CN110690003A - 66kV wind power high-voltage torsion cable and production process thereof - Google Patents
66kV wind power high-voltage torsion cable and production process thereof Download PDFInfo
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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
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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
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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
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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
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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
- 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
- H01B3/28—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances natural or synthetic rubbers
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- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
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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
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Abstract
本发明公开了66kV风电高压扭转电缆及其生产工艺,电缆包括:马鞍形支撑填充层;位于电缆中心,设有三个弧形缺口,表面涂覆有石墨粉;三根主线芯;设置在所述填充层的三个弧形缺口中,表面涂覆有石墨粉;三根接地电芯;分别设置在两根所述主线芯之间,并由填充层支撑,表面涂覆有石墨粉;半导电内护层、纤维丝编织层和外护套,依次设置于三根主线芯外部。本发明的填充层有弧形缺口,与主电芯形状互相卡嵌,既加强了电缆抗拉和抗耐扭性能,且结构紧凑,安装占用空间小,同时绞合节距大。
The invention discloses a 66kV wind power high-voltage torsion cable and a production process thereof. The cable comprises: a saddle-shaped support filling layer; three arc-shaped gaps are arranged in the center of the cable, and the surface is coated with graphite powder; three main wire cores; In the three arc-shaped gaps of the layer, the surface is coated with graphite powder; three grounded cells are respectively arranged between the two main cores and supported by the filling layer, and the surface is coated with graphite powder; semi-conductive inner protection The layer, the fiber braided layer and the outer sheath are sequentially arranged outside the three main cores. The filling layer of the present invention has an arc-shaped notch, which is interlocked with the shape of the main electric core, which not only enhances the tensile and torsional resistance of the cable, but also has a compact structure, small installation space, and large twisting pitch.
Description
技术领域technical field
本发明涉及一种电缆,尤其涉及一种66kV风电高压扭转电缆及其生产工艺。The invention relates to a cable, in particular to a 66kV wind power high-voltage torsion cable and a production process thereof.
背景技术Background technique
当前全球热衷于持续性可再生新能源,其中风力发电占有举足轻重的地位。未来风电技术发展的驱动力主要来自蓬勃崛起的海上风电场建设,这一发展趋势已不可逆转。海上风电机组将逐步向10MW以上的大型化机组发展,并且支撑基础将从固定式走向漂浮式。海上风电场的规模也将继续向大型化发展。随着海上风电单机容量的不断增长,以33kV作为场内海缆的电压等级逐渐成为制约海缆系统设计的瓶颈。因此,一些欧洲海上风电场率先开始尝试提高场内海缆的电压等级。在建的英国Blyth海上示范风电场是全球第一个以66kV作为场内海缆电压等级的海上风电场,许多正在规划中或已中标的项目也将采用66kV电压等级方案。根据丹麦风能咨询机构预测,欧洲市场将于2019年起全面转向66kV电压等级。但我们国内的高压橡套电缆外径大、重量重,不能满足高压风电扭转电缆的使用要求。At present, the world is keen on sustainable renewable energy, among which wind power plays a pivotal role. The driving force for the development of wind power technology in the future will mainly come from the booming construction of offshore wind farms, and this development trend is irreversible. Offshore wind turbines will gradually develop to large-scale units of more than 10MW, and the support foundation will change from fixed to floating. The scale of offshore wind farms will also continue to develop to large-scale. With the continuous growth of offshore wind power unit capacity, 33kV as the voltage level of the submarine cable in the field has gradually become a bottleneck restricting the design of the submarine cable system. Therefore, some European offshore wind farms are the first to try to increase the voltage level of the submarine cables in the field. The British Blyth Offshore Demonstration Wind Farm under construction is the first offshore wind farm in the world to use 66kV as the voltage level of the submarine cable in the field. Many projects under planning or winning bids will also adopt the 66kV voltage level scheme. According to the forecast of the Danish Wind Energy Consulting Agency, the European market will fully switch to the 66kV voltage level from 2019. However, our domestic high-voltage rubber sheathed cables have large outer diameters and heavy weights, which cannot meet the requirements of high-voltage wind power torsion cables.
发明内容SUMMARY OF THE INVENTION
本发明的目的是解决现有电缆性能无法满足的问题,提供耐扭性能强,电性能优异、外径小、重量轻的一种66kV耐扭风电软电缆及其生产工艺。The purpose of the present invention is to solve the problem that the performance of the existing cables cannot be satisfied, and to provide a 66kV torsion-resistant flexible wind power cable with strong torsion resistance, excellent electrical performance, small outer diameter and light weight, and a production process thereof.
实现本发明目的的技术方案是66kV风电高压扭转电缆,包括:马鞍型支撑填充层;位于电缆中心,设有三个弧形缺口,表面涂覆有石墨粉;三根主线芯;设置在所述填充层的三个弧形缺口中,表面涂覆有石墨粉;三根接地电芯;分别设置在两根所述主线芯之间,并由填充层支撑,表面涂覆有石墨粉;半导电内护层、纤维丝编织层和外护套,依次设置于三根主线芯外部。本发明的填充层有弧形缺口,与主电芯形状互相卡嵌,既加强了电缆抗拉和抗耐扭性能,且结构紧凑,电缆外径小、重量小。The technical solution for realizing the purpose of the present invention is a 66kV wind power high-voltage torsion cable, which includes: a saddle-shaped support filling layer; three arc-shaped gaps are arranged in the center of the cable, and the surface is coated with graphite powder; three main cores are arranged on the filling layer. In the three arc-shaped gaps, the surface is coated with graphite powder; three grounded battery cores are respectively arranged between the two main cores and supported by the filling layer, and the surface is coated with graphite powder; semiconductive inner protective layer , a fiber braided layer and an outer sheath, which are arranged outside the three main cores in sequence. The filling layer of the present invention has an arc-shaped notch, which is interlocked with the shape of the main electric core, which not only enhances the tensile and torsional resistance of the cable, but also has a compact structure, small outer diameter and low weight of the cable.
进一步的,所述主线芯由内至外依次为主线芯导体、导电尼龙带、半导电内屏蔽层、绝缘层和可剥离半导电外屏蔽层;Further, the main wire core is the main wire core conductor, the conductive nylon tape, the semiconductive inner shielding layer, the insulating layer and the peelable semiconducting outer shielding layer in sequence from the inside to the outside;
所述绝缘层采用HEPR超洁净乙丙橡胶。本发明的乙丙橡胶绝缘层体积电阻率高,在满足绝缘性的同时厚度降低,使电缆外径和重量降低,节约安装占用空间。The insulating layer adopts HEPR ultra-clean ethylene-propylene rubber. The ethylene-propylene rubber insulating layer of the invention has high volume resistivity, reduces the thickness while satisfying the insulating property, reduces the outer diameter and weight of the cable, and saves the installation space.
作为优选,所述主线芯导体采用五类镀锡铜导体,单丝直径为0.485~0.490mm的镀锡铜丝绞合成一股直径为2.5mm的镀锡铜丝束,然后37股镀锡铜丝束按照1+6+12+18的排列结构左向绞合成主线芯导体,由内至外的绞合节距依次为20~22D、16~18D和12~14D。本发明的导体采用分层微紧压,该电缆结构柔软,导体圆整,外观光滑且间隙小。有利于66kV高压电缆绝缘生产,可以减小绝缘偏心度和导体间隙放电现象,提高电缆的电性能和耐扭转性能。Preferably, the main core conductor is made of five types of tinned copper conductors, tinned copper wires with a single wire diameter of 0.485-0.490mm are twisted into a tinned copper wire bundle with a diameter of 2.5mm, and then 37 strands of tinned copper wire are used. The tow is twisted leftward into the main core conductor according to the arrangement structure of 1+6+12+18, and the twisting pitch from the inside to the outside is 20-22D, 16-18D and 12-14D in turn. The conductor of the present invention adopts layered micro-compression, the cable structure is soft, the conductor is round, the appearance is smooth and the gap is small. It is beneficial to the production of 66kV high voltage cable insulation, can reduce the insulation eccentricity and conductor gap discharge phenomenon, and improve the electrical performance and torsion resistance of the cable.
作为进一步的优选,所述纤维丝编织层采用D1500涤纶丝浸渍间苯二酚-甲醛树脂与乳胶的混合液后编织,编织节距为80~90mm,编织密度为25%~30%。浸渍的混合胶水在挤出外护进入硫化管道后,在高温高压下能够使内护层和外护套在涤纶丝位置能够粘合起来,从而提高了护层的抗拉强度和抗撕性能。As a further preference, the fiber filament weaving layer is woven with D1500 polyester filament impregnated with a mixture of resorcinol-formaldehyde resin and latex, the weaving pitch is 80-90 mm, and the weaving density is 25%-30%. After extruding the outer sheath into the vulcanized pipe, the impregnated mixed glue can bond the inner sheath and the outer sheath at the polyester yarn position under high temperature and high pressure, thereby improving the tensile strength and tear resistance of the sheath.
进一步的,所述接地电芯由内至外依次为接地导体和地线芯屏蔽层。Further, the grounded electric cores are, from inside to outside, a grounding conductor and a grounding core shielding layer in sequence.
作为优选,所述接地导体采用五类镀锡铜导体,单丝直径为0.29~0.30mm的镀锡铜丝绞合成一股直径为3.3mm的镀锡铜丝束,然后7股镀锡铜丝束按照1+6的排列结构左向绞合成接地导体,绞合节距为16~18D。该种结构地线芯与主线芯保持相同的弯曲半径及扭转幅度,可以提高电缆的弯曲性能和扭转性能。Preferably, five types of tinned copper conductors are used for the grounding conductor, and tinned copper wires with a single wire diameter of 0.29-0.30 mm are twisted into a tinned copper wire bundle with a diameter of 3.3 mm, and then 7 strands of tinned copper wires are formed. The bundles are twisted to the left into ground conductors according to the arrangement of 1+6, and the twisting pitch is 16-18D. The ground wire core of this structure maintains the same bending radius and torsional amplitude as the main wire core, which can improve the bending performance and torsional performance of the cable.
更进一步的,所述填充层每个边的宽度至少为2.5mm,能够起到很好地支撑作用。Further, the width of each side of the filling layer is at least 2.5mm, which can play a good supporting role.
本发明还提供66kV风电高压扭转电缆的生产工艺,包括以下步骤:The present invention also provides a production process of the 66kV wind power high-voltage torsion cable, comprising the following steps:
S1:制备填充层,在填充层外部涂覆石墨粉;S1: prepare a filling layer, and coat graphite powder on the outside of the filling layer;
S2:制备主线芯,在主线芯导体外绕包导电尼龙带,挤出半导电内屏蔽层、绝缘层和可剥离半导电外屏蔽层,在主线芯外部涂覆石墨粉;S2: prepare the main wire core, wrap the conductive nylon tape around the main wire core conductor, extrude the semiconductive inner shielding layer, the insulating layer and the strippable semiconducting outer shielding layer, and coat the outside of the main wire core with graphite powder;
S3:制备接地电芯,在接地导体外挤出地线芯屏蔽层外部涂覆石墨粉;S3: Prepare the grounding cell, and coat the graphite powder on the outside of the grounding core shielding layer extruded outside the grounding conductor;
S4:将主线芯放入填充层的弧形缺口处,将接地电芯放置在主线芯间的凹槽内一起形成缆芯,在缆芯外挤出半导电内护层,再编织纤维丝编织层,最后挤出外护套。S4: Put the main core into the arc-shaped gap of the filling layer, place the grounding cell in the groove between the main cores to form a cable core, extrude a semi-conductive inner sheath outside the cable core, and then weave fiber filaments layer and finally extrude the outer sheath.
进一步的,所述S2步中,所述挤出绝缘层的具体方法为:采用66KV高电性能超洁净的乙丙绝缘材料HEPR,绝缘材料的20℃体积电阻率3.0*1016Ω·cm,生产车间单独隔离,加料系统采用百万级净化级别净化房,落料系统采用重力自动落料系统,并在机颈位置配备杂质分析仪;挤出前使用35kV电压等级的清洗料对挤橡机的机身和模具进行清洗三遍,再用66kV绝缘材料进行排料。Further, in the step S2, the specific method of extruding the insulating layer is: using 66KV high electrical performance ultra-clean ethylene propylene insulating material HEPR, the 20 ℃ volume resistivity of the insulating material is 3.0*10 16 Ω·cm, The production workshop is isolated separately, the feeding system adopts a million-level purification room, the blanking system adopts a gravity automatic blanking system, and an impurity analyzer is equipped at the neck position; before extrusion, a 35kV voltage level cleaning material is used to control the extruder. The fuselage and mold are cleaned three times, and then discharged with 66kV insulating material.
更进一步的,所述S2步中半导电内屏蔽层、绝缘层和可剥离半导电外屏蔽层三层共挤,三层共挤塑的模具尺寸为:内模直径16.6mm,中模直径18.2mm,外模直径39mm,模套直径40.6mm;中模与外模的锥角角度差为5~10°,内模与模套的锥角角度差在5~10°,可以大大增加内屏和外屏挤出压力,保证内外屏蔽与绝缘紧密结合程度。Further, in the step S2, the semi-conductive inner shielding layer, the insulating layer and the peelable semi-conductive outer shielding layer are co-extruded in three layers, and the dimensions of the three-layer co-extrusion die are: the diameter of the inner die is 16.6 mm, and the diameter of the middle die is 18.2 mm. mm, the diameter of the outer die is 39mm, and the diameter of the die sleeve is 40.6mm; the angle difference of the taper angle between the middle die and the outer die is 5 to 10°, and the difference between the taper angle of the inner die and the die sleeve is 5 to 10°, which can greatly increase the inner screen. And the extrusion pressure of the outer screen to ensure the tightness of the inner and outer shielding and insulation.
采用了上述技术方案后,本发明具有积极的效果:(1)本发明的填充层有弧形缺口,与主电芯形状互相卡嵌,而且使电缆主线芯和地线芯分布更加均匀,既加强了电缆抗拉和抗耐扭性能,且结构紧凑,安装占用空间小,同时绞合节距大。After adopting the above technical solutions, the present invention has positive effects: (1) the filling layer of the present invention has an arc-shaped notch, which is interlocked with the shape of the main battery core, and the distribution of the main wire core and the ground wire core of the cable is more uniform, not only The tensile and torsional resistance of the cable is enhanced, and the structure is compact, the installation space is small, and the twisting pitch is large.
(2)本发明的乙丙橡胶绝缘层电性能优异,在满足电性能的同时可以降低绝缘厚度,使电缆外径和重量降低,安装更方便,且能保证电缆的电性能和柔软度。(2) The ethylene-propylene rubber insulating layer of the present invention has excellent electrical properties, can reduce the insulating thickness while meeting the electrical properties, reduce the outer diameter and weight of the cable, make installation more convenient, and ensure the electrical properties and softness of the cable.
(3)本发明在主线芯、地线芯、填充层表面均涂石墨粉,降低了过渡电阻,控制过渡电阻500MΩ以下。(3) In the present invention, graphite powder is all coated on the surface of the main wire core, the ground wire core and the filling layer, which reduces the transition resistance and controls the transition resistance to be less than 500MΩ.
(4)本发明的导体采用分层微紧压,该电缆结构柔软,股线和复绞方向相同,外观光滑且缝隙小,有利于66kv高压电缆绝缘生产,减小偏心度,减少间隙放电现象,提高电缆的电性能,导体截距大可有提高电缆耐扭转性能。(4) The conductor of the present invention adopts layered micro-compression, the cable structure is soft, the strands and the twisting direction are the same, the appearance is smooth and the gap is small, which is conducive to the production of 66kv high-voltage cable insulation, reduces the eccentricity, and reduces the gap discharge phenomenon , Improve the electrical performance of the cable, the conductor intercept can improve the torsion resistance of the cable.
(5)本发明的纤维丝编织层采用D1500涤纶丝浸渍间苯二酚-甲醛树脂与乳胶的混合液后编织,浸渍的混合胶水在挤出外护进入硫化管道后,在高温高压下能够使内护层和外护套在涤纶丝位置能够粘合起来,从而提高了护层的抗拉强度和抗撕性能。(5) The fiber filament braided layer of the present invention adopts D1500 polyester filament impregnated with the mixed solution of resorcinol-formaldehyde resin and latex and then woven. The inner sheath and the outer sheath can be bonded together at the position of the polyester yarn, thereby improving the tensile strength and tear resistance of the sheath.
(6)填充层每个边的宽度至少为2.5mm,能够起到很好地支撑作用。(6) The width of each side of the filling layer is at least 2.5mm, which can play a good supporting role.
附图说明Description of drawings
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In order to make the content of the present invention easier to understand clearly, the present invention will be described in further detail below according to specific embodiments and in conjunction with the accompanying drawings, wherein
图1为本发明电缆的示意图。Figure 1 is a schematic diagram of the cable of the present invention.
附图中标号为:The numbers in the attached drawings are:
填充层100;filling layer 100;
主线芯200;主线芯导体210、导电尼龙带220、半导电内屏蔽层230、绝缘层240和、可剥离半导电外屏蔽层250;Main wire core 200; main wire core conductor 210, conductive nylon tape 220, semi-conductive inner shielding layer 230, insulating layer 240 and strippable semi-conductive outer shielding layer 250;
接地电芯300;接地导体310、地线芯屏蔽层320;grounding cell 300; grounding conductor 310, grounding core shielding layer 320;
半导电内护层400;Semi-conductive inner sheath 400;
纤维丝编织层500;Fiber filament braided layer 500;
外护套600。Outer sheath 600.
具体实施方式Detailed ways
(实施例1)(Example 1)
为使本发明实施例的目的、技术方案和优点更加清楚,下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例是本发明一部分实施例,而不是全部的实施例。通常在此处附图中描述和示出的本发明实施例的组件可以以各种不同的配置来布置和设计。In order to make the purposes, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments These are some embodiments of the present invention, but not all embodiments. The components of the embodiments of the invention generally described and illustrated in the drawings herein may be arranged and designed in a variety of different configurations.
因此,以下对在附图中提供的本发明的实施例的详细描述并非旨在限制要求保护的本发明的范围,而是仅仅表示本发明的选定实施例。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。Thus, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the invention as claimed, but is merely representative of selected embodiments of the invention. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.
应注意到:相似的标号和字母在下面的附图中表示类似项,因此,一旦某一项在一个附图中被定义,则在随后的附图中不需要对其进行进一步定义和解释。It should be noted that like numerals and letters refer to like items in the following figures, so once an item is defined in one figure, it does not require further definition and explanation in subsequent figures.
在本发明实施例的描述中,需要理解的是,术语“中心”、“上”、“下”、“左”、“右”、“竖直”、“水平”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系,或者是该发明产品使用时惯常摆放的方位或位置关系,或者是本领域技术人员惯常理解的方位或位置关系,仅是为了便于描述本发明和简化描述,而不是指示或暗示所指的设备或元件必须具有特定的方位、以特定的方位构造和操作,因此不能理解为对本发明的限制。In the description of the embodiments of the present invention, it should be understood that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" The azimuth or positional relationship indicated by ” etc. is based on the azimuth or positional relationship shown in the accompanying drawings, or the azimuth or positional relationship that is usually placed when the product of the invention is used, or the azimuth or positional relationship that is commonly understood by those skilled in the art, It is only for the convenience of describing the present invention and simplifying the description, not to indicate or imply that the device or element referred to must have a particular orientation, be constructed and operate in a particular orientation, and therefore should not be construed as a limitation of the present invention.
在本发明实施例的描述中,还需要说明的是,除非另有明确的规定和限定,术语“设置”、“安装”、“相连”、“连接”应做广义理解,例如,可以是固定连接,也可以是可拆卸连接,或一体地连接;可以是直接相连,也可以通过中间媒介间接相连,可以是两个元件内部的连通。对于本领域的普通技术人员而言,可以具体情况理解上述术语在本发明中的具体含义。In the description of the embodiments of the present invention, it should also be noted that, unless otherwise expressly specified and limited, the terms "arranged", "installed", "connected" and "connected" should be understood in a broad sense, for example, it may be a fixed The connection can also be a detachable connection, or an integral connection; it can be a direct connection, or an indirect connection through an intermediate medium, and it can be the internal communication of the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood in specific situations.
本发明提供了一种66kV风电高压扭转电缆,用于解决现有技术中电缆性能差的问题,为了解决上述问题,本发明的总体思路如下:The present invention provides a 66kV wind power high-voltage torsion cable, which is used to solve the problem of poor cable performance in the prior art. In order to solve the above problem, the general idea of the present invention is as follows:
66kV风电高压扭转电缆,包括:66kV wind power high voltage torsion cable, including:
填充层100;位于电缆中心,设有三个弧形缺口,表面涂覆有石墨粉;Filling layer 100; located in the center of the cable, with three arc-shaped gaps, and the surface is coated with graphite powder;
三根主线芯200;设置在所述填充层100的三个弧形缺口中,表面涂覆有石墨粉;Three main wire cores 200; arranged in the three arc-shaped notches of the filling layer 100, and the surface is coated with graphite powder;
三根接地电芯300;分别设置在两根所述主线芯200之间,并由填充层100支撑,表面涂覆有石墨粉;Three grounded battery cores 300; respectively disposed between the two main cores 200, supported by the filling layer 100, and coated with graphite powder on the surface;
半导电内护层400、纤维丝编织层500和外护套600,依次设置于三根主线芯200外部。The semi-conductive inner sheath 400 , the fiber braided layer 500 and the outer sheath 600 are sequentially arranged outside the three main cores 200 .
本发明的填充层有弧形缺口,与主电芯形状互相卡嵌,既加强了电缆抗拉和抗耐扭性能,且结构紧凑,安装占用空间小,同时绞合节距大。The filling layer of the present invention has an arc-shaped notch, which is interlocked with the shape of the main electric core, which not only enhances the tensile and torsional resistance of the cable, but also has a compact structure, small installation space, and large twisting pitch.
为了更好的理解上述技术方案,下面将结合说明书附图以及具体的实施方式对上述技术方案进行详细的说明。In order to better understand the above technical solutions, the above technical solutions will be described in detail below with reference to the accompanying drawings and specific embodiments.
(实施例1)(Example 1)
见图1,本实施例的66kV风电高压扭转电缆,包括:Referring to Figure 1, the 66kV wind power high-voltage torsion cable of this embodiment includes:
填充层100;形状为马鞍形,位于电缆中心,设有三个弧形缺口,表面涂覆有石墨粉;所述填充层100每个边的宽度至少为2.5mm。具体结构是中心为钢丝加强芯,外部半硫化挤出半导电橡皮材料,其中,钢丝加强芯选用单丝直径为0.22~0.26mm的镀锌钢芯钢丝绳,绞合方向为左向,绞合节距不超过中心加强钢丝绳外径的16倍。本发明的填充层有弧形缺口,与主电芯形状互相卡嵌,而且使电缆主线芯和地线芯分布更加均匀,既加强了电缆抗拉和抗耐扭性能,且结构紧凑,安装占用空间小,同时绞合节距大。并有中心加强钢丝绳提高电缆的负重能力。电缆采用3+3结构,外径更小,重量轻,弯曲半径小,能够整根铺设,降低了安装成本。填充层每边宽度最小为2.5mm,能够起到很好地支撑作用。The filling layer 100 is in the shape of a saddle, located in the center of the cable, with three arc-shaped notches, and the surface is coated with graphite powder; the width of each side of the filling layer 100 is at least 2.5mm. The specific structure is that the center is a steel wire reinforced core, and the external semi-vulcanized extruded semi-conductive rubber material is used. The distance should not exceed 16 times the outer diameter of the central reinforcing steel wire rope. The filling layer of the present invention has an arc-shaped gap, which is interlocked with the shape of the main electric core, and the distribution of the main wire core and the ground wire core of the cable is more uniform, which not only enhances the tensile and torsional resistance of the cable, but also has a compact structure and occupies less space for installation. The space is small and the twisting pitch is large at the same time. And there is a central reinforced steel wire rope to improve the load-bearing capacity of the cable. The cable adopts a 3+3 structure, with a smaller outer diameter, light weight, and a small bending radius, which can be laid in one piece, reducing the installation cost. The width of each side of the filling layer is at least 2.5mm, which can play a good supporting role.
三根主线芯200;设置在所述填充层100的三个弧形缺口中,表面涂覆有石墨粉;所述主线芯200由内至外依次为主线芯导体210、导电尼龙带220、半导电内屏蔽层230、绝缘层240和可剥离半导电外屏蔽层250;所述主线芯导体210采用五类镀锡铜导体,单丝直径为0.49~0.50mm的镀锡铜丝绞合成一股直径为3.3mm的镀锡铜丝束,然后37股镀锡铜丝束按照1+6+12+18的排列结构左向绞合成主线芯导体210,由内至外的绞合节距依次为20~22D、16~18D和12~14D。所述绝缘层240采用HEPR超洁净乙丙橡胶,绝缘材料的20℃体积电阻率3.0*1016Ω·cm。Three main wire cores 200; are arranged in the three arc-shaped notches of the filling layer 100, and the surface is coated with graphite powder; the main wire cores 200 are the main wire core conductor 210, the conductive nylon tape 220, the semiconductive wire from the inside to the outside in sequence The inner shielding layer 230, the insulating layer 240 and the peelable semiconducting outer shielding layer 250; the main core conductor 210 adopts five types of tinned copper conductors, and the single wire diameter of 0.49-0.50mm is twisted into a single diameter It is a 3.3mm tinned copper wire bundle, and then 37 strands of tinned copper wire bundles are twisted leftward into the main core conductor 210 according to the arrangement structure of 1+6+12+18, and the twisting pitch from the inside to the outside is 20 ~22D, 16~18D and 12~14D. The insulating layer 240 is made of HEPR ultra-clean ethylene-propylene rubber, and the volume resistivity of the insulating material at 20° C. is 3.0*10 16 Ω·cm.
三根接地电芯300;分别设置在两根所述主线芯200之间,并由填充层100支撑,表面涂覆有石墨粉;所述接地电芯300由内至外依次为接地导体310和地线芯屏蔽层320。所述接地导体310采用五类镀锡铜导体,单丝直径为0.29~0.30mm的镀锡铜丝绞合成一股直径为3.3mm的镀锡铜丝束,然后7股镀锡铜丝束按照1+6的排列结构左向绞合成接地导体310,绞合节距为16~18D。The three grounding cells 300 are respectively arranged between the two main cores 200 and are supported by the filling layer 100, and the surface is coated with graphite powder; the grounding cells 300 are the grounding conductor 310 and the grounding conductor 310 and the grounding conductor from inside to outside. Wire core shielding layer 320 . The grounding conductor 310 adopts five types of tinned copper conductors, tinned copper wires with a single wire diameter of 0.29-0.30 mm are twisted into a tinned copper wire bundle with a diameter of 3.3 mm, and then 7 strands of tinned copper wire bundles are arranged as follows. The arrangement structure of 1+6 is twisted to the left to form a ground conductor 310, and the twisting pitch is 16-18D.
半导电内护层400、纤维丝编织层500和外护套600,依次设置于三根主线芯200外部。所述纤维丝编织层500采用D1500涤纶丝浸渍间苯二酚-甲醛树脂与乳胶的混合液后编织,编织节距为80~90mm,编织密度为25%~30%。The semi-conductive inner sheath 400 , the fiber braided layer 500 and the outer sheath 600 are sequentially arranged outside the three main cores 200 . The fiber silk braided layer 500 is braided by D1500 polyester silk impregnated with a mixture of resorcinol-formaldehyde resin and latex, the braiding pitch is 80-90mm, and the braiding density is 25%-30%.
具体来说,涂覆的石墨粉为超精细石墨粉,不仅能起到导电作用还能减小电缆使用时因为扭转而引起线芯之间的摩擦力。在没使用石墨粉前主线芯和地线芯之间的过渡电阻过渡电阻大于1500Ω,使用后过渡电阻为350~480Ω,过渡电阻大,主线芯和地线芯之间导通能力差,当主线芯出现故障时,不能及时和地线芯导通,不能把故障电流导通出去,故障电流的积累容易引起电缆发热甚至爆炸。Specifically, the coated graphite powder is ultra-fine graphite powder, which can not only play a conductive role but also reduce the friction between the cores caused by twisting when the cable is in use. The transition resistance between the main wire core and the ground wire core is greater than 1500Ω before the graphite powder is used, and the transition resistance after use is 350~480Ω, the transition resistance is large, and the conduction ability between the main wire core and the ground wire core is poor. When the core fails, it cannot be connected to the ground core in time, and the fault current cannot be conducted out. The accumulation of fault current may easily cause the cable to heat up or even explode.
66kV风电高压扭转电缆的生产工艺,包括以下步骤:The production process of 66kV wind power high-voltage torsion cable includes the following steps:
S1:制备填充层100,在填充层100外部采用湿法工艺涂覆石墨粉;填充层100的形状为马鞍形,位于电缆中心,设有三个弧形缺口,表面涂覆有石墨粉;所述填充层100每个边的宽度至少为2.5mm。具体结构是中心为钢丝加强芯,外部半硫化挤出半导电橡皮材料,其中,钢丝加强芯选用单丝直径为0.22~0.26mm的镀锌钢芯钢丝绳,绞合方向为左向,绞合节距不超过中心加强钢丝绳外径的16倍。S1: prepare the filling layer 100, and coat the graphite powder on the outside of the filling layer 100 by a wet process; the filling layer 100 is in the shape of a saddle, located in the center of the cable, with three arc-shaped gaps, and the surface is coated with graphite powder; the The width of each side of the filling layer 100 is at least 2.5 mm. The specific structure is that the center is a steel wire reinforced core, and the external semi-vulcanized extruded semi-conductive rubber material is used. The distance should not exceed 16 times the outer diameter of the central reinforcing steel wire rope.
S2:制备主线芯200,在主线芯导体210外绕包导电尼龙带220,挤出半导电内屏蔽层230、绝缘层240和可剥离半导电外屏蔽层250,在主线芯200外部干法工艺涂覆石墨粉。S2: prepare the main wire core 200, wrap the conductive nylon tape 220 around the main wire core conductor 210, extrude the semiconducting inner shielding layer 230, the insulating layer 240 and the peelable semiconducting outer shielding layer 250, and dry the main wire core 200 by a dry process Coated with graphite powder.
具体来说,石墨粉可以是干法工艺或者湿法工艺涂覆。干法工艺采用粉刷与漏筛相结合方式涂粉,涂覆厚度均匀,且涂粉厚度在0.005~0.01mm之间,涂粉是在粉箱中进行,石墨粉不会污染环境,石墨粉均匀牢固的附着在电缆线芯表面。湿法涂覆技术中,石墨浆中加入的丙酮对人体有害,还要增加烘干工艺,因此干法涂覆方法能提高生产效率,但湿法工艺适合不规则的结构。Specifically, the graphite powder can be coated by a dry process or a wet process. The dry process adopts the combination of brushing and sifting to coat powder, and the coating thickness is uniform, and the thickness of the powder coating is between 0.005 and 0.01mm. The powder coating is carried out in the powder box, and the graphite powder will not pollute the environment. Firmly attached to the surface of the cable core. In the wet coating technology, the acetone added to the graphite slurry is harmful to the human body, and the drying process needs to be added. Therefore, the dry coating method can improve the production efficiency, but the wet process is suitable for irregular structures.
挤出绝缘层240的具体方法为:采用66KV高电性能超洁净的乙丙绝缘材料HEPR,绝缘材料的20℃体积电阻率3.0*1016Ω·cm,生产车间单独隔离,加料系统采用百万级净化级别净化房,落料系统采用重力自动落料系统,并在机颈位置配备杂质分析仪,严格控制洁净度。挤出前使用35kV电压等级的清洗料对挤橡机的机身和模具进行清洗三遍,再用66kV绝缘材料进行排料,保证生产过程绝缘层纯净度。所述S2步中半导电内屏蔽层230、绝缘层240和可剥离半导电外屏蔽层250三层共挤,三层共挤塑的模具尺寸为:内模直径16.6mm,中模直径18.2mm,外模直径39mm,模套直径40.6mm;为了减小绝缘偏心度,内模比导体外径大0.2~0.4mm,并在导体进入挤橡胶之前要通过预成型导轮,以矫直导体外形圆整度;中模与外模的锥角角度差为5~10°,内模与模套的锥角角度差在5~10°,以保证半导电内屏蔽层及可剥离半导电外屏蔽层与绝缘紧密结合,增大半导电内屏蔽层和可剥离半导电外屏蔽层挤出压力。The specific method of extruding the insulating layer 240 is as follows: using 66KV high electrical performance ultra-clean ethylene propylene insulating material HEPR, the 20 ℃ volume resistivity of the insulating material is 3.0*10 16 Ω·cm, the production workshop is isolated separately, and the feeding system adopts millions of First-class purification-level purification room, the blanking system adopts gravity automatic blanking system, and is equipped with an impurity analyzer at the machine neck position to strictly control the cleanliness. Before extrusion, use the cleaning material of 35kV voltage level to clean the body and mold of the extruder three times, and then use 66kV insulating material for discharging to ensure the purity of the insulating layer during the production process. In the step S2, the semi-conductive inner shielding layer 230, the insulating layer 240 and the peelable semi-conductive outer shielding layer 250 are co-extruded in three layers. The dimensions of the three-layer co-extrusion die are: the diameter of the inner die is 16.6 mm, and the diameter of the middle die is 18.2 mm. , the diameter of the outer die is 39mm, and the diameter of the die sleeve is 40.6mm; in order to reduce the eccentricity of the insulation, the inner die is 0.2-0.4mm larger than the outer diameter of the conductor, and before the conductor enters the extrusion rubber, it must pass through the pre-formed guide wheel to straighten the shape of the conductor Roundness; the difference between the cone angle of the middle mold and the outer mold is 5-10°, and the difference between the cone angle of the inner mold and the mold sleeve is 5-10° to ensure the semi-conductive inner shielding layer and the peelable semi-conductive outer shield The layer is tightly bonded to the insulation, increasing the extrusion pressure of the semiconducting inner shield and the peelable semiconducting outer shield.
在本步骤中,半导电尼龙带220厚度为0.12mm,宽度为40mm,搭盖率20%~25%。采用90挤橡机生产半导电内屏蔽层230,机身温度为95℃~105℃。采用150挤橡机生产乙丙橡胶材质的绝缘层240,机身温度为90℃~100℃。采用90挤橡机生产可剥离半导电外屏蔽层250,机身温度为90℃~100℃。三层共挤时机头温度设定为100℃~110℃。生产速度为6~7m/min,气压为7~8bar。采用在线监测外径偏心度设备实时监测半导电内屏蔽层230、绝缘层240和半导电外屏蔽层250的厚度。半导电内屏蔽层厚度为0.8mm。缘层厚度平均为10.5mm,最薄点厚度9.35mm。可剥离半导电外屏蔽层厚度为1.0mm。In this step, the thickness of the semi-conductive nylon tape 220 is 0.12 mm, the width is 40 mm, and the overlap ratio is 20% to 25%. The semi-conductive inner shielding layer 230 is produced by a 90 extruder, and the temperature of the body is 95°C to 105°C. The insulating layer 240 made of ethylene-propylene rubber is produced by a 150 extruder, and the temperature of the body is 90°C to 100°C. The peelable semi-conductive outer shielding layer 250 is produced by a 90 extruder, and the body temperature is 90°C to 100°C. The temperature of the head of the three-layer co-extrusion was set at 100°C to 110°C. The production speed is 6~7m/min, and the air pressure is 7~8bar. The thicknesses of the semiconducting inner shielding layer 230 , the insulating layer 240 and the semiconducting outer shielding layer 250 are monitored in real time by using an on-line monitoring outer diameter eccentricity device. The thickness of the semiconducting inner shield is 0.8mm. The average thickness of the edge layer is 10.5mm, and the thickness of the thinnest point is 9.35mm. The peelable semiconducting outer shield has a thickness of 1.0mm.
S3:制备接地电芯300,在接地导体310外挤出地线芯屏蔽层320,在接地电芯300外部干法工艺涂覆石墨粉;S3: preparing the grounding cell 300, extruding the grounding core shielding layer 320 outside the grounding conductor 310, and coating the outside of the grounding cell 300 with graphite powder by dry process;
S4:将主线芯200放入填充层100的弧形缺口处,将接地电芯300放置在主线芯200间的凹槽内一起形成缆芯,在缆芯外挤出厚度为1mm的半导电内护层400,再编织纤维丝编织层500,最后挤出外护套600。外护套600采用符合EN50363-2-1中EM 2的高耐机油耐柴油高阻燃耐盐雾环保乙烯醋酸乙烯酯混合物,标称厚度5mm,最薄点4.15mm。S4: Put the main wire core 200 into the arc-shaped gap of the filling layer 100, place the grounding cell 300 in the groove between the main wire cores 200 to form a cable core, and extrude a semi-conductive inner core with a thickness of 1 mm outside the cable core The sheath 400 is then braided with the fiber filament braid 500, and finally the outer sheath 600 is extruded. The outer sheath 600 is made of high oil resistance, diesel oil resistance, high flame retardant, salt spray resistance and environmental protection ethylene vinyl acetate mixture that conforms to EM 2 in EN50363-2-1. The nominal thickness is 5mm, and the thinnest point is 4.15mm.
编织纤维丝编织层500的编织工序采用的是32锭编织机,编织截距为80~90mm,编织密度为25%~30%,编织速度为1.5m/min,该电缆使用时主要承受轴向承受扭转力,为了提到径向受力范围,将编织角度控制在45°~50°。The braiding process of the braided fiber braided layer 500 adopts a 32-spindle braiding machine, the braiding intercept is 80-90mm, the braiding density is 25%-30%, and the braiding speed is 1.5m/min. The cable is mainly used in the axial direction. To withstand the torsional force, in order to mention the radial force range, the braiding angle is controlled at 45°~50°.
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。The specific embodiments described above further describe the purpose, technical solutions and beneficial effects of the present invention in further detail. It should be understood that the above descriptions are only specific embodiments of the present invention, and are not intended to limit the present invention. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.
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