CN111679383A - High-strength side pressure-resistant and impact-resistant submarine optical cable core and preparation method thereof - Google Patents
High-strength side pressure-resistant and impact-resistant submarine optical cable core and preparation method thereof Download PDFInfo
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- CN111679383A CN111679383A CN202010428293.9A CN202010428293A CN111679383A CN 111679383 A CN111679383 A CN 111679383A CN 202010428293 A CN202010428293 A CN 202010428293A CN 111679383 A CN111679383 A CN 111679383A
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4401—Optical cables
- G02B6/4415—Cables for special applications
- G02B6/4427—Pressure resistant cables, e.g. undersea cables
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4401—Optical cables
- G02B6/4429—Means specially adapted for strengthening or protecting the cables
- G02B6/443—Protective covering
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4401—Optical cables
- G02B6/4429—Means specially adapted for strengthening or protecting the cables
- G02B6/44384—Means specially adapted for strengthening or protecting the cables the means comprising water blocking or hydrophobic materials
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4479—Manufacturing methods of optical cables
- G02B6/4486—Protective covering
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B11/00—Communication cables or conductors
- H01B11/22—Cables including at least one electrical conductor together with optical fibres
Abstract
A high-strength side pressure-resistant and impact-resistant submarine optical cable core and a preparation method thereof belong to the technical field of submarine cables. The submarine optical cable core comprises an optical unit and is characterized in that an inner enhancement layer is arranged on the periphery of the optical unit and formed by twisting a plurality of Z-shaped steel wires on the periphery of the optical unit, water-blocking glue is filled in gaps of the inner enhancement layer, and a feed protection layer is coated on the periphery of the inner enhancement layer. The volume of the steel wire can be increased by about 27% by adopting the Z-shaped steel wire, so that the mechanical tension of the submarine cable core is increased by about 27% under the condition of the same diameter, and the lateral pressure resistance and the impact resistance of the inner cable core can be improved; the stability of the inner reinforcing layer structure when the cable core is bent is reduced, and the mechanical damage of the inner reinforcing layer of the steel wire to the outer-layer copper pipe is reduced; the Z-shaped steel wire can greatly reduce the using amount of glue and improve the water resistance of the cable core. The semi-conducting layer is added in front of the insulating layer, so that the electric field can be balanced, the point discharge phenomenon of the conductor can be eliminated, and the breakdown of the external insulating layer can be effectively avoided.
Description
Technical Field
The invention relates to a high-strength side pressure-resistant and impact-resistant submarine optical cable core and a preparation method thereof, belonging to the technical field of submarine cables.
Background
The submarine optical cable has a complex use environment, and is often subjected to large lateral pressure and impact force in the processes of manufacturing, storing, transporting, laying, working, salvaging and recovering, so that lateral pressure resistance and impact resistance need to be considered particularly when the submarine optical cable core structure is designed. In addition, the feeding conductor of the submarine optical cable must be insulated from seawater, so the reliability of the insulating layer is also required to be considered when designing the submarine optical cable core structure.
The mainstream structure of submarine optical cable core in the existing market has three kinds:
1. two layers of three circular steel wires with different diameters are twisted around the light unit to form an inner reinforcing layer for protecting the light unit, and adjacent steel wires of the inner reinforcing layer can be tightly close to each other to effectively resist external pressure. This kind of cable core structure can refer to the authority bulletin number: chinese patents CN210142533U and CN 210270296U.
Although the round steel wires can be closely leaned together, no obvious control force exists between the adjacent round steel wires, and the round steel wires are restrained by the copper pipe tightly wrapped by the outer layer to keep the round steel wires in a relatively stable position. When the cable core is bent, the inner side steel wire is extruded, the outer side steel wire is stretched, the steel wire is easily subjected to strand scattering and wire jumping due to the deformation difference, and an outer copper pipe can be damaged in serious cases. In addition, more gaps still exist among the round steel wires, and more water-blocking glue needs to be filled to prevent seawater from longitudinally permeating into the cable core.
2. The fan-shaped stranded wires are used as the inner enhancement layer outside the optical unit to improve the lateral pressure resistance of the cable core, simultaneously reduce the gaps among the stranded wires and reduce the probability of seawater longitudinally permeating into the cable core when the submarine optical cable is broken; this kind of cable core structure can refer to the authority bulletin number: chinese patent CN 209373202U.
Although the structure of the fan-shaped stranded wires can effectively reduce gaps, prevent seawater from longitudinally permeating into the cable core, and improve lateral pressure resistance and impact resistance, the problem that no obvious control force exists between adjacent stranded wires is also faced, and the restraint is carried out by depending on an outer layer structure.
3. In addition, the structure that the insulating layer is directly extruded outside the feed conductor of the cable core without the shielding layer is also insufficient, namely: the surface of the feed conductor may generate a "point discharge" phenomenon when the conductor is energized due to burrs and protrusions caused during production or use, and may induce a risk of breakdown of the insulation layer.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides a high-strength lateral pressure and impact resistant submarine optical cable core and a preparation method thereof, so as to improve the lateral pressure and impact resistance of the cable core.
The technical scheme of the invention is as follows:
the invention aims to provide a high-strength lateral pressure-resistant and impact-resistant submarine optical cable core, which comprises an optical unit and is characterized in that an inner reinforcing layer is arranged on the periphery of the optical unit and is formed by twisting a plurality of Z-shaped steel wires on the periphery of the optical unit, water-blocking glue is filled in gaps of the inner reinforcing layer, and a feed copper pipe is wrapped on the periphery of the inner reinforcing layer.
Preferably, the feed copper pipe is sequentially extruded and wrapped with a semi-conducting layer and an insulating layer.
Preferably, an adhesive layer is extruded between the feed copper pipe and the semi-conducting layer.
Preferably, the light unit is formed of a stainless steel tube containing an optical fiber and a fiber paste.
Preferably, all the chamfers of the Z-shaped steel wire are arc chamfers.
Preferably, the cross section of each Z-shaped steel wire is composed of an outer arc section and an inner arc section which are mutually staggered, and the heights of the outer arc section and the inner arc section are equal.
Preferably, the staggered part of the outer arc segment relative to the inner arc segment and the staggered part of the inner arc segment relative to the outer arc segment have the same taper angle.
The second purpose of the invention is to provide a preparation method of the submarine optical cable core with high strength, lateral pressure resistance and impact resistance, which is characterized by comprising the following steps:
1) making optical elements
Longitudinally wrapping the stainless steel band subjected to edge cutting treatment into a tubular shape through a forming die, and welding into a seamless stainless steel tube by adopting laser welding equipment;
during welding, the optical fiber enters the formed stainless steel tube together with the fiber paste through the fiber guide die;
continuously reducing and drawing the formed stainless steel tube to obtain reasonable and uniform excess length of the optical fiber;
2) making internal reinforcement layers
Determining the size and the number of the Z-shaped steel wires according to the index requirement of the cable core breaking force;
the Z-shaped steel wire is tightly stranded around the light unit by adopting cage type stranded wire equipment through the control of a bunch mold to form a Z-shaped steel wire inner reinforcing layer; due to the characteristic that the Z-shaped steel wires are locked with each other, a steel wire pay-off rack of the wire stranding equipment is set to be in a non-back-twist mode;
in the twisting process of the Z-shaped steel wires, liquid water-blocking glue is sprayed on the optical units and the Z-shaped steel wires, so that the gaps between the steel wires of the inner enhancement layer are filled with the water-blocking glue, and after a period of time, the water-blocking glue is converted into a gel state;
3) manufacturing feed copper pipe
The Z-shaped steel wires are twisted and then enter argon arc welding pipe manufacturing equipment; longitudinally wrapping the copper strip subjected to the edge cutting treatment around the Z-shaped steel wire by a forming die to form a tubular shape, and welding the copper strip into a seamless copper pipe;
then reducing and drawing the welded seamless copper pipe to tightly wrap the seamless copper pipe around the Z-shaped steel wire so as to generate enough binding force;
4) extruding adhesive layer, semi-conducting layer and insulating layer
A bonding layer is extruded outside the feed copper pipe by adopting an extruding machine, and the bonding material adopts a mixture of low-density polyethylene and ethylene acrylic acid copolymer;
extruding a semi-conducting layer outside the bonding layer by using an extruding machine, wherein the semi-conducting layer is a mixture of a polyolefin high polymer material and superconducting carbon black;
and extruding an insulating layer outside the semi-conducting layer by using an extruding machine, wherein the insulating material is high-density polyethylene.
Preferably, the portion of the Z-shaped wire where the outer arc segment overlaps the inner arc segment has a taper angle of α1The outer arc section is staggered relative to the inner arc section and has a cone angle of α2The inner arc section has a staggered part relative to the outer arc section and has a cone angle of α3；
And (3) calculating the number n of the Z-shaped steel wires:
wherein, α1、α2、α3Unit is degree α2＝α3。
Preferably, the total breaking force F of the Z-shaped steel wire is calculatedrts：
1) Calculating the total cross-sectional area S of the Z-shaped steel wireZ：
SZ＝[π(D0+t)t-0.858r2n]k1；
Wherein S isZUnit mm2；D0Is the outer diameter of the light unit in mm; t is the height of the Z-shaped steel wire in mm; r is the radius of the arc chamfer of the Z-shaped steel wire and is in mm; k is a radical of1Taking 0.95 as a correction coefficient;
2) calculating the total clearance area S of the Z-shaped steel wire1(unit mm)2)：
S1＝π(D0+t)t-Sz；
3) Calculating the total breaking force F of the Z-shaped steel wirerts：
Wherein, FrtsThe unit kN; sigma is the tensile strength of the Z-shaped steel wire and the unit of N/mm2The tensile strength of the phosphated steel wire is 2200N/mm2；k2Taking 0.9 as a correction coefficient; lambda is the twisting coefficient of the Z-shaped steel wire, and lambda is 1.015.
The cable core structure of the invention is as follows:
1) when the optical unit is manufactured, a plurality of communication optical fibers are brought into a stainless steel pipe formed by longitudinal wrapping and welding, and the stainless steel pipe is drawn by continuous reducing to obtain a certain extra length for the internal optical fibers so as to form a loose state of the optical fibers; the gap in the stainless steel tube is filled with a fiber paste with buffering, water-blocking and hydrogen-absorbing functions. The optical unit consisting of the optical fiber, the fiber paste and the stainless steel tube is the core part of the submarine optical cable core, and provides a loose, sealed and pressure-resistant safe environment for the optical fiber.
2) A layer of Z-shaped steel wires is twisted around the light units to form an inner reinforcing layer protecting the light units. Because the adjacent Z-shaped steel wires are tightly locked, and have the characteristics of mutual dependence, mutual support and mutual restraint, the steel wires are stable in structure, strong in lateral pressure resistance and impact resistance, not easy to loosen when bearing radial load, the control tension of the outer-layer copper tube on the steel wires is reduced, the space utilization rate is high, the generated gaps are few, the using amount of water-blocking glue is reduced, and the probability of seawater longitudinally permeating into the cable core is reduced. The Z-shaped steel wire is prepared by drawing through a roller die or an integral die according to the designed size, and has higher mechanical strength and corrosion resistance after phosphating treatment.
The gaps of the Z-shaped steel wires are filled with the water-blocking glue formed by mixing the two-component glue, and the water-blocking glue is solidified for a period of time, so that the gaps can be further reduced, and the aim of effectively preventing seawater from longitudinally permeating into the cable core is fulfilled. The water-blocking glue is bi-component glue which is formed by mixing polyurethane and polyol or isocyanate and polyol according to a certain proportion, is in a fluid state when being filled, is in a gel state after a period of time, and plays a role of longitudinal water blocking.
The feed copper pipe is formed by longitudinally wrapping and welding annealed soft copper strips, the feed copper pipe, the Z-shaped steel wire and the stainless steel pipe are tightly combined into a composite conductor, the composite conductor is used as a repeater power supply conductor in a relayed submarine optical cable system, and is used as a fault positioning conductor in a non-relayed submarine optical cable system, and meanwhile, the feed copper pipe also provides mechanical protection and radial water and hydrogen blocking functions for optical fibers.
And longitudinally wrapping a copper strip on the periphery of the Z-shaped steel wire, welding the copper strip into a copper pipe, closely combining the copper pipe with the Z-shaped steel wire after reducing and drawing, and forming a composite conductor together with the stainless steel pipe on the inner layer to be used as a repeater power supply conductor or a fault positioning conductor of the submarine optical cable.
3) An adhesive layer, a semi-conducting layer and an insulating layer are respectively extruded on the periphery of the feed copper pipe from the inner layer to the outer layer; the bonding layer is a mixture of low-density polyethylene and ethylene acrylic acid copolymer, and can increase the bonding force between the internal feed copper pipe and the external semi-conducting layer, so that the phenomenon of movement of the inner layer is not easy to occur when the outer layer is stressed; a semi-conducting layer with a shielding effect is extruded outside the bonding layer, and the semi-conducting layer is made of a mixture of polyolefin high polymer materials and superconducting carbon black, so that an electric field can be balanced, the point discharge phenomenon at the protruding part of the surface of the conductor can be effectively reduced, and an outer insulating layer can be protected from being punctured; the insulating layer adopts high density polyethylene insulating material, and the insulating layer possesses sufficient thickness, insulation resistance, dielectric strength and water proofness, can effectively guarantee the mutual insulation between feed copper pipe and the sea water.
The invention has the following beneficial effects:
1) the twisted Z-shaped steel wires are used as the inner enhancement layer of the optical unit, and because the adjacent Z-shaped steel wires have the functions of mutual dependence, mutual support and mutual constraint, and the Z-shaped steel wires can be tightly attached to the periphery of the optical unit through accurate size calculation, the obvious advantages brought are as follows:
a) compared with twisted round steel wires and fan-shaped steel wires, the Z-shaped steel wires can greatly improve the lateral pressure resistance and impact resistance of the inner reinforcement layer;
b) compared with twisted round steel wires and fan-shaped steel wires, the Z-shaped steel wires can effectively keep the stability of the structure of the inner reinforcing layer of the steel wires when the cable core is bent, and reduce the mechanical damage of the inner reinforcing layer of the steel wires to the outer copper pipe;
c) compared with twisted round steel wires, the Z-shaped steel wires can effectively improve the space utilization rate of the inner enhancement layer, reduce the gaps among the steel wires and reduce the outer diameter of the inner enhancement layer, so that the risk of longitudinal seawater penetration into the cable core is reduced, and the material consumption can be reduced;
d) compared with the twisted fan-shaped steel wires, the number of the adopted Z-shaped steel wires is obviously more than that of the fan-shaped steel wires, so that the twisting pitch is more favorably adjusted in the twisting process, and the cable core has a smaller bending radius.
2) Before the polyethylene insulating layer is extruded, the semi-conducting layer is extruded, and compared with other existing cable cores without the semi-conducting layer, the insulating layer has more reliable insulating performance. In the series production process of the steel wire and the welded copper pipe of the enhancement layer in the optical unit, some burrs and projections are generated under the action of operation tension of steel wire twisting, copper belt trimming, copper belt longitudinal wrapping, copper pipe welding, copper pipe drawing and the like, and a part of burrs and projections may be generated in the later use process. When a composite conductor consisting of copper pipes, steel wires and stainless steel pipes in the submarine optical cable is electrified, the burrs and protrusions on the conductor can generate a point discharge phenomenon, and the insulating layer can be broken through to generate faults. The semi-conducting layer is added in front of the insulating layer, so that the electric field can be balanced, the point discharge phenomenon of the conductor can be eliminated, and the breakdown of the external insulating layer can be effectively avoided.
The submarine optical cable core can be directly used in deep sea as a light submarine optical cable (LW type), and different protective layers can be continuously added on the outer layer to be used as a light protective submarine optical cable (LWP type), a single-layer armored light submarine optical cable (SAL type), a single-layer armored submarine optical cable (SA type), a double-layer armored submarine optical cable (DA type) and a rock armored submarine optical cable (RA type) in the submarine with special requirements.
Drawings
FIG. 1 is a cross-sectional view of a core for a submarine optical cable according to the present invention;
FIG. 2 is a three-dimensional schematic view of a core of an undersea optical fiber cable according to the present invention;
FIG. 3 is a schematic view of a Z-shaped steel wire structure in the submarine optical cable core according to the present invention;
FIG. 4 is a schematic view of the present invention showing the feeding of an optical fiber and a fiber paste into a stainless steel tube;
FIG. 5 is a comparison of stainless steel tube before and after drawing;
in the figure: 1. an optical fiber; 2. fiber paste; 3. a stainless steel tube; 4. a light unit; 5. a Z-shaped steel wire; 6. water-blocking glue; 7. a feed copper pipe; 8. a bonding layer; 9. a semiconducting layer; 10. an insulating layer; 5-1, an outer circular arc section; 5-2 and an inner arc section.
Detailed Description
As shown in figures 1 and 2, the high-strength lateral pressure-resistant and impact-resistant submarine optical cable core comprises an optical unit 4, which is a core part of the submarine optical cable core, and is formed by a stainless steel pipe 3 containing optical fibers 1 and fiber paste 2; the optical fiber is a G652.D, G654 and G655 single-mode optical fiber which is used as a signal transmission medium; the high-viscosity deep-sea special hydrogen absorption fiber paste is selected as the fiber paste, and the effects of buffering and longitudinal water resistance are provided for the optical fiber; the stainless steel tube is formed by longitudinally wrapping and welding 304 or 316 austenitic stainless steel bands, and provides mechanical protection and radial water and hydrogen blocking functions for the optical fiber. Twisting a Z-shaped steel wire 5 at the periphery of the light unit to form an inner enhancement layer for protecting the light unit; filling water-blocking glue 6 in the clearance of the reinforcing layer in the Z-shaped steel wire; a feed copper pipe 7 is welded on the periphery of the reinforcing layer in the Z-shaped steel wire; an adhesive layer 8, a semi-conducting layer 9 and an insulating layer 10 are respectively extruded on the periphery of the feed copper pipe from the inner layer to the outer layer.
As shown in figure 3, the cross section of each Z-shaped steel wire is composed of an outer arc section 5-1 and an inner arc section 5-2 which are staggered with each other, the heights of the outer arc section and the inner arc section are equal, and the cone angle of the overlapped part of the outer arc section and the inner arc section is α1The outer arc section is staggered relative to the inner arc section and has a cone angle of α2The inner arc section has a staggered part relative to the outer arc section and has a cone angle of α3。
A preparation method of a high-strength side pressure-resistant and impact-resistant submarine optical cable core comprises the following steps:
1) laser welding pipe making process (namely making optical unit)
The main process flow of laser welding pipe manufacturing comprises the following steps: steel belt paying-off → steel belt cleaning → steel belt trimming → steel belt molding, optical fiber paying-off, fiber paste filling → steel pipe laser welding → reducing drawing → traction → eddy current inspection → steel pipe taking-up; controlling the tension of the optical fiber to be 0.5-1.2N during paying off; controlling the temperature of a machine head to be 100-110 ℃ during filling of the fiber paste; the laser power is less than or equal to 1 kW; the traction tension is less than or equal to 2000N; the take-up tension is less than or equal to 100N. Specifically, the method comprises the following steps:
a. and longitudinally wrapping the stainless steel band subjected to the edge cutting treatment into a tubular shape through a forming die, and welding the stainless steel band into a seamless stainless steel tube by adopting laser welding equipment.
b. During welding, after the optical fiber is discharged from a pay-off rack, the optical fiber and thixotropic water-blocking fiber paste enter a formed stainless steel tube through a fiber guide die; as shown in fig. 4, a plurality of optical fibers are gathered together from a pay-off rack through a guide die and pass through a filling conduit, a filling device is arranged on the filling conduit and is used for filling fiber paste, the front end of the filling conduit extends into the inner cavity of the formed steel pipe before the steel strip longitudinal package is folded and crosses a welding point, and the optical fibers and the fiber paste are continuously sent into the welded stainless steel pipe.
The filling ratio of the fiber paste is not less than 80%, and the filling ratio is the volume of the fiber paste/(the volume of the stainless steel tube-the volume of the optical fiber) × 100%. The viscosity of the fiber paste is inversely proportional to the temperature, in order to avoid the phenomenon that the optical fiber is subjected to larger friction resistance due to overlarge viscosity, the fiber paste needs to be heated before filling, and the temperature of a machine head is controlled to be 100-110 ℃ during filling of the fiber paste.
c. The welded stainless steel tube is subjected to continuous reducing drawing through a drawing device and is drawn through wheel drawing after drawing, so that reasonable and uniform excess length of the optical fiber is obtained (after the optical fiber and the fiber paste are introduced into the stainless steel tube, the stainless steel tube is drawn through the wheel drawing, and the take-up tension is smaller than the wheel drawing tension, the stainless steel tube releases the tension, and the stainless steel tube rebounds, so that the excess length of the optical fiber is formed).
Wherein, the welded stainless steel pipe is drawn twice, and when obtaining the specified external diameter, because the effect of cold hardening, the tensile strength of steel pipe promotes, as shown in fig. 5:
drawing elongation coefficient λ ═ L1/L0 ═ [ (D0-t0) × t0]/[ (D1-t1) × t1 ];
since the tube wall thickness is approximately constant after drawing, namely: t0 ≈ t 1;
then λ ═ L1/L0 ≈ D0-t0)/(D1-t 1);
wherein: l1: length after drawing; l0 pre-draw length; d0 outside diameter before drawing; t0 wall thickness before drawing; d1 outer diameter after drawing; t1 wall thickness after drawing; the drawing extension coefficient is controlled to be 1.2-1.6.
According to design and calculation, the wall thickness of the stainless steel pipe is in the range of 0.15-0.30 mm; the outer diameter range of the stainless steel pipe is 2.0-5.0 mm; the surplus length range of the optical fiber is 1-6 per mill; the filling rate of the fiber paste is more than or equal to 80 percent; the number of the optical fiber cores contained in the stainless steel tube is less than or equal to 96 cores.
2) Stranded steel wire (namely manufacturing inner reinforcement layer)
a. According to the tensile strength F of the cable corertsThe size and the number of the Z-shaped steel wires are determined by calculation and computer aided design.
The Z-shaped steel wire is manufactured by drawing through a roller die or an integral die, and the main process flow is as follows: wire rod → cold drawing → heat treatment → ultrasonic pickling → phosphating → drying → wire drawing → rolling. The wire rod material is high carbon steel, is used as the blank of Z shape steel wire, and the cold drawing process is drawn the wire diameter to the demand for the first time with the steel wire, through 1000 ℃ of quenching and 500 ℃ of annealing, improves the tissue of wire rod and inhomogeneity and eliminate the internal stress, and ultrasonic pickling is used for getting rid of the bonderizing of wire rod self and the impurity of heat treatment introduction, and the bonderizing is used for promoting steel wire overall stability, corrosion resisting property.
b. Adopt cage type stranded conductor equipment with Z shape steel wire through the management and control of bunch mould, closely the transposition forms enhancement layer in the Z shape steel wire around the light unit.
Due to the characteristic that the Z-shaped steel wires are locked with each other, a steel wire pay-off rack of the wire stranding equipment is set to be in a non-back-twist mode; according to design and calculation, the range of the twisting pitch is 25-40 times of the outer diameter of the inner enhancement layer; the number of the Z-shaped steel wires is less than or equal to 16, and the core breaking force FrtsThe nominal value of (A) is more than or equal to 50 kN.
c. In the twisting process of the Z-shaped steel wire, liquid water-blocking glue formed by mixing polyurethane and polyol or isocyanate and polyol is sprayed on the optical unit and the Z-shaped steel wire, so that the gaps of the steel wire of the inner reinforcing layer are filled with the water-blocking glue. The filling rate of the water-blocking glue is more than or equal to 70 percent, and the water-blocking glue can be converted into a gel state after a period of time.
Water-blocking glue
The formula I is as follows:
vorite (polyurethane) blended with Polycin (polyol) at a weight ratio of Vorite/Polycin of 17/83 and a volume ratio of Vorite/Polycin of 15/85;
and a second formula:
isocynate (Isocyanate) was mixed with Polyol (Polyol) at a weight ratio of Isocynate/Polyol of 23/77 and a volume ratio of Isocynate/Polyol of 22/78.
The water-blocking glue is mixed and then is conveyed to a steel wire twisting point through a pump and a pipeline, and the nozzles are respectively positioned right above a middle light unit of the cable core and right above the steel wire twisting point before twisting, namely in front of a bunching mold, and the water-blocking glue is directly sprayed on the cable core by gravity. The pump passes through the AC motor drive, and the flow size is controllable, and the continuity sprays, then the cable core passes through the silica gel board of several trompils, scrapes the unnecessary water blocking glue in surface clean, does not influence and gets into next copper pipe welding process immediately, and water blocking glue can solidify gradually under natural state.
3) Argon arc welding pipe (namely feed copper pipe)
a.Z-shaped steel wires are twisted and then enter argon arc welding pipe-making equipment, the copper strips subjected to edge cutting treatment are longitudinally wrapped around the Z-shaped steel wires through a forming die to form a pipe shape, and the seamless copper pipes are welded by using an inert gas shielded welding technology;
b. and then, reducing and drawing the welded copper pipe through a traction device and a drawing device to tightly wrap the copper pipe around the Z-shaped steel wire, so that enough binding force is generated.
The copper pipe, the Z-shaped steel wire and the stainless steel pipe form a composite conductor, and the direct current resistance of the composite conductor at 20 ℃ is less than or equal to 1.5 omega/km in the submarine optical cable with the relay; the number of omega/km in the unrepeatered submarine optical cable is less than or equal to 7 omega/km.
The argon arc welding equipment and the cage type stranded wire equipment can form a linkage control series production line, and can successively and continuously complete the welding process of twisting the Z-shaped steel wire and the copper pipe.
4) Extruding adhesive layer, semi-conducting layer and insulating layer
a. A plastic extruding machine is adopted to extrude a bonding layer outside the feed copper pipe, the bonding material is a mixture of low-density polyethylene (LDPE) and ethylene acrylic acid copolymer (EAA), the extrusion thickness range is 0.15-0.3 mm, and the bonding layer can effectively increase the bonding force between the inner layer and the outer layer. The adhesive layer is formed by mixing 75/25 weight parts of Low Density Polyethylene (LDPE) and 75/25 weight parts of ethylene acrylic acid copolymer (EAA), uniformly stirring, adding into a charging barrel of an extruding machine, heating and plasticizing by the extruding machine, extruding by a screw, wrapping outside a feed copper pipe, and cooling and shaping by circulating water.
b. And a semi-conducting layer is extruded outside the bonding layer by using an extruding machine, the extruding thickness is not less than 0.8mm, and the semi-conducting layer is a mixture of polyolefin polymer materials and superconducting carbon black, so that an electric field can be balanced, the phenomenon of conductor point discharge can be eliminated, and an external insulating layer can be prevented from being punctured. The polyolefin high polymer material can be Linear Low Density Polyethylene (LLDPE) or Low Density Polyethylene (LDPE), the addition amount of the superconducting carbon black is about 10 weight percent, and the volume resistivity of the prepared mixture is required to be less than or equal to 1.0 omega.m at 23 ℃.
c. And an insulating layer is extruded outside the semi-conducting layer by using an extruding machine, the extrusion thickness is not less than 2.5mm, the insulating material is high-density polyethylene (HDPE), the insulating material has sufficient insulation resistance and dielectric strength, the insulation resistance is not less than 10G omega.km, and the composite conductor in the cable core can work for a long time under the condition of applying a direct current voltage of not less than 15 kV.
In this embodiment, the outer diameter D of the light unit03.0mm, 1.8mm height t of Z-shaped steel wire, 0.2mm radius r of arc chamfer of Z-shaped steel wire, and α mm taper angle of Z-shaped steel wire1＝60°；α2＝α3＝15°。
1) Calculating the number n of the Z-shaped steel wires:
α therein1、α2、α3Unit is degree α2＝α3(ii) a This example calculates n to 8.
2) Calculating the total cross-sectional area S of the Z-shaped steel wireZ：
SZ＝[π(D0+t)t-0.858r2n]k1
Wherein SZUnit mm2；D0T, r in mm; k is a radical of1Taking 0.95 as a correction coefficient; this example calculates SZ＝25.53mm2。
3) Calculating the total clearance area S of the Z-shaped steel wire1：
S1＝π(D0+t)t-Sz
Wherein S1Unit mm2(ii) a This example calculates S1＝1.61mm2。
4) Calculating the total breaking force F of the Z-shaped steel wirerts：
Wherein FrtsThe unit kN; sigma is the tensile strength of the Z-shaped steel wire and the unit of N/mm2The tensile strength of the phosphated steel wire is 2200N/mm2；k2Taking 0.9 as a correction coefficient; lambda is the twisting coefficient of the Z-shaped steel wire; in this example, λ was 1.015, and F was calculatedrts＝50kN。
The invention can be used as the cable core of the submarine optical cable, can be directly used as the deep-sea optical cable, and can also be added with a steel-plastic bonding sheath, a single-layer steel wire armor, a double-layer steel wire armor and a protective layer wound by asphalt filling and polypropylene ropes to meet the use requirements of special underwater environments. The volume of the steel wire can be increased by about 27% by adopting the Z-shaped steel wire, so that the mechanical tension of the submarine cable core is increased by about 27% under the condition of the same diameter, and the lateral pressure resistance and the impact resistance of the inner cable core can be improved; the stability of the inner reinforcing layer structure when the cable core is bent is reduced, and the mechanical damage of the inner reinforcing layer of the steel wire to the outer-layer copper pipe is reduced; the Z-shaped steel wire can greatly reduce the using amount of glue and improve the water resistance of the cable core. The semi-conducting layer is added in front of the insulating layer, so that the electric field can be balanced, the point discharge phenomenon of the conductor can be eliminated, and the breakdown of the external insulating layer can be effectively avoided.
Claims (10)
1. The submarine optical cable core with high strength, side pressure resistance and impact resistance comprises an optical unit (4) and is characterized in that an inner enhancement layer is arranged on the periphery of the optical unit and formed by twisting a plurality of Z-shaped steel wires (5) on the periphery of the optical unit, a gap of the inner enhancement layer is filled with water-blocking glue (6), and a feed copper pipe (7) is coated on the periphery of the inner enhancement layer.
2. The submarine optical cable core with high strength, lateral pressure resistance and impact resistance according to claim 1, wherein the feed copper tube is sequentially extruded with a semi-conducting layer (9) and an insulating layer (10) at the periphery.
3. A high strength lateral pressure resistant, impact resistant submarine optical cable core according to claim 2, wherein said feed copper tube is extruded with an adhesive layer (8) between the semi-conducting layer.
4. A high strength lateral pressure resistant, impact resistant submarine optical cable core according to claim 1, wherein said optical unit is made of stainless steel tube (3) containing optical fiber (1) and fiber paste (2).
5. The high strength, lateral pressure resistant, impact resistant submarine optical cable core according to claim 1, wherein all chamfers of said Z-shaped wires are rounded chamfers.
6. The high-strength lateral pressure-resistant and impact-resistant submarine optical cable core according to claim 1, wherein each Z-shaped steel wire has a cross section comprising an outer arc section (5-1) and an inner arc section (5-2) which are staggered with each other, and the outer arc section and the inner arc section have the same height.
7. The high strength, side pressure resistant, impact resistant submarine optical cable core according to claim 6, wherein the portion of said outer arc segment that is offset with respect to the inner arc segment has the same taper angle as the portion of said inner arc segment that is offset with respect to the outer arc segment.
8. A preparation method of a high-strength side pressure-resistant and impact-resistant submarine optical cable core is characterized by comprising the following steps:
1) making optical elements
Longitudinally wrapping the stainless steel band subjected to edge cutting treatment into a tubular shape through a forming die, and welding into a seamless stainless steel tube by adopting laser welding equipment;
during welding, the optical fiber enters the formed stainless steel tube together with the fiber paste through the fiber guide die;
continuously reducing and drawing the formed stainless steel tube to obtain reasonable and uniform excess length of the optical fiber;
2) making internal reinforcement layers
Determining the size and the number of the Z-shaped steel wires according to the index requirement of the cable core breaking force;
the Z-shaped steel wire is tightly stranded around the light unit by adopting cage type stranded wire equipment through the control of a bunch mold to form a Z-shaped steel wire inner reinforcing layer; due to the characteristic that the Z-shaped steel wires are locked with each other, a steel wire pay-off rack of the wire stranding equipment is set to be in a non-back-twist mode;
in the twisting process of the Z-shaped steel wires, liquid water-blocking glue is sprayed on the optical units and the Z-shaped steel wires, so that the gaps between the steel wires of the inner enhancement layer are filled with the water-blocking glue, and after a period of time, the water-blocking glue is converted into a gel state;
3) manufacturing feed copper pipe
The Z-shaped steel wires are twisted and then enter argon arc welding pipe manufacturing equipment; longitudinally wrapping the copper strip subjected to the edge cutting treatment around the Z-shaped steel wire by a forming die to form a tubular shape, and welding the copper strip into a seamless copper pipe;
then reducing and drawing the welded seamless copper pipe to tightly wrap the seamless copper pipe around the Z-shaped steel wire so as to generate enough binding force;
4) extruding adhesive layer, semi-conducting layer and insulating layer
A bonding layer is extruded outside the feed copper pipe by adopting an extruding machine, and the bonding material adopts a mixture of low-density polyethylene and ethylene acrylic acid copolymer;
extruding a semi-conducting layer outside the bonding layer by using an extruding machine, wherein the semi-conducting layer is a mixture of a polyolefin high polymer material and superconducting carbon black;
and extruding an insulating layer outside the semi-conducting layer by using an extruding machine, wherein the insulating material is high-density polyethylene.
9. The method of claim 8, wherein the Z-shaped steel wire has a cone angle of α at the portion where the outer arc section overlaps the inner arc section1The outer arc section is staggered relative to the inner arc section and has a cone angle of α2The inner arc section has a staggered part relative to the outer arc section and has a cone angle of α3；
And (3) calculating the number n of the Z-shaped steel wires:
wherein, α1、α2、α3Unit is degree α2＝α3。
10. The method for preparing a high-strength lateral pressure-resistant and impact-resistant submarine optical cable core according to claim 9, wherein the total breaking force F of the Z-shaped steel wires is calculatedrts：
1) Calculating the total cross-sectional area S of the Z-shaped steel wireZ：
SZ＝[π(D0+t)t-0.858r2n]k1；
Wherein S isZUnit mm2；D0Is the outer diameter of the light unit in mm; t is the height of the Z-shaped steel wire in mm; r is the radius of the arc chamfer of the Z-shaped steel wire and is in mm; k is a radical of1Taking 0.95 as a correction coefficient;
2) calculating the total clearance area S of the Z-shaped steel wire1(unit mm)2)：
S1＝π(D0+t)t-Sz；
3) Calculating the total breaking force F of the Z-shaped steel wirerts：
Wherein, FrtsThe unit kN; sigma is the tensile strength of the Z-shaped steel wire and the unit of N/mm2The tensile strength of the phosphated steel wire is 2200N/mm2；k2Taking 0.9 as a correction coefficient; lambda is the twisting coefficient of the Z-shaped steel wire, and lambda is 1.015.
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Application publication date: 20200918 |