CN107274989B - Intelligent energy high-speed rail high-wear-resistant high-temperature-resistant cable and production process thereof - Google Patents
Intelligent energy high-speed rail high-wear-resistant high-temperature-resistant cable and production process thereof Download PDFInfo
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- CN107274989B CN107274989B CN201710307366.7A CN201710307366A CN107274989B CN 107274989 B CN107274989 B CN 107274989B CN 201710307366 A CN201710307366 A CN 201710307366A CN 107274989 B CN107274989 B CN 107274989B
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/1895—Internal space filling-up means
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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
- H01B13/02—Stranding-up
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- 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
- H01B13/08—Insulating conductors or cables by winding
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- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
- H01B3/441—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes
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- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
- H01B7/0258—Disposition of insulation comprising one or more longitudinal lapped layers of insulation
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- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/26—Reduction of losses in sheaths or armouring
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- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
- H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
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Abstract
The invention discloses a smart energy high-speed rail high-wear-resistant high-temperature-resistant cable and a production process thereof, wherein the cable sequentially comprises a center filling part, a cable core part, a side gap filling part, a polyester belt, a first fluorine-containing mica tape, a second fluorine-containing mica tape, a silicone rubber inner sheath and a low-smoke halogen-free flame-retardant rubber sheath from inside to outside; the cable cores comprise 1 neutral cable core and 3 power cable cores; the center filling material is hemp ropes; the side gap filling material is a rubber strip and comprises 2 first side gap filling materials filled between the neutral cable core and the power cable core and 2 second side gap filling materials filled between the power cable core and the power cable core; the cable provided by the invention provides a calculation formula of the number of center filling and a calculation formula of the diameter of side gap filling, and the roundness and the structural stability of the cable are effectively improved through accurate calculation, so that the cable disclosed by the invention is compact in structure, round in appearance, excellent in wear resistance, excellent in flame resistance, excellent in oil resistance, high in softness and excellent in performance.
Description
Technical Field
The invention relates to the field of locomotive cables, in particular to a high-wear-resistance high-temperature-resistance cable for smart energy high-speed rail and a production process thereof.
Background
The running and laying environment of cables in a train of the motor train unit is complex, and particularly, the high-speed motor train unit with the speed up to 350km in running has high locomotive power and long high-speed running time, so that the local temperature is increased sharply, and the maximum temperature can be up to 150 ℃. The locomotive cable used in this area therefore requires the use of a silicone rubber material. The vibration or acceleration and deceleration process of the train of the motor train unit in the running process can lead to the cable to be pulled or swung, the cable can be stretched and rubbed continuously, and the silicon rubber material can be damaged due to poor tensile strength and wear resistance. Lubricating oil in a train of the motor train unit can corrode a cable, and the silicone rubber can swell after being corroded by oil stains, so that the tensile strength, insulating property and wear resistance of the silicone rubber are greatly reduced. The requirements of the motor train unit and the train on environmental protection are very high, the cable is required to have good flame retardant property and light transmittance, and the flame retardant property of the silicone rubber is poor. The narrow space in the train of the motor train unit has high requirements on the structural size and the roundness of the cable, so that the cable is fully filled when being formed, and the center filling and side gap filling materials are accurately calculated, so that the cable is guaranteed to be round, and meanwhile, the sheath material can be saved.
The wear-resistant high-temperature-resistant tensile environment-friendly railway locomotive cable disclosed in China patent 201420706323.8 adopts polyether-ether-ketone material for insulation, and a thermoplastic polyurethane elastomer sheath layer is extruded outside the isolation layer, so that the sheath of the cable has excellent wear resistance, but the thermoplastic polyurethane elastomer sheath layer is softened at high temperature, so that the mechanical property and wear resistance of the sheath are reduced, and the service life of the cable is reduced.
Disclosure of Invention
The first object of the invention is to provide a high-wear-resistance and high-temperature-resistance cable for smart energy high-speed rail.
The technical scheme for realizing the first purpose of the invention is that the core filling, the cable core, the polyester belt, the first fluorine-based mica tape, the second fluorine-based mica tape, the silicone rubber inner sheath and the low smoke halogen-free flame retardant rubber sheath are sequentially arranged from inside to outside, and the side gap filling is arranged between the cable core and the polyester belt; the cable cores comprise 1 neutral cable core and 3 power cable cores; the center filling material is hemp ropes, and the calculation formula of the number of the hemp ropes filled in the center is as follows: n=/, d 1 Is the outer diameter of a neutral cable core, d 2 Is the outer diameter d of the power cable core Hemp (hemp) Is the outer diameter of the hemp rope; the side gap filling comprises 2 first side gap filling parts filled between the neutral cable core and the power cable core and 2 second side gap filling parts filled between the power cable core and the power cable core; the first gap filling comprises a first gap filling comprising a first traction cotton and a first filling rubber; the second side gap filling comprises a second traction cotton thread and a second filling rubber; the calculation formula of the diameter of each first filling rubber in the first gap filling is as follows: d (D) dz ＝0.3583×d 2 ，d 2 Is the outer diameter of the power cable core; the calculation formula of the diameter of each second filling rubber in the second side gap filling is as follows: d (D) dd ＝0.4337×d 2 ，d 2 Is the outer diameter of the power cable core.
The silicone rubber inner sheath adopts EM107 type ultralow temperature resistant and oil resistant silicone rubber meeting EN50382 standard, adopts double five as vulcanizing agent, and the dosage of double two five is 0.75% of the weight of the EM107 type ultralow temperature resistant and oil resistant silicone rubber.
The neutral cable core comprises a neutral cable core tinned copper conductor and a neutral cable core insulator; the power cable core comprises a power cable core tin-plated copper conductor and a power cable core insulator.
The rubber of the first filling rubber filled with the first side gap, the rubber of the second filling rubber filled with the second side gap and the rubber of the low-smoke halogen-free flame-retardant rubber sheath adopt low-smoke halogen-free flame-retardant rubber with the temperature resistance of 150 ℃.
The area of the center filling is 13.4mm 2 The number of the filling hemp ropes is 17, and the outer diameter of each hemp rope is 1.0mm; each first filling rubber of the first gap filling is straightThe diameter is 3.7mm; each second filling rubber of the second side gap filling has a diameter of 4.5mm; the cross section area of the neutral cable core tin-plated copper conductor is 16mm 2 The number of the tin-plated copper wires is 126, and the wire diameter is 0.40mm; the thickness of the insulation of the neutral cable core is 1.0mm; the sectional area of the power cable core tin-plated copper conductor is 25mm 2 The number of the tin-plated copper wires is 196, and the wire diameter is 0.40mm; the thickness of the insulation of the power cable core is 2.5mm; the thickness of the polyester belt is 0.05mm, the width of the polyester belt is 16mm, and the overlapping rate is 20% -30%; the thickness of the first fluoromica tape and the second fluoromica tape is 0.17mm, the width of the first fluoromica tape and the second fluoromica tape is 16mm, and the overlap ratio is 15% -20%; the thickness of the silicon rubber inner sheath is 2.5mm; the thickness of the low-smoke halogen-free flame retardant rubber sheath is 1.5mm; the neutral cable core insulation and the power cable core insulation adopt EI112 type ultralow temperature resistant silicon rubber meeting EN50382 standard, and adopt a double-four vulcanizing agent, wherein the weight of the double-four vulcanizing agent is 1% of that of the EI112 type ultralow temperature resistant silicon rubber.
The second object of the invention is to provide a production process of the high-wear-resistance high-temperature-resistance cable for smart energy high-speed rail.
The technical scheme for realizing the second purpose of the invention is a production process of a high-wear-resistance high-temperature-resistant cable for smart energy high-speed rail, which comprises the following steps:
step one: determining a cable structure;
step two: preparing a neutral cable core insulating and power cable core insulating material: adding 1% by weight of biquad into EI 112-type ultralow-temperature-resistant silicon rubber by taking biquad as a vulcanizing agent, mixing for 3 times on an open mill, and cutting into strips with the width of 10cm and the thickness of 0.8cm, wherein the sulfur starting time is 15 seconds, and the vulcanizing time is 1 minute and 25 seconds;
step three: preparing a neutral cable core: the method comprises the steps that a neutral cable core tinned copper conductor is formed by twisting 7 strands, each strand is formed by twisting 18 copper wires, the diameter of each copper wire is 0.40mm, the arrangement mode of each copper wire is that the inner layer is 1, the number of the secondary outer layers is 6, the number of the secondary outer layers is 11, the twisting pitch is larger than 16mm, a diamond die with the aperture of 1.9mm is used for compacting, then the 7 strands are twisted, the arrangement mode of each strand is that the inner layer is 1, the number of the outer layers is 6, the twisting pitch is 40mm, and the diamond die with the aperture of 5.5mm is used for compacting; then extruding the insulating material obtained in the second step outside the tin-copper plated conductor of the neutral cable core to serve as the neutral cable core for insulation, vulcanizing by adopting a hot air drying channel, wherein the temperature of the hot air drying channel is 280 ℃, and the thickness of the neutral cable core for insulation is 1.0mm;
step four: preparing a power cable core: the power cable core tinned copper conductor is formed by twisting 7 strands, each strand is formed by twisting 28 copper wires, the diameter of each copper wire is 0.40mm, the arrangement mode of each copper wire is that the inner layer is 4, the secondary outer layer is 9, the outer layer is 15, the twisting pitch is larger than 20mm, the power cable core tinned copper conductor is tightly pressed by adopting a diamond die with the aperture of 2.3mm, then 7 strands are twisted, the arrangement mode of each strand is that the inner layer is 1, the outer layer is 6, the twisting pitch is 60mm, and the power cable core tinned copper conductor is tightly pressed by adopting a diamond die with the aperture of 7.0 mm; then extruding the insulating material obtained in the second step outside the power cable core tinned copper conductor to serve as power cable core insulation, vulcanizing by adopting a hot air drying channel, wherein the temperature of the hot air drying channel is 280 ℃, or vulcanizing by adopting a hot steam pipeline, the temperature of the hot steam pipeline is 280 ℃, and the thickness of the power cable core insulation is 2.5mm;
step five: preparing a first gap filling: the first traction cotton thread is made of 8 cotton threads in parallel, extrusion type first filling rubber is adopted outside the first traction cotton thread, and the first filling rubber is made of low-smoke halogen-free flame retardant rubber with the temperature resistant of 150 ℃;
step six: preparing a second side gap filling: the second traction cotton thread is made of 10 cotton threads in parallel, extrusion type second filling rubber is adopted outside the second traction cotton thread, and the second filling rubber is made of low-smoke halogen-free flame retardant rubber with the temperature resistant of 150 ℃;
step seven: and (3) cabling: 1 neutral cable core and 3 power cable cores are tangentially arranged into cables in a way of 3+1 small, the center of each cable core is filled with hemp ropes, a first side gap is filled between each neutral cable core and each power cable core, and a second side gap is filled between each power cable core and each power cable core;
step eight: wrapping a polyester belt after cabling, wherein the polyester belt is 0.05mm thick, 16mm wide and 20% -30% in overlapping rate;
step nine: wrapping a first fluoromica tape and a second fluoromica tape outside the polyester tape, wherein the thickness of the first fluoromica tape and the second fluoromica tape is 0.17mm, the width of the first fluoromica tape and the second fluoromica tape is 16mm, and the lap rate is 15% -20%;
step ten: preparing a material for a silicone rubber inner sheath: adding 0.75% of double-five into EM107 ultralow-temperature-resistant oil-resistant silicon rubber serving as a vulcanizing agent, mixing for 5 times on an open mill, and cutting into strips with the width of 10cm and the thickness of 0.8cm, wherein the sulfur starting time is 1 minute, zero and 10 seconds, and the vulcanizing time is 7 minutes and 45 seconds;
step eleven: and (3) co-extruding a silicone rubber inner sheath and a low-smoke halogen-free flame-retardant rubber sheath outside the second fluorophlogopite band in a double-layer co-extrusion saturated steam vulcanization production mode, wherein the silicone rubber inner sheath is made of the material obtained in the step (ten), and the low-smoke halogen-free flame-retardant rubber sheath is made of low-smoke halogen-free flame-retardant rubber with the temperature resistance of 150 ℃.
In the fifth step, according to the calculation formula of the diameter of each gap rubber strip in the first gap filling: d (D) dz ＝0.3583×d 2 Calculating that the diameter of the rubber strip filled with the first side gap is 3.7mm; in the sixth step, according to the calculation formula of the diameter of each gap rubber strip in the second side gap filling: d (D) dd ＝0.4337×d 2 Calculating, wherein the diameter of the rubber strip filled with the second side gap is 4.5mm; in the seventh step, according to the calculation formula of the number of hemp ropes filled in the center: n=/calculation, area of center fill was 13.4mm 2 The number of the filling hemp ropes is 17, and the outer diameter of each hemp rope is 1.0mm.
In the eleventh step, in the double-layer co-extrusion saturated steam vulcanization process, the extrusion temperature is designed according to the Mooney viscosity and vulcanization characteristics of the two materials, namely the silicone rubber inner sheath and the low-smoke halogen-free flame retardant rubber sheath; adopting a 90 rubber extruder to produce a silicone rubber inner sheath, wherein the temperature of the machine body is 20-30 ℃; adopting a 150 rubber extruder to produce a low-smoke halogen-free flame-retardant rubber sheath, wherein the temperature of the machine body is 50-60 ℃; the temperature of the head during double-layer coextrusion is set to be 60 ℃; the extruded sizing material is uniform and smooth in appearance, the production speed is 4-5 m/min, and the air pressure is 6-7 bar.
The thickness and the eccentricity of the silicone rubber inner sheath and the low-smoke halogen-free flame retardant rubber sheath are monitored on line by adopting SIKORA, the eccentricity is debugged according to the display of the SIKORA, the thickness of the silicone rubber inner sheath is ensured to be 2.5mm, and the thickness of the low-smoke halogen-free flame retardant rubber sheath is ensured to be 1.5mm.
By adopting the technical scheme, the invention has the following beneficial results: (1) The cable provided by the invention provides a calculation formula of the number of center filling and a calculation formula of the diameter of side gap filling, and the roundness and the structural stability of the cable are effectively improved through accurate calculation, so that the cable disclosed by the invention is compact in structure, round in appearance, excellent in wear resistance, excellent in oil resistance, excellent in flame retardance, high in softness and excellent in performance.
(2) At present, the silicon rubber is vulcanized in an electrically heated drying tunnel after being extruded by a special rubber extruder, the low-smoke halogen-free flame-retardant rubber is vulcanized in a saturated steam pipeline after being extruded by the rubber extruder, and the vulcanizing modes and the vulcanizing equipment adopted by the two materials are different. The invention improves the types and the amounts of the silicon rubber insulating vulcanizing agents, and the double-layer co-extrusion: meanwhile, a 90 rubber extruder is adopted to extrude the silicone rubber insulation and a 150 rubber extruder is adopted to extrude the low-smoke halogen-free flame retardant rubber, then the low-smoke halogen-free flame retardant rubber enters a saturated steam pipeline for vulcanization, the silicone rubber and the low-smoke halogen-free flame retardant rubber are vulcanized together, and the interface binding force is effectively improved, so that the problems of bending wrinkling and sheath shrinkage of a cable caused by twice extrusion of a silicone rubber inner sheath and a low-smoke halogen-free flame retardant rubber sheath are solved, and the wear resistance and oil resistance of the cable are effectively improved.
(3) The silicone rubber inner sheath of the cable adopts double five replacing double four as vulcanizing agent, and simultaneously reduces the using amount of the vulcanizing agent from 1% to 0.75%, so that the sulfur rising speed and the vulcanizing speed of the EM107 type ultralow temperature and oil resistant silicone rubber are effectively reduced, the scorching problem caused by vulcanizing the silicone rubber by saturated steam is solved, and the surface quality of the inner sheath is effectively improved.
(4) The cable is provided with the low-smoke halogen-free flame-retardant rubber sheath outside the silicone rubber inner sheath, so that the cable not only has high-temperature resistance and flexibility, but also effectively solves the problem that the tensile strength, the wear resistance, the flame retardance and the oil resistance of the silicone rubber material are poor.
(5) When the cable is used for producing the silicone rubber inner sheath and the low-smoke halogen-free flame-retardant rubber sheath by adopting a double-layer co-extrusion saturated steam vulcanization process, the thickness and the eccentricity of the silicone rubber inner sheath and the low-smoke halogen-free flame-retardant rubber sheath are monitored on line by adopting SIKORA, the eccentricity adjusting time can be shortened, the cable can be started up quickly to prevent the silicone rubber inner sheath from being burnt, the surface quality of the inner sheath is effectively improved, and the eccentricity of the cable can be reduced.
(6) The 3 power cable cores and the 1 neutral cable core of the cable are tangentially arranged into the cable in a size of 3+1, the hemp ropes are filled in the central side gaps, rubber strips are filled in the side gaps, the structure is compact, and the structural stability of the cable is high.
(7) The tinned copper wires are stranded during conductor processing, and the copper wires and the stranded wires are tightly pressed by the diamond die, so that the outer diameter of the conductor and burrs on the surface of the conductor are effectively reduced, and the roundness of the conductor is 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 cable core comprises a center filling 1, a cable core 2, a neutral cable core 21, a neutral cable core tin-copper plated conductor 21-1, a neutral cable core insulation 21-2, a power cable core 22, a power cable core tin-copper plated conductor 22-1, a power cable core insulation 22-2, a side gap filling 3, a first side gap filling 31, a first traction cotton wire 31-1, a first filling rubber 31-2, a second side gap filling 32, a second traction cotton wire 32-1, a second filling rubber 32-2, a polyester belt 4, a first fluoromica tape 5, a second fluoromica tape 6, a silicone rubber inner sheath 7 and a low smoke zero halogen flame retardant rubber sheath 8.
Detailed Description
Example 1
Referring to fig. 1, the smart energy high-speed rail high-wear-resistance high-temperature-resistance cable sequentially comprises a core filling 1, a cable core 2, a side gap filling 3, a polyester belt 4, a first fluorous-mica belt 5, a second fluorous-mica belt 6, a silicone rubber inner sheath 7 and a low-smoke halogen-free flame retardant rubber sheath 8 from inside to outside; the cable core 2 comprises 1 neutral cable core 21 and 3 power cable cores22; the material of the center filling 1 is hemp ropes, and the calculation formula of the number of the hemp ropes of the center filling 1 is as follows: n=0.2×d 1 2 +0.02×d 2 2 /0.7854×d Hemp (hemp) 2 ，d 1 Is the outer diameter of a neutral cable core, d 2 Is the outer diameter d of the power cable core Hemp (hemp) Is the outer diameter of the hemp rope; the gap filling 3 is made of rubber strips and comprises 2 first gap filling 31 filled between the neutral cable core 21 and the power cable core 22 and 2 second gap filling 32 filled between the power cable core 22 and the power cable core 22; the calculation formula of the diameter of each gap rubber band in the first gap filling 31 is as follows: d (D) dz ＝0.3583×d 2 ，d 2 Is the outer diameter of the power cable core; the calculation formula for each gap rubber strip diameter in the second gap filler 32 is: d (D) dd ＝0.4337×d 2 ，d 2 Is the outer diameter of the power cable core. The neutral cable core 21 comprises a neutral cable core tin-plated copper conductor 21-1 and a neutral cable core insulation 21-2; the power cable core 22 includes a power cable core tin-plated copper conductor 22-1 and a power cable core insulation 22-2. The area of the center-fill 1 was 13.4mm 2 The number of the filling hemp ropes is 17, and the outer diameter of each hemp rope is 1.0mm. The first gap filler 31 comprises a first traction cotton thread 31-1 and a first filler rubber 31-2, and the diameter of each gap rubber strip of the first gap filler 31 is 3.7mm; the second gap filler 32 includes a second traction cotton 32-1 and a second filler rubber 32-2, each gap rubber strip of the second gap filler 32 having a diameter of 4.5mm. The cross-sectional area of the neutral cable core tin-plated copper conductor 21-1 is 16mm 2 The number of the tin-plated copper wires is 126, and the wire diameter is 0.40mm; the thickness of the neutral cable core insulation 21-2 is 1.0mm; the power cable core tin-plated copper conductor 22-1 has a cross-sectional area of 25mm 2 The number of the tin-plated copper wires is 196, and the wire diameter is 0.40mm; the thickness of the power cable core insulation 22-2 is 2.5mm; the thickness of the polyester belt 4 is 0.05mm, the width is 16mm, and the covering rate is 20% -30%; the thickness of the first fluoromica tape 5 and the second fluoromica tape 6 is 0.17mm, the width is 16mm, and the overlap ratio is 15% -20%; the thickness of the silicone rubber inner sheath 7 is 2.5mm; the thickness of the low-smoke halogen-free flame retardant rubber sheath 8 is 1.5mm. The neutral cable core insulation 21-2 and the power cable core insulation 22-2 adopt EI112 type ultralow temperature resistant silicon rubber meeting EN50382 standardAdopts bi-di-tetra as a vulcanizing agent, weight of the double-four is EI112 1% of ultralow temperature resistant silicon rubber. The silicone rubber inner sheath 7 adopts EM107 type ultralow temperature resistant and oil resistant silicone rubber meeting EN50382 standard, adopts double five as vulcanizing agent, and the dosage weight of double five is 0.75% of the EM107 type ultralow temperature resistant and oil resistant silicone rubber. The first gap filling 31, the second gap filling 32 and the low-smoke halogen-free flame-retardant rubber sheath 8 adopt low-smoke halogen-free flame-retardant rubber with the temperature resistance of 150 ℃.
The production process comprises the following steps:
step one: determining the cable structure as in fig. 1;
step two: preparing a neutral cable core insulation 21-2 and a power cable core insulation 22-2 material: adding 1% by weight of Biqual-tetrad into EI 112-type ultralow-temperature-resistant silicon rubber as a vulcanizing agent, mixing for 3 times on an open mill, and cutting into strips with the width of 10cm and the thickness of 0.8cm, wherein the sulfur starting time is 15 seconds, and the vulcanizing time is 1 minute and zero 25 seconds;
step three: preparing a neutral cable core 21: the neutral cable core tin-plated copper conductor 21-1 is formed by twisting tin-plated copper wires, 7 strands are twisted, 18 copper wires are twisted for each strand, the diameter of each copper wire is 0.40mm, the arrangement mode of each copper wire is that the inner layer is 1, the secondary outer layer is 6, the outer layer is 11, the twisting pitch is larger than 16mm, a diamond die with the aperture of 1.9mm is used for compacting, then 7 strands are twisted, the arrangement mode of each strand is that the inner layer is 1, the outer layer is 6, the twisting pitch is 40mm, and a diamond die with the aperture of 5.5mm is used for compacting; then extruding the insulating material obtained in the second step outside the neutral cable core tin-copper plated conductor 21-1 to serve as a neutral cable core insulation 21-2, vulcanizing by adopting a hot air drying channel, wherein the temperature of the hot air drying channel is 280 ℃, or extruding the neutral cable core insulation 21-2 outside the neutral cable core tin-copper plated conductor 21-1 by using a silicone rubber extruder, vulcanizing by adopting a hot steam pipeline, wherein the temperature of the hot steam pipeline is 280 ℃, and the thickness of the neutral cable core insulation 21-2 is 1.0mm;
step four: preparation of the power cable core 22: the power cable core tinned copper conductor 22-1 is formed by twisting 7 strands, each strand is formed by twisting 28 copper wires, the diameter of each copper wire is 0.40mm, the arrangement mode of each copper wire is that the inner layer is 4, the secondary outer layer is 9, the outer layer is 15, the twisting pitch is larger than 20mm, the power cable core tinned copper conductor is tightly pressed by adopting a diamond die with the aperture of 2.3mm, then the 7 strands are twisted, the arrangement mode of each strand is that the inner layer is 1, the outer layer is 6, the twisting pitch is 60mm, and the power cable core is tightly pressed by adopting the diamond die with the aperture of 7.0 mm; then, extruding the insulating material obtained in the second step outside the power cable core tin-plated copper conductor 22-1 to serve as a power cable core insulator 22-2, vulcanizing by adopting a hot air drying channel, wherein the temperature of the hot air drying channel is 280 ℃, and the thickness of the power cable core insulator 22-2 is 2.5mm;
step five: preparation of first gap filling 31: the first traction cotton thread 31-1 is made of 8 cotton threads in parallel, extrusion type first filling rubber 31-2 is adopted outside the first traction cotton thread 31-1, and the first filling rubber 31-2 is made of low-smoke halogen-free flame retardant rubber with the temperature resistant of 150 ℃; the rubber band diameter of the first gap filling 31 is 3.7mm;
step six: preparing a second gap filler 32: the second traction cotton thread 32-1 is made of 10 cotton threads in parallel, extrusion type second filling rubber 31-2 is adopted outside the second traction cotton thread 32-1, and the second filling rubber 32-2 is made of low-smoke halogen-free flame retardant rubber with the temperature resistant of 150 ℃; the diameter of the rubber band of the second gap filler 32 is 4.5mm
Step seven: and (3) cabling: 1 neutral cable core 21 and 3 power cable cores 22 are tangentially arranged into cables in a way of 3+1 small, the central filling 1 is a hemp rope, a first gap filling 31 is filled between the neutral cable cores 21 and the power cable cores 22, and a second gap filling 32 is filled between the power cable cores 22 and the power cable cores 22; the area of the center-fill 1 was 13.4mm 2 The number of the filling hemp ropes is 17, and the outer diameter of each hemp rope is 1.0mm
Step eight: wrapping the polyester belt 4 after cabling, wherein the thickness of the polyester belt 4 is 0.05mm, the width is 16mm, and the covering rate is 20% -30%;
step nine: wrapping a first fluoromica tape 5 and a second fluoromica tape 6 outside the polyester tape 4, wherein the thickness of the first fluoromica tape 5 and the second fluoromica tape 6 is 0.17mm, the width is 16mm, and the lap rate is 15% -20%;
step ten: preparation of a material for the silicone rubber inner sheath 7: adopts two to five as the vulcanizing agent, adding 0.75% of double-five rubber into EM107 ultralow temperature resistant and oil resistant silicone rubber, mixing for 5 times on an open mill, cutting into strips with the width of 10cm and the thickness of 0.8cm, the sulfur starting time is 1 minute and zero 10 seconds, and the vulcanizing time is 7 minutes and 45 seconds;
step eleven: and (3) co-extruding a silicone rubber inner sheath 7 and a low-smoke halogen-free flame-retardant rubber sheath 8 outside the second fluorous-gold-mica tape 6 by adopting a production mode of double-layer co-extrusion saturated steam vulcanization, wherein the silicone rubber inner sheath 7 adopts the material obtained in the step (ten), and the low-smoke halogen-free flame-retardant rubber sheath 8 adopts low-smoke halogen-free flame-retardant rubber with the temperature resistance of 150 ℃. The Mooney viscosity and the vulcanization characteristics of the two materials of the silicone rubber inner sheath 7 and the low-smoke halogen-free flame retardant rubber sheath 8 are used for designing extrusion temperature; adopting a 90 rubber extruder to produce a silicone rubber inner sheath 7, wherein the temperature of the machine body is 20-30 ℃; a 150 rubber extruder is adopted to produce a low-smoke halogen-free flame retardant rubber sheath 8, and the temperature of a machine body is 50-60 ℃; the temperature of the head during double-layer coextrusion is set to be 60 ℃; the appearance of the extruded sizing material is uniform and smooth, the production speed is 4-5 m/min, and the air pressure is 6-7 bar; the thickness and the eccentricity of the silicone rubber inner sheath 7 and the low-smoke halogen-free flame-retardant rubber sheath 8 are monitored on line by adopting SIKORA, the eccentricity adjusting time is shortened, the machine is started up quickly to prevent the silicone rubber inner sheath 7 from being burnt, the eccentricity is adjusted according to the display of the SIKORA, the thickness of the silicone rubber inner sheath 7 is ensured to be 2.5mm, and the thickness of the low-smoke halogen-free flame-retardant rubber sheath 8 is ensured to be 1.5mm.
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 (9)
1. Wisdom energy high-speed railway is with high wear-resisting high temperature resistant cable, its characterized in that: the cable core (2) is sequentially filled with a center (1), a cable core (2), a polyester belt (4), a first fluorogold mica belt (5), a second fluorogold mica belt (6), a silicone rubber inner jacket (7) and a low-smoke halogen-free flame retardant rubber jacket (8) from inside to outside, and a side gap is filled between the cable core (2) and the polyester belt (4); the cable core (2) comprises 1 neutral cable core (21) and 3 power cable cores (22); the material of the center filling (1) is hemp ropes, and the calculation formula of the number of the hemp ropes of the center filling (1) is as follows: n= (0.2×d12+0.02×d22)/(0.7854 ×d2), d1 is the outer diameter of the neutral cable core (21), d2 is the outer diameter of the power cable core (22), and d hemp is the outer diameter of the hemp rope; the side gap filling device comprises a neutral cable core (21) and a power cable core (22), wherein the side gap filling device comprises 2 first side gap filling devices (31) filled between the neutral cable core (21) and the power cable core (22) and 2 second side gap filling devices (32) filled between the power cable core (22) and the power cable core (22); the first gap filler (31) comprises a first gap filler (31) comprising a first traction cotton (31-1) and a first filler rubber (31-2); the second side gap filler (32) comprises a second traction cotton thread (32-1) and a second filling rubber (32-2); the calculation formula of the diameter of each first filling rubber (31-2) in the first gap filling rubber (31) is as follows: ddz = 0.3583 ×d2, d2 being the outer diameter of the power cable core (22); the calculation formula of the diameter of each second filling rubber (32-2) in the second side gap filling (32) is as follows: ddd = 0.4337 ×d2, d2 being the outer diameter of the power cable core (22).
2. The smart energy high-speed rail high-wear-resistant and high-temperature-resistant cable according to claim 1, wherein: the silicone rubber inner sheath (7) adopts EM107 type ultralow temperature and oil resistant silicone rubber meeting EN50382 standard, adopts two-five as vulcanizing agent, and the dosage of the two-five is 0.75 percent of the weight of the EM107 type ultralow temperature and oil resistant silicone rubber.
3. The smart energy high-speed rail cable of claim 2, wherein: the neutral cable core (21) comprises a neutral cable core tin-plated copper conductor (21-1) and a neutral cable core insulator (21-2); the power cable core (22) comprises a power cable core tin-plated copper conductor (22-1) and a power cable core insulator (22-2).
4. A smart energy high-speed rail high-wear-resistant and high-temperature-resistant cable according to claim 3, wherein: the rubber of the first filling rubber (31-2) of the first gap filling rubber (31), the rubber of the second filling rubber (33-2) of the second gap filling rubber (32) and the rubber of the low-smoke halogen-free flame-retardant rubber sheath (8) adopt low-smoke halogen-free flame-retardant rubber with the temperature resistance of 150 ℃.
5. The smart energy high-speed railway is with high wear-resisting high temperature resistant cable of claim 4, wherein: the area of the center filling (1) is 13.4mm < 2 >, the number of the filling hemp ropes is 17, and the outer diameter of each hemp rope is 1.0mm; each first filling rubber (31-2) of the first gap filling (31) has a diameter of 3.7mm; each second filling rubber (32-2) of the second gap filling (32) has a diameter of 4.5mm; the cross section of the neutral cable core tin-copper plated conductor (21-1) is 16mm < 2 >, the number of tin-copper plated wires is 126, and the wire diameter is 0.40mm; the thickness of the neutral cable core insulation (21-2) is 1.0mm; the sectional area of the power cable core tinned copper conductor (22-1) is 25mm < 2 >, the number of the tinned copper conductors is 196, and the wire diameter is 0.40mm; the thickness of the power cable core insulation (22-2) is 2.5mm; the thickness of the polyester belt (4) is 0.05mm, the width is 16mm, and the covering rate is 20% -30%; the thickness of the first fluorous-to-mica tape (5) and the second fluorous-to-mica tape (6) is 0.17mm, the width is 16mm, and the overlap ratio is 15% -20%; the thickness of the silicon rubber inner sheath (7) is 2.5mm; the thickness of the low-smoke halogen-free flame retardant rubber sheath (8) is 1.5mm; the neutral cable core insulation (21-2) and the power cable core insulation (22-2) adopt EI112 type ultralow temperature resistant silicon rubber meeting EN50382 standard, and adopt a double-four vulcanizing agent, wherein the weight of the double-four vulcanizing agent is 1% of that of the EI112 type ultralow temperature resistant silicon rubber.
6. The production process of the high-wear-resistant and high-temperature-resistant cable for the smart energy high-speed rail is characterized by comprising the following steps of:
step one: determining the cable structure as claimed in claim 4;
step two: preparing a neutral cable core insulation (21-2) and a power cable core insulation (22-2) material: adding 1% by weight of biquad into EI 112-type ultralow-temperature-resistant silicon rubber by taking biquad as a vulcanizing agent, mixing for 3 times on an open mill, and cutting into strips with the width of 10cm and the thickness of 0.8cm, wherein the sulfur starting time is 15 seconds, and the vulcanizing time is 1 minute and 25 seconds;
step three: preparation of neutral core (21): the neutral cable core tin-plated copper conductor (21-1) is formed by twisting tin-plated copper wires, 7 strands are twisted, 18 copper wires are twisted for each strand, the diameter of each copper wire is 0.40mm, the arrangement mode of each copper wire is that of an inner layer, the number of each copper wire is 6, the number of each copper wire is 11, the twisting pitch is larger than 16mm, a diamond die with the aperture of 1.9mm is used for compacting, then 7 strands are twisted, the arrangement mode of each strand is that of the inner layer, the number of each copper wire is that of the outer layer, the twisting pitch is 40mm, and the diameter of each copper wire is that of the diamond die with the aperture of 5.5mm is used for compacting; then extruding the insulating material obtained in the second step outside the neutral cable core tin-plated copper conductor (21-1) to serve as a neutral cable core insulator (21-2), vulcanizing by adopting a hot air drying channel, wherein the temperature of the hot air drying channel is 280 ℃, and the thickness of the neutral cable core insulator (21-2) is 1.0mm;
step four: preparation of a power cable core (22): the power cable core tin-plated copper conductor (22-1) is formed by twisting 7 strands, wherein each strand is formed by twisting 28 copper wires, the diameter of each copper wire is 0.40mm, the arrangement mode of each copper wire is that of an inner layer and an outer layer is 4, the number of each copper wire is that of an outer layer, the number of each copper wire is 15, the twisting pitch is larger than 20mm, a diamond die with the aperture of 2.3mm is used for compacting, then the 7 strands are twisted, the arrangement mode of each strand is that of the inner layer and the outer layer is that of the 6 strands, the twisting pitch is 60mm, and the diamond die with the aperture of 7.0mm is used for compacting; then extruding the insulating material obtained in the second step outside the power cable core tin-plated copper conductor (22-1) to serve as power cable core insulation (22-2), vulcanizing by adopting a hot air drying channel, wherein the temperature of the hot air drying channel is 280 ℃, or vulcanizing by adopting a hot steam pipeline, the temperature of the hot steam pipeline is 280 ℃, and the thickness of the power cable core insulation (22-2) is 2.5mm;
step five: preparation of first gap filling (31): the first traction cotton thread (31-1) is made of 8 cotton threads in a doubling way, extrusion type first filling rubber (31-2) is adopted outside the first traction cotton thread (31-1), and the first filling rubber (31-2) is made of low-smoke halogen-free flame retardant rubber with the temperature resistance of 150 ℃;
step six: preparation of a second gap filling (32): the second traction cotton thread (32-1) is made of 10 cotton threads in a doubling way, extrusion type second filling rubber (31-2) is adopted outside the second traction cotton thread (32-1), and the second filling rubber (32-2) is made of low-smoke halogen-free flame retardant rubber with the temperature resistance of 150 ℃;
step seven: and (3) cabling: 1 neutral cable core (21) and 3 power cable cores (22) are tangentially arranged into cables with 3 large plus 1 small, the central filling (1) is a hemp rope, a first gap filling (31) is filled between the neutral cable cores (21) and the power cable cores (22), and a second gap filling (32) is filled between the power cable cores (22) and the power cable cores (22);
step eight: wrapping the polyester belt (4) after cabling, wherein the thickness of the polyester belt (4) is 0.05mm, the width is 16mm, and the covering rate is 20% -30%;
step nine: wrapping a first fluoromica tape (5) and a second fluoromica tape (6) outside the polyester tape (4), wherein the thickness of the first fluoromica tape (5) and the second fluoromica tape (6) is 0.17mm, the width is 16mm, and the lap rate is 15% -20%;
step ten: preparation of a material for a silicone rubber inner sheath (7): adopts biwu as vulcanizing agent, adds biwu with 0.75 percent of rubber weight into EM107 type ultralow temperature resistant oil resistant silicon rubber, mixing for 5 times on an open mill, cutting into strips with the width of 10cm and the thickness of 0.8cm, wherein the sulfur starting time is 1 minute and 10 seconds, and the sulfur curing time is 7 minutes and 45 seconds;
step eleven: and (3) co-extruding a silicone rubber inner sheath (7) and a low-smoke halogen-free flame-retardant rubber sheath (8) outside the second fluorous-gold-mica tape (6) by adopting a production mode of double-layer co-extrusion saturated steam vulcanization, wherein the silicone rubber inner sheath (7) adopts the material obtained in the step (ten), and the low-smoke halogen-free flame-retardant rubber sheath (8) adopts low-smoke halogen-free flame-retardant rubber with the temperature resistance of 150 ℃.
7. The production process of the high-wear-resistant and high-temperature-resistant cable for smart energy high-speed rail, which is characterized by comprising the following steps of: in the fifth step, according to a calculation formula of the diameter of each gap rubber strip in the first gap filling (31): ddz = 0.3583 x d2, the rubber band diameter of the first gap filling (31) being 3.7mm; in the step six, according to a calculation formula of the diameter of each gap rubber strip in the second side gap filling (32): ddd = 0.4337 x d2, the second gap filling (32) rubber band diameter being 4.5mm; in the seventh step, according to the calculation formula of the hemp rope number of the center filling (1): n= (0.2×d12+0.02×d22)/(0.7854 ×d2) calculated, the area of the center fill (1) was 13.4mm2, the number of fill twines was 17, and the outer diameter of each twine was 1.0mm.
8. The production process of the high-wear-resistant and high-temperature-resistant cable for smart energy high-speed rail, which is characterized by comprising the following steps of: in the eleventh step, in the double-layer co-extrusion saturated steam vulcanization process, the Mooney viscosity and vulcanization characteristics of the two materials of the silicone rubber inner sheath (7) and the low-smoke halogen-free flame retardant rubber sheath (8) are designed to be extrusion temperatures; adopting a 90 rubber extruder to produce a silicone rubber inner sheath (7), wherein the temperature of the machine body is 20-30 ℃; a 150 rubber extruder is adopted to produce a low-smoke halogen-free flame retardant rubber sheath (8), and the temperature of a machine body is 50-60 ℃; the temperature of the head during double-layer coextrusion is set to be 60 ℃; the extruded sizing material is uniform and smooth in appearance, the production speed is 4-5 m/min, and the air pressure is 6-7 bar.
9. The production process of the high-wear-resistant and high-temperature-resistant cable for smart energy high-speed rail, which is characterized by comprising the following steps of: the thickness and the eccentricity of the silicone rubber inner sheath (7) and the low-smoke halogen-free flame retardant rubber sheath (8) are monitored on line by adopting SIKORA, the eccentricity is debugged according to the display of the SIKORA, the thickness of the silicone rubber inner sheath (7) is ensured to be 2.5mm, and the thickness of the low-smoke halogen-free flame retardant rubber sheath (8) is ensured to be 1.5mm.
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| CN105006282A (en) * | 2015-07-28 | 2015-10-28 | 远东电缆有限公司 | Thin-wall cable used for smart energy motor train unit and production technology thereof |
| CN105185464A (en) * | 2015-09-28 | 2015-12-23 | 远东电缆有限公司 | Standard wall cable for smart energy motor train unit and production process |
| CN205004081U (en) * | 2015-10-20 | 2016-01-27 | 江西电缆有限责任公司 | Mineral substance insulated cable's structure |
| CN206774281U (en) * | 2017-05-03 | 2017-12-19 | 远东电缆有限公司 | A kind of wisdom energy high ferro heat-resistant fireproof cable |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| US9412492B2 (en) * | 2009-04-17 | 2016-08-09 | Schlumberger Technology Corporation | Torque-balanced, gas-sealed wireline cables |
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Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105006282A (en) * | 2015-07-28 | 2015-10-28 | 远东电缆有限公司 | Thin-wall cable used for smart energy motor train unit and production technology thereof |
| CN105185464A (en) * | 2015-09-28 | 2015-12-23 | 远东电缆有限公司 | Standard wall cable for smart energy motor train unit and production process |
| CN205004081U (en) * | 2015-10-20 | 2016-01-27 | 江西电缆有限责任公司 | Mineral substance insulated cable's structure |
| CN206774281U (en) * | 2017-05-03 | 2017-12-19 | 远东电缆有限公司 | A kind of wisdom energy high ferro heat-resistant fireproof cable |
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