CN112272852A - 水冷式电缆及相关的制造方法 - Google Patents
水冷式电缆及相关的制造方法 Download PDFInfo
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
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- H01B7/423—Insulated conductors or cables characterised by their form with arrangements for heat dissipation or conduction for heat dissipation using a cooling fluid
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2667/00—Use of polyesters or derivatives thereof for preformed parts, e.g. for inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
- B29K2705/08—Transition metals
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Abstract
水冷式电缆包括缠绕在内部支撑管(2)上的多根铜绳(1)、在端部处约束至铜绳(1)上的电端子(3)、以密封方式固定的外管(4)、以及多个护套(5),每根铜绳(1)一个护套,所述护套以塑料或橡胶材料挤出铸造在每根铜绳(1)上,随后被刺穿。
Description
技术领域
本发明涉及水冷式电缆及其制造工艺。
背景技术
水冷式铜电缆被广泛地用于其中这种电缆必须传输特别高的电流并且因此承受相当大的焦耳热的行业中。每根电缆由多根铜线绳组成,所述铜线绳缠绕在中空支撑管上并且在它们的端部处接合至铜端子。电缆还具有橡胶覆盖物,所述橡胶覆盖物通过非磁性的不锈钢带固定至该端子。水通过从一个端子进入并且通过相对的端子离开而沿着电缆的整个长度流动,并且容许电缆以高电流密度工作。上述电缆具有达大约2-4年的平均寿命。
特别地,这种类型的电缆还被用于旨在由废料生产钢的电弧炉中。在这些炉中,通过电弧使废料熔化,所述电弧在以120°圆周地布置的三个石墨电极之间反射。由于大约1000伏的工作电压以及可达100KA以上的电极电流,所使用的变压器以非常高的功率(大约数百MVA的量级)工作:为了传输如此高的电流,为三相中的每一相以并行格式组装2至4根电缆,总计6至12根。电缆是二次电系统中的唯一柔性部件并且使得能够实现电极的运动,电极随着废料的体积由于熔化而减少而在熔化炉内降低,然后移动以容许打开炉的拱顶来插入新的废铁负载。
每次铸造熔化两至三个负载的废料,其中现代化的炉每天能够进行35次以上的铸造:因此,炉的拱顶每天可能被打开甚至一百次以上。在该步骤中,从炉朝管辐射的热量达到介于200℃与400℃之间的温度。
在运行期间,高电流生成强电磁场,该强电磁场引起随时间变化的高强度力(也被称为“洛伦兹力”)。这些力在电缆上产生机械应力,该机械应力以各种方式起作用:每根绳的线被朝绳轴线吸引,从而在线之间产生磨损;电缆内的绳被朝电缆轴线吸引,从而在绳自身之间产生磨损;同相的电缆被朝该相的轴线吸引,而其它相的电缆被排斥,从而导致强烈的电缆振动、拍打和摩擦,这导致电缆覆盖物过早地磨损,并且在内部绳及其组成线上引起巨大的应力。
可以以几种方式制造这些电缆:最常见的设计是“绳捻(rope lay)”设计,所述绳捻设计由一定数量的平行铜绳形成,所述铜绳具有相同的横截面并且环形地布置在通常为橡胶管的柔性支撑件上;绳的数量可以根据电缆的总横截面而为4至16根。
为了解决上面所列出的缺点,并且如文献US3265803中所述,将预刺穿的护套装配至每根绳上,以限制由与相邻绳的摩擦所引起的磨损。该护套通常被装配至仅仅一半的铜绳上并且不排除与冷却水接触,从而确保良好的热交换。
替代地,如文献FR2559613中所述,使护套在挤压工艺期间被直接刺穿,其中必须使用更复杂且昂贵的仪器来实现非均匀的覆盖,当在存在强电磁场的情况下使用时,这可能引起问题。
通过钎焊或机械压制接合至绳的端子被施加至“绳捻”电缆的端部。
然后,外部橡胶管被装配至配备有端子的绳上并且利用不锈钢夹固定,以确保对它进行密封以抵抗在电缆内流动的冷却水的压力。
使用“绳捻”电缆的主要缺点是强电磁场引起降低电缆本身的平均寿命的振动和冲击。
发明内容
因此,本发明的目的是消除上述缺点。
特征在于各权利要求的本发明通过借助挤压将具有均匀厚度的覆盖护套施加至构成电缆的所有绳上而实现该目的,所述覆盖护套随后被刺穿。要解决的问题是如何在不损坏铜的情况下在已被填充的覆盖物上进行刺穿。
通过本发明获得的主要优点基本上是,新的覆盖物保持铜绳更紧凑,从而限制铜绳的运动能力并且减少由其组成铜线之间的摩擦所引起的磨损:这使得电缆具有更长的预期寿命。
实际上,由于电缆内的所有绳都被护套覆盖,所以在绳自身之间存在更大的耐摩擦能力,从而限制它们之间的任何磨损并且大大地延长了构成电缆的绳的寿命。
此外,通过被以这种方式覆盖,绳更刚性并且因此具有更高的弯曲强度。此后,电缆的平均寿命被进一步延长,首先是因为绳覆盖物具有在绳本身上更均匀地分配电动力的优势,因此大大地减少了在端子的区域中确定的典型故障点处的机械应力,其次是因为增大的抗弯曲性抵消了由电磁场所引起的力,从而在维持相同电流的同时减少了电缆之间的振动和冲击。
最后,端子的整个表面上的均匀机械压制工艺确保了更好的密封。
附图说明
参考附图,通过下面的详细描述,本发明的其他优点和特征将变得更明显,附图示出了非限制性的实施例,其中:
-图1根据制造工艺期间的立体图示出了本发明;
-图2根据制造之后的立体图示出了本发明,其中一些部分被移除以更好地突出其它部分;
-图3示出了制造工艺的细节。
具体实施方式
如图2中所示,本发明涉及一种水冷式电缆,其包括缠绕在通常由中空管形成的中心支撑件(2)上的多根铜绳(1)、在端部处约束至铜绳(1)上的电端子(3)以及用夹(6)以密封方式固定的外管(4),其中每根铜绳(1)被护套(5)覆盖,所述护套(5)以塑料或橡胶材料挤出铸造在铜绳(1)本身上,并且随后被刺穿。
用于制造这种水冷式电缆(10)的工艺包括形成由铜线组成的多根铜绳(1)的预备步骤,之后是在每根铜绳(1)上挤出塑料或橡胶材料以便在每根铜绳(1)上形成完全覆盖铜绳(1)的外部护套(5)的步骤。然后刺穿护套(5),并且随后根据电缆所针对的装置的尺寸特征将如此覆盖的并且甚至可能长数十米的铜绳(1)切割成具有预定长度的段。
护套(5)的刺穿也可以通过几种方法进行。当今最优选的解决方案涉及通过用加压水切割护套(5)而移除护套(5)的部分,如图3中所示:所涉及的压力可达大约3000巴的值,尽管该过程的成本相当显著,但是切割被非常好地限定并且下面的铜不被损坏;而且,操作的速度容许该操作在线进行。
替代的解决方案可以涉及使用激光切割和模切。在第一种情况下,尽管切割质量高,但是操作具有速度慢的缺点,这迫使该操作离开生产线进行;另一方面,在第二种情况下,切割的速度与去除废料的困难以及构成铜绳(1)的铜更容易被损坏的事实形成对比。
为了避免该缺点,在将塑料或橡胶材料铺设至铜绳(1)上之前,可以在铜绳(1)之上施加例如由聚酯制成的并且几微米厚的聚合物膜。
如图1中所示,然后将铜绳(1)以螺旋形布置组装在中心支撑件(2)上,并且将电端子(3)固定至铜绳(1)的端部:可以通过钎焊或机械压制进行电端子(3)至铜绳(1)端部的固定。在后一种情况下,有利的是,在电端子(3)的整个圆柱形表面(3a)上同时且均匀地执行机械压制。
最后,将该组铜绳(1)和电端子(3)穿入至外管(4)中,然后夹紧以进行密封。
Claims (8)
1.一种水冷式电缆,其包括缠绕在中心支撑件(2)上的多根铜绳(1)、在端部处约束至铜绳(1)上的电端子(3)、以及以密封方式固定的外管(4),其特征在于,所述水冷式电缆包括多个护套(5),每根铜绳(1)一个护套,所述护套被以塑料或橡胶材料挤出铸造在每根铜绳(1)上并且随后被刺穿。
2.一种用于制造水冷式电缆的工艺,其包括形成由铜线组成的多根铜绳(1)的预备步骤,其特征在于,所述工艺按顺序包括以下步骤:
-在每根铜绳(1)上挤出塑料或橡胶材料以在每根铜绳(1)上形成外部的护套(5);
-刺穿外部的护套(5);
-将铜绳(1)组装在中心支撑件(2)上;
-将电端子(3)固定至铜绳(1)的端部上;
-将铜绳(1)和电端子(3)穿入至外管(4)中;
-夹紧外管(4)以对水冷式电缆进行密封。
3.根据权利要求2所述的工艺,其特征在于,通过用加压水切割护套(5)来刺穿护套。
4.根据权利要求2所述的工艺,其特征在于,通过激光切割来刺穿护套(5)。
5.根据权利要求2所述的工艺,其特征在于,通过模切来刺穿护套(5)。
6.根据权利要求2所述的工艺,其特征在于,所述工艺包括将铜绳(1)切割成具有预定长度的段的切割步骤,所述切割步骤介于刺穿护套(5)的步骤与将铜绳(1)组装在中心支撑件(2)上的步骤之间。
7.根据权利要求2所述的工艺,其特征在于,所述工艺包括紧接在进行挤出以形成护套(5)的步骤之前在铜绳(1)上铺设比如聚酯膜的聚合物膜的步骤。
8.根据权利要求2所述的工艺,其特征在于,通过电端子(3)的整个圆柱形表面(3a)上的同时且均匀的机械压制工艺执行电端子(3)至铜绳(1)的端部上的固定。
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IT102018000007053 | 2018-07-10 | ||
IT201800007053 | 2018-07-10 | ||
PCT/IT2019/050161 WO2020012515A1 (en) | 2018-07-10 | 2019-07-08 | A water-cooled electric cable and relative manufacturing method |
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CN112272852A true CN112272852A (zh) | 2021-01-26 |
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US (1) | US20210151219A1 (zh) |
EP (1) | EP3821449A1 (zh) |
CN (1) | CN112272852A (zh) |
WO (1) | WO2020012515A1 (zh) |
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2019
- 2019-07-08 EP EP19749810.8A patent/EP3821449A1/en active Pending
- 2019-07-08 CN CN201980039252.6A patent/CN112272852A/zh active Pending
- 2019-07-08 WO PCT/IT2019/050161 patent/WO2020012515A1/en unknown
- 2019-07-08 US US17/056,214 patent/US20210151219A1/en not_active Abandoned
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US3265803A (en) * | 1964-01-14 | 1966-08-09 | Gar Wood Ind Inc | Flexible electrical cable |
US3784722A (en) * | 1972-07-17 | 1974-01-08 | D Goodman | Water-cooled electric furnace cable |
CA961126A (en) * | 1973-11-08 | 1975-01-14 | Daniel J. Goodman | Water-cooled electric furnace cable |
GB1418270A (en) * | 1974-03-09 | 1975-12-17 | Goodman D J | Safetyanchored cable and terminal construction for an electric arc furnace |
FR2559613A1 (fr) * | 1984-02-10 | 1985-08-16 | Cables De Lyon Geoffroy Delore | Cable electrique pour le transport de tres fortes intensites sous de faibles tensions et procede de fabrication d'un tel cable |
CN1486514A (zh) * | 2001-01-02 | 2004-03-31 | �ɲ����� | 铌基超导体及制造方法 |
RU56060U1 (ru) * | 2005-08-22 | 2006-08-27 | Олег Алексеевич Чадов | Водоохлаждаемый кабель |
CN204143918U (zh) * | 2014-09-18 | 2015-02-04 | 江苏亨鑫科技有限公司 | 一种防护可滤集成电缆及其外防护套打孔装置 |
CN204303433U (zh) * | 2014-11-26 | 2015-04-29 | 埃博普感应系统(上海)有限公司 | 一种感应电炉用中空式水冷电缆 |
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WO2020012515A1 (en) | 2020-01-16 |
US20210151219A1 (en) | 2021-05-20 |
EP3821449A1 (en) | 2021-05-19 |
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