CN101447253A - A manufacturing method of power cable for psychrotolerant wind generating device - Google Patents

A manufacturing method of power cable for psychrotolerant wind generating device Download PDF

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CN101447253A
CN101447253A CNA2008101480621A CN200810148062A CN101447253A CN 101447253 A CN101447253 A CN 101447253A CN A2008101480621 A CNA2008101480621 A CN A2008101480621A CN 200810148062 A CN200810148062 A CN 200810148062A CN 101447253 A CN101447253 A CN 101447253A
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cable
check
manufacturing
oversheath
psychrotolerant
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CN101447253B (en
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王娟
盛业武
陈贵德
沈智飞
李勇军
宋强
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Sunway Co Ltd
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Sichuan Star Cable Co Ltd
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Abstract

This invention discloses a manufacturing method of power cable for psychrotolerant wind generating device, comprising following steps: selecting material, drawing wire, binding wire, twisting conductor, extruding an insulated layer, stranding and belting, extruding an external sleeve, detecting performance, finishing. The cable manufactured by this invention has high performances of weather-resistant, ultraviolet irradiation resistance, deflecting resistance and ozone corrodibility resistance. In addition, the low temperature resistance can be -80 degrees centigrade. This cable can resist the low temperature environment and stand the machine impact, and can greatly improve the safety performance and service life of the wind generating device.

Description

A kind of manufacturing method of power cable for psychrotolerant wind generating device
Technical field
The present invention relates to the cable technology field, exactly relate to a kind of manufacture method that is applicable to the cold resistance wind energy generating plant with power cable.
Background technology
Day by day extensive along with wind power generation, thereby driven development with the wind power generation Related product, because wind power generation system usually is to use under severe environmental conditions, as the bigger temperature difference and ultraviolet radiation, especially in the highlands, day and night temperature is big, and cable will rotate with blower fan and reverse, if do not adopt the private cable that adapts with surrounding environment, common wiring cable or traditional wind energy cable long-term solar light irradiation of process in blower fan, wind and rain and ozone corrode and reverse the back cable surface and crack performance will occur, and cable material meeting quick aging under the big situation of circumstance of temperature difference scope, the physical and mechanical properties of product reduces greatly, so traditional cable has more potential hazard in the process of using, useful life is not long.And will directly have influence on the useful life of whole wind power generation system the useful life of cable.Based on all factors, serviceability is good in wind energy system special-purpose wind energy cable and parts are very important.At present the wind energy cable of making adopts the ethylene-propylene rubber insulation, and anti-daylight, the erosion of anti-ozone, heatproof difference scope, performance such as warping strength are good inadequately.
Summary of the invention
For solving the problems of the technologies described above, the present invention proposes a kind of manufacture method that is applicable to wind energy generating plant with power cable, adopt the produced cable flexible resistance of this method, weatherability, UV resistant and anti-ozone aggressivity height, in addition, its heatproof degree scope can reach-80 ℃~120 ℃, can resist extreme climate environment and stand mechanical shock, can significantly improve the security performance and the useful life of wind energy generating plant.
The present invention is achieved through the following technical solutions:
A kind of manufacturing method of power cable for psychrotolerant wind generating device, it is characterized in that manufacturing process flow is as follows: the strand-insulating barrier of selecting materials-wire drawing-synnema-answer extrudes-and cable core band-oversheath extrudes-finished product, it is to adopt plsitive mold that described insulating barrier is extruded, silicone rubber insulation layer adopts special-purpose extrusion equipment, extrude at normal temperatures, extrude after the drying tunnel baking, its drying tunnel temperature is controlled at 150~250 ℃, and insulating barrier is extruded die sleeve than the actual little 2~3%mm of actual size that extrudes external diameter; Described oversheath is extruded before extruding and should fully be dried, at 80 ℃~100 ℃ environment is dry 2~3 hours, adopt half plsitive mold, compression ratio is that 2.5~4:1, draw ratio are the screw rod of 24~30:1, on silicone rubber insulation layer, extrude flame-proof thermoplastic polyurethane again and form oversheath, processing temperature is controlled at 170~210 ℃, and screw speed is 20~80, adopts the quench cooled mode;
Described selecting materials is meant and chooses the raw material of electrician's round copper rod as cable, also can select versatile material of the prior art for use simultaneously
Described wire drawing is meant that electrician's round copper rod is drawn into the copper monofilament through a plurality of wire-drawing dies of drawing device.
Described conductor synnema, multiple strand are meant the thin copper wire that forms behind the wire-drawing process, again by stranded copper wire according to 15~17 times of synnema pitch multiples, twist the standard of 14~17 times of pitch multiples again and carry out synnema and multiple strand, the doubling mould of selecting for use in the synnema process is the wolfram steel mould, size is than the little 3%d of doubling mould size (d is a mould sizing area diameter) of the common twisted wire of same specification, it is wooden doubling mould that multiple twisted wire is selected mould for use, in the twisted wire process, adopt the doubling mould of reduced size, make the conductor thread core outward appearance rounding, tight, bright and clean of strand system, and help insulating extrude effect.
Described cable core band is meant that wrapped equably non-hygroscopic band forms belting layer on the cable core of making behind the insulated wire cores twisting step, and wrapped Duplication is 15%, and forms the cable core belting layer.
Described Performance Detection is right at normal temperatures conductor DC resistance check, power frequency withstand test and insulation resistance check, oversheath is carried out weather periodic survey, the check of weather low-temperature bending, cryogenic tensile check, oil resistant check, warping strength check test, burn check and the check of anti-ozone, and insulating barrier is carried out anti-ozone check.
Passing through checking procedure after the finished product packing warehouse-in that is up to the standards.
The periodic survey of described oversheath weather is meant extrudes cable after the operation 15~20min that sprinkles water with finishing oversheath under 45 ℃ of environment, treat behind xenon lamp drying 100~110min to do bend test later in 500~700 hours, checks whether free from flaw of result.
The check of described oversheath weather low-temperature bending is meant cable is continued 15~20 hours under temperature-40 ℃ environment, whether checks free from flaw after the test.
The anti-ozone check of described oversheath and insulating barrier is meant cable is continued 24 hours under ozone concentration 250~300ppm whether inspection 180 degree sweeps do not have cracking.
In the stranded process of conductor, adopt the doubling mould of reduced size, make the conductor thread core outward appearance rounding, tight, bright and clean of strand system, and help insulating extrude effect.
The employing compression ratio is big, the long screw rod of major diameter, its objective is in order to guarantee that CABLE MATERIALS is plastified fully when extruding, make the CABLE MATERIALS plasticizing good, even, highly polished after extruding, not plasticizing inequality and incipient scorch phenomenon, and need extrusion equipment to have good cooling device.
The invention has the advantages that:
1, since the present invention adopt select materials-wire drawing-synnema-conductor is stranded-insulating barrier extrudes-stranding band-oversheath extrudes-the such operation of finished product makes cable, and emphasis improve be in insulating barrier extrude, oversheath extrudes this two specific processing steps, after extruding, insulating barrier carried out the drying tunnel baking, the mechanical strength of the insulating barrier after the sulfuration increases, good aging, the variation and the raising of the most important thing is to insulate thermal endurance, solvent resistance and resistance to cracking.Its low temperature resistant reaching-80 of cable that processes by said method ℃, high temperature resistant degree can reach 180 ℃, can resist extreme climate environment and stand mechanical shock, under adverse circumstances, this class cable is best weather resistance, UV resistant and ozone aggressivity of tool not only, and can bear wider variations in temperature, improved the security performance and the useful life of wind energy generating plant.
2, for the extruding of flame-proofed thermoplastic material urethane jacking, extrusion die is selected half plsitive mold for use.Because the packing material height of flame-retardant polyurethane CABLE MATERIALS, this just causes the intensity of its melt under the melting state and viscosity and other CABLE MATERIALS of draw ratio to exist bigger difference, so the apolegamy to mould is also different, adopt the extrusion die of this form, fully guarantee tensile strength and the percentage elongation and the surface smoothness of material.Next is the selection of die sleeve, when using plsitive mold,, make that the pressure of head is very big because the viscosity of material is bigger, extrude when CABLE MATERIALS and can expand to some extent when leaving mould, the mechanical performance of thermoplastic material's polyurethane CABLE MATERIALS is good not as the plain edition CABLE MATERIALS again, and its draw ratio is little, has only about 2.5~3.2, if the die sleeve apolegamy is excessive, what cause cable extrudes not fine and close, the pine of effect, so that the die sleeve size is selected for use is smaller than the actual size of choosing die sleeve usually, cable extrude better effects if.
3, because the present invention adopts 2.5:1 and above compression ratio, draw ratio is 24:1 and above screw rod, satisfied the requirement of flame-proofed thermoplastic material polyurethane cable jacket material particularity.
Description of drawings
Fig. 1 is a process chart of the present invention.
Embodiment
Embodiment 1
A kind of manufacturing method of power cable for psychrotolerant wind generating device, its manufacturing process flow is specific as follows: and the strand-insulating barrier of selecting materials-wire drawing-synnema-answer extrudes-and cable core band-oversheath extrudes-finished product, it is to adopt plsitive mold that described insulating barrier is extruded, silicone rubber insulation layer adopts special-purpose extrusion equipment, extrude at normal temperatures, extrude after the drying tunnel baking, its drying tunnel temperature is controlled at 150 ℃, and insulating barrier is extruded die sleeve than the actual little 2%mm of actual size that extrudes external diameter; Described oversheath is extruded before extruding and should fully be dried, at 80 ℃ of environment is dry 2 hours, adopt half plsitive mold, compression ratio is that 2.5:1, draw ratio are the screw rod of 24:1, on silicone rubber insulation layer, extrude flame-proof thermoplastic polyurethane again and form oversheath, processing temperature is controlled at 170 ℃, and screw speed is 20, adopts the quench cooled mode;
The raw material of choosing in selecting materials is electrician's round copper rod; Wire drawing is meant that a plurality of wire-drawing dies with electrician's round copper rod process drawing device are drawn into the copper monofilament; Conductor synnema, multiple strand are meant for the thin copper wire that forms behind the wire-drawing process, again by stranded copper wire according to 15 times of synnema pitch multiples, twist the standard of 14 times of pitch multiples again and carry out synnema and multiple strand, the doubling mould of selecting for use in the synnema process is the wolfram steel mould, size is than the little 3%d of doubling mould size (d is a mould sizing area diameter) of the common twisted wire of same specification, it is wooden doubling mould that multiple twisted wire is selected mould for use, in the twisted wire process, adopt the doubling mould of reduced size, make the conductor thread core outward appearance rounding, tight, bright and clean of strand system, and help insulating extrude effect.
Described cable core band is meant that wrapped equably non-hygroscopic band forms belting layer on the cable core of making behind the insulated wire cores twisting step, and wrapped Duplication is 15%, and forms the cable core belting layer.
Described Performance Detection is right at normal temperatures conductor DC resistance check, power frequency withstand test and insulation resistance check, oversheath is carried out weather periodic survey, the check of weather low-temperature bending, cryogenic tensile check, oil resistant check, warping strength check test, burn check and the check of anti-ozone, and insulating barrier is carried out anti-ozone check.
The periodic survey of described oversheath weather is meant extrudes cable after the operation 15min that sprinkles water with finishing oversheath under 45 ℃ of environment, treat to do bend test later in 500 hours behind the dry 100min of xenon lamp, checks whether free from flaw of result.
The check of described oversheath weather low-temperature bending is meant cable is continued 15 hours under temperature-40 ℃ environment, whether checks free from flaw after the test.
The anti-ozone check of described oversheath and insulating barrier is meant cable is continued 24 hours under ozone concentration 250ppm whether inspection 180 degree sweeps do not have cracking.
In the stranded process of conductor, adopt the doubling mould of reduced size, make the conductor thread core outward appearance rounding, tight, bright and clean of strand system, and help insulating extrude effect.
The employing compression ratio is big, the long screw rod of major diameter, its objective is in order to guarantee that CABLE MATERIALS is plastified fully when extruding, make the CABLE MATERIALS plasticizing good, even, highly polished after extruding, not plasticizing inequality and incipient scorch phenomenon, and need extrusion equipment to have good cooling device.
For through checking procedure after the cable finished product packing that is up to the standards warehouse-in.
Embodiment 2
A kind of manufacturing method of power cable for psychrotolerant wind generating device, manufacturing process flow is as follows: and the strand-insulating barrier of selecting materials-wire drawing-synnema-answer extrudes-and cable core band-oversheath extrudes-finished product, it is to adopt plsitive mold that described insulating barrier is extruded, silicone rubber insulation layer adopts special-purpose extrusion equipment, extrude at normal temperatures, extrude after the drying tunnel baking, its drying tunnel temperature is controlled at 250 ℃, and insulating barrier is extruded die sleeve than the actual little 3%mm of actual size that extrudes external diameter; Described oversheath is extruded before extruding and should fully be dried, at 100 ℃ of environment is dry 3 hours, adopt half plsitive mold, compression ratio is that 4:1, draw ratio are the screw rod of 30:1, on silicone rubber insulation layer, extrude flame-proof thermoplastic polyurethane again and form oversheath, processing temperature is controlled at 210 ℃, and screw speed is 80, adopts the quench cooled mode;
Described selecting materials selected versatile material of the prior art for use.
Described wire drawing is meant that a plurality of wire-drawing dies with electrician's round copper rod process drawing device are drawn into the copper monofilament.
Described conductor synnema, multiple strand are meant the thin copper wire that forms behind the wire-drawing process, again by stranded copper wire according to 17 times of synnema pitch multiples, twist the standard of 17 times of pitch multiples again and carry out synnema and multiple strand, the doubling mould of selecting for use in the synnema process is the wolfram steel mould, size is than the little 3%d of doubling mould size (d is a mould sizing area diameter) of the common twisted wire of same specification, it is wooden doubling mould that multiple twisted wire is selected mould for use, in the twisted wire process, adopt the doubling mould of reduced size, make the conductor thread core outward appearance rounding, tight, bright and clean of strand system, and help insulating extrude effect.
Described cable core band is meant that wrapped equably non-hygroscopic band forms belting layer on the cable core of making behind the insulated wire cores twisting step, and wrapped Duplication is 15%, and forms the cable core belting layer.
Described performance monitoring is right at normal temperatures conductor DC resistance check, power frequency withstand test and insulation resistance check, oversheath is carried out weather periodic survey, the check of weather low-temperature bending, cryogenic tensile check, oil resistant check, warping strength check test, burn check and the check of anti-ozone, and insulating barrier is carried out anti-ozone check.
The periodic survey of described oversheath weather is meant extrudes cable after the operation 20min that sprinkles water with finishing oversheath under 45 ℃ of environment, treat to do bend test later in 700 hours behind the dry 110min of xenon lamp, checks whether free from flaw of result.
The check of described oversheath weather low-temperature bending is meant cable is continued 20 hours under temperature-40 ℃ environment, whether checks free from flaw after the test.
The anti-ozone check of described oversheath and insulating barrier is meant cable is continued 24 hours under ozone concentration 300ppm whether inspection 180 degree sweeps do not have cracking.
In the stranded process of conductor, adopt the doubling mould of reduced size, make the conductor thread core outward appearance rounding, tight, bright and clean of strand system, and help insulating extrude effect.
The employing compression ratio is big, the long screw rod of major diameter, its objective is in order to guarantee that CABLE MATERIALS is plastified fully when extruding, make the CABLE MATERIALS plasticizing good, even, highly polished after extruding, not plasticizing inequality and incipient scorch phenomenon, and need extrusion equipment to have good cooling device.
For through checking procedure after the cable finished product packing that is up to the standards warehouse-in.
Embodiment 3
A kind of manufacturing method of power cable for psychrotolerant wind generating device, its manufacturing process flow is as follows: and the strand-insulating barrier of selecting materials-wire drawing-synnema-answer extrudes-and cable core band-oversheath extrudes-finished product, it is to adopt plsitive mold that described insulating barrier is extruded, silicone rubber insulation layer adopts special-purpose extrusion equipment, extrude at normal temperatures, extrude after the drying tunnel baking, its drying tunnel temperature is controlled at 200 ℃, and insulating barrier is extruded die sleeve than the actual little 2%mm of actual size that extrudes external diameter; Described oversheath is extruded before extruding and should fully be dried, at 90 ℃ of environment is dry 2 hours, adopt half plsitive mold, compression ratio is that 3:1, draw ratio are the screw rod of 27:1, on silicone rubber insulation layer, extrude flame-proof thermoplastic polyurethane again and form oversheath, processing temperature is controlled at 190 ℃, and screw speed is 50, adopts the quench cooled mode;
Described selecting materials is meant and chooses the raw material of electrician's round copper rod as cable.
Described wire drawing is meant that electrician's round copper rod is drawn into the copper monofilament through a plurality of wire-drawing dies of drawing device.
Described conductor synnema, multiple strand are meant the thin copper wire that forms behind the wire-drawing process, again by stranded copper wire according to 16 times of synnema pitch multiples, twist the standard of 16 times of pitch multiples again and carry out synnema and multiple strand, the doubling mould of selecting for use in the synnema process is the wolfram steel mould, size is than the little 3%d of doubling mould size (d is a mould sizing area diameter) of the common twisted wire of same specification, it is wooden doubling mould that multiple twisted wire is selected mould for use, in the twisted wire process, adopt the doubling mould of reduced size, make the conductor thread core outward appearance rounding, tight, bright and clean of strand system, and help insulating extrude effect.
Described cable core band is meant that wrapped equably non-hygroscopic band forms belting layer on the cable core of making behind the insulated wire cores twisting step, and wrapped Duplication is 15%, and forms the cable core belting layer.
Described performance monitoring is right at normal temperatures conductor DC resistance check, power frequency withstand test and insulation resistance check, oversheath is carried out weather periodic survey, the check of weather low-temperature bending, cryogenic tensile check, oil resistant check, warping strength check test, burn check and the check of anti-ozone, and insulating barrier is carried out anti-ozone check.
The periodic survey of described oversheath weather is meant extrudes cable after the operation 18min that sprinkles water with finishing oversheath under 45 ℃ of environment, treat to do bend test later in 600 hours behind the dry 105min of xenon lamp, checks whether free from flaw of result.
The check of described oversheath weather low-temperature bending is meant cable is continued 18 hours under temperature-40 ℃ environment, whether checks free from flaw after the test.
The anti-ozone check of described oversheath and insulating barrier is meant cable is continued 24 hours under ozone concentration 280ppm whether inspection 180 degree sweeps do not have cracking.
In the stranded process of conductor, adopt the doubling mould of reduced size, make the conductor thread core outward appearance rounding, tight, bright and clean of strand system, and help insulating extrude effect.
The employing compression ratio is big, the long screw rod of major diameter, its objective is in order to guarantee that CABLE MATERIALS is plastified fully when extruding, make the CABLE MATERIALS plasticizing good, even, highly polished after extruding, not plasticizing inequality and incipient scorch phenomenon, and need extrusion equipment to have good cooling device.
For through checking procedure after the cable finished product packing that is up to the standards warehouse-in.
Because the present invention adopts and to select materials-and wire drawing-synnema-conductor is stranded-insulating barrier extrudes-stranding band-oversheath extrudes-and the such operation of finished product makes cable, and emphasis improve be in insulating barrier extrude, oversheath extrudes this two specific processing steps, after extruding, insulating barrier carried out the drying tunnel baking, the mechanical strength of the insulating barrier after the sulfuration increases, good aging, the variation and the raising of the most important thing is to insulate thermal endurance, solvent resistance and resistance to cracking.Its low temperature resistant reaching-80 of cable that processes by said method ℃, high temperature resistant degree can reach 180 ℃, can resist extreme climate environment and stand mechanical shock, under adverse circumstances, this class cable is best weather resistance, UV resistant and ozone aggressivity of tool not only, and can bear wider variations in temperature, improved the security performance and the useful life of wind energy generating plant.
For extruding of flame-proofed thermoplastic material urethane jacking, extrusion die is selected half plsitive mold for use.Because the packing material height of flame-retardant polyurethane CABLE MATERIALS, this just causes the intensity of its melt under the melting state and viscosity and other CABLE MATERIALS of draw ratio to exist bigger difference, so the apolegamy to mould is also different, adopt the extrusion die of this form, fully guarantee tensile strength and the percentage elongation and the surface smoothness of material.Next is the selection of die sleeve, when using plsitive mold,, make that the pressure of head is very big because the viscosity of material is bigger, extrude when CABLE MATERIALS and can expand to some extent when leaving mould, the mechanical performance of thermoplastic material's polyurethane CABLE MATERIALS is good not as the plain edition CABLE MATERIALS again, and its draw ratio is little, has only about 2.5~3.2, if the die sleeve apolegamy is excessive, what cause cable extrudes not fine and close, the pine of effect, so that the die sleeve size is selected for use is smaller than the actual size of choosing die sleeve usually, cable extrude better effects if.
Because it is 24:1 and above screw rod that the present invention adopts 2.5:1 and above compression ratio, draw ratio, has satisfied the requirement of flame-proofed thermoplastic material polyurethane cable jacket material particularity.
The inventive method is simple, easy to operate, and the cable practicality that produces is suitable for promoting.

Claims (9)

1, a kind of manufacturing method of power cable for psychrotolerant wind generating device is characterized in that: manufacturing step adopts following technological process: select materials-wire drawing-synnema-conductor is stranded-insulating barrier extrudes-stranding band-oversheath extrudes-Performance Detection-finished product; It is to adopt plsitive mold that wherein said insulating barrier is extruded, and extrudes silicon rubber and form insulating barrier on conductor, and normal temperature is extruded, and the drying tunnel processing temperature is controlled at 150~250 ℃; Described oversheath is extruded employing half plsitive mold, and the last compression ratio of 2.5~4:1, draw ratio are that the screw rod of 24~30:1 is forming oversheath through extruding flame-proof thermoplastic polyurethane on the insulating barrier again, and processing temperature is controlled at 170~210 ℃.
2, a kind of manufacturing method of power cable for psychrotolerant wind generating device according to claim 1 is characterized in that: described selecting materials is meant and chooses the raw material of electrician's round copper rod as cable conductor.
3, wind energy generating plant according to claim 1 electric power cable making method is characterized in that: described wire drawing is meant that electrician's round copper rod is drawn into the copper monofilament through a plurality of wire-drawing dies of drawing device.
4, a kind of manufacturing method of power cable for psychrotolerant wind generating device according to claim 1 is characterized in that: the stranded multiply copper monofilament that forms behind wire-drawing process that is meant of described synnema and conductor carries out synnema, multiple strand according to the standard of 15~17 times of synnema pitch multiples.
5, a kind of manufacturing method of power cable for psychrotolerant wind generating device according to claim 1, it is characterized in that: described stranding band is meant that wrapped equably non-hygroscopic band forms separator on the cable core of making behind the core twisting step, wrapped Duplication is 15%, and forms the cable core belting layer.
6, a kind of manufacturing method of power cable for psychrotolerant wind generating device according to claim 1, it is characterized in that: described Performance Detection comprises at normal temperatures carries out the D.C. resistance check to conductor, power frequency withstand test and insulation resistance check, oversheath is carried out weather periodic survey, the check of weather low-temperature bending, cryogenic tensile check, oil resistant check, warping strength check, burning check and the check of anti-ozone respectively, insulating barrier is carried out anti-ozone check.
7, a kind of manufacturing method of power cable for psychrotolerant wind generating device according to claim 6, it is characterized in that: the periodic survey of described oversheath weather is meant extrudes cable after the operation 15~20min that sprinkles water with finishing oversheath under 45 ℃ of environment, treat behind xenon lamp drying 100~110min to do bend test later in 500~700 hours, check whether free from flaw of result.
8, a kind of manufacturing method of power cable for psychrotolerant wind generating device according to claim 6, it is characterized in that: the check of described oversheath weather low-temperature bending is meant cable is continued 15~20 hours under temperature-40 ℃ environment, whether checks free from flaw after the test.
9, a kind of manufacturing method of power cable for psychrotolerant wind generating device according to claim 6, it is characterized in that: the anti-ozone check of described oversheath and insulating barrier is meant cable is continued 24 hours under ozone concentration 250~300ppm whether inspection 180 degree sweeps do not have cracking.
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