CN211125080U - Cable core cooling cable - Google Patents
Cable core cooling cable Download PDFInfo
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- CN211125080U CN211125080U CN201922224817.8U CN201922224817U CN211125080U CN 211125080 U CN211125080 U CN 211125080U CN 201922224817 U CN201922224817 U CN 201922224817U CN 211125080 U CN211125080 U CN 211125080U
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Abstract
A cable core cooling cable is formed by sequentially wrapping a non-woven fabric layer and an outer sheath outside a cable core; the cable core is a circular-section cable formed by filling and twisting a pair of cooling hoses, a pair of main wire cores, a pair of auxiliary power supply wire cores, a pair of 2-core signal wire cores, a pair of 4-core signal wire cores and the cable core; the range of the twist pitch diameter ratio is 12-14 times; on any radial section of the cable, the paired cooling hoses, the main wire core, the auxiliary power supply wire core, the 2-core signal wire core and the 4-core signal wire core are in mirror symmetry; the outer diameter range of the cooling hose is 6.5mm to 7.5mm, the outer diameter range of the main wire core is 10.8mm to 11.4mm, the outer diameter range of the auxiliary power wire core is 4.3mm to 4.7mm, the outer diameter range of the 2-core signal wire core is 6.6mm to 7.0mm, and the outer diameter range of the 4-core signal wire core is 7.2mm to 7.8 mm. The cooling hose is a hollow conduit of elastomeric material.
Description
Technical Field
This technical scheme belongs to cable technical field, specifically is a cable core cooling cable.
Background
The new energy electric automobile mostly adopts a high-power charging mode, the current of the mode is large (increased from 250A to 400A or above), in order to solve the heating phenomenon of the cable, the diameter of a wire harness is thickened (more than 50 mm), the charging operability is reduced, and the economical efficiency of the scheme is reduced. Therefore, a cable with a small wire diameter is used for transmitting a large current, and a heat generating source of the cable is cooled. The commonly used refrigerant includes water cooling or air cooling, and compared, the water cooling is higher just to the waterproof insulating requirement of interface and cable, and the cost is also higher, is applicable to the shorter transmission distance of length. For longer transmission distances, air cooling is more appropriate. In terms of cooling effect, the heating source of the cable is a conductor, and on the premise of not influencing the function/performance of the cable, the closer the refrigerant is to the conductor, the better, and the development direction of the cooling cable is realized.
Disclosure of Invention
In order to solve the problem that the cooling efficiency of the air-cooled cable is improved and the wire diameter of the cable is reduced on the premise of not influencing the function/performance of the cable in the prior art, the technical scheme provides a cable core cooling cable and a preparation method of the air-cooled cable for the cable, and the preparation method specifically comprises the following steps:
a cable core cooling cable is formed by sequentially wrapping a non-woven fabric layer and an outer sheath outside a cable core;
the cable core is a circular-section cable formed by filling and twisting a pair of cooling hoses, a pair of main wire cores, a pair of auxiliary power supply wire cores, a pair of 2-core signal wire cores, a pair of 4-core signal wire cores and the cable core; the range of the twist pitch diameter ratio is 12-14 times;
on any radial section of the cable, the paired cooling hoses, the main wire core, the auxiliary power supply wire core, the 2-core signal wire core and the 4-core signal wire core are in mirror symmetry; the radial section of the cable core is circular; according to the size of the wire diameter, functional cables with larger wire diameter are arranged inside, and functional cables with smaller wire diameter are arranged outside in sequence; the two functional cables with the closest wire diameters are in axial symmetry along a straight line passing through the circle center;
the outer diameter range of the cooling hose is 6.5mm to 7.5mm, the outer diameter range of the main wire core is 10.8mm to 11.4mm, the outer diameter range of the auxiliary power wire core is 4.3mm to 4.7mm, the outer diameter range of the 2-core signal wire core is 6.6mm to 7.0mm, and the outer diameter range of the 4-core signal wire core is 7.2mm to 7.8 mm;
the cooling hose is a hollow pipe made of an elastomer material;
the main wire core is formed by sequentially wrapping a main wire core insulating layer, an aluminum foil layer and a metal wire braid layer outside a main wire core conductor; the main wire core conductor is composed of bare copper monofilaments; the outer diameter range of the main wire core conductor is 8.0mm to 8.6 mm; the thickness range of the main wire core insulating layer is 1.2mm to 1.6 mm;
the auxiliary power supply wire core is formed by wrapping an auxiliary power supply insulating layer outside an auxiliary power supply conductor;
the 2-core signal wire core is formed by sequentially wrapping a metal wrapping tape layer and a metal wire braid after 2 signal core conductors with signal core insulating layers and 2 signal cores are filled and twisted;
the 4-core signal wire core is formed by sequentially wrapping a metal winding belting layer and a metal wire braiding layer after 4 signal core conductors with signal core insulating layers are twisted.
The cable core filling is a polypropylene filling rope;
the auxiliary power supply conductor is composed of a copper foil conductor; the outer diameter of the auxiliary power supply conductor ranges from 2.6mm to 3.0 mm; the thickness of the auxiliary power supply insulating layer ranges from 0.7mm to 1.0 mm.
For 2-core signal wire cores and 4-core signal wire cores:
the signal core conductors of the two are all made of copper foil conductors;
the thickness of the signal core insulating layers is 0.5mm to 0.7mm, and the insulating material of the signal core insulating layers is a thermosetting elastomer insulating material;
the metal wrapping tape layers of the metal wrapping tapes are all formed by overlapping metal wrapping tapes, the overlapping rate is not less than 25%, and the thickness range of the metal wrapping tapes is 0.02-0.05 mm; the metal wire braided layers are all formed by braiding copper monofilaments, the diameter of each copper monofilament is not more than 0.2mm, and the braiding density is 80-90%.
The copper foil conductor is formed by twisting copper foils and copper monofilaments after the copper foils are butted and loosely wound on the surfaces of the fibers; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m。
The main wire core conductor is formed by stranding a plurality of strands of copper monofilaments, and each strand of copper monofilament is formed by stranding copper monofilaments; the diameter range of the copper monofilament is 0.1 mm-0.2 mm; the twisting distance of copper monofilaments is not more than 18 times of the outer diameter of the conductor after twisting, and the twisting distance of each strand of copper monofilaments is not more than 35 times of the outer diameter of the strand after twisting; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m；
The thickness of the aluminum foil layer of the main wire core ranges from 0.02mm to 0.05 m;
the metal wire braid layer of the main wire core is formed by weaving tinned copper wires, the diameter of each tinned copper wire is not more than 0.2mm, and the weaving density is 80-90%.
The non-woven fabric layer is formed by wrapping non-woven fabric tapes, the wrapping covering rate is not less than 5mm, and the thickness of the non-woven fabric tapes is 0.1 mm;
the thickness of the outer sheath is 3.0mm to 4.0mm, and the sheath material is a thermoplastic elastomer material.
The insulating layer of each wire core can adopt a thermosetting elastomer insulating material.
The problems encountered in the actual production of the cable are mainly that the cable which can not reach theoretical performance or even meet the conventional requirements can not be produced by adopting a new structure and adopting the traditional production process or correcting the cable on the traditional production process according to experience and the like. Therefore, the invention provides a new manufacturing method which is specially used for the cable, and the method comprises the following specific steps:
the manufacturing method of the cable comprises the following steps:
the cable is formed by sequentially wrapping a wrapping layer and an outer sheath outside a cable core; the cable core is formed by twisting a circulating cooling hose and a plurality of cables, and the gaps of the cables are filled with filling;
1) firstly, manufacturing a stranded wire for a conductor and a copper foil conductor:
strand for conductors: is formed by stranding copper monofilaments; the diameter range of the copper monofilament is 0.1 mm-0.2 mm; the stranding pitch of the copper monofilaments is not more than 18 times of the outer diameter of the stranded conductor; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m；
Copper foil conductor: the copper foil is formed by loosely winding fibers and then twisting the fibers with copper monofilaments; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m；
The copper foil conductor is respectively used as an auxiliary power supply conductor and a signal core conductor for standby according to different wire diameters;
2) manufacturing of each wire core:
2.1) manufacturing a main wire core:
firstly, taking a stranded wire for a conductor, stranding a plurality of stranded wires by using a stranding cage machine to form a main wire core conductor, and extruding a thermosetting insulating material outside the main wire core conductor to obtain a main wire core insulating layer; then overlapping and lapping aluminum foil tapes, wherein the lapping and covering rate is not less than 25%; finally, wrapping a tinned copper wire braid outside the aluminum foil tape, wherein the diameter of the tinned copper wire is not more than 0.2mm, and the braiding density is 80-90%; standby;
2.2) manufacturing an auxiliary power supply wire core:
firstly, taking a copper foil conductor as an auxiliary power supply wire core conductor, and then extruding a thermosetting insulating material outside the copper foil conductor to prepare an auxiliary power supply insulating layer; standby;
2.3) manufacturing 2-core signal wire cores:
firstly, taking 2 copper foil conductors as 2-core signal core conductors; then respectively extruding and coating thermosetting insulating materials outside the two layers to prepare 2-core signal core conductor insulating layers; then twisting the core with two twisted filling ropes to form a 2-core signal wire core; standby;
the stranding pitches of the paired 2 signal wire cores with 2 cores are different, so that signal interference is avoided;
2.4) manufacturing a 4-core signal wire core:
firstly, taking 4 copper foil conductors as 4-core signal core conductors; then respectively extruding and coating thermosetting insulating materials outside the conductor to prepare 4-core signal core conductor insulating layers; then twisting and twisting the cable with a polypropylene filling rope to form a 4-core signal cable core; standby;
the stranding pitches of the paired 2 4-core signal wire cores are different, so that signal interference is avoided;
3) filling the cable prepared in the step 2), the cooling hose and the cable core, twisting together to form a cable core, and winding a non-woven fabric belt, wherein the stranding pitch range is 12-14 times of the outer diameter of the cable core after stranding;
4) the non-woven fabric layer is extruded with thermoplastic elastomer material to form an outer sheath.
In the step 3), the twisting equipment of the cable core is a back-twist type cable former, the rotating speed of a twisting cage of the cable former is 85-90 r/min (preferably 87r/min), the traction speed is 4-5 m/min (preferably 4m/min), and the rotating speed of a wrapping head is 10-20 r/min; the cabling doubling die of the cabling machine adopts a tungsten steel die, the inner aperture is equal to the stranding outer diameter of the wire cores, and the cabling direction is the right direction;
the lapping rate of the non-woven fabric belt lapping is not less than 25%; when wrapping, the traction speed is 4-5 m/min, the wrapping pitch is 40 +/-5 mm, and the tension on the non-woven fabric belt is 40-45N (preferably 40N); the wrapping direction is the right direction, and is 0.1mm around wrapping tape thickness.
In the step 2), the thermosetting insulating material is a thermosetting elastomer insulating material, and the insulating material is extruded and cooled by adopting a corresponding die according to the structure of each insulating layer; a mould core and a mould sleeve are arranged on a machine head of a plastic extruding machine, and the aperture of the mould core is equal to the diameter of the conductor plus 0.2 mm;
the extrusion requirements of the thermosetting insulating material are as follows:
from the feeding to the ejection of compact direction, extruding machine fuselage temperature zone is respectively: the first zone is 100 +/-5 ℃, the second zone is 125 +/-5 ℃, the third zone is 145 +/-5 ℃, the fourth zone is 155 +/-5 ℃ and the fifth zone is 165 +/-5 ℃; temperature of machine head and machine neck: first zone 170 + -5 deg.C, second zone 170 + -5 deg.C, third zone 170 + -5 deg.C, fourth zone: 170 +/-5 ℃; the machine body and the machine head are heated by a thermocouple;
wherein: the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections;
after the thermosetting insulating material is extruded, the irradiation is finished through electron acceleration, the irradiation energy is 1.2-3.0 MEV, the beam current is 20-40 mA, the energy ratio is 1.2-1.5, and the production line speed is 30-160 m/min;
in the step 4), extruding the thermoplastic elastomer material by using an extruding machine;
from feeding to ejection of compact direction, fuselage warm area are: the first zone is 175 +/-5 ℃, the second zone is 185 +/-5 ℃, the third zone is 190 +/-5 ℃, the fourth zone is 195 +/-5 ℃ and the fifth zone is 200 +/-5 ℃; temperature of machine head and machine neck: first region 205 + -5 deg.C, second region 215 + -5 deg.C, third region 220 + -5 deg.C, and fourth region: 220 +/-5 ℃; the machine body is heated by a thermocouple; the cooling of the machine body is carried out by adopting a blower.
Wherein: the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections.
The cable is fully charged within 15min through specific design of materials and structures, the endurance is 400km, the weight and the outer diameter of the cable are reduced, the charging heating temperature rise is less than 20 ℃, and the application of the technology can solve the bottleneck problem of long charging time of new energy automobiles in China at low cost and is beneficial to popularization and use of the new energy automobiles. The cable manufactured by the method can meet the design requirement, and meanwhile, the qualification rate reaches more than 98%.
The weight of the main power insulation core conductor of the cable is reduced by 50%, the cable is full of the cable within 15min of charging time, the weight and the outer diameter of the cable are reduced, the bottleneck problem that the new energy automobile is long in charging time in China can be solved at low cost by applying the technology, and the popularization and the use of the new energy automobile are facilitated.
Drawings
FIG. 1 is a schematic radial cross-sectional view of the cable of the present embodiment;
in the figure: the main core conductor 1, main core insulating layer 2, aluminium foil layer and wire weaving layer 3, auxiliary power supply conductor 4, auxiliary power supply insulating layer 5, 2 core signal core conductors 6, 2 core signal core conductor insulating layers 7, 2 core signal core packs 8, 2 core metal is around band layer 9, 2 core wire weaving layers 10, 4 core signal core conductors 11, 4 core signal core conductor insulating layers 12, 4 core signal core's packing 13, 4 core metal is around band layer 14, 4 core wire weaving layers 15, cooling hose 16, cable core packing 17, non-woven fabrics layer 18, oversheath 19.
Detailed Description
The technical solution is further described below with reference to specific examples as follows:
referring to fig. 1, a cable core cooling cable is formed by sequentially wrapping a non-woven fabric layer and an outer sheath outside a cable core;
the cable core is a circular-section cable formed by filling and twisting a pair of cooling hoses, a pair of main wire cores, a pair of auxiliary power supply wire cores, a pair of 2-core signal wire cores, a pair of 4-core signal wire cores and the cable core; the range of the twisting pitch is 12-14 times;
on any radial section of the cable, the paired cooling hoses, the main wire core, the auxiliary power supply wire core, the 2-core signal wire core and the 4-core signal wire core are in mirror symmetry;
the outer diameter range of the cooling hose is 6.5mm to 7.5mm, the outer diameter range of the main wire core is 10.8mm to 11.4mm, the outer diameter range of the auxiliary power wire core is 4.3mm to 4.7mm, the outer diameter range of the 2-core signal wire core is 6.6mm to 7.0mm, and the outer diameter range of the 4-core signal wire core is 7.2mm to 7.8 mm;
the cooling hose is a hollow pipe made of an elastomer material;
the main wire core is formed by sequentially wrapping a main wire core insulating layer, an aluminum foil layer and a metal wire braid layer outside a main wire core conductor; the main wire core conductor is composed of bare copper monofilaments; the outer diameter range of the main wire core conductor is 8.0mm to 8.6 mm; the thickness range of the main wire core insulating layer is 1.2mm to 1.6 mm;
the auxiliary power supply wire core is formed by wrapping an auxiliary power supply insulating layer outside an auxiliary power supply conductor;
the 2-core signal wire core is formed by sequentially wrapping a metal wrapping tape layer and a metal wire braid after 2 signal core conductors with signal core insulating layers and 2 signal cores are filled and twisted;
the 4-core signal wire core is formed by sequentially wrapping a metal winding belting layer and a metal wire braiding layer after 4 signal core conductors with signal core insulating layers are twisted.
The cable core filling is a polypropylene filling rope.
The auxiliary power supply conductor is composed of a copper foil conductor; the outer diameter of the auxiliary power supply conductor ranges from 2.6mm to 3.0 mm; the thickness of the auxiliary power supply insulating layer ranges from 0.7mm to 1.0 mm.
For 2-core signal wire cores and 4-core signal wire cores:
the signal core conductors of the two are all made of copper foil conductors;
the thickness of the signal core insulating layers is 0.5mm to 0.7mm, and the insulating material of the signal core insulating layers is a thermosetting elastomer insulating material;
the metal wrapping tape layers of the metal wrapping tapes are all formed by overlapping metal wrapping tapes, the overlapping rate is not less than 25%, and the thickness range of the metal wrapping tapes is 0.5mm to 0.7 mm; the metal wire braided layers are all formed by braiding copper monofilaments, the diameter of each copper monofilament is not more than 0.2mm, and the braiding density is 80-90%.
The copper foil conductor is formed by twisting copper foils and copper monofilaments after the copper foils are butted and loosely wound on the surfaces of the fibers; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m。
The main wire core conductor is formed by stranding a plurality of strands of copper monofilaments, and each strand of copper monofilament is formed by stranding copper monofilaments; the diameter range of the copper monofilament is 0.1 mm-0.2 mm; the lay length of the copper single wires is not more than 18 times of the outer diameter of the conductor after being stranded, and the lay length of each copper single wire is not more than35 times of the outer diameter of the stranded wire after stranding; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m；
The thickness of the aluminum foil layer of the main wire core ranges from 0.02mm to 0.05 mm;
the metal wire braid layer of the main wire core is formed by weaving tinned copper wires, the diameter of each tinned copper wire is not more than 0.2mm, and the weaving density is 80-90%.
The non-woven fabric layer is formed by lapping non-woven fabric belts, the lapping and covering rate is not less than 5mm, and the thickness of the non-woven fabric belts is 0.1 mm;
the thickness of the outer sheath is 3.0mm to 4.0mm, and the sheath material is a thermoplastic elastomer material.
A method for manufacturing an air-cooled cable comprises the following steps:
the cable is formed by sequentially wrapping a wrapping layer and an outer sheath outside a cable core; the cable core is formed by twisting a circulating cooling hose and a plurality of cables, and the gaps of the cables are filled with filling;
1) firstly, manufacturing a stranded wire for a conductor and a copper foil conductor:
strand for conductors: is formed by stranding copper monofilaments; the diameter range of the copper monofilament is 0.1 mm-0.2 mm; the stranding pitch of the copper monofilaments is not more than 18 times of the outer diameter of the stranded conductor; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m；
Copper foil conductor: the copper foil is formed by loosely winding fibers and then twisting the fibers with copper monofilaments; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m；
The copper foil conductor is respectively used as an auxiliary power supply conductor and a signal core conductor for standby according to different wire diameters;
2) manufacturing of each wire core:
2.1) manufacturing a main wire core:
firstly, taking a stranded wire for a conductor, stranding a plurality of stranded wires by using a stranding cage machine to form a main wire core conductor, and extruding a thermosetting insulating material outside the main wire core conductor to obtain a main wire core insulating layer; then overlapping and lapping aluminum foil tapes, wherein the lapping and covering rate is not less than 25%; finally, wrapping a tinned copper wire braid outside the aluminum foil tape, wherein the diameter of the tinned copper wire is not more than 0.2mm, and the braiding density is 80-90%; standby;
2.2) manufacturing an auxiliary power supply wire core:
firstly, taking a copper foil conductor as an auxiliary power supply wire core conductor, and then extruding a thermosetting insulating material outside the copper foil conductor to prepare an auxiliary power supply insulating layer; standby;
2.3) manufacturing 2-core signal wire cores:
firstly, taking 2 copper foil conductors as 2-core signal core conductors; then respectively extruding and coating thermosetting insulating materials outside the two layers to prepare 2-core signal core conductor insulating layers; then twisting the core with two twisted filling ropes to form a 2-core signal wire core; standby;
the stranding pitches of the paired 2 signal wire cores with 2 cores are different, so that signal interference is avoided;
2.4) manufacturing a 4-core signal wire core:
firstly, taking 4 copper foil conductors as 4-core signal core conductors; then respectively extruding and coating thermosetting insulating materials outside the conductor to prepare 4-core signal core conductor insulating layers; then twisting and twisting the cable with a polypropylene filling rope to form a 4-core signal cable core; standby;
the stranding pitches of the paired 2 4-core signal wire cores are different, so that signal interference is avoided;
3) filling the cable prepared in the step 2), the cooling hose and the cable core, twisting together to form a cable core, and winding a non-woven fabric belt, wherein the stranding pitch range is 12-14 times of the outer diameter of the cable core after stranding;
4) the non-woven fabric layer is extruded with thermoplastic elastomer material to form an outer sheath.
In the step 3), the twisting equipment of the cable core is a back-twist type cable former, the rotating speed of a twisting cage of the cable former is 85-90 r/min, the traction speed is 4-5 m/min, and the rotating speed of a wrapping head is 10-20 r/min; the cabling doubling die of the cabling machine adopts a tungsten steel die, the inner aperture is equal to the stranding outer diameter of the wire cores, and the cabling direction is the right direction;
the lapping rate of the non-woven fabric belt lapping is not less than 25%; when wrapping, the traction speed is 4-5 m/min, the wrapping pitch is 40 +/-5 mm, and the tension on the non-woven fabric belt is 40-45N; the wrapping direction is the right direction, and is 0.1mm around wrapping tape thickness.
In the step 2), the thermosetting insulating material is a thermosetting elastomer insulating material, and the insulating material is extruded and cooled by adopting a corresponding die according to the structure of each insulating layer; a mould core and a mould sleeve are arranged on a machine head of a plastic extruding machine, and the aperture of the mould core is equal to the diameter of the conductor plus 0.2 mm;
the extrusion requirements of the thermosetting insulating material are as follows:
from the feeding to the ejection of compact direction, extruding machine fuselage temperature zone is respectively: the first zone is 100 +/-5 ℃, the second zone is 125 +/-5 ℃, the third zone is 145 +/-5 ℃, the fourth zone is 155 +/-5 ℃ and the fifth zone is 165 +/-5 ℃; temperature of machine head and machine neck: first zone 170 + -5 deg.C, second zone 170 + -5 deg.C, third zone 170 + -5 deg.C, fourth zone: 170 +/-5 ℃; the machine body and the machine head are heated by a thermocouple;
wherein: the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections;
after the thermosetting insulating material is extruded, the irradiation is finished through electron acceleration, the irradiation energy is 1.2-3.0 MEV, the beam current is 20-40 mA, the energy ratio is 1.2-1.5, and the production line speed is 30-160 m/min;
in the step 4), extruding the thermoplastic elastomer material by using an extruding machine;
from feeding to ejection of compact direction, fuselage warm area are: the first zone is 175 +/-5 ℃, the second zone is 185 +/-5 ℃, the third zone is 190 +/-5 ℃, the fourth zone is 195 +/-5 ℃ and the fifth zone is 200 +/-5 ℃; temperature of machine head and machine neck: first region 205 + -5 deg.C, second region 215 + -5 deg.C, third region 220 + -5 deg.C, and fourth region: 220 +/-5 ℃; the machine body is heated by a thermocouple; the cooling of the machine body is carried out by adopting a blower.
Wherein: the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections
In this example, the back-twist type cabling machine is a 3+6 cabling machine, and the cable equipment of the cabling machine comprises 9 pay-off reels and 2 rear pay-off rack wheel type pay-off frames; the pay-off reels are respectively set as A1, A2, A3, A4, A5, A6, A7, A8 and A9;
a1 places a2 core signal sinle silks, A2 places a2 core signal sinle silks, an auxiliary power supply sinle silk is placed to A3, an auxiliary power supply sinle silk is placed to A4, a4 core signal sinle silks are placed to A5, a4 core signal sinle silks are placed to A6, a principal line core is placed to A7, a cooling hose is placed to A8, a principal line core is placed to A9, a cooling hose is placed to two wheeled pay off rack wire releasing frames in back.
The thermosetting elastomer material is an EVA (ethylene-vinyl acetate) base material, is matched with a toughening system, a flame-retardant system, an anti-aging system and a lubricating system and is formed by physical and chemical modification, the tear resistance is not less than 15N/mm, the water resistance passes the requirement of an 80 ℃ × 168 test, the insulation hardness is not less than 90 Shore A, the insulation resistance constant is not less than 3670 MOmega-km at 20 ℃, the insulation tensile strength is not less than 10MPa, the elongation at break is not less than 300%, the tensile strength change rate is not more than +/-30% under the conditions of 158 ℃ and 168h, the elongation at break change rate is not more than +/-30%, the elongation at break is not more than +/-30% under the conditions of minus 40 ℃, the elongation at break is not less than 3.67% at 90 ℃, the high-temperature pressure indentation at 90 ℃ is not more than 50%, the shrinkage at 130 ℃ is not more than 4%, and the requirements of.
Irradiating the insulating layer, sampling the insulating layer, and making the sample at 250 deg.C for 15min to obtain a product with elongation at break of not more than 100% and permanent deformation of not more than + -25%
The cable core filling rope is made of a high-temperature-resistant twisted filling rope, and the main base material of the filling rope is a polypropylene material; filling ropes with different sizes are placed aiming at different gaps in the cable core; in addition, the filling material can not deform, age, decompose, crack and the like under the condition of 125 ℃ for 240 hours, and still keeps the original good shape.
The outer sheath material is prepared by taking an elastomer as a base material and matching with a toughening system, a flame retardant system, an anti-aging system and a lubricating system through physical and chemical modification, has good flexibility, oil resistance, wear resistance, UV resistance, hydrolysis resistance, acid and alkali resistance, excellent flame retardance, no precipitation, halogen and red phosphorus, and resistance to 720h weather, and has the tear strength of not less than 20N/mm through a single vertical combustion test. The slipping force of the cable is still kept above 500N at 105 ℃ for 4 h.
The sheath material of the outer sheath is required to be as follows: high tear resistance, high wear resistance, water resistance, weather resistance, low temperature resistance of-40 ℃, flame retardance, environmental protection, chemical liquid resistance and ultraviolet resistance.
The cable is fully charged within 15min through specific design of materials and structures, the endurance is 400km, the weight and the outer diameter of the cable are reduced, the charging heating temperature rise is less than 20 ℃, and the application of the technology can solve the bottleneck problem of long charging time of new energy automobiles in China at low cost and is beneficial to popularization and use of the new energy automobiles.
The cable selects copper as a conductor material; stranding a plurality of annealed metal filaments to form a conductor, the metal filaments having a resistivity of not more than 0.01701 Ω mm2M: a plurality of metal monofilaments are twisted into a bundle, and the plurality of metal monofilaments are divided into a plurality of layers from inside to outside; two adjacent metal monofilaments in each layer of metal monofilaments are tightly attached to each other; in the two adjacent layers of metal monofilaments, the inner layer metal monofilament and the outer layer metal monofilament are tightly attached; the twisting direction of the metal monofilament at the outermost layer is the left direction, and the twisting directions of the adjacent two layers of metal monofilaments are opposite; the stranding pitch of the metal monofilaments at the outermost layer is not more than 16 times of the external diameter after stranding; and wrapping the insulating layer outside the corresponding conductor by adopting an extrusion wrapping mode. The elastomer insulating material can be prepared by adding flame retardant, antioxidant lubricant, toner and the like into EVA base material, melting and plasticizing, and cutting into ground wire cores, signal wire cores and the like. A plastic extruding machine is adopted, and a mould core and a mould sleeve are arranged on a machine head. And after the ground wire core, the signal wire core and other materials are extruded, the irradiation is finished through electron acceleration. The lapping rate of the aluminum foil material is not less than 20%. No leakage and no corrugation are generated in the wrapping process. The density of the metal braided shield is 88 to 90 percent. Selected circulative cooling hose, the material is resistant to chemical liquid, soft and flexible, resistant to vehicle rolling, resistant to aging, resistant to low temperature of-40 ℃ and thermosetting. The cable core wrapping tape is non-woven fabric, and the wrapping and covering rate is not less than 20%. Adding filler, color master, plasticizer, softening oil, SEBS, phase solvent, release agent and the like into the elastomer base material for melting and plasticizing, and cutting the elastomer base material into outer sheath material; and tightly wrapping the sheath material outside the cable core by adopting an extrusion production mode to form a sheath layer, and cooling to form the cable.
The manufacturing method of the cable is explained as follows:
in the selection of the process parameters, when the intermediate value and the preferred value are selected, the one-time excellent rate of the product reaches 99.4%, and when the intermediate value and the preferred value are relaxed within the range, although the product meeting the quality requirement can be obtained, the one-time excellent rate is more between 98% and 99%.
As a result, the cable has the characteristics that:
1) shortening charging time
Direct current charging is shortened to 15min, the electric automobile continues a journey for 400 kilometers, and the charging time of the cooling cable is shortened by 90%.
2) The cable purchasing cost is reduced: the cost is reduced by 50% during cable purchase.
3) The cable has light weight and small outer diameter
The outer diameter of the cooling cable for high-power quick charging is controlled to be less than 40mm, and compared with a 400A direct current charging cable, the weight of a finished cable is reduced by 50%.
4) Small temperature rise
The cooling cable for high-power quick charging is full in 15min, the electric automobile can continue to run for 400 kilometers, and the temperature rise does not exceed 35 ℃.
5) High electrical property
The inspected product is detected by a third party, and the volume resistivity of the insulation and the sheath is actually measured 1015Omega, mm, and fills up the high pressure 10 in the silicon rubber vehicle of the new energy automobile in ISO international and GB countries9Ω.mm。
6) High and low temperature resistance
The main power supply can be used under the working condition of 125 ℃. The requirements of-40 ℃ low-temperature impact, -40 ℃ low-temperature winding and-40 ℃ low-temperature tensile test are met.
7) And (3) flame retardant test:
meets the single combustion of GB/T18380.12.
8) Chemical resistance
Meanwhile, the requirements of a method I, a method II and a battery acid test in the ISO6722-1 standard are met, and the requirements of working conditions are met.
9) Rolling resistance of vehicle
The cable is repeatedly used after 3 times of reciprocating rolling, voltage application test and cooling circulation test of a vehicle.
Claims (7)
1. A cable core cooling cable is characterized in that a non-woven fabric layer and an outer sheath are sequentially wrapped outside a cable core;
the cable core is a circular-section cable formed by filling and twisting a pair of cooling hoses, a pair of main wire cores, a pair of auxiliary power supply wire cores, a pair of 2-core signal wire cores, a pair of 4-core signal wire cores and the cable core; the range of the twist pitch diameter ratio is 12-14 times;
on any radial section of the cable, the paired cooling hoses, the main wire core, the auxiliary power supply wire core, the 2-core signal wire core and the 4-core signal wire core are in mirror symmetry;
the outer diameter range of the cooling hose is 6.5mm to 7.5mm, the outer diameter range of the main wire core is 10.8mm to 11.4mm, the outer diameter range of the auxiliary power wire core is 4.3mm to 4.7mm, the outer diameter range of the 2-core signal wire core is 6.6mm to 7.0mm, and the outer diameter range of the 4-core signal wire core is 7.2mm to 7.8 mm;
the cooling hose is a hollow pipe made of an elastomer material;
the main wire core is formed by sequentially wrapping a main wire core insulating layer, an aluminum foil layer and a metal wire braid layer outside a main wire core conductor; the main wire core conductor is composed of bare copper monofilaments; the outer diameter range of the main wire core conductor is 8.0mm to 8.6 mm; the thickness range of the main wire core insulating layer is 1.2mm to 1.6 mm;
the auxiliary power supply wire core is formed by wrapping an auxiliary power supply insulating layer outside an auxiliary power supply conductor;
the 2-core signal wire core is formed by sequentially wrapping a metal wrapping tape layer and a metal wire braid after 2 signal core conductors with signal core insulating layers and 2 signal cores are filled and twisted;
the 4-core signal wire core is formed by sequentially wrapping a metal winding belting layer and a metal wire braiding layer after 4 signal core conductors with signal core insulating layers are twisted.
2. The cable core cooling cable of claim 1, wherein the core filler is a polypropylene filler rope.
3. The cable core cooling cable of claim 1 wherein said auxiliary power conductor is comprised of a copper foil conductor; the outer diameter of the auxiliary power supply conductor ranges from 2.6mm to 3.0 mm; the thickness of the auxiliary power supply insulating layer ranges from 0.7mm to 1.0 mm.
4. The cable core cooling cable of claim 1, wherein for 2-core signal cores and 4-core signal cores:
the signal core conductors of the two are all made of copper foil conductors;
the thickness of the signal core insulating layers is 0.5mm to 0.7mm, and the insulating material of the signal core insulating layers is a thermosetting elastomer insulating material;
the metal wrapping tape layers of the metal wrapping tapes are all formed by overlapping metal wrapping tapes, the overlapping rate is not less than 25%, and the thickness range of the metal wrapping tapes is 0.02mm to 0.05 mm; the metal wire braided layers are all formed by braiding copper monofilaments, the diameter of each copper monofilament is not more than 0.2mm, and the braiding density is 80-90%.
5. The cable core cooling cable of claim 3 or 4, wherein the copper foil conductor is formed by butt-jointing and loosely-winding copper foils on the surfaces of fibers and then twisting the copper foils and copper monofilaments; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m。
6. The cable core cooling cable of claim 1, wherein the cable core cooling cable comprises a plurality of cooling fins
The main wire core conductor is formed by stranding a plurality of strands of copper monofilaments, and each strand of copper monofilament is formed by stranding copper monofilaments; the diameter range of the copper monofilament is 0.1 mm-0.2 mm; the twisting distance of copper monofilaments is not more than 18 times of the outer diameter of the conductor after twisting, and the twisting distance of each strand of copper monofilaments is not more than 35 times of the outer diameter of the strand after twisting; the copper monofilament is annealed bare copper monofilament, the oxygen content of copper in the copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01701 omega2/m；
The thickness of the aluminum foil layer of the main wire core ranges from 0.02mm to 0.05 mm;
the metal wire braid layer of the main wire core is formed by weaving tinned copper wires, the diameter of each tinned copper wire is not more than 0.2mm, and the weaving density is 80-90%.
7. The cable core cooling cable of claim 1, wherein the non-woven fabric layer is a lapped non-woven fabric tape, the lapping and covering rate is not less than 5mm, and the thickness of the non-woven fabric tape is 0.1 mm;
the thickness of the outer sheath is 3.0mm to 4.0mm, and the sheath material is a thermoplastic elastomer material.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201922224817.8U CN211125080U (en) | 2019-12-12 | 2019-12-12 | Cable core cooling cable |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201922224817.8U CN211125080U (en) | 2019-12-12 | 2019-12-12 | Cable core cooling cable |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN211125080U true CN211125080U (en) | 2020-07-28 |
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ID=71702508
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201922224817.8U Active CN211125080U (en) | 2019-12-12 | 2019-12-12 | Cable core cooling cable |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN211125080U (en) |
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2019
- 2019-12-12 CN CN201922224817.8U patent/CN211125080U/en active Active
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