CN115240921A - Semicircular cable core and preparation method of communication cable - Google Patents
Semicircular cable core and preparation method of communication cable Download PDFInfo
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- CN115240921A CN115240921A CN202210847727.8A CN202210847727A CN115240921A CN 115240921 A CN115240921 A CN 115240921A CN 202210847727 A CN202210847727 A CN 202210847727A CN 115240921 A CN115240921 A CN 115240921A
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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
- H01B13/02—Stranding-up
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B11/00—Communication cables or conductors
- H01B11/02—Cables with twisted pairs or quads
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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
- H01B13/02—Stranding-up
- H01B13/0207—Details; Auxiliary devices
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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
- H01B13/143—Insulating conductors or cables by extrusion with a special opening of the extrusion head
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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
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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
- 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
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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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Abstract
The invention discloses a preparation method of a semicircular cable core, which comprises the following steps: s1, stranding a plurality of metal monofilaments to form a stranded conductor; s2, enabling a plurality of stranded conductors to penetrate through the doubling die and be bundled by the doubling die; and S3, when the stranded conductors bundled by the doubling die pass through a first extrusion die with at least an outlet section inner hole in a semicircular shape, at least one part of the stranded conductors is extruded and dispersed by the wall surface of the first extrusion die inner hole and matched with the outlet section of the first extrusion die, and then the stranded conductors are wrapped by the insulating material injected into the first extrusion die and extruded together to form the semicircular cable core with the first insulating layer. The invention has the characteristics of preventing the metal monofilament from breaking and reducing the manufacturing cost.
Description
Technical Field
The invention relates to the technical field of cables, in particular to a semicircular cable core and a preparation method of a communication cable.
Background
CN105448413B discloses a manufacturing method of a semicircular conductor power cable, which comprises the following steps: 1) Pressing the stranded conductor into a semicircular shape through a roller die; 2) Wrapping the insulating material outside the conductor by adopting an extrusion wrapping mode, and cooling; 3) Stranding two identical wire cores prepared in the steps 1) and 2) and a filling material to form a cable core; 4) Wrapping a first layer of wrapping tape; 5) Wrapping the inner sheath material outside the first layer of wrapping tape by adopting an extrusion wrapping mode; 6) The inner sheath material is armored by a metal armor layer; 7) Wrapping a second layer of wrapping tape outside the metal armor layer; 8) And extruding the outer sheath material to the outside of the second lapping tape in an extruding way, thereby obtaining the semicircular conductor power cable shown in figure 1.
Wherein, the specific process of the step 1) is as follows: for any conductor, a plurality of metal monofilaments are stranded to form the conductor; the metal monofilament is divided into a plurality of layers from inside to outside; two adjacent metal monofilaments in each layer of metal monofilaments are tightly attached to each other; in the two adjacent layers of metal monofilaments, the inner layer metal monofilament and the outer layer metal monofilament are tightly attached; and pressing the twisted conductor into a semicircular shape through a roller die.
The manufacturing method of the semicircular conductor power cable has the following defects:
(1) The method has the problems that the section of the conductor formed by twisting a plurality of metal monofilaments is circular, gaps exist among the twisted metal wires before roller pressing, a part of the gaps are filled by the metal monofilaments in the pressing process to cause broken wires, in the process of forming the semicircle, the semicircle is formed by chords, arcs, connecting chords and arcs and has round corners, the metal monofilaments at the round corners are deformed in the pressing process and cannot be matched with the die due to stress, so that the round corners of the formed semicircle conductor have burrs, due to the existence of the burrs, after the insulation layer is extruded on the peripheral surface of the semicircle conductor, the thickness of the insulation layer corresponding to the burrs is thin, the burrs have the hidden danger of cutting the insulation layer, the semicircular conductor needs to be detected through a spark machine after the insulation layer is extruded, and in the detection process, the insulation layer corresponding to the burrs is easy to be broken by voltage.
(2) The existing semi-circular conductors are pressed to determine that the pitch of the twisted metal monofilaments cannot be too large, and the specific reason is that if the pitch is set to be too large, the twisted conductors become loose, and become loose in the pressing process, so that the twisted conductors cannot be tightly combined into a whole, and according to calculation, the twisting pitch of the twisted single conductors for pressing is 10-15 times of the twisting outer diameter, and under the condition of the small twisting pitch, the required raw materials are increased, so that the cost of the twisted single conductors is higher.
(3) In the pressing process, the single twisted conductor is influenced by the pressing process, the pressure is unstable, or the precision problem of the die and the matching degree of the wire passing speed are poor, and the like, so that the deformation of each part is inconsistent, the resistance phase deviation of each part is larger, and after the current flows through the semicircular conductor, the fluctuation of the formed electric signal is larger, and the stable state performance of the electric signal is poor.
Disclosure of Invention
The invention provides a semicircular cable core and a preparation method of a communication cable.
The technical scheme for solving the technical problems is as follows:
the preparation method of the semicircular cable core comprises the following steps:
s1, forming a stranded conductor by twisting a plurality of metal monofilaments;
s2, enabling a plurality of stranded conductors to penetrate through a doubling die and be bundled by the doubling die, wherein an inner hole of a first outlet section on the doubling die is surrounded by a first chord, a first arc, a second arc and a third arc, the first chord and the first arc are arranged oppositely, one end of the first chord is connected with one end of the first arc through the second arc, the other end of the first chord is connected with the other end of the first arc through the third arc, and the maximum distance between the first chord and the first arc is smaller than half of the chord length of the first chord;
and S3, when the stranded conductors bundled by the doubling die pass through a first extrusion die with at least an outlet section inner hole in a semicircular shape, at least one part of the stranded conductors is extruded and dispersed by the wall surface of the first extrusion die inner hole and matched with the outlet section of the first extrusion die, and then the stranded conductors are wrapped by the insulating material injected into the first extrusion die and extruded together to form the semicircular cable core with the first insulating layer.
The preparation method of the communication cable comprises the following steps:
s11, combining the two semicircular cable cores to form a circular cable core, and wrapping the circular cable core by using a wrapping tape to form a wrapping layer;
s12, weaving a metal material on the lapping layer in a weaving mode to form a metal woven layer;
s13, extruding the sheath material to the outside of the metal braided layer by adopting an extruding mode to form an outer sheath.
After a plurality of stranded conductors are firstly wound through a doubling die, the cross section shape formed by the stranded conductors is close to a semicircle, and the stranded conductors are extruded and dispersed by a first extrusion die when passing through the first extrusion die, so that the shapes of the stranded conductors and the outlet section of the first extrusion die are matched, and then the stranded conductors and the insulating material are extruded together. The advantages of this approach are:
(1) According to the invention, the stranded conductors are not required to be pressed by a roller die, although the stranded conductors are passively extruded by the first extrusion die, the extruded stranded conductors are dispersed to fill the gaps between two adjacent stranded conductors and the first extrusion die, and finally the cross sections of all conductor components are semicircular, so that the metal monofilaments are not broken as in the prior art, burrs are not formed on each stranded conductor, and the first insulation layer is prevented from being weakened by the stranded conductors, therefore, the thickness of the extruded first insulation layer in each part is uniform.
(2) The method of the invention is adopted to lead the twisting pitch of the twisted conductor to be much larger than that of the prior art, therefore, on one hand, the amount of the metal monofilament used in the invention is much smaller than that of the prior art, thereby reducing the cost, and on the other hand, after the twisting pitch is increased, the method mainly aims to play the roles of dispersing and filling gaps when passing through the first extrusion die, and simultaneously avoids the occurrence of broken wires.
(3) The method can form the twisted conductor into a semicircle without pressing, so that each metal monofilament keeps the original shape after the semicircle cable core is formed, the resistance of each part of the cable core is equal or very close, and the fluctuation of electric signals caused by the factors of the cable core is avoided in the specific use process.
In conclusion, compared with the power cable manufacturing method disclosed in the publication No. CN105448413B, the method disclosed by the invention has the advantages that under the condition of realizing the same functions and performance, conductor materials are saved, the conductor resistance is better controlled, the method is more beneficial to mass production, conductors can be recycled, the insulation layer breakdown is less, and the defective rate is low.
Drawings
Fig. 1 is a schematic view of a production line for semicircular cable cores according to the present invention;
FIG. 2 is a cross-sectional view of a doubling die;
FIG. 3 is a right side view of FIG. 2;
FIG. 4 is a schematic view of the inner profile of the first outlet section;
FIG. 5 is a schematic view of a stranded conductor as it passes through the first outlet section in cooperation with the first outlet section;
FIG. 6 is a half sectional view of a first extrusion die;
FIG. 7 is a top view of FIG. 6;
FIG. 8 is a cross-sectional view of a semicircular cable core;
FIG. 9 is a cross-sectional view of a communication cable;
reference numbers in the figures:
the cable drawing device comprises a first stranded conductor 1, a second stranded conductor 2, a doubling mold 3, a body 30, a doubling guide hole 31, a first inlet section 31a, a first outlet section 31b, a first chord 3a, a first arc 3b, a second arc 3c, a third arc 3d, a first central angle alpha, a second central angle beta, a first extrusion mold 4, an outlet section 4a, a first insulating layer 5, a first pay-off rack 6, a second pay-off rack 7, a third pay-off rack 8, a tension rack 9, a take-up rack 10, a semicircular cable core 11, a vacuumizing device 12, a first water tank 13, a second water tank 14, a wrapping layer 15, a metal woven layer 16 and an outer sheath 17.
Detailed Description
As shown in fig. 1, the production line of the semicircular cable core of the present invention includes a pay-off stand for winding a stranded conductor, a cooling device, a doubling die 3, and a first extrusion die 4, and the following describes each part and the relationship between each part in detail:
in this embodiment, a plurality of metal monofilaments are twisted to form a twisted conductor, the twisted conductor includes a first twisted conductor 1 and a second twisted conductor 2, the outer diameters of the first twisted conductor 1 and the second twisted conductor 2 are not equal, the number of the first twisted conductors 1 is two, and the number of the second twisted conductors 2 is one.
The multiple stranded conductors move in parallel along the doubling mold 3, and the doubling mold 3 is positioned at the downstream of the pay-off rack; a tension frame 9 is arranged between the pay-off rack and the doubling mold 3, in this embodiment, the pay-off rack includes a first pay-off rack 6, a second pay-off rack 7 and a third pay-off rack 8, the first twisted conductor 1 is wound on the first pay-off rack 6, the second twisted conductor 2 is wound on the second pay-off rack 7, the second first twisted conductor 1 is wound on the third pay-off rack 8, and the first twisted conductor 1 and the second twisted conductor 2 respectively paid off from the first pay-off rack 6 and the third pay-off rack 8 and the second twisted conductor 2 paid off from the second pay-off rack 7 are respectively tensioned by the tension frame 9 and then sent into the doubling mold 3.
In this embodiment, since the plurality of stranded conductors move in parallel, the movement of each stranded conductor is stabilized by the tensioning action of the tension bracket 9 and the guiding action of the doubling mold 3, so that the adjacent stranded conductors are prevented from shifting or interfering and being stuck with the doubling mold 3, and the cross-sectional shapes of the stranded conductors are close to the cross-sectional shape of the doubling mold 3 after the stranded conductors are output from the doubling mold 3.
The doubling mold 3 comprises a body 30 and a doubling guide hole 31 penetrating through the body 30, the doubling guide hole 31 comprises a first inlet section 31a and a first outlet section 31b, the first inlet section 31a is a conical hole, the diameter of the input end of the first inlet section 31a is larger than the diameter of the joint of the first inlet section 31a and the first outlet section 31b, and the first inlet section 31a is provided with a conical hole, so that the formation and the guide of each twisted conductor into the first outlet section 31b can be facilitated.
The inner hole profile of the first outlet section 31b is composed of a first chord 3a, a first arc 3b, a second arc 3c, and a third arc 3d, the first chord 3a is arranged opposite to the first arc 3b, one end of the first chord 3a is connected with one end of the first arc 3b through the second arc 3c, the other end of the first chord 3a is connected with the other end of the first arc 3b through the third arc 3d, and the maximum distance H between the first chord 3a and the first arc 3b is less than half of the chord length of the first chord 3 a.
Since the maximum distance H between the first chord 3a and the first arc 3b is smaller than half of the first chord 3a, for example, half of the first chord 3a is 1.04-1.13 times of the maximum distance H, the inner bore profile of the first outlet section 31b is not a semicircle but is close to a semicircle, and the first outlet section 31b has a binding effect on the plurality of twisted conductors, so that the twisting die 3 effectively forms a binding on the twisted conductors after the twisted conductors pass through the twisting die 3, and the cross-sectional shape of the plurality of twisted conductors after being arranged is close to a semicircle. In addition, since the stranded conductor is respectively matched with the second arc 3c and the third arc 3d or slides along the second arc 3c and the third arc 3d when passing through the doubling mold 3, the second arc 3c and the third arc 3d are respectively used for connecting the first chord 3a and the first arc 3b, and the round shapes of the second arc 3c and the third arc 3d are matched with the peripheral surface of the stranded conductor, so that the stranded conductor can be prevented from being scratched.
In this embodiment, the second arc 3c and the third arc 3d are preferably arranged to be mirror-symmetric to each other, the first central angle α corresponding to the first arc 3b is smaller than the second central angle β corresponding to the second arc 3c and the third arc 3d, the first central angle α is an acute angle, and the second central angle β is an obtuse angle, in this embodiment, the first central angle α is preferably 82 ° and the second central angle β is preferably 138 °, so that the arc length of the first arc 3b is smaller than the arc length of a quarter of the circle corresponding to the first arc 3b, the arc length of the second arc 3c is smaller than the arc length of a semicircle corresponding to the second arc 3c, and the arc length of the third arc 3d is smaller than the arc length of a semicircle corresponding to the third arc 3 d.
The foregoing describes the central angles of the first arc 3b, the second arc 3c, and the third arc 3d, and the relationship between the arc lengths of the first arc 3b and the second arc 3c, and the third arc 3d, by which it is further clear that the inner bore profile of the first outlet section 31b is not a semicircle, but is close to a semicircle.
The first extrusion die 4 is used for extruding the stranded conductor and the insulating material together, the first extrusion die 4 is located at the downstream of the doubling die 3 and at the upstream of the cooling device, an outlet section used for enabling at least one part of the stranded conductor to be scattered is arranged on the first extrusion die 4, an inner hole of the outlet section is semicircular, and a taper hole is also adopted in the inlet section of the first extrusion die 4.
In this embodiment, it is preferable that the area of the first outlet section 31b of the doubling die 3 is larger than the area of the outlet section 4a of the first extrusion die 4, and the diameter of the outlet section of the first extrusion die 4 is smaller than the chord length of the first outlet section 31 b. Therefore, the strand conductor is pressed by the outlet section 4a of the first extrusion die 4, facilitating spreading of at least a portion of the strand conductor.
In the present embodiment, since the twisted conductors have a relatively large twisting pitch, the twisted conductors in the present embodiment are less compact than the twisted conductors in the prior art, and therefore easily spread after being subjected to a corresponding pressing force, in the present embodiment, the area of the first outlet section 31b of the doubling mold 3 is greater than the area of the outlet section 4a of the first extrusion mold 4, the twisted conductors pass through the doubling mold 3 first, and are bundled while passing through the doubling mold 3, the twisted conductors are arranged and then the cross-sectional shape formed by the twisted conductors together is close to a semicircle, but the twisted conductors do not receive a large pressing force when passing through the doubling mold 3, and when the twisted conductors reach the outlet section 4a of the first extrusion mold 4, at least a portion of the twisted conductors are spread due to the area of the outlet section 4a of the first extrusion mold 4 being reduced relative to the area of the first outlet section 31b of the doubling mold 3, and the inner wall surfaces of the spread conductors are matched with the area of the outlet section 4a of the first extrusion mold 4, so that the cross-sectional shape of the extruded conductors is a semicircle formed by the extruded conductors. In the embodiment, the cable core is molded into a semicircular structure by skillfully utilizing the structures of the doubling die 3 and the first extrusion die 4.
The present embodiment further includes a vacuum-pumping device 12 for vacuum-pumping the doubling mold 3 and/or the first extrusion mold 4. In this embodiment, it is preferable that the doubling mold 3 and the first extrusion mold 4 are mounted on the same extruder head, the vacuum extractor 12 is connected to the extruder head, and when the vacuum extractor 12 operates, the vacuum extractor simultaneously performs a vacuum-extracting function on the doubling mold 3 and the first extrusion mold 4.
Above-mentioned through evacuating device 12 to doubling mould 3 and first extrusion tooling 4 evacuation simultaneously, the technological effect who reaches is, evacuating device 12 provides the negative pressure effort for doubling mould 3 and first extrusion tooling 4, can make the stranded conductor no matter in doubling mould 3 like this, still in first extrusion tooling 4, the homoenergetic is more regular to can promote semicircle cable core 11 shape, avoid extruding the condition emergence that has the swell or collapse on semicircle cable core 11 after first insulation layer 5.
After the co-extrusion of the stranded conductor and the insulating material, the temperature of the first insulating layer 5 is high, so that the semicircular cable core 11 is cooled by a cooling device to accelerate the solidification of the first insulating layer 5 and prevent the deformation. In the embodiment, the cooling device comprises the first water tank 13 with the first cooling water temperature and the second water tank 14 with the second cooling water temperature, and the semicircular cable cores 11 are cooled in a sectional mode by adopting different temperatures, so that the cooling efficiency is improved.
The preparation method for manufacturing the semicircular cable core by adopting the production line comprises the following steps:
s1, forming a stranded conductor by twisting a plurality of metal monofilaments; in this step, the pitch of each stranded conductor is 20-30 times of the outer diameter of the strand, and the pitch of each stranded conductor is preferably 30 times of the outer diameter of the strand. In this step, the stranded conductor formed by stranding includes a first stranded conductor 1 and a second stranded conductor 2.
In the semicircular cable core 11 of this embodiment, two first twisted conductors 1 are preferably used, one second twisted conductor 2 is preferably used, the outer diameters of the first twisted conductor 1 and the second twisted conductor 2 are not equal, and the outer diameter of the second twisted conductor 2 is greater than the outer diameter of the first twisted conductor 1.
Arranging the obtained first stranded conductor 1 and the second stranded conductor 2 on a pay-off rack respectively, and specifically: the first twisted conductor 1 is wound on a first pay-off stand 6, the second twisted conductor 2 is wound on a second pay-off stand 7, the second first twisted conductor 1 is wound on a third pay-off stand 8, the first twisted conductor 1 paid out from the first pay-off stand 6 and the third pay-off stand 8 and the second twisted conductor 2 paid out from the second pay-off stand 7 are respectively, and tension is generated on the first twisted conductor 1 and the second twisted conductor 2 by a tension stand 9 respectively.
S2, pass many strand conductors and carry out the beam by doubling mould 3, namely first strand conductor 1 and second strand conductor 2 enter into doubling mould 3 after passing through tension bracket 9, in this embodiment, the arrangement mode of first strand conductor 1 and second strand conductor 2 when passing through doubling mould 3 is: one first stranded conductor 1 is disposed on each side of the second stranded conductor 2.
Because the inner hole of the first outlet section 31b on the doubling die 3 is enclosed by the first chord 3a, the first arc 3b, the second arc 3c and the third arc 3d, the first chord 3a is arranged opposite to the first arc 3b, one end of the first chord 3a is connected with one end of the first arc 3b through the second arc 3c, the other end of the first chord 3a is connected with the other end of the first arc 3b through the third arc 3d, and the maximum distance H between the first chord 3a and the first arc 3b is less than half of the chord length of the first chord 3 a; a first central angle α corresponding to the first arc 3b is smaller than a second central angle β corresponding to the second arc 3c and the third arc 3d, and an arc length of the first arc 3b is larger than arc lengths of the second arc 3c and the third arc 3 d.
According to the above structure, the stranded conductor passes through the doubling die 3, wherein: the outer peripheral surface of the first twisted conductor 1 is respectively matched with a first chord 3a, a first arc 3b and a second arc 3c of a first outlet section 31b of the doubling die 3; the outer peripheral surface of the second first twisted conductor 1 is respectively matched with a first chord 3a, a first arc 3b and a third arc 3d of a first outlet section 31b of the doubling die 3; the outer peripheral surfaces of the second stranded conductors 2 are respectively fitted with the first chords 3a, the first arcs 3b of the first outlet sections 31b of the doubling dies 3.
Based on the inner hole profile of the first outlet section 31b of the doubling die 3, wherein an arbitrary distance between the first chord 3a and the first arc 3b is greater than a distance between the first chord 3a and the second arc 3c or the third arc 3d, therefore, the space height of the middle part in the inner hole of the first outlet section 31b is greater than the space heights of the two side parts, and since the outer diameter of the second stranded conductor 2 is greater than the outer diameter of the first stranded conductor 1, one first stranded conductor 1 is respectively arranged on each of the two sides of the second stranded conductor 2, and after the stranded conductors are wound by the doubling die 3, the cross sections of the stranded conductors are favorably close to a semicircle.
And S3, when the stranded conductors bundled by the doubling die 3 pass through the first extrusion die 4 with at least an inner hole of the outlet section 4a being semicircular, at least one part of the stranded conductors is extruded and dispersed by the wall surface of the inner hole of the first extrusion die 4 and matched with the outlet section 4a of the first extrusion die 4, and then the stranded conductors are wrapped by the insulating material injected into the first extrusion die 4 and extruded together to form the semicircular cable core 11 with the first insulating layer 5. The insulating material forming the first insulating layer 5 is low-smoke halogen-free flame-retardant polyolefin insulating material, the insulating nominal thickness of the first insulating layer 5 is 0.9mm, and the thickness of the thinnest part is not less than 0.71mm. The semicircular cable core 11 obtained in this embodiment has a ratio of width to height of 9.9-10.3:4.5-4.9.
Since the outer diameter of the second stranded conductor 2 is larger than the outer diameter of the first stranded conductor 1, the first stranded conductor 1 and the second stranded conductor 2 have a gap. Since the inner hole area of the first outlet section 31b of the doubling die 3 is larger than the inner hole area of the outlet section 4a of the first extrusion die 4, the strand conductors are pressed by the outlet section 4a of the first extrusion die 4, at least a part of the strand conductors are scattered, and the scattered strand conductors fill the gaps, and in this process, although the strand conductors are passively pressed, the strand conductors are scattered to fill the gaps by the pressing, and finally, all the conductors have semicircular cross sections, so that the metal filaments are not broken as in the prior art, burrs are not formed on each strand conductor, and the first insulating layer 5 is prevented from being weakened by the strand conductors, and therefore, the thickness of the extruded first insulating layer 5 in each part is uniform in this embodiment.
The method also comprises the step of continuously vacuumizing the doubling die 3 and the first extrusion die 4. And after the twisted conductor is extruded together with the insulating material to form the semicircular cable core 11, the method further comprises the step of cooling the semicircular cable core 11, namely, sequentially passing the semicircular cable core 11 through a first water tank 13 with a first cooling water temperature and a second water tank 14 with a second cooling water temperature, and cooling the semicircular cable core 11 in a sectional manner through the first water tank 13 and the second water tank 14, wherein the cooling water temperature in the first water tank 13 is 50-70 ℃, and the cooling water in the second water tank 14 is normal temperature. After cooling, the first insulating layer 5 is shaped, whereby the obtained semicircular cable core 11 is wound up by means of a take-up stand 10. Accordingly, the process of preparing the semicircular cable core is completed. By the process, the qualification rate of the semicircular cable core 11 reaches more than 99%.
The semi-circular cable core 11 manufactured by the above method can be applied to various places, such as the fields of petrochemical industry, communication, etc., in this embodiment, the method for manufacturing a communication cable having the semi-circular cable core 11 is described by taking the application to the communication field as an example, and includes the following steps:
s11, combining the two semicircular cable cores 11 to form a circular cable core, and wrapping the circular cable core by using a wrapping tape to form a wrapping layer 15; in this embodiment, the tape is preferably compound to adopt the aluminium-plastic, and in the process of lapping, the average value of the rate of taking the lid of tape is not less than 15%.
S12, weaving a metal material on the lapping layer in a weaving mode to form a metal woven layer 16; in the embodiment, the alloy material weaving wires with the monofilament diameter of 0.15-0.18mm are adopted for weaving.
And S13, extruding the sheath material outside the metal braided layer by adopting an extruding mode to form an outer sheath 17. In the embodiment, the jacket material is preferably a low-smoke halogen-free flame-retardant polyolefin jacket material, the nominal thickness of the outer jacket 17 is 1.6mm, and the thickness of the thinnest part is not less than 1.22mm.
The radial cross-sectional area of the conductor is 25mm 2 The copper core cable is taken as an example, and the main technical indexes are as follows:
TABLE 1
| Specification of | 2×25mm 2 |
| Conductor material/shape | Copper/semicircular |
| Structure (number/filament nominal diameter, mm) | 196/0.4 |
| Elongation at Break (%) | ≥20 |
| Conductor maximum direct current resistance (omega/km) at 20 DEG C | ≤0.78 |
The maximum direct current resistance of the conductor at 20 ℃ is one of the aspects of judging whether the product is qualified, and the direct current resistance (omega/km) of the conductor at 20 ℃ is detected by the method, specifically as follows:
detection standard: GB/T3048.4-2007
Sample preparation: a sample of not less than 1m is taken from the cable to be tested, and the covers at both ends and the connecting portion are removed to expose the conductor.
Test environment temperature: the sample is placed in a test environment at a temperature of 15-25 ℃ and an air humidity of not more than 85% for a time sufficient to allow temperature equilibration.
Test equipment: the test was performed using a fixed bridge dedicated to the laboratory.
The test results show that the direct current resistance of the conductor at 20 ℃ is as follows: 0.768-0.773 omega/km.
Finally, it should be noted that: the above embodiments are only preferred embodiments of the present invention to illustrate the technical solutions of the present invention, but not to limit the technical solutions, and not to limit the scope of the present invention; while the invention has been described in detail and with reference to the foregoing embodiments, those skilled in the art will appreciate that: the technical solutions described in the foregoing embodiments may still be modified, or some or all of the technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit of the corresponding technical solutions and the scope of the appended claims.
Claims (10)
1. The preparation method of the semicircular cable core comprises the following steps:
s1, forming a stranded conductor by twisting a plurality of metal monofilaments;
s2, a plurality of stranded conductors penetrate through a doubling mold (3) to be bundled by the doubling mold (3), the inner hole profile of a first outlet section (31 b) on the doubling mold (3) is defined by a first chord (3 a), a first arc (3 b), a second arc (3 c) and a third arc (3 d), the first chord (3 a) and the first arc (3 b) are oppositely arranged, one end of the first chord (3 a) is connected with one end of the first arc (3 b) through the second arc (3 c), the other end of the first chord (3 a) is connected with the other end of the first arc (3 b) through the third arc (3 d), and the maximum distance between the first chord (3 a) and the first arc (3 b) is smaller than half of the chord length of the first chord (3 a);
s3, when a plurality of stranded conductors bundled by the doubling die (3) pass through the first extrusion die (4) with at least an outlet section (4 a) inner hole being semicircular, at least one part of the stranded conductors is extruded and dispersed by the inner hole wall surface of the first extrusion die (4) and matched with the outlet section (4 a) of the first extrusion die (4), and then the stranded conductors are wrapped by the insulating material injected into the first extrusion die (4) and extruded together to form the semicircular cable core (11) with the first insulating layer (5).
2. The method for preparing a semicircular cable core according to claim 1, wherein the pitch of the stranded conductor in the step S1 is 20-30 times the strand outer diameter.
3. The method for preparing a semi-circular cable core according to claim 1, wherein in step S1, the stranded conductor formed by stranding includes a first stranded conductor (1) and a second stranded conductor (2), and outer diameters of the first stranded conductor (1) and the second stranded conductor (2) are not equal.
4. A method for preparing a semicircular cable core according to claim 3, wherein the number of the first twisted conductors (1) is two, the number of the second twisted conductors (2) is one, and the following steps are further performed before the plurality of twisted conductors are bundled by the doubling die (3):
the method comprises the steps of winding a first twisted conductor (1) on a first pay-off rack (6), winding a second twisted conductor (2) on a second pay-off rack (7), winding a second first twisted conductor (1) on a third pay-off rack (8), and feeding the first twisted conductor (1) and the second twisted conductor (2) which are respectively paid off from the first pay-off rack (6) and the third pay-off rack (8) and are paid off from the second pay-off rack (7) into a doubling die (3) after the first twisted conductor and the second twisted conductor are respectively tensioned by a tension frame (9).
5. A method for preparing a semicircular cable core according to claim 3, wherein the first and second stranded conductors (1, 2) are arranged in the doubling die (3) in such a manner that at least one first stranded conductor (1) is disposed on each side of each second stranded conductor (2).
6. Method for preparing a semi-circular cable core according to claim 4, wherein the stranded conductor is passed through a doubling die (3), wherein:
the outer peripheral surface of the first twisted conductor (1) is respectively matched with a first chord (3 a), a first arc (3 b) and a second arc (3 c) of a first outlet section (31 b) of the doubling die (3);
the outer peripheral surface of the second first twisted conductor (1) is respectively matched with a first chord (3 a), a first arc (3 b) and a third arc (3 d) of a first outlet section (31 b) of the doubling die (3);
the outer peripheral surface of the second stranded conductor (2) is respectively matched with a first chord (3 a) and a first arc (3 b) of a first outlet section (31 b) of the doubling die (3).
7. Method for the preparation of a semi-circular cable core according to claim 1, characterized in that the inner hole area of the first outlet section (31 b) of the doubling die (3) is larger than the inner hole area of the outlet section (4 a) of the first extrusion die (4).
8. The method for preparing a semicircular cable core according to claim 1, further comprising the step of continuously evacuating the doubling die (3) and the first extrusion die (4).
9. Method for the preparation of a semi-circular cable core according to any of claims 1 to 8, characterized in that said first arc (3 b) corresponds to a first central angle (α) which is smaller than a second central angle (β) corresponding to a second arc (3 c) and a third arc (3 d), and that the first arc (3 b) has an arc length which is larger than the arc lengths of the second arc (3 c) and the third arc (3 d).
10. The preparation method of the communication cable is characterized by comprising the following steps:
s11, combining the two semicircular cable cores (11) to form a circular cable core by adopting the two semicircular cable cores (11) prepared according to any one of claims 1 to 9, and lapping the circular cable core by adopting a lapping tape to form a lapping layer;
s12, weaving a metal material on the lapping layer in a weaving mode to form a metal woven layer;
s13, extruding the sheath material to the outside of the metal braided layer by adopting an extruding mode to form an outer sheath.
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