CN113345639B - Power cable, cable core and preparation method thereof - Google Patents
Power cable, cable core and preparation method thereof Download PDFInfo
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- CN113345639B CN113345639B CN202110761453.6A CN202110761453A CN113345639B CN 113345639 B CN113345639 B CN 113345639B CN 202110761453 A CN202110761453 A CN 202110761453A CN 113345639 B CN113345639 B CN 113345639B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/006—Constructional features relating to the conductors
-
- 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
-
- 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
- H01B13/0036—Details
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/02—Power cables with screens or conductive layers, e.g. for avoiding large potential gradients
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Wire Processing (AREA)
Abstract
The invention relates to the technical field of cables, in particular to a cable core, which comprises: the core unit is a wire with a circular section; the prefabricated core materials are wrapped outside the core unit and comprise a first prefabricated core material group and a second prefabricated core material group, and the first prefabricated core material group and the second prefabricated core material group are symmetrically wrapped on the outer side of the core unit to form a cable core with a circular section; the first prefabricated core material group and the second prefabricated core material group are of the same structure and comprise a plurality of layers of prefabricated core materials which are distributed in a nested mode and are semicircular in section, and the inner diameters of the prefabricated core materials of the adjacent layers are increased in a periodic gradient mode from the inner layer to the outer layer. According to the invention, the semi-circular prefabricated members are extruded from gold bars, and then the cable core with a circular cross section is formed by pressing the prefabricated members to prepare the cable.
Description
Technical Field
The invention relates to the technical field of cables, in particular to a power cable, a cable core, a preparation method and a preparation system thereof.
Background
The electric wire cable mainly comprises a cable core and a functional layer wrapped outside the cable core, and a proper cable core structure and a proper functional layer are selected according to different cable types. For example, in the power cable, the cable core comprises a plurality of conductors, a filling layer is added after the conductors are combined to form a circular cable core structure, and an insulating layer, a fire-proof layer, a sheath layer, an armor layer, an outer sleeve and the like are extruded outside the cable core structure to prepare the cable body.
In the manufacturing process, a common copper or aluminum rod is used as a raw material of a conductor, and a metal wire is manufactured through hot drawing or rolling, and the process is also called wire drawing processing and is completed through a wire drawing machine. Then, a plurality of monofilaments are stranded to form a conductor wire core. Before twisting, the twisted yarn is straightened. The twisting form of the conductor wire core can be divided into regular twisting and irregular twisting. The irregular twisting is further classified into bundle twisting, concentric compound twisting, special twisting, and the like. After the conductor wire core is manufactured, an insulating layer and the like are extruded to form the cable conductor.
The production process of the cable comprises the steps of wire drawing, straightening, twisting, extruding, cabling, wrapping, extruding and the like. The hot drawing process of the wire drawing process usually needs to be carried out for multiple times, the process is complex, and the wire drawing and twisting process is needed when the conductor is formed, so that the hot drawing process belongs to a high-energy-consumption process. Meanwhile, the conductor is formed by twisting the monofilaments, so that the problem of gaps often exists in the existing large-scale production process, and the existence of the gaps affects the conductivity of the cable.
Meanwhile, the existing cable preparation usually adopts a fixed-size design, that is, for the design requirements of cables with different voltage grades, the cross-sectional area and the cable core structure of the cable need to be redesigned according to the design requirements, the design and the production process of a production line need to be redesigned, and the problem of the shortage of the production capacity of the production line is brought due to the design of one cable.
Disclosure of Invention
Aiming at the problems in the prior art, the invention provides the cable core with the prefabricated structure, so that the multiplexing of cables with different sectional areas (sectional dimensions) and the compact design of the cable core are realized, and the electric conductivity is improved.
The invention provides a cable core with a prefabricated structure in a first aspect, which comprises:
the core unit is a wire with a circular section, and the diameter of the wire is d 0;
the prefabricated core materials are wrapped outside the core unit and comprise a first prefabricated core material group and a second prefabricated core material group, and the first prefabricated core material group and the second prefabricated core material group are symmetrically wrapped on the outer side of the core unit to form a cable core with a circular section;
the first prefabricated core material group and the second prefabricated core material group are of the same structure and comprise a plurality of layers of prefabricated core materials which are distributed in a nested mode and are semicircular in section, the inner diameters of the prefabricated core materials of the adjacent layers are increased in a periodic gradient mode from the inner layer to the outer layer, and the inner diameter d1 of the prefabricated core material of the innermost layer is equal to the diameter d0 of the wire material.
So, through the design of two sets of prefabricated core material symmetry parcel core unit wire, the structure, thickness and the size of prefabricated core material are controllable to thickness is the same, can realize the use of the cable of many cross-section size requirements, only needs to confirm the diameter of cable core and select the prefabricated core material of different quantity to make up according to the sectional area requirement, can realize the quick design and the preparation of cable, improves productivity and efficiency.
Meanwhile, in the cable core design provided by the invention, the prefabricated core material is prepared by adopting melting and pressing dies with different sizes for melting, pressing and extruding, and the conductor unit is prepared by pressing, compared with the traditional wire drawing, straightening and twisting processes, the cable core design provided by the invention has the advantages that the preparation process can be shortened, the energy consumption is reduced, meanwhile, the occupied area is small in the production line arrangement compared with the traditional process, the space utilization rate of a factory building is improved, more production lines can be arranged under the same condition, and the productivity is improved.
Preferably, the prefabricated core material has a semicircular inner wall surface and a semicircular outer wall surface, so that the adjacent prefabricated core materials and the core units can be attached to each other.
Preferably, the inner diameter of the prefabricated core material of the adjacent layer increases according to a preset fixed value gradient.
Preferably, the thickness of each layer of prefabricated core material is the same. The thickness of the prefabricated core material is 1-3 mm.
Therefore, the prefabricated core materials are the same in thickness, when different cables are designed, the sectional area is determined to be calculated into the diameter range according to the design requirements of the cables, the prefabricated core materials corresponding to the number and the size are selected to be combined, the required cable cores are obtained, and the cables required by different designs can be rapidly designed, combined and prepared conveniently.
Preferably, the core unit and the prefabricated core material are made of the same metal or alloy material, including one of copper, copper alloy and aluminum alloy.
The invention also provides a power cable, which comprises the cable core with the prefabricated structure and a functional layer arranged outside the cable core, wherein the functional layer comprises one of an insulating layer, a shielding layer and a sheath layer.
The third aspect of the present invention further provides a system for preparing the cable core with the prefabricated structure, including:
the high-temperature melt-pressing extrusion system is used for carrying out high-temperature high-pressure melting on the metal bar and controlling the metal bar to be extruded into a prefabricated core material with a semicircular section in a semi-solid state; and
the extrusion system is used for symmetrically pressing the multilayer prefabricated core materials which are distributed in a nested manner outside the core unit to form a cable core with a circular section;
wherein the extrusion system comprises:
the pressing mechanism comprises a machine body, a pressing mechanism and a pressing mechanism, wherein the machine body is provided with a driving cavity and a pressing cavity, and a piston part connected to the pressing cavity is arranged in the driving cavity;
the pressure driver is connected to the driving cavity and used for generating positive pressure or negative pressure in the driving cavity so as to enable the piston component to move up and down;
the upper die is positioned in the pressing cavity, can move up and down along the inner wall of the pressing cavity, is connected to the piston part and is provided with a first arc-shaped wall surface;
the lower die is fixedly arranged in the pressing cavity and is provided with a second arc-shaped wall surface, and when the upper die is pressed on the lower die, a cabling space with a circular section is formed;
the multilayer prefabricated core materials distributed in a nested manner are respectively located in the upper die and the lower die, and when the upper die is driven by the pressure driver and preset pressure to press the lower die, the multilayer prefabricated core materials distributed in the nested manner are pressed in the cabling space.
Preferably, the machine body is provided with a plurality of pressure drivers connected to the stitching cavity and at least one pressure feedback component connected to the stitching cavity, and the pressure in the stitching cavity is obtained through the pressure feedback component.
Therefore, compared with the traditional pressure control system, the uniform pressure transmission and control system is adopted in the preparation system, namely, the upper dies in the pressing cavity are connected and linked with the piston assembly, and the piston assembly generates constant pressure and forms surface applied pressure under the uniform action of air pressure from the driving cavity, so that the pressure applied to the upper dies is constant, and the problems of system errors and non-uniform pressure caused by direct rigid connection driving are solved.
Preferably, the pressure driver is configured to maintain the pressure at a preset pressure for a predetermined time after the upper and lower molds are pressed.
Preferably, the length of the press cavity and the piston part is longer than the length of the upper die and the lower die.
Preferably, the upper die is detachably connected with the piston component, and the lower die is detachably connected with the machine body.
Preferably, the preparation system further comprises an annealing system configured to perform a high temperature annealing treatment on the extruded prefabricated core material.
The fourth aspect of the invention also provides a preparation method of the cable core with the prefabricated structure, which comprises the following steps:
step 2, cooling and forming the prepared prefabricated core material;
and 4, pressurizing the die to enable the prefabricated core material to be compressed and wrapped outside the wire material, so as to form the cable core with the circular section.
Preferably, the mold comprises a lower mold and a driven upper mold, the first prefabricated core material group and the second prefabricated core material group are distributed in the mold in a vertical symmetrical manner, and the arrangement sequence comprises:
the prefabricated core materials of the first prefabricated core material group positioned below are sequentially placed on the lower die from large to small in inner diameter, arranged from the prefabricated core material with the largest inner diameter and sequentially arranged in an upward nested manner;
filling wire materials into the inner wall surface of the prefabricated core material with the smallest inner diameter;
the prefabricated core materials of the second prefabricated core material group located above are sequentially arranged on the wire materials from small to large in inner diameter, and are arranged from the prefabricated core material with the smallest inner diameter and are sequentially nested upwards.
Preferably, in step 4, the upper mold is uniformly pressed along the length direction of the prefabricated core material to press and shape the prefabricated core material, and the pressure maintaining process is performed for a certain time according to a preset pressure.
Preferably, the dwell time is related to the wall thickness of the prefabricated core material, t = t0D, t is the compaction time in seconds. d is the wall thickness of the prefabricated core material, preferably in the range of 1-3 mm. I.e. t0Denotes the compaction coefficient, t0=30, i.e. a dwell time of 30s per mm thickness. Wherein, for the aluminum alloy cable, the material has a pressure range of 50-70MPa when being compressed, and the pressure maintaining time is 0.5-1.5 min.
It should be understood that all combinations of the foregoing concepts and additional concepts described in greater detail below can be considered as part of the inventive subject matter of this disclosure unless such concepts are mutually inconsistent. In addition, all combinations of claimed subject matter are considered a part of the presently disclosed subject matter.
The foregoing and other aspects, embodiments and features of the present teachings will be more fully understood from the following description taken in conjunction with the accompanying drawings. Additional aspects of the present invention, such as features and/or advantages of exemplary embodiments, will be apparent from the description which follows, or may be learned by practice of the specific embodiments according to the teachings of the present invention.
Drawings
The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures may be represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. Embodiments of various aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
figure 1 is a flow chart of a method of making a cable core according to an exemplary embodiment of the present invention;
figure 2 is a schematic diagram of a process for preparing a cable core according to an exemplary embodiment of the invention;
figure 3 is a schematic structural view of a cable core according to an exemplary embodiment of the present invention;
figure 4 is a schematic representation of a moulded state of a cable core according to an exemplary embodiment of the invention;
figure 5 is a schematic structural view of a molding system for a cable core according to an exemplary embodiment of the present invention;
figure 6 is a schematic structural view of a molding system for a cable core according to another embodiment of the present invention.
Detailed Description
In order to better understand the technical content of the present invention, specific embodiments are described below with reference to the accompanying drawings.
In this disclosure, aspects of the present invention are described with reference to the accompanying drawings, in which a number of illustrative embodiments are shown. Embodiments of the present disclosure are not necessarily intended to include all aspects of the invention. It should be understood that the various concepts and embodiments described above, and those described in more detail below, may be implemented in any of numerous ways, including as a cable core and method and apparatus for producing the same, as the disclosed concepts and embodiments are not limited to any embodiment. In addition, some aspects of the present disclosure may be used alone, or in any suitable combination with other aspects of the present disclosure.
Cable core and cable
Referring to fig. 1-3, the present invention provides a cable core and a preparation process thereof, wherein the cable core mainly comprises a core unit 11 and a plurality of groups of prefabricated core materials 10. Groups of prefabricated core materials 10 are wrapped outside the core units.
The core unit 11 is provided as a wire rod having a circular cross section.
Outer prefabricated core 10 of the wire comprising a first prefabricated core group 10A on the upper part and a second prefabricated core group 10B on the lower part, as shown in fig. 3, first prefabricated core group 10A and second prefabricated core group 10B are arranged to be symmetrically wrapped on the outside of core unit 11 forming a cable core with a circular cross-section. The same structure is used for first prefabricated core material group 10A and second prefabricated core material group 10B, which includes a plurality of layers of prefabricated core materials 10 having a semi-circular cross section and nested distribution, the inner diameters of the prefabricated core materials 10 of adjacent layers are increased in a periodic gradient in a direction from the inner layer to the outer layer, and the inner diameter d1 of the prefabricated core material of the innermost layer is equal to the diameter d0 of the metal wire.
Therefore, the design of the prefabricated structure is adopted, the rapid design and preparation of the cable core can be realized, the prefabricated core material for preparing the cable core is designed in a standardized and universal mode, the multiplexing, high-efficiency and high-quality preparation is realized, and the productivity and the efficiency are improved.
According to the cable core structure prepared by the invention, the compactness of the cable section can be realized through the prefabricated structure and the pressing process of the prefabricated structure, the gaps of the stranded wire cores caused in the traditional cable stranding process are reduced and eliminated, and the electric conductivity of the cable is improved.
Wherein, in connection with fig. 3, each of the first set of preform cores 10A and the second set of preform cores 10B comprises a plurality of nested distribution of preform cores 10, the cross-section of the preform cores 10 being semi-circular, also called curved tiles.
In each of the first preform core group 10A and the corresponding second preform core group 10B, the semicircular ring-shaped preform cores 10 have different dimensions, are small in diameter at the inner layer and large in diameter at the outer layer, and have a semicircular inner wall surface and a semicircular outer wall surface.
Referring to fig. 3, each of first prefabricated core group 10A and corresponding second prefabricated core group 10B is structured to include a plurality of prefabricated core materials 10 having a semi-circular cross section and nested in a plurality of layers, and the inner diameters of prefabricated core materials 10 of adjacent layers are increased in a periodic gradient in a direction from the inner layer to the outer layer, and inner diameter d1 of the prefabricated core material of the innermost layer is equal to diameter d0 of the wire.
In the example shown in fig. 3, a preform core group consisting of three sets of preform cores is taken as an example, and thus, when a first preform core group 10A and a corresponding second preform core group 10B are compressed by a molding system, adjacent preform cores and preform core and core units can be pressed and bonded to each other.
The combination of the nested prefabricated core materials and the mould pressing and pressing design can keep the cable core to form a round section with a compact and complete section, improve the current flux and quickly combine and design to form cable core structures with different diameters as required.
In the preferred embodiment, to facilitate assembly to form cable cores of different diameters, and to facilitate manufacture and processing, each of the preformed core materials 10 is of the same thickness to form a substantially preformed unit, which is assembled and then compressed to form the cable core.
Preferably, the inner diameter of the prefabricated core material 10 of adjacent layers increases according to a preset fixed value gradient.
In an alternative embodiment, the thickness of the prefabricated core material 10 is 1-3 mm.
Thus, cable cores of different diameters can be formed by combining prefabricated core materials 10 of different numbers of layers according to the required diameter.
In an alternative embodiment, the core unit 11 is made of the same metal or alloy material as the prefabricated core material 10, including one of copper, copper alloy and aluminum alloy.
Thus, in the design requirements of cables with different diameter sizes, after the cable core is rapidly designed and prepared, different functional layers can be coated outside the cable core, such as an extruded insulating layer, a fire-proof layer and the like, or a fire-proof layer (such as a mica tape), a waterproof layer (such as a semiconductive water-blocking tape), a shielding layer (such as a wire mesh shielding layer or a composite shielding layer) and the like are prepared in a wrapping manner, or a sheath layer (such as a wear-resistant outer sheath layer) and the like are prepared in an extruded manner.
Preparation of Cable cores
Referring to fig. 2-6, the present invention discloses a system for preparing a cable core with a prefabricated structure, which includes a high temperature melt-extrusion system and an extrusion system.
The high-temperature melt-extrusion system is used for melting metal bars (such as aluminum alloy or copper alloy) at high temperature and high pressure and extruding the metal bars into prefabricated core materials with semicircular sections in a semi-solid state. It should be understood that the melting temperature may be determined according to the melting temperature of the aluminum alloy or the copper alloy.
And the extrusion system is used for symmetrically pressing the multilayer prefabricated core materials distributed in a nested manner outside the core unit to form the cable core with a circular section.
As an alternative embodiment, the high temperature melt extrusion system includes an extruder for heating the rod to form the rod into a semi-solid paste, and then extruding the paste from the die head 100 to form the prefabricated core material 10 with a certain dimension. The prefabricated core material 10 is then placed in an extrusion system and compressed to form a cable core.
In an alternative embodiment, a rod (taking an aluminum alloy rod as an example) is heated inside the extruder by induction heating or plasma heating, the aluminum alloy rod is heated to a semi-molten state at 480 ℃, a semi-arc extrusion opening is arranged on a film head of the extruder, and the semi-molten aluminum alloy rod is extruded from a semi-arc section to form the prefabricated core material 10. As shown in fig. 2, the membrane head 100 has a predetermined shape and size, i.e., designed according to a predetermined thickness and inner and outer diameter dimensions.
Further, a cooling device is disposed at an output end of the film head 100 of the extruder, and is used for conveying and cooling the prefabricated core material 10 extruded from the film head 100 for molding, and optionally, the cooling device may adopt an air cooling or water cooling mode, and convey the molded prefabricated core material 10 while cooling, so as to lower the temperature of the prefabricated core material 10.
Preferably, the preparation system further comprises an annealing system configured to anneal the extruded prefabricated core material to improve creep resistance and conductivity.
Preferably, the annealing temperature is 280-320 ℃ and the annealing time is 2 hours.
In an alternative embodiment, shown in connection with fig. 5, an extrusion system 200 is used to press together the pre-formed core material 10 and the core units 11 to form a cable core having a circular cross-section.
The extrusion system 200 includes a machine body 201, an upper die 22, a lower die 21, a piston member 23, and a pressure driver 24.
The machine body 201 is provided with a driving cavity 203 and a pressing cavity.
A piston member 23 connected to the pressing chamber is provided in the driving chamber 203. A partition plate 202 is provided between the drive chamber 203 and the compression chamber, and a slide groove for passing only the piston member 23 is left in the partition plate 202.
The upper die 22 and the lower die 21 are both disposed inside the press-fit cavity and below the partition plate 202.
The pressure driver 24 is connected to the driving chamber 203 for generating a positive pressure or a negative pressure in the driving chamber 203, so that the piston member 23 is moved downward by the positive pressure or moved upward by the negative pressure.
In an alternative embodiment, the pressure actuator 24 is a pneumatic or hydraulic cylinder, and the actuation chamber 203 is a sealed space formed by the inner wall surface of the body 201 and the top wall of the piston member 23. In this way, the air cylinder or the hydraulic cylinder can inject the pressure medium into the driving chamber 203, change the pressure of the driving chamber 203, form a surface pressure on the upper wall surface of the piston member 23, and uniformly move the piston member 23, wherein the side wall of the piston member 23 is attached to the inner wall surface of the machine body 201.
In an alternative example, a sub-compression chamber for driving the piston member 23 is formed below the piston member 23, and the driving of the piston member 23 upward is facilitated by pressurizing the sub-compression chamber.
In an alternative embodiment, the pressure driver 24 is used to pressurize the driving cavity 203, and the pressure is pressurized in the driving cavity 203 by air pressure or hydraulic pressure, so that the piston member 23 is pressurized integrally and downward pressure is kept balanced, and the downward pressure is the same in the length direction of the whole piston member 23, so that the cable with the length of 4-5 meters is uniformly pressurized, the thickness and the tightness of the molded cable are the same, and the uniformity of the cable core is ensured. As shown in fig. 6, in the process of preparing the cable core, in order to ensure the uniformity of pressing in the length direction of the cable core, the present invention can ensure that the downward pressure is uniform and the same in the length direction of the entire piston member 23.
Further, an upper die 22 is located in the pressing cavity, can move up and down along the inner wall of the pressing cavity, is connected to the piston member 23, and has a first arc-shaped wall surface; the lower die 21 is fixedly disposed in the pressing cavity, for example, at the bottom, and has a second arc-shaped wall surface, so that when the upper die 22 is pressed onto the lower die 21, a cabling space with a circular cross section and two open ends is formed.
The multilayer prefabricated core materials 10 distributed in a nested manner are respectively positioned in the upper die 22 and the lower die 21, and when the upper die 22 is driven by the pressure driver and preset pressure to press the lower die 21, the multilayer prefabricated core materials distributed in the nested manner are pressed in the cabling space.
As shown in fig. 6, the length of the upper mold 22 is the same as the length of the core preform 10 to be pressed, the upper mold 22 and the lower mold 21 are equal in length, the upper mold 22 and the lower mold 21 are attached to the inner wall of the machine body 201, and the upper mold 22 can only move up and down as shown in the figure to tightly press the stacked core preforms 10.
In the present embodiment, after the prefabricated core material 10 and the core units 11 are arranged in a predetermined manner, the upper mold 22 and the lower mold 21 are clamped by pressurizing the inside of the driving chamber 203 to a predetermined pressure by the air cylinder or the hydraulic cylinder, and the stacked prefabricated core material 10 and core units 11 between the upper mold 22 and the lower mold 21 are pressed, so that the prefabricated core material 10 and core units 11 are compressed into the cable core.
In an alternative embodiment, the lower mold 21 may be provided in a movable form, and the lower mold 21 is transferred to a position away from the upper mold 22 while laying the prefabricated core 10 to increase an operation space and then moved again to a position below the upper mold 22 after laying.
Further, in order to accurately control the pressure applied to the upper mold 22, the machine body 201 is provided with a plurality of pressure drivers 24 connected to the press-fit chamber 203, and at least one pressure feedback member connected to the press-fit chamber 203 to detect the pressure in the press-fit chamber 203.
In an alternative embodiment, the pressure feedback component is a pressure sensor connected to the pressing cavity 203, the pressure of the pressing cavity 203, that is, the pressure applied to the piston component 23, is monitored, and the pressure applied to the piston component 23 is fed back to form a closed-loop control, so that the magnitude of the pressure applied to the prefabricated core material 10 and the core unit 11 in the pressing process can be controlled more accurately, and overpressure or insufficient pressing can be avoided.
Further, the length of the press-fit cavity 203 and the piston member 23 is longer than the length of the upper and lower dies 22 and 21. Therefore, the upper die 22 can be uniformly stressed, and the thickness and the dense consistency of the pressed cable core along the length direction can be kept good.
In an alternative embodiment, the upper mold 22 is detachably coupled to the piston member 23, and the lower mold 21 is detachably coupled to the machine body 201.
Referring to fig. 5, the piston member 23 includes a piston body and a connection portion 231, a sealing ring is disposed outside the piston body to maintain the sealing of the pressing chamber 203, the connection portion 231 of the piston member 23 is provided with a dovetail groove, and the upper mold 22 is provided with a connection block 221 connected to the dovetail groove.
Further, a screw for positioning the upper die 22 and the piston member 23 relative to each other in the longitudinal direction thereof is provided on the side surface of the connecting portion 231 of the piston member 23, and the mounted upper die 22 is held in a fixed position in the longitudinal direction of the piston member 23.
Thus, the diameters of the arc surfaces of the upper die 22 and the lower die 21 can be different in a mode of replacing the upper die 22 and the lower die 21, and the device can be suitable for producing cables with different sizes.
Preparation process
With reference to the drawings, according to the embodiments disclosed in the present invention, there is also provided a method for preparing a cable core with a prefabricated structure, the method comprising the following steps:
step 2, cooling and forming the prepared prefabricated core material;
and 4, pressurizing the die to enable the prefabricated core material to be compressed and wrapped outside the wire material, so as to form the cable core with the circular section.
As shown in fig. 5, the mold includes a lower mold and a driven upper mold, and the first prefabricated core group and the second prefabricated core group are distributed in the mold in a vertically symmetrical manner, and the arrangement sequence includes:
the prefabricated core materials of the first prefabricated core material group positioned below are sequentially placed on the lower die from large to small in inner diameter, arranged from the prefabricated core material with the largest inner diameter and sequentially arranged in an upward nested manner;
filling wire materials into the inner wall surface of the prefabricated core material with the smallest inner diameter;
the prefabricated core materials of the second prefabricated core material group located above are sequentially arranged on the wire materials from small to large in inner diameter, and are arranged from the prefabricated core material with the smallest inner diameter and are sequentially nested upwards.
Therefore, the prefabricated core materials 10 are conveniently placed between the upper die 22 and the lower die 21 one by one, firstly, the prefabricated core material 10 with the largest diameter is placed on the upper arc surface 211 of the lower die 21, the end surfaces of two sides of the prefabricated core material 10 are flush with the upper end surface of the lower die 21, then the prefabricated core materials 10 with descending diameter gradient are placed in sequence, the end surfaces of two sides are kept flush with the upper end surface of the lower die 21, the prefabricated core materials 10 are sequenced in sequence in this way, then the core body units 11 are placed on the inner wall of the prefabricated core material 10 with the smallest diameter, and then the prefabricated core materials 10 are placed above the core body units 11 in sequence from small diameter to large diameter one by one.
Preferably, in step 4, the upper mold is uniformly pressed along the length direction of the prefabricated core material to press and form the prefabricated core material, and the pressure maintaining treatment is performed for a certain time according to a preset pressure.
Preferably, the dwell time is related to the wall thickness of the prefabricated core material, t = t0D, t is the compaction time in seconds. d is the wall thickness of the prefabricated core material, preferably in the range of 1-3 mm. I.e. t0Denotes the compaction coefficient, t0=30, i.e. a dwell time of 30s per mm thickness.
For example, in the examples of the present invention, 8000-series aluminum alloys are used as examples, the pressure range for holding pressure is 50 to 70MPa, and the holding pressure time is 0.5 to 1.5 min.
In an alternative embodiment, the bar is made of aluminum alloy bar, the length of the extruded prefabricated core material is 4-5 m/section, and the extruded prefabricated core material is especially applied to short-distance high-power transmission occasions, such as buried high-power cables, for example buried cables in subway stations, or cables for transformers and transformer substations.
Furthermore, the extruded prefabricated core material in the prefabricated shape is shaped after air cooling and/or water cooling and then temporarily stored in a material bin with a corresponding specification. Wherein, the film head 100 of the extruder comprises extrusion holes with different specifications, the extruded materials have different specifications, and in the subsequent steps, prefabricated core materials 10 with different specifications and quantities are selected to be pressed to form cable cores according to the diameters of the actually produced cables.
In an alternative embodiment, the output end of the film head 100 of the extruder is connected to a cooling bed, the cooling bed has a conveying belt and a water cooling environment, so that the prefabricated core material 10 just extruded is conveyed to the tail end of the cooling bed after being cooled and formed, and different temporary storage parts are used for storing prefabricated core materials 10 with different specifications, such as thickness of 1mm, specification of 2-3mm, specification of 3-4mm, specification of 4-5mm, specification of 5-6mm, specification of 6-7mm, specification of 7-8mm, specification of 8-9mm and the like. Taking a prefabricated core material of 2-3mm as an example, the inner diameter is 2mm, the outer diameter is 5mm, the thickness is 1mm, and so on.
In an alternative embodiment, the thickness of the prefabricated core material 10 is 2mm, and the specification is 3-5mm, 5-7mm, etc. Taking a prefabricated core material of 3-5mm as an example, the inner diameter is 3mm, the outer diameter is 5mm, the thickness is 2mm, and so on.
The core unit 11 is 1-3mm, and the core unit 11 can be formed by hot drawing a bar.
The invention uses aluminum alloy wire with the diameter of 1mm, 8000 series aluminum alloy, uses prefabricated core material as shown in figure 3, five layers are superposed, when the thickness of each layer is 2mm, the diameter of the prepared cable core structure is 11mm, 5 sections of the prepared cable core are selected for mechanical test, the tensile strength test result of the monofilament (namely a single cable core) is 120-140MPa, the tensile strength is higher, and the monofilament is not easy to break.
In an alternative embodiment, the lower mold 21 may be provided in a movable form, and the lower mold 21 is transferred to a position away from the upper mold 22 while laying the prefabricated core 10 to increase an operation space and then moved again to a position below the upper mold 22 after laying.
In step 4, the upper mold of the mold is uniformly pressed along the length of the preform core 10 to press the preform core.
Preferably, in order to maintain the thickness of the prefabricated core material 10 uniform and the tight consistency, pressure is uniformly applied to the upper surface of the whole length of the prefabricated core material 10 in the pressing direction, so that the connection between the pressed prefabricated core materials 10 is uniform and tight to form the cable core.
By combining the above embodiments, the cable is formed by extruding the aluminum alloy bar into the semi-circular prefabricated members and then forming the cable core with the circular cross section by pressing the prefabricated members, the production process comprises the steps of extruding, distributing a die and pressing, the process is simple, the conductors with different diameters can be manufactured, and the conductors have small heat productivity and strong power transmission capability under the power transmission environment with short distance and high power.
Although the present invention has been described with reference to the preferred embodiments, it is not intended to be limited thereto. Those skilled in the art can make various changes and modifications without departing from the spirit and scope of the invention. Therefore, the protection scope of the present invention should be determined by the appended claims.
Claims (16)
1. A cable core of a prefabricated construction, comprising:
the core unit is a wire with a circular section, and the diameter of the wire is d 0;
the prefabricated core materials are wrapped outside the core unit and comprise a first prefabricated core material group and a second prefabricated core material group, and the first prefabricated core material group and the second prefabricated core material group are symmetrically wrapped on the outer side of the core unit to form a cable core with a circular section;
the first prefabricated core material group and the second prefabricated core material group are of the same structure and comprise a plurality of layers of prefabricated core materials which are distributed in a nested mode and are semicircular in section, the inner diameters of the prefabricated core materials of the adjacent layers are increased in a periodic gradient mode from the inner layer to the outer layer, and the inner diameter d1 of the prefabricated core material of the innermost layer is equal to the diameter d0 of the wire material.
2. The cable core according to claim 1 wherein the pre-formed core material has a semi-circular inner wall surface and a semi-circular outer wall surface such that adjacent pre-formed core materials and pre-formed core materials are attached to the core units.
3. The cable core according to claim 1 or 2, wherein the inner diameter of the prefabricated core material of the adjacent layers increases according to a preset fixed value gradient.
4. Cable core according to claim 1, wherein the thickness of each layer of pre-formed core material is the same.
5. The cable core according to claim 3, wherein the thickness of the pre-formed core material is 1-3 mm.
6. The cable core according to claim 1, wherein the core units and the pre-formed core material are made of the same metal or alloy material, including one of copper, copper alloy and aluminum alloy.
7. An electric power cable comprising the cable core of the prefabricated structure according to any one of claims 1 to 6 and a functional layer disposed outside the cable core, wherein the functional layer comprises one of an insulating layer, a shielding layer and a sheath layer.
8. A system for preparing a cable core of a preformed structure according to claim 1, comprising:
the high-temperature melt-pressing extrusion system is used for carrying out high-temperature high-pressure melting on the metal bar and controlling the metal bar to be extruded into a prefabricated core material with a semicircular section in a semi-solid state; and
the extrusion system is used for symmetrically pressing the multilayer prefabricated core materials which are distributed in a nested manner outside the core unit to form a cable core with a circular section;
wherein the extrusion system comprises:
the pressing mechanism comprises a machine body, a pressing mechanism and a pressing mechanism, wherein the machine body is provided with a driving cavity and a pressing cavity, and a piston part connected to the pressing cavity is arranged in the driving cavity;
the pressure driver is connected to the driving cavity and used for generating positive pressure or negative pressure in the driving cavity so as to enable the piston component to move up and down;
the upper die is positioned in the pressing cavity, can move up and down along the inner wall of the pressing cavity, is connected to the piston part and is provided with a first arc-shaped wall surface;
the lower die is fixedly arranged in the pressing cavity and is provided with a second arc-shaped wall surface, and when the upper die is pressed on the lower die, a cabling space with a circular section is formed;
the multilayer prefabricated core materials distributed in a nested manner are respectively located in the upper die and the lower die, and when the upper die is driven by the pressure driver and preset pressure to press the lower die, the multilayer prefabricated core materials distributed in the nested manner are pressed in the cabling space.
9. The manufacturing system according to claim 8, wherein the pressure driver is configured to maintain the pressure at a preset pressure for a predetermined time after the upper and lower molds are pressed.
10. The manufacturing system of claim 8, wherein the machine body is provided with a plurality of pressure drivers connected to the bonding chambers, and at least one pressure feedback member connected to the bonding chambers, and the pressure in the bonding chambers is obtained through the pressure feedback member.
11. The manufacturing system of any of claims 8-10, wherein the length of the press cavity is longer than the length of the upper and lower dies, and the length of the piston member is longer than the length of the upper and lower dies.
12. The manufacturing system of any one of claims 8-10, wherein the upper die is removably coupled to the piston member and the lower die is removably coupled to the body.
13. A manufacturing system according to any of claims 8-10, further comprising an annealing system arranged to anneal the extruded prefabricated core material at a high temperature.
14. A method for preparing a cable core of a prefabricated structure according to claim 1, wherein the preparation system of claim 8 is used, and the preparation method comprises the following steps:
step 1, performing high-temperature and high-pressure smelting on a metal bar, and extruding the metal bar into a prefabricated core material with a semicircular section in a semi-solid state; the section of the molding cavity of the mold is semicircular, and the thickness of the molding cavities of different molds is the same;
step 2, cooling and forming the prepared prefabricated core material;
step 3, arranging prefabricated core materials required for forming a first prefabricated core material group and a second prefabricated core material group in the upper die and the lower die, arranging wire materials, and forming multilayer nested arrangement of the prefabricated core materials with the inner diameters changing in a periodic gradient manner, wherein the number of the prefabricated core materials contained in the first prefabricated core material group is the same as that of the prefabricated core materials contained in the second prefabricated core material group, and the inner diameters of the prefabricated core materials used on the corresponding layers are the same;
and 4, pressurizing the die to enable the prefabricated core material to be compressed and wrapped outside the wire material, so as to form the cable core with the circular section.
15. A method according to claim 14, wherein the mould comprises a lower mould and a drivable upper mould, and the first and second prefabricated core groups are symmetrically distributed in the mould from top to bottom in a sequence comprising:
the prefabricated core materials of the first prefabricated core material group positioned below are sequentially placed on the lower die from large to small in inner diameter, arranged from the prefabricated core material with the largest inner diameter and sequentially arranged in an upward nested manner;
filling wire materials into the inner wall surface of the prefabricated core material with the smallest inner diameter;
the prefabricated core materials of the second prefabricated core material group located above are sequentially arranged on the wire materials from small to large in inner diameter, and are arranged from the prefabricated core material with the smallest inner diameter and are sequentially nested upwards.
16. The manufacturing method according to claim 14, wherein in step 4, the upper mold is uniformly pressed in a longitudinal direction of the preform core to press-mold the preform core, and the pressure maintaining process is performed for a certain time at a preset pressure.
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| CN110911035A (en) * | 2019-09-05 | 2020-03-24 | 广州岭南电缆股份有限公司 | Large-section special-shaped monofilament layer split conductor and manufacturing method thereof |
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