped single conductor are located, a cross-sectional area S of the Z-shaped single conductor, an overlap value d of the adjacent Z-shaped single conductors and the chamfer r of the
Z-shaped single conductor, where Oois determined by the number of frames of the
frame strander on each layer, the angle 01 is equal to the angle02 and ranges from
1/4 Ooto 1/6 Oo, the overlap value d is an arc length of the angle 01 on a central
circle R 3 which is an arc radius of the central circle of the Z-shaped single
conductor, where R3 = RI+H/2; a diameter D of a copper bar for drawing is a
diameter of the smallest round single conductor holding the cross section of the
Z-shaped copper single conductor and is determined according to values W and V;
when W/V > 1, D = W; when W/V < 1, D = V.
10. The method of claim 3, wherein optimizing the Z-shaped single conductor in 6)
comprises adjusting sizes of four chamfers r connected to an arc R3 to R, where R
= H/2, and an angle corresponding to an outer arc of the Z-shaped single
conductor is 03.
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