CN219800539U - High-voltage aluminum cable suitable for new energy vehicle of full-automatic wire stripping equipment - Google Patents
High-voltage aluminum cable suitable for new energy vehicle of full-automatic wire stripping equipment Download PDFInfo
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- CN219800539U CN219800539U CN202321010394.XU CN202321010394U CN219800539U CN 219800539 U CN219800539 U CN 219800539U CN 202321010394 U CN202321010394 U CN 202321010394U CN 219800539 U CN219800539 U CN 219800539U
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- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 64
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 64
- 239000004020 conductor Substances 0.000 claims abstract description 46
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims abstract description 22
- 239000004810 polytetrafluoroethylene Substances 0.000 claims abstract description 22
- -1 polytetrafluoroethylene Polymers 0.000 claims abstract description 16
- 229920002379 silicone rubber Polymers 0.000 claims abstract description 16
- 238000004804 winding Methods 0.000 claims abstract description 5
- 239000000853 adhesive Substances 0.000 claims abstract description 4
- 230000001070 adhesive effect Effects 0.000 claims abstract description 4
- 239000004033 plastic Substances 0.000 claims description 21
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 17
- 239000002131 composite material Substances 0.000 claims description 9
- 238000009954 braiding Methods 0.000 claims description 8
- 238000009941 weaving Methods 0.000 claims description 4
- 239000004945 silicone rubber Substances 0.000 claims description 3
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 239000010949 copper Substances 0.000 claims description 2
- 238000009413 insulation Methods 0.000 abstract description 10
- 238000001125 extrusion Methods 0.000 abstract description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 abstract description 2
- 239000000741 silica gel Substances 0.000 abstract description 2
- 229910002027 silica gel Inorganic materials 0.000 abstract description 2
- 238000004519 manufacturing process Methods 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000012360 testing method Methods 0.000 description 4
- 239000011810 insulating material Substances 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 230000008859 change Effects 0.000 description 2
- 238000005056 compaction Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 230000032683 aging Effects 0.000 description 1
- 210000001367 artery Anatomy 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000008054 signal transmission Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
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- Insulated Conductors (AREA)
Abstract
The utility model discloses a high-voltage aluminum cable for a new energy vehicle, which is suitable for full-automatic wire stripping equipment, and belongs to the technical field of new energy automobile wires and cables, and is characterized in that: the novel high-voltage cable comprises a conductor, a wrapping layer, an insulating layer, a shielding layer and a sheath layer which are sequentially arranged from inside to outside, wherein the wrapping layer is in non-adhesive contact with the insulating layer, and the wrapping layer is formed by winding polytetrafluoroethylene wrapping tape. The aluminum conductor is wrapped by the wrapping tape, so that the compactness of conductor stranding is improved, the conductor is not easy to loose and deform, the smoothness of the contact surface on the inner side of the silicon rubber insulation is improved, the silicon rubber is extruded on the wrapping tape during insulation extrusion, the situation that the stripping force is large due to the fact that silica gel is embedded into a gap on the surface of the aluminum conductor is avoided, and the high-voltage aluminum cable structure is adjusted.
Description
Technical Field
The utility model belongs to the technical field of wires and cables of new energy automobiles, and particularly relates to a high-voltage aluminum cable for a new energy vehicle, which is suitable for full-automatic wire stripping equipment.
Background
In recent years, with the high emphasis and support of new energy automobiles in China, the new energy automobile industry rapidly develops and sales volume is continuously increasing. However, harness enterprises that are associated with new energy automobiles also face significant challenges. As the 'big artery' of the new energy automobile electric energy transmission, the assembly efficiency of the high-voltage cable is important to the productivity improvement of the wire harness enterprises.
At present, the wire harness enterprises commonly adopt full-automatic wire stripping equipment to replace manual wire stripping equipment so as to improve the assembly efficiency of the high-voltage cable and save the labor cost. In the process of stripping the high-voltage cable by the full-automatic wire stripping equipment, the stripping force between the insulating layer and the metal conductor is particularly important. If the stripping force is too small, the insulation material layer may retract after stripping, so that the metal conductor is exposed; if the stripping force is too large, the insulating material layer and the metal conductor can not be separated, so that the full-automatic equipment is stopped in an alarm mode, and the machining efficiency is affected.
The high-voltage aluminum cable conductor used in the new energy vehicle at present adopts aluminum monofilaments with larger diameter, gaps among conductors are larger, a glue clamping phenomenon is easy to occur, and the surface smoothness of the conductor is poor, so that the silicon rubber insulating material and the metal aluminum conductor are difficult to strip. This is not suitable for stripping using fully automatic wire stripping equipment. Therefore, for these situations, the harness enterprises need to find solutions to ensure that the high-voltage cable can be successfully stripped in the full-automatic wire stripping equipment, so that the assembly efficiency is improved, and the production quality is ensured.
Disclosure of Invention
Aiming at the problems existing in the prior art, the utility model provides the high-voltage aluminum cable for the new energy vehicle, which is suitable for the full-automatic wire stripping equipment and solves the problems of the prior art that the assembly efficiency is reduced and the production quality is affected due to the difficulty in stripping the high-voltage aluminum cable of the new energy vehicle in the full-automatic wire stripping equipment.
The utility model is realized in such a way that a new energy vehicle high-voltage aluminum cable suitable for full-automatic wire stripping equipment is characterized in that: the cable comprises a conductor, a wrapping layer, an insulating layer, a shielding layer and a sheath layer which are sequentially arranged from inside to outside, wherein the wrapping layer is in non-adhesive contact with the insulating layer.
In the above technical solution, preferably, the wrapping layer is formed by winding polytetrafluoroethylene wrapping tape.
In the above technical scheme, preferably, the thickness of the polytetrafluoroethylene wrapping tape is 0.05mm, the width of the polytetrafluoroethylene wrapping tape is 25mm, and the overlap ratio of the wrapping layer is 5%.
In the above technical solution, preferably, the conductor is formed by twisting strands in a form of 1+6+12 three layers, wherein the pitch of the middle layer is 105-115mm, and the pitch of the outer layer is 125-135mm; the strand wires are formed by twisting aluminum monofilament bundles, and the twisting direction of each layer of the conductor is the same as the twisting direction of the aluminum monofilament bundles.
In the technical scheme, preferably, the insulating layer is silicon rubber with the thickness of 0.75-1.1mm, and the concentricity of the wire core of the insulating layer is more than or equal to 85%.
In the above technical scheme, preferably, the shielding layer is composed of a tinned copper wire braided layer and an aluminum plastic wrapping layer, the aluminum plastic wrapping layer is wrapped on the outer side of the copper wire braided layer, and the aluminum plastic wrapping layer is made of an aluminum plastic composite belt.
In the above technical scheme, preferably, the diameter of the tinned copper wire is required to be less than or equal to 0.21mm, the braiding density of the tinned copper wire braiding layer is more than or equal to 85%, and the braiding angle of the tinned copper wire braiding layer is controlled to be 50-60 degrees.
In the above technical scheme, preferably, the width of the aluminum-plastic composite belt is 25mm, the thickness of the aluminum-plastic composite belt is 0.025mm, and the wrapping covering rate of the aluminum-plastic wrapping layer is more than or equal to 20%.
In the above technical solution, preferably, the sheath layer is a silicone rubber with a thickness of 0.9-1.3 mm.
The utility model has the advantages and effects that:
aiming at the problems existing in the production of the wire harness of the high-voltage aluminum cable of the new energy automobile, the utility model introduces a layer of wrapping tape wrapped outside the aluminum conductor by changing the structural composition of the cable, and the wrapping tape has a surface which is not adhered to an outer insulating layer. The design improves the situation that the silicon rubber is embedded into the gaps on the surface of the aluminum conductor, reduces the adhesion phenomenon between the silicon rubber insulation and the aluminum conductor, and solves the problem that the silicon rubber is difficult to strip in the stripping process. Meanwhile, the compaction of the wrapping tape can also increase the compaction of aluminum conductor stranding, so that the aluminum conductor is not easy to loose and deform after the cable stripping processing is finished, and the follow-up conductor ultrasonic welding and terminal processing processes are facilitated.
In the production of the high-voltage aluminum cable with the adjusted structure, the winding belt can effectively improve the adhesion condition between the insulating material and the aluminum conductor, reduce the stripping force and improve the wire stripping efficiency, thereby improving the production efficiency and the productivity of wire harness enterprises. Meanwhile, the aluminum conductor twisting compactness is improved, so that the stability and the reliability of the cable are maintained, and the problems of poor electrical connection and signal transmission failure caused by loose deformation of the conductor are avoided.
Therefore, the high-voltage aluminum cable structure is adjusted, an effective solution is provided for the production of the new energy automobile wire harness by solving the problem of adhesion between the silicon rubber insulation and the aluminum conductor, reducing the stripping force and improving the twisting compactness of the aluminum conductor, and the further development of the new energy automobile industry is expected to be promoted.
Drawings
Fig. 1 is a schematic structural view of the high-voltage aluminum cable according to the present utility model.
Detailed Description
The present utility model will be described in further detail with reference to the following examples in order to make the objects, technical solutions and advantages of the present utility model more apparent. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the utility model.
The utility model provides a high-voltage aluminum cable for a new energy vehicle, which is particularly suitable for the full-automatic wire stripping equipment and aims to solve the problems that the high-voltage aluminum cable of the new energy vehicle is difficult to strip in the full-automatic wire stripping equipment, so that the assembly efficiency is reduced and the production quality is affected. For further explanation of the structure of the present utility model, the detailed description is as follows in connection with the accompanying drawings:
referring to fig. 1, a high-voltage aluminum cable for a new energy vehicle suitable for a full-automatic wire stripping device comprises a conductor 1, a wrapping layer 2, an insulating layer 3, a shielding layer 4 and a sheath layer 5 which are sequentially arranged from inside to outside, wherein the wrapping layer is in non-adhesive contact with the insulating layer.
The wrapping layer is formed by winding polytetrafluoroethylene wrapping tape. The thickness of the polytetrafluoroethylene wrapping tape is 0.05mm, the width of the polytetrafluoroethylene wrapping tape is 25mm, and the lap rate of the wrapping layer is 5%.
The wrapping layer is made of a wrapping belt made of Polytetrafluoroethylene (PTFE) materials, and aluminum conductors are wrapped through the wrapping belt, so that the compactness of conductor stranding is improved, the conductor is not easy to deform loosely, the smoothness of the contact surface of the inner side of the silicon rubber insulation is improved, the silicon rubber is extruded on the wrapping belt during insulation extrusion, and the situation that the stripping force is large due to the fact that silica gel is embedded into gaps on the surface of the aluminum conductors is avoided.
Polytetrafluoroethylene (PTFE) has a low coefficient of friction, non-adhesion, high temperature resistance (up to 260 ℃), aging resistance and excellent chemical stability.
The conductor is formed by twisting strands in a 1+6+12 three-layer mode, wherein the pitch of the middle layer is 105-115mm, and the pitch of the outer layer is 125-135mm; the strand wires are formed by twisting aluminum monofilament bundles 1-1, and the twisting direction of each layer of the conductor is the same as the twisting direction of the aluminum monofilament bundles. Specifically, the conductor is made of soft round aluminum wires with the purity of more than 99.7 percent, and is formed by twisting three layers of strands, the conductor structure is designed to be a normal twisting structure, and the number of strands from inside to outside is sequentially 1, 6 and 12. In the embodiment, taking a high-voltage line of 50mm2 as an example, the high-voltage line is composed of 247 monofilaments of 0.50mm, firstly, carrying out beam twisting processing, wherein 13 metal aluminum monofilaments with the diameter of 0.50mm are twisted into the strands, and the pitch of the strands is 50-60mm; and then cage twisting the stranded wires, wherein the first layer has no pitch, the second layer has a pitch of 105-115mm, the third layer has a pitch of 125-135mm, and the twisting direction of each layer of the conductor is the same as the twisting direction of the monofilaments of the stranded wires.
The insulating layer is made of silicon rubber with the thickness of 0.75-1.1mm, and the concentricity of the wire core of the insulating layer is more than or equal to 85%.
The shielding layer is composed of a tinned copper wire weaving layer 4-1 and an aluminum plastic wrapping layer 4-2, the aluminum plastic wrapping layer is wrapped on the outer side of the tinned copper wire weaving layer, and the aluminum plastic wrapping layer is made of an aluminum plastic composite belt. The diameter of copper wires of the tinned copper wire braided layer is required to be less than or equal to 0.21mm, the braiding density of the tinned copper wire braided layer is more than or equal to 85%, and the braiding angle of the tinned copper wire braided layer is controlled to be 50-60 degrees. The width of the aluminum-plastic composite belt is 25mm, the thickness of the aluminum-plastic composite belt is 0.025mm, and the wrapping covering rate of the aluminum-plastic wrapping layer is more than or equal to 20%.
The sheath layer is made of silicone rubber with the thickness of 0.9-1.3 mm. The sheath layer is made of a silicon rubber material with the temperature resistance grade of 180 ℃ by one-step extrusion, and the thickness of the sheath layer is between 0.9 and 1.3 mm.
50mm 2 According to the technical scheme of the utility model, the peeling force between the insulating layer and the metal conductor of the high-voltage aluminum cable is tested according to the peeling force testing method in the automobile cable industry standard before and after the change, and the testing data are shown in the following table 1:
table 1 test values of peel force before and after change
As shown in the above table, the average force of stripping the conductor and insulation of the unpicked Polytetrafluoroethylene (PTFE) taping was 159.85N, the maximum value was 176.37N, and the minimum value was 148.66N. The average value of the stripping force of the conductor and the insulation of the wrapping tape of the wrapping Polytetrafluoroethylene (PTFE) is 64.44N, the maximum value is 73.31N, and the minimum value is 56.89N. After the conductor is wrapped with Polytetrafluoroethylene (PTFE) wrapping tape by data comparison, the stripping force between the conductor and the insulation is obviously lower than that before wrapping.
In summary, by changing the design of the cable structure, a layer of Polytetrafluoroethylene (PTFE) wrapping tape is added outside the aluminum conductor, so that the stripping force between insulation and the conductor is obviously reduced, and the stripping force test data after the cable structure is changed are all between 50 and 80N, thus the cable is suitable for full-automatic wire stripping equipment.
The foregoing description of the preferred embodiments of the utility model is not intended to be limiting, but rather is intended to cover all modifications, equivalents, and alternatives falling within the spirit and principles of the utility model.
Claims (9)
1. The utility model provides a new energy vehicle is with high-voltage aluminum cable suitable for full-automatic wire stripping equipment which characterized in that: the cable comprises a conductor, a wrapping layer, an insulating layer, a shielding layer and a sheath layer which are sequentially arranged from inside to outside, wherein the wrapping layer is in non-adhesive contact with the insulating layer.
2. The high-voltage aluminum cable for new energy vehicles suitable for full-automatic wire stripping equipment according to claim 1, wherein the high-voltage aluminum cable is characterized in that: the wrapping layer is formed by winding polytetrafluoroethylene wrapping tape.
3. The high-voltage aluminum cable for new energy vehicles suitable for full-automatic wire stripping equipment according to claim 2, characterized in that: the thickness of the polytetrafluoroethylene wrapping tape is 0.05mm, the width of the polytetrafluoroethylene wrapping tape is 25mm, and the lap rate of the wrapping layer is 5%.
4. The high-voltage aluminum cable for new energy vehicles suitable for full-automatic wire stripping equipment according to claim 3, wherein: the conductor is formed by twisting strands in a 1+6+12 three-layer mode, wherein the pitch of the middle layer is 105-115mm, and the pitch of the outer layer is 125-135mm; the strand wires are formed by twisting aluminum monofilament bundles, and the twisting direction of each layer of the conductor is the same as the twisting direction of the aluminum monofilament bundles.
5. The high-voltage aluminum cable for new energy vehicles suitable for full-automatic wire stripping equipment according to claim 4, wherein: the insulating layer is made of silicon rubber with the thickness of 0.75-1.1mm, and the concentricity of a wire core of the insulating layer is more than or equal to 85%.
6. The high-voltage aluminum cable for new energy vehicles suitable for full-automatic wire stripping equipment according to claim 5, wherein the high-voltage aluminum cable is characterized in that: the shielding layer is composed of a tinned copper wire weaving layer and an aluminum plastic wrapping layer, the aluminum plastic wrapping layer is wrapped on the outer side of the tinned copper wire weaving layer, and the aluminum plastic wrapping layer is made of an aluminum plastic composite belt.
7. The high-voltage aluminum cable for new energy vehicles suitable for full-automatic wire stripping equipment according to claim 6, wherein: the diameter of copper wires of the tinned copper wire braided layer is required to be less than or equal to 0.21mm, the braiding density of the tinned copper wire braided layer is more than or equal to 85%, and the braiding angle of the tinned copper wire braided layer is controlled to be 50-60 degrees.
8. The high-voltage aluminum cable for new energy vehicles suitable for full-automatic wire stripping equipment according to claim 6, wherein: the width of the aluminum-plastic composite belt is 25mm, the thickness of the aluminum-plastic composite belt is 0.025mm, and the wrapping covering rate of the aluminum-plastic wrapping layer is more than or equal to 20%.
9. The high-voltage aluminum cable for new energy vehicles suitable for full-automatic wire stripping equipment according to claim 7 or 8, characterized in that: the sheath layer is made of silicone rubber with the thickness of 0.9-1.3 mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202321010394.XU CN219800539U (en) | 2023-04-28 | 2023-04-28 | High-voltage aluminum cable suitable for new energy vehicle of full-automatic wire stripping equipment |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202321010394.XU CN219800539U (en) | 2023-04-28 | 2023-04-28 | High-voltage aluminum cable suitable for new energy vehicle of full-automatic wire stripping equipment |
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| Publication Number | Publication Date |
|---|---|
| CN219800539U true CN219800539U (en) | 2023-10-03 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202321010394.XU Active CN219800539U (en) | 2023-04-28 | 2023-04-28 | High-voltage aluminum cable suitable for new energy vehicle of full-automatic wire stripping equipment |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN219800539U (en) |
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2023
- 2023-04-28 CN CN202321010394.XU patent/CN219800539U/en active Active
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