UA132600U - METHOD OF MANUFACTURING ARMED SUSPENSION CONTACT (TROLLEY) WIRE - Google Patents

Abstract

A method of manufacturing a reinforced suspension (trolley) wire on the basis of Conform-process consists in conformal coating of pre-heated steel wire with copper or copper alloy of any composition by continuous pressing (extrusion) of copper material in an extruder container with a die and using a die revolving. Steel wire in the amount of one or two spaced strands of the same or different diameter is pre-deformed in two sequentially installed strands with a compression of 1 to 2% in each. Using the guide nipples is fed into the working cavity of the extruder container, which is filled with plastic copper material. The plastic copper coating of the wire and its final shape and size are formed by a die fixed at the outlet of the folded extruder container. In the insulated cavity provided at the entrance to the first roll for pre-deformation of steel wire cores, a surfactant water-air mixture, for example, polyvinyl acetate adhesive, is fed. In a sealed cavity made between the first and second rolls for pre-deformation of steel wire cores, copper or copper-graphite powder is preferably introduced under pressure.

Description

The utility model belongs to the field of engineering, namely to the processing of metals under pressure, and can be used to obtain a reinforced suspended contact (trolley) wire, which serves to transmit electrical energy to ground electrified transport.

There is a known method of manufacturing a steel-aluminum contact wire, which consists in applying an annular layer of pressed aluminum to the core on an aluminum press using a technological tool in the form of a matrix and a mandrel, which has at least one conical working surface, cooling with water and winding on a receiving drum, while the steel core are made of one steel wire, and the mandrel has a working surface in the form of two conical surfaces that connect, and the angle of the cone on the side of the head of the wire is greater than the acute angle of the cone on the side of the base of the wire (Russian Patent Mo 2351485, IPC VbOM 1/13.

The method of manufacturing a contact steel-aluminum wire; published 10.04.2009, Bull. Mo 101.

There is a known method of reinforcing a suspended contact wire, which consists in the fact that a groove is extruded along the longitudinal axis of the workpiece, the width of which is equal to the diameter of the reinforcing wire, and the height of the groove is determined by the required depth of the reinforcing wire in the workpiece, and after laying the wire in the groove, its walls are shifted by cold deformation of the workpiece in the area of the groove location, and the longitudinal seam obtained after closing the groove is rolled up, and the welding of the seam is carried out either by the method of melting in argon, helium and nitrogen, or by the method of cold plastic deformation of the workpiece, compressing the workpiece with the application of pressure in the area of the welding surfaces Patent RF Mo 2195730, IPC NO18 13/22,

VbOM 1/13. The method of reinforcing the suspended contact wire; published 27.12.2002, Bull. Mo zbi

There is a known method of manufacturing a contact wire, which consists in feeding the melt into the space between the chute of the crystallizer, which rotates, and the endless belt, rolling and further calibrating the obtained shaped blank by drawing, which is characterized by the fact that a metal rod pre-bent in radius is introduced into the space between the chute and the belt at a distance of 0.5...1.5 diameter of the rod from the bottom part of the chute at a speed equal to the linear speed of a point on the surface of the crystallizer located at a radius equal to the distance from the point of insertion of the rod to the center of the crystallizer, while rolling is carried out while maintaining the spatial position cross-sectional planes of the continuously cast workpiece, connecting the zone,

From the formed bottom part, with the working area of the contact wire (AS USSR Mo 1101323,

IPC v220 11/06. The method of manufacturing a contact wire; published 07.07.1984, Bull. Mo 251.

There is also a known method of making round wire based on the Sopiopt process by extruding copper or a copper alloy around a steel wire followed by hot rolling, the copper material being first fed into the gap between a rotating rotor with an annular groove and a shoe that covers part of it of the rotor, as a result of which, under the action of frictional forces on the surfaces of the groove of the rotor and the shoe, the copper material heats up and enters the extrusion container with a die, into which, after preliminary induction heating, a steel wire is also fed for coating with copper material, and after this plastic coating with copper the material is finally formed with the help of a die around a steel wire, it is additionally subjected to hot rolling in rolls at a temperature of 400 "С and more with crimping from 10 to 40 95. (Patent UR 11105586 (А), МПК ВбОМ 1/13, НО1В 1/02.

Mapygasishige oi sorreg og sorreg aiIou soaiiea vievy! sopiasi mige / Opaia Mozike, Matada T5ikKavza,

Oia Khozpipiza, Ki-zakKai diocese; patent holder ESHLKIOVA AND TO.-Meo OR 19970271553 19971003; statement 03.10.1997; published 20.04.1999).

The closest analogue to the proposed method is the method of manufacturing trolley wire based on the Sopiopt process, which consists in the conformal ring coating of steel wire with a heat-resistant copper alloy, followed by providing the peripheral layer with the required cross-sectional profile by rolling in calibrated rolls or drawing through a die (UR Patent 2001180337 (A) Japan. IPC В21С 23/21, В21С 23/22, ВБОМ 1/13. TioiIeu mige oi sorreg-aIPou-soaiviea v5ievi, apa teiioi oi tapiitasiyiipd ilipe zate /

OpNaia Mozike, Imauata Nigoagi, Matada T5yKaza, Totigiga Tovpiti2y; patent owner RSHLKOV

TRP.- Mo UR1I9990366270 19991224; statement 24.12.1999; published 07/03/2001.

Common essential features of the closest analogue and the proposed method are the use of the Sopiopt process for the manufacture of suspended contact (trolley) wire, reinforcement of the suspended contact (trolley) wire with steel wire by conformal coating of the latter with copper or a copper alloy of any composition, formation of the copper component of the suspended contact ( trolley) wire by continuous pressing (extrusion) of copper material in an extrusion container with a die using a shoe and a calibrated rotor that rotates, preheating the steel wire before feeding it to the extrusion container.

The known disadvantages of the method are the coaxial arrangement of the steel wire in the peripheral layer of the copper alloy, which does not allow obtaining a suspended contact wire of a more complex shape and thus narrows the range of reinforced suspended contact (trolley) wires, as well as, in the conditions of ensuring higher tensile strength of the wire, does not allow an increase in the limit of the possible degree of wear of its copper layer before the steel wire exits, which reduces the durability of the contact wire; lack of an operation to clean the surface of the steel wire from oxides before coating it with a copper alloy, which does not ensure reliable adhesion of the coating to the steel wire and, as a result, reduces the quality of the wire; the need for an additional operation of rolling in calibrated rolls or drawing through a die to give the peripheral layer of coverage the necessary cross-sectional profile, which complicates the composition and increases the cost of the equipment, as well as leads to an increase in current costs; the use of a special heating device to heat the steel wire before it is fed into the extrusion container, which also increases capital and running costs.

The useful model is based on the task of improving the known method of manufacturing reinforced suspended contact (trolley) wire to expand the assortment of reinforced suspended contact (trolley) wire, improve its quality and increase its service life, reduce capital and current costs associated with the production of wire, reduce costs of expensive copper.

The task is solved by the fact that the method of manufacturing reinforced suspended contact (trolley) wire based on the Sopiopt process consists in the conformal coating of preheated steel wire with copper or a copper alloy of any composition by means of continuous pressing (extrusion) of copper material in an extrusion container with a die with using a shoe and a calibrated rotating rotor, according to a useful model, steel wire in the amount of one or two spaced cores of the same or different diameter is pre-strained in two successively installed drags with compression from 1 to 2595 in each, and then with the help of guide nipples are fed into the working cavity of the extrusion container, which is filled with plastic copper material, while the plastic copper coating of the wire and its final shape and dimensions are formed with the help of a die fixed at the exit from the assembled extrusion container. In addition, in isolated

A surface-active water-air mixture, for example, polyvinyl acetate glue, is fed into the cavity provided at the entrance to the first draw for the preliminary deformation of the steel wire strands, and copper is introduced into the hermetic cavity made between the first and second draws for the preliminary deformation of the steel wire strands or copper-graphite powder preferably under pressure.

The essence of the proposed method is explained by the drawings, which show: fig. 1 - scheme of the unit for the manufacture of reinforced suspended contact (trolley) wire; fig. 2 - diagram of the drawing-extrusion unit; fig. C - cross section along A-A of the extrusion container of the drawing-extrusion unit; fig. 4 - cross section along B-B of the finished reinforced suspended contact (trolley) wire with steel wire in the gripping head; fig. 5 - cross-section along B-B of the finished reinforced suspended contact (trolley) wire with a steel wire at the base; fig. 6 - cross section along B-B of the finished reinforced suspended contact (trolley) wire with steel wire cores in the gripping head and base.

The method of manufacturing reinforced suspended contact (trolley) wire is carried out as follows.

The workpiece 1 of copper material from the unwinder 2 is fed into the gap between the shoe 3 and the rotating calibrated rotor 4 (the rotor drive is not shown), which are placed in the bed 5. The workpiece 1 of copper material is drawn into the specified gap under the action of frictional forces, heating up and acquiring increased plasticity. Having reached the stop 6, the formed plastic copper material 7 enters the drawing-extrusion block 8, which is also installed in the bed 5. At the same time, one or two cores of steel wire 11 and 12 of the same size are fed into the drawing-extrusion block 8 from the unwinders 9 and 10 or different diameters, which are subjected to a conformal coating with a plastic copper material 7 to form a ready-made reinforced suspended contact (trolley) wire 13, which is pulled out of the drawing-extrusion block 8 with the help of drawing rollers 14 and sent to the cooler 15. After cooling, the ready-made reinforced suspended contact ( trolley) wire 13 is subjected to winding in a riot on one of the winders 16 working in turn. Scissors 17 are used to divide wire 13 after 60 formed a riot of the required mass.

Before starting the unit for the production of reinforced suspended contact (trolley) wire, the ends of the steel wire cores 11, 12, previously sharpened to the filling length, are passed freely through the working channels of the first 19 and second 20 draglines with the help of wiring 18 and are oriented with the help of nipples 21 in the opening of the working channel die 22, fixed at the exit from the folded extrusion container 23, part of the working cavity 24 of which is occupied by the insert 25, made in the form of a cylinder, one of the bases of which is made oblique. The pointed ends of the cores of the steel wire 11, 12 are fixed in a collet clamp connected to one of the ends of the charging cable (not shown), the other end of which is fixed on the drum of one of the winders 16. By turning the drum of the winder 16, the cores of the steel wire 11, 12 using the collet clamp and the charging cable are moved to the entrance to the drag 19 of the unsharpened sections of the steel wire cores 11, 12 with the initial diameters to and dgo. The winder 16 creates tension in the cores of the steel wire 11, 12 and at the same time turns on the drive of the calibrated rotor 4, which rotates, having previously inserted the blank 1 of copper material into the gap formed by the shoe 3 and the stream 26 of the calibrated rotor 4. Thus, the process of forming plastic copper material begins 7, which under the action of frictional forces arising on the working surface of the stream 26 of the calibrated rotor 4, directed by the inclined surface of the base of the insert 25, fills the free part of the working cavity 24 of the extrusion container 23 and, flowing around its bridge 277, enters the die 22 with oriented in the hole its working channel with the help of nipples 21 with strands of steel wire 11, 12. In the die 22, the plastic copper coating of the strands of steel wire 11, 12 and the formation of the transverse profile of the reinforced suspended contact (trolley) wire 13 are carried out in accordance with its specified dimensions and shape. When the full profile of the wire 13 enters the traction rolls 14, their drive is turned on and the charging cable with a collet clamp is removed, and after the front end of the finished reinforced suspended contact (trolley) wire 13 reaches the drum of the first winder 16, it is fixed on the drum of this winders and include its drive. Thus, due to the work of the traction rolls 14, the winder 16 and the axial forces arising when the plastic copper material 7 is extruded from the working cavity 24 of the extrusion container 23, a total axial force is created, which ensures the movement of the finished reinforced suspended contact (trolley) wire 13 and the previous deformation of steel wire cores 11, 12 in serially installed drags 19, 20.

At the same time, the speed of moving the wire 13 (Mi), the peripheral speeds of the traction rolls 14 (Mv) and the winder drum 16 (Um) are synchronized.

Crimping the cores of the steel wire 11, 12 in the wires 19, 20 within the limits of 1...2 95 in each of them provides preliminary heating of the steel wire due to the frictional forces on the working contact surfaces of the wires 19, 20 and removal of the oxide film from the surface of the steel wires wires 11, 12. This contributes to their better adhesion to the plastic copper material 7 in the working area of the die 22. Along with the above, the surface of the steel wire cores 11, 12 is subjected to slander, and their core remains without deformation processing (soft), which ensures higher strength of the reinforced suspended contact (trolley) wire 13 in general along with a sufficiently high degree of its flexibility (reduced stiffness). This helps to improve the quality of the wire and facilitate its installation.

Before crimping the steel wire strands 11, 12 in the draws 19, 20, a surface-active water-air mixture, for example, polyvinyl acetate glue, is fed into the insulated cavity 28, which serves as a lubricant during the deformation of the steel wire strands 11, 12 in the first draw 19, and the thinnest its film, which remains on the surfaces of the veins at the exit from the draw 19, contributes to more effective drawing of the copper or copper-graphite powder into the center of deformation of the second draw 20, which, using the accumulator 29, is fed mainly under pressure into the hermetic cavity 30, which is made between the first 19 and the second with 20 drags. Copper or copper-graphite powder acts as a lubricant during the deformation of the steel wire cores 11, 12 in the second draw 20 and adheres to the surface of these cores, which, along with the other techniques mentioned above, contributes to a stronger adhesion of the steel wire cores 11, 12 to the plastic copper material 7 in the working area of die 22.

As an example, consider the manufacture of reinforced suspended contact (trolley) shaped wire with a nominal cross-section of 85 mm", with an estimated weight of 1000 meters of wire - 755 kg and a required construction length of 1400...2000 meters (GOST 2584-86), which is intended for contact networks of trams and trolleybuses.

For the reinforcement of wire 13, we use two cores of steel wire: 11 - with an initial diameter of c:o-4.0 mm and 12 - with an initial diameter of dgo-2.5 mm with a length of at least 1400...2000 m made of low-carbon steel (GOST 2771 -81). At the same time, we mean that in order to increase the productivity of the unit intended for obtaining a reinforced suspended contact bo (trolley) wire, the output length of the reinforcing cores of the steel wire 11, 12 on the unwinders 9 and

10 should be greater and at least exceed the required construction length of the finished wire 13 by 3...5 times (a multiple of the selected construction length). Accordingly, with the initial diameters of the steel wire cores selected, the diameters of the guide holes of the wiring 18 are chosen to be slightly larger than the initial diameters of the wire cores, namely equal to 4.3 mm and 2.7 mm. For the preliminary deformation of steel wire cores with diameters of 4.0 and 2.5 mm in drafts 19, 20, we take a relative compression of 6-2 95. In this case, in draft 19, we set the diameters of the calibration zones of its working channels to be equal to 3.92 mm and 2.45 mm, and for the implementation of relative compressions of the same magnitude (0-2 95) in the draw 20, into which the steel wire strands already deformed in the draw 19 enter, the diameters of the calibration zones of the working channels of the draw 20 are chosen equal to 3.84 mm and 2.40 mm .

The calibrating zone of the working channel of the die 22 practically corresponds to the profile and dimensions of the finished reinforced suspended contact (trolley) wire 13 (shaped) with a section of 85 -0.05 mm: and has a height of 10.80 mm, a width of the gripping head of 8.05 mm, and a width of base 11.767022 mm (GOST 2584-86). Cores of steel wire with diameters a, - ЗВ mm and b - 20 mm with the help of nipples 21, which have guide holes with diameters of 3.95 mm and 2.50 mm, respectively, are oriented in the opening of the working channel of the die 22 along its vertical axis in such a way that in order to ensure the possibility of critical 30-percent wear of the base of the current-conducting part of the contact wire 13 to the OUTPUT of the core of the steel wire 11. For this purpose, the axis of the core of the steel wire 11 with a diameter of "0777 mm is located at a distance of 5.60 mm from the lower point of the contour of the base of the contact wire, and the intercenter the distance between wires 11 and 12 of the steel wire is chosen equal to 3.80 mm.

A round blank 1 with a diameter of 12.50 mm made of copper low alloyed with magnesium in a coil with a mass of 3672 kg is fed from the unwinder 2 into the gap between the shoe C and the calibrated rotating rotor 4.

At the same time, we feed both strands of steel wire 11 and 12 with the above-mentioned output diameters into the drawing-extrusion unit 8 from the unwinders 9 and 10. Before the task, the front ends of the cores of the steel wire are sharp by pre-crimping the cores to the following values of their diameters: 11-3.5 mm and 12-21 mm, which ensures their unhindered task through the wiring 18 into the working channels of the drags 19 and 20 and the holes of the nipples 21. The length of the pointed ends is chosen equal to 800 mm, based on the distance from the drag 19 to the place where the ends can be captured with a collet clamp. Using a refueling cable with a collet clamp and a winder 16, we create

From the tension of the front ends of the cores of the steel wire 11, 12 and, turning on the drive of the calibrated rotor 4, we begin the process of producing the contact wire 13. When the complete profile of the wire 13 enters the traction rolls 14, we turn on their drive, remove the charging cable with a collet clamp, and when reaching end of the finished wire of the drum of the first winder, fasten it on the drum and switch the operation of the winder drive to the operating mode with the circumferential speed of winding the finished wire 13, equal to 0.19 m/s. During the operation of the unit, we feed 10 95 solution of polyvinyl acetate glue (PVA, 5K-2250 TU У 20.5-32175958-001-2013) into the insulated cavity 28 in the air flow, and copper powder into the sealed cavity З. The temperature of the finished contact wire 13 at the exit from the spinneret 22 is about 630 "C, and after passing through the cooler 15 before winding on the winder drum, it is 16-70 "C.

After collecting on the drum of the first winder 16 a bundle of ready-made reinforced suspended contact (trolley) wire 13 with a mass of 1478 kg (when the length of the wire in the bundle is 2000 m), we turn on the scissors 17, and the end of the wire 13, which continues to move from the side of the drawing-extrusion unit 8 after dividing with the scissors, is turned on fasten on the drum of the second winder 16 and turn on its drive. During the operation of the second winder 16, we tie and clean the bundle of finished wire 13 from the drum of the first winder 16.

Note that the masses of the coils of the round workpiece 1 made of copper (3672.0 kg) and the cores of steel wire 11-550 kg and 12-215 kg are selected based on the calculation of obtaining from the coils the finished reinforced suspended contact (trolley) wire 13 with a length of turns in the coil 2000 m with the mass of the riot - 1478 kg.

In the considered case, the saving of copper (due to the volume of copper replaced by steel wires) per 1000 m of reinforced suspended contact (trolley) wire with a nominal cross-section of 85 mm: is 143.26 kg, and the weight of the wire, due to the lower value of the density of steel, is reduced by 16 ,42 kg.

The use of the proposed method of manufacturing reinforced suspended contact (trolley) wire allows to expand the assortment of reinforced suspended contact (trolley) wire, improve its quality and increase its service life, reduce capital and current costs associated with the manufacture of wire, reduce the consumption of expensive copper.

Claims (1)

USEFUL MODEL FORMULA The method of manufacturing reinforced suspended contact (trolley) wire based on the Sopiogt process, which consists in conformal coating of preheated steel wire with copper or copper alloy of any composition by continuous pressing (extrusion) of copper material in an extrusion container with a die using a shoe and a calibrated rotating rotor, which differs in that the steel wire in the amount of one or two spaced strands of the same or different diameter is preliminarily subjected to deformation in two consecutively installed drags with a crimp from 1 to 2 95 in each, and then with the help of guide nipples fed into the working cavity of the extrusion container, which is filled with plastic copper material, while the plastic copper coating of the wire and its final shape and dimensions are formed with the help of a die fixed at the exit from the assembled extrusion container, while in the isolated cavity provided at the entrance to the first wire for preliminary deformation of steel wire cores, a surface-active water-air mixture, for example, polyvinyl acetate glue, is fed, and copper or copper-graphite powder is introduced, preferably under pressure, into the hermetic cavity made between the first and second wire ropes for preliminary deformation of steel wire cores . - іх ех У я шчи же о Й b Б ТЯ в Ши Ту: Я я gl Uk х х se ri шк te g Ka е KU х i n Lad, su y ih FAK Х х ri Ko х ; H N N Z Her Z GZ i z i Ko: sec a Kom ee DE Ide z i r r ohh: so, t. ХК НИ Mi a , Zh zhi y 7 x sha Asya k o - TU Zoo zh Khan they ni ee and RM I Y ke. ke a In: - a kh i em In: NO kh kh - i: "u oz - vy kh ukh kh kh, kh g 6 viya: y M kh y dy rn shin Zh h.i 5 3 che i and a ss o Fig. 1