CN110504053B - 风力发电机组用中压抗扭动力电缆 - Google Patents
风力发电机组用中压抗扭动力电缆 Download PDFInfo
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Abstract
本发明公开一种中压抗扭动力电缆,包括至少一根动力线芯、与动力线芯绞合的至少一根接地线芯、包绕在动力线芯、接地线芯外部的护套层,动力线芯包括导体、包覆导体的绝缘层;绝缘层包括以下各组份:三元乙丙橡胶;微晶蜡;石蜡油;三氧化二锑;钛白粉;纳米氧化锌;煅烧高岭土;偶联剂;防老剂;硫化剂;硫化助剂;护套层包括以下各组份:氯化聚乙烯;氢氧化镁;白炭黑;改性煅烧高岭土;热塑性弹性体;防老剂;红丹母胶;三氧化二锑;轻质氧化镁;钙锌稳定剂;硬脂酸;高耐磨炭黑;增塑剂;耐寒增塑剂;偶联剂;硫化剂;硫化促进剂。本发能够解决8MW海上风力发电机组抗扭动力电缆长期高载流量、弯曲疲劳、老化、撕裂等导致使用寿命下降的问题。
Description
技术领域
本发明涉及风力发电技术领域,具体涉及一种8MW海上风力发电机组用中压抗扭动力电缆。
背景技术
海上风场相对于陆地风电场,风场风机所处的海洋环境十分复杂和恶劣,承受着多种随时间和空间变化的随机荷载,包括风、海浪、海流、海冰和潮汐等作用于结构,同时还受到地震作用的威胁。在如此恶劣的环境条件下,环境腐蚀、海生物附着、地基土冲刷和基础动力软化、材料老化、构件缺陷和机械损伤、疲劳和裂纹扩展的损伤积累等不利因素都将导致海上风机结构构件和整体抗力的衰减,影响风机结构的运行安全度和耐久性。大功率海上风力发电机组高载流量抗扭动力电缆作为海上风力发电机组传输电力的重要构件,也承受大部分风机所处恶劣环境的影响,严重影响产品的使用寿命。
8MW海上风机采用的是中压抗扭动力电缆,其要求缆在同等截面下应具有更高的载流量,而动力电缆的载流量与使用温度相关。目前,常规中压抗扭动力电缆使用乙丙橡皮绝缘、氯丁橡皮护套层,最高使用温度在90℃,抗张强度、耐老化性和抗撕裂性都不高,使得其用在8MW海上风机上会因为复杂和恶劣的使用环境造成使用寿命短、维护成本高的问题。
发明内容
本发明实施例提供一种风力发电机组用中压抗扭动力电缆,使用最高耐受105℃的乙丙橡胶绝缘料制成动力线芯的绝缘层、最高耐受105℃的氯化聚乙烯护套料制成动力电缆的护套层,绝缘抗涨强度不小于11MPa、断裂伸长率大于300%,满足海上风力发电机组高载流量抗扭电缆在正常工作环境下(工作温度-40℃~+105℃)的各项电力传输和使用性能,解决8MW海上风力发电机组抗扭动力电缆长期高载流量、弯曲疲劳、老化、撕裂等导致使用寿命下降的问题。
为了解决上述技术问题,本发明提供了一种风力发电机组用中压抗扭动力电缆,包括至少一根动力线芯、与所述动力线芯相绞合的至少一根接地线芯、包绕在所述动力线芯、接地线芯外部的护套层,所述动力线芯包括导体、包覆在所述导体外部的绝缘层;
所述绝缘层由绝缘料制成,所述绝缘料包括按重量份数计的以下各组份:
所述护套层由护套料制成,所述护套料包括按重量份数计的以下各组份:
本发明一个较佳实施例中,进一步包括所述绝缘料的制备方法包括以下步骤,
(1)取全部份数的三元乙丙橡胶放入密炼机中混炼均匀;
(2)取全部份数的三氧化二锑、钛白粉、纳米氧化锌、微晶蜡、防老剂和一半份数的煅烧高岭土加入密炼机中混炼,混炼2~3分钟后,加入全部份数的石蜡油继续混炼至均匀;
(3)取全部份数的偶联剂和一半份数的煅烧高岭土加入密炼机中混炼均匀;
(4)取全部份数的硫化剂和硫化助剂加入密炼机中混炼均匀,获得制成所述绝缘材料的绝缘混炼胶料。
本发明一个较佳实施例中,进一步包括取所述绝缘混炼胶料在开炼机上薄通1~2次、摆胶2~3次,随后在压延机上开条出片,输出的橡页冷却后过滑石粉箱,制备获得所述绝缘材料。
本发明一个较佳实施例中,进一步包括所述护套料的制备方法包括以下步骤,
(1)取全部份数的氯化聚乙烯放入密炼机中混炼均匀;
(2)取全部份数的氢氧化镁、白炭黑、改性煅烧高岭土、热塑性弹性体、防老剂、红丹母胶、三氧化二锑、轻质氧化镁、钙锌稳定剂、硬脂酸、高耐磨炭黑加入密炼机中混炼均匀;
(3)取全部份数的耐寒增塑剂、增塑剂、偶联剂加入密炼机中混炼均匀;
(4)取全部份数的硫化剂和硫化促进剂加入密炼机中混炼均匀,获得制成所述护套材料的护套混炼胶料。
本发明一个较佳实施例中,进一步包括取所述护套混炼胶料在开炼机上薄通1~2次、摆胶2~3次,随后在压延机上开条出片,输出的橡页冷却后过滑石粉箱,制备获得所述护套材料。
本发明一个较佳实施例中,进一步包括所述密炼机的混炼温度为100℃~120℃。
本发明一个较佳实施例中,进一步包括所述动力线芯还包括导体屏蔽层和绝缘屏蔽层,所述导体屏蔽层包覆在导体的外部,所述绝缘层包覆在导体屏蔽层外部,所述绝缘屏蔽层包覆在绝缘层外部。
本发明一个较佳实施例中,进一步包括该动力电缆还包括编织屏蔽层,所述编织屏蔽层包绕在动力线芯、接地线芯外部,所述护套层包绕在编织屏蔽层外部,所述编织屏蔽层为纤维丝和镀锡铜丝混合编织的屏蔽层。
本发明一个较佳实施例中,进一步包括所述动力线芯、接地线芯绞合后通过填充层填充,所述填充层为半导电橡胶。
本发明一个较佳实施例中,进一步包括该动力电缆包括三根动力线芯和三根接地线芯。
本发明的有益效果:
其一、本发明的风力发电机组用中压抗扭动力电缆,使用最高耐受105℃的乙丙橡胶绝缘料制成动力线芯的绝缘层、最高耐受105℃的氯化聚乙烯护套料制成动力电缆的护套层,绝缘抗涨强度不小于11MPa、断裂伸长率大于300%,满足海上风力发电机组高载流量抗扭电缆在正常工作环境下(工作温度-40℃~+105℃)的各项电力传输和使用性能,解决8MW海上风力发电机组抗扭动力电缆长期高载流量、弯曲疲劳、老化、撕裂等导致使用寿命下降的问题。
其二、绝缘材料配方中含有一定比例的三氧化二锑,能够增强耐热性能,提高三元乙丙橡胶在高温下吸收热氧自由原子性能,避免热氧自由原子和橡胶主链接触而发生反应,相对于现有乙丙橡皮绝缘料能够极大提高耐热性能。
其三、绝缘材料配方中含有一定比例的煅烧高岭土,易于分散,颗粒容量较小,达到纳米级,悬浮性能好;通过纳米级刚性颗粒进行填充,补充橡胶分子链间的空隙,增加补强效果,提高配方材料的抗张强度。
其四,氯化聚乙烯在挤出成型过程中,因受到强热和机械剪力的影响,致使聚氯乙烯结构式中的B-碳原子上的氯原子极易和相邻碳原子上的氢原子结合,放出HCl气体,从而产生双键,使相邻的氯原子活化,该氯原子极不稳定,又促使相邻的碳原子放出HCl气体形成多稀链段,使聚合物降解,从而影响护套层的机械强度,使寿命相应缩减。为了解决此技术问题,本申请动力线芯的护套料中加入一定组份的钙锌稳定剂,钙锌稳定剂的加入可以缓慢反应速度,保持化学平衡,降低表面涨力,达到防止光热和氧化作用,使护套层中氯的活度降低,结构稳定。同时加入防老剂、红丹母胶可促使高分子聚合,增加分子量,从而产生高分子链结构的主价键,断裂力也因此而增大,形成以络合物链为主体的牢固束缚在一起的结晶实体,使护套料的结构致密,各种性能得到改善。
其五,护套料中使用增塑剂替代现有配方中的石蜡油、氯化石蜡等热稳定比较差的增塑剂,具有高散点的特性,不容易挥发,确保护套配方材料在高温条件下的热稳定效果。
附图说明
图1是本发明实施例中抗扭动力电缆的剖面示意图;
图2是抗扭动力电缆成缆工艺流程图。
图中标号说明:2-动力线芯,21-导体,22-导体屏蔽层,23-绝缘层,24-绝缘屏蔽层;
4-接地线芯,6-编织屏蔽层,8-填充层,10-护套层。
具体实施方式
下面结合附图和具体实施例对本发明作进一步说明,以使本领域的技术人员可以更好地理解本发明并能予以实施,但所举实施例不作为对本发明的限定。
参照如图1所示的一种风力发电机组用中压抗扭动力电缆,该电缆包括三根动力线芯2、三根接地线芯4以及填充层8绞合成缆芯,缆芯外部包绕编织屏蔽层6,编织屏蔽层6外部挤塑护套层10。
本实施例优选技术方案中,上述填充层8为半导电橡胶。上述编织屏蔽层为纤维丝和镀锡铜丝混合编织的屏蔽层。
具体的,动力线芯2包括导体21、包覆在导体1外部的导体屏蔽层22、包覆在导体屏蔽层22外部的绝缘层23、包覆在绝缘层23外部的绝缘屏蔽层。
参照图2所示,制成动力线芯2时,铜丝束绞后绕包半导电带,随后三层共挤,挤出半导电导体屏蔽料+105℃乙丙橡胶绝缘料+半导电绝缘屏蔽料;105℃乙丙橡胶绝缘料的具体组份如下表1:
表1
该105℃乙丙橡胶绝缘料的制备方法包含以下步骤:
(1)取全部份数的三元乙丙橡胶Kep510放入100℃~120℃密炼机中混炼均匀;
(2)取全部份数的三氧化二锑、钛白粉、纳米氧化锌、微晶蜡、防老剂XH-3和一半份数的煅烧高岭土B7加入密炼机中混炼,混炼2~3分钟后,加入全部份数的石蜡油2280继续混炼至均匀;
(3)取全部份数的偶联剂KH550和一半份数的煅烧高岭土B7加入密炼机中混炼均匀;
(4)取全部份数的过氧化二异丙苯和三烯丙基异氰脲酸酯加入密炼机中混炼均匀,获得制成105℃乙丙橡胶绝缘料的混炼胶料;
(5)取混炼胶料在开炼机上薄通1~2次、摆胶2~3次,随后在压延机上开条出片,输出的橡页冷却后过滑石粉箱,制备获得105℃乙丙橡胶绝缘料。
取实施例二中各组份制成的105℃乙丙橡胶绝缘料,其各项测试性能如下表2所示:
表2
本实施例技术方案中,以主料为氯化聚乙烯的105℃特种护套料挤塑成型护套层10,105℃特种护套料的具体组份如下表3:
表3
该105℃特种护套料的制备方法包含以下步骤:
(1)取全部份数的氯化聚乙烯CM135B放入100℃~120℃密炼机中混炼均匀;
(2)取全部份数的氢氧化镁、白炭黑、改性煅烧高岭土、热塑性弹性体POE、防老剂RD、红丹母胶、三氧化二锑、轻质氧化镁、钙锌稳定剂、硬脂酸1801、高耐磨炭黑N-330加入密炼机中混炼均匀;
(3)取全部份数的耐寒增塑剂DOS、增塑剂(偏苯三酸三辛酯)、偶联剂KH550加入密炼机中混炼均匀;
(4)取全部份数的硫化剂过氧化二异丙苯)和硫化促进剂(三烯丙基异氰脲酸酯)加入密炼机中混炼均匀,获得制成所述护套材料的混炼胶料;
(5)取混炼胶料在开炼机上薄通1~2次、摆胶2~3次,随后在压延机上开条出片,输出的橡页冷却后过滑石粉箱,制备获得护套材料。
取实施例二中各组份制成的105℃特种护套料,其各项测试性能如下表4所示:
表4
以下具体阐述抗扭动力缆的工艺流程:
参照图2所示,(1)型号电压规格:FDEH(105)26/35kV 3x95,
电缆名称及具体说明:105℃特种护套、105℃乙丙橡胶绝缘8MW海上风力发电机组抗扭动力电缆,动力线芯3芯95mm2标称截面,电压等级26/35kV。
(2)具体方案:如上图1所示,
动力线芯:先用铜丝束绞后,绕包半导电带,挤出半导电导体屏蔽料+特种105℃乙丙橡胶绝缘料+半导电绝缘屏蔽料;
地线芯:先用铜丝束绞后,绕包半导电带,再挤出半导电橡皮;
编织屏蔽层:采用纤维丝+镀锡铜丝混合编织屏蔽层;
总成缆:将金属屏蔽动力线芯、地线芯结构按照合适的节径比一起成缆,在中心填充半导电橡胶;
外护套:在缆芯外挤包105℃特种护套料作为外护套。
以上所述实施例仅是为充分说明本发明而所举的较佳的实施例,本发明的保护范围不限于此。本技术领域的技术人员在本发明基础上所作的等同替代或变换,均在本发明的保护范围之内。本发明的保护范围以权利要求书为准。
Claims (9)
1.一种风力发电机组用中压抗扭动力电缆,其特征在于:包括至少一根动力线芯、与所述动力线芯相绞合的至少一根接地线芯、包绕在所述动力线芯、接地线芯外部的护套层,所述动力线芯包括导体、包覆在所述导体外部的绝缘层;
所述绝缘层由绝缘料制成,所述绝缘料包括按重量份数计的以下各组份:
所述护套层由护套料制成,所述护套料包括按重量份数计的以下各组份:
所述绝缘料的制备方法包括以下步骤,
(1)取全部份数的三元乙丙橡胶放入密炼机中混炼均匀;
(2)取全部份数的三氧化二锑、钛白粉、纳米氧化锌、微晶蜡、防老剂和一半份数的煅烧高岭土加入密炼机中混炼,混炼2~3分钟后,加入全部份数的石蜡油继续混炼至均匀;
(3)取全部份数的偶联剂和一半份数的煅烧高岭土加入密炼机中混炼均匀;
(4)取全部份数的硫化剂和硫化助剂加入密炼机中混炼均匀,获得制成所述绝缘料的绝缘混炼胶料。
2.如权利要求1所述的风力发电机组用中压抗扭动力电缆,其特征在于:取所述绝缘混炼胶料在开炼机上薄通1~2次、摆胶2~3次,随后在压延机上开条出片,输出的橡页冷却后过滑石粉箱,制备获得所述绝缘料。
3.如权利要求1所述的风力发电机组用中压抗扭动力电缆,其特征在于:所述护套料的制备方法包括以下步骤,
(1)取全部份数的氯化聚乙烯放入密炼机中混炼均匀;
(2)取全部份数的氢氧化镁、白炭黑、改性煅烧高岭土、热塑性弹性体、防老剂、红丹母胶、三氧化二锑、轻质氧化镁、钙锌稳定剂、硬脂酸、高耐磨炭黑加入密炼机中混炼均匀;
(3)取全部份数的耐寒增塑剂、偏苯三酸三辛酯、偶联剂加入密炼机中混炼均匀;
(4)取全部份数的硫化剂和硫化促进剂加入密炼机中混炼均匀,获得制成所述护套料的护套混炼胶料。
4.如权利要求3所述的风力发电机组用中压抗扭动力电缆,其特征在于:取所述护套混炼胶料在开炼机上薄通1~2次、摆胶2~3次,随后在压延机上开条出片,输出的橡页冷却后过滑石粉箱,制备获得所述护套料。
5.如权利要求1或3所述的风力发电机组用中压抗扭动力电缆,其特征在于:所述密炼机的混炼温度为100℃~120℃。
6.如权利要求1所述的风力发电机组用中压抗扭动力电缆,其特征在于:所述动力线芯还包括导体屏蔽层和绝缘屏蔽层,所述导体屏蔽层包覆在导体的外部,所述绝缘层包覆在导体屏蔽层外部,所述绝缘屏蔽层包覆在绝缘层外部。
7.如权利要求1所述的风力发电机组用中压抗扭动力电缆,其特征在于:该动力电缆还包括编织屏蔽层,所述编织屏蔽层包绕在动力线芯、接地线芯外部,所述护套层包绕在编织屏蔽层外部,所述编织屏蔽层为纤维丝和镀锡铜丝混合编织的屏蔽层。
8.如权利要求1所述的风力发电机组用中压抗扭动力电缆,其特征在于:所述动力线芯、接地线芯绞合后通过填充层填充,所述填充层为半导电橡胶。
9.如权利要求1所述的风力发电机组用中压抗扭动力电缆,其特征在于:该动力电缆包括三根动力线芯和三根接地线芯。
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