CN118315127A - Cable production process - Google Patents
Cable production process Download PDFInfo
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- CN118315127A CN118315127A CN202410527825.2A CN202410527825A CN118315127A CN 118315127 A CN118315127 A CN 118315127A CN 202410527825 A CN202410527825 A CN 202410527825A CN 118315127 A CN118315127 A CN 118315127A
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- copper
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- insulating layer
- cable
- production process
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 46
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 178
- 229910052802 copper Inorganic materials 0.000 claims abstract description 113
- 239000010949 copper Substances 0.000 claims abstract description 113
- 238000000137 annealing Methods 0.000 claims abstract description 53
- 238000000034 method Methods 0.000 claims abstract description 39
- 238000009413 insulation Methods 0.000 claims abstract description 25
- 238000001953 recrystallisation Methods 0.000 claims abstract description 20
- 238000005242 forging Methods 0.000 claims abstract description 18
- 238000002347 injection Methods 0.000 claims abstract description 13
- 239000007924 injection Substances 0.000 claims abstract description 13
- 238000005253 cladding Methods 0.000 claims abstract description 7
- 239000000203 mixture Substances 0.000 claims abstract description 7
- 238000012360 testing method Methods 0.000 claims description 24
- 239000004020 conductor Substances 0.000 claims description 13
- -1 polyethylene Polymers 0.000 claims description 13
- 229910052709 silver Inorganic materials 0.000 claims description 13
- 239000004332 silver Substances 0.000 claims description 13
- 239000011248 coating agent Substances 0.000 claims description 12
- 238000000576 coating method Methods 0.000 claims description 12
- 238000001514 detection method Methods 0.000 claims description 12
- 238000005868 electrolysis reaction Methods 0.000 claims description 12
- 239000003792 electrolyte Substances 0.000 claims description 12
- 238000005096 rolling process Methods 0.000 claims description 12
- 239000000463 material Substances 0.000 claims description 11
- 239000000243 solution Substances 0.000 claims description 7
- 239000004709 Chlorinated polyethylene Substances 0.000 claims description 6
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 claims description 6
- 239000004698 Polyethylene Substances 0.000 claims description 6
- 238000005452 bending Methods 0.000 claims description 6
- XTVVROIMIGLXTD-UHFFFAOYSA-N copper(II) nitrate Chemical compound [Cu+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O XTVVROIMIGLXTD-UHFFFAOYSA-N 0.000 claims description 6
- 238000005520 cutting process Methods 0.000 claims description 6
- 229920002681 hypalon Polymers 0.000 claims description 6
- 229910017604 nitric acid Inorganic materials 0.000 claims description 6
- 150000004767 nitrides Chemical class 0.000 claims description 6
- 229920001084 poly(chloroprene) Polymers 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 6
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 6
- 239000004800 polyvinyl chloride Substances 0.000 claims description 6
- 238000003825 pressing Methods 0.000 claims description 6
- 238000007670 refining Methods 0.000 claims description 6
- 238000003466 welding Methods 0.000 claims description 6
- 239000010410 layer Substances 0.000 description 106
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 11
- 239000001301 oxygen Substances 0.000 description 6
- 229910052760 oxygen Inorganic materials 0.000 description 6
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 5
- 239000003063 flame retardant Substances 0.000 description 5
- 238000005260 corrosion Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 241001391944 Commicarpus scandens Species 0.000 description 2
- AZDRQVAHHNSJOQ-UHFFFAOYSA-N alumane Chemical group [AlH3] AZDRQVAHHNSJOQ-UHFFFAOYSA-N 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- 238000002485 combustion reaction Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000011241 protective layer Substances 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 230000002929 anti-fatigue Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000009954 braiding Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 229920002313 fluoropolymer Polymers 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 238000007750 plasma spraying Methods 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Landscapes
- Manufacturing Of Electric Cables (AREA)
Abstract
The invention discloses a cable production process, which is characterized by comprising the following steps: the method comprises the following steps: s1, preparing ultra-high purity copper; s2, forging a copper billet: placing the deposited copper in a die for die forging, and manufacturing the deposited copper into a blank; s3, drawing a core wire: at 60-90 ℃, a turbine and a plurality of stretching dies are matched, and the mixture is drawn into filaments; s4, core wire destressing: firstly adopting an annealing process to remove the stress of the monofilament, carrying out recrystallization annealing on the copper monofilament, wherein the recrystallization annealing temperature is 440-520 ℃, preserving the heat for 3 hours, then carrying out low-temperature annealing, and preserving the heat for 1 hour at the low-temperature annealing temperature of 240-250 ℃; s5, twisting: more than 10 single wires are formed into an interweaving state in a anticlockwise or clockwise mode; s6, inner layer cladding: and (3) enabling the hinged copper wire to pass through an injection mold, so that the surface of the copper wire is coated with an inner insulation layer. The invention has simple process and low production cost.
Description
Technical Field
The invention belongs to the field of cables, and particularly relates to a cable production process.
Background
Copper cables have many advantages, such as: the resistivity of the copper core is low: the resistivity of the aluminum core is about 1.68 times higher than that of the copper core; the copper core has good ductility; the copper core has high strength: allowable stress at normal temperature can reach 20 percent, and the aluminum is 15.6kgt/mm < 2 >; copper core anti-fatigue: the aluminum material is repeatedly bent and is easy to break, and copper is not easy to break; the copper core has good stability and corrosion resistance: copper cores are oxidation resistant and corrosion resistant, while aluminum cores are susceptible to oxidation and corrosion.
Reference may be made to chinese patent publication No. CN111403115B, which relates to a process for producing a cable with stable amplitude and phase, which comprises the following steps: the method comprises the steps that a low-density polytetrafluoroethylene wrapping tape wrapping process is adopted on a central conductor to serve as an insulating medium layer of a cable; and carrying out a silver tape wrapping process on the medium layer after high-temperature shaping to form an inner layer shield of the cable, carrying out a silver-plated copper wire braiding process on the inner layer shield to serve as a protective layer of the outer shield layer and the cable, and then extruding out high-temperature fluoroplastic to form an environment-resistant protective layer of the cable, wherein the medium layer is required to be subjected to high-low temperature cold and heat treatment, the cable after the high-low temperature cold and heat treatment is subjected to plasma spraying treatment in advance during the silver-plated copper tape wrapping production in the next procedure, and on the basis of not changing the original stable-amplitude and stable-phase cable structure, the thermal expansion coefficient and the cold contraction coefficient of the cable are close when the cable is extruded out of the sheath at high temperature by controlling the production process, so that the gap between the second medium layer and the third layer of the inner layer shield is reduced, and the stable-phase performance is improved.
The above patent has many advantages, but it also has drawbacks such as: the production process is complex and the production cost is high.
Disclosure of Invention
The present invention is directed to a cable production process, which solves the problems set forth in the above-mentioned background art.
In order to achieve the above purpose, the present invention provides the following technical solutions:
a cable production process comprising the steps of:
S1, preparing ultra-high purity copper: firstly, adopting electrolytic copper nitrate solution to refine copper, then adopting 4N-level copper as an anode to electrolyze, and after one-time re-electrolysis, improving the 4N-level copper to 5N-level ultra-high purity copper; then, dissolving high-purity copper with the purity of 5N in electronic pure HNO3, and carrying out electrolytic refining by taking the high-purity copper with the purity of 5N as an anode to obtain deposited copper;
s2, forging a copper billet: placing the deposited copper in a die for die forging, and manufacturing the deposited copper into a blank;
S3, drawing a core wire: at 60-90 ℃, a turbine and a plurality of stretching dies are matched, and the mixture is drawn into filaments;
S4, core wire destressing: firstly adopting an annealing process to remove the stress of the monofilament, carrying out recrystallization annealing on the copper monofilament, wherein the recrystallization annealing temperature is 440-520 ℃, preserving the heat for 3 hours, then carrying out low-temperature annealing, and preserving the heat for 1 hour at the low-temperature annealing temperature of 240-250 ℃;
s5, twisting: more than 10 single wires are formed into an interweaving state in a anticlockwise or clockwise mode, spiral regular stranding is adopted, and a compacting mode is adopted while conductors are stranded, so that the single wires are fastened into a whole;
S6, inner layer cladding: the hinged copper wire passes through an injection mold, and the surface of the copper wire is coated with an inner insulating layer;
s7, coating the outer layer: coating an outer insulating layer on the cable coated with the inner insulating layer through an injection mold again;
S8, flaw detection: checking whether an inner insulating layer and an outer insulating layer in the cable are damaged;
S9, marking and rolling: and marking the qualified cable by using a marking machine, and rolling the qualified cable into a roll.
Preferably, in S1, when silver in the electrolyte is greater than 0.08ppm, nitride in the electrolyte is removed under a weak vacuum, and the silver is removed by electrolysis using an insoluble anode.
Preferably, in the step S2, the deposited copper is put in a die to be die-forged when forging the copper billet, the deposited copper is manufactured into a billet, and the die and the copper billet are heated to 300-400 ℃ to be hot-forged when forging.
Preferably, when the inner layer is coated, the inner layer insulating layer at least comprises two layers, and the inner layer insulating layer is made of two of polyvinyl chloride, polyethylene and poly (perfluoroethylene propylene).
Preferably, the S3 is to prepare the copper wire and the wire coil when the core wire is drawn, measure the required length and thickness, fix one end of the copper wire on the pliers and transmit to the turbine, in the turbine, pull the copper wire to the designed length and thickness by adjusting the force, speed and angle parameters of the machine, extend to the position needed to be used, cut the tail of the copper wire and fix the tail of the copper wire at the designed position.
Preferably, when the S4 core wire is destressed, an annealing process is adopted to remove the stress of the monofilament, the copper monofilament is subjected to recrystallization annealing at 480-500 ℃ for 3 hours, then low-temperature annealing is carried out at 240-245 ℃ for 1 hour.
Preferably, the step S5 of inspecting the apparatus before the start of the twisting process when twisting the copper wire includes: checking whether each part of the stranding machine is normal or not and whether the operation part has an obstacle or not; checking whether the safety of the electromechanical equipment, an electric switch and a hurdle is normal or not; checking whether the butt welding machine is normal; checking whether the tool and the measuring tool are complete; selecting a pressing die according to the requirements of a dispatching bill and a process card, replacing a pitch tooth-lapping gear, and replacing a twisting direction to measure the wire diameter; after twisting, checking whether the twisted wire core is compact, round, straight, free of severe bending, free of strand jump, free of scratch and flattening, whether the wire diameter meets the tolerance regulation and whether the length meets the regulation requirement.
Preferably, when the outer layer is coated with the S7, the outer insulating layer includes at least two layers, and the outer insulating layer is two of chlorinated polyethylene, chlorosulfonated polyethylene and neoprene.
Preferably, when the flaw detection is performed in the step S8, the cut-off part of the material is subjected to a conductor direct current resistance test, an insulation resistance test, a finished product voltage test and an insulation wire core voltage test, and whether the tensile strength and the elongation at break of the inner insulation layer and the outer insulation layer meet the requirements is detected.
Compared with the prior art, the invention has the beneficial effects that:
the cable core in the cable production process is formed by intertwisting stranded wires and wrapping the stranded wires by an inner insulating layer and an outer insulating layer, has high pressure resistance and high wear resistance, and in addition, the copper core in the cable is high-purity copper and has good conductivity. The invention has simple production process and low production cost.
Drawings
FIG. 1 is a flow chart of 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.
Example 1
A cable production process comprising the steps of:
S1, preparing ultra-high purity copper: firstly, adopting electrolytic copper nitrate solution to refine copper, then adopting 4N-level copper as an anode to electrolyze, and after one-time re-electrolysis, improving the 4N-level copper to 5N-level ultra-high purity copper; then, dissolving high-purity copper with the purity of 5N in electronic pure HNO3, and carrying out electrolytic refining by taking the high-purity copper with the purity of 5N as an anode to obtain deposited copper;
s2, forging a copper billet: placing the deposited copper in a die for die forging, and manufacturing the deposited copper into a blank;
S3, drawing a core wire: at 60-90 ℃, a turbine and a plurality of stretching dies are matched, and the mixture is drawn into filaments;
S4, core wire destressing: firstly adopting an annealing process to remove the stress of the monofilament, carrying out recrystallization annealing on the copper monofilament, wherein the recrystallization annealing temperature is 440-520 ℃, preserving the heat for 3 hours, then carrying out low-temperature annealing, and preserving the heat for 1 hour at the low-temperature annealing temperature of 240-250 ℃;
s5, twisting: more than 10 single wires are formed into an interweaving state in a anticlockwise or clockwise mode, spiral regular stranding is adopted, and a compacting mode is adopted while conductors are stranded, so that the single wires are fastened into a whole;
S6, inner layer cladding: the hinged copper wire passes through an injection mold, and the surface of the copper wire is coated with an inner insulating layer;
s7, coating the outer layer: coating an outer insulating layer on the cable coated with the inner insulating layer through an injection mold again;
S8, flaw detection: checking whether an inner insulating layer and an outer insulating layer in the cable are damaged;
S9, marking and rolling: and marking the qualified cable by using a marking machine, and rolling the qualified cable into a roll.
In the step S1, when the silver content in the electrolyte is more than 0.08ppm, nitride in the electrolyte is removed under a weak vacuum, and the silver is removed by electrolysis with an insoluble anode.
In the step S2, when the copper billet is forged, the deposited copper is put in a die to be die forged, the deposited copper is manufactured into a billet, and when the copper billet is forged, the die and the copper billet are heated to 300-400 ℃ and then are hot forged.
And when the S6 is coated on the inner layer, the inner insulating layer at least comprises two layers, and the inner insulating layer is made of two of polyvinyl chloride, polyethylene and poly (perfluoroethylene propylene).
And S3, when the core wire is drawn, preparing the copper wire and the wire coil, measuring the required length and thickness, fixing the copper wire at one end on the pliers, transmitting the copper wire to a turbine, drawing the copper wire out to the designed length and thickness by adjusting the force, speed and angle parameters of the machine in the turbine, extending to the position required to be used, cutting the tail of the copper wire, and fixing the tail of the copper wire at the designed position.
When the S4 core wire is subjected to stress relief, an annealing process is adopted to remove the stress of the monofilament, the copper monofilament is subjected to recrystallization annealing at 480-500 ℃ for 3 hours, then low-temperature annealing is carried out at 240-245 ℃ for 1 hour.
Wherein, when the copper wire is twisted, the S5 checks the equipment before the twisting process starts, and the method comprises the following steps: checking whether each part of the stranding machine is normal or not and whether the operation part has an obstacle or not; checking whether the safety of the electromechanical equipment, an electric switch and a hurdle is normal or not; checking whether the butt welding machine is normal; checking whether the tool and the measuring tool are complete; selecting a pressing die according to the requirements of a dispatching bill and a process card, replacing a pitch tooth-lapping gear, and replacing a twisting direction to measure the wire diameter; after twisting, checking whether the twisted wire core is compact, round, straight, free of severe bending, free of strand jump, free of scratch and flattening, whether the wire diameter meets the tolerance regulation and whether the length meets the regulation requirement.
Wherein, when the S7 is coated on the outer layer, the outer insulating layer at least comprises two layers, and the outer insulating layer is two of chlorinated polyethylene, chlorosulfonated polyethylene and neoprene.
And when the flaw detection is carried out in the S8, the cut-off part material is subjected to a conductor direct current resistance test, an insulation resistance test, a finished product voltage test and an insulation wire core voltage test, and whether the tensile strength and the elongation at break of the inner insulation layer and the outer insulation layer meet the requirements is detected.
The cable core in the cable production process is formed by intertwisting stranded wires and wrapping the stranded wires by an inner insulating layer and an outer insulating layer, and has high pressure resistance and high wear resistance. The invention has simple production process and low production cost.
Example 2
A cable production process comprising the steps of:
S1, preparing ultra-high purity copper: firstly, adopting electrolytic copper nitrate solution to refine copper, then adopting 4N-level copper as an anode to electrolyze, and after one-time re-electrolysis, improving the 4N-level copper to 5N-level ultra-high purity copper; then, dissolving high-purity copper with the purity of 5N in electronic pure HNO3, and carrying out electrolytic refining by taking the high-purity copper with the purity of 5N as an anode to obtain deposited copper;
s2, forging a copper billet: placing the deposited copper in a die for die forging, and manufacturing the deposited copper into a blank;
S3, drawing a core wire: at 60-90 ℃, a turbine and a plurality of stretching dies are matched, and the mixture is drawn into filaments;
S4, core wire destressing: firstly adopting an annealing process to remove the stress of the monofilament, carrying out recrystallization annealing on the copper monofilament, wherein the recrystallization annealing temperature is 440-520 ℃, preserving the heat for 3 hours, then carrying out low-temperature annealing, and preserving the heat for 1 hour at the low-temperature annealing temperature of 240-250 ℃;
s5, twisting: more than 10 single wires are formed into an interweaving state in a anticlockwise or clockwise mode, spiral regular stranding is adopted, and a compacting mode is adopted while conductors are stranded, so that the single wires are fastened into a whole;
S6, inner layer cladding: the hinged copper wire passes through an injection mold, and the surface of the copper wire is coated with an inner insulating layer;
s7, coating the outer layer: coating an outer insulating layer on the cable coated with the inner insulating layer through an injection mold again;
S8, flaw detection: checking whether an inner insulating layer and an outer insulating layer in the cable are damaged;
S9, marking and rolling: and marking the qualified cable by using a marking machine, and rolling the qualified cable into a roll.
In the step S1, when the silver content in the electrolyte is more than 0.08ppm, nitride in the electrolyte is removed under a weak vacuum, and the silver is removed by electrolysis with an insoluble anode.
In the step S2, when the copper billet is forged, the deposited copper is put in a die to be die forged, the deposited copper is manufactured into a billet, and when the copper billet is forged, the die and the copper billet are heated to 300-400 ℃ and then are hot forged.
And when the S6 is coated on the inner layer, the inner insulating layer at least comprises two layers, and the inner insulating layer is made of two of polyvinyl chloride, polyethylene and poly (perfluoroethylene propylene).
And S3, when the core wire is drawn, preparing the copper wire and the wire coil, measuring the required length and thickness, fixing the copper wire at one end on the pliers, transmitting the copper wire to a turbine, drawing the copper wire out to the designed length and thickness by adjusting the force, speed and angle parameters of the machine in the turbine, extending to the position required to be used, cutting the tail of the copper wire, and fixing the tail of the copper wire at the designed position.
When the S4 core wire is subjected to stress relief, an annealing process is adopted to remove the stress of the monofilament, the copper monofilament is subjected to recrystallization annealing at 480-500 ℃ for 3 hours, then low-temperature annealing is carried out at 240-245 ℃ for 1 hour.
Wherein, when the copper wire is twisted, the S5 checks the equipment before the twisting process starts, and the method comprises the following steps: checking whether each part of the stranding machine is normal or not and whether the operation part has an obstacle or not; checking whether the safety of the electromechanical equipment, an electric switch and a hurdle is normal or not; checking whether the butt welding machine is normal; checking whether the tool and the measuring tool are complete; selecting a pressing die according to the requirements of a dispatching bill and a process card, replacing a pitch tooth-lapping gear, and replacing a twisting direction to measure the wire diameter; after twisting, checking whether the twisted wire core is compact, round, straight, free of severe bending, free of strand jump, free of scratch and flattening, whether the wire diameter meets the tolerance regulation and whether the length meets the regulation requirement.
Wherein, when the S7 is coated on the outer layer, the outer insulating layer at least comprises two layers, and the outer insulating layer is two of chlorinated polyethylene, chlorosulfonated polyethylene and neoprene.
And when the flaw detection is carried out in the S8, the cut-off part material is subjected to a conductor direct current resistance test, an insulation resistance test, a finished product voltage test and an insulation wire core voltage test, and whether the tensile strength and the elongation at break of the inner insulation layer and the outer insulation layer meet the requirements is detected.
The cable core in the cable production process is formed by intertwisting stranded wires and wrapping the stranded wires by an inner insulating layer and an outer insulating layer, and has high pressure resistance and high wear resistance. The invention has simple production process and low production cost.
Example 3
A cable production process comprising the steps of:
S1, preparing ultra-high purity copper: firstly, adopting electrolytic copper nitrate solution to refine copper, then adopting 4N-level copper as an anode to electrolyze, and after one-time re-electrolysis, improving the 4N-level copper to 5N-level ultra-high purity copper; then, dissolving high-purity copper with the purity of 5N in electronic pure HNO3, and carrying out electrolytic refining by taking the high-purity copper with the purity of 5N as an anode to obtain deposited copper;
s2, forging a copper billet: placing the deposited copper in a die for die forging, and manufacturing the deposited copper into a blank;
S3, drawing a core wire: at 60-90 ℃, a turbine and a plurality of stretching dies are matched, and the mixture is drawn into filaments;
S4, core wire destressing: firstly adopting an annealing process to remove the stress of the monofilament, carrying out recrystallization annealing on the copper monofilament, wherein the recrystallization annealing temperature is 440-520 ℃, preserving the heat for 3 hours, then carrying out low-temperature annealing, and preserving the heat for 1 hour at the low-temperature annealing temperature of 240-250 ℃;
s5, twisting: more than 10 single wires are formed into an interweaving state in a anticlockwise or clockwise mode, spiral regular stranding is adopted, and a compacting mode is adopted while conductors are stranded, so that the single wires are fastened into a whole;
S6, inner layer cladding: the hinged copper wire passes through an injection mold, and the surface of the copper wire is coated with an inner insulating layer;
s7, coating the outer layer: coating an outer insulating layer on the cable coated with the inner insulating layer through an injection mold again;
S8, flaw detection: checking whether an inner insulating layer and an outer insulating layer in the cable are damaged;
S9, marking and rolling: and marking the qualified cable by using a marking machine, and rolling the qualified cable into a roll.
In the step S1, when the silver content in the electrolyte is more than 0.08ppm, nitride in the electrolyte is removed under a weak vacuum, and the silver is removed by electrolysis with an insoluble anode.
In the step S2, when the copper billet is forged, the deposited copper is put in a die to be die forged, the deposited copper is manufactured into a billet, and when the copper billet is forged, the die and the copper billet are heated to 300-400 ℃ and then are hot forged.
And when the S6 is coated on the inner layer, the inner insulating layer at least comprises two layers, and the inner insulating layer is made of two of polyvinyl chloride, polyethylene and poly (perfluoroethylene propylene).
And S3, when the core wire is drawn, preparing the copper wire and the wire coil, measuring the required length and thickness, fixing the copper wire at one end on the pliers, transmitting the copper wire to a turbine, drawing the copper wire out to the designed length and thickness by adjusting the force, speed and angle parameters of the machine in the turbine, extending to the position required to be used, cutting the tail of the copper wire, and fixing the tail of the copper wire at the designed position.
When the S4 core wire is subjected to stress relief, an annealing process is adopted to remove the stress of the monofilament, the copper monofilament is subjected to recrystallization annealing at 480-500 ℃ for 3 hours, then low-temperature annealing is carried out at 240-245 ℃ for 1 hour.
Wherein, when the copper wire is twisted, the S5 checks the equipment before the twisting process starts, and the method comprises the following steps: checking whether each part of the stranding machine is normal or not and whether the operation part has an obstacle or not; checking whether the safety of the electromechanical equipment, an electric switch and a hurdle is normal or not; checking whether the butt welding machine is normal; checking whether the tool and the measuring tool are complete; selecting a pressing die according to the requirements of a dispatching bill and a process card, replacing a pitch tooth-lapping gear, and replacing a twisting direction to measure the wire diameter; after twisting, checking whether the twisted wire core is compact, round, straight, free of severe bending, free of strand jump, free of scratch and flattening, whether the wire diameter meets the tolerance regulation and whether the length meets the regulation requirement.
Wherein, when the S7 is coated on the outer layer, the outer insulating layer at least comprises two layers, and the outer insulating layer is two of chlorinated polyethylene, chlorosulfonated polyethylene and neoprene.
And when the flaw detection is carried out in the S8, the cut-off part material is subjected to a conductor direct current resistance test, an insulation resistance test, a finished product voltage test and an insulation wire core voltage test, and whether the tensile strength and the elongation at break of the inner insulation layer and the outer insulation layer meet the requirements is detected.
The cable core in the cable production process is formed by intertwisting stranded wires and wrapping the stranded wires by an inner insulating layer and an outer insulating layer, and has high pressure resistance and high wear resistance. The invention has simple production process and low production cost.
Example 4
A cable production process comprising the steps of:
S1, preparing ultra-high purity copper: firstly, adopting electrolytic copper nitrate solution to refine copper, then adopting 4N-level copper as an anode to electrolyze, and after one-time re-electrolysis, improving the 4N-level copper to 5N-level ultra-high purity copper; then, dissolving high-purity copper with the purity of 5N in electronic pure HNO3, and carrying out electrolytic refining by taking the high-purity copper with the purity of 5N as an anode to obtain deposited copper;
s2, forging a copper billet: placing the deposited copper in a die for die forging, and manufacturing the deposited copper into a blank;
S3, drawing a core wire: at 60-90 ℃, a turbine and a plurality of stretching dies are matched, and the mixture is drawn into filaments;
S4, core wire destressing: firstly adopting an annealing process to remove the stress of the monofilament, carrying out recrystallization annealing on the copper monofilament, wherein the recrystallization annealing temperature is 440-520 ℃, preserving the heat for 3 hours, then carrying out low-temperature annealing, and preserving the heat for 1 hour at the low-temperature annealing temperature of 240-250 ℃;
s5, twisting: more than 10 single wires are formed into an interweaving state in a anticlockwise or clockwise mode, spiral regular stranding is adopted, and a compacting mode is adopted while conductors are stranded, so that the single wires are fastened into a whole;
S6, inner layer cladding: the hinged copper wire passes through an injection mold, and the surface of the copper wire is coated with an inner insulating layer;
s7, coating the outer layer: coating an outer insulating layer on the cable coated with the inner insulating layer through an injection mold again;
S8, flaw detection: checking whether an inner insulating layer and an outer insulating layer in the cable are damaged;
S9, marking and rolling: and marking the qualified cable by using a marking machine, and rolling the qualified cable into a roll.
In the step S1, when the silver content in the electrolyte is more than 0.08ppm, nitride in the electrolyte is removed under a weak vacuum, and the silver is removed by electrolysis with an insoluble anode.
In the step S2, when the copper billet is forged, the deposited copper is put in a die to be die forged, the deposited copper is manufactured into a billet, and when the copper billet is forged, the die and the copper billet are heated to 300-400 ℃ and then are hot forged.
And when the S6 is coated on the inner layer, the inner insulating layer at least comprises two layers, and the inner insulating layer is made of two of polyvinyl chloride, polyethylene and poly (perfluoroethylene propylene).
And S3, when the core wire is drawn, preparing the copper wire and the wire coil, measuring the required length and thickness, fixing the copper wire at one end on the pliers, transmitting the copper wire to a turbine, drawing the copper wire out to the designed length and thickness by adjusting the force, speed and angle parameters of the machine in the turbine, extending to the position required to be used, cutting the tail of the copper wire, and fixing the tail of the copper wire at the designed position.
When the S4 core wire is subjected to stress relief, an annealing process is adopted to remove the stress of the monofilament, the copper monofilament is subjected to recrystallization annealing at 480-500 ℃ for 3 hours, then low-temperature annealing is carried out at 240-245 ℃ for 1 hour.
Wherein, when the copper wire is twisted, the S5 checks the equipment before the twisting process starts, and the method comprises the following steps: checking whether each part of the stranding machine is normal or not and whether the operation part has an obstacle or not; checking whether the safety of the electromechanical equipment, an electric switch and a hurdle is normal or not; checking whether the butt welding machine is normal; checking whether the tool and the measuring tool are complete; selecting a pressing die according to the requirements of a dispatching bill and a process card, replacing a pitch tooth-lapping gear, and replacing a twisting direction to measure the wire diameter; after twisting, checking whether the twisted wire core is compact, round, straight, free of severe bending, free of strand jump, free of scratch and flattening, whether the wire diameter meets the tolerance regulation and whether the length meets the regulation requirement.
Wherein, when the S7 is coated on the outer layer, the outer insulating layer at least comprises two layers, and the outer insulating layer is two of chlorinated polyethylene, chlorosulfonated polyethylene and neoprene.
And when the flaw detection is carried out in the S8, the cut-off part material is subjected to a conductor direct current resistance test, an insulation resistance test, a finished product voltage test and an insulation wire core voltage test, and whether the tensile strength and the elongation at break of the inner insulation layer and the outer insulation layer meet the requirements is detected.
The cable core in the cable production process is formed by intertwisting stranded wires and wrapping the stranded wires by an inner insulating layer and an outer insulating layer, and has high pressure resistance and high wear resistance. The invention has simple production process and low production cost.
The cables of example 1, example 2 and example 3 and the conventional cables were tested for flame retardance by the flame retardant cable evaluation method-oxygen index method according to the electric wire and cable combustion standard specified in GB 12666-1990, the specific operation being that the cable material maintains the minimum oxygen content required for smooth combustion in an oxygen and nitrogen mixed gas stream under the specified conditions, the high oxygen index indicates that the cable material is not easy to burn, the low oxygen index indicates that the cable material is easy to burn, wherein the oxygen index (LoI) of the cable material corresponds to the flame retardance thereof as follows: the LOI <23 is flammable, the LOI 24-28 is slightly flame retardant, the LOI29-35 is flame retardant, the LOI >36 is highly flame retardant, and the LOI values of the cables of the example 1, the example 2 and the example 3 and the conventional cables obtained by the experiment are uniformly given in the following table:
| example 1 | Example 2 | Example 3 | Conventional cable | |
| LOI value | 51 | 23 | 45 | 43 |
From the above table, it is clear that the cables of examples 1 to 3 all belong to high flame retardant cables, all are superior to the conventional cables, and the flame retardancy of the cable of example 1 is strongest.
Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (9)
1. The cable production process is characterized by comprising the following steps of:
S1, preparing ultra-high purity copper: firstly, adopting electrolytic copper nitrate solution to refine copper, then adopting 4N-level copper as an anode to electrolyze, and after one-time re-electrolysis, improving the 4N-level copper to 5N-level ultra-high purity copper; then, dissolving high-purity copper with the purity of 5N in electronic pure HNO3, and carrying out electrolytic refining by taking the high-purity copper with the purity of 5N as an anode to obtain deposited copper;
s2, forging a copper billet: placing the deposited copper in a die for die forging, and manufacturing the deposited copper into a blank;
S3, drawing a core wire: at 60-90 ℃, a turbine and a plurality of stretching dies are matched, and the mixture is drawn into filaments;
S4, core wire destressing: firstly adopting an annealing process to remove the stress of the monofilament, carrying out recrystallization annealing on the copper monofilament, wherein the recrystallization annealing temperature is 440-520 ℃, preserving the heat for 3 hours, then carrying out low-temperature annealing, and preserving the heat for 1 hour at the low-temperature annealing temperature of 240-250 ℃;
s5, twisting: more than 10 single wires are formed into an interweaving state in a anticlockwise or clockwise mode, spiral regular stranding is adopted, and a compacting mode is adopted while conductors are stranded, so that the single wires are fastened into a whole;
S6, inner layer cladding: the hinged copper wire passes through an injection mold, and the surface of the copper wire is coated with an inner insulating layer;
s7, coating the outer layer: coating an outer insulating layer on the cable coated with the inner insulating layer through an injection mold again;
S8, flaw detection: checking whether an inner insulating layer and an outer insulating layer in the cable are damaged;
S9, marking and rolling: and marking the qualified cable by using a marking machine, and rolling the qualified cable into a roll.
2. A cable production process according to claim 1, wherein in S1, when silver in the electrolyte is greater than 0.08ppm, nitride in the electrolyte is removed under a weak vacuum, and the silver is removed by electrolysis using an insoluble anode.
3. A cable production process according to claim 1, wherein in S2, the deposited copper is put in a die for forging to be made into a billet, and the die and the copper billet are heated to 300-400 ℃ for hot forging.
4. A cable production process according to claim 1, wherein: and S6, when the inner layer is coated, the inner layer insulating layer at least comprises two layers, and the inner layer insulating layer is made of two of polyvinyl chloride, polyethylene and poly (perfluoroethylene propylene).
5. A cable production process according to claim 1, wherein: and S3, when the core wire is drawn, preparing the copper wire and the wire coil, measuring the required length and thickness, fixing the copper wire at one end on pliers, transmitting the copper wire to a turbine, drawing the copper wire to the designed length and thickness by adjusting the force, speed and angle parameters of the machine in the turbine, extending the copper wire to the position required to be used, cutting the tail of the copper wire, and fixing the copper wire at the designed position.
6. A cable production process according to claim 1, wherein: when the S4 core wire is subjected to stress relief, an annealing process is adopted to remove the stress of the monofilament, the copper monofilament is subjected to recrystallization annealing at 480-500 ℃ for 3 hours, then low-temperature annealing is carried out at 240-245 ℃ for 1 hour.
7. A cable production process according to claim 1, wherein: and S5, when the copper wire is twisted, checking equipment before the twisting process starts, wherein the method comprises the following steps of: checking whether each part of the stranding machine is normal or not and whether the operation part has an obstacle or not; checking whether the safety of the electromechanical equipment, an electric switch and a hurdle is normal or not; checking whether the butt welding machine is normal; checking whether the tool and the measuring tool are complete; selecting a pressing die according to the requirements of a dispatching bill and a process card, replacing a pitch tooth-lapping gear, and replacing a twisting direction to measure the wire diameter; after twisting, checking whether the twisted wire core is compact, round, straight, free of severe bending, free of strand jump, free of scratch and flattening, whether the wire diameter meets the tolerance regulation and whether the length meets the regulation requirement.
8. A cable production process according to claim 1, wherein: and when the S7 is coated on the outer layer, the outer insulating layer at least comprises two layers, and the outer insulating layer is made of two of chlorinated polyethylene, chlorosulfonated polyethylene and neoprene.
9. A cable production process according to claim 1, wherein: and S8, during flaw detection, cutting off part of materials to perform a conductor direct current resistance test, an insulation resistance test, a finished voltage test and an insulation wire core voltage test, and detecting whether the tensile strength and the elongation at break of the inner insulation layer and the outer insulation layer meet the requirements.
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| CN202410527825.2A CN118315127A (en) | 2024-04-29 | 2024-04-29 | Cable production process |
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