CN118116650A - Cable for 10 kV-level high-performance coal mining machine and manufacturing process thereof - Google Patents
Cable for 10 kV-level high-performance coal mining machine and manufacturing process thereof Download PDFInfo
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- CN118116650A CN118116650A CN202410343975.8A CN202410343975A CN118116650A CN 118116650 A CN118116650 A CN 118116650A CN 202410343975 A CN202410343975 A CN 202410343975A CN 118116650 A CN118116650 A CN 118116650A
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- FPAFDBFIGPHWGO-UHFFFAOYSA-N dioxosilane;oxomagnesium;hydrate Chemical compound O.[Mg]=O.[Mg]=O.[Mg]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O FPAFDBFIGPHWGO-UHFFFAOYSA-N 0.000 claims description 16
- 239000000395 magnesium oxide Substances 0.000 claims description 16
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 16
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- YHMYGUUIMTVXNW-UHFFFAOYSA-N 1,3-dihydrobenzimidazole-2-thione Chemical compound C1=CC=C2NC(S)=NC2=C1 YHMYGUUIMTVXNW-UHFFFAOYSA-N 0.000 claims description 7
- 239000003963 antioxidant agent Substances 0.000 claims description 7
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- 229910001220 stainless steel Inorganic materials 0.000 claims description 7
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- FGUUSXIOTUKUDN-IBGZPJMESA-N C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 Chemical compound C1(=CC=CC=C1)N1C2=C(NC([C@H](C1)NC=1OC(=NN=1)C1=CC=CC=C1)=O)C=CC=C2 FGUUSXIOTUKUDN-IBGZPJMESA-N 0.000 claims description 6
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Classifications
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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
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
- H01B7/041—Flexible cables, conductors, or cords, e.g. trailing cables attached to mobile objects, e.g. portable tools, elevators, mining equipment, hoisting cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
- H01B13/141—Insulating conductors or cables by extrusion of two or more insulating layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—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
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/28—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances natural or synthetic rubbers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/0009—Details relating to the conductive cores
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
- H01B7/0208—Cables with several layers of insulating material
- H01B7/0225—Three or more layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
-
- 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
- H01B7/1875—Multi-layer sheaths
-
- 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
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Physics & Mathematics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Insulated Conductors (AREA)
Abstract
The invention discloses a cable for a 10kV high-performance coal mining machine, which comprises an inner wire core assembly and a sheath assembly coated outside the inner wire core assembly, wherein the sheath assembly comprises an inner sheath, a braiding layer and an outer sheath which are sequentially arranged from inside to outside; the inner wire core assembly comprises a plurality of power wire core units, a plurality of control wire core units and optical fibers. The invention provides a cable for a 10kV high-performance coal mining machine, which is suitable for the coal mining machine and has the characteristics of difficult breakdown, strong ageing resistance, long service life and the like.
Description
Technical Field
The invention belongs to the technical field of cables, and particularly relates to a cable for a 10kV high-performance coal mining machine and a manufacturing process thereof.
Background
At present, the highest voltage level of the cable for the domestic coal mining machine is 1.9/3.3kV, the cable for the coal mining machine is in 2-3 times of bending radius to-and-fro motion in operation, the cable for the coal mining machine is rubbed with a cable clamp in bending motion, a cable sheath layer is extremely easy to wear, meanwhile, the cable is possibly extruded by coal blocks in the cable clamp, the cable sheath is further damaged, and then the cable insulating layer is affected, so that the cable is short-circuited, equipment is stopped, and safety accidents are caused. The service life of the cable is not long, and continuous use of a plurality of coal faces is hardly realized.
The cable for the coal mining machine is always in a dynamic bending state when in operation, after the voltage level is improved, the performance requirement on the insulating material is higher, the conventional material is greatly deformed when being impacted by external force, and further electric breakdown, heating caused by partial discharge, accelerated aging and rapid performance reduction are possibly caused, so that the service life of the cable is short. At the same time, an outer protective layer is also of critical importance for protecting the long-term reliability of the insulating core.
Disclosure of Invention
The invention aims to overcome the problems in the prior art and provide the cable for the 10 kV-level high-performance coal mining machine, which is suitable for the coal mining machine and has the characteristics of impact resistance, difficult breakdown, strong ageing resistance, long service life and the like.
In order to achieve the technical purpose and the technical effect, the invention is realized by the following technical scheme:
in a first aspect, a cable for a 10kV high-performance coal mining machine comprises an inner wire core assembly and a sheath assembly coated outside the inner wire core assembly, wherein the sheath assembly comprises an inner sheath, a braiding layer and an outer sheath which are sequentially arranged from inside to outside;
the inner wire core assembly comprises a plurality of power wire core units, a plurality of control wire core units and optical fibers;
The power line core unit comprises a plurality of power conductors and conductor insulation layer groups coated on the outer parts of the power conductors, wherein each conductor insulation layer group comprises a conductor shielding layer, a power insulation layer and an insulation shielding layer which are sequentially arranged from inside to outside, and the outer parts of the insulation shielding layers are coated with conductor metal shielding layers.
Preferably, the control wire core unit comprises a plurality of control wire cores and a control metal shielding layer coated outside the control wire cores;
the control wire core comprises a plurality of control conductors and a control insulating layer group coated outside the control conductors;
The control insulating layer group has the same structure as the conductor insulating layer group, and the control insulating layer group has the same structure as the conductor insulating layer group.
In a second aspect, a manufacturing process of a cable for a 10kV high-performance coal mining machine, the manufacturing process comprising the steps of:
S01: power conductor stranding
Twisting a plurality of power conductors, performing primary annealing treatment on the twisted power conductors under a nitrogen atmosphere after twisting, standing for 1-2d after primary annealing treatment, and performing secondary annealing treatment to prepare flexible conductors, wherein the annealing temperature of the primary annealing treatment and the secondary annealing treatment is 230-280 ℃ and the annealing time is 3-5h;
S02: preparation of a Power core Unit
Respectively conveying an internal insulating material, a rubber material and an external insulating material into three extruders for plasticizing, respectively conveying the plasticized products into three extrusion heads of a three-layer co-extruder, placing a flexible conductor into the three-layer co-extruder, forming a conductor shielding layer, a power insulating layer and an insulating shielding layer outside the flexible conductor by adopting a three-layer co-extrusion process, and braiding a conductor metal shielding layer outside the insulating shielding layer to prepare a power wire core unit, wherein the conductor insulating layer group is prepared by plasticizing the internal insulating material through the extruder and extruding the internal insulating material through the extrusion heads of the three-layer co-extruder, and the power insulating layer is prepared by plasticizing the rubber material through the extrusion heads of the three-layer co-extruder and extruding the external insulating material through the extrusion heads of the three-layer co-extruder;
wherein, the steps are all carried out in a dust-free workshop;
S03: control conductor twisting
Twisting a plurality of control conductors to prepare a control wire harness;
S04: preparation control wire core unit
According to the operation method of the step S02, a control insulation layer group is formed outside the control wire harness in a coating mode, a control wire core is prepared, after a plurality of control wire cores are twisted, a control metal shielding layer is woven outside the twisted control wire cores, and a control wire core unit is prepared;
wherein, the steps are all carried out in a dust-free workshop;
s05: cabling cable
Preparing a plurality of power wire core units, a plurality of control wire core units and optical fibers into an inner wire core assembly by adopting a cage winch;
S06: sheath serial extrusion
Coating an inner sheath outside the inner wire core assembly by adopting a serial extrusion device in sequence, braiding a braiding layer outside the inner sheath, coating an outer sheath outside the braiding layer, and performing thermal crosslinking to prepare the cable; the series extrusion equipment comprises a first rubber extruder, a braiding machine, a second rubber extruder and a vulcanization pipeline which are sequentially arranged along the moving direction of the inner wire core assembly, wherein the inner sheath is extruded by the first rubber extruder, the braiding layer is braided by the braiding machine, and the outer sheath is extruded by the second rubber extruder.
Preferably, the rubber material comprises the following raw materials in parts by weight: 47708-12 parts of EPDM, 815035-45 parts of POE, 250430-40 parts of EPDM, 8-12 parts of paraffin oil, 20-30 parts of talcum powder, 70-80 parts of calcined clay, 1-2 parts of paraffin wax, 1.0-1.4 parts of anti-aging agent RD, 0.5-1.5 parts of anti-aging agent MB, 0.4-0.6 part of coupling agent A-1720.4, 0.6 part of stearic acid, 2-3 parts of polyethylene, 3-5 parts of zinc oxide, 2-4 parts of carbon black N3302-4 parts of vulcanizing agent DCP and 1-3 parts of vulcanizing aid TAIC.
More preferably, the rubber material comprises the following raw materials in parts by weight: 477010 parts of EPDM, 815040 parts of POE, 250435 parts of EPDM, 10 parts of paraffin oil, 25 parts of talcum powder, 75 parts of calcined clay, 1.5 parts of paraffin, 1.2 parts of antioxidant RD, 1 part of antioxidant MB, 0.5 part of coupling agent A-1720.5 parts of stearic acid, 2.5 parts of polyethylene, 4 parts of zinc oxide, 3 parts of carbon black N3303 parts of vulcanizing agent DCP, 3.2 parts of vulcanizing aid TAIC and 2 parts of vulcanizing aid.
Preferably, the preparation process of the rubber material is carried out in a dust-free workshop, and comprises the following steps of:
step a: weighing all raw materials of the rubber material according to a formula;
Step b: mixing the raw materials at 110-120 ℃ to prepare sizing material, wherein a vulcanizing agent and a vulcanizing auxiliary agent are not added in the mixing process;
Step c: filtering the sizing material at 120-130 ℃ by using a primary filter screen; the primary filter screen comprises a first filter layer, a second filter layer, a third filter layer, a fourth filter layer and a fifth filter layer which are sequentially stacked, wherein the apertures of the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are sequentially 40 meshes, 80 meshes, 100 meshes, 80 meshes and 40 meshes, and the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are all made of stainless steel;
Step d: using a secondary filter screen to carry out secondary filtration on the sizing material subjected to primary filtration at 110-130 ℃; the secondary filter screen comprises a sixth filter layer, a seventh filter layer, an eighth filter layer, a ninth filter layer and a tenth filter layer which are sequentially stacked, wherein the pore diameters of the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are 40 meshes, 100 meshes, 80 meshes and 40 meshes in sequence, and the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are all made of stainless steel;
step e: adding a vulcanizing agent and a vulcanizing aid into the rubber material subjected to secondary filtration, granulating by a granulator, and cooling to prepare a rubber material;
Step f: placing the prepared rubber material into a hanging bag for sealing and storing; wherein, the hanging bag is made of PP material;
After the preparation of the rubber material is completed, the rubber material is put into a hanging bag made of PP material for standby, so that the cleanliness of the rubber material is ensured.
Preferably, the raw material components and weight ratio of the inner insulating material and the outer insulating material are the same;
The internal insulating material comprises the following raw materials in parts by weight: 30-40 parts of chlorinated polyethylene, 30-40 parts of ethylene-vinyl acetate copolymer, 7-8 parts of magnesium oxide, 12-18 parts of chlorinated paraffin, 3-5 parts of dioctyl phthalate, 6-8 parts of paraffin oil, 6-10 parts of Vaseline, 60-68 parts of conductive carbon black, 1-3 parts of polyethylene wax, 0.5-1.5 parts of carbon black dispersing agent, 1-3 parts of anti-aging agent RD, 1-2 parts of anti-aging agent MB, 2-2.6 parts of cross-linking agent DCP and 0.5-0.9 part of accelerator TAC.
More preferably, the internal insulating material comprises the following raw materials in parts by weight: 35 parts of chlorinated polyethylene, 35 parts of ethylene-vinyl acetate copolymer, 7.2 parts of magnesium oxide, 15 parts of chlorinated paraffin, 4 parts of dioctyl phthalate, 7 parts of paraffin oil, 8 parts of Vaseline, 64 parts of conductive carbon black, 2 parts of polyethylene wax, 1 part of carbon black dispersing agent, 2 parts of antioxidant RD, 1.5 parts of antioxidant MB, 2.3 parts of cross-linking agent DCP and 0.7 part of accelerator TAC.
Preferably, the raw material components and the weight ratio of the inner sheath and the outer sheath are the same;
The inner sheath comprises the following raw materials in parts by weight: 70-90 parts of chlorinated polyethylene, 4-6 parts of calcium carbonate, 16-20 parts of talcum powder, 2-8 parts of white carbon black, 1-2 parts of microcrystalline wax, 6-10 parts of plasticizer DOP, 15-30 parts of chlorinated paraffin, 4-6 parts of magnesium oxide, 1-2 parts of calcium zinc stabilizer, 25010-20 parts of GLC, GZRY-15 parts of DCP, 1-2 parts of TAIC powder and 2-3 parts of TAIC powder.
More preferably, the inner sheath comprises the following raw materials in parts by weight: 80 parts of chlorinated polyethylene, 5 parts of calcium carbonate, 18 parts of talcum powder, 5 parts of white carbon black, 1.7 parts of microcrystalline wax, 8 parts of plasticizer DOP, 19 parts of chlorinated paraffin, 5.2 parts of magnesium oxide, 1.5 parts of calcium zinc stabilizer, 25015 parts of GLC, GZRY-110 parts of DCP, 1.75 parts of TAIC powder and 2.6 parts of TAIC powder.
Compared with the prior art, the invention has the beneficial effects that:
1. The cable for the 10 kV-level high-performance coal mining machine is suitable for the coal mining machine, is not easy to break down, has strong ageing resistance and has long service life.
2. The invention provides a cable for a 10kV high-performance coal mining machine and a manufacturing process thereof, wherein a plurality of power conductors are stranded, and the conductors are high in roundness, soft and good in tensile property; after the conductors are twisted, the elongation at break of the monofilaments of the conductors are improved, so that the conductors can show larger deformation capacity, and the applicability and durability of the conductors in the use process can be improved, so that the conductors are more suitable for use in the production environment of a coal mining machine.
3. The invention provides a cable for a 10kV high-performance coal mining machine and a manufacturing process thereof, wherein a conductor insulating layer group and a control insulating layer group are of the same structure and are composed of a conductor shielding layer, a power insulating layer and an insulating shielding layer, wherein the formula composition of the conductor shielding layer and the insulating shielding layer which are connected with the power insulating layer is the same, the conductor shielding layer and the insulating shielding layer can be tightly attached to the power insulating layer and can be stripped later, and no residue and insulation loss are caused during stripping; the power insulating layer with good extrusion resistance and deformation resistance can be prepared by the formula composition of the rubber material adopted by the power insulating layer, and the rubber material adopted by the power insulating layer is carried out in a dust-free workshop, so that the probability of dust and impurity pollution is reduced, and voltage breakdown is avoided.
4. The conductor insulating layer group and the control insulating layer group are all of the same structure and are composed of a conductor shielding layer, a power insulating layer and an insulating shielding layer, wherein the conductor shielding layer, the power insulating layer and the insulating shielding layer are prepared by adopting a three-layer coextrusion process, and further the reliability of the insulating layer in movement is ensured.
5. The cable for the 10 kV-level high-performance coal mining machine provided by the invention has the advantages that the inner sheath, the braiding layer and the outer sheath are sequentially coated outside the inner wire core assembly, wherein the inner sheath and the outer sheath are formed by adopting the same formula, and the inner sheath and the outer sheath prepared by the formula have the performances of high strength, high wear resistance and the like, and can meet the use requirement of the coal mining machine.
6. The application provides a manufacturing process of a cable for a 10kV high-performance coal mining machine, which is characterized in that a serial extrusion device is used for coating an inner sheath, a braiding layer and an outer sheath on an inner wire core component, the serial extrusion device is composed of a first rubber extruder, a braiding machine, a second rubber extruder and a vulcanization pipeline which are sequentially arranged along the moving direction of the inner wire core component, the inner wire core component firstly passes through the first rubber extruder in the moving process, the part of the inner wire core component in the first rubber extruder is coated with the inner sheath, then the inner wire core component is continuously transmitted to the braiding machine, the braiding machine is used for braiding a braiding layer outside the inner wire core component coated with the inner sheath, then the inner wire core component is continuously transmitted to the second rubber extruder, and finally the inner wire core component coated with the outer sheath is continuously transmitted into the vulcanization pipeline to be heated and crosslinked so as to achieve the combination of molecular levels, and further the braiding layer and the inner sheath form an integral body, the structure can resist torsion of the cable, the bending performance of the cable is not influenced; in addition, the traditional external protection procedure is generally that the first internal sheath is processed through an extrusion unit, heated through a vulcanization pipeline, the material of the internal sheath is crosslinked and formed, after the water cooling is carried out in a circulating way, the second layer, namely the braiding layer, is braided, and after the braiding is completed, the material of the external sheath is heated through the extrusion unit and crosslinked and formed through the vulcanization pipeline, the internal sheath and the external sheath are contacted together through the gaps of the braiding layers.
Drawings
The accompanying drawings, which are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification, illustrate embodiments of the application and together with the description serve to explain the application and do not constitute a limitation on the application. In the drawings:
FIG. 1 is a schematic view of the structure provided by the present invention;
FIG. 2 is a schematic view of the structure of the inner wire core assembly provided by the present invention;
FIG. 3 is a flow chart of a preparation process of the cable for the 10kV high-performance coal mining machine, which is provided by the invention;
Fig. 4 is a schematic structural diagram of a tandem extrusion apparatus provided by the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the description of the present invention, it should be understood that the terms "open," "upper," "lower," "thickness," "top," "middle," "length," "inner," "peripheral," and the like indicate orientation or positional relationships, merely for convenience in describing the present invention and to simplify the description, and do not indicate or imply that the components or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and thus should not be construed as limiting the present invention.
As shown in fig. 1 to 2, as an embodiment of the first aspect of the present invention, there is provided a cable for a 10kV high-performance coal mining machine, which is composed of an inner core assembly 1 and a sheath assembly 20 coated outside the inner core assembly 1, wherein the sheath assembly 20 includes an inner sheath 2, a braid 3 and an outer sheath 4 sequentially arranged from inside to outside, and the inner sheath 2 is coated outside the inner core assembly 1;
The braid layer 3 adopts Kevlar fiber, the tensile strength is 2.5GPa, the twisting phenomenon in the process of installing and laying the cable is effectively prevented, and the service life of the cable is prolonged;
The inner wire core assembly 1 is composed of a plurality of power wire core units 11, a plurality of control wire core units 12 and optical fibers 13, wherein the optical fibers 13 are composed of 8 single-mode optical fibers and are reinforced by high-strength fibers;
Wherein, in the inner wire core assembly 1, the optical fibers 13 are distributed among a plurality of power wire core units 11; the plurality of control wire core units 12 form a wire harness, and the plurality of control wire core units 12 are positioned outside the wire harness;
in the inner wire core assembly 1, the number of the power wire core units 11 is the same as the number of the control wire core units 12;
The power wire core unit 11 comprises a plurality of power conductors 5 and a conductor insulation layer group 6 coated outside the power conductors 5, wherein the conductor insulation layer group 6 comprises a conductor shielding layer 61, a power insulation layer 62 and an insulation shielding layer 63 which are sequentially arranged from inside to outside;
Wherein the cross section area of the stranded power conductors 5 is 25-185mm 2;
In the conductor insulation layer group 6, the thickness of the conductor shielding layer 61 is 0.5-1mm, the thickness of the power insulation layer 62 is 5.5-6.5mm, and the thickness of the insulation shielding layer 63 is 0.5-1.0mm;
the power conductor 5 is made of tin-plated soft copper, and has excellent performance, and the number of the power conductors 5 in the power wire core unit 11 is 3-4;
The insulating shielding layer 63 is externally coated with a conductor metal shielding layer 7 with the thickness of 0.2-0.4mm;
the control wire core unit 12 comprises a plurality of control wire cores 8 and a control metal shielding layer 9 coated outside the plurality of control wire cores 8;
the control wire core 8 comprises a plurality of control conductors 81 and a control insulating layer group 10 coated outside the plurality of control conductors 81;
the control conductor 81 is made of tin-plated soft copper, the cross section area is 2.5mm 2-10mm2, the number is 3-10, and the optimal number is 6;
The control insulating layer group 10 has the same structure as the conductor insulating layer group 6;
In the control insulation layer group 10, a three-layer structure which is the same as that of the conductor insulation layer group 6 is adopted, and the control insulation layer group comprises a control shielding layer, a control insulation layer and a control insulation shielding layer, wherein the control shielding layer is the same as that of the conductor shielding layer 61, the control insulation layer is the same as that of the power insulation layer 62, and the control insulation shielding layer is the same as that of the insulation shielding layer 63; the thickness of the shielding layer is controlled to be 0.1-0.2mm, the thickness of the insulating layer is controlled to be 0.8-2.0mm, and the thickness of the insulating shielding layer is controlled to be 0.15-0.3mm.
As an example of the second aspect of the present invention, as shown in fig. 3, there is provided a process for manufacturing a cable for a 10 kV-class high-performance shearer loader, the process comprising the steps of:
S01: power conductor stranding
Twisting a plurality of power conductors 5, wherein the processing technological parameters are as follows: the bundle twisting pitch diameter ratio is 14-20, the inner layer pitch diameter ratio of the compound twisting is 14-16, and the outer layer pitch diameter ratio of the compound twisting is 12-14;
After stranding, carrying out primary annealing treatment on the stranded power conductor 5 in a nitrogen atmosphere, after the primary annealing treatment, placing for 1-2d, carrying out secondary annealing treatment, and preparing a flexible conductor after the secondary annealing treatment;
wherein the annealing temperature of the primary annealing treatment and the secondary annealing treatment are both 230-280 ℃ and the time is 3-5h;
After the secondary annealing treatment, the elongation at break of the monofilaments of the flexible conductor is increased from 18-20% to 28-31% before annealing;
S02: preparation of a Power core Unit
Respectively feeding an internal insulating material, a rubber material and an external insulating material into three extruders for plasticizing, respectively feeding the plasticized products into three extruder heads of a three-layer co-extruder, placing a flexible conductor into the three-layer co-extruder, forming a conductor shielding layer 61, a power insulating layer 62 and an insulating shielding layer 63 outside the flexible conductor by adopting a three-layer co-extrusion process, and weaving a conductor metal shielding layer 7 outside the insulating shielding layer 63 to prepare a power wire core unit 11;
In step S02, the conductor insulation layer group 6 is made by plasticizing an internal insulation material by an extruder and extruding the plasticized material by an extruder head of a three-layer co-extruder, the power insulation layer 7 is made by plasticizing a rubber material by an extruder and extruding the plasticized material by an extruder head of the three-layer co-extruder, and the insulation shielding layer 71 is made by plasticizing an external insulation material by an extruder and extruding the plasticized material by an extruder head of the three-layer co-extruder;
In step S02, the rubber material includes the following raw materials in parts by weight: the novel high-strength heat-resistant rubber comprises, by weight, 47708-12 parts of EPDM (ethylene-propylene-diene monomer), 815035-45 parts of POE (polyolefin elastomer), 250430-40 parts of EPDM (ethylene-propylene-diene monomer), 8-12 parts of paraffin oil, 20-30 parts of talcum powder, 70-80 parts of calcined clay, 1-2 parts of paraffin wax, 1.0-1.4 parts of anti-aging agent RD (red), 0.5-1.5 parts of anti-aging agent MB (ethylene-propylene-diene monomer), 1720.4-0.6 part of coupling agent A, 0.4-0.6 part of stearic acid, 2-3 parts of polyethylene, 3-5 parts of zinc oxide, 2-4 parts of carbon black N330, 2-4 parts of vulcanizing agent DCP and 1-3 parts of vulcanizing aid TAIC (rubber);
the production process of the rubber material is as follows, and the production is carried out in a dust-free workshop:
step a: weighing all raw materials of the rubber material according to a formula;
Step b: mixing the raw materials at 110-120 ℃ to prepare sizing material, wherein a vulcanizing agent and a vulcanizing auxiliary agent are not added in the mixing process;
Step c: filtering the sizing material at 120-130 ℃ by using a primary filter screen; the primary filter screen comprises a first filter layer, a second filter layer, a third filter layer, a fourth filter layer and a fifth filter layer which are sequentially stacked, wherein the apertures of the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are sequentially 40 meshes, 80 meshes, 100 meshes, 80 meshes and 40 meshes, and the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are all made of stainless steel;
Step d: using a secondary filter screen to carry out secondary filtration on the sizing material subjected to primary filtration at 110-130 ℃; the secondary filter screen comprises a sixth filter layer, a seventh filter layer, an eighth filter layer, a ninth filter layer and a tenth filter layer which are sequentially stacked, wherein the pore diameters of the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are 40 meshes, 100 meshes, 80 meshes and 40 meshes in sequence, and the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are all made of stainless steel;
the quality and the performance of the rubber material prepared subsequently can be ensured through twice filtration;
In the two filtering processes, the primary filter screen is used, and when the total mass of the filtering sizing material filtered by the primary filter screen reaches 400-500kg, the primary filter screen needs to be replaced;
when the total mass of the rubber material filtered by the secondary filter screen after primary filtration reaches 400-500kg, the secondary filter screen is required to be replaced;
In the two-time filtering process, the primary filter screen and the secondary filter screen are both multi-layer stainless steel filter screens with different apertures and are used for removing impurities, and the rubber material prepared by the two-time filtering process has the characteristics of high filtering efficiency, high flexibility, one-level improvement of product quality and the like, does not contain larger impurities or substances which are difficult to remove, so that the impurities are prevented from damaging subsequent processing equipment;
step e: adding a vulcanizing agent and a vulcanizing aid into the rubber material subjected to secondary filtration, granulating by a granulator, and cooling to prepare a rubber material;
Step f: placing the prepared rubber material into a hanging bag for sealing and storing; wherein, the hanging bag is made of PP material;
In the in-service use, the hanging bag can be hung at a high position, the discharge hole at the bottom of the hanging bag is positioned at the feed inlet of the extruder, the discharge hole at the bottom of the hanging bag is opened, and materials automatically fall into the feed inlet of the extruder, so that the time that rubber materials in the hanging bag are exposed to the external environment is reduced, the cleanliness of the rubber materials is ensured, the probability of dust and impurity pollution is reduced, and voltage breakdown is avoided.
In step S02, the raw material components and weight ratio of the internal insulating material and the external insulating material are the same;
In step S02, the internal insulating material includes the following raw materials in parts by weight: 30-40 parts of chlorinated polyethylene, 30-40 parts of ethylene-vinyl acetate copolymer, 7-8 parts of magnesium oxide, 12-18 parts of chlorinated paraffin, 3-5 parts of dioctyl phthalate, 6-8 parts of paraffin oil, 6-10 parts of Vaseline, 60-68 parts of conductive carbon black, 1-3 parts of polyethylene wax, 0.5-1.5 parts of carbon black dispersing agent, 1-3 parts of anti-aging agent RD, 1-2 parts of anti-aging agent MB, 2-2.6 parts of cross-linking agent DCP and 0.5-0.9 part of accelerator TAC;
S03: control conductor twisting
Twisting the plurality of control conductors 81 to prepare a control harness;
wherein, the control conductor 81 adopts a double-layer stranding process: the first layer bundle has a pitch diameter ratio of 4-8, and the second layer bundle has a pitch diameter ratio of 3-6;
S04: preparation control wire core unit
According to the operation mode of the step S02, a control insulation layer group 10 is formed by coating the outside of a control wire harness, a control wire core 8 is prepared, after a plurality of control wire cores 8 are twisted, a control metal shielding layer 9 is woven on the outside of the twisted plurality of control wire cores 8, and a control wire core unit 12 is prepared;
s05: cabling cable
The method comprises the steps of preparing a plurality of power wire core units 11, a plurality of control wire core units 12 and optical fibers 13 into an internal wire core assembly by adopting a cage winch, wherein in the process, parameters of the cage winch are set as follows: the pitch diameter ratio is 5-8 times;
wherein the optical fibers 13 are positioned among the plurality of power core units 11;
S06: sheath serial extrusion
And coating an inner sheath 2 outside the inner wire core assembly 1 by adopting a serial extrusion device, braiding a braiding layer 3 outside the inner sheath 2, and coating an outer sheath 4 outside the braiding layer 3 to prepare the cable.
In step S06, the raw material components and weight ratios of the inner sheath 2 and the outer sheath 4 are the same;
the inner sheath 2 comprises the following raw materials in parts by weight: 70-90 parts of chlorinated polyethylene, 4-6 parts of calcium carbonate, 16-20 parts of talcum powder, 2-8 parts of white carbon black, 1-2 parts of microcrystalline wax, 6-10 parts of plasticizer DOP, 15-30 parts of chlorinated paraffin, 4-6 parts of magnesium oxide, 1-2 parts of calcium zinc stabilizer, 25010-20 parts of GLC, GZRY-15 parts of DCP, 1-2 parts of TAIC powder and 2-3 parts of TAIC powder;
as shown in fig. 4, the tandem extrusion apparatus includes a first rubber extruder 100, a braiding machine 200, a second rubber extruder 300 and a vulcanization pipe 400 which are sequentially arranged along the moving direction of the inner wire core assembly 1, wherein the inner sheath 2 is extruded by the first rubber extruder 100, the braiding layer 3 is braided by the braiding machine 200, and the outer sheath 4 is extruded by the second rubber extruder 300;
The specific flow of step S06 is as follows: the head of the inner wire core component is firstly transmitted to the first rubber extruder 100, the part of the inner wire core component, which is positioned in the first rubber extruder 100, is coated with an inner sheath 2, is continuously transmitted to the braiding machine 200, a braiding layer 3 is braided by the braiding machine 200, is continuously transmitted to the second rubber extruder 300, is coated with an outer sheath 4, is finally heated and crosslinked by the vulcanization pipeline 400, is continuously transmitted, and is completely extruded in series along the length direction, so that the cable is prepared.
The following description is made in connection with specific 10kV high-performance cables for shearer mining and production processes thereof to further explain the contents of the embodiments of the first aspect and the embodiments of the second aspect of the present invention.
Example 1
The embodiment provides a cable for a 10kV high-performance coal mining machine, which consists of an inner wire core assembly 1 and a sheath assembly 20 coated outside the inner wire core assembly 1, wherein the sheath assembly 20 comprises an inner sheath 2, a braiding layer 3 and an outer sheath 4 which are sequentially arranged from inside to outside, and the inner sheath 2 is coated outside the inner wire core assembly 1;
the inner wire core assembly 1 is composed of three power wire core units 11, three control wire core units 12 and an optical fiber 13, wherein the optical fiber 13 is composed of 8 single-mode optical fibers and is reinforced by high-strength fibers; the optical fibers 13 are arranged among the three power wire core units 11;
The power wire core unit 11 comprises three power conductors 5 and a conductor insulation layer group 6 coated outside the three power conductors 5, wherein the conductor insulation layer group 6 comprises a conductor shielding layer 61, a power insulation layer 62 and an insulation shielding layer 63 which are sequentially arranged from inside to outside; wherein, the power conductor 5 is made of tin-plated soft copper, the cross-sectional area of the three power conductors 5 after being twisted is 100mm 2, the thickness of the conductor shielding layer 61 in the conductor insulating layer group 6 is 0.75mm, the thickness of the power insulating layer 62 is 6.0mm, and the thickness of the insulating shielding layer 63 is 0.75mm;
the outside of the insulating shielding layer 63 is coated with a conductor metal shielding layer 7;
the control wire core unit 12 comprises three control wire cores 8 and a control metal shielding layer 9 coated outside the three control wire cores 8, wherein the control wire cores 8 comprise six control conductors 81 and a control insulating layer group 10 coated outside the six control conductors 81; the control conductor 81 is tin-plated soft copper, and the cross-sectional area is 2.5mm 2;
the control insulation layer group 10 has the same structure as the conductor insulation layer group 6, and in the control insulation layer group 10, a three-layer structure which is the same as the conductor insulation layer group 6 is adopted, and the control insulation layer group comprises a control shielding layer, a control insulation layer and a control insulation shielding layer; wherein, the thickness of the control wire conductor shield is 0.15mm, the thickness of the insulation layer is 1.4mm, and the thickness of the control wire insulation shield is 0.20mm.
The embodiment also provides a manufacturing process of the cable for the 10kV high-performance coal mining machine, which comprises the following steps of:
S01: power conductor stranding
Three power conductors 5 are twisted, and the processing technological parameters are as follows: bundle twisting pitch diameter ratio 17, compound twisting inner layer pitch diameter ratio 15 and compound twisting outer layer pitch diameter ratio 13;
After stranding, carrying out primary annealing treatment on the stranded power conductor 5 in a nitrogen atmosphere, after the primary annealing treatment, placing for 1.5d, carrying out secondary annealing treatment, and preparing a flexible conductor after the secondary annealing treatment;
Wherein the annealing temperature of the primary annealing treatment and the secondary annealing treatment are 255 ℃ and the time is 4 hours;
S02: preparation of a Power core Unit
Respectively feeding an internal insulating material, a rubber material and an external insulating material into three extruders for plasticizing, respectively feeding the plasticized products into three extruder heads of a three-layer co-extruder, placing a flexible conductor into the three-layer co-extruder, forming a conductor shielding layer 61, a power insulating layer 62 and an insulating shielding layer 63 outside the flexible conductor by adopting a three-layer co-extrusion process, and weaving a conductor metal shielding layer 7 outside the insulating shielding layer 63 to prepare a power wire core unit 11;
In step S02, the conductor insulation layer group 6 is made by plasticizing an internal insulation material by an extruder and extruding the plasticized material by an extruder head of a three-layer co-extruder, the power insulation layer 7 is made by plasticizing a rubber material by an extruder and extruding the plasticized material by an extruder head of the three-layer co-extruder, and the insulation shielding layer 71 is made by plasticizing an external insulation material by an extruder and extruding the plasticized material by an extruder head of the three-layer co-extruder;
In step S02, the rubber material includes the following raw materials in parts by weight: 477010 parts of EPDM, 815040 parts of POE, 250435 parts of EPDM, 10 parts of paraffin oil, 25 parts of talcum powder, 75 parts of calcined clay, 1.5 parts of paraffin, 1.2 parts of antioxidant RD, 1 part of antioxidant MB, 0.5 part of coupling agent A-1720.5 parts of stearic acid, 2.5 parts of polyethylene, 4 parts of zinc oxide, 3 parts of carbon black N3303, 3.2 parts of vulcanizing agent DCP and 2 parts of vulcanizing aid TAIC;
The production process of the rubber material is as follows, and the production process is carried out in a dust-free workshop:
step a: weighing all raw materials of the rubber material according to the formula of the rubber material;
Step b: mixing the raw materials at 115 ℃, and preparing the sizing material after mixing without adding a vulcanizing agent and a vulcanizing auxiliary agent in the mixing process;
step c: filtering the sizing material once by using a primary filter screen at 125 ℃;
step d: the sizing material after the primary filtration is subjected to secondary filtration by using a secondary filter screen at 120 ℃;
step e: adding a vulcanizing agent and a vulcanizing aid into the rubber material subjected to secondary filtration, granulating by a granulator, and cooling to prepare a rubber material;
Step f: and (5) placing the prepared rubber material into a hanging bag for sealing and storing.
After the rubber material is produced, the extrusion resistance and deformation resistance of the rubber material are detected, the performance parameters are shown in table 1, and the specific measurement method is as follows:
and (3) preparing a fully vulcanized rubber material into a sample with the length and width of 10mm plus or minus 0.5mm, putting the sample into an oven, applying pressure of 1.0MPa, standing for 30min at the temperature of 180+/-3 ℃, taking out, removing the external pressure, naturally cooling to normal temperature, measuring the dimensional change value in the compression direction, wherein the change value/original value is the deformation rate, and judging that the deformation rate is less than 15%.
TABLE 1
| Project | Unit (B) | Typical value |
| Tensile strength | MPa | 9.0 |
| Elongation at break | ％ | 210 |
| Hardness of | Shore A | 78 |
| Dielectric strength | kV/mm | 32 |
| Deformation rate | ％ | 6 |
In step S02, the raw material components and weight ratio of the internal insulating material and the external insulating material are the same;
In step S02, the internal insulating material includes the following raw materials in parts by weight: 35 parts of chlorinated polyethylene, 35 parts of ethylene-vinyl acetate copolymer, 7.2 parts of magnesium oxide, 15 parts of chlorinated paraffin, 4 parts of dioctyl phthalate, 7 parts of paraffin oil, 8 parts of Vaseline, 64 parts of conductive carbon black, 2 parts of polyethylene wax, 1 part of carbon black dispersing agent, 2 parts of age resister RD, 1.5 parts of age resister MB, 2.3 parts of cross-linking agent DCP and 0.7 part of accelerator TAC;
S03: control conductor twisting
Twisting the six control conductors 81 to prepare a control harness;
wherein, the control conductor 81 adopts a double-layer stranding process: the first layer bundle pitch diameter ratio is 6, and the second layer bundle pitch diameter ratio is 4;
S04: preparation control wire core unit
According to the operation mode of the step S02, a control insulation layer group 10 is formed by coating the outside of a control wire harness, a control wire core 8 is prepared, after three control wire cores 8 are twisted, a control metal shielding layer 9 is woven on the outside of the three twisted control wire cores 8, and a control wire core unit 12 is prepared;
s05: cabling cable
The three power wire core units 11, the three control wire core units 12 and the optical fibers 13 are prepared into an internal wire core assembly by adopting a cage winch, wherein in the process, parameters of the cage winch are set as follows: the pitch diameter ratio is 6 times; the optical fibers 13 are positioned among the three power core units 11;
S06: sheath serial extrusion
Coating an inner sheath 2 outside the inner wire core assembly by adopting a serial extrusion device, braiding a braiding layer 3 outside the inner sheath 2, and coating an outer sheath 4 outside the braiding layer 3 to prepare a cable;
in step S06, the raw material components and weight ratios of the inner sheath 2 and the outer sheath 4 are the same;
the inner sheath 2 comprises the following raw materials in parts by weight: 80 parts of chlorinated polyethylene, 5 parts of calcium carbonate, 18 parts of talcum powder, 5 parts of white carbon black, 1.7 parts of microcrystalline wax, 8 parts of plasticizer DOP, 19 parts of chlorinated paraffin, 5.2 parts of magnesium oxide, 1.5 parts of calcium zinc stabilizer, 25015 parts of GLC, GZRY-110 parts of DCP, 1.75 parts of TAIC powder and 2.6 parts of TAIC powder.
Wherein, the performance of the inner sheath 2 and the outer sheath 4 is detected, and the performance parameters are shown in table 2;
TABLE 2
| Project | Unit (B) | Typical value |
| Tensile strength | MPa | 21.0 |
| Elongation at break | ％ | 380 |
| Hardness of | Shore A | 80 |
| Tear strength | N/mm | 8.0 |
| Volume abrasion loss | mm3 | 0.98 |
The inner sheath 2 and the outer sheath 4 have the aging resistance of 100 ℃ multiplied by 10 days and the performance retention rate of 72 percent.
The specific flow of step S06 and the specific composition of the serial extrusion device are all described in the embodiment of the second aspect of the present invention.
Example 2
The embodiment provides a cable for a 10kV high-performance coal mining machine, which consists of an inner wire core assembly 1 and a sheath assembly 20 coated outside the inner wire core assembly 1, wherein the sheath assembly 20 comprises an inner sheath 2, a braiding layer 3 and an outer sheath 4 which are sequentially arranged from inside to outside, and the inner sheath 2 is coated outside the inner wire core assembly 1;
the inner wire core assembly 1 is composed of three power wire core units 11, three control wire core units 12 and an optical fiber 13, wherein the optical fiber 13 is composed of 8 single-mode optical fibers and is reinforced by high-strength fibers; the optical fibers 13 are arranged among the three power wire core units 11;
The power wire core unit 11 comprises four power conductors 5 and a conductor insulation layer group 6 coated outside the four power conductors 5, wherein the conductor insulation layer group 6 comprises a conductor shielding layer 61, a power insulation layer 62 and an insulation shielding layer 63 which are sequentially arranged from inside to outside; wherein, the power conductor 5 is made of tin-plated soft copper, the cross-sectional area of the four power conductors 5 after being twisted is 25mm 2, the thickness of the conductor shielding layer 61 in the conductor insulating layer group 6 is 0.5mm, the thickness of the power insulating layer 62 is 5.5mm, and the thickness of the insulating shielding layer 63 is 0.5mm;
the outside of the insulating shielding layer 63 is coated with a conductor metal shielding layer 7;
The control wire core unit 12 comprises two control wire cores 8 and a control metal shielding layer 9 coated outside the two control wire cores 8, wherein the control wire cores 8 comprise three control conductors 81 and a control insulating layer group 10 coated outside the three control conductors 81; the control conductor 81 is tin-plated soft copper, and the cross-sectional area is 2.5mm 2;
The control insulation layer group 10 has the same structure as the conductor insulation layer group 6, and in the control insulation layer group 10, a three-layer structure which is the same as the conductor insulation layer group 6 is adopted, and the control insulation layer group comprises a control shielding layer, a control insulation layer and a control insulation shielding layer; wherein, the thickness of the control wire conductor shield is 0.1mm, the thickness of the insulation layer is 0.8mm, and the thickness of the control wire insulation shield is 0.3mm.
The embodiment also provides a manufacturing process of the cable for the 10kV high-performance coal mining machine, which comprises the following steps of:
S01: power conductor stranding
Twisting four power conductors 5, wherein the processing technological parameters are as follows: bundle lay pitch diameter ratio 14, double lay inner layer pitch diameter ratio 14, double lay outer layer pitch diameter ratio 12;
after stranding, carrying out primary annealing treatment on the stranded power conductor 5 in a nitrogen atmosphere, after the primary annealing treatment, placing for 1d, carrying out secondary annealing treatment, and preparing a flexible conductor after the secondary annealing treatment;
wherein the annealing temperature of the primary annealing treatment and the secondary annealing treatment are both 230 ℃ and the time is 3h;
S02: preparation of a Power core Unit
Respectively feeding an internal insulating material, a rubber material and an external insulating material into three extruders for plasticizing, respectively feeding the plasticized products into three extruder heads of a three-layer co-extruder, placing a flexible conductor into the three-layer co-extruder, forming a conductor shielding layer 61, a power insulating layer 62 and an insulating shielding layer 63 outside the flexible conductor by adopting a three-layer co-extrusion process, and weaving a conductor metal shielding layer 7 outside the insulating shielding layer 63 to prepare a power wire core unit 11;
In step S02, the conductor insulation layer group 6 is made by plasticizing an internal insulation material by an extruder and extruding the plasticized material by an extruder head of a three-layer co-extruder, the power insulation layer 7 is made by plasticizing a rubber material by an extruder and extruding the plasticized material by an extruder head of the three-layer co-extruder, and the insulation shielding layer 71 is made by plasticizing an external insulation material by an extruder and extruding the plasticized material by an extruder head of the three-layer co-extruder;
In step S02, the rubber material includes the following raw materials in parts by weight: 477012 parts of EPDM, 815045 parts of POE, 250430 parts of EPDM, 8 parts of paraffin oil, 20 parts of talcum powder, 70 parts of calcined clay, 1 part of paraffin, 1 part of anti-aging agent RD, 0.5 part of anti-aging agent MB, 0.4 part of coupling agent A-1720.4 parts of stearic acid, 2 parts of polyethylene, 3 parts of zinc oxide, 2 parts of carbon black N3302 parts of vulcanizing agent DCP and 1 part of vulcanizing aid TAIC;
The production process of the rubber material is as follows, and the production process is carried out in a dust-free workshop:
step a: weighing all raw materials of the rubber material according to the formula of the rubber material;
step b: mixing the raw materials at 110 ℃, and preparing sizing materials after mixing without adding vulcanizing agents and vulcanizing aids in the mixing process;
step c: filtering the sizing material at 120 ℃ by using a primary filter screen;
Step d: the sizing material after primary filtration is subjected to secondary filtration by using a secondary filter screen at 110 ℃;
step e: adding a vulcanizing agent and a vulcanizing aid into the rubber material subjected to secondary filtration, granulating by a granulator, and cooling to prepare a rubber material;
Step f: and (5) placing the prepared rubber material into a hanging bag for sealing and storing.
In step S02, the raw material components and weight ratio of the internal insulating material and the external insulating material are the same;
in step S02, the internal insulating material includes the following raw materials in parts by weight: 40 parts of chlorinated polyethylene, 30 parts of ethylene-vinyl acetate copolymer, 7 parts of magnesium oxide, 12 parts of chlorinated paraffin, 3 parts of dioctyl phthalate, 6 parts of paraffin oil, 6 parts of Vaseline, 60 parts of conductive carbon black, 1 part of polyethylene wax, 0.5 part of carbon black dispersing agent, 1 part of antioxidant RD, 1 part of antioxidant MB, 2.6 parts of cross-linking agent DCP and 0.9 part of accelerator TAC;
S03: control conductor twisting
Twisting the three control conductors 81 to prepare a control harness;
Wherein, the control conductor 81 adopts a double-layer stranding process: the first layer bundle pitch diameter ratio is 4, and the second layer bundle pitch diameter ratio is 6;
S04: preparation control wire core unit
According to the operation mode of the step S02, a control insulation layer group 10 is formed by coating the outside of a control wire harness, a control wire core 8 is prepared, after the two control wire cores 8 are twisted, a control metal shielding layer 9 is woven on the outside of the two twisted control wire cores 8, and a control wire core unit 12 is prepared;
s05: cabling cable
The three power wire core units 11, the three control wire core units 12 and the optical fibers 13 are prepared into an internal wire core assembly by adopting a cage winch, wherein in the process, parameters of the cage winch are set as follows: the pitch diameter ratio is 5 times; the optical fibers 13 are positioned among the three power core units 11;
S06: sheath serial extrusion
Coating an inner sheath 2 outside the inner wire core assembly by adopting a serial extrusion device, braiding a braiding layer 3 outside the inner sheath 2, and coating an outer sheath 4 outside the braiding layer 3 to prepare a cable;
wherein the raw material components and weight ratio of the inner sheath 2 and the outer sheath 4 are the same;
The inner sheath 2 comprises the following raw materials in parts by weight: 90 parts of chlorinated polyethylene, 4 parts of calcium carbonate, 16 parts of talcum powder, 2 parts of white carbon black, 1 part of microcrystalline wax, 6 parts of plasticizer DOP, 15 parts of chlorinated paraffin, 4 parts of magnesium oxide, 1 part of calcium zinc stabilizer, 25010 parts of GLC, GZRY-15 parts of DCP, 1 part of TAIC powder and 2 parts of TAIC powder.
The specific flow of step S06 and the specific composition of the serial extrusion device are all described in the embodiment of the second aspect of the present invention.
Example 3
The embodiment provides a cable for a 10kV high-performance coal mining machine, which consists of an inner wire core assembly 1 and a sheath assembly 20 coated outside the inner wire core assembly 1, wherein the sheath assembly 20 comprises an inner sheath 2, a braiding layer 3 and an outer sheath 4 which are sequentially arranged from inside to outside, and the inner sheath 2 is coated outside the inner wire core assembly 1;
The inner wire core assembly 1 is composed of three power wire core units 11, three control wire core units 12 and an optical fiber 13, wherein the optical fiber 13 is composed of 8 single-mode optical fibers and is reinforced by high-strength fibers; the optical fibers 13 are arranged among the four power wire core units 11;
The power wire core unit 11 comprises three power conductors 5 and a conductor insulation layer group 6 coated outside the three power conductors 5, wherein the conductor insulation layer group 6 comprises a conductor shielding layer 61, a power insulation layer 62 and an insulation shielding layer 63 which are sequentially arranged from inside to outside; wherein, the power conductors 5 are made of tin-plated soft copper, the cross-sectional area of the power conductors 5 after being twisted is 185mm 2, the thickness of the conductor shielding layer 61 in the conductor insulating layer group 6 is 1mm, the thickness of the power insulating layer 62 is 6.5mm, and the thickness of the insulating shielding layer 63 is 1.0mm;
the outside of the insulating shielding layer 63 is coated with a conductor metal shielding layer 7;
The control wire core unit 12 comprises three control wire cores 8 and a control metal shielding layer 9 coated outside the three control wire cores 8, and the control wire cores 8 comprise four control conductors 81 and a control insulating layer group 10 coated outside the four control conductors 81; the control conductor 81 is tin-plated soft copper, and the cross-sectional area is 2.5mm 2;
the control insulation layer group 10 has the same structure as the conductor insulation layer group 6, and in the control insulation layer group 10, a three-layer structure which is the same as the conductor insulation layer group 6 is adopted, and the control insulation layer group comprises a control shielding layer, a control insulation layer and a control insulation shielding layer; wherein, the thickness of the control wire conductor shield is 0.2mm, the thickness of the insulation layer is 2.0mm, and the thickness of the control wire insulation shield is 0.15mm.
The embodiment also provides a manufacturing process of the cable for the 10kV high-performance coal mining machine, which comprises the following steps of:
S01: power conductor stranding
Three power conductors 5 are twisted, and the processing technological parameters are as follows: bundle twisting pitch diameter ratio 20, double twisting inner layer pitch diameter ratio 16 and double twisting outer layer pitch diameter ratio 14;
After stranding, carrying out primary annealing treatment on the stranded power conductor 5 in a nitrogen atmosphere, after the primary annealing treatment, placing for 2d, carrying out secondary annealing treatment, and preparing a flexible conductor after the secondary annealing treatment;
wherein the annealing temperature of the primary annealing treatment and the secondary annealing treatment are 280 ℃ and the time is 5 hours;
S02: preparation of a Power core Unit
Respectively feeding an internal insulating material, a rubber material and an external insulating material into three extruders for plasticizing, respectively feeding the plasticized products into three extruder heads of a three-layer co-extruder, placing a flexible conductor into the three-layer co-extruder, forming a conductor shielding layer 61, a power insulating layer 62 and an insulating shielding layer 63 outside the flexible conductor by adopting a three-layer co-extrusion process, and weaving a conductor metal shielding layer 7 outside the insulating shielding layer 63 to prepare a power wire core unit 11;
In step S02, the conductor insulation layer group 6 is made by plasticizing an internal insulation material by an extruder and extruding the plasticized material by an extruder head of a three-layer co-extruder, the power insulation layer 7 is made by plasticizing a rubber material by an extruder and extruding the plasticized material by an extruder head of the three-layer co-extruder, and the insulation shielding layer 71 is made by plasticizing an external insulation material by an extruder and extruding the plasticized material by an extruder head of the three-layer co-extruder;
in step S02, the rubber material includes the following raw materials in parts by weight: 47708 parts of EPDM, 815035 parts of POE, 250440 parts of EPDM, 12 parts of paraffin oil, 30 parts of talcum powder, 80 parts of calcined clay, 2 parts of paraffin, 1.4 parts of anti-aging agent RD, 1.5 parts of anti-aging agent MB, 0.6 part of coupling agent A-1720.6 parts of stearic acid, 3 parts of polyethylene, 5 parts of zinc oxide, 3304 parts of carbon black N, 4 parts of vulcanizing agent DCP and 3 parts of vulcanizing aid TAIC;
The production process of the rubber material is as follows, and the production process is carried out in a dust-free workshop:
step a: weighing all raw materials of the rubber material according to the formula of the rubber material;
Step b: mixing the raw materials at 120 ℃, and preparing sizing materials after mixing without adding vulcanizing agents and vulcanizing aids in the mixing process;
Step c: filtering the sizing material at 130 ℃ by using a primary filter screen;
step d: the sizing material after the primary filtration is subjected to secondary filtration by using a secondary filter screen at 130 ℃;
step e: adding a vulcanizing agent and a vulcanizing aid into the rubber material subjected to secondary filtration, granulating by a granulator, and cooling to prepare a rubber material;
Step f: and (5) placing the prepared rubber material into a hanging bag for sealing and storing.
In step S02, the raw material components and weight ratio of the internal insulating material and the external insulating material are the same;
In step S02, the internal insulating material includes the following raw materials in parts by weight: 40 parts of chlorinated polyethylene, 40 parts of ethylene-vinyl acetate copolymer, 8 parts of magnesium oxide, 18 parts of chlorinated paraffin, 5 parts of dioctyl phthalate, 8 parts of paraffin oil, 10 parts of Vaseline, 68 parts of conductive carbon black, 3 parts of polyethylene wax, 1.5 parts of carbon black dispersing agent, 3 parts of antioxidant RD, 2 parts of antioxidant MB, 2 parts of cross-linking agent DCP and 0.5 part of accelerator TAC;
S03: control conductor twisting
Twisting the four control conductors 81 to prepare a control harness;
Wherein, the control conductor 81 adopts a double-layer stranding process: the first layer bundle pitch diameter ratio is 8, and the second layer bundle pitch diameter ratio is 3;
S04: preparation control wire core unit
According to the operation mode of the step S02, a control insulation layer group 10 is formed by coating the outside of a control wire harness, a control wire core 8 is prepared, after three control wire cores 8 are twisted, a control metal shielding layer 9 is woven on the outside of the three twisted control wire cores 8, and a control wire core unit 12 is prepared;
s05: cabling cable
The three power wire core units 11, the three control wire core units 12 and the optical fibers 13 are prepared into an internal wire core assembly by adopting a cage winch, wherein in the process, parameters of the cage winch are set as follows: the pitch diameter ratio is 5 times; the optical fibers 13 are positioned among the power core units 11;
S06: sheath serial extrusion
Coating an inner sheath 2 outside the inner wire core assembly by adopting a serial extrusion device, braiding a braiding layer 3 outside the inner sheath 2, and coating an outer sheath 4 outside the braiding layer 3 to prepare a cable;
wherein the raw material components and weight ratio of the inner sheath 2 and the outer sheath 4 are the same;
The inner sheath 2 comprises the following raw materials in parts by weight: 70 parts of chlorinated polyethylene, 6 parts of calcium carbonate, 20 parts of talcum powder, 8 parts of white carbon black, 2 parts of microcrystalline wax, 10 parts of plasticizer DOP, 30 parts of chlorinated paraffin, 6 parts of magnesium oxide, 2 parts of calcium zinc stabilizer, 25020 parts of GLC, GZRY-115 parts of DCP, 2 parts of TAIC powder and 3 parts of TAIC powder.
The specific flow of step S06 and the specific composition of the serial extrusion device are all described in the embodiment of the second aspect of the present invention.
Comparative example
The comparative example adopts the existing cable for the coal mining machine, and the model is MCPT.
Experimental example
The cables prepared in examples 1 to 3 and the cables prepared in comparative examples were tested by a test method prescribed by MT818, the cables prepared in examples 1 to 3 were bent 12 ten thousand times, the control core unit and the optical fiber were not broken, the cables in comparative examples were bent 12 ten thousand times, and the control core unit and the optical fiber were broken;
the power frequency voltage test is carried out on the cables prepared in the examples 1-3, and the test results show that the cables prepared in the examples 1-3 can resist 40kV/5min and are not broken down; the cable in the comparative example has large leakage current, withstand voltage of less than 10kV and obvious damage to the insulating layer.
The prepared cables of examples 1-3 were tested for their properties in conductor insulation pack 6 and control insulation pack 10 and inner jacket 2 and outer jacket 4, and the test results are shown in table 3.
TABLE 3 Table 3
As can be seen from the data in table 3, the performance of the conductor insulation pack 6 and the control insulation pack 10 and the inner and outer jackets 2, 4 provided in examples 1-3 are better than the performance of the model MCPT cable provided in the comparative example, indicating that the performance of the 10kV high-performance shearer cable provided by the present invention is better than the performance of the model MCPT cable.
The cable for the 10 kV-level high-performance coal mining machine is suitable for the coal mining machine, and has the advantages of impact resistance, difficult breakdown, strong ageing resistance, long service life and the like.
In the description of the present specification, the descriptions of the terms "one embodiment," "example," "specific example," and the like, mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present invention. In this specification, schematic representations of the above terms do not necessarily refer to the same embodiments or examples. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The foregoing has shown and described the basic principles, principal features and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, and that the above embodiments and descriptions are merely illustrative of the principles of the present invention, and various changes and modifications may be made without departing from the spirit and scope of the invention, which is defined in the appended claims.
Claims (10)
1. The cable for the 10 kV-level high-performance coal mining machine is characterized by comprising an inner wire core assembly (1) and a sheath assembly (20) which is coated outside the inner wire core assembly (1), wherein the sheath assembly (20) comprises an inner sheath (2), a braiding layer (3) and an outer sheath (4) which are sequentially arranged from inside to outside;
the inner wire core assembly (1) comprises a plurality of power wire core units (11), a plurality of control wire core units (12) and optical fibers (13);
The power wire core unit (11) comprises a plurality of power conductors (5) and conductor insulation layer groups (6) coated on the outer parts of the power conductors (5), each conductor insulation layer group (6) comprises a conductor shielding layer (61), a power insulation layer (62) and an insulation shielding layer (63) which are sequentially arranged from inside to outside, and a conductor metal shielding layer (7) is coated on the outer parts of the insulation shielding layers (63).
2. The cable for a 10kV high-performance coal mining machine according to claim 1, wherein: the control wire core unit (12) comprises a plurality of control wire cores (8) and a control metal shielding layer (9) coated outside the control wire cores (8);
The control wire core (8) comprises a plurality of control conductors (81) and a control insulating layer group (10) coated outside the control conductors (81);
The control insulating layer group (10) has the same structure as the conductor insulating layer group (6).
3. A process for manufacturing a cable for a 10 kV-level high-performance coal mining machine according to any one of claims 1 to 2, characterized by comprising the steps of:
S01: power conductor stranding
Twisting a plurality of power conductors (5), after twisting, carrying out primary annealing treatment on the twisted power conductors (5) under a nitrogen atmosphere, after the primary annealing treatment, placing for 1-2d, carrying out secondary annealing treatment, and preparing the flexible conductors after the secondary annealing treatment, wherein the annealing temperatures of the primary annealing treatment and the secondary annealing treatment are 230-280 ℃ and the time is 3-5h;
S02: preparation of a Power core Unit
Respectively feeding an internal insulating material, a rubber material and an external insulating material into three extruders for plasticizing, respectively feeding the plasticized products into three extrusion heads of a three-layer co-extruder, placing a flexible conductor into the three-layer co-extruder, forming a conductor shielding layer (61), a power insulating layer (62) and an insulating shielding layer (63) outside the flexible conductor by adopting a three-layer co-extrusion process, braiding a conductor metal shielding layer (7) outside the insulating shielding layer (63), and preparing a power wire core unit (11), wherein the conductor insulating layer group (6) is prepared by plasticizing the internal insulating material through the extruder and extruding the plasticized material through the extrusion heads of the three-layer co-extruder, the power insulating layer (7) is prepared by plasticizing the rubber material through the extruder and extruding the plasticized material through the extrusion heads of the three-layer co-extruder, and the insulating shielding layer (71) is prepared by plasticizing the external insulating material through the extruder and extruding the plasticized material through the extrusion heads of the three-layer co-extruder;
S03: control conductor twisting
Twisting a plurality of control conductors (81) to prepare a control harness;
S04: preparation control wire core unit
According to the operation mode of the step S02, a control insulation layer group (10) is formed by coating the outside of a control wire harness, a control wire core (8) is prepared, after a plurality of control wire cores (8) are twisted, a control metal shielding layer (9) is woven outside the twisted control wire cores (8), and a control wire core unit (12) is prepared;
s05: cabling cable
Preparing a plurality of power wire core units (11), a plurality of control wire core units (12) and optical fibers (13) into an inner wire core assembly (1) by adopting a cage winch;
S06: sheath serial extrusion
Coating an inner sheath (2) outside the inner wire core assembly (1) sequentially by adopting a serial extrusion device, braiding a braiding layer (3) outside the inner sheath (2), coating an outer sheath (4) outside the braiding layer (3), and performing thermal crosslinking to prepare the cable; the series extrusion equipment comprises a first rubber extruder, a braiding machine, a second rubber extruder and a vulcanization pipeline which are sequentially arranged along the moving direction of the inner wire core assembly (1), wherein the inner sheath (2) is extruded by the first rubber extruder, the braiding layer (3) is braided by the braiding machine, and the outer sheath (4) is extruded by the second rubber extruder.
4. A process for manufacturing a cable for a 10kV high-performance coal mining machine according to claim 3, characterized in that: the rubber material comprises the following raw materials in parts by weight: 47708-12 parts of EPDM, 815035-45 parts of POE, 250430-40 parts of EPDM, 8-12 parts of paraffin oil, 20-30 parts of talcum powder, 70-80 parts of calcined clay, 1-2 parts of paraffin wax, 1.0-1.4 parts of anti-aging agent RD, 0.5-1.5 parts of anti-aging agent MB, 0.4-0.6 part of coupling agent A-1720.4, 0.6 part of stearic acid, 2-3 parts of polyethylene, 3-5 parts of zinc oxide, 2-4 parts of carbon black N3302-4 parts of vulcanizing agent DCP and 1-3 parts of vulcanizing aid TAIC.
5. The process for manufacturing the cable for the 10kV high-performance coal mining machine according to claim 4, wherein the process comprises the following steps of: the rubber material comprises the following raw materials in parts by weight: 477010 parts of EPDM, 815040 parts of POE, 250435 parts of EPDM, 10 parts of paraffin oil, 25 parts of talcum powder, 75 parts of calcined clay, 1.5 parts of paraffin, 1.2 parts of antioxidant RD, 1 part of antioxidant MB, 0.5 part of coupling agent A-1720.5 parts of stearic acid, 2.5 parts of polyethylene, 4 parts of zinc oxide, 3 parts of carbon black N3303 parts of vulcanizing agent DCP, 3.2 parts of vulcanizing aid TAIC and 2 parts of vulcanizing aid.
6. A process for manufacturing a cable for a 10kV high-performance coal mining machine according to claim 3, wherein the preparation process of the rubber material is performed in a dust-free workshop, and the preparation process of the rubber material comprises the following steps:
step a: weighing all raw materials of the rubber material according to a formula;
Step b: mixing the raw materials at 110-120 ℃ to prepare sizing material, wherein a vulcanizing agent and a vulcanizing auxiliary agent are not added in the mixing process;
Step c: filtering the sizing material at 120-130 ℃ by using a primary filter screen; the primary filter screen comprises a first filter layer, a second filter layer, a third filter layer, a fourth filter layer and a fifth filter layer which are sequentially stacked, wherein the apertures of the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are sequentially 40 meshes, 80 meshes, 100 meshes, 80 meshes and 40 meshes, and the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are all made of stainless steel;
Step d: using a secondary filter screen to carry out secondary filtration on the sizing material subjected to primary filtration at 110-130 ℃; the secondary filter screen comprises a sixth filter layer, a seventh filter layer, an eighth filter layer, a ninth filter layer and a tenth filter layer which are sequentially stacked, wherein the pore diameters of the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are 40 meshes, 100 meshes, 80 meshes and 40 meshes in sequence, and the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are all made of stainless steel;
step e: adding a vulcanizing agent and a vulcanizing aid into the rubber material subjected to secondary filtration, granulating by a granulator, and cooling to prepare a rubber material;
step f: placing the prepared rubber material into a hanging bag for sealing and storing; wherein, the material of hanging bag is PP material.
7. A process for manufacturing a cable for a 10kV high-performance coal mining machine according to claim 3, characterized in that: the internal insulating material and the external insulating material have the same raw material components and weight ratio;
The internal insulating material comprises the following raw materials in parts by weight: 30-40 parts of chlorinated polyethylene, 30-40 parts of ethylene-vinyl acetate copolymer, 7-8 parts of magnesium oxide, 12-18 parts of chlorinated paraffin, 3-5 parts of dioctyl phthalate, 6-8 parts of paraffin oil, 6-10 parts of Vaseline, 60-68 parts of conductive carbon black, 1-3 parts of polyethylene wax, 0.5-1.5 parts of carbon black dispersing agent, 1-3 parts of anti-aging agent RD, 1-2 parts of anti-aging agent MB, 2-2.6 parts of cross-linking agent DCP and 0.5-0.9 part of accelerator TAC.
8. The process for manufacturing the cable for the 10kV high-performance coal mining machine according to claim 7, wherein the process comprises the following steps of: the internal insulating material comprises the following raw materials in parts by weight: 35 parts of chlorinated polyethylene, 35 parts of ethylene-vinyl acetate copolymer, 7.2 parts of magnesium oxide, 15 parts of chlorinated paraffin, 4 parts of dioctyl phthalate, 7 parts of paraffin oil, 8 parts of Vaseline, 64 parts of conductive carbon black, 2 parts of polyethylene wax, 1 part of carbon black dispersing agent, 2 parts of antioxidant RD, 1.5 parts of antioxidant MB, 2.3 parts of cross-linking agent DCP and 0.7 part of accelerator TAC.
9. A process for manufacturing a cable for a 10kV high-performance coal mining machine according to claim 3, characterized in that: the raw material components and weight ratio of the inner sheath (2) and the outer sheath (4) are the same;
the inner sheath (2) comprises the following raw materials in parts by weight: 70-90 parts of chlorinated polyethylene, 4-6 parts of calcium carbonate, 16-20 parts of talcum powder, 2-8 parts of white carbon black, 1-2 parts of microcrystalline wax, 6-10 parts of plasticizer DOP, 15-30 parts of chlorinated paraffin, 4-6 parts of magnesium oxide, 1-2 parts of calcium zinc stabilizer, 25010-20 parts of GLC, GZRY-15 parts of DCP, 1-2 parts of TAIC powder and 2-3 parts of TAIC powder.
10. The process for manufacturing the cable for the 10 kV-level high-performance coal mining machine according to claim 9, wherein the process comprises the following steps of: the inner sheath (2) comprises the following raw materials in parts by weight: 80 parts of chlorinated polyethylene, 5 parts of calcium carbonate, 18 parts of talcum powder, 5 parts of white carbon black, 1.7 parts of microcrystalline wax, 8 parts of plasticizer DOP, 19 parts of chlorinated paraffin, 5.2 parts of magnesium oxide, 1.5 parts of calcium zinc stabilizer, 25015 parts of GLC, GZRY-110 parts of DCP, 1.75 parts of TAIC powder and 2.6 parts of TAIC powder.
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| CN202410343975.8A CN118116650A (en) | 2024-03-25 | 2024-03-25 | Cable for 10 kV-level high-performance coal mining machine and manufacturing process thereof |
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