CN108878007A - 一种风力发电用屏蔽软电缆及其制造方法 - Google Patents
一种风力发电用屏蔽软电缆及其制造方法 Download PDFInfo
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Abstract
本发明公开了一种风力发电用屏蔽软电缆及其制造方法。电缆由内至外依次为绝缘线芯、硅橡胶内护层、总屏蔽层和外护套;所述绝缘线芯为三根,每根由内至外依次为导体、无纺布绕包带、绝缘层、半导电绕包带和分屏蔽层;所述总屏蔽层和分屏蔽层均采用镀锡铜丝编织与铝塑复合带地复合屏蔽层结构。本发明采用铜丝编织+铝塑复合带进行分屏和总屏,电缆抗磁场干扰性能好,能将风力发电稳定的传输。同时,编织层柔软度高,可以满足电缆6D(D为电缆直径)弯曲半径。
Description
技术领域
本发明涉及一种风力发电用屏蔽软电缆及其制造方法。
背景技术
数据显示,在2005至2016年间,全球海上风电装机容量增长了近15倍,到2018年底,全球海上风电累计装机有望达到32948MW,占到全球风电装机规模的6%。
目前世界海上风电的发展以环绕在北海的英国、德国、荷兰、比利时和丹麦等发达国为领跑者。海上风电行业的发展催生了对风力发电电缆的需求,风力发电用电缆具有优异的耐严寒、耐高温、耐扭曲、耐油浸、耐腐蚀、抗开裂等性能,为满足海上风电用电缆的特殊的使用环境和要求,有必要开发风力发电用屏蔽软电缆。
发明内容
本发明的目的是提供一种风力发电用屏蔽软电缆及其制造方法。
实现本发明目的的技术方案是一种风力发电用屏蔽软电缆,由内至外依次为绝缘线芯、硅橡胶内护层、总屏蔽层和外护套;所述绝缘线芯为三根,每根由内至外依次为导体、无纺布绕包带、绝缘层、半导电绕包带和分屏蔽层;所述总屏蔽层和分屏蔽层均采用镀锡铜丝编织与铝塑复合带地复合屏蔽层结构。
所述绝缘层采用125℃乙丙橡胶,组成及配比,以质量份计为:
二元乙丙橡胶:100份;
硫化剂:5.0~9.0份;
氧化锌:4.0~6.0份;
硬脂酸:0.5~2.0份;
防老剂:1.5~5.0份;
微晶石蜡:4.0~7.0份;
偶联剂:1.0~3.0份;
石蜡油:6.0~10.0份;
气相白炭黑:4.0~6.0份;
改性煅烧白陶土:60.0~80.0份;
滑石粉:30.0~50.0份;
钛白粉:3.0~5.0份。
所述硫化剂为DCP与TAIC混合的复合硫化剂,以质量份计,DPC:3.0~5.0份,TAIC:2.0~4.0份。
所述防老剂为防老剂MB和防老剂RD混合的复合防老剂,以质量份计,防老剂MB:1.0~3.0份,防老剂RD:0.5~2.0份。
所述滑石粉粒径为2500目。
所述绝缘层采用125℃乙丙橡胶,组成及配比,以质量份计为:
二元乙丙橡胶:100份;
硫化剂:6.5份;
氧化锌:5.0份;
硬脂酸:1.0份;
防老剂:2.5份;
微晶石蜡:6.0份;
偶联剂:1.5份;
石蜡油:8.0份;
气相白炭黑:5.0份;
改性煅烧白陶土:80.0份;
滑石粉:40.0份;
钛白粉:4.0份。
所述镀锡铜丝编织选用32锭,9根直径为0.245mm铜丝编织。
风力发电用屏蔽软电缆还包括设置于三根绝缘纤芯之间的橡皮条填充。
本发明还提供一种风力发电用屏蔽软电缆的制造方法,包括以下步骤:
步骤一:确定电缆结构;
步骤二:制备绝缘层用的125℃乙丙橡胶,组成及配比,以质量份计为:
二元乙丙橡胶:100份;
硫化剂:5.0~9.0份;
氧化锌:4.0~6.0份;
硬脂酸:0.5~2.0份;
防老剂:1.5~5.0份;
微晶石蜡:4.0~7.0份;
偶联剂:1.0~3.0份;
石蜡油:6.0~10.0份;
气相白炭黑:4.0~6.0份;
改性煅烧白陶土:60.0~80.0份;
滑石粉:30.0~50.0份;
钛白粉:3.0~5.0份;
步骤三:导体经拉丝和绞合生产出符合IEC 60228的五类软导体,导体截面根据输电容量而定;在导体外部绕包无纺布;
步骤四:将步骤二得到的绝缘层材料挤包在无纺布外层,并进行硫化;
步骤五:制作分屏蔽层,在绝缘层表面绕包半导电带,采用0.1~0.3mm镀锡铜丝进行编织,编织密度在80~85%,编织完成后绕包铝塑复合带;
步骤六:成缆,节径比10~12,在内部空隙填充橡皮条;
步骤七:在成缆外部挤包硅橡胶内护;
步骤八:制作总屏蔽层,硅橡胶内护外绕包聚酯带,采用0.1~0.3mm镀锡铜丝进行编织,编织密度在80~85%,编织完成后绕包铝塑复合带;
步骤九:护套,采用125℃EVA低烟无卤橡皮护套,护套厚度为2.0~6.0mm。
所述步骤二中,在密炼机中加入除硫化剂外的原料,翻斗清扫,压上顶栓,混炼7~8min,混炼出胶温度110℃~120℃,至少混炼三次;然后加入DCP和TAIC两种硫化剂,低速混炼,混炼温度95~105℃,混炼时间不超过1min;开炼机压片,压片厚度0.8~1mm。
采用了上述技术方案后,本发明具有以下的积极的效果:(1)本发明采用铜丝编织+铝塑复合带进行分屏和总屏,电缆抗磁场干扰性能好,能将风力发电稳定的传输。同时,编织层柔软度高,可以满足电缆6D(D为电缆直径)弯曲半径。
(2)本发明采用自主开发125℃乙丙橡胶绝缘,具有电性能优异、强度高、耐高温特性,提高电缆高温下绝缘性能,能有效的控制成本和产品性能,可在125℃环境中长期运行。
(3)本发明的护套采用125℃EVA低烟无卤橡皮护套耐严寒、耐高温、耐扭曲、耐油浸、耐腐蚀、抗开裂等性能,环保可以满足RoHS和低烟无卤要求;耐油性能满足902#、Tribol1710/320齿轮油和Mobil DTE 13M液压用油,以及壳牌Tellus Arctic 32和Castrol AWH-M32,可在100℃油温下坚持24小时。
(4)本发明的绝缘、填充、内护和外护均采用橡胶材料,橡皮条填充成缆线芯内部空隙,硅橡胶内护,电缆结构稳定性好,作为风电动力传输电缆具有良好的弯曲性能,固定敷设≥4D,移动使用≥6D,从+150℃到-150℃到+150℃为周期的扭转,大于2000次不出现开裂。
(5)本发明的绝缘导体、绝缘、内护、外护均为软结构,固定使用最小弯曲半径为4D(D为电缆直径),移动使用最小弯曲半径为6D。
附图说明
为了使本发明的内容更容易被清楚地理解,下面根据具体实施例并结合附图,对本发明作进一步详细的说明,其中
图1为本发明的电缆的截面示意图。
附图中标号为:
绝缘线芯1、导体1-1、无纺布绕包带1-2、绝缘层1-3、半导电绕包带1-4、分屏蔽层1-5、硅橡胶内护层2、总屏蔽层3、外护套4、橡皮条填充5。
具体实施方式
(实施例1-3)
见图1,实施例1-3的结构为:由内至外依次为绝缘线芯1、硅橡胶内护层2、总屏蔽层3和外护套4;绝缘线芯1为三根,每根由内至外依次为导体1-1、无纺布绕包带1-2、绝缘层1-3、半导电绕包带1-4和分屏蔽层1-5;总屏蔽层3和分屏蔽层1-5均采用镀锡铜丝编织与铝塑复合带地复合屏蔽层结构。根镀锡铜丝编织选用32锭,9根直径为0.245mm铜丝编织。三根绝缘纤芯1之间填充橡皮条填充5。外护套4采用125℃EVA低烟无卤橡皮护套。
绝缘层1-3采用125℃乙丙橡胶,组成及配比,以质量份计为:
二元乙丙橡胶:100份;
硫化剂:5.0~9.0份;
氧化锌:4.0~6.0份;
硬脂酸:0.5~2.0份;
防老剂:1.5~5.0份;
微晶石蜡:4.0~7.0份;
偶联剂:1.0~3.0份;
石蜡油:6.0~10.0份;
气相白炭黑:4.0~6.0份;
改性煅烧白陶土:60.0~80.0份;
滑石粉:30.0~50.0份;
钛白粉:3.0~5.0份。
三个实施例的用量见表1:
表1:
材料 | 型号 | 实施例1 | 实施例2 | 实施例3 |
二元乙丙胶4044 | 4044 | 100.0 | 100.0 | 100.0 |
DCP | - | 3.0 | 3.5 | 5.0 |
TAIC | - | 2.0 | 3.0 | 4.0 |
氧化锌 | - | 4.0 | 5.0 | 6.0 |
硬脂酸 | - | 0.5 | 1.0 | 2.0 |
防老剂MB | - | 1.0 | 1.5 | 3.0 |
防老剂RD | - | 0.5 | 1.0 | 2.0 |
微晶石蜡 | - | 4.0 | 6.0 | 7.0 |
偶联剂 | KH-570 | 1.0 | 1.5 | 3.0 |
石蜡油 | T-16 | 6.0 | 8.0 | 10.0 |
气相白炭黑 | K200 | 4.0 | 5.0 | 6.0 |
改性煅烧白陶土 | DC-70 | 60.0 | 80 | 80.0 |
2500目滑石粉 | - | 30.0 | 40 | 50.0 |
钛白粉 | R-996 | 3.0 | 4 | 5.0 |
二元乙丙胶4044具有较好的强度和电性能,胶片强度可以达到6.0MPa,电性能达到6.0*1012Ω.m。氧化锌能促进交联速度和提高交联程度,硬脂酸和微晶石蜡改善胶料的加工性能。防老剂MB和RD复合使用提高胶料的抗老化性能,偶联剂KH-570提高乙丙胶与无机填料的相容性,提升胶料强度。石蜡油起到内增塑作用,提高胶料的挤出性能。气相白炭黑能较好的起到补强作用,提升胶料强度。改性煅烧白陶土具有较好的电性能,在提高胶料强度同时保证胶料的电性能。2500滑石粉填料具有高的比表面积,与胶料结合性好,能显著提高胶料强度,同时能提高胶料的挤出性能。钛白粉用于提高胶料的白度,使胶料外观更好。
实施例1-3得到的乙丙橡胶经检测性能如表2:
表2:
制造方法包括以下步骤:
步骤一:确定如附图1的结构;
步骤二:制备绝缘层用的125℃乙丙橡胶;在密炼机中加入除硫化剂外的原料,翻斗清扫,压上顶栓,混炼7~8min,混炼出胶温度110℃~120℃,至少混炼三次;然后加入DCP和TAIC两种硫化剂,低速混炼,混炼温度95~105℃,混炼时间不超过1min;开炼机压片,压片厚度0.8~1mm。
步骤三:导体经拉丝和绞合生产出符合IEC 60228的五类软导体,导体截面根据输电容量而定;在导体外部绕包无纺布;
步骤四:将步骤二得到的绝缘层材料挤包在无纺布外层,并进行硫化;采用挤压式模具,硫化气压8~9bar,硫化温度175~185℃,绝缘厚度1.2~5.0mm,对应牵引速度16.9~7.8m/min;
步骤五:制作分屏蔽层以防止多芯电缆之间互相干扰,在绝缘层表面绕包半导电带,采用0.1~0.3mm镀锡铜丝进行编织,编织密度在80~85%,编织完成后绕包铝塑复合带,防止编织空袭泄露电场;
步骤六:成缆,节径比10~12,在内部空隙填充橡皮条,以提高电缆稳定性;
步骤七:在成缆外部挤包硅橡胶内护,提高电缆的稳定性,内护厚度1.0~1.5mm;
步骤八:制作总屏蔽层,硅橡胶内护外绕包聚酯带,采用0.1~0.3mm镀锡铜丝进行编织,编织密度在80~85%,编织完成后绕包铝塑复合带;
步骤九:护套,采用125℃EVA低烟无卤橡皮护套,护套厚度为2.0~6.0mm。
按照前述工艺得到的电缆与现有电缆的性能对比见表3:
表3:
以上所述的具体实施例,对本发明的目的、技术方案和有益效果进行了进一步详细说明,所应理解的是,以上所述仅为本发明的具体实施例而已,并不用于限制本发明,凡在本发明的精神和原则之内,所做的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (10)
1.一种风力发电用屏蔽软电缆,其特征在于:由内至外依次为绝缘线芯(1)、硅橡胶内护层(2)、总屏蔽层(3)和外护套(4);所述绝缘线芯(1)为三根,每根由内至外依次为导体(1-1)、无纺布绕包带(1-2)、绝缘层(1-3)、半导电绕包带(1-4)和分屏蔽层(1-5);所述总屏蔽层(3)和分屏蔽层(1-5)均采用镀锡铜丝编织与铝塑复合带地复合屏蔽层结构。
2.根据权利要求1所述的一种风力发电用屏蔽软电缆,其特征在于:所述绝缘层(1-3)采用125℃乙丙橡胶,组成及配比,以质量份计为:
二元乙丙橡胶:100份;
硫化剂:5.0~9.0份;
氧化锌:4.0~6.0份;
硬脂酸:0.5~2.0份;
防老剂:1.5~5.0份;
微晶石蜡:4.0~7.0份;
偶联剂:1.0~3.0份;
石蜡油:6.0~10.0份;
气相白炭黑:4.0~6.0份;
改性煅烧白陶土:60.0~80.0份;
滑石粉:30.0~50.0份;
钛白粉:3.0~5.0份。
3.根据权利要求2所述的一种风力发电用屏蔽软电缆,其特征在于:所述硫化剂为DCP与TAIC混合的复合硫化剂,以质量份计,DPC:3.0~5.0份,TAIC:2.0~4.0份。
4.根据权利要求2所述的一种风力发电用屏蔽软电缆,其特征在于:所述防老剂为防老剂MB和防老剂RD混合的复合防老剂,以质量份计,防老剂MB:1.0~3.0份,防老剂RD:0.5~2.0份。
5.根据权利要求2所述的一种风力发电用屏蔽软电缆,其特征在于:所述滑石粉粒径为2500目。
6.根据权利要求2所述的一种风力发电用屏蔽软电缆,其特征在于:所述绝缘层(1-3)采用125℃乙丙橡胶,组成及配比,以质量份计为:
二元乙丙橡胶:100份;
硫化剂:6.5份;
氧化锌:5.0份;
硬脂酸:1.0份;
防老剂:2.5份;
微晶石蜡:6.0份;
偶联剂:1.5份;
石蜡油:8.0份;
气相白炭黑:5.0份;
改性煅烧白陶土:80.0份;
滑石粉:40.0份;
钛白粉:4.0份。
7.根据权利要求1至6之一所述的一种风力发电用屏蔽软电缆,其特征在于:所述镀锡铜丝编织选用32锭,9根直径为0.245mm铜丝编织。
8.根据权利要求8所述的一种风力发电用屏蔽软电缆,其特征在于:还包括设置于三根绝缘纤芯(1)之间的橡皮条填充(5)。
9.一种风力发电用屏蔽软电缆的制造方法,其特征在于包括以下步骤:
步骤一:确定如权利要求8所述的电缆结构;
步骤二:制备绝缘层用的125℃乙丙橡胶,组成及配比,以质量份计为:
二元乙丙橡胶:100份;
硫化剂:5.0~9.0份;
氧化锌:4.0~6.0份;
硬脂酸:0.5~2.0份;
防老剂:1.5~5.0份;
微晶石蜡:4.0~7.0份;
偶联剂:1.0~3.0份;
石蜡油:6.0~10.0份;
气相白炭黑:4.0~6.0份;
改性煅烧白陶土:60.0~80.0份;
滑石粉:30.0~50.0份;
钛白粉:3.0~5.0份;
步骤三:导体经拉丝和绞合生产出符合IEC 60228的五类软导体,导体截面根据输电容量而定;在导体外部绕包无纺布;
步骤四:将步骤二得到的绝缘层材料挤包在无纺布外层,并进行硫化;
步骤五:制作分屏蔽层,在绝缘层表面绕包半导电带,采用0.1~0.3mm镀锡铜丝进行编织,编织密度在80~85%,编织完成后绕包铝塑复合带;
步骤六:成缆,节径比10~12,在内部空隙填充橡皮条;
步骤七:在成缆外部挤包硅橡胶内护;
步骤八:制作总屏蔽层,硅橡胶内护外绕包聚酯带,采用0.1~0.3mm镀锡铜丝进行编织,编织密度在80~85%,编织完成后绕包铝塑复合带;
步骤九:护套,采用125℃EVA低烟无卤橡皮护套,护套厚度为2.0~6.0mm。
10.根据权利要求9所述的一种风力发电用屏蔽软电缆的制造方法,其特征在于:所述步骤二中,在密炼机中加入除硫化剂外的原料,翻斗清扫,压上顶栓,混炼7~8min,混炼出胶温度110℃~120℃,至少混炼三次;然后加入DCP和TAIC两种硫化剂,低速混炼,混炼温度95~105℃,混炼时间不超过1min;开炼机压片,压片厚度0.8~1mm。
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CN116153588A (zh) * | 2023-04-14 | 2023-05-23 | 上海电气集团腾恩驰科技(苏州)有限公司 | 一种抗干扰屏蔽通信电缆的生产系统 |
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