CN107256733B - Wisdom energy high tensile cable and production process thereof - Google Patents
Wisdom energy high tensile cable and production process thereof Download PDFInfo
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- CN107256733B CN107256733B CN201710307368.6A CN201710307368A CN107256733B CN 107256733 B CN107256733 B CN 107256733B CN 201710307368 A CN201710307368 A CN 201710307368A CN 107256733 B CN107256733 B CN 107256733B
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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
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/182—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring comprising synthetic filaments
- H01B7/1825—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring comprising synthetic filaments forming part of a high tensile strength core
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B11/00—Communication cables or conductors
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/0016—Apparatus or processes specially adapted for manufacturing conductors or cables for heat treatment
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
- H01B13/145—Pretreatment or after-treatment
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/228—After-treatment
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
- H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
- H01B7/045—Flexible cables, conductors, or cords, e.g. trailing cables attached to marine objects, e.g. buoys, diving equipment, aquatic probes, marine towline
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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
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/1865—Sheaths comprising braided non-metallic layers
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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
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/1875—Multi-layer sheaths
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
- Y02A30/14—Extreme weather resilient electric power supply systems, e.g. strengthening power lines or underground power cables
Abstract
The invention discloses an intelligent energy high-tensile cable and a production process thereof, wherein the cable comprises a reinforced core, a cable core, a first polyester belt, a rubber cushion layer, an aluminum-plastic composite belt, a copper wire shielding layer, a second polyester belt, an inner sheath, a first braiding layer, an outer sheath and a second braiding layer from inside to outside in sequence; the cable core comprises 36 wire cores; each wire core comprises a conductor and fluoroplastic insulation from inside to outside; the reinforced core (1) is woven by bulletproof yarns, and the outer diameter of the reinforced core (1) is determined according to the formula: d= (4.154+k) ×d, k is a compression coefficient, when D is 1.0-2.0 mm, k is 0.05, when D is 2.0-4.0 mm, k is 0.07, D is the diameter of the insulated wire core; the weight kg of the reinforcing core that can bear the weight is determined according to the formula: m=37.7×d 2 D is the outer diameter of the reinforcing core, and is in mm. The cable has compact and stable structure, high tensile strength, high softness, small collision sound between water spray and the cable and excellent performance.
Description
Technical Field
The invention relates to an intelligent energy low-noise high-tensile cable for connecting signal transmission of ground acoustic equipment and underwater equipment and a production process thereof.
Background
The product is used for signal transmission of the underwater acoustic device and underwater equipment, and the cable can move in the water along with the underwater acoustic device, so that the problems of swing, noise, sealing and the like are easy to occur, and the requirement on the cable is very high. The cable has 4 key points: 1. reducing the swing along with water flow or sea wave; 2. noise caused by the fact that the spray hits the cable is reduced; 3. waterproof at the end of the cable; 4. the water pressure tends to cause the shield to scratch the insulation and fail.
In order to reduce the swing of the cable with water flow or sea waves, a heavy object is hung below the cable, so that the cable is required to have high tensile strength. The traditional cable center adopts the steel wire to strengthen, and creep extension can appear in this kind of scheme, rust and lead to the cable hardness to increase scheduling problem, consequently, need adopt novel enhancement core, not only need guarantee cable softness and cable stable in structure, need guarantee simultaneously that the enhancement core can bear the heavy object for a long time, consequently need carry out accurate calculation to the structural dimension and the weighing capacity of enhancement core, the sheath of this cable needs to have very high intensity and tear resistance simultaneously, avoid bearing the pulling force back sheath fracture, consequently need design novel structure to strengthen cable sheath. The common cable is a smooth surface, and big noise can appear when the common cable collides with water spray, so that the accuracy of the test result of the underwater detection equipment is influenced, and the surface of the cable is required to be improved, so that the noise caused by the collision of water spray and the cable is reduced. The neoprene material has excellent elasticity, waterproof performance, mechanical performance and bonding performance, so that the cable adopts the neoprene sheath, and meanwhile, the cable connector also adopts the same material, so that the cable is ensured to be bonded well, and the waterproof effect is achieved. The pressure under water is very high, and the copper wire shield is easy to puncture the insulation, so that the copper wire shield must be specially designed in structure to avoid failure caused by insulation scratching of the copper wire shield layer.
The oil-resistant high-temperature-resistant high-tensile cable for the oil well heater disclosed in Chinese patent ZL 200820223672.9 is characterized in that a stranded steel wire rope is arranged in the center of the cable to improve the tensile property of the cable, so that the cable can be suitable for the use environment with high strength in an oil well. However, the cable is used for signal transmission for connecting the ground acoustic equipment and the underwater equipment, and the cable is required to have high tensile strength and high flexibility, so that the stranded steel wire is easy to wet and rust in water to reduce the strength, and the steel wire is used as a reinforcing core to greatly increase the hardness of the cable.
Disclosure of Invention
A first object of the present invention is to provide a smart energy high tensile cable.
The technical scheme for realizing the first purpose of the invention is that the smart energy high-tensile cable comprises a reinforced core, a cable core formed by a plurality of insulating wire cores, a first polyester belt, a rubber cushion layer, an aluminum-plastic composite belt, a copper wire shielding layer, a second polyester belt, an inner sheath, a first braiding layer, an outer sheath and a second braiding layer from inside to outside in sequence; the cable core comprises 36 insulating wire cores, and the arrangement mode is that two layers are arranged outside the reinforced core in a 15+21 mode; each insulation wire core comprises a conductor and fluoroplastic insulation from inside to outside; the reinforced core is woven by bulletproof wires, and the outer diameter of the reinforced core is determined according to the formula: d= ×d, k is a compression coefficient, when D is 1.0-2.0 mm, k is 0.05, when D is 2.0-4.0 mm, k is 0.07, D is the diameter of the insulated wire core; the weight of the reinforcing core that can bear the weight is determined according to the formula: m=37.7×d 2 D is the outer diameter of the reinforcing core, in mm and the weight in kg.
The second braiding layer is braided by polyester yarns, each polyester yarn is 8000D, the number of the yarns is 32, and each yarn is 1 yarn.
The reinforced core is formed by twisting 120000D bulletproof wires, and can bear 1692kg of heavy weight.
The diameter of the copper wire shielding layer is 0.15mm, the number of ingots is 24, the number of each ingot is 8, and the pitch is not more than 25mm; the first braiding layer is braided by aramid fiber filaments, the aramid fiber filaments are 1500D, the number of the ingots is 12, and 1 aramid fiber filament is used for each ingot.
The rubber cushion layer is made of chlorinated polyethylene rubber; the inner sheath and the outer sheath both adopt 5GM3 type chloroprene rubber meeting the requirements of VDE0207Teil 21.
The outer diameter of the reinforcing core is 6.7mm; the cross-sectional area of the conductor is 0.5mm 2 Twisting 16 tin-plated copper wires with the wire diameter of 0.195mm according to the pitch of not more than 16 mm; the insulation thickness of the fluoroplastic is 0.35mm; the thickness of the rubber cushion layer is 1.0mm; the thickness of the aluminum-plastic composite belt is 0.1mm, the width of the aluminum-plastic composite belt is 5mm, and the overlap ratio of the aluminum-plastic composite belt is 20% -25%; the copper wire shielding layer is braided by copper wires, and the braiding density is 80%; the thickness of the first polyester belt and the second polyester belt are 0.05mm, the width of the first polyester belt and the second polyester belt is 5mm, and the covering rate of the polyester belts is 20% -25%; the thickness of the inner sheath is 0.80mm; the first braiding layer is braided by aramid filaments, and the braiding density is 30% -40%; the thickness of the outer sheath is 2.5mm; the second braiding layer is braided by polyester yarns, and the braiding density is 80%.
The technical scheme for realizing the second purpose of the invention is a production process of the smart energy high-tensile cable, which comprises the following steps:
step one: determining a cable structure;
step two: preparation of the reinforcing core: 10 1000D bulletproof wires are combined to form small strands, then 4 small strands are twisted to form strands, the twisting direction is right, and the twisting pitch is not more than 36mm; and finally, twisting the three strands to form a reinforced core, wherein the twisting direction is the left direction, and the twisting pitch is not more than 50mm.
Step two: preparation of an insulating wire core: the conductors are stranded by adopting tinned copper wires, the number of the wires is 16, the diameter of the wires is 0.195mm, the arrangement mode is that the wires are 4 in the inner layer, 12 in the outer layer, the stranding pitch is larger than 16mm, and the wires are tightly pressed by adopting a diamond die with the aperture of 0.9 mm; the conductors are externally extruded with fluoroplastic insulation, the fluoroplastic insulation is fluoroplastic 46, and the thickness of the fluoroplastic insulation is 0.35mm.
Step three: preparing a cable core: the 36 wire cores are cabled, wherein 15 insulating wire cores are arranged outside the reinforcing core, 21 insulating wire cores are arranged on the outermost layer, and meanwhile, a first polyester belt is wrapped, and the covering rate of the polyester belt is 20% -25%;
step four: extruding a rubber cushion layer outside the first polyester band, wherein the rubber cushion layer is chlorinated polyethylene rubber, and the thickness of the rubber cushion layer is 1.0mm;
step five: wrapping the rubber cushion layer with an aluminum-plastic composite belt, wherein the aluminum surface of the aluminum-plastic composite belt faces outwards, the thickness of the aluminum-plastic composite belt is 0.1mm, the width of the aluminum-plastic composite belt is 5mm, and the covering rate of the aluminum-plastic composite belt is 20% -25%;
step six: braiding a copper wire shielding layer outside the aluminum-plastic composite band, wherein the copper wire shielding layer is braided by copper wires, and the braiding density is 80%; the diameter of the copper wire is 0.15mm, the number of ingots is 24, the number of each ingot is 8, and the pitch is not more than 25mm;
step seven: a second polyester belt is wound outside the copper wire shielding layer, and the covering rate of the polyester belt is 20% -25%;
step eight: extruding an inner sheath outside the second polyester band, wherein the inner sheath is 5GM3 neoprene which meets the requirements of VDE0207Teil21, and the thickness of the inner sheath is 0.80mm;
step nine: the first braiding layer is braided outside the inner sheath, the first braiding layer is braided by aramid filaments, the aramid filaments are 1500D, the number of ingots is 12, 1 ingot per ingot, and the pitch is not more than 80mm;
step ten: extruding an outer sheath outside the first braiding layer, wherein the outer sheath is 5GM3 neoprene which meets the requirements of VDE0207Teil21, and the thickness of the outer sheath is 2.5mm;
step eleven: outside the outer sheath, the outer sheath is 5GM3 type chloroprene rubber which meets the requirements of VDE0207Teil21, and the thickness of the outer sheath is 2.5mm;
step twelve: and (3) braiding a second braiding layer outside the outer sheath, wherein the second braiding layer is braided by polyester yarns, each polyester yarn is 8000D, the number of ingots is 32, and 1 ingot is used for each ingot.
The fluoroplastic insulation processing step in the step two is as follows: preheating a conductor by adopting induction type preheating equipment, extruding an insulating material by adopting an extrusion pipe type die when the temperature of the conductor reaches 100-120 ℃, wherein the temperature of a machine body is 350 ℃, and the extrusion temperature of a machine head is 355 ℃; the fluoroplastic insulating cooling adopts staged cooling, the water temperature of the first section of water tank is 80 ℃, the water temperature of the second section of water tank is 60 ℃, and the water temperature of the third section of water tank is 60 ℃. And finally, placing the insulated wire core in an oven at 160 ℃ for 2 hours for tempering.
In the eighth step, the vulcanization degree of the inner sheath is 80%, and the extrusion process and the vulcanization process of the inner sheath are set according to the Mooney viscosity and the vulcanization characteristic of the chloroprene rubber: the neoprene rubber is extruded by a 90 rubber extruder, the temperature of the extruder body is 60 ℃, the extrusion temperature of the extruder head is 65 ℃, the steam pressure is 6bar, the linear speed is 10m/min, and the vulcanization time is 8min.
In the eleventh step, the extrusion process and the vulcanization process of the outer sheath are set according to the Mooney viscosity and the vulcanization characteristics of the chloroprene rubber: the neoprene rubber is extruded by a 90 rubber extruder, the temperature of the extruder body is 60 ℃, the extrusion temperature of the extruder head is 65 ℃, the steam pressure is 7bar, the linear speed is 8m/min, and the vulcanization time is 10min.
By adopting the technical scheme, the invention has the following beneficial results: (1) The cable of the invention is used to bear heavy objects and has high flexibility, so the invention adopts the bulletproof wire stranded rope as the reinforcing core, and simultaneously the cable core of the cable is disordered because the cable is always swung in the use process, so the invention determines the outer diameter of the reinforcing core and the calculation formula of the weight (kg) of the reinforcing core which can bear heavy objects through a great deal of researches and accurate calculation, thereby greatly improving the tensile property and the structural stability of the cable, and the cable has compact structure, high softness, good tensile property and excellent performance.
(2) According to the cable disclosed by the invention, the rubber cushion layer is arranged in the aluminum-plastic composite belt, so that the cable core failure caused by the fact that the copper wire shielding is pressed into the insulation by water pressure is effectively avoided.
(3) When the hydrophone towing array and the seawater relatively move, turbulent pulsation of the seawater medium is generated near the outer surface of the sheath, hydrodynamic noise which is called flow noise and is mainly caused by turbulent microscale movement and vortex shedding on the surface can greatly interfere signal receiving of the hydrophone, so that the signal to noise ratio of the hydrophone is greatly reduced, and the detection capability of the hydrophone array is influenced. The cable is braided with the polyester yarns outside the outer sheath, the polyester yarns have the advantages of good waterproof performance, softness, good tensile performance and the like, the polyester yarn braiding layer has good elasticity, the surface of the polyester yarn braiding layer has uniform roughness and uniform gaps, the flexible polyester yarn braiding layer prevents water flow from directly colliding with the outer sheath of the cable, turbulent boundary layers of fluid and the outer sheath can be stabilized, noise between the cable and seawater under high-speed movement of the towing array is reduced, and flow noise can be reduced by more than 20 dB.
(4) The inner sheath and the outer sheath of the cable disclosed by the invention are made of 5GM3 neoprene which meets the requirements of VDE0207Teil21, and have excellent tensile strength and elasticity.
(5) The temperature of the fluoroplastic extruded is very high, if the temperature of the conductor and the water tank is normal temperature, the conductor can lead the insulation temperature of the fluoroplastic to drop suddenly, therefore, when the fluoroplastic insulation is processed, the induction type preheating equipment is used for preheating the conductor, the staged cooling mode from high to low is adopted after the fluoroplastic is extruded on the conductor in an insulation manner, the shrinkage of the insulation material is effectively reduced, the insulation smoothness is improved, meanwhile, the binding force between the conductor and the insulation material is effectively increased, the tempering process enables the molecular chain of the insulation material to be fully regulated and crystallized, the internal stress of the fluoroplastic is eliminated, the elongation at break and the softness of the insulation material are effectively improved, and meanwhile, the problem that the fluoroplastic is easy to crack is effectively solved.
(6) When the cable is used for processing the inner sheath, the vulcanizing degree of the inner sheath is 80%, so that the inner sheath has certain tensile and wear-resisting properties, and simultaneously is vulcanized together with the outer sheath, so that the inner sheath and the outer sheath are well bonded with the aramid fiber yarn weaving layer, and the tensile property and the tear resistance of the sheath are effectively improved.
Drawings
In order that the invention may be more readily understood, a more particular description of the invention will be rendered by reference to specific embodiments that are illustrated in the appended drawings, in which:
fig. 1 is a schematic structural view of the present invention.
The reference numerals in the drawings are: the reinforced cable comprises a reinforced core 1, an insulated cable core 2, a conductor 2-1, fluoroplastic insulation 2-2, a first polyester belt 3, a rubber cushion layer 4, an aluminum-plastic composite belt 5, a copper wire shielding layer 6, a second polyester belt 7, an inner sheath 8, a first braiding layer 9, an outer sheath 10 and a second braiding layer 11.
Detailed Description
Example 1
Referring to fig. 1, the smart energy high tensile cable of the embodiment sequentially comprises a reinforcing core 1, a cable core, a first polyester belt 3, a rubber cushion layer 4, an aluminum-plastic composite belt 5, a copper wire shielding layer 6, a second polyester belt 7, an inner sheath 8, a first braiding layer 9, an outer sheath 10 and a second braiding layer 11 from inside to outside; the cable core comprises 36 insulating wire cores 2, and the arrangement mode is that a layer of 15 insulating wire cores 2 and a layer of 21 insulating wire cores 2 are arranged outside the reinforced core 1; each insulation wire core 2 comprises a conductor 2-1 and fluoroplastic insulation 2-2 from inside to outside; the reinforced core 1 is woven by bulletproof yarns, and the outer diameter of the reinforced core 1 is determined according to the formula: d= (4.154+k) ×d, k is a compression coefficient, when D is 1.0-2.0 mm, k is 0.05, when D is 2.0-4.0 mm, k is 0.07, D is the diameter of the insulated wire core 2; the weight (kg) that the reinforcing core 1 can bear a heavy object is determined according to the formula: m=37.7×d 2 D is the outer diameter of the reinforcing core 1 in mm. The outer diameter of the reinforcing core 1 is 6.7mm; the cross-sectional area of the conductor 2-1 was 0.5mm 2 Twisting 16 tin-plated copper wires with the wire diameter of 0.195mm according to the pitch of not more than 16 mm; the thickness of the fluoroplastic insulation 2-2 is 0.35mm; the thickness of the rubber cushion layer 4 is 1.0mm; the thickness of the aluminum-plastic composite belt 5 is 0.1mm, the width is 5mm, and the covering rate of the aluminum-plastic composite belt 5 is 20% -25%; the copper wire shielding layer 6 is braided by copper wires, and the braiding density is 80%; the thickness of the first polyester belt 3 and the second polyester belt 7 are 0.05mm, the width is 5mm, and the covering rate of the polyester belts is 20% -25%; the thickness of the inner sheath 8 is 0.80mm; the first braiding layer 9 is braided by aramid fiber, and the braiding density is 30% -40%; the thickness of the outer sheath 10 is 2.5mm; the second braiding layer 11 is braided by polyester yarns, and the braiding density is 80%. The outer diameter of the reinforcing core 1 is 6.7mm, and the reinforcing core 1 can bear 1692kg of heavy weight by twisting 120000D bulletproof wires. The diameter of the copper wire shielding layer 6 is 0.15mm, the number of ingots is 24, the number of each ingot is 8, and the pitch is not more than 25mm. The first braiding layer 9 is braided by aramid filaments, the aramid filaments are 1500D, the number of the ingots is 12, and 1 aramid filament is used for each ingot. Rubber (Oak)The cushion rubber layer 4 is made of chlorinated polyethylene rubber. Both the inner sheath 8 and the outer sheath 10 employed neoprene satisfying 5GM3 in VDE0207 ceil 21. The second braiding layer 11 is braided by polyester yarns, each polyester yarn is 8000D, the number of the yarns is 32, and each yarn is 1 yarn.
The production process comprises the following steps:
step one: determining a cable structure;
step two: preparation of reinforcing core 1: 10 1000D bulletproof wires are combined to form small strands, then 4 small strands are twisted to form strands, the twisting direction is right, and the twisting pitch is not more than 36mm; and finally, twisting the three strands to form a reinforced core, wherein the twisting direction is the left direction, and the twisting pitch is not more than 50mm.
Step two: preparation of the insulated wire core 2: the conductors 2-1 are stranded by adopting tinned copper wires, the number of the wires is 16, the diameter of the wires is 0.195mm, the arrangement mode is that the wires are 4 in the inner layer and 12 in the outer layer, the stranding pitch is larger than 16mm, and the wires are tightly pressed by adopting a diamond die with the aperture of 0.9 mm; the conductor 2-1 is externally extruded with fluoroplastic insulation 2-2, the fluoroplastic insulation 2-2 is fluoroplastic 46, and the thickness of the fluoroplastic insulation 2-2 is 0.35mm. Preheating a conductor 2-1 by adopting induction type preheating equipment, extruding an insulating material by adopting an extrusion pipe type die when the temperature of the conductor 2-1 reaches 100-120 ℃, wherein the temperature of a machine body is 350 ℃, and the extrusion temperature of a machine head is 355 ℃; the fluoroplastic insulation 2-2 is cooled by stages, the water temperature of the first stage water tank is 80 ℃, the water temperature of the second stage water tank is 60 ℃, and the water temperature of the third stage water tank is 60 ℃. And finally, placing the insulated wire core 2 in an oven at 160 ℃ for 2 hours for tempering.
Step three: preparing a cable core: the 36 wire cores are cabled, wherein 15 insulated wire cores 2 are arranged outside the reinforced core 1, 21 insulated wire cores 2 are arranged on the outermost layer, and meanwhile, a first polyester belt 3 is wrapped, and the covering rate of the polyester belt is 20% -25%;
step four: extruding a rubber cushion layer 4 outside the first polyester belt 3, wherein the rubber cushion layer 4 is chlorinated polyethylene rubber, and the thickness of the rubber cushion layer 4 is 1.0mm;
step five: wrapping the rubber cushion layer 4 with an aluminum-plastic composite belt 5, wherein the aluminum surface of the aluminum-plastic composite belt 5 faces outwards, the thickness of the aluminum-plastic composite belt 5 is 0.1mm, the width is 5mm, and the covering rate of the aluminum-plastic composite belt 5 is 20% -25%;
step six: the copper wire shielding layer 6 is woven outside the aluminum-plastic composite belt 5, the copper wire shielding layer 6 is woven by copper wires, and the weaving density is 80%; the diameter of the copper wire is 0.15mm, the number of ingots is 24, the number of each ingot is 8, and the pitch is not more than 25mm;
step seven: a second polyester belt 7 is wound outside the copper wire shielding layer 6, and the covering rate of the polyester belt is 20% -25%;
step eight: extruding an inner sheath 8 outside the second polyester belt 7, wherein the inner sheath 8 is 5GM3 neoprene which meets VDE0207Teil21, and the thickness of the inner sheath 8 is 0.80mm; the vulcanization degree of the inner sheath 8 was 80%, and the extrusion process and vulcanization process of the inner sheath 8 were set according to the mooney viscosity and vulcanization characteristics of chloroprene rubber: the neoprene rubber is extruded by a 90 rubber extruder, the temperature of the extruder body is 60 ℃, the extrusion temperature of the extruder head is 65 ℃, the steam pressure is 6bar, the linear speed is 10m/min, and the vulcanization time is 8min.
Step nine: the first braiding layer 9 is braided outside the inner sheath 8, the first braiding layer 9 is braided by aramid filaments, the aramid filaments are 1500D, the number of ingots is 12, 1 ingot per ingot, and the pitch is not more than 80mm;
step ten: extruding an outer sheath 10 outside the first braiding layer 9, wherein the outer sheath 10 is 5GM3 type chloroprene rubber in VDE0207Teil21, and the thickness of the outer sheath 10 is 2.5mm;
step eleven: outside the outer sheath 10, the outer sheath 10 is 5GM3 type chloroprene rubber in VDE0207Teil21, and the thickness of the outer sheath 10 is 2.5mm; the extrusion process and the vulcanization process of the outer sheath 10 are set according to the mooney viscosity and the vulcanization characteristics of the neoprene: the neoprene rubber is extruded by a 90 rubber extruder, the temperature of the extruder body is 60 ℃, the extrusion temperature of the extruder head is 65 ℃, the steam pressure is 7bar, the linear speed is 8m/min, and the vulcanization time is 10min.
Step twelve: and a second braiding layer 11 is braided outside the outer sheath 10, the second braiding layer 11 is braided by polyester yarns, each polyester yarn is 8000D, the number of ingots is 32, 1 ingot is obtained, and the pitch is not more than 80mm.
The following table shows the comparison of the measured values of the existing cable and the cable of the present invention:
while the foregoing is directed to embodiments of the present invention, other and further details of the invention may be had by the present invention, it should be understood that the foregoing description is merely illustrative of the present invention and that no limitations are intended to the scope of the invention, except insofar as modifications, equivalents, improvements or modifications are within the spirit and principles of the invention.
Claims (10)
1. Wisdom energy high tensile cable, its characterized in that: the cable comprises a reinforcing core (1), a cable core formed by a plurality of insulating cable cores (2), a first polyester belt (3), a rubber cushion layer (4), an aluminum-plastic composite belt (5), a copper wire shielding layer (6), a second polyester belt (7), an inner sheath (8), a first braiding layer (9), an outer sheath (10) and a second braiding layer (11) from inside to outside in sequence; the cable core comprises 36 insulating wire cores (2), and the arrangement mode is that two layers are arranged outside the reinforced core (1) in a 15+21 mode; each insulation wire core (2) comprises a conductor (2-1) and fluoroplastic insulation (2-2) from inside to outside; the reinforced core (1) is woven by bulletproof yarns, and the outer diameter of the reinforced core (1) is determined according to the formula: d= (4.154+k) ×d, k is a compression coefficient, k is 0.05 when D is 1.0-2.0 mm, k is 0.07 when D is 2.0-4.0 mm, D is the diameter of the insulated wire core (2); the weight of the reinforcing core (1) which can bear the weight is determined according to the formula: m=37.7×d 2 D is the outer diameter of the reinforcing core (1), the unit is mm, and the weight unit is kg.
2. The smart energy high tensile cable of claim 1, wherein: the second braiding layers (11) are braided by polyester yarns, each polyester yarn is 8000D, the number of the yarns is 32, and each yarn is 1 yarn.
3. The smart energy high tensile cable of claim 2, wherein: the reinforced core (1) is formed by twisting 120000D bulletproof wires, and the reinforced core (1) can bear 1692kg of heavy weight.
4. A smart energy high tensile cable according to claim 3, wherein: the diameter of the copper wire shielding layer (6) is 0.15mm, the number of ingots is 24, the number of each ingot is 8, and the pitch is not more than 25mm; the first braiding layers (9) are braided by aramid filaments, the number of the aramid filaments is 1500D, the number of the aramid filaments is 12, and 1 aramid filament is used for each aramid filament.
5. The smart energy high tensile cable of claim 4, wherein: the rubber cushion layer (4) adopts chlorinated polyethylene rubber; the inner sheath (8) and the outer sheath (10) both adopt a material meeting VDE
0207Teil21, model 5GM3 neoprene.
6. The smart energy high tensile cable of claim 5, wherein: the outer diameter of the reinforcing core (1) is 6.7mm; the sectional area of the conductor (2-1) is 0.5mm2, and 16 tin-plated copper wires with the wire diameters of 0.195mm are twisted according to the pitch of not more than 16 mm; the thickness of the fluoroplastic insulation (2-2) is 0.35mm; the thickness of the rubber cushion layer (4) is 1.0mm; the thickness of the aluminum-plastic composite belt (5) is 0.1mm, the width is 5mm, and the covering rate of the aluminum-plastic composite belt (5) is 20% -25%; the copper wire shielding layer (6) is braided by copper wires, and the braiding density is 80%; the thickness of the first polyester belt (3) and the second polyester belt (7) are 0.05mm, the width is 5mm, and the covering rate of the polyester belts is 20% -25%; the thickness of the inner sheath (8) is 0.80mm; the first braiding layer (9) is braided by aramid filaments, and the braiding density is 30% -40%; the thickness of the outer sheath (10) is 2.5mm; the second braiding layer (11) is braided by polyester yarns, and the braiding density is 80%.
7. The production process of the smart energy high-tensile cable is characterized by comprising the following steps of:
step one: determining the cable construction as claimed in claim 6;
step two: preparation of the reinforcing core (1): 10 1000D bulletproof wires are combined to form small strands, then 4 small strands are twisted to form strands, the twisting direction is right, and the twisting pitch is not more than 36mm; finally, twisting the three strands to form a reinforced core, wherein the twisting direction is the left direction, and the twisting pitch is not more than 50mm;
step two: preparation of an insulating wire core (2): the conductors (2-1) are stranded by adopting tinned copper wires, the number of the wires is 16, the wire diameter is 0.195mm, the arrangement mode is that the number of the wires is 4 for the inner layer, the number of the wires is 12 for the outer layer, the stranding pitch is larger than 16mm, and the wires are tightly pressed by adopting a diamond die with the aperture of 0.9 mm; the conductor (2-1) is externally extruded with fluoroplastic insulation (2-2), the fluoroplastic insulation (2-2) is fluoroplastic 46, and the thickness of the fluoroplastic insulation (2-2) is 0.35mm;
step three: preparing a cable core: the 36 wire cores are cabled, wherein 15 insulated wire cores (2) are arranged outside the reinforced core (1), 21 insulated wire cores (2) are arranged on the outermost layer, and meanwhile, a first polyester belt (3) is wrapped, and the covering rate of the polyester belt is 20% -25%;
step four: extruding a rubber cushion layer (4) outside the first polyester belt (3), wherein the rubber cushion layer (4) is chlorinated polyethylene rubber, and the thickness of the rubber cushion layer (4) is 1.0mm;
step five: wrapping the rubber cushion layer (4) with an aluminum-plastic composite belt (5), wherein the aluminum surface of the aluminum-plastic composite belt (5) faces outwards, the thickness of the aluminum-plastic composite belt (5) is 0.1mm, the width is 5mm, and the covering rate of the aluminum-plastic composite belt (5) is 20% -25%;
step six: a copper wire shielding layer (6) is woven outside the aluminum-plastic composite belt (5), wherein the copper wire shielding layer (6) is woven by copper wires, and the weaving density is 80%; the diameter of the copper wire is 0.15mm, the number of ingots is 24, the number of each ingot is 8, and the pitch is not more than 25mm;
step seven: a second polyester belt (7) is wound outside the copper wire shielding layer (6), and the covering rate of the polyester belt is 20% -25%;
step eight: extruding an inner sheath (8) outside the second polyester belt (7), wherein the inner sheath (8) is 5GM3 type chloroprene rubber in VDE0207Teil21, and the thickness of the inner sheath (8) is 0.80mm;
step nine: a first braiding layer (9) is braided outside the inner sheath (8), the first braiding layer (9) is braided by aramid filaments, the aramid filaments are 1500D, the number of ingots is 12, each ingot is 1, and the pitch is not more than 80mm;
step ten: extruding an outer sheath (10) outside the first braiding layer (9), wherein the outer sheath (10) meets VDE
5GM3 type chloroprene rubber in 0207Teil21, the thickness of the outer sheath (10) is 2.5mm;
step eleven: and a second braiding layer (11) is braided outside the outer sheath (10), the second braiding layer (11) is braided by polyester yarns, each polyester yarn is 8000D, the number of ingots is 32, each ingot has 1, and the pitch is not more than 80mm.
8. The process for producing the smart energy high-tensile cable according to claim 7, wherein: the processing steps of the fluoroplastic insulation (2-2) in the step II are as follows: preheating a conductor (2-1) by adopting induction type preheating equipment, extruding an insulating material by adopting an extrusion pipe type die when the temperature of the conductor (2-1) reaches 100-120 ℃, wherein the machine body temperature is 350 ℃, and the machine head extrusion temperature is 355 ℃; the fluoroplastic insulation (2-2) is cooled by stages, wherein the water temperature of the first water tank is 80 ℃, the water temperature of the second water tank is 60 ℃, and the water temperature of the third water tank is 60 ℃; finally, placing the insulated wire core (2) in an oven at 160 ℃ for 2 hours for tempering.
9. The process for producing the smart energy high-tensile cable according to claim 8, wherein: in the eighth step, the vulcanization degree of the inner sheath (8) is 80%, and the extrusion process and the vulcanization process of the inner sheath (8) are set according to the Mooney viscosity and the vulcanization characteristic of the chloroprene rubber: the neoprene rubber is extruded by a 90 rubber extruder, the temperature of the extruder body is 60 ℃, the extrusion temperature of the extruder head is 65 ℃, the steam pressure is 6bar, the linear speed is 10m/min, and the vulcanization time is 8min.
10. The process for producing the smart energy high-tensile cable according to claim 9, wherein: in the eleventh step, the extrusion process and the vulcanization process of the outer sheath (10) are set according to the Mooney viscosity and the vulcanization characteristics of the chloroprene rubber: the neoprene rubber is extruded by a 90 rubber extruder, the temperature of the extruder body is 60 ℃, the extrusion temperature of the extruder head is 65 ℃, the steam pressure is 7bar, the linear speed is 8m/min, and the vulcanization time is 10min.
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| CN108320843B (en) * | 2018-03-27 | 2023-10-17 | 河北华通线缆集团股份有限公司 | Reel sling cable and manufacturing method |
| CN109036655A (en) * | 2018-07-31 | 2018-12-18 | 山东华凌电缆有限公司 | A kind of oil resistant resist bending cable for robot arm |
| CN110120283B (en) * | 2019-05-09 | 2021-04-06 | 江苏亨通线缆科技有限公司 | Towline cable and cable preparation method |
| CN111584133A (en) * | 2020-05-25 | 2020-08-25 | 金世纪电缆集团有限公司 | High-strength cable core structure and production process thereof |
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