CN217588459U - High-voltage cable bending structure - Google Patents
High-voltage cable bending structure Download PDFInfo
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- CN217588459U CN217588459U CN202220623819.3U CN202220623819U CN217588459U CN 217588459 U CN217588459 U CN 217588459U CN 202220623819 U CN202220623819 U CN 202220623819U CN 217588459 U CN217588459 U CN 217588459U
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Abstract
The utility model discloses a high-voltage cable bending structure, which comprises a conductor wire bundle bent at a certain angle, wherein a first insulating layer, a shielding layer and a second insulating layer are sequentially arranged on the conductor wire bundle positioned at two sides of the bent position from inside to outside; a first insulating layer plastic-coated layer, a transition shielding layer and a second insulating layer plastic-coated layer are sequentially arranged at the bending position of the conductor filament bundle from inside to outside; the two ends of the first insulating layer plastic-coated layer are respectively connected with the first insulating layer, the two ends of the transition shielding layer are respectively connected with the shielding layer, and the two ends of the second insulating layer plastic-coated layer are respectively connected with the second insulating layer. The utility model discloses under the conductor silk bundle of guaranteeing the high-voltage cable is complete, not damaged (keeping former definite current-carrying capacity to guarantee performances such as leakproofness, wearability, the insulating nature of shielding layer effect and double insulation layer), realize that conductor silk bundle and whole pencil are bent with required arbitrary angle and direction, improved design flexibility and space utilization.
Description
Technical Field
The utility model relates to a high-voltage cable bending structure belongs to electric motor car high-voltage cable technical field.
Background
When the existing high-voltage power cable is connected with high-voltage equipment, the connection form is divided into a high-voltage quick plug-in unit, a junction box and the like, the tail part of the high-voltage power cable is in a waterproof mode of a Glan head property, and after the high-voltage power cable is connected with the high-voltage equipment, the high-voltage power cable needs to be arranged and fixed in a good wiring mode when being connected with another equipment, so that the requirements of cable bending fixation such as wire outlet direction adjustment or midway bending need to be considered.
The high-voltage quick plug-in unit realizes the switching of the outlet direction of the equipment socket and the actual cable routing direction in a 90-degree elbow form, but the high-voltage quick plug-in unit is high in cost, limited in terminal current-carrying capacity and high in contact resistance, and meanwhile, the purchase cycle of the plug-in unit is long, and has adverse factors on cost, service life and high-power performance. The outgoing line direction of the junction box can only be realized through the mode that the cable is bent, and the high-voltage cable diameter is big, the hardness is high, bend and need reserve the bending that is not less than 5 times of cable external diameter and walk the line space, be unfavorable for the integrated utilization of high-voltage cable arrangement space, there is the problem that leads to whole car space arrangement inefficiency because of a large amount of line spaces of walking, and the excessive bending of cable causes the insulating skin fold damage of cable easily, the ageing fracture of insulating material and the insulating deterioration that the intaking leads to with higher speed, and occupy whole car space, the cable internal stress has been increased after bending, also be unfavorable for high-voltage part near adjacent concentrated demand of arranging, there are the drawback of a great deal of design integration level and assembly convenience and use reliability, this demand is solved to not have effectual high-voltage cable bending technique in the present stage, it is convenient for the technical scheme of arranging to walk the line to bend to need that the high-voltage cable possesses fixed angle.
Disclosure of Invention
To the problem that above-mentioned prior art exists, the utility model provides a high-voltage cable bending structure satisfies the high-voltage cable angle of being qualified for the next round of competitions change and convenient bending beam forming to save arranging the fixed demand of walking of space.
In order to achieve the purpose, the high-voltage cable bending structure adopted by the utility model comprises a conductor wire bundle bent at a certain angle, wherein a first insulating layer, a shielding layer and a second insulating layer are sequentially arranged on the conductor wire bundle positioned at two sides of the bent position from inside to outside; a first insulating layer plastic-coated layer, a transition shielding layer and a second insulating layer plastic-coated layer are sequentially arranged at the bending position of the conductor filament bundle from inside to outside;
the two ends of the first insulating layer plastic-coated layer are respectively connected with the first insulating layer, the two ends of the transition shielding layer are respectively connected with the shielding layer, and the two ends of the second insulating layer plastic-coated layer are respectively connected with the second insulating layer.
As an improvement, two ends of the transition shielding layer are directly welded with the shielding layer, or two ends of the transition shielding layer are respectively connected with the shielding layer through shielding rings.
As an improvement, the conductor tows are bent and shaped by a positioning die, and the bent conductor tows are welded into a whole by an ultrasonic welding die.
As an improvement, the material of the first insulating layer plastic-coated layer is the same as that of the first insulating layer; the second insulating layer plastic-coated layer and the second insulating layer are made of the same material.
As a further improvement, the first insulating layer plastic-coated layer is connected and fused with the insulating skin of the first insulating layer into a whole; the second insulating layer plastic coating layer is connected and fused with the insulating skin of the second insulating layer into a whole.
As an improvement, the conductor tows are bent at 90 °.
The principle of the utility model is that:
the method comprises the steps of adopting a cable overmolding (overmolding) process twice to realize fixed-angle bending preforming of the high-voltage cable (when the high-voltage cable is provided with only one insulating layer, only adopting a overmolding process once), adopting an ultrasonic welding mode to realize angle shaping and maintaining of conductor tows at a cable bending point, and adopting a shielding ring to realize connection of a shielding layer.
Compared with the prior art, the utility model discloses following beneficial effect has:
1) Under the condition of ensuring that the conductor tows of the high-voltage cable are complete and free of damage (the original current carrying capacity is reserved, and the shielding layer effect and the performances of sealing property, wear resistance, insulativity and the like of the double insulating layers are ensured), the conductor tows and the whole wire harness are bent in any required angle and direction, and the design flexibility and the space utilization rate are improved.
2) The stress of the bending internal stress of the bent cable on the cable fixing structure and the plug-in units on the two sides is avoided, and the problems that the cable is worn, the insulation effect and the shielding effect are influenced due to the fact that the cable is damaged and damaged by the crease deformation and the damage after the insulation Pi Shewan, the filament bundle is damaged due to excessive bending, the current carrying capacity is influenced and the like are avoided.
3) The space size is reduced, the high integration degree of the whole vehicle arrangement can be realized, and the size of the structure part is compressed to realize the purposes of reducing cost and weight, miniaturization, light weight and modular design.
Drawings
Fig. 1 is a schematic sectional structure view of a high-voltage cable before bending;
FIG. 2 is a schematic view of a high-voltage cable clamped by a bending clamp;
FIG. 3 is a schematic view of the plastic coating process of the first insulating layer;
FIG. 4 is a schematic view of the formation of the first plastic-clad layer and the processing of the transition shielding layer;
FIG. 5 is a schematic view of the plastic coating process of the second insulating layer;
FIG. 6 is a schematic view of the formation of a second plastic-coated insulating layer;
in the figure: 1. bending points, 2, conductor tows, 3, a first insulating layer, 4, a shielding layer, 5, a second insulating layer, 6, a bending die and a welding die, 7, a first insulating layer plastic coating die, 8, a first insulating layer plastic coating space, 9, a transition shielding layer, 10, a first insulating layer plastic coating layer, 11, a shielding ring, 12, a second insulating layer plastic coating die, 13, a second insulating layer plastic coating space, 14 and a second insulating layer plastic coating layer.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more clear, the present invention is further described in detail below. It should be understood, however, that the description herein of specific embodiments is only intended to illustrate the invention and not to limit the scope of the invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs, and the terms used herein in the specification of the present invention are for the purpose of describing particular embodiments only and are not intended to limit the present invention.
As shown in fig. 2 to 6, a high-voltage cable bending structure includes a conductor strand 2 bent at a certain angle, and a first insulating layer 3, a shielding layer 4 and a second insulating layer 5 are sequentially arranged on the conductor strand 2 located on the peripheries of both sides of a bending point 1 (the sectional views are both sides, and the actual cable insulating layers are circumferentially arranged) from inside to outside;
the bending part of the conductor tow 2 is sequentially provided with a first insulating layer plastic coating layer 10, a transition shielding layer 9 and a second insulating layer plastic coating layer 14 from inside to outside; the two ends of the first insulating layer plastic-coated layer 10 are respectively connected with the first insulating layer 3, the two ends of the transition shielding layer 9 are respectively connected with the shielding layer 4, and the two ends of the second insulating layer plastic-coated layer 14 are respectively connected with the second insulating layer 5.
Referring to fig. 1 to 6, before bending a high-voltage cable, the position, the bending direction, and the bending angle of a bending point 1, the specification of the cross-sectional area of a cable conductor, and the outer diameters of a first insulating layer 3 and a second insulating layer 5 are determined, and a plastic-coated mold, a bending mold, and a welding mold 6 corresponding to the specification and the size are selected, and the specific steps are as follows:
1) Stripping the second insulating layer 5 within the distance length range of the X around the bending point 1;
2) Cutting off the shielding layer 4 from the bending point 1 and separating the shielding layer to two sides, and turning outwards the shielding layer to two sides to reserve enough operating space;
3) Stripping the first insulating layer 3 within the distance length range of Y around the bending point 1, leaking the inner conductor tows 2, and ensuring the conductor tows 2 to be complete and undamaged;
4) X is larger than Y, the middle points of X and Y are overlapped, and the error of the contact ratio is not larger than Z;
5) Calculating the (X-Y)/2 size, namely the single-side difference space of the stripping sizes of the first insulating layer 3 and the second insulating layer 5, and meeting the process space required by the shielding layer connection through the shielding ring 11;
6) The method comprises the steps of adopting a positioning die corresponding to the outer diameter specification of a conductor strand of a cable, enabling the cable to be subjected to bending and shaping according to a required angle (the angle can be defined according to actual requirements, such as any angle between 0 and 180 degrees, and the bending direction can also be defined, for example, assuming that the cable is placed in an XYZ three-axis space coordinate system, a first bending point is bent to the right by 90 degrees on an XY axis plane, and a next bending point is bent to the upward by 60 degrees on an XZ plane), and adopting an ultrasonic welding die corresponding to the specification to weld the bent conductor strand 2 into a whole and solidify the bending and shaping state, so that the bending or pulling caused by the conditions of cable transportation, storage, assembly, fixation, vibration and the like is avoided, and the bending effect is weakened and the conductor strand at the bending point is scattered;
specifically, as shown in fig. 3, a first insulating layer plastic-coated mold 7 corresponding to the outer diameter of the first insulating layer 3 of the cable conductor is adopted to perform plastic coating on the bent and welded part of the cable (i.e., the first insulating layer plastic-coated space 8) to obtain a first insulating layer plastic-coated layer 10, so that the insulating coating of the outer surface of the conductor strand and the connection and fusion of insulating skins at two ends are realized, and the effects of insulation, water prevention, angle shaping, strength reinforcement and the like are realized;
7) As shown in fig. 4, the transition shielding layer 9 is sleeved into the cable and sent to the position of the bending point after the compound molding, the two ends of the transition shielding layer 9 are overlapped and overlapped for a distance of M with the end of the shielding layer 4 which is separated from the transition shielding layer, and a shielding ring 11 is respectively adopted at the two overlapped positions to compress and fix (the shielding ring 11 can be fixed by adopting a welding mode or the shielding ring is cancelled to directly weld the shielding layer), the compression joint position of the shielding ring 11 is within the reserved range of (X-Y)/2 size, and the specific positioning error is determined according to the process standard requirement;
8) The second insulating layer plastic coating die 12 corresponding to the outer diameter of the second insulating layer 5 of the cable conductor is adopted to perform plastic coating on the bent and welded part of the cable (namely, the second insulating layer plastic coating space 13 in the figure 5) to obtain a second insulating layer plastic coating layer 14, so that the insulating coating of the outer surface of the conductor wire bundle 2 and the connection and fusion of the insulating coatings at two ends are realized, the effects of insulation, water resistance, angle shaping, strength reinforcement and the like are realized, and the bending plastic coating process of the high-voltage cable is completed.
In the actual use process, the same high-voltage cable can be bent in a multi-position compound molding mode, and the bending angle, the position point and the bending direction are determined according to the use requirement. Meanwhile, the material of the first insulating layer plastic-coated layer 10 can be the same as or different from that of the first insulating layer 3, and the material of the second insulating layer plastic-coated layer 14 can be the same as or different from that of the second insulating layer 5, but each insulating layer plastic-coated layer needs to meet the requirements of firm fusion with the original insulating skin and relevant mechanical, electrical and chemical properties of insulation, water resistance, wear resistance, weather resistance and the like which are not lower than those of the original insulating skin. Wherein, the insulating layer (or insulating layer plastic-coated layer) can be selected from conventional cross-linked polyolefin or silicon rubber (of course, any material meeting the related technical requirement index); the shielding layer (or the transition shielding layer) can be selected from a conventional metal wire mesh grid, copper foil or aluminum foil (any material meeting the requirement). In addition, the utility model provides a X, Y, Z, M equidistance, in the work progress, can confirm according to actual conditions is nimble.
The utility model provides an original conductor silk bundle because of toughness and the difficult direct bending of hardness, need satisfy minimum bend radius for the cable external diameter more than 5 times bend the space and the circular arc of bending, and can't realize the scheduling problem of bending with various angles, design flexibility and space utilization have been improved, the effect of internal stress to cable fixed knot structure and both sides plug-in components has been avoided bending, avoid contact failure, fixed knot is bad, the fixed knot constructs the atress, avoid cable wearing and tearing, insulating Pi Shewan back fold deformation with damage influence insulating and shielding effect and bend the impaired and influence current-carrying capacity scheduling problem of conductor silk bundle that excessively leads to, space size reduces simultaneously, can realize the high integration degree that whole car was arranged, and the compressive structures size realizes reducing originally to subtract heavy and miniaturized, the lightweight, the modularized design.
The above description is only exemplary of the present invention and should not be taken as limiting the scope of the present invention, as any modification, equivalent replacement or improvement made within the spirit and principle of the present invention should be included in the present invention.
Claims (6)
1. A high-voltage cable bending structure comprises conductor tows (2) bent at a certain angle, wherein a first insulating layer (3), a shielding layer (4) and a second insulating layer (5) are sequentially arranged on the conductor tows (2) on two sides of a bent position from inside to outside;
the cable is characterized in that a first insulating layer plastic coated layer (10), a transition shielding layer (9) and a second insulating layer plastic coated layer (14) are sequentially arranged at the bending part of the conductor tow (2) from inside to outside;
two ends of the first insulating layer plastic-coated layer (10) are respectively connected with the first insulating layer (3), two ends of the transition shielding layer (9) are respectively connected with the shielding layer (4), and two ends of the second insulating layer plastic-coated layer (14) are respectively connected with the second insulating layer (5).
2. The high-voltage cable bending structure according to claim 1, wherein two ends of the transition shielding layer (9) are directly welded to the shielding layer (4), or two ends of the transition shielding layer (9) are respectively connected to the shielding layer (4) through a shielding ring (11).
3. The high-voltage cable bending structure according to claim 1, wherein the conductor tows (2) are bent and shaped by a positioning die, and the bent conductor tows (2) are welded into a whole by an ultrasonic welding die.
4. The high-voltage cable bending structure according to claim 1, wherein the first insulating layer plastic-coated layer (10) and the first insulating layer (3) are made of the same material; the second insulating layer plastic-coated layer (14) and the second insulating layer (5) are made of the same material.
5. A high-voltage cable bending structure according to claim 4, wherein the first insulating layer plastic-coated layer (10) is integrated with the insulating skin of the first insulating layer (3); the second insulating layer plastic coating layer (14) is connected and fused with the insulating skin of the second insulating layer (5) into a whole.
6. High voltage cable bending structure according to claim 1, wherein the conductor tows (2) are bent at 90 °.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202220623819.3U CN217588459U (en) | 2022-03-22 | 2022-03-22 | High-voltage cable bending structure |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202220623819.3U CN217588459U (en) | 2022-03-22 | 2022-03-22 | High-voltage cable bending structure |
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| CN217588459U true CN217588459U (en) | 2022-10-14 |
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| Application Number | Title | Priority Date | Filing Date |
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| CN202220623819.3U Active CN217588459U (en) | 2022-03-22 | 2022-03-22 | High-voltage cable bending structure |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117374671A (en) * | 2023-12-08 | 2024-01-09 | 成都壹为新能源汽车有限公司 | Cable shielding connection structure for new energy vehicle and manufacturing method |
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2022
- 2022-03-22 CN CN202220623819.3U patent/CN217588459U/en active Active
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117374671A (en) * | 2023-12-08 | 2024-01-09 | 成都壹为新能源汽车有限公司 | Cable shielding connection structure for new energy vehicle and manufacturing method |
| CN117374671B (en) * | 2023-12-08 | 2024-03-12 | 成都壹为新能源汽车有限公司 | Cable shielding connection structure for new energy vehicle and manufacturing method |
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