CN115679727A - Unbonded prestressed steel strand for low-grease thick-sheath wind tower and production method thereof - Google Patents
Unbonded prestressed steel strand for low-grease thick-sheath wind tower and production method thereof Download PDFInfo
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- CN115679727A CN115679727A CN202211719547.8A CN202211719547A CN115679727A CN 115679727 A CN115679727 A CN 115679727A CN 202211719547 A CN202211719547 A CN 202211719547A CN 115679727 A CN115679727 A CN 115679727A
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- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
Abstract
The invention relates to an unbonded prestressed steel strand for a low-grease thick sheath wind tower and a production method thereof, wherein the unbonded prestressed steel strand comprises a steel strand body, a sheath and a grease layer arranged between the steel strand body and the sheath, and the sheath is tightly wrapped outside the steel strand body in a way that the outer contour of the steel strand body is visible and the contour between steel wires of the steel strand body is not sunken; the thickness of the sheath is 1.5-2.0mm, and the whole thickness is uniform and consistent; the oil quantity of the grease layer is as follows: 15-40g/m. The production method comprises the following steps: 1. paying off the steel strand body; 2. coating grease; 3. coating a sheath; 4. cooling; 5. traction; 6. taking up; 7. checking; 8. and (6) packaging. According to the invention, through improving and designing a plurality of factors of two process links of coating grease and coating the sheath, the produced unbonded prestressed steel strand meets the technical requirements of low grease and thick sheath.
Description
Technical Field
The invention belongs to production equipment of unbonded steel stranded wires, and particularly relates to an unbonded prestressed steel stranded wire for a low-grease thick sheath wind tower and a production method thereof.
Background
At present, wind power generation is widely developed and utilized as a new energy source. The wind power generation system mainly comprises a plurality of components such as a wind wheel, a generator, a wind tower, an energy storage device and the like, wherein the support of the wind power generator mainly comes from the wind tower, and the safety and the stability of the wind tower are directly related to whether the wind power generator can normally operate.
At present, wind generating sets are popularized and used in high wind speed and low wind speed areas, the height of a tower barrel reaches more than 100m, the height of a wind tower needs to be increased in order to obtain larger wind energy in low wind speed areas and can reach more than 160m, therefore, the wind tower is used as a supporting structure, a mixed structure formed by a concrete foundation and a steel structure tower barrel is adopted, namely, the first section of the tower barrel at the bottom is of a prestressed concrete structure, and the upper part of the tower barrel is of a steel structure.
The prestressed concrete tower barrel is of a prestressed concrete structure, during construction, a prestressed steel strand is penetrated into a tensioning pipe, one end of the prestressed steel strand is fixed above a concrete column pier through an anchorage device, the other end of the prestressed steel strand is fixed inside a built wind tower concrete tower foundation, the built wind power concrete tower foundation and the concrete column pier are tightly connected through tensioning the prestressed steel strand, and the steel strand is used as a bearing construction material in the concrete structure and plays a role in ensuring the stability of a wind tower.
At present, the prestressed steel strands used in the wind power field are mostly external cable structures, the most essential difference between the external prestressed structure and the internal prestressed structure is that the external prestressed cable is arranged outside a main body structure, and the external prestressed cable structure and the internal prestressed structure are used for comparing the defects that the prestressed structure cannot be detected and replaced after grouting tensioning is finished, the quality of external cable construction can be judged easily, and the external cable construction can be replaced at any time when necessary. However, the problems of protection and corrosion prevention of the external cable are always key factors restricting the development of the external cable construction technology, but with the continuous development of the prestress construction technology, the external cable technology is also rapidly developed, and a galvanized steel strand or a steel strand with a coating on the surface is mostly adopted, and an external wrapping belt PE protects the unbonded steel strand.
Based on the requirements of the prior art, the invention discloses an unbonded prestressed steel strand for a wind tower with a low-grease and thick HDPE sheath. The design significance lies in that: the low grease can increase the frictional resistance between the steel strand and the sheath, form an integrated structure and play a bearing role. Compared with a grease-free thin sheath, the anti-corrosion effect is increased; on the other hand, the steel strand is used in the wind tower, is stressed longitudinally, adopts low grease, is not easy to slide, and can meet the design requirement of an external cable structure. (the friction resistance of the low oil is more than or equal to 3300N/m, and the friction resistance of the high oil is less than or equal to 60N/m).
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provides an unbonded prestressed steel strand for a wind tower with a low grease thickness sheath and a production method thereof.
One of the above objects of the present invention is achieved by the following technical solutions:
the utility model provides a thick sheath of low grease wind tower is with no bonding prestress wire, includes steel strand wires body, sheath and sets up the grease layer between steel strand wires body and sheath, its characterized in that: the sheath is tightly wrapped outside the steel strand body in a way that the outer contour of the steel strand body is visible and no recess exists between the steel wires of the steel strand body; the thickness of the sheath is as follows: 1.5-2.0mm, and the whole thickness is uniform and consistent; the oil amount of the grease layer is as follows: 15-40g/m.
The second purpose of the invention is realized by the following technical scheme:
a production method of an unbonded prestressed steel strand for a low-grease thick-sheath wind tower comprises the following steps: 1. paying off the steel strand body; 2. coating grease; 3. coating a sheath; 4. cooling; 5. traction; 6. taking up; 7. checking; 8. packaging; the coating grease adopts an oil storage tank and a coating die, the coating sheath adopts a feeder and a plastic extruding machine, the plastic extruding machine comprises a plastic extruding die and a driving motor, the plastic extruding die comprises a die core and a plastic extruding die sleeve, and a plastic extruding space is formed between the outer contour of the die core and the inner hole of the plastic extruding die sleeve; the method is characterized in that:
the difference between the oil outlet hole diameter of the coating die and the outer diameter of the steel strand body is 0-0.1mm, and the oiling pressure output to the coating die by the oil storage tank is 0.40MPa;
the coating sheath is prepared from the following raw materials in parts by mass (60-75) as a mixture, wherein the raw materials comprise a polyethylene resin raw material, a high-density polyethylene raw material for bridge cables and a color master batch: (34-19): 6;
putting the mixture into drying equipment for drying treatment, wherein the heating temperature for drying is 70 ℃, and the drying time is 1 hour;
a discharge port of the feeder is welded and connected with a lengthened section to form a buffer storage area;
the extrusion molding space is formed by connecting a conical annular space and a cylindrical annular space from a feeding end to a discharging end, and the cylindrical annular space forms an annular sizing belt playing a role in buffering materials;
the frequency of a driving motor of the extruding machine is set to be 50Hz, and the running speed of the steel strand in the extruding die is 28m/min.
And further: the cooling adopts the water cooling circulation mode, and the power of water pump is 3kW.
And further: the extrusion temperature in the extruder is from 180 to 260 ℃.
The invention has the advantages and positive effects that:
1. the invention realizes the low-grease coating by optimizing the size of the oil outlet of the coating die and matching the proper oil outlet pressure.
2. According to the invention, a brand-new sheath raw material is adopted, the sheath raw material is subjected to drying pretreatment, the extrusion molding die is optimally designed, the production speed and the extrusion molding speed are matched, and the discharge port of the feeder is optimally designed, so that the uniformity and the smoothness of the thickness of the sheath are ensured on the basis of reaching the set thick sheath.
In conclusion, the invention improves and designs a plurality of factors of two process links of coating grease and coating HDPE (high density polyethylene) sheaths, so that the produced unbonded prestressed steel strand meets the technical requirements of low grease and thick sheaths.
Drawings
FIG. 1 is a structural view of an extrusion mold used in the production method of the present invention;
fig. 2 is a modified structural view of a feeder used in the production method of the present invention.
Detailed Description
The structure of the present invention will be further described by way of examples with reference to the accompanying drawings. It is to be understood that this embodiment is illustrative and not restrictive.
An unbonded prestressed steel strand for a low-grease thick-sheath wind tower and a production method thereof are disclosed, please refer to fig. 1-2, and the invention points are as follows: the unbonded prestressed steel strand for the wind tower with the low-grease thick sheath is different from the common unbonded steel strand in appearance, grease amount and sheath thickness, and specifically comprises the following steps:
the common unbonded steel strand has the appearance characteristics that: the surface is smooth, no depression exists, no visible steel strand profile exists, no air holes exist, no mechanical damage exists, no cracks exist, and no obvious wrinkles exist; the oil content is as follows: the standard value is more than or equal to 50g/m; the thickness of the sheath: the standard value is more than or equal to 1.0mm. The unbonded prestressed steel strand has the appearance characteristics that: the HDPE jacket tightly wraps the smooth steel strand, so that the outline of the steel strand and the outline between steel wires do not have obvious depressions. The sheath has uniform appearance and smooth surface without obvious impurities; the grease amount is: 15-40g/m; the thickness of the sheath is: 1.5-2.0mm.
The technological process of the unbonded prestressed steel strand comprises the following steps:
1. paying off the steel strand body; 2. coating grease; 3. coating a sheath; 4. cooling; 5. traction; 6. taking up; 7. checking; 8. and (6) packaging. And packaging and then generally warehousing.
The process flow of the invention refers to the existing common unbonded steel strand process flow, but is innovatively designed from the following aspects, specifically comprising the following steps:
1. improvement of grease coating process
The oil coating amount of the common unbonded steel strand is more than or equal to 50g/m, and the main innovation and improvement for realizing the low-grease requirement of the invention is as follows:
1) Redesigning the oil exit hole size of a coating die
Compared with the steel strand with the same specification, the common coating die has the advantages that the oil outlet hole diameter of the die is large, the oil outlet amount is large, the oil outlet hole diameter of the coating die is redesigned, the hole diameter is designed to be almost the same as the diameter of the steel strand, specifically, the difference between the oil outlet hole diameter of the coating die and the outer diameter of the steel strand body is 0-0.1mm, and the oil outlet amount is reduced.
2) Redesigns the oil outlet pressure
The grease in the oil storage tank is conveyed into the grease coating cavity through certain pressure, and the grease is coated on the traveling steel strand under the operation of the production line speed. The steerable oil yield of degree of opening and shutting of adjustment fat liquoring control valve, for guaranteeing that the steel strand wires seam is full of grease and grease content satisfies low grease requirement, through debugging many times after, obtained the best technological parameter, promptly: the oiling pressure is determined to be 0.40MPa, and the opening degree of the valve is 8 degrees at the moment.
2. The selection and treatment of sheath materials are different from the prior ordinary unbonded steel stranded wire, and specifically comprise the following steps:
2.1 optimization of HDPE raw Material
The common unbonded steel stranded wire has no requirement on the raw material of Polyethylene (PE) resin selected by the conventional unbonded steel stranded wire, but has a requirement on the tensile property of a formed sheath, and steel stranded wire manufacturers are allowed to use reclaimed materials according to the industrial standard requirement, but the produced sheath must meet the tensile property index (the standard value of the tensile yield stress of the sheath is more than or equal to 15 MPa), while the unbonded steel stranded wire for the wind power outer cable is definitely specified, and the sheath material does not allow the reclaimed materials to be used.
1. The polyethylene raw material of the ordinary unbonded steel strand is used, no reclaimed material is added, production trial production is carried out, and after trial production, the surface quality of the steel strand sheath is found to be rough and is orange peel surface, so that the requirement of the surface quality of the unbonded steel strand sheath for external cables cannot be met.
2. Through the study of the mark, high density polyethylene sheath material for bridge cable has been chooseed for use again, through the trial-manufacture, the sheath surface of this raw materials production is smooth, it is careful, can satisfy the requirement of external cable with unbonded steel strand wires sheath surface quality, but the fuse-element velocity of flow value of this kind of raw materials is little, the mobility is poor, in process of production, only can rely on the reduction speed of a motor vehicle to match, otherwise, the sheath thickness can't satisfy the requirement, production efficiency is very low, and the price of this raw materials is about 2000 yuan higher than the raw materials price per ton of ordinary unbonded steel strand wires, the research and development cost that causes the new product is very high, also do not benefit to the popularization and application of new product. The ratio of the properties of the two raw materials is shown in table 1.
Table one: comparison of two Material Properties
On the basis of trial production, the raw materials are optimized, the two raw materials are innovatively mixed, a large number of proportioning tests are carried out, and the optimal proportion scheme of the ingredients is determined by verifying the surface quality and the performance of the product, namely, the raw materials are as follows: the high-density polyethylene raw material for the bridge cable comprises the following components: color masterbatch (different colors after addition) = (60-75): (34-19):6.
2.2 improvement of Process and tooling
The thickness of the sheath is found to be uneven in the trial-manufacturing process, the thinnest part is 0.8mm, the thickest part can reach 2.1mm, a large number of production trial-manufacturing processes are carried out in the early period, the bottleneck of uneven thickness of the sheath cannot be broken through, therefore, the influence factors of all links are searched, and the following processes and equipment are improved:
(1) Increases the drying process of the HDPE raw material
The common unbonded steel stranded wire is produced, and the raw materials do not need to be dried before use. However, when the steel strand for the external cable of the wind power generation device is trial-produced, because the mixed raw materials are used, the flow rate of a melt is lower than that of a polyethylene raw material used by a common unbonded steel strand, and because moisture exists in polyethylene raw material particles, particularly the moisture is more obvious in summer, the wet raw material is easy to adhere, and the flow rate is low, the phenomenon that the thickness of a sheath is uneven can be caused in the heating extrusion molding process.
In order to solve the problems, drying equipment is purchased, a dryer adopts bottom feeding, the interior of the dryer is driven by a worm gear, raw materials are sucked into a drying funnel, a motor is used for conveying hot air to dry the raw materials, a stirrer is arranged in the funnel to stir the raw materials, the drying process comprises the steps of heating at 70 ℃, drying for 1 hour, drying the raw materials, discharging the dried raw materials into a raw material storage box from two discharge ports, using the dried raw materials, matching with other improved schemes, and obtaining a better effect through trial production.
(2) The design improvement is carried out on the extrusion molding die
The mould of the PE plastic extruding machine matched with the original production line is suitable for producing products with the sheath thickness of 1.0mm, and the thickness of the plastic extruding can not meet the thickness requirement of more than 1.5 mm. Aiming at the thickness of the sheath with the thickness of more than 1.5mm, when the sheath is designed initially, a die hole is only enlarged, namely, a gap between an original mold core and an extrusion molding die sleeve is enlarged, but in the trial production process, the thickness of the sheath is still uneven, the thickness of the sheath is thick, the improvement such as alignment, leveling and the like is carried out, the effect is not obvious, reason analysis is carried out, and after the mixed raw materials are used, the flow rate of a melt is lower than that of common raw materials, the fluidity is relatively slow, the production speed is not matched with the extrusion molding speed slightly, the raw materials are accumulated, and the phenomenon of uneven thickness occurs.
In order to solve the bottleneck problem, the invention innovatively designs the die core 1 and the extrusion molding die sleeve 2 at the wire outlet end, and adds a section of annular bearing belt 3, namely the die core adopts an outer cylinder at the wire outlet end, the extrusion molding die sleeve adopts an inner cylinder hole structure at the wire outlet end, the aperture of the outer cylinder is smaller than that of the inner cylinder hole, an annular bearing belt is formed between the outer cylinder and the inner cylinder hole, the unilateral clearance of the annular bearing belt is 3-4mm, and the length of the annular bearing belt is 10-13mm. The annular bearing can play the role of temporarily storing raw materials, the raw materials can be uniformly extruded under the speed effects of a production line and an extruding machine, an improved extruding mould is shown in figure 1, and the improvement is matched with other improvement schemes to obtain a better effect.
(3) The feeder is improved
The existing feeder is adopted for feeding, the problem that the thickness of a sheath is uneven in the trial production process exists, one of analysis reasons is that the feeder directly feeds raw materials into the extruding machine, and the PE material is uneven in thickness during extrusion due to slow material mixing fluidity and accumulation of the raw materials in the extruding machine. Aiming at the problem of uneven thickness of the sheath, the feeder is innovatively improved, a lengthening section 5 is welded and connected to a discharge port (corresponding to an original feed port of the plastic extruding machine) of the feeder 4 to form a buffering storage area, please refer to fig. 2, the effect of buffering materials is achieved, the raw materials are prevented from being injected into the plastic extruding machine to be heated in a centralized mode, the raw materials can be stored in the storage area temporarily, and therefore the raw materials can enter the plastic extruding machine uniformly.
(4) Implements improvement on process parameters
The thickness of the sheath can be influenced by process parameters, such as production speed, extrusion temperature and extrusion speed, the extrusion temperature mainly influences the final tensile property of the sheath, on the basis of accumulating the traditional process, the influence of the extrusion temperature on the nonuniformity of the sheath thickness is not large, in the product trial production process, the production speed and the extrusion speed are mainly matched, the motor frequency of an extruder is set to be 50Hz (full-load extrusion), at the moment, the vehicle speed is adjusted according to the required sheath thickness, and the optimal sheath thickness can be obtained when the vehicle speed (the travelling speed of the steel strand in an extrusion mould) is 28m/min through a plurality of process trial production.
(5) A high-power water pump is selected, so that the cooling effect is improved
If the cooling effect is not good after the sheath cladding, also cause the sheath thickness uneven thickness easily, for this reason, changed high-power water pump, the power of water pump is 3kW, ensures the cooling effect.
In conclusion, the best process parameters are obtained after the innovation and the improvement:
the production speed is 28m/min, the motor frequency is 50Hz, the extrusion molding temperature is 180-260 ℃, and the oiling pressure is 0.4MPa; the grease amount is obviously reduced under the control of speed and pressure; the grease is continuously coated and sufficient along the whole length of the steel strand, and the grease completely fills the gap between the steel wire and the PE layer. The obtained sheath has uniform thickness, 1.5mm in multi-angle measurement, and fine, bright, uniform and compact surface.
Through the design of the scheme and the process trial production of the product, the developed unbonded prestressed steel strand for the wind tower with the low-grease and thick HDPE sheath realizes the requirements of high thickness and low grease content, the surface quality can meet the customer requirements, the product is subjected to a plurality of tests such as a sheath tensile test, water tightness, frictional resistance, impact resistance and the like, and the test results all meet the technical requirements of the steel strand for the external cable of the wind power plant.
Although the embodiments of the present invention and the accompanying drawings are disclosed for illustrative purposes, those skilled in the art will appreciate that: various substitutions, changes and modifications are possible without departing from the spirit of the invention and the scope of the appended claims, and therefore the scope of the invention is not limited to the disclosure of the embodiments and the accompanying drawings.
Claims (4)
1. The utility model provides a thick sheath of low grease wind tower is with no bonding prestress wire, includes steel strand wires body, sheath and sets up the grease layer between steel strand wires body and sheath, its characterized in that: the sheath is tightly wrapped outside the steel strand body in a way that the outer contour of the steel strand body is visible and no recess exists between the steel wires of the steel strand body; the thickness of the sheath is as follows: 1.5-2.0mm, and the whole thickness is uniform and consistent; the oil quantity of the grease layer is as follows: 15-40g/m.
2. A method for producing unbonded prestressed steel strands for a wind tower based on the low-grease thick sheath in claim 1 comprises the following steps: 1. paying off the steel strand body; 2. coating grease; 3. coating a sheath; 4. cooling; 5. traction; 6. taking up; 7. checking; 8. packaging; the coating oil adopts an oil storage tank and a coating die, the coating sheath adopts a feeding machine and a plastic extruding machine, the plastic extruding machine comprises a plastic extruding die and a driving motor, the plastic extruding die comprises a die core and a plastic extruding die sleeve, and a plastic extruding space is formed between the outer contour of the die core and the inner hole of the plastic extruding die sleeve; the method is characterized in that:
the difference between the oil outlet hole diameter of the coating die and the outer diameter of the steel strand body is 0-0.1mm, and the oiling pressure output to the coating die by the oil storage tank is 0.40MPa;
the coating sheath is prepared from the following raw materials in parts by mass (60-75) as a mixture, wherein the raw materials comprise a polyethylene resin raw material, a high-density polyethylene raw material for bridge cables and a color master batch: (34-19) 6;
putting the mixture into a drying device for drying treatment, wherein the heating temperature for drying is 70 ℃, and the drying time is 1 hour;
a discharge port of the feeder is welded and connected with a lengthening section to form a buffer storage area;
the extrusion molding space is formed by connecting a conical annular space and a cylindrical annular space from a feeding end to a discharging end, and the cylindrical annular space forms an annular sizing belt playing a role in buffering materials;
the frequency of a driving motor of the extruding machine is set to be 50Hz, and the running speed of the steel strand in the extruding die is 28m/min.
3. The method for producing unbonded prestressed steel strands for the wind tower with the thick low-grease sheath according to claim 2, wherein the method comprises the following steps: the cooling adopts the circulating water cooling mode, and the power of water pump is 3kW.
4. The method for producing unbonded prestressed steel strands for low-grease thick-jacket wind towers according to claim 2, wherein the method comprises the following steps: the extrusion temperature in the extruder is from 180 to 260 ℃.
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| Application Number | Priority Date | Filing Date | Title |
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| CN202211719547.8A CN115679727B (en) | 2022-12-30 | 2022-12-30 | Unbonded prestressed steel strand for low-grease thick-sheath wind tower and production method thereof |
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| CN202211719547.8A CN115679727B (en) | 2022-12-30 | 2022-12-30 | Unbonded prestressed steel strand for low-grease thick-sheath wind tower and production method thereof |
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| CN115679727A true CN115679727A (en) | 2023-02-03 |
| CN115679727B CN115679727B (en) | 2023-04-04 |
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| CN105925878A (en) * | 2016-04-28 | 2016-09-07 | 交通运输部公路科学研究所 | Stainless steel wire cold casting anchor cable for bridge and inhaul cable used for stainless steel wire cold casting anchor cable for bridge |
| CN109853270A (en) * | 2017-11-30 | 2019-06-07 | 涂巨丹 | A kind of preparation process of 12 strand cable |
| CN109853274A (en) * | 2018-12-26 | 2019-06-07 | 天津冶金钢线钢缆集团有限公司 | HDPE hot dip allumen prestress wire production technology |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JPH08209567A (en) * | 1994-11-29 | 1996-08-13 | Sumitomo Electric Ind Ltd | Metal cord, its production and composite material of the cord with rubber |
| CN2299886Y (en) * | 1997-08-29 | 1998-12-09 | 北京市建筑工程研究院 | Core oiled adhesiveless prestressed steel strand |
| CN201128974Y (en) * | 2007-11-13 | 2008-10-08 | 天津市鑫坤泰银桥预应力商贸有限公司 | Non-bonded prestressed wire |
| JP3166917U (en) * | 2010-11-24 | 2011-03-31 | 東京製綱株式会社 | Resin powder coated metal rope |
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