CN117410006A - Aluminum alloy rod for cable, aluminum alloy flexible cable for offshore wind power generation and production process of aluminum alloy flexible cable - Google Patents

Aluminum alloy rod for cable, aluminum alloy flexible cable for offshore wind power generation and production process of aluminum alloy flexible cable Download PDF

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Publication number
CN117410006A
CN117410006A CN202310840642.1A CN202310840642A CN117410006A CN 117410006 A CN117410006 A CN 117410006A CN 202310840642 A CN202310840642 A CN 202310840642A CN 117410006 A CN117410006 A CN 117410006A
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China
Prior art keywords
aluminum alloy
cable
core
strand
power generation
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CN202310840642.1A
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Chinese (zh)
Inventor
张群
李佩柏
肖成龙
袁朝彦
臧德峰
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Tbea Shandong Luneng Taishan Cable Co ltd
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Tbea Shandong Luneng Taishan Cable Co ltd
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Priority to CN202310840642.1A priority Critical patent/CN117410006A/en
Publication of CN117410006A publication Critical patent/CN117410006A/en
Pending legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
    • H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
    • H01B1/023—Alloys based on aluminium
    • 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
    • H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
    • H01B5/02—Single bars, rods, wires, or strips
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/0009—Details relating to the conductive cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/22—Metal wires or tapes, e.g. made of steel
    • H01B7/221—Longitudinally placed metal wires or tapes
    • H01B7/223—Longitudinally placed metal wires or tapes forming part of a high tensile strength core
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/2806—Protection against damage caused by corrosion

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

Abstract

The invention discloses an aluminum alloy rod for a cable, an aluminum alloy flexible cable for offshore wind power generation and a production process thereof, and the aluminum alloy rod is characterized by comprising the following alloy components in parts by weight: 0.03-0.1 part of Si, 0.30-0.8 part of Fe, 0.01-0.05 part of Mg, 0.15-0.3 part of Cu, 0.01-0.04 part of B, 0.006-0.03 part of Ni, less than 0.03 part of single impurity, less than 0.1 part of total impurity and the balance of Al, wherein the impurities are substances except Si, fe, mg, cu, B, ni, al. The cable greatly improves the tensile strength, creep resistance, corrosion resistance and torsion resistance of the cable, has the characteristics of cracking resistance and mold resistance, and meets the laying requirements of the cable in the special use environment of offshore power generation.

Description

Aluminum alloy rod for cable, aluminum alloy flexible cable for offshore wind power generation and production process of aluminum alloy flexible cable
Technical Field
The invention belongs to the technical field of cables, and particularly relates to an aluminum alloy rod for a cable, an aluminum alloy flexible cable for offshore wind power generation and a production process thereof.
Background
According to statistics of wind energy professional Committee (CWEA) of China renewable energy society, in 2021, the newly installed capacity of offshore wind power in China reaches 1448.2 kilowatts, and is increased by 27 in a same ratio
6.7 percent, newly increased installed capacity and accumulated installed capacity are the first two-digit living world.
Because the copper conductor has good conductivity and mechanical property, the current torsion-resistant cable for the offshore wind turbine still takes the copper cable as the main part, but along with the increase of cost pressure, part of wind turbine manufacturers already start to try to replace part of fixedly laid copper cable with an aluminum alloy cable with lighter weight and lower cost, and the part of aluminum alloy cable does not need torsion resistance, so the second class of aluminum alloy conductors are adopted, but the second class of aluminum alloy conductors are required to be connected with the copper cable at the upper end of the wind turbine tower through a copper-aluminum transition terminal in the use process, and a certain risk exists in long-term operation. The existing aluminum alloy conductor has the defects of poor tensile strength, poor creep resistance, poor electrical property and the like compared with a copper conductor, so that the existing aluminum alloy conductor cannot be directly added into a torsion-resistant cable for use.
Meanwhile, due to the harsher use environment at sea, after the cable is used for a period of time, the cable is easier to crack, mold and the like in comparison with the cable on land, the conductor is also extremely easy to oxidize and corrode, objective factors are included, and the maintenance cost of the cable of the offshore wind turbine is extremely high.
Disclosure of Invention
The invention aims to solve the technical problems in the prior art, and provides an aluminum alloy rod for a cable, an aluminum alloy flexible cable for offshore wind power generation and a production process thereof, which greatly improve the tensile strength, creep resistance, corrosion resistance and torsion resistance of the cable, have the characteristics of cracking resistance and mould resistance, and meet the laying requirements of the cable under the special use environment of offshore power generation.
The technical scheme adopted for solving the technical problem of the invention is to provide an aluminum alloy rod for cables, which comprises the following alloy components in parts by weight: 0.03-0.1 part of Si, 0.30-0.8 part of Fe, 0.01-0.05 part of Mg, 0.15-0.3 part of Cu, 0.01-0.04 part of B, 0.006-0.03 part of Ni, less than 0.03 part of single impurity, less than 0.1 part of total impurity and the balance of Al, wherein the impurities are substances except Si, fe, mg, cu, B, ni, al.
The invention also provides an aluminum alloy flexible cable for offshore wind power generation, which comprises a cable core, an isolation layer, an insulation layer and a sheath layer which are sequentially arranged from inside to outside, wherein the cable core is made of the aluminum alloy rod.
Preferably, the cable core comprises at least two strand cores, the cable core is formed by twisting strand cores, the strand cores comprise at least two aluminum alloy monofilaments, the strand cores are formed by twisting aluminum alloy monofilaments, and the aluminum alloy monofilaments are made of aluminum alloy rods.
Preferably, the aluminum alloy monofilament has a diameter of 0.45 to 0.55mm.
Preferably, the aluminum alloy monofilaments are stranded in the same direction in the left direction, and the strand cores are stranded in the same direction in the left direction.
Preferably, the outer diameter of the cable core is 28.6-29.4 mm.
Preferably, the cable core comprises: the core is arranged at the center, and at least two cores are sequentially arranged outside the center core. The central strand core is circular.
Preferably, the strand cores include a first strand core, a second strand core, a third strand core, a fourth strand core, and the cable core includes: the novel plastic composite material comprises a first strand core arranged in the center, six second strand cores arranged on the periphery of the first strand core, twelve third strand cores arranged on the periphery of the second strand core, and eighteen fourth strand cores arranged on the periphery of the third strand core. The cable core is circular.
Preferably, the isolating layer is non-woven fabric or high-temperature resistant polyester tape;
the insulating layer is ethylene propylene rubber;
the sheath layer is any one of chlorinated polyethylene sheath rubber, chloroprene rubber and ethylene-vinyl acetate copolymer rubber.
The invention also provides a production process of the aluminum alloy flexible cable for offshore wind power generation, which comprises the following steps of:
1) Processing the aluminum alloy rod into a cable core;
2) An isolation layer is arranged outside the cable core;
3) And extruding the insulating layer and the sheath layer through a sulfur connecting machine by adopting a double-layer co-extrusion process to manufacture the cable.
Preferably, the extrusion temperature of the extrusion process in the step 3) is 75-90 ℃, the vulcanization temperature is 150-210 ℃, the vulcanization pressure is 0.9-1.2 MPa, the production speed is 6-10 m/min, the tube sealing pressure is 0.8-1.1 MPa, and the tube sealing time is 8-12 min.
According to the aluminum alloy rod for the cable, a special material formula is adopted, and the proportion of each element in the aluminum alloy is regulated, particularly the proportion of Ni and Fe elements is regulated, so that an Al-Ni-Fe intermetallic compound is formed in the aluminum alloy rod, and the corrosion resistance of the aluminum alloy rod is greatly improved; by adjusting the proportion of Fe and Mg, the conductivity, the tensile strength and the creep resistance are improved. The invention comprehensively considers the influence of each element on the performance of the aluminum alloy rod, the tensile strength of the developed novel formula cable core can reach 110-150Mpa, the tensile strength of aluminum alloy monofilaments can reach 100-130Mpa, the elongation at break is not less than 20%, and the resistivity is 0.028Ω·mm before 2 The/m is reduced to 0.026Ω.mm 2 /m。
Drawings
Fig. 1 is a schematic structural view of an aluminum alloy flexible cable for upper wind power generation in embodiment 2 of the present invention;
fig. 2 is a schematic structural view of a cable core in embodiment 2 of the present invention.
In the figure: 1. a cable core; 2. an isolation layer; 3. an insulating layer; 4. a sheath layer; 5-strand core.
Detailed Description
The present invention will be described in further detail below with reference to the drawings and detailed description for the purpose of better understanding of the technical solution of the present invention to those skilled in the art.
Embodiments of the present patent are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below by referring to the drawings are exemplary only for explaining the present patent and are not to be construed as limiting the present patent.
In the description of this patent, it should be understood that the terms "center," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like indicate orientations or positional relationships based on the orientation or positional relationships shown in the drawings, merely to facilitate describing the patent and simplify the description, and do not indicate or imply that the devices or elements being referred to must have a particular orientation, be configured and operated in a particular orientation, and are therefore not to be construed as limiting the patent.
In the description of this patent, it should be noted that, unless explicitly stated and limited otherwise, the terms "mounted," "connected," and "disposed" are to be construed broadly, and may be fixedly connected, disposed, detachably connected, disposed, or integrally connected, disposed, for example. The specific meaning of the terms in this patent will be understood by those of ordinary skill in the art as the case may be.
Since the electrical conductivity of aluminum alloys is generally about 61.8% IACS, i.e., 400mm 2 Aluminum alloy conductor resistance with section of 240mm 2 The copper conductor of the comparative example was selected to be 2 because the copper conductor of the cross section was equivalent40mm 2 A cross section.
Example 1
The embodiment provides an aluminum alloy rod for cables, which comprises the following alloy components in parts by weight: 0.03-0.1 part of Si, 0.30-0.8 part of Fe, 0.01-0.05 part of Mg, 0.15-0.3 part of Cu, 0.01-0.04 part of B, 0.006-0.03 part of Ni, less than 0.03 part of single impurity, less than 0.1 part of total impurity and the balance of Al, wherein the impurities are substances except Si, fe, mg, cu, B, ni, al.
The embodiment also provides an aluminum alloy flexible cable for offshore wind power generation, which comprises a cable core, an isolation layer, an insulation layer and a sheath layer which are sequentially arranged from inside to outside, wherein the cable core is made of the aluminum alloy rod.
The embodiment also provides a production process of the aluminum alloy flexible cable for offshore wind power generation, which comprises the following steps of:
1) Processing the aluminum alloy rod into a cable core;
2) An isolation layer is arranged outside the cable core;
3) And extruding the insulating layer and the sheath layer through a sulfur connecting machine by adopting a double-layer co-extrusion process to manufacture the cable.
The aluminum alloy rod for the cable in the embodiment adopts a special material formula, and the corrosion resistance of the aluminum alloy rod is greatly improved by adjusting the proportion of each element in the aluminum alloy, particularly the proportion of Ni and Fe, and forming an Al-Ni-Fe intermetallic compound in the aluminum alloy rod; by adjusting the proportion of Fe and Mg, the conductivity, the tensile strength and the creep resistance are improved. In the embodiment, the influence of each element on the performance of the aluminum alloy rod is comprehensively considered, the tensile strength of the developed novel formula cable core can reach 110-150Mpa, the tensile strength of aluminum alloy monofilaments can reach 100-130Mpa, the elongation at break can reach more than 20%, and the resistivity is 0.028Ω.mm in the past 2 The/m is reduced to 0.026Ω.mm 2 /m。
Example 2
The embodiment provides an aluminum alloy rod for cables, which comprises the following alloy components in parts by weight: the alloy comprises 0.05 part of Si, 0.50 part of Fe, 0.03 part of Mg, 0.20 part of Cu, 0.01 part of B, 0.01 part of Ni, less than 0.03 part of single impurity, less than 0.1 part of total impurity and the balance of Al, wherein the impurities are substances except Si, fe, mg, cu, B, ni, al.
Specifically, the impurity in this embodiment is Fe 2 O 3 、SiO 2 、CaSi 2 。
Specifically, the components of the aluminum alloy rod for the cable in the embodiment include the following components: si, fe, mg, cu, B, ni, zn, the balance being aluminum and other impurities.
As shown in fig. 1, this embodiment also provides an aluminum alloy flexible cable for offshore wind power generation, which includes a cable core 1, an isolation layer 2, an insulation layer 3, and a sheath layer 4 sequentially disposed from inside to outside, where the cable core 1 is made of the aluminum alloy rod.
Preferably, the cable core 1 comprises at least two strand cores 5, the cable core 1 is formed by twisting the strand cores 5, the strand cores 5 comprise at least two aluminum alloy monofilaments, the strand cores 5 are formed by twisting aluminum alloy monofilaments, and the aluminum alloy monofilaments are made of aluminum alloy rods.
Specifically, the strand core 5 in this embodiment is a flexible strand core 5 formed by twisting a plurality of aluminum alloy monofilaments, and the cable core 1 is a flexible cable core 1 formed by twisting a plurality of strand cores 5.
Preferably, the aluminum alloy monofilament has a diameter of 0.45mm.
Preferably, the aluminum alloy monofilaments are twisted in the same direction in the left direction, and the twisted direction of the strand core 5 is twisted in the same direction in the left direction.
Preferably, the outer diameter of the cable core 1 is 29.4mm.
Preferably, the cable core 1 comprises: the core 5 is arranged at the center, and at least two cores 5 are sequentially arranged outside the center core 5. The central strand core 5 is circular.
As shown in fig. 2, it is preferable that the strand core 5 includes a first strand core, a second strand core, a third strand core, a fourth strand core, and the cable core 1 includes: the novel plastic composite material comprises a first strand core arranged in the center, six second strand cores arranged on the periphery of the first strand core, twelve third strand cores arranged on the periphery of the second strand core, and eighteen fourth strand cores arranged on the periphery of the third strand core. The cable core 1 is circular.
Specifically, the strand core 5 in this embodiment is twisted sequentially by adopting a 1+6+12+18 multi-twisting rule to form a circular structure.
The twisted structure of the cable core 1 was ((1+6+12+18). Times.54)/0.5 mm.
Preferably, the isolation layer 2 is a non-woven fabric or a high-temperature resistant polyester tape; specifically, the nonwoven fabric in this embodiment is a high-temperature-resistant composite nonwoven fabric.
The insulating layer 3 is ethylene propylene rubber;
the sheath layer 4 is any one of Chlorinated Polyethylene (CPE) sheath rubber, chloroprene rubber and ethylene-vinyl acetate copolymer rubber.
Specifically, the isolation layer 2 in this embodiment is a high-temperature-resistant reinforced composite non-woven fabric;
the sheath layer 4 in this embodiment is a crack-resistant and mold-resistant CPE sheath glue layer.
Specifically, the cable core 1 in the embodiment is a homodromous stranded aluminum alloy conductor, so that the flexibility of the cable is greatly improved. The sheath layer 4 is a cracking-resistant and mildew-resistant CPE sheath, and has excellent flame retardance, weather resistance, salt fog resistance, mildew resistance and cracking resistance. And set up isolation layer 2 between cable core 1 and insulating layer 3, play the effect of preventing gum dipping and cable core 1 broken wire to satisfy the laying requirement of its marine special service environment tower section of thick bamboo torsion. Example Cable selection model specification is FDLHEH-40 0.6/1 1X 400.
The isolation layer 2 is high temperature resistant reinforced non-woven fabric with the thickness of 0.1mm, and has the functions of homogenizing an electric field, preventing the wire breakage of the cable core 1 and reducing the electric loss.
The insulating layer 3 is ethylene propylene rubber EPR insulation, can meet the use requirements of a wind power plant in a low-temperature environment of 40 ℃ below zero and a conductor in a highest working temperature of 90 ℃, and has excellent electrical performance, ozone resistance and weather aging resistance.
The sheath layer 4 is a cracking-resistant and mould-resistant CPE sheath, so that the sheath layer 4 has higher mechanical strength and simultaneously has the characteristics of flame retardance, weather resistance, salt mist resistance, mould resistance, cracking resistance and the like.
The embodiment also provides a production process of the aluminum alloy flexible cable for offshore wind power generation, which comprises the following steps of:
1) Manufacturing a cable core 1: an aluminum alloy rod is adopted to manufacture aluminum alloy monofilaments, a plurality of aluminum alloy monofilaments are adopted to twist in the same direction to form a round strand core 5, and a plurality of round strand cores 5 are adopted to twist in the same direction to form a round cable core 1;
2) An isolating layer 2 is arranged outside the cable core 1: wrapping a layer of high-temperature-resistant composite non-woven fabric outside the cable core 1 to prepare an isolation layer 2, wherein the wrapping coverage rate reaches 20%;
3) And extruding the insulating layer 3 and the sheath layer 4 through inlet sulfur connecting equipment by adopting a double-layer co-extrusion process to manufacture the cable.
Preferably, the extrusion temperature of the extrusion process in the step 3) is 85 ℃, the vulcanization temperature is 180 ℃, the vulcanization pressure is 1.0MPa, the production speed is 9m/min, the tube-sealing pressure is 0.8MPa, and the tube-sealing time is 10min.
Specifically, the aluminum alloy monofilament in the embodiment has good mechanical properties while ensuring good electrical properties, and the insulating layer 3 is an ethylene propylene rubber insulating layer 3; the sheath layer 4 is a cracking-resistant and mildew-resistant CPE sheath adhesive layer; therefore, the cable is ensured to have excellent electrical performance, torsion resistance and corrosion resistance, replaces the traditional torsion-resistant copper cable, meets the severe torsion requirement of the offshore wind turbine on the cable, and simultaneously can minimize the cost.
By adopting the technical scheme, the embodiment has the following beneficial effects:
(1) The aluminum alloy rod for the cable in the embodiment adopts a special material formula, and the corrosion resistance of the aluminum alloy rod is greatly improved by adjusting the proportion of each element in the aluminum alloy, particularly the proportion of Ni and Fe, and forming an Al-Ni-Fe intermetallic compound in the aluminum alloy rod; by adjusting the proportion of Fe and Mg, the conductivity, the tensile strength and the creep resistance are improved. In the embodiment, the influence of each element on the performance of the aluminum alloy rod is comprehensively considered, the tensile strength of the developed novel formula cable core 1 can reach 110-150Mpa, the tensile strength of aluminum alloy monofilaments can reach 100-130Mpa, the elongation at break can reach not less than 20%, and the resistivity of the novel formula cable core is 0.028Ω & mm in the past 2 Reduced to/m0.026Ω·mm 2 /m。
(2) The torsion-resistant cable made of the aluminum alloy monofilament with the special formula is adopted, the weight of the torsion-resistant cable is reduced by about 40% compared with that of a copper cable according to the same current carrying capacity, the cost is reduced by more than 50%, and the torsion-resistant, corrosion-resistant, salt spray-resistant, corrosion-resistant, cold-resistant, mold-resistant and other performances are achieved, so that the severe running environment of the offshore wind turbine is met, the manufacturing cost of the offshore wind turbine is effectively reduced, and the torsion-resistant cable has higher use value and application prospect.
(3) The aluminum alloy cable core 1 of the cable in the embodiment is formed by twisting a round twisted core 5 in the center and a round twisted core 5 surrounding the round twisted core 5 in the same direction, compared with the traditional twisting mode, the structure of the cable in the embodiment is softer, the torsion resistance is improved, the outer diameter is smaller, the space is saved, and the installation and the laying are convenient.
(4) The cable aluminum alloy cable core 1 in the embodiment adopts a normal 1+6+12+18 stranded structure, and ensures the stability of the operation of the cable while meeting the requirements of flexibility and tensile strength.
(5) The isolating layer 2 of the cable in the embodiment is high-temperature-resistant reinforced non-woven fabric, and the conductor is tightly tied and the glue stock is prevented from penetrating into the conductor; meanwhile, the wire breakage caused by interaction of the aluminum alloy conductor monofilaments in the twisting process can be effectively prevented.
(6) The aluminum alloy monofilament in the embodiment has the diameter of 0.45mm, belongs to five types of aluminum alloy soft conductors, has good bending performance, and can be well matched with the torsion performance of the cable.
(7) The insulating layer 3 in the embodiment is insulated by ethylene propylene rubber EPR, can meet the use requirements of a low-temperature environment of a wind power plant at-40 ℃ and a maximum working temperature of a conductor at 90 ℃, and has good electrical performance.
(8) The sheath layer 4 in the embodiment adopts a cracking-resistant and mildew-resistant CPE sheath, has the characteristics of flame retardance, weather resistance, salt fog resistance, mildew resistance, cracking resistance and the like, and can meet the use requirements of the offshore generator set.
(9) In the cable production process in this embodiment, the insulating layer 3 and the sheath layer 4 adopt an inlet continuous sulfur machine device, and a double-layer co-extrusion process, compared with the traditional single-layer separate extrusion process of the insulating layer 3 and the sheath layer 4, the process can remarkably improve the production efficiency of the product, improve the purity of the insulating layer 3, enable the product to have excellent electrical properties, and simultaneously adopt an annealing process for the conductor, thereby further optimizing the mechanical properties of the conductor and enabling the conductor to have better flexibility.
The beneficial effects of this embodiment lie in:
(1) The cable sheath has excellent mechanical properties, the tensile strength is more than or equal to 10MPa, and the elongation at break is more than or equal to 400%.
(2) The cable insulating layer has excellent high-temperature aging resistance, and the tensile strength change rate and the elongation at break change rate are both within +/-15% after being subjected to hot air aging treatment for 7 days at 135 ℃.
(3) The cable has excellent salt fog resistance, corrosion resistance and mould resistance.
(4) The cable has excellent torsion resistance, is resistant to 10000 times of torsion at normal temperature and 2000 times of torsion at the low temperature of minus 40 ℃.
(5) The aluminum alloy flexible cable for offshore wind power generation has the advantages of simple operation method, low cost, universality and easiness in large-scale production.
Example 3
This example provides an aluminum alloy rod for cables, which differs from the aluminum alloy rod for cables in example 2 in that: the alloy comprises the following components in parts by weight: the alloy comprises 0.03 part of Si, 0.80 part of Fe, 0.01 part of Mg, 0.3 part of Cu, 0.02 part of B, 0.03 part of Ni, less than 0.03 part of single impurity, less than 0.1 part of total impurity and the balance of Al, wherein the impurities are substances except Si, fe, mg, cu, B, ni, al.
The present embodiment also provides an aluminum alloy flexible cable for offshore wind power generation, which is different from the cable in embodiment 2 in that:
in this example, the diameter of the aluminum alloy monofilament was 0.50mm.
In this embodiment, the outer diameter of the cable core is 29.0mm.
In the embodiment, the isolation layer is a non-woven fabric, and the non-woven fabric is a high-temperature-resistant impermeable non-woven fabric;
the insulating layer is ethylene propylene rubber;
the sheath layer is neoprene.
The present embodiment also provides a production process of the aluminum alloy flexible cable for offshore wind power generation, which is different from the production process of the cable in embodiment 2 in that:
the extrusion temperature of the extrusion process in the step 3) is 90 ℃, the vulcanization temperature is 210 ℃, the vulcanization pressure is 0.9MPa, the production speed is 6m/min, the tube sealing pressure is 1.1MPa, and the tube sealing time is 8min.
By adopting the technical scheme, the embodiment has the following beneficial effects:
(1) The aluminum alloy rod for the cable in the embodiment adopts a special material formula, and the corrosion resistance of the aluminum alloy rod is greatly improved by adjusting the proportion of each element in the aluminum alloy, particularly the proportion of Ni and Fe, and forming an Al-Ni-Fe intermetallic compound in the aluminum alloy rod; by adjusting the proportion of Fe and Mg, the conductivity, the tensile strength and the creep resistance are improved. In the embodiment, the influence of each element on the performance of the aluminum alloy rod is comprehensively considered, the tensile strength of the developed novel formula cable core can reach 110-150Mpa, the tensile strength of aluminum alloy monofilaments can reach 100-130Mpa, the elongation at break can reach not less than 20%, and the resistivity of the novel formula cable core is 0.028Ω & mm in the past 2 The/m is reduced to 0.026Ω.mm 2 /m。
(2) The torsion-resistant cable made of the aluminum alloy monofilament with the special formula is adopted, the weight of the torsion-resistant cable is reduced by about 40% compared with that of a copper cable according to the same current carrying capacity, the cost is reduced by more than 50%, and the torsion-resistant, corrosion-resistant, salt spray-resistant, corrosion-resistant, cold-resistant, mold-resistant and other performances are achieved, so that the severe running environment of the offshore wind turbine is met, the manufacturing cost of the offshore wind turbine is effectively reduced, and the torsion-resistant cable has higher use value and application prospect.
(3) The aluminum alloy cable core of the cable in this embodiment is formed by equidirectional transposition of the circular stranded core in the center and the circular stranded core that encircles circular stranded core, compares with traditional transposition mode, and the structure of cable in this embodiment is softer, and the resistant performance of turning round improves, and the external diameter is littleer, saves space, is convenient for install and lay.
(4) The cable aluminum alloy cable core in the embodiment adopts a normal 1+6+12+18 stranded structure, and ensures the running stability of the cable while meeting the requirements of flexibility and tensile strength.
(5) The isolating layer of the cable in the embodiment is high-temperature-resistant reinforced non-woven fabric, so that the conductor is tightly tied and the glue stock is prevented from penetrating into the conductor; meanwhile, the wire breakage caused by interaction of the aluminum alloy conductor monofilaments in the twisting process can be effectively prevented.
(6) The aluminum alloy monofilament in the embodiment has the diameter of 0.45mm, belongs to five types of aluminum alloy soft conductors, has good bending performance, and can be well matched with the torsion performance of the cable.
(7) The insulating layer in the embodiment is insulated by ethylene propylene rubber EPR, can meet the use requirements of a wind power plant in a low-temperature environment of 40 ℃ below zero and a conductor in a highest working temperature of 90 ℃ at the same time, and has good electrical performance.
(8) The sheath layer in the embodiment adopts the anti-cracking and anti-mildew CPE sheath, has the characteristics of flame retardance, weather resistance, salt fog resistance, mildew resistance, cracking resistance and the like, and can meet the use requirements of the offshore generator set.
(9) In the cable production process, the insulating layer and the sheath layer adopt an inlet continuous sulfur machine device and a double-layer co-extrusion process, and compared with the traditional single-layer extrusion process of the insulating layer and the sheath layer, the process can remarkably improve the production efficiency of products, improve the purity of the insulating layer, enable the products to have excellent electrical properties, and simultaneously adopt an annealing process for conductors, thereby further optimizing the mechanical properties of the conductors and enabling the conductors to have better flexibility.
The beneficial effects of this embodiment lie in:
(1) The cable sheath has excellent mechanical properties, the tensile strength is more than or equal to 10MPa, and the elongation at break is more than or equal to 400%.
(2) The cable insulating layer has excellent high-temperature aging resistance, and the tensile strength change rate and the elongation at break change rate are both within +/-15% after being subjected to hot air aging treatment for 7 days at 135 ℃.
(3) The cable has excellent salt fog resistance, corrosion resistance and mould resistance.
(4) The cable has excellent torsion resistance, is resistant to 10000 times of torsion at normal temperature and 2000 times of torsion at the low temperature of minus 40 ℃.
(5) The aluminum alloy flexible cable for offshore wind power generation has the advantages of simple operation method, low cost, universality and easiness in large-scale production.
Example 4
This example provides an aluminum alloy rod for cables, which differs from the aluminum alloy rod for cables in example 2 in that: the alloy comprises the following components in parts by weight: the alloy comprises 0.1 part of Si, 0.30 part of Fe, 0.05 part of Mg, 0.15 part of Cu, 0.04 part of B, 0.006 part of Ni, less than 0.03 part of single impurity, less than 0.1 part of total impurity and the balance of Al, wherein the impurities are substances except Si, fe, mg, cu, B, ni, al. Specifically, the impurity is Fe 2 O 3 、SiO 2 、CaSi 2 Etc.
The present embodiment also provides an aluminum alloy flexible cable for offshore wind power generation, which is different from the cable in embodiment 2 in that:
in this example, the diameter of the aluminum alloy monofilament was 0.55mm.
In this embodiment, the outer diameter of the cable core is 28.6mm.
In the embodiment, the isolation layer is a high-temperature resistant polyester tape;
the insulating layer is ethylene propylene rubber;
the sheath layer is made of ethylene-vinyl acetate copolymer rubber.
The present embodiment also provides a production process of the aluminum alloy flexible cable for offshore wind power generation, which is different from the production process of the cable in embodiment 2 in that:
the extrusion temperature of the extrusion process in the step 3) is 75 ℃, the vulcanization temperature is 150 ℃, the vulcanization pressure is 1.2MPa, the production speed is 10m/min, the tube sealing pressure is 0.9MPa, and the tube sealing time is 12min.
By adopting the technical scheme, the embodiment has the following beneficial effects:
(1)the aluminum alloy rod for the cable in the embodiment adopts a special material formula, and the corrosion resistance of the aluminum alloy rod is greatly improved by adjusting the proportion of each element in the aluminum alloy, particularly the proportion of Ni and Fe, and forming an Al-Ni-Fe intermetallic compound in the aluminum alloy rod; by adjusting the proportion of Fe and Mg, the conductivity, the tensile strength and the creep resistance are improved. In the embodiment, the influence of each element on the performance of the aluminum alloy rod is comprehensively considered, the tensile strength of the developed novel formula cable core can reach 110-150Mpa, the tensile strength of aluminum alloy monofilaments can reach 100-130Mpa, the elongation at break can reach not less than 20%, and the resistivity of the novel formula cable core is 0.028Ω & mm in the past 2 The/m is reduced to 0.026Ω.mm 2 /m。
(2) The torsion-resistant cable made of the aluminum alloy monofilament with the special formula is adopted, the weight of the torsion-resistant cable is reduced by about 40% compared with that of a copper cable according to the same current carrying capacity, the cost is reduced by more than 50%, and the torsion-resistant, corrosion-resistant, salt spray-resistant, corrosion-resistant, cold-resistant, mold-resistant and other performances are achieved, so that the severe running environment of the offshore wind turbine is met, the manufacturing cost of the offshore wind turbine is effectively reduced, and the torsion-resistant cable has higher use value and application prospect.
(3) The aluminum alloy cable core of the cable in this embodiment is formed by equidirectional transposition of the circular stranded core in the center and the circular stranded core that encircles circular stranded core, compares with traditional transposition mode, and the structure of cable in this embodiment is softer, and the resistant performance of turning round improves, and the external diameter is littleer, saves space, is convenient for install and lay.
(4) The cable aluminum alloy cable core in the embodiment adopts a normal 1+6+12+18 stranded structure, and ensures the running stability of the cable while meeting the requirements of flexibility and tensile strength.
(5) The isolating layer of the cable in the embodiment is high-temperature-resistant reinforced non-woven fabric, so that the conductor is tightly tied and the glue stock is prevented from penetrating into the conductor; meanwhile, the wire breakage caused by interaction of the aluminum alloy conductor monofilaments in the twisting process can be effectively prevented.
(6) The aluminum alloy monofilament in the embodiment has the diameter of 0.45mm, belongs to five types of aluminum alloy soft conductors, has good bending performance, and can be well matched with the torsion performance of the cable.
(7) The insulating layer in the embodiment is insulated by ethylene propylene rubber EPR, can meet the use requirements of a wind power plant in a low-temperature environment of 40 ℃ below zero and a conductor in a highest working temperature of 90 ℃ at the same time, and has good electrical performance.
(8) The sheath layer in the embodiment adopts the anti-cracking and anti-mildew CPE sheath, has the characteristics of flame retardance, weather resistance, salt fog resistance, mildew resistance, cracking resistance and the like, and can meet the use requirements of the offshore generator set.
(9) In the cable production process, the insulating layer and the sheath layer adopt an inlet continuous sulfur machine device and a double-layer co-extrusion process, and compared with the traditional single-layer extrusion process of the insulating layer and the sheath layer, the process can remarkably improve the production efficiency of products, improve the purity of the insulating layer, enable the products to have excellent electrical properties, and simultaneously adopt an annealing process for conductors, thereby further optimizing the mechanical properties of the conductors and enabling the conductors to have better flexibility.
The beneficial effects of this embodiment lie in:
(1) The cable sheath has excellent mechanical properties, the tensile strength is more than or equal to 10MPa, and the elongation at break is more than or equal to 400%.
(2) The cable insulating layer has excellent high-temperature aging resistance, and the tensile strength change rate and the elongation at break change rate are both within +/-15% after being subjected to hot air aging treatment for 7 days at 135 ℃.
(3) The cable has excellent salt fog resistance, corrosion resistance and mould resistance.
(4) The cable has excellent torsion resistance, is resistant to 10000 times of torsion at normal temperature and 2000 times of torsion at the low temperature of minus 40 ℃.
(5) The aluminum alloy flexible cable for offshore wind power generation has the advantages of simple operation method, low cost, universality and easiness in large-scale production.
Comparative example 1
This comparative example provides an aluminum alloy flexible cable for offshore wind power generation, which differs from the aluminum alloy flexible cable for offshore wind power generation in example 2 in that:
the structure of the existing copper core wind power generation cable comprises: the cable core, the insulating layer and the sheath layer are sequentially arranged from inside to outside, and the cable core is formed by twisting round copper monofilaments.
The insulating layer is made of ethylene-propylene insulating rubber with the temperature resistant of 90 ℃, and the sheath layer is made of CPE sheath.
The cable is selected to be FDEH-40.6/1 1 multiplied by 240.
Comparative example 2
This comparative example provides an aluminum alloy flexible cable for offshore wind power generation, which differs from the aluminum alloy flexible cable for offshore wind power generation in example 2 in that:
five types of conductors (Shenzhen Altaike) of the outsourced 8030 aluminum alloy were used, and the structure of the cable of this comparative example included: the cable core, the insulating layer and the sheath layer are sequentially arranged from inside to outside, and the cable core is formed by twisting round aluminum alloy monofilaments. The aluminum alloy monofilament is made of five types of conductors (Shenzhen Altaig) of aluminum alloy 8030 which are purchased outsourced.
The insulating layer is made of ethylene-propylene insulating rubber with the temperature resistant of 90 ℃, and the sheath layer is made of CPE sheath.
The cable selection model specification is FDLHEH-40.6/1 1 multiplied by 400.
Example 1, comparative example 1 and comparative example 2 were tested under the same test conditions, which were GB/T29631-2013, and the results are shown in the following Table
Table 1 comparison of torsion resistance of cables
Table 2 table of cable sheath performance parameters
TABLE 3 salt spray test parameter table
It is to be understood that the above embodiments are merely illustrative of the application of the principles of the present invention, but not in limitation thereof. Various modifications and improvements may be made by those skilled in the art without departing from the spirit and substance of the invention, and are also considered to be within the scope of the invention.

Claims (11)

1. The aluminum alloy rod for the cable is characterized by comprising the following alloy components in parts by weight: 0.03-0.1 part of Si, 0.30-0.8 part of Fe, 0.01-0.05 part of Mg, 0.15-0.3 part of Cu, 0.01-0.04 part of B, 0.006-0.03 part of Ni, less than 0.03 part of single impurity, less than 0.1 part of total impurity and the balance of Al, wherein the impurities are substances except Si, fe, mg, cu, B, ni, al.
2. An aluminum alloy flexible cable for offshore wind power generation is characterized by comprising a cable core, an isolation layer, an insulation layer and a sheath layer which are sequentially arranged from inside to outside, wherein the cable core is made of the aluminum alloy rod disclosed in claim 1.
3. The aluminum alloy flexible cable for offshore wind power generation according to claim 2, wherein the cable core comprises at least two strand cores, the cable core is formed by twisting strand cores, the strand cores comprise at least two aluminum alloy monofilaments, the strand cores are formed by twisting aluminum alloy monofilaments, and the aluminum alloy monofilaments are made of aluminum alloy rods.
4. An aluminum alloy flexible cable for offshore wind power generation according to claim 3, wherein the diameter of the aluminum alloy monofilament is 0.45 to 0.55mm.
5. An aluminum alloy flexible cable for offshore wind power generation according to claim 3, wherein the twisting direction of the aluminum alloy monofilament is left-hand co-twisting, and the twisting direction of the strand core is left-hand co-twisting.
6. An aluminum alloy flexible cable for offshore wind power generation according to claim 3, wherein the outer diameter of the cable core is 28.6-29.4 mm.
7. An aluminum alloy flexible cable for offshore wind power generation according to claim 3, wherein the cable core comprises: the core is arranged at the center, and at least two cores are sequentially arranged outside the center core.
8. The aluminum alloy flexible cable for offshore wind power generation according to any one of claims 3 to 7, wherein the strand core includes a first strand core, a second strand core, a third strand core, and a fourth strand core, and the cable core includes: the novel plastic composite material comprises a first strand core arranged in the center, six second strand cores arranged on the periphery of the first strand core, twelve third strand cores arranged on the periphery of the second strand core, and eighteen fourth strand cores arranged on the periphery of the third strand core.
9. The aluminum alloy flexible cable for offshore wind power generation according to any one of claims 2 to 7, wherein the insulation layer is a non-woven fabric or a high temperature resistant polyester tape;
the insulating layer is ethylene propylene rubber;
the sheath layer is any one of chlorinated polyethylene sheath rubber, chloroprene rubber and ethylene-vinyl acetate copolymer rubber.
10. A process for producing an aluminum alloy flexible cable for offshore wind power generation according to any one of claims 2 to 9, characterized by comprising the steps of:
1) Processing the aluminum alloy rod into a cable core;
2) An isolation layer is arranged outside the cable core;
3) And extruding the insulating layer and the sheath layer through a sulfur connecting machine by adopting a double-layer co-extrusion process to manufacture the cable.
11. The process for producing an aluminum alloy flexible cable for offshore wind power generation according to claim 10, wherein the extrusion temperature of the extrusion process in the step 3) is 75-90 ℃, the vulcanization temperature is 150-210 ℃, the vulcanization pressure is 0.9-1.2 MPa, the production speed is 6-10 m/min, the tube-sealing air pressure is 0.8-1.1 MPa, and the tube-sealing time is 8-12 min.
CN202310840642.1A 2023-07-10 2023-07-10 Aluminum alloy rod for cable, aluminum alloy flexible cable for offshore wind power generation and production process of aluminum alloy flexible cable Pending CN117410006A (en)

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