CN112201392A - Production method of high-precision special-shaped stranded wire small-diameter cable - Google Patents
Production method of high-precision special-shaped stranded wire small-diameter cable Download PDFInfo
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- CN112201392A CN112201392A CN202011418141.7A CN202011418141A CN112201392A CN 112201392 A CN112201392 A CN 112201392A CN 202011418141 A CN202011418141 A CN 202011418141A CN 112201392 A CN112201392 A CN 112201392A
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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
- H01B7/0009—Details relating to the conductive cores
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
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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
- H01B13/141—Insulating conductors or cables by extrusion of two or more insulating 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
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
- H01B13/148—Selection of the insulating material therefor
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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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- 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
- H01B7/02—Disposition of insulation
- H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
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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
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
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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
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
Abstract
A production method of a high-precision special-shaped strand small-diameter cable comprises the following steps: 1) manufacturing a cable conductor; 2) extruding and wrapping semi-conductive chloroprene rubber to prepare a conductor shielding layer; 3) extruding ethylene propylene rubber to prepare an insulating layer; 4) extruding and wrapping semi-conductive chloroprene rubber to prepare an insulating shielding layer; 5) extruding and wrapping the semiconductive chloroprene rubber to prepare a semiconductive sheath layer; 6) coating nanometer semi-conductive glue to prepare the semi-conductive nanometer coating. According to the method, through a specific conductor processing process, an extrusion coating process of each functional layer and the like, the manufactured cable has the characteristic of high precision, and meanwhile, the performance can meet the laying requirement of the cable for high-speed rail transit. The technical problem that the product precision is improved by a process method in the production process is solved.
Description
Technical Field
The invention relates to a method for producing a high-precision small-diameter cable of a special-shaped folded yarn for high-speed rail transit, belonging to the technical field of cable manufacturing.
Background
The cable for high-speed rail transit is used for power transmission for train operation. Supply cables along the line are used to supply the long stator of the traction motor. Each single-track railway has two groups of mutually independent three-phase cables which respectively supply power to long motor stators on two sides of the high-speed railway. Each phase is made up of multiple strands of wire to reduce cable reactance. Due to the special design, the cable is S-shaped in the track, and the characteristics of small bending radius, ultraviolet resistance, corrosion resistance, vibration resistance, aging resistance, flame retardance, light weight and the like are required. Because the cable requires small outer diameter, the cable can be laid in a stator slot and does not fall off, the overall structure of the cable is fixed, and the cable is difficult to be added with a function/performance layer to improve the applicability of the cable. Therefore, the precision of the product is improved by a technological method in the production process. Such as "a traffic cable" under the publication No. CN210667842U, in order to ensure the use, the outer diameter of the finished cable needs to be controlled as small as possible to ensure that the cable can be laid in the stator slot without falling off.
Disclosure of Invention
In order to solve the technical problems, the invention provides a method for producing a small-diameter cable with high-precision special-shaped stranded wires. Specifically, the method comprises the following steps:
a production method of a high-precision special-shaped strand small-diameter cable comprises the following steps:
1) manufacturing a cable conductor;
2) extruding and wrapping semi-conductive chloroprene rubber to prepare a conductor shielding layer;
3) extruding ethylene propylene rubber to prepare an insulating layer;
4) extruding and wrapping semi-conductive chloroprene rubber to prepare an insulating shielding layer;
5) extruding and wrapping the semiconductive chloroprene rubber to prepare a semiconductive sheath layer;
6) coating nanometer semi-conductive glue to prepare the semi-conductive nanometer coating.
The step 1) comprises the following steps:
1.1) preformed monofilaments:
drawing: drawing the aluminum alloy rod into a fan-shaped monofilament, a Z-shaped monofilament and an S-shaped monofilament respectively by adopting corresponding wire drawing dies;
the wire drawing process comprises the following steps: the aluminum rod is sequentially inserted into 11 wire drawing dies according to the pass, the single wire cambered surface corresponds to the die hole cambered groove, the stable stress of the aluminum wire is ensured, and the single wire section has no deviation;
1.2) twisting the three monofilaments prepared in the step 1.1) to form a conductor, and preparing the fan-shaped monofilaments into an inner layer of the conductor; the Z-shaped monofilaments and the S-shaped monofilaments are sequentially wrapped outside the inner conductor layer;
the conductor is provided with n layers from inside to outside, the inner layer of the conductor is the 1 st layer, and n is a natural number; the twisting directions of the conductors of the adjacent layers are opposite; from the 2 nd layer, the section of the monofilament of the adjacent layer conductor is mirror-symmetrical, and finally the nth layer conductor is manufactured to obtain the cable conductor;
the technical principle and effect required by the process are as follows: the aluminum rod is drawn into the special-shaped monofilaments, and then the special-shaped monofilaments are sequentially twisted into a round shape through the twisting process, so that the effect is that when the conductor is bent, the monofilaments are mutually embedded, the phenomenon of explosion is avoided, and the tightness of the conductor is ensured.
In the specific implementation, the conductor has three layers, the inner layer of the conductor is made of 4 fan-shaped monofilaments, the middle layer of the conductor is made of a plurality of Z-shaped monofilaments, and the outer layer of the conductor is made of a plurality of S-shaped monofilaments;
in the step 1.1), the fan-shaped monofilament, the Z-shaped monofilament and the S-shaped monofilament are all formed by sequentially penetrating an aluminum rod into 11 corresponding wire drawing dies according to the pass, the single wire arc surface corresponds to the die hole arc groove, and the parameters of the wire drawing machine comprise:
fan-shaped monofilaments: the speed ratio of the constant speed wheel is 1.19, the diameter of a finished product die is 4.20mm, the wire arranging pitch is 0.1mm, and the wire drawing speed is 8 m/s;
z-shaped monofilaments: the speed ratio of the constant speed wheel is 1.16, the diameter of a finished product die is 3.30mm, the wire arranging pitch is 0.1mm, and the wire drawing speed is 10 m/s;
s-shaped monofilaments: the speed ratio of the constant speed wheel is 1.16, the diameter of a finished product die is 3.29mm, the wire arranging pitch is 0.1mm, and the wire drawing speed is 12 m/s;
in the step 1.2), three kinds of monofilaments are stranded on a stranding machine, and the parameters of the stranding machine include: the rotating speed of the inner layer of the stranded conductor is 40-45 r/min; the rotating speed of the middle layer of the stranded conductor is 30-35 r/min; the rotating speed of the outer layer of the stranded conductor is 30-33 r/min; the linear speed of the finished product is 7-8 m/min;
1.3) annealing the cable conductor prepared in the step 1.2) on a metal wire continuous annealing production line, wherein:
the temperature of the heating stage is 500 ℃, and the heating time is 30-40 min;
the temperature of the heat preservation stage is 500 ℃, and the heat preservation time is 3 hours;
the cooling speed of the cooling stage is 40 ℃/h, and the cooling time is 12 h.
The steps 2) to 4) are realized by a three-layer co-extrusion process:
the temperature zone of the first rubber extruding machine for extruding the semiconductive chloroprene rubber is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 80-90 ℃ and the temperature of the fifth zone is 90-100 ℃; 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;
the second rubber extruding machine temperature zone for extruding ethylene propylene rubber is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 65-75 ℃ and the temperature of the fifth zone is 75-80 ℃; 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;
the third temperature zone of the rubber extruder for extruding the semi-conductive chloroprene rubber is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 80-90 ℃ and the temperature of the fifth zone is 90-100 ℃; 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;
setting the temperature of the machine head: 110 ℃;
in the extrusion process, during production, the steam pressure is 8-12 bar, the production speed is 5-6 m/min, the rotating speed of a first rubber extrusion machine screw is 15-20 r/min, the rotating speed of a second rubber extrusion machine screw is 8-12 r/min, and the rotating speed of a third rubber extrusion machine screw is 8-12 r/min.
After the steps are finished, water cooling is carried out in a cold water tank, and the cooling time is 15 min; the water temperature of the cold water tank is controlled to be 5-10 ℃.
Step 5), extruding and wrapping the semiconductive chloroprene rubber to prepare a semiconductive sheath layer:
and (3) for the cable prepared in the step 4), extruding the semi-conductive chloroprene rubber in a fourth rubber extruding machine, wherein the temperature zone of the fourth rubber extruding machine is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 65-75 ℃ and the temperature of the fifth zone is 75-80 ℃; 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;
during production, the steam pressure is 7-8 bar, the production speed is 5-6 m/min, and the rotating speed of a screw of a fourth rubber extruding machine is 18-20 r/min;
water cooling in a cold water tank for 20 min; the water temperature of the cold water tank is controlled to be 5-10 ℃.
And 6) coating the nanoscale semi-conductive glue outside the cable prepared in the step 5) on line, wherein the coating step is as follows: the cable is walked on the coating machine, and the spraying is carried out to the semi-conductive glue, and infrared heating pipe heats the stoving solidification.
Most of the traditional cable semi-conducting layers are films or belt products (such as polyester films and semi-conducting non-woven fabrics) coated with nano semi-conducting layers, and the films are wrapped outside the cable in a wrapping mode. This increases the outer diameter of the cable for the present cable. In order to further reduce the outer diameter of the cable, a mode of directly coating nanoscale semiconductive glue is adopted. In the prior art, the glue product is used for manufacturing a nano-scale semiconductive film, and mainly comprises a mixture of oil acrylic emulsion containing nano carbon black or carbon pipes, ethyl ester and the like.
During gluing, the linear speed of the cable is 4-5 m/min, the glue curing time is 5min, and the thickness range of the semi-conductive nano coating prepared by the process can reach 5-50 mu m, is very thin and has good firmness.
The viscosity of the semiconductive glue is controlled to be 15-18 seconds (Engler viscosity), and an electric pressure cylinder is adopted to stir uniformly at a constant speed;
adjustment of coating thickness: the cable conveying speed and the spraying pressure are synchronous, the cable conveying speed is 4-5 m/min, the spraying pressure is 0.8-1 MPa, and the thickness of glue on each surface of the cable is ensured to be uniform;
controlling the drying temperature: and heating and drying by an infrared heating pipe, wherein the curing heating temperature is 200 ℃, and the surface temperature of the cross section of the cable is uniform and consistent.
Cable conveying: the cable is always positioned in the center of the spraying machine in the spraying process, so that the coating is prevented from being scratched, and the thickness of the cable is uniform.
In the step 1), the aluminum alloy adopted by the conductor is AA8000 series aluminum alloy. Used for improving the mechanical strength and creep resistance.
Through the production process, the control deviation of the outer diameter of a cable conductor is +/-0.1 mm, the control deviation of the outer diameter of an insulated wire core is +/-0.2 mm, and the control deviation of the outer diameter of a finished cable is +/-0.2 mm, so that the cable can be laid in a stator slot and cannot fall off.
By controlling the conductor annealing process, the conductor has the advantages of high softness, small bending stress, no deformation, no looseness, creep resistance and the like after being laid. And, through the detection, the elongation at break of the central conductor is 25% -35%.
The cable manufactured by the production method of the high-precision special-shaped stranded wire small-diameter cable is used for supplying power to a long stator of a traction motor of high-speed rail transit.
The cable prepared by the method is suitable for power transmission of high-speed rail transit, and not only has the outer diameter strictly controlled, but also has reliable electrical properties (such as voltage resistance and other insulation properties), and simultaneously has the characteristics of excellent bending property, weather resistance, flame retardance and the like.
Through production control, the insulation shielding layer, the semi-conductive sheath layer and the semi-conductive nano coating are of an integrated structure, and the surface resistance of the finished cable is not more than 200 omega. The induced current, the capacitance current and the leakage current of the cable during the operation can be effectively reduced, and the use safety of the cable during the long-term operation is ensured.
The principle and the beneficial effects of the technical scheme are explained as follows:
1. in order to meet the special application environment for laying the high-speed rail traffic line rails, the cables are required to meet the requirements of excellent electrical performance, weather resistance, flexibility and the like.
The special cable adopts a special-shaped annealed aluminum conductor, and a central layer is formed by stranding 4 fan-shaped monofilaments with 90 degrees; the secondary inner layer is formed by twisting Z-shaped monofilaments; the outer layer is formed by twisting S-shaped monofilaments; the conductor is integrally annealed, so that the conductor has the advantages of high flexibility, small bending stress, no deformation, no looseness, creep resistance and the like after being laid; the ethylene propylene rubber is used as an insulating material, and a three-layer co-extrusion process is adopted to process the insulating layer. The material can meet the low temperature resistance of 40 ℃ below zero and the high temperature resistance of 105 ℃ below zero under the condition of meeting the requirement of high voltage performance.
The high-strength rubber is used as a sheath material, adopts a single-layer structure, and can meet the requirements of weather resistance and semi-conductivity under the condition of meeting high mechanical performance.
2. The special application environment has high requirements on the outer diameter of the cable, and meanwhile, the requirement of extremely small deviation of the outer diameter of the cable is required for the requirement of an embedded part of the cable embedded on the stator core.
The method and the prepared cable have excellent outer diameter consistency, and the production process has the advantages that the control deviation of the outer diameter of a cable conductor is +/-0.1 mm, the control deviation of the outer diameter of an insulated wire core is +/-0.2 mm, and the control deviation of the outer diameter of a finished cable is +/-0.2 mm, so that the cable can be laid in a stator slot and cannot fall off.
Drawings
Fig. 1 is a schematic radial cross-section of a conductor of the cable of the present embodiment.
Fig. 2 is a schematic cross-sectional structure diagram of the cable according to the embodiment.
In the figure: the cable comprises a conductor inner layer 1, a conductor middle layer 2, a conductor outer layer 3, a Z-shaped monofilament 4, a fan-shaped monofilament 5, an S-shaped monofilament 6, a conductor 7, a conductor shielding layer 8, an insulating layer 9, an insulating shielding layer 10, a semi-conductive sheath layer 11 and a semi-conductive nano coating 12.
Detailed Description
The technical scheme is further explained by combining the drawings and the specific embodiment as follows:
referring to the attached figures 1 and 2, the high-precision special-shaped stranded wire small-diameter cable manufactured by the manufacturing method has the structure that: the cable comprises a conductor 7, a conductor shielding layer 8, an insulating layer 9, an insulating shielding layer 10, a semi-conductive sheath layer 11 and a semi-conductive nano coating layer 12, wherein the conductor 7 is wrapped outside the conductor 7. The cable is used for supplying power to a long stator of a traction motor of high-speed rail transit.
The diameter of the conductor 7 is in the range of 19.5-20.5 mm; the thickness range of the insulating layer 9 is 5.2-5.8 mm; the thickness range of the semi-conductive sheath layer 11 is 1.8-2.4 mm; the thickness of the semiconductive nanocoating 12 ranges from 5-50 μm;
the conductor 7 is made of aluminum alloy; the conductor shielding layer 8 is made of semi-conductive chloroprene rubber; the insulating layer 9 is made of ethylene propylene rubber; the insulation shielding layer 10 is made of semiconductive chloroprene rubber; the sheath material of the semi-conductive sheath layer 11 is formed by extruding semi-conductive chloroprene rubber;
the conductor 7 is divided into 1 st to n th layers from inside to outside, and n is a natural number (3 layers in the example);
-for layer 1 conductors:
the multi-core-spun yarn is formed by twisting a plurality of axially symmetrical fan-shaped monofilaments, and the pitch-diameter ratio of the twisting is 20-25 times;
for the 2 nd to n th layer conductors 7:
they are respectively formed by mutually splicing and twisting a plurality of same monofilaments with Z-shaped or S-shaped sections; the single wires of the conductors in the adjacent layers are twisted in opposite directions; the monofilaments of adjacent layer conductors are mirror-symmetrical;
any special-shaped monofilament is formed by extrusion molding of aluminum alloy monofilament. The pitch-diameter ratio of the single-wire stranding of each layer conductor is 10-18 times (the pitch-diameter ratio of the outermost layer is the smallest, and the conductors are compact and not loose).
The conductor 7 is a conductor made of an aluminum alloy rod through drawing, twisting and annealing processes. The conductor shielding layer 8 is a shielding layer made of a semi-conductive material (semi-conductive chloroprene rubber) through a rubber extrusion and sulfur connecting process. The insulating layer 9 is made of insulating material (ethylene propylene rubber) through a rubber extrusion and sulfur connecting process. The insulation shielding layer 10 is made of a semi-conductive material (semi-conductive chloroprene rubber) through a rubber extrusion and sulfur connecting process. The semi-conductive sheath layer 11 is a sheath layer prepared from a sheath material (semi-conductive chloroprene rubber) through a rubber extrusion and sulfur connecting process. The semiconductive nano coating 12 is a nano coating prepared from a semiconductive adhesive through a spraying process.
The cable manufactured by the production method of the high-precision special-shaped stranded wire small-diameter cable is used for supplying power to a long stator of a traction motor of high-speed rail transit.
The production method of the high-precision special-shaped stranded wire small-diameter cable comprises the following steps: 1) manufacturing the conductor 7 of the cable; 2) extruding and wrapping semi-conductive chloroprene rubber to prepare a conductor shielding layer 8; 3) extruding ethylene propylene rubber to prepare an insulating layer 9; 4) extruding and wrapping semi-conductive chloroprene rubber to prepare an insulating shielding layer 10; 5) extruding and wrapping the semiconductive chloroprene rubber to prepare a semiconductive sheath layer 11; 6) and coating nanoscale semiconductive glue to prepare the semiconductive nano coating 12.
The step 1) comprises the following steps:
1.1) preformed monofilaments:
drawing: drawing the aluminum alloy rod into a fan-shaped monofilament 5, a Z-shaped monofilament 4 and an S-shaped monofilament 6 by adopting corresponding wire drawing dies respectively;
the wire drawing process comprises the following steps: the aluminum rod is sequentially inserted into 11 wire drawing dies according to the pass, the single wire cambered surface corresponds to the die hole cambered groove, the stable stress of the aluminum wire is ensured, and the single wire section has no deviation;
1.2) twisting the three monofilaments prepared in the step 1.1) to form a conductor 7, and preparing the fan-shaped monofilament 5 into a conductor inner layer 1; the Z-shaped monofilaments 4 and the S-shaped monofilaments 6 are wrapped outside the conductor inner layer 1 in sequence;
the conductor 7 is provided with n layers from inside to outside, the inner layer 1 of the conductor is the 1 st layer, and n is a natural number; the twisting directions of the monofilaments of the conductors of the adjacent layers are opposite; from the 2 nd layer, the section of the monofilament of the adjacent layer conductor is mirror symmetry, and finally the nth layer conductor is manufactured to obtain the conductor 7 of the cable;
1.3) annealing the cable conductor prepared in the step 1.2) on a metal wire continuous annealing production line, wherein: the temperature of the heating stage is 500 ℃, and the heating time is 30-40 min; the temperature of the heat preservation stage is 500 ℃, and the heat preservation time is 3 hours; the cooling speed of the cooling stage is 40 ℃/h, and the cooling time is 12 h;
the steps 2) to 4) are realized by a three-layer co-extrusion process:
the temperature zone of the first rubber extruding machine for extruding the semiconductive chloroprene rubber is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 80-90 ℃ and the temperature of the fifth zone is 90-100 ℃; 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;
the second rubber extruding machine temperature zone for extruding ethylene propylene rubber is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 65-75 ℃ and the temperature of the fifth zone is 75-80 ℃; 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;
the third temperature zone of the rubber extruder for extruding the semi-conductive chloroprene rubber is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 80-90 ℃ and the temperature of the fifth zone is 90-100 ℃; 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;
setting the temperature of the machine head: 110 ℃;
in the extrusion process, during production, the steam pressure is 8-12 bar, the production speed is 5-6 m/min, the rotating speed of a first rubber extrusion machine screw is 15-20 r/min, the rotating speed of a second rubber extrusion machine screw is 8-12 r/min, and the rotating speed of a third rubber extrusion machine screw is 8-12 r/min;
water cooling in a cold water tank for 15 min; the water temperature of the cold water tank is controlled to be 5-10 ℃.
The step 5) of extruding and wrapping the semiconductive chloroprene rubber to prepare a semiconductive sheath layer 11;
and (3) for the cable prepared in the step 4), extruding the semi-conductive chloroprene rubber in a fourth rubber extruding machine, wherein the temperature zone of the fourth rubber extruding machine is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 65-75 ℃ and the temperature of the fifth zone is 75-80 ℃; 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;
during production, the steam pressure is 7-8 bar, the production speed is 5-6 m/min, and the rotating speed of a screw of a fourth rubber extruding machine is 18-20 r/min;
water cooling in a cold water tank for 20 min; the water temperature of the cold water tank is controlled to be 5-10 ℃.
And 6) coating the nanoscale semi-conductive glue outside the cable prepared in the step 5) on line, wherein the coating step is as follows: the cable is wired on a coating machine, the semi-conductive adhesive is sprayed, and the infrared heating pipe is heated and dried; when gluing, the linear speed of the cable is 4-5 m/min; the glue curing time is 5 min.
The thickness range of the semiconductive nano coating 12 is 5-50 microns, and an infrared heating pipe is adopted for heating and drying at 200 ℃;
1) preparing a coating: adopting a bi-component system, adding a curing agent and a diluent into the coating, controlling the viscosity of the coating to be 15-18 seconds, and uniformly stirring by adopting a voltage cylinder at a constant speed;
2) adjustment of coating thickness: the cable conveying speed and the spraying pressure are synchronous (the cable conveying speed is 4-5 m/min, and the spraying pressure is 0.8-1 MPa), so that the uniform thickness of the glue on each surface of the cable is ensured;
3) controlling the drying temperature: heating and drying the cable by the infrared heating pipe, wherein the surface temperature of the cross section of the cable is uniform and consistent;
4) cable conveying: the cable is always positioned in the center of the spraying machine in the spraying process, so that the coating is prevented from being scratched, and the thickness of the cable is uniform.
In this example, the conductor 7 has three layers (i.e., n = 3), the conductor inner layer 1 is made of 4 fan-shaped monofilaments 5, the conductor intermediate layer 2 is made of a plurality of Z-shaped monofilaments 4, and the conductor outer layer 3 is made of a plurality of S-shaped monofilaments 6;
in the step 1.1), the fan-shaped monofilaments 5, the Z-shaped monofilaments 4 and the S-shaped monofilaments 6 are all formed by sequentially penetrating an aluminum rod into 11 corresponding wire drawing dies according to the pass, the monofilament arc surfaces correspond to the die hole arc grooves, and the parameters of the wire drawing machine comprise:
the fan-shaped monofilaments 5: the speed ratio of the constant speed wheel is 1.19, the diameter of a finished product die is 4.20mm, the wire arranging pitch is 0.1mm, and the wire drawing speed is 8 m/s;
z-shaped monofilament 4: the speed ratio of the constant speed wheel is 1.16, the diameter of a finished product die is 3.30mm, the wire arranging pitch is 0.1mm, and the wire drawing speed is 10 m/s;
s-shaped monofilaments 6: the speed ratio of the constant speed wheel is 1.16, the diameter of a finished product die is 3.29mm, the wire arranging pitch is 0.1mm, and the wire drawing speed is 12 m/s.
In the step 1.2), three kinds of monofilaments are stranded on a stranding machine, and the parameters of the stranding machine include:
the rotating speed of the inner layer 1 of the stranded conductor is 40-45 r/min; the rotating speed of the stranded conductor intermediate layer 2 is 30-35 r/min; the rotating speed of the outer layer 3 of the stranded conductor is 30-33 r/min;
the linear speed of the finished product is 7-8 m/min.
The extrusion process has certain influence on the yield of the cable, and through comparison, the optimal extrusion process with the highest yield of the cable manufactured in the embodiment is the process in the embodiment 2:
| example 1 | A region | Two zones | Three zones | Four zones | Five zones | Screw rotation speed |
| First rubber extruding machine | 50℃ | 55℃ | 65℃ | 80℃ | 90℃ | 15r/min |
| Second rubber extruding machine | 50℃ | 55℃ | 65℃ | 65℃ | 75℃ | 8r/min |
| Third rubber extruding machine | 50℃ | 55℃ | 65℃ | 80℃ | 90℃ | 8r/min |
| Fourth rubber extruding machine | 50℃ | 55℃ | 65℃ | 65℃ | 75℃ | 18r/min |
| Example 2 | A region | Two zones | Three zones | Four zones | Five zones | Screw rotation speed |
| First rubber extruding machine | 56℃ | 60℃ | 68℃ | 86℃ | 96℃ | 18r/min |
| Second rubber extruding machine | 55℃ | 59℃ | 67℃ | 70℃ | 77℃ | 10r/min |
| Third rubber extruding machine | 53℃ | 58℃ | 66℃ | 83℃ | 94℃ | 9r/min |
| Fourth rubber extruding machine | 55℃ | 60℃ | 68℃ | 70℃ | 78℃ | 18r/min |
| Example 3 | A region | Two zones | Three zones | Four zones | Five zones | Screw rotation speed |
| First rubber extruding machine | 60℃ | 65℃ | 70℃ | 90℃ | 100℃ | 20r/min |
| Second rubber extruding machine | 60℃ | 65℃ | 70℃ | 75℃ | 80℃ | 12r/min |
| Third rubber extruding machine | 60℃ | 65℃ | 70℃ | 90℃ | 100℃ | 12r/min |
| Fourth rubber extruding machine | 60℃ | 65℃ | 70℃ | 75℃ | 80℃ | 20r/min |
Detection by destructive dissection experiments: the control deviation of the outer diameter of the cable conductor is +/-0.1 mm, the control deviation of the outer diameter of the insulated wire core is +/-0.2 mm, and the control deviation of the outer diameter of the finished cable is +/-0.2 mm, so that the cable can be laid in a stator slot and cannot fall off. And (3) controlling the softness: the hardness of the material is controlled, wherein the hardness of the insulating and sheathing material is less than or equal to 70A.
Through detection, the detection requirements of the cable on the electrical property and the mechanical property are as follows, and in the detection items in the following table, the results are all qualified:
the present invention is not limited to the above-described embodiments, and all technical solutions formed by equivalent or equivalent replacement fall within the protection scope of the present invention.
Claims (4)
1. A production method of a high-precision special-shaped strand small-diameter cable comprises the following steps: 1) manufacturing a cable conductor; 2) extruding and wrapping semi-conductive chloroprene rubber to prepare a conductor shielding layer; 3) extruding ethylene propylene rubber to prepare an insulating layer; 4) extruding and wrapping semi-conductive chloroprene rubber to prepare an insulating shielding layer; 5) extruding and wrapping the semiconductive chloroprene rubber to prepare a semiconductive sheath layer; 6) coating nanometer semi-conductive glue to prepare the semi-conductive nanometer coating, which is characterized in that
The step 1) comprises the following steps:
1.1) preformed monofilaments:
drawing: drawing the aluminum alloy rod into a fan-shaped monofilament, a Z-shaped monofilament and an S-shaped monofilament respectively by adopting corresponding wire drawing dies;
the wire drawing process comprises the following steps: the aluminum rod is sequentially inserted into 11 wire drawing dies according to the pass, the single wire cambered surface corresponds to the die hole cambered groove, the stable stress of the aluminum wire is ensured, and the single wire section has no deviation;
1.2) stranding the three monofilaments prepared in the step 1.1) to form a conductor,
making the fan-shaped monofilaments into a conductor inner layer; the Z-shaped monofilaments and the S-shaped monofilaments are sequentially wrapped outside the inner conductor layer;
the conductor is provided with n layers from inside to outside, the inner layer of the conductor is the 1 st layer, and n is a natural number; the twisting directions of the conductors of the adjacent layers are opposite; from the 2 nd layer, the section of the monofilament of the adjacent layer conductor is mirror-symmetrical, and finally the nth layer conductor is manufactured to obtain the cable conductor;
1.3) annealing the cable conductor prepared in the step 1.2) on a metal wire continuous annealing production line, wherein: the temperature of the heating stage is 500 ℃, and the heating time is 30-40 min; the temperature of the heat preservation stage is 500 ℃, and the heat preservation time is 3 hours; the cooling speed of the cooling stage is 40 ℃/h, and the cooling time is 12 h;
the steps 2) to 4) are realized by a three-layer co-extrusion process:
the temperature zone of the first rubber extruding machine for extruding the semiconductive chloroprene rubber is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 80-90 ℃ and the temperature of the fifth zone is 90-100 ℃; 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;
the second rubber extruding machine temperature zone for extruding ethylene propylene rubber is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 65-75 ℃ and the temperature of the fifth zone is 75-80 ℃; 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;
the third temperature zone of the rubber extruder for extruding the semi-conductive chloroprene rubber is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 80-90 ℃ and the temperature of the fifth zone is 90-100 ℃; 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;
setting the temperature of the machine head: 110 deg.C
In the extrusion process, during production, the steam pressure is 8-12 bar, the production speed is 5-6 m/min, the rotating speed of a first rubber extrusion machine screw is 15-20 r/min, the rotating speed of a second rubber extrusion machine screw is 8-12 r/min, and the rotating speed of a third rubber extrusion machine screw is 8-12 r/min;
water cooling in a cold water tank for 15 min; the water temperature of the cold water tank is controlled to be 5-10 ℃;
the step 5) of extruding and wrapping the semiconductive chloroprene rubber to prepare a semiconductive sheath layer;
and (3) for the cable prepared in the step 4), extruding the semi-conductive chloroprene rubber in a fourth rubber extruding machine, wherein the temperature zone of the fourth rubber extruding machine is controlled as follows: the temperature of the first zone is 50-60 ℃, the temperature of the second zone is 55-65 ℃, the temperature of the third zone is 65-70 ℃, the temperature of the fourth zone is 65-75 ℃ and the temperature of the fifth zone is 75-80 ℃; 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;
during production, the steam pressure is 7-8 bar, the production speed is 5-6 m/min, and the rotating speed of a screw of a fourth rubber extruding machine is 18-20 r/min;
water cooling in a cold water tank for 20 min; the water temperature of the cold water tank is controlled to be 5-10 ℃;
and 6) coating the nanoscale semi-conductive glue outside the cable prepared in the step 5) on line, wherein the coating step is as follows: the cable is wired on a coating machine, the semiconductive glue is sprayed, and the infrared heating pipe is heated and dried; when gluing, the linear speed of the cable is 4-5 m/min; the glue curing time is 5 min.
2. The method for producing a small-diameter cable with a high-precision special-shaped strand as claimed in claim 1, wherein the thickness of the semiconductive nano coating is 5-50 μm, and the semiconductive nano coating is heated and dried by an infrared heating tube at a temperature of 200 ℃;
1) the viscosity of the nanoscale semiconductive glue is 15-18 seconds;
2) adjustment of coating thickness: the cable conveying speed and the spraying pressure are synchronous, the cable conveying speed is 4-5 m/min, the spraying pressure is 0.8-1 MPa, and the thickness of glue on each surface of the cable is ensured to be uniform;
3) controlling the drying temperature: heating and drying the cable by the infrared heating pipe, wherein the surface temperature of the cross section of the cable is uniform and consistent;
4) cable conveying: the cable is always positioned in the center of the spraying machine in the spraying process, so that the coating is prevented from being scratched, and the thickness of the cable is uniform.
3. The method as claimed in claim 1, wherein the number of the conductors is three, the inner layer of the conductor is made of 4 fan-shaped monofilaments, the middle layer of the conductor is made of a plurality of Z-shaped monofilaments, and the outer layer of the conductor is made of a plurality of S-shaped monofilaments;
in the step 1.1) described above,
fan-shaped monofilament, Z shape monofilament and S shape monofilament all are the drawing die that penetrates 11 correspondences in proper order with the aluminium pole according to the pass, and the monofilament cambered surface corresponds with the nib arc groove, and the parameter of wire drawing machine includes:
fan-shaped monofilaments: the speed ratio of the constant speed wheel is 1.19, the diameter of a finished product die is 4.20mm, the wire arranging pitch is 0.1mm, and the wire drawing speed is 8 m/s;
z-shaped monofilaments: the speed ratio of the constant speed wheel is 1.16, the diameter of a finished product die is 3.30mm, the wire arranging pitch is 0.1mm, and the wire drawing speed is 10 m/s;
s-shaped monofilaments: the speed ratio of the constant speed wheel is 1.16, the diameter of a finished product die is 3.29mm, the wire arranging pitch is 0.1mm, and the wire drawing speed is 12 m/s;
in the step 1.2), three kinds of monofilaments are stranded on a stranding machine, and the parameters of the stranding machine include:
the rotating speed of the inner layer of the stranded conductor is 40-45 r/min; the rotating speed of the middle layer of the stranded conductor is 30-35 r/min; the rotating speed of the outer layer of the stranded conductor is 30-33 r/min;
the linear speed of the finished product is 7-8 m/min.
4. The method for producing a small-diameter cable with high-precision special-shaped strands as claimed in claim 1, wherein the cable produced by the method is used for supplying power to a long stator of a traction motor for high-speed rail transit.
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011418141.7A CN112201392A (en) | 2020-12-07 | 2020-12-07 | Production method of high-precision special-shaped stranded wire small-diameter cable |
| PCT/CN2020/136651 WO2022120905A1 (en) | 2020-12-07 | 2020-12-16 | Method for producing high-precision special-shaped strand small-diameter cable |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011418141.7A CN112201392A (en) | 2020-12-07 | 2020-12-07 | Production method of high-precision special-shaped stranded wire small-diameter cable |
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| CN112201392A true CN112201392A (en) | 2021-01-08 |
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| CN202011418141.7A Pending CN112201392A (en) | 2020-12-07 | 2020-12-07 | Production method of high-precision special-shaped stranded wire small-diameter cable |
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| WO (1) | WO2022120905A1 (en) |
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| CN114334253A (en) * | 2022-01-25 | 2022-04-12 | 远东电缆有限公司 | Heat tracing cable and preparation method and application thereof |
| CN114822996A (en) * | 2022-04-15 | 2022-07-29 | 江苏上上电缆集团有限公司 | Composite special-shaped stranded conductor manufacturing method and conductor |
| CN115312271A (en) * | 2022-06-28 | 2022-11-08 | 江苏上上电缆集团有限公司 | Three-layer co-extrusion production method of medium-voltage polypropylene insulated wire core |
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| WO2022120905A1 (en) | 2022-06-16 |
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Application publication date: 20210108 |