CN112652426A - 一种高速机车线缆的制备工艺 - Google Patents

一种高速机车线缆的制备工艺 Download PDF

Info

Publication number
CN112652426A
CN112652426A CN201910968881.9A CN201910968881A CN112652426A CN 112652426 A CN112652426 A CN 112652426A CN 201910968881 A CN201910968881 A CN 201910968881A CN 112652426 A CN112652426 A CN 112652426A
Authority
CN
China
Prior art keywords
cable
sheath
cabling
manufacturing
wire
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201910968881.9A
Other languages
English (en)
Inventor
沈云康
姚云翔
倪冬华
沈福良
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Zhejiang Zhaolong Interconnection Technology Co ltd
Original Assignee
Zhejiang Zhaolong Interconnection Technology Co ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Zhejiang Zhaolong Interconnection Technology Co ltd filed Critical Zhejiang Zhaolong Interconnection Technology Co ltd
Priority to CN201910968881.9A priority Critical patent/CN112652426A/zh
Publication of CN112652426A publication Critical patent/CN112652426A/zh
Pending legal-status Critical Current

Links

Images

Classifications

    • 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
    • H01B13/02—Stranding-up
    • 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
    • H01B11/02—Cables with twisted pairs or quads
    • H01B11/06—Cables with twisted pairs or quads with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens
    • 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
    • H01B13/145—Pretreatment or after-treatment
    • 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
    • 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
    • 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
    • H01B13/228—After-treatment
    • 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
    • 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
    • H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
    • H01B13/2606—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by braiding
    • 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
    • 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
    • H01B7/0233—Cables with a predominant gas dielectric
    • 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
    • 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
    • H01B7/041—Flexible cables, conductors, or cords, e.g. trailing cables attached to mobile objects, e.g. portable tools, elevators, mining equipment, hoisting cables
    • 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
    • H01B7/187—Sheaths comprising extruded non-metallic layers
    • 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
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • 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
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • 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
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Insulated Conductors (AREA)

Abstract

本发明涉及一种高速机车线缆的制备工艺，包括以下步骤，1）单线制作；2）单线辐照；3）对绞制作；4）成缆制作；5）编织制作；6）护套制作；7）护套辐照。本发明对线缆的结构进行改进，采用多股镀锡铜导体，增加了线缆的柔软性；采用了发泡聚乙烯绝缘，对绞结构，且每对绞线进行铝箔屏蔽，再将四对绞线按照一定的绞距进行成缆，使得线缆的传输频率能够达到600MHz；本发明中绝缘与护套均采用电子束辐照加工工艺，使得整体耐温等级提高到‑40℃~+105℃；本发明在缆芯的外部增加一层编织后，再在最外面押出一层交联低烟无卤外被；使得线缆能够应对机车内部狭小的布线环境，四周的线缆及设备产生的磁场对其造成的干扰。

Description

一种高速机车线缆的制备工艺
技术领域
本发明属于线缆技术领域，具体涉及一种高速机车线缆的制备工艺。
背景技术
机车的电力和信号传输中，需要用到机车电缆，由于电缆布线环境较为恶劣，因此需要机车电缆除具有良好的传输性能外，还要具有耐油、耐扭曲、弯曲和良好的阻燃性能，在高速运行的机车上应用的线缆，还要保证在剧烈震动的环境下可以安装敷设，并保证性能。
现有技术中的线缆大多为单根或多根导体，发泡聚乙烯绝缘或发泡聚丙烯绝缘，2根单线进行绞合，再在绞合线的外面包覆一层铝箔，每对线包覆铝箔之后，4组绞线进行总绞，在缆芯的外面用镀锡铜编织，最后包裹一层护套；目前该结构的线缆虽然其传输频率能够达到600MHz，但是其他性能不能够满足EN50264-1标准，如耐温等级-40℃至+105℃，耐矿物油和燃料油，低烟及无毒等要求。
发明内容
为了解决上述的技术问题，本发明的目的是提供一种高速机车线缆的制备工艺，该工艺生产出来的高速机车线缆耐油、耐弯曲、抗干扰且适用温度范围广。
为了实现上述目的，本发明采用了以下的技术方案：
一种高速机车线缆的制备工艺，包括以下步骤，
1）单线制作：选用26AWG线规及其以上的7根或19根镀锡铜多股绞合导体，且导体绞合节距小于等于16mm，单丝延伸率大于等于10%，且整体绞合外径均匀；导体外的绝缘层使用低密度聚乙烯、发泡聚乙烯、高密度聚乙烯的皮泡皮结构，绝缘层押出后，单线外径为1.35±0.10mm，且同心度为80%以上，椭圆度小于0.05mm，单线绝缘的断裂伸长率大于等于150%，其抗张强度大于等于10MPa；
2）单线辐照：经步骤1）中的单线经过电子加速器辐照加工，使用0-10Mrad的辐照剂量；
3）对绞制作：单线放线，2根单线绞合成双绞线，对绞节距控制在15~30mm之间，然后对绞收线；
4）成缆制作：对绞放线，4对双绞线按照一定顺序成缆，在成缆的同时，对每组对绞线进行铝箔屏蔽，铝箔铝基控制在0.035mm以上，铝基面朝外，成缆时铝箔的合口需朝外包覆，整体的节距控制在50~200mm之间；
5）编织制作：缆芯外面再采用编织层屏蔽结构包裹，编织丝一般选用单丝直径0.08~0.15mm的镀锡铜丝；编织层覆盖率大于80%，编织节距一般控制在15~35mm之间，然后成缆收线；
6）护套制作：成缆放线，总缆芯外挤覆交联低烟无卤塑料护套；
7）护套辐照：护套线再次经过电子加速器辐照加工，一般这里使用热延伸来控制整体工艺，热延伸需小于等于25%，该工序完成后便形成电缆成品。
本发明对线缆的结构进行改进，采用多股镀锡铜导体，增加了线缆的柔软性；采用了发泡聚乙烯绝缘，对绞结构，且每对绞线进行铝箔屏蔽，再将四对绞线按照一定的绞距进行成缆，使得线缆的传输频率能够达到600MHz；本发明中绝缘与护套均采用电子束辐照加工工艺，使得整体耐温等级提高到-40℃~+105℃；本发明在缆芯的外部增加一层编织后，再在最外面押出一层交联低烟无卤外被；使得线缆能够应对机车内部狭小的布线环境，四周的线缆及设备产生的磁场对其造成的干扰。
附图说明
图1为本发明的工艺流程示意图。
图2为本发明工艺中辐照剂量与产品性能的关系示意图。
具体实施方式
为了相关技术人员更清晰的了解本发明的技术方案，现结合附图对本发明做进一步的详细说明。
如图1所示，一种高速机车线缆的制备工艺，包括以下步骤，
1）单线制作：选用26AWG线规及其以上的7根或19根镀锡铜多股绞合导体，且导体绞合节距小于等于16mm，单丝延伸率大于等于10%，且整体绞合外径均匀；提高了线缆整体的柔软性，同时保证了后续的传输性能。
导体外的绝缘层使用低密度聚乙烯、发泡聚乙烯、高密度聚乙烯的皮泡皮结构，提高了传输速率，改善了衰减等性能；绝缘层押出后，单线外径为0.95~1.60mm，且同心度为80%以上，椭圆度小于0.05mm，单线绝缘的延伸率大于等于150%，其抗张强度大于等于10MPa；对于单线的品质将直接影响后续性能的好坏。
2）单线辐照：经步骤1）中的单线经过电子加速器辐照加工，使用0-10Mrad的辐照剂量；提高了绝缘强度及耐热性，使绝缘的耐温等级达到-40℃~+105℃，通过数据研究，辐照的工艺对绝缘的机械和传输性能有很大的影响，具体见图2。
3）对绞制作：单线放线，2根单线绞合成双绞线，对绞节距控制在15~30mm之间，然后对绞收线。
4）成缆制作：对绞放线，4对双绞线按照一定顺序成缆，在成缆的同时，对每组对绞线进行铝箔屏蔽，考虑到机车环境中的强电磁干扰，铝箔铝基控制在0.035mm以上，铝基面朝外，成缆时铝箔的合口需朝外包覆，整体的节距控制在50~200mm之间。
5）编织制作：缆芯外面再采用编织层屏蔽结构包裹，编织丝一般选用单丝直径0.08~0.15mm的镀锡铜丝；为了更好地屏蔽外界的强电磁干扰，参考IEC61156-6，通过对线缆转移阻抗性能进行对比分析，编织层覆盖率大于80%，编织节距一般控制在15~35mm之间，然后成缆收线。
6）护套制作：成缆放线，总缆芯外挤覆交联低烟无卤塑料护套7）护套辐照：护套线再次经过电子加速器辐照加工，一般这里使用热延伸来控制整体工艺，热延伸需小于等于25%，该工序完成后便形成电缆成品。
为了使护套具有良好的耐油性能和机械性能，本发明放弃了常规的低烟无卤护套料，而选用了交联低烟无卤护套料，在缆芯外押出护套料之后，再进行辐照；护套的辐照有别于单线辐照，它需要更强的电子束，需将其高分子链打断，重新组合，将原来的链状分子结构变成三维网状的分子结构，从而形成交联；辐照工艺的调整将直接影响线缆的整体机械性能，如耐高温、抗拉强度以及耐油等；一般这里使用热延伸来控制其辐照的整体工艺，热延伸需小于等于25%；此外考虑到机车的使用环境多为人口密集的空间，本发明采用低烟无毒的环保材料，烟密度满足EN61034-2标准，毒性指数满足EN 45545-2标准，阻燃满足IEC60332-3-24标准。
以上所述的仅是本发明的优选实施方式。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明原理的情况下，还可以作出若干改进和变型，这也视为本发明的保护范围。

Claims (1)

1.一种高速机车线缆的制备工艺，其特征在于：包括以下步骤，
1）单线制作：选用26AWG线规及其以上的7根或19根镀锡铜多股绞合导体，且导体绞合节距小于等于16mm，单丝延伸率大于等于10%，且整体绞合外径均匀；导体外的绝缘层使用低密度聚乙烯、发泡聚乙烯、高密度聚乙烯的皮泡皮结构，绝缘层押出后，单线外径为0.95~1.35mm，且同心度为80%以上，椭圆度小于0.05mm，单线绝缘的断裂伸长率大于等于150%，其抗张强度大于等于10MPa；
2）单线辐照：经步骤1）中的单线经过电子加速器辐照加工，使用0-10Mrad的辐照剂量；
3）对绞制作：单线放线，2根单线绞合成双绞线，对绞节距控制在15~30mm之间，然后对绞收线；
4）成缆制作：对绞放线，4对双绞线按照一定顺序成缆，在成缆的同时，对每组对绞线进行铝箔屏蔽，铝箔铝基控制在0.035mm以上，铝基面朝外，成缆时铝箔的合口需朝外包覆，整体的节距控制在50~200mm之间；
5）编织制作：缆芯外面再采用编织层屏蔽结构包裹，编织丝一般选用单丝直径0.08~0.15mm的镀锡铜丝；编织层覆盖率大于80%，编织节距一般控制在15~35mm之间，然后成缆收线；
6）护套制作：成缆放线，总缆芯外挤覆交联低烟无卤塑料护套；
7）护套辐照：经步骤6）中的护套线再次经过电子加速器辐照加工，一般这里使用热延伸来控制整体工艺，热延伸需小于等于25%，该工序完成后便形成电缆成品。
CN201910968881.9A 2019-10-12 2019-10-12 一种高速机车线缆的制备工艺 Pending CN112652426A (zh)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN201910968881.9A CN112652426A (zh) 2019-10-12 2019-10-12 一种高速机车线缆的制备工艺

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN201910968881.9A CN112652426A (zh) 2019-10-12 2019-10-12 一种高速机车线缆的制备工艺

Publications (1)

Publication Number Publication Date
CN112652426A true CN112652426A (zh) 2021-04-13

Family

ID=75342963

Family Applications (1)

Application Number Title Priority Date Filing Date
CN201910968881.9A Pending CN112652426A (zh) 2019-10-12 2019-10-12 一种高速机车线缆的制备工艺

Country Status (1)

Country Link
CN (1) CN112652426A (zh)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113314269A (zh) * 2021-05-21 2021-08-27 中天科技装备电缆有限公司 一种高耐磨轨道交通车辆用薄壁绝缘电缆及其制备方法

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0757560A (ja) * 1993-08-18 1995-03-03 Furukawa Electric Co Ltd:The 耐熱性被覆電線とその製造方法
CN110098002A (zh) * 2019-05-23 2019-08-06 南京全信传输科技股份有限公司 一种柔软型7类以太网电缆及其制备工艺

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0757560A (ja) * 1993-08-18 1995-03-03 Furukawa Electric Co Ltd:The 耐熱性被覆電線とその製造方法
CN110098002A (zh) * 2019-05-23 2019-08-06 南京全信传输科技股份有限公司 一种柔软型7类以太网电缆及其制备工艺

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113314269A (zh) * 2021-05-21 2021-08-27 中天科技装备电缆有限公司 一种高耐磨轨道交通车辆用薄壁绝缘电缆及其制备方法
CN113314269B (zh) * 2021-05-21 2022-07-26 中天科技装备电缆有限公司 一种高耐磨轨道交通车辆用薄壁绝缘电缆及其制备方法

Similar Documents

Publication Publication Date Title
CN104715840B (zh) 海工平台用本质安全型耐油耐泥浆防火电缆及制备工艺
CN201177998Y (zh) 10g以太网用非屏蔽对称数据电缆
RU169338U1 (ru) Высокочастотный симметричный теплостойкий кабель
CN105206346A (zh) 多功能耐火环保型音频信号电缆及其制备工艺
CN105788706A (zh) 一种航空航天用星绞通信电缆及其制作方法
CN201259799Y (zh) 10g以太网用屏蔽对称数据电缆
CN101707075A (zh) 海洋工程设备局域网用Cat7软结构电缆及其制造方法
CN112652426A (zh) 一种高速机车线缆的制备工艺
CN111091926A (zh) 一种八类线及其生产工艺
CN105845263A (zh) 新型计算机传输电缆及其制备方法
CN210223653U (zh) 一种通信电缆
CN204463936U (zh) 新型计算机传输电缆
CN210535373U (zh) 一种高速机车线缆
CN112133473A (zh) 一种适用于真空环境的通信线材及生产工艺
RU2417470C1 (ru) Кабель монтажный преимущественно взрывобезопасный для высокоскоростных систем автоматики (варианты)
CN113205920A (zh) 一种星形八类网线及其制造方法
CN214671878U (zh) 一种单晶铜导体低烟无卤阻燃聚烯烃绝缘双层屏蔽电缆
CN206401055U (zh) 一种利于保护绝缘层的异型导体绞合电缆
CN215527333U (zh) 一种耐火型高速数据电缆
CN114999742B (zh) 一种防火数据通信电缆的生产方法
CN217444153U (zh) 一种拖包电缆
CN218069402U (zh) 一种高频传输用抗干扰双绞线
CN218826304U (zh) 一种耐温抗拉防水耐磨硅橡胶护套电缆
CN216450404U (zh) 一种柔软型高清晰音频线缆
CN211208027U (zh) 一种高屏蔽性能七类数据电缆

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination
RJ01 Rejection of invention patent application after publication

Application publication date: 20210413

RJ01 Rejection of invention patent application after publication