CN110718336A

CN110718336A - Locomotive cable manufacturing method and cable

Info

Publication number: CN110718336A
Application number: CN201910953142.2A
Authority: CN
Inventors: 王永财; 潘冬雪; 汤陈旦; 夏正军; 殷赛莲; 王力; 朱瑜; 王梦娜; 朱斌
Original assignee: Jiangsu Shangshang Cable Group Co Ltd
Current assignee: Jiangsu Shangshang Cable Group Co Ltd
Priority date: 2019-10-08
Filing date: 2019-10-08
Publication date: 2020-01-21

Abstract

The manufacturing method of the locomotive cable comprises the following steps that the outer diameter of the locomotive cable is 25.0-28.0 mm; the structure of the locomotive cable is as follows: the cable comprises a conductor, an isolating layer, an insulating layer, a braided layer and an outer sheath in sequence from inside to outside; the conductor is formed by synthesizing folded yarns by tinned copper tows and then twisting the folded yarns in a compound manner; the isolation layer is formed by wrapping an isolation belt, and the outer diameter of the conductor after the isolation belt is wrapped is 15.2-15.5 mm; the insulating layer is formed by extruding and wrapping insulating materials; the outer part of the insulating layer is a braided layer braided by aramid fibers; the outer sheath is formed by extruding sheath materials; the manufacturing steps of the locomotive cable comprise: 1) conductor manufacturing, 2) isolation layer manufacturing, 3) insulation layer manufacturing, 4) braid manufacturing and 5) outer sheath manufacturing.

Description

Locomotive cable manufacturing method and cable

Technical Field

The technical scheme relates to the technical field of cables, in particular to a cable for a railway rolling stock and a manufacturing method thereof.

Background

At present, the running environment of a railway locomotive is relatively complex, the requirements of various used equipment and the like are higher, for example, when the railway locomotive is used in a low-temperature environment in northern areas, firstly, a cable has a stronger low-temperature-40 ℃ resistant requirement, and when the railway locomotive is used in a high-temperature environment in Africa and other areas, the cable has a higher running temperature. In addition, when the railway locomotive runs, the environments such as acid rain, oil stain and the like need to be considered, the cable needs to have acid-base resistance and oil resistance, harmful gas and a large amount of smoke cannot be generated in the cable combustion process in case of fire, the body health of personnel is damaged, equipment is corroded, and higher requirements on the flexibility and the scraping and abrasion resistance of the cable are also provided when the cable is installed and used.

Disclosure of Invention

In order to solve the problems in the prior art, the technical scheme provides a method for manufacturing a locomotive cable, wherein the outer diameter of the locomotive cable is 25.0-28.0 mm; the structure of the locomotive cable is as follows: the cable comprises a conductor, an isolating layer, an insulating layer, a braided layer and an outer sheath in sequence from inside to outside; the conductor is formed by synthesizing folded yarns by tinned copper tows and then twisting the folded yarns in a compound manner; the isolation layer is formed by wrapping an isolation belt, and the outer diameter of the conductor after the isolation belt is wrapped is 15.2-15.5 mm; the insulating layer is formed by extruding and wrapping insulating materials; the outer part of the insulating layer is a braided layer braided by aramid fibers; the outer sheath is formed by extruding sheath materials;

the manufacturing steps of the locomotive cable comprise:

1) manufacturing a conductor:

1.1) synthesizing a strand from a tin-plated copper tow: when the conductors are bundled into the folded yarns, a Nichhoff bunching machine is adopted for bundling, and when the conductors are bundled, 12 strands are arranged in the left direction, and 25 strands are arranged in the right direction; the bunching pitch of the folded yarns is 50-54 mm, and the bunching pitch-diameter ratio is 20-25;

1.2) twisting the folded yarn again to form a conductor; when the compound stranding of the compound strands is carried out, stranding is carried out by adopting a back-twist cage stranding device, and the traction speed of a traction wheel is 13 m/min;

the inner layer is a twisted layer of 1+6 strands, the direction of the twisting cage is left, the rotating speed of the twisting cage is 136.7rpm, and the twisting pitch is 100-110 mm;

the middle layer is a 12-strand stranding layer, the direction of the stranding cage is the right direction, the rotating speed of the stranding cage is 87rpm, and the stranding pitch is 170-180 mm;

the outermost layer is 18 strand wire twisted layers, the direction of the twisting cage is in the left direction, the rotating speed of the twisting cage is 87rpm, and the twisting pitch is 170-180 mm;

the pitch diameter ratio of the outermost layer of the conductor is 10-14, and the final stranding outer diameter of the conductor is 15.0-15.5 mm;

2) manufacturing an isolation layer:

wrapping a semi-conductive Teflon isolation belt with a covering width not less than 5 mm;

3) manufacturing an insulating layer:

extruding and wrapping insulating materials:

the temperature zone of the rubber extruding machine is controlled as follows: the temperature of the first zone is 40-48 ℃, the temperature of the second zone is 50-54 ℃, the temperature of the third zone is 55-63 ℃, the temperature of the fourth zone is 60-63 ℃ and the temperature of the fifth zone is 65-72 ℃;

the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections;

head temperature: the temperature of the first area is 65-75 ℃, the temperature of the second area is 73-75 ℃ and the temperature of the third area is 75-78 ℃;

the first area is a machine head section, the second area is a machine neck section, and the third area is a die opening section;

steam pressure is 6-8 bar, production speed is 13-16 m/min, cooling water is introduced into a machine body and a machine head of the rubber extruding machine for cooling, and the rotating speed of a screw is 12-15 r/min;

4) manufacturing a braided layer:

knitting is carried out by 16 spindles in a 32-spindle knitting machine, the knitting angle is 55 degrees, and the unidirectional coverage rate: 0.20 to 0.30;

5) outer sheath manufacture

Extruding sheath materials:

the temperature zone of the rubber extruder is controlled as follows: the temperature of the first zone is 40-45 ℃, the temperature of the second zone is 45-50 ℃, the temperature of the third zone is 50-60 ℃, the temperature of the fourth zone is 60-65 ℃ and the temperature of the fifth zone is 60-70 ℃;

head temperature: 68-72 ℃ in the first area, 68-75 ℃ in the second area and 75-80 ℃ in the third area;

during production, the steam pressure is 6-10 bar, the production speed is 10-13 m/min, cooling water is introduced into the machine body and the machine head for cooling, and the rotating speed of the screw is 18-25 r/min.

The optimal scheme is as follows:

in the step 1), in the process of bunching and twisting:

a) when the wires are combined, the conductor combination pitch is 50mm, and the strand combination pitch ratio is 20;

b) when the wires are combined, the conductor combination pitch is 53mm, and the strand combination pitch ratio is 22;

c) during re-twisting, 1+6 strand layers: the rotating speed of a stranding cage is 136.7rpm, and the strand bundle combination pitch-diameter ratio is 108;

d) during compound twisting, 12 strand layers: the rotating speed of a stranding cage is 87rpm, and the strand bundle combination pitch-diameter ratio is 174;

e) during compound twisting, 18 strand layers: the stranding cage speed was 87rpm and the strand lay ratio was 174.

In the step 2), the wrapping tape is a semiconductive Teflon isolation tape with the thickness of 0.25 mm; when the tape is wrapped, the rotating speed of the wrapping head is 327r/min, the width of the tape is 40mm, and the wrapping pitch is 38 mm.

In the step 3), during the extrusion process:

the temperature zone of the rubber extruder is controlled as follows: the first zone is 40 ℃, the second zone is 54 ℃, the third zone is 60 ℃, the fourth zone is 63 ℃ and the fifth zone is 70 ℃;

head temperature: 75 ℃ in the first area, 75 ℃ in the second area and 75 ℃ in the third area;

steam pressure is 7bar, production speed is 15m/min, cooling water is introduced into the machine body and the machine head of the rubber extruding machine for cooling, the rotating speed of a screw is 15r/min, and the water level of cooling water in a vulcanization pipe is 15%.

In the step 4), the aramid fiber is woven by adopting 16 spindles in a 32-spindle weaving machine, and the gear pitch Z1-24mm and the gear pitch Z2-23mm are adopted during weaving.

In the step 5), in the extrusion process:

the temperature zone of the rubber extruder is controlled as follows: the first zone is 40 ℃, the second zone is 50 ℃, the third zone is 60 ℃, the fourth zone is 63 ℃ and the fifth zone is 65 ℃;

head temperature: the first zone is 70 ℃, the second zone is 70 ℃ and the third zone is 75 ℃;

when the jacket material is extruded and produced, the steam pressure is 8bar, the production speed is 10m/min, the machine body and the machine head of the extrusion rubber machine are both cooled by cooling water, the rotating speed of a screw is 20r/min, and the water level of the cooling water in a vulcanizing pipe is 18 percent.

The outer diameter range of the locomotive cable prepared by the method is 25.0-28.0 mm; the structure of the locomotive cable is as follows:

the structure of the locomotive cable is as follows: the cable comprises a conductor, an isolating layer, an insulating layer, a braided layer and an outer sheath in sequence from inside to outside; the conductor is formed by synthesizing folded yarns by tinned copper tows and then twisting the folded yarns in a compound manner; the isolation layer is formed by wrapping an isolation belt, and the outer diameter of the conductor after the isolation belt is wrapped is 15.2-15.5 mm; the insulating layer is formed by extruding and wrapping insulating materials; the outer part of the insulating layer is a braided layer braided by aramid fibers; the outer sheath is formed by extruding sheath materials; wherein:

the material of the conductor is 6 th tin-plated copper conductor which conforms to the GB/T3956; the binding pitch diameter ratio is 20-25, and the pitch diameter ratio of the outermost layer of the conductor complex twisting is 10-14;

the isolation belt is a semi-conductive extra-heavy tangential belt, and the width of the lapping cover is not less than 5 mm;

the nominal thickness of the insulating layer is 3.00mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 2.60 mm;

the weaving angle of the woven layer is 55 degrees, and the one-way coverage rate is 0.20-0.30;

the outer sheath has a nominal thickness of 1.70mm, an average thickness of no less than the nominal thickness, and a thinnest thickness of no less than 1.35 mm.

Compared with the prior art, the cable has better technical performance and can completely meet the following technical requirements:

1. the maximum long-term allowable operating temperature of the cable conductor is 180 ℃.

2. When the cable is laid, the environmental temperature is not lower than-15 ℃; when the cable is used, the ambient temperature is not lower than-40 ℃.

3. The maximum temperature of the cable at short circuit (maximum duration not exceeding 5s) is 250 ℃.

4. The allowable bend radius of the cable is 4D (D-cable diameter).

5. The mineral oil resistance of the sheath can meet the requirements (100 ℃, 24h), the tensile strength change rate after oil resistance is 15 percent, and the elongation at break change rate after oil resistance is-19 percent.

6. The cable meets the requirements of passing a single and bundled test.

7. The smoke density and light transmittance of the cable can reach 82%.

8. The toxicity indexes of the insulation and the sheath are not more than 3.

The cable is particularly suitable for a power supply system of a railway rolling stock.

Drawings

Fig. 1 is a schematic radial cross-sectional view of the cable of the present embodiment.

In the figure: conductor 1, isolation layer 2, insulating layer 3, weaving layer 4, oversheath 5.

Detailed Description

The technical scheme is further explained by combining the drawings and the detailed implementation mode as follows:

the manufacturing method of the locomotive cable comprises the following steps that the outer diameter of the locomotive cable is 25.0-28.0 mm; as shown in fig. 1, the structure of the locomotive cable is as follows: the cable comprises a conductor, an isolating layer, an insulating layer, a braided layer and an outer sheath in sequence from inside to outside; the conductor is formed by synthesizing folded yarns by tinned copper tows and then twisting the folded yarns in a compound manner; the isolation layer is formed by wrapping an isolation belt, and the outer diameter of the conductor after the isolation belt is wrapped is 15.2-15.5 mm; the insulating layer is formed by extruding and wrapping insulating materials; the outer part of the insulating layer is a braided layer braided by aramid fibers; the outer sheath is formed by extruding sheath materials;

the manufacturing steps of the locomotive cable comprise:

1) manufacturing a conductor:

the inner layer is a stranding layer of 1+6 strands (the axial position is 1 strand, the outer layer is 6 strands) and the stranding cage turns to the left direction, the rotating speed of the stranding cage is 136.7rpm, and the stranding pitch (100 plus 110) mm;

the middle layer is formed by twisting 12 strand layers (12 strands surround the same axis), the twisting cage turns to the right direction, the rotating speed of the twisting cage is 87rpm, and the twisting pitch (170 and 180) mm;

the outermost layer is a stranding cage of 18 strand stranding layers (18 strands surround the same axis) and turns to the left direction, the rotation speed of the stranding cage is 87rpm, and the stranding pitch (170) and 180mm are achieved;

the pitch diameter ratio of the outermost layer of the conductor is 10-14, and the final stranding outer diameter (15.0-15.5) mm of the conductor is obtained;

2) manufacturing an isolation layer:

a layer of semiconductive Teflon isolation tape with the thickness of 0.25mm is adopted outside the conductor for wrapping, the covering width of the wrapping tape is not less than 5mm, the rotating speed of a wrapping head is 327r/min during wrapping, the width of the wrapping tape is 40mm, and the wrapping pitch is 38 mm;

3) manufacturing an insulating layer:

extruding and wrapping insulating materials:

the insulation material comprises the following components in parts by weight: 100 parts of methyl vinyl silicone rubber, 20-50 parts of filler, 60-120 parts of flame retardant, 1-3 parts of antioxidant and 4-20 parts of softener; the filler is argil, the flame retardant is antimony trioxide, the antioxidant is DAPD, and the softener is dimethyl silicone oil.

The preparation method comprises the following steps:

1) banburying methyl vinyl silicone rubber in an internal mixer for 4-6 min;

2) adding other components into an internal mixer at one time, and mixing with the material obtained in the step 1) for 6-11 min;

3) moving the materials obtained in the step 2) out of the internal mixer, mixing on a double-roll open mill, and then adding into a rubber filter for rubber filtration; the temperature of the rubber filter in the step 3) is less than 80 ℃;

4) and 3) mixing the materials obtained in the step 3) by an open mill and discharging to obtain a mixed rubber sample. The mixing temperature in the step 2) is less than 70 ℃.

Before the insulating material is used for the extrusion production of the insulating layer of the cable, adding rubber compound on a room-temperature open mill, adding vulcanizing agent when a roll is uniformly coated, basically dispersing the vulcanizing agent, and rolling for 5 times, so that the sheet can be cut according to the required test piece thickness to prepare vulcanized mixed silicon rubber; the open mill mixing temperature here is less than 60 ℃.

The extruded insulating material is produced by adopting an imported Telex continuous sulfur production line; in the extrusion process:

4) Manufacturing a braided layer:

the aramid fiber is braided outside the wire core by weaving a layer of aramid fiber, 16 spindles of a 32-spindle braiding machine are used for braiding, the pitch of the gears is Z1-24mm and Z2-23mm during braiding (because the braiding speed of the braiding machine is changed by the gears, Z1 and Z2 respectively represent gears with different specifications, so that different pitches of braiding are realized), the braiding angle is 55 degrees, and the unidirectional coverage rate is as follows: 0.20 to 0.30;

5) outer sheath manufacture

Extruding sheath materials:

the sheath material comprises the following components in parts by weight: 100 parts of methyl vinyl silicone rubber, 20-50 parts of filler, 80-140 parts of flame retardant, 1-3 parts of antioxidant and 4-20 parts of softener; the filler is argil, the flame retardant is antimony trioxide, the antioxidant is DAPD, and the softener is dimethyl silicone oil.

The preparation method comprises the following steps:

1) banburying methyl vinyl silicone rubber in an internal mixer for 4-6 min;

2) adding the filler, the flame retardant, the antioxidant and the softener into an internal mixer at one time, and mixing with the material obtained in the step 1) for 6-11 min;

3) moving the materials obtained in the step 2) out of the internal mixer, mixing on a double-roll open mill, and then adding into a rubber filter for rubber filtration;

4) and 3) mixing the materials obtained in the step 3) by an open mill and discharging to obtain a mixed rubber sample.

The mixing temperature in the step 2) is less than 70 ℃. The temperature of the rubber filter in the step 3) is less than 80 ℃.

Before the extrusion production of the silicon rubber, adding a proper amount of rubber compound on a room-temperature open mill, adding a vulcanizing agent when a roll is uniformly coated, and rolling for 5 times after the vulcanizing agent is basically dispersed, so that the silicon rubber can be cut according to the required test piece thickness to prepare the vulcanized mixed silicon rubber. The mixing temperature of the open mill is less than 60 ℃.

The braided wire core is extruded with low-smoke halogen-free flame-retardant oil-resistant silicone rubber sheath material, the sheath is made of silicone rubber mixed by double 24 vulcanizing agents, and the silicone rubber is extruded and produced by an imported Telestt continuous sulfur production line. In the extrusion process:

In the present example, the number of the first and second,

in the step 1), in the process of bunching and twisting:

In the step 2), the lapping width of the lapping tape is not less than 5mm, the rotating speed of the lapping head is 327r/min during lapping, the width of the lapping tape is 40mm, and the lapping pitch is 38 mm.

The nominal thickness of the insulating layer is 3.00mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 3.00mm multiplied by 90% -0.1 mm.

In the step 4), the aramid fiber is woven by adopting 16 spindles in a 32-spindle weaving machine, the gear pitches Z124mm and Z223 mm are adopted during weaving, the weaving angle is 55 degrees, and the unidirectional coverage rate is as follows: 0.20 to 0.30.

The nominal thickness of the sheath layer is 1.70mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 1.70mm multiplied by 85% -0.1 mm.

In the trial production, the following parameters were also tested for steps 3) and 5), but from the results, their cable yields (in terms of adhesion characteristics between the various functional layers, concentricity of the cable, roundness, mechanical and electrical properties of the cable) were all lower than the preferred solution described above.

Step 3) of example 1:

the temperature zone of the rubber extruding machine is controlled as follows: the first zone is 40 ℃, the second zone is 50 ℃, the third zone is 55 ℃, the fourth zone is 60 ℃ and the fifth zone is 65 ℃;

head temperature: the first zone is 65 ℃, the second zone is 73 ℃ and the third zone is 75 ℃;

steam pressure is 6bar, production speed is 13m/min, cooling water is introduced into the machine body and the machine head of the rubber extruding machine for cooling, and the rotating speed of a screw is 12 r/min;

step 5) of example 1:

extruding sheath materials:

the temperature zone of the rubber extruder is controlled as follows: the first zone is 45 ℃, the second zone is 45 ℃, the third zone is 50 ℃, the fourth zone is 60 ℃ and the fifth zone is 60 ℃;

head temperature: 68 ℃ in the first area, 68 ℃ in the second area and 75 ℃ in the third area;

during production, the steam pressure is 6bar, the production speed is 10m/min, the machine body and the machine head are cooled by introducing cooling water, and the rotating speed of the screw is 18 r/min.

Step 3) of example 2:

the temperature zone of the rubber extruding machine is controlled as follows: the first zone is 48 ℃, the second zone is 54 ℃, the third zone is 63 ℃, the fourth zone is 63 ℃ and the fifth zone is 72 ℃;

head temperature: 75 ℃ in the first area, 75 ℃ in the second area and 78 ℃ in the third area;

steam pressure is 8bar, production speed is 16m/min, cooling water is introduced into the machine body and the machine head of the rubber extruding machine for cooling, and the rotating speed of a screw is 15 r/min;

step 5) of example 2:

extruding sheath materials:

the temperature zone of the rubber extruder is controlled as follows: the first zone is 45 ℃, the second zone is 50 ℃, the third zone is 60 ℃, the fourth zone is 65 ℃ and the fifth zone is 70 ℃;

head temperature: the first zone is 72 ℃, the second zone is 75 ℃ and the third zone is 80 ℃;

during production, the steam pressure is 10bar, the production speed is 13m/min, the machine body and the machine head are cooled by introducing cooling water, and the rotating speed of the screw is 25 r/min.

In the locomotive cable manufactured by the embodiment, the conductor is a 6 th tin-plated copper conductor in accordance with GB/T3956; the binding pitch diameter ratio is 20-25, and the pitch diameter ratio of the outermost layer of the conductor complex twisting is 10-14. And a layer of semi-conductive extra-heavy tangential tape is wrapped outside the conductor, and the lapping width of the wrapping tape is not less than 5 mm. The nominal thickness of the insulating layer is 3.00mm, the average thickness is not less than the nominal thickness, and the thickness of the thinnest part is not less than 2.60 mm; the material of weaving layer is aramid fiber, and aramid fiber adopts 16 spindle among the 32 spindle braiders to weave, weaves angle 55, and one-way coverage: 0.20 to 0.30. The outer sheath has a nominal thickness of 1.70mm, an average thickness of no less than the nominal thickness, and a thinnest thickness of no less than 1.35 mm.

By adopting the structural design of the product, the wear-resisting property of the cable is improved, the service life of the cable is prolonged, and the performance of the product is ensured to meet the relevant requirements. By adopting the production process, when the sheath is extruded, the insulation and the sheath can be contacted at the gap of the weaving layer, and finally the insulation and the sheath are bonded together, so that the insulation, the weaving and the sheath form a whole, and the service life of the cable is prolonged. Because weave and adopt aramid fiber to weave, aramid fiber's intensity is great to aramid fiber twists, improves holistic intensity, can not appear the disconnected silk condition when weaving, can improve the speed of weaving greatly, improves and weaves production efficiency.

Main detection data of locomotive cable:

1. the tensile strength of the insulation is 9.1Mpa, and the elongation at break of the insulation is 450%.

2. Aging of an insulating air box: (200 ℃ C. + -. 1, 240h)

The tensile strength after insulation aging is 7.5Mpa, and the elongation at break after insulation aging is 250%.

3. Insulation-40 low temperature stretching: 105 percent.

4. The tensile strength of the sheath is 10.3Mpa, and the elongation at break of the insulation is 510%.

5. Aging of a sheath air box: (200 ℃ C. + -. 1, 240h)

Tensile strength after insulation aging is 8.0Mpa, and elongation at break after insulation aging is 280%.

6. Sheath-40 low temperature stretching: 110 percent.

7. The mineral oil resistance of the sheath can meet the requirements (100 ℃, 24h), the tensile strength change rate after oil resistance is 15 percent, and the elongation at break change rate after oil resistance is-19 percent.

8. Insulation resistance at 20 ℃: 7800M omega. km.

9. Insulation resistance at 90 ℃: 66 M.OMEGA.km.

10. The cable meets the requirements of passing a single and bundled test.

11. The smoke density and light transmittance of the cable can reach 82%.

12. The toxicity indexes of the insulation and the sheath are not more than 3.

Claims

1. A locomotive cable manufacturing method is characterized in that the outer diameter of the locomotive cable is 25.0-28.0 mm; the structure of the locomotive cable is as follows: the cable comprises a conductor, an isolating layer, an insulating layer, a braided layer and an outer sheath in sequence from inside to outside; the conductor is formed by synthesizing folded yarns by tinned copper tows and then twisting the folded yarns in a compound manner; the isolation layer is formed by wrapping an isolation belt, and the outer diameter of the conductor after the isolation belt is wrapped is 15.2-15.5 mm; the insulating layer is formed by extruding and wrapping insulating materials; the outer part of the insulating layer is a braided layer braided by aramid fibers; the outer sheath is formed by extruding sheath materials;

the manufacturing steps of the locomotive cable comprise:

1) manufacturing a conductor:

2) manufacturing an isolation layer:

3) manufacturing an insulating layer:

extruding and wrapping insulating materials:

4) manufacturing a braided layer:

5) outer sheath manufacture

Extruding sheath materials:

2. The manufacturing method according to claim 1, wherein in the step 1), the bundling and twisting process comprises the following steps:

3. The manufacturing method according to claim 1, wherein in the step 2), the lapping tape is a semi-conductive Teflon isolating tape with the thickness of 0.25 mm; when the tape is wrapped, the rotating speed of the wrapping head is 327r/min, the width of the tape is 40mm, and the wrapping pitch is 38 mm.

4. The method of claim 1, wherein the step of forming the composite sheet is performed by a press

In the step 3), during the extrusion process:

5. The method of claim 1, wherein the step of forming the composite sheet is performed by a press

6. The method of claim 1, wherein the step of forming the composite sheet is performed by a press

In the step 5), in the extrusion process:

7. A locomotive cable made by the method of any one of claims 1 to 6, wherein said locomotive cable has an outer diameter in the range of 25.0 to 28.0 mm; the structure of the locomotive cable is as follows: