WO2020228457A1 - 用于电动汽车充电桩的电缆、制备方法及弱电柔性线芯的绞合装置 - Google Patents

用于电动汽车充电桩的电缆、制备方法及弱电柔性线芯的绞合装置 Download PDF

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Publication number
WO2020228457A1
WO2020228457A1 PCT/CN2020/084055 CN2020084055W WO2020228457A1 WO 2020228457 A1 WO2020228457 A1 WO 2020228457A1 CN 2020084055 W CN2020084055 W CN 2020084055W WO 2020228457 A1 WO2020228457 A1 WO 2020228457A1
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WO
WIPO (PCT)
Prior art keywords
layer
twisting
deflector
aramid
telescopic
Prior art date
Application number
PCT/CN2020/084055
Other languages
English (en)
French (fr)
Inventor
张林锐
王经逸
程斌
华健
华洪彬
Original Assignee
无锡市华美电缆有限公司
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Filing date
Publication date
Application filed by 无锡市华美电缆有限公司 filed Critical 无锡市华美电缆有限公司
Publication of WO2020228457A1 publication Critical patent/WO2020228457A1/zh
Priority to AU2021101392A priority Critical patent/AU2021101392A4/en
Priority to ZA2021/04377A priority patent/ZA202104377B/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60LPROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
    • B60L53/00Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
    • B60L53/10Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles characterised by the energy transfer between the charging station and the vehicle
    • B60L53/14Conductive energy transfer
    • B60L53/18Cables specially adapted for charging electric vehicles
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00Communication cables or conductors
    • H01B11/02Cables with twisted pairs or quads
    • H01B11/04Cables with twisted pairs or quads with pairs or quads mutually positioned to reduce cross-talk
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00Communication cables or conductors
    • H01B11/02Cables with twisted pairs or quads
    • H01B11/12Arrangements for exhibiting specific transmission characteristics
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22Sheathing; Armouring; Screening; Applying other protective layers
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/221Sheathing; Armouring; Screening; Applying other protective layers filling-up interstices
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/24Sheathing; Armouring; Screening; Applying other protective layers by extrusion
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/26Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B3/00Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/30Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
    • H01B3/42Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes polyesters; polyethers; polyacetals
    • H01B3/421Polyesters
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/02Disposition of insulation
    • H01B7/0208Cables with several layers of insulating material
    • H01B7/0225Three or more layers
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/1875Multi-layer sheaths
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/1895Internal space filling-up means
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01BCABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00Insulated conductors or cables characterised by their form
    • H01B7/17Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/22Metal wires or tapes, e.g. made of steel
    • H01B7/228Metal braid
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02ATECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00Adapting or protecting infrastructure or their operation
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/70Energy storage systems for electromobility, e.g. batteries
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00Road transport of goods or passengers
    • Y02T10/60Other road transportation technologies with climate change mitigation effect
    • Y02T10/7072Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02TCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T90/00Enabling technologies or technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02T90/10Technologies relating to charging of electric vehicles
    • Y02T90/14Plug-in electric vehicles

Definitions

  • the invention relates to the technical field of new energy vehicles, in particular to a charging cable used on a charging pile.
  • charging piles need to be arranged like gas stations for traditional fuel vehicles.
  • Charging piles have been vigorously developed as the most direct support for electric vehicles, which involves power supplies. Conversion, charging control, billing and cables, power conversion, charging control, and billing are all software design issues, and only cable design is a hardware design issue.
  • the cable of the charging pile needs to transmit electric energy and data information, including electric power core (strong wire core) and weak wire core. During the actual charging process, it is often dragged and bent.
  • Car rolling, or even folding in half is easy to cause damage to the cable, especially the damage to the thinner weak wire core during rolling and the damage to the strong wire core when bending in half, thus affecting the ductility, High requirements are put forward in many aspects such as bending resistance, heat resistance, and pressure resistance.
  • the prior art has conducted a lot of research on the bending performance of cables.
  • a strong wire core is used to combine a braided copper mesh and a twisted monofilament to improve the bending resistance, or a separate multi-strand soft copper wire is used.
  • Stranded conductor, and extruded elastomer insulation layer outside the conductor but although these methods have contributed to the bending resistance and can improve the performance, but from the perspective of the weak current and strong wire core of the charging cable , There is still room and necessity for improvement to improve shielding performance, bending resistance and high temperature resistance.
  • the flexible core has an important impact on the quality of the cable.
  • the traditional production method of the flexible core requires manual control to mix and twist the raw materials, which cannot guarantee the tightness of the flexible core, which directly affects the use of the cable. .
  • the purpose of the present invention is to provide a cable for electric vehicle charging piles with excellent shielding and good bending resistance.
  • the present invention proposes the following technical solutions:
  • a cable for an electric vehicle charging pile includes: a battery having a charging battery core and a weak current battery, the charging battery is configured as an electric energy transmission medium between the charging pile and the electric vehicle; the weak current battery structure It is a signal cell and a control cell with the same structure; multiple charging cells and multiple weak current cells are distributed tangentially;
  • Isolation layer wrapped around the overall shielding layer
  • An outer sheath layer arranged outside the braided layer; and a filling layer filled between the charging cell and the weak current cell and covered by the polyester tape layer;
  • the weak current battery includes a flexible wire core and a copper wire wound on the flexible wire core, the flexible wire core is formed by concentrically twisted aramid fiber and stainless steel wire, which contains 80%-90% aramid fiber, Pitch multiple is 5-10 times;
  • the copper wire is extruded with an insulating layer
  • the insulating layer is wrapped with a composite shielding layer formed by weaving metal wires and fibers;
  • the composite shielding layer is covered with polyester tape;
  • the composite shielding layer contains 60%-70% metal wires, the braiding angle is controlled at 45 ⁇ 5°, the braiding density is greater than 80%, and the shielding layer thickness is 0.3mm-0.5mm;
  • the rechargeable battery core is composed of multiple silver-plated copper wires or tin-plated copper wires that are twisted and then weaved an additional layer of silver-plated copper wires or tin-plated copper wires.
  • the thickness of the outer protective layer of the polyester tape is 0.04-0.2 mm.
  • the insulating layer of the weak current cell includes a high tear resistance silicone rubber insulating layer with a thickness of 0.5-1 mm.
  • the isolation layer includes a polyvinyl chloride, polyethylene or polyolefin isolation layer with a thickness of 0.8-2 mm.
  • the braided layer includes an aramid braided layer with a thickness of 0.3-0.5 mm and a braiding density greater than 80%.
  • the outer sheath layer is formed by extruding a polyvinyl chloride-rubber mixture on the braided layer, and the thickness is 1-3mm;
  • the polyvinyl chloride-rubber mixture is doped with alumina or silicon carbide wear-resistant particles and graphite powder.
  • the wear-resistant particles have a particle size of 40-60 nm, and the particle size of the graphite powder 30-40nm.
  • a method for manufacturing a cable for an electric vehicle charging pile which includes the following steps:
  • Step 3 Combine into a cable
  • step 1 and step 2 Combine the cells prepared in step 1 and step 2 into a cable, where three charging cells form an upright equilateral triangle distribution and are tangent to each other, and three weak current cells form an inverted equilateral triangle distribution and are located in the phase of the charge cell. Cut the gap position; wrap the polyester tape polyester tape layer on the outside of the six batteries with a thickness of 0.3-0.4mm; fill the gap between the six batteries with filler;
  • Step 4 After the cable is formed, the total shielding layer is wrapped around the polyester tape layer, and the composite shielding layer is adopted, which contains 60%-70% metal wire and 30%-40% fiber, and the braid angle is controlled At 45 ⁇ 5°, the braid density is greater than 80%, and the thickness is 0.04mm-0.2mm;
  • Step 5 Cover the isolation layer outside the composite shielding layer, the isolation layer is a polyvinyl chloride isolation layer or a cross-linked polyethylene isolation layer, 0.8-2mm;
  • Step 6 Wrap a braided layer outside the isolation layer.
  • the braided layer is an aramid braided layer with a thickness of 0.05-0.2mm and a weaving density of more than 80%.
  • Step 7 Extrude the PVC-rubber mixture outside the braided layer to form an outer sheath layer on the braided layer with a thickness of 1-3mm.
  • the PVC-rubber mixture is doped with oxidation Aluminum or silicon carbide wear-resistant particles and graphite powder, the size of wear-resistant particles is 40-60nm, and the size of graphite powder is 30-40nm.
  • the flexible core is prepared by an integrated twisting device
  • the integrated twisting device has a bottom plate, an electric slider is installed on the bottom plate, a moving frame is installed on the electric slider, and the moving frame is
  • the rotating motor is installed through the motor seat, the output shaft of the rotating motor is provided with a twisting mechanism, the middle of the bottom plate is provided with a guide frame, and the rear end of the bottom plate is provided with a diversion mechanism;
  • the guide frame is a cavity structure and the guide The frame is a trumpet-shaped structure with a gradually increasing diameter along the axial direction;
  • the twisting mechanism includes a twisting turret mounted on the output shaft of the rotating motor.
  • the twisting turret is provided with twisting collars.
  • the upper and lower sides of the twisting turret are symmetrically provided with twisting locking grooves and twisting collars.
  • There are symmetrical holes on the sidewalls the twisted collar is provided with a fastening cover, the outer wall of the fastening cover is symmetrically provided with a fastening block, the middle of the fastening cover is provided with a through hole to fasten the outer wall of the cover
  • the thickness gradually increases from left to right;
  • the deflector mechanism includes a deflector installed on the bottom plate.
  • the deflector is symmetrically provided with deflector holes, and the deflector is provided with a deflector that cooperates with the deflector, and the lower side of the front end of the deflector passes through the bearing
  • a guide roller is provided, and a locking hole is provided on the upper side of the guide frame;
  • a bidirectional driving cylinder is installed on the side wall of the guide plate, a locking block is provided on the bidirectional driving cylinder, and a twisting groove is provided on the locking block;
  • a telescopic tube is installed on the side wall of the deflector, the telescopic tube is provided with a telescopic hole, a telescopic frame is arranged in the telescopic hole by sliding fit, and a telescopic spring is sleeved between the telescopic frame and the inner wall of the telescopic hole, and the telescopic tube passes through
  • the motor base is equipped with an executive motor, the output shaft of the executive motor is provided with an executive cam, the executive cam is against the telescopic frame, and the execution block is set on the telescopic frame, and the execution block is a round table whose diameter increases from left to right. Shaped structure; buffer grooves are uniformly arranged on the execution block along its circumferential direction, and buffer plates are arranged in the buffer grooves through springs;
  • the stranding process includes the following steps: the aramid and the stainless steel wire crosstalk from back to front through the diversion hole, the diversion frame, the guide frame, the through hole and the stranding locking groove, and the guide frame reduces the pre-stranding process.
  • the distance between the aramid fiber and the stainless steel wire is such that the twisting point of the aramid fiber and the stainless steel wire is controlled in the guide frame; then the fastening cover is fastened, and the fastening cover and the twisting lock groove are matched with each other.
  • the left end of the aramid and stainless steel wire is locked; the rotation of the twisting turret is controlled by the rotating motor, and the twisting turret makes the aramid and the stainless steel wire twist together; at the same time, the moving frame in the twisting industry is controlled from the right by the electric slider Moving at a constant speed to the left drives the aramid and stainless steel wire to move synchronously from right to left;
  • the execution of the motor control execution of the cam rotation
  • the interaction between the execution cam and the telescopic spring controls the execution block to perform reciprocating operations
  • the execution block and the guide frame interact with each other, so that the execution block in motion can be inserted Go to the inside of the guide frame to hit the twisting point between the aramid fiber and the stainless steel wire to ensure the tightness of the twist between the aramid fiber and the stainless steel wire.
  • buffer grooves are uniformly provided on the execution block along its circumferential direction, and buffer plates are provided in the buffer grooves through springs; wherein, during the stranding process, the buffer grooves are The aramid fiber and the stainless steel wire to be twisted are guided in the middle, so that the friction between the aramid fiber and the stainless steel wire is reduced with the aid of the buffer plate and the spring.
  • a twisting device for weak current flexible cores which includes a bottom plate, an electric slider, a moving frame, a guide frame, a rotating motor, a twisting mechanism, a diversion mechanism and an executive motor, wherein:
  • the electric sliding block is installed on the bottom plate, a moving frame is installed on the electric sliding block, and a rotating motor is installed on the moving frame through a motor seat; a twisting mechanism is arranged on the output shaft of the rotating motor;
  • the guide frame is arranged in the middle of the bottom plate; the diversion mechanism is arranged at the rear end of the bottom plate; the guide frame is a cavity structure, and the guide frame is a trumpet-shaped structure with a gradually increasing diameter along the axial direction;
  • the twisting mechanism includes a twisting turret mounted on the output shaft of the rotating motor.
  • the twisting turret is provided with twisting collars.
  • the upper and lower sides of the twisting turret are symmetrically provided with twisting locking grooves and twisting collars.
  • There are symmetrical holes on the sidewalls the twisted collar is provided with a fastening cover, the outer wall of the fastening cover is symmetrically provided with a fastening block, the middle of the fastening cover is provided with a through hole to fasten the outer wall of the cover
  • the thickness gradually increases from left to right;
  • the deflector mechanism includes a deflector installed on the bottom plate.
  • the deflector is symmetrically provided with deflector holes, and the deflector is provided with a deflector that cooperates with the deflector, and the lower side of the front end of the deflector passes through the bearing
  • a guide roller is provided, and a locking hole is provided on the upper side of the guide frame;
  • a bidirectional driving cylinder is installed on the side wall of the guide plate, a locking block is provided on the bidirectional driving cylinder, and a twisting groove is provided on the locking block;
  • a telescopic tube is installed on the side wall of the deflector, the telescopic tube is provided with a telescopic hole, a telescopic frame is arranged in the telescopic hole by sliding fit, and a telescopic spring is sleeved between the telescopic frame and the inner wall of the telescopic hole, and the telescopic tube passes through
  • the motor base is equipped with an executive motor, the output shaft of the executive motor is provided with an executive cam, the executive cam is against the telescopic frame, and the execution block is set on the telescopic frame, and the execution block is a round table whose diameter increases from left to right. Shaped structure; buffer grooves are uniformly arranged on the execution block along its circumferential direction, and buffer plates are arranged in the buffer grooves through springs;
  • the execution block is uniformly provided with a buffer groove along its circumferential direction, and a buffer plate is provided in the buffer groove through a spring; wherein, during the stranding process, the buffer groove guides the part of the aramid fiber and stainless steel wire to be stranded during the operation. Guide, so that the friction between the aramid and stainless steel wire is reduced with the assistance of the buffer plate and the spring.
  • aramid Since aramid is used as the flexible center in traditional cables, it is because aramid has high tensile strength and initial modulus, but its elongation is low, heat resistance is not good, and the quality of the flexible core directly affects the wire
  • the traditional method is selected to prepare the mixed twist of aramid and stainless steel wire, which cannot guarantee the tightness of the twisting of the flexible core, which directly affects the use effect of the cable.
  • the present invention uses a composite of aramid and stainless steel to twist The combination is conducive to the characteristics of high strength and high toughness of aramid, and at the same time, it is conducive to the excellent heat resistance of stainless steel wire and the characteristics of high modulus.
  • the flexible center belt formed has good temperature resistance, high modulus and excellent elongation effect. Flexural resistance;
  • the metal copper wire is wound on the basis of the flexible center, and the twisting is controlled at a small pitch to further improve the bending resistance of the weak current battery;
  • the composite shield is used in the weak current cell and the overall shielding layer to realize signal interference shielding, and at the same time, the braid of metal and fiber is used to further enhance the bending resistance;
  • the outer sheath layer uses a composite mixture, in which the doped particles enhance the wear resistance and tensile properties of the cable, and increase the service life of the cable;
  • the present invention adopts an efficient twisting device to ensure the tightness of the aramid and stainless steel wire in the core; at the same time, it ensures that the aramid and the stainless steel wire are twisted tightly. At the same time, it can ensure that the aramid fiber and stainless steel wire in operation will not be affected by external forces and cause their own wear.
  • Figure 1 is a schematic cross-sectional view of a cable for an electric vehicle charging pile according to the present invention.
  • Fig. 2 is a schematic diagram of the weak current cable of the cable for the electric vehicle charging pile of the present invention.
  • Fig. 3 is a preparation flow chart of the cable of the electric vehicle charging pile of the present invention.
  • Figure 4 is a cross-sectional view of the twisting device of the present invention.
  • Figure 5 is a structural diagram of the twisting device of the present invention.
  • Figure 6 is a cross-sectional view of the execution block in the twisting device of the present invention.
  • the first aspect of the present invention discloses a cable for an electric vehicle charging pile, which includes a battery core, a polyester tape layer 30 wrapped around the battery core, and a polyester tape layer wrapped around the battery core.
  • the total shielding layer 40 outside 30, the isolation layer 50 wrapped around the composite shielding layer 40, the braided layer 60 wrapped around the isolation layer 50, the outer sheath layer 80 provided outside the braided layer 60 and the charging battery The filling layer 90 between the core 10 and the weak electric cell 20 and covered by the polyester tape layer 30.
  • the outer sheath layer 80 is formed by extruding polyvinyl chloride-rubber mixture on the braided layer, and has a thickness of 1-3 mm.
  • the filling layer 90 is filled with nylon filling material.
  • the battery core has a rechargeable battery core 10 (a strong current battery) and a weak current battery 20.
  • the rechargeable battery core 10 is configured as an electric energy transmission medium between the charging pile and the electric vehicle.
  • the weak current cell 20 has a signal cell and a control cell with the same structure; a plurality of rechargeable cells 10 and a plurality of weak current cells 20 are distributed tangentially.
  • the three rechargeable batteries form an upright equilateral triangle distribution and are tangent to each other.
  • the three weak current batteries form an inverted equilateral triangle distribution and are located at the gap between the rechargeable batteries, forming a symmetrical structure. .
  • the weak current battery core 20 includes a flexible wire core 21 and a copper wire 22 wound on the flexible wire core 21.
  • the flexible wire core 21 is formed by concentrically twisted aramid fiber and stainless steel wire, which contains 80% aramid fiber. -90%, the pitch multiple is 5-10 times.
  • the copper wire 22 is extruded with an insulating layer 23.
  • a composite shielding layer 24 formed by braiding metal wires and fibers is wrapped around the insulating layer.
  • the composite shielding layer 24 is coated with a polyester tape layer 25. In this way, the formed weak current battery achieves excellent bending resistance through the flexible core (flexible center) combined with the winding of the copper wire.
  • the composite shielding layer 24 contains 60%-70% of metal wires, the braiding angle is controlled at 45 ⁇ 5°, the braiding density is greater than 80%, and the thickness is 0.3mm-0.5mm.
  • the weak current battery 20 of the above embodiment and the cable using such battery 20 are still in good condition and have good electrical contact after 5,000 bending tests at an ambient temperature of 25 degrees Celsius.
  • the surface of the outer sheath layer has no cracks, and has good heat resistance and bending resistance.
  • 1T corresponding to A0, A1 and other miniature and compact electric vehicles, hybrid vehicles
  • 2T corresponding to mid-to-high-end electric vehicles, hybrid vehicles
  • the outer protective layer 30 is a polyester tape wrapping layer, and the thickness of the polyester tape wrapping layer is 0.04-0.2 mm.
  • the insulating layer of the weak current cell 20 includes a silicone rubber insulating layer with a thickness of 0.5-1 mm.
  • the isolation layer 50 includes a polyvinyl chloride isolation layer or a polyethylene or polyolefin isolation layer, with a thickness of 0.8-2 mm.
  • the braided layer 60 includes an aramid braided layer with a thickness of 0.05-0.2 mm and a braiding density of more than 80%.
  • the polyvinyl chloride-rubber mixture is doped with alumina or silicon carbide wear-resistant particles and graphite powder, and the size of the wear-resistant particles is 40-60 nm.
  • the graphite powder has a particle size of 30-40 nm.
  • a method for preparing a cable for an electric vehicle charging pile is also proposed, which includes the following steps:
  • the copper wire is made of annealed copper wire, the diameter is 0.12-0.3mm, and the pitch multiple is 5-10 times; then the insulating layer is extruded outside the copper wire, and the insulating layer is a silicon rubber insulating layer with a thickness of 0.5-1mm ; Then wrap the composite shielding layer outside the insulating layer, the composite shielding layer contains 60%-70% metal wire and 30%-40% fiber, the braiding angle is controlled at 45 ⁇ 5°, the braiding density is greater than 80%, and the thickness is 0.3mm-0.8mm; wrap the polyester tape on the outer surface of the composite shielding layer;
  • Step 3 Combine into a cable
  • step 1 and step 2 Combine the cells prepared in step 1 and step 2 into a cable, where three charging cells form an upright equilateral triangle distribution and are tangent to each other, and three weak current cells form an inverted equilateral triangle distribution and are located in the phase of the charge cell. Cut the gap position; wrap the polyester tape polyester tape layer on the outside of the six batteries with a thickness of 0.3-0.4mm; fill the gap between the six batteries with filler;
  • Step 4 After the cable is formed, the total shielding layer 40 is wrapped around the polyester tape layer, and the composite shielding layer is adopted, which contains 60%-70% metal wire and 30%-40% fiber, and the braid angle Control at 45 ⁇ 5°, braid density is greater than 80%, thickness is 0.04mm-0.2mm;
  • Step 5 Cover the isolation layer outside the composite shielding layer, the isolation layer is a polyvinyl chloride isolation layer or a cross-linked polyethylene isolation layer, 0.8-2mm;
  • Step 6 Wrap a braided layer outside the isolation layer.
  • the braided layer is an aramid braided layer with a thickness of 0.05-0.2mm and a weaving density of more than 80%.
  • Step 7 Extrude the PVC-rubber mixture outside the braided layer to form an outer sheath layer on the braided layer with a thickness of 1-3mm.
  • the PVC-rubber mixture is doped with oxidation Aluminum or silicon carbide wear-resistant particles and graphite powder, the size of wear-resistant particles is 40-60nm, and the size of graphite powder is 30-40nm.
  • a special integrated twisting device is used when preparing the composite flexible core. Twisting, in conjunction with Figures 4-6, the schematic diagram of the structure of the twisting device is shown as an example.
  • the twisting device includes a bottom plate 1 as a twisting base.
  • An electric slider 2 is installed on the bottom plate 1
  • a moving frame 3 is installed on the electric slider 2
  • a rotating motor is installed on the moving frame 3 through a motor seat. 4.
  • a twisting mechanism 5 is provided on the output shaft of the rotating motor 4.
  • a guide frame 6 is provided in the middle of the bottom plate 1, and a guide mechanism 7 is provided at the rear end of the bottom plate 1.
  • the twisting mechanism 5 includes a twisting turret 51 installed on the output shaft of the rotating motor 4, a twisting collar 52 is provided on the twisting turret 51, and a twisting lock is symmetrically provided on the upper and lower sides of the twisting turret 51
  • the groove and the side wall of the twisted collar 52 are symmetrically provided with through holes.
  • a fastening cover 53 is provided on the twisted collar 52, a through hole is provided in the middle of the fastening cover 53, and the thickness of the outer wall of the fastening cover 53 gradually increases from left to right.
  • the outer wall of the fastening cover 53 is symmetrically provided with fastening blocks 54.
  • the fastening blocks 54 are made of plastic material.
  • the aramid fiber and the stainless steel wire are sequentially crosstalked from back to front through the diversion hole, the diversion frame 72, the guide frame 6, the through hole and the twisted locking groove.
  • the guide frame 6 can reduce the distance between the aramid fiber and the stainless steel wire before twisting, so that the twisting point of the aramid fiber and the stainless steel wire is controlled in the guide frame 6, thereby improving the aramid fiber and the stainless steel wire in the twisting industry. Tightness.
  • the rotating motor 4 controls the twisting turret 51 to rotate, the twisting turret 51 drives the aramid and stainless steel wire twisting industry, and the electric slider 2 controls the moving frame 3 in the twisting industry to move at a uniform speed from right to left, thereby driving Fang Lun and stainless steel wire move synchronously from right to left.
  • the guide frame 6 is a cavity structure, and the guide frame 6 is a horn-like structure whose diameter gradually increases from left to right;
  • the deflector mechanism 7 includes a deflector 71 installed on the bottom plate 1.
  • the deflector 71 is provided with deflector holes symmetrically, and the deflector 71 is provided with a deflector 72 that cooperates with the deflector.
  • a guide roller 73 is provided on the lower side of the front end of the guide 72 through a bearing, and a locking hole is provided on the upper side of the guide frame 72.
  • a bidirectional drive cylinder 74 is installed on the side wall of the deflector 71, a locking block 75 is arranged on the bidirectional driving cylinder 74, and a stranding groove is arranged on the locking block 75.
  • Aramid and stainless steel wire pass through the deflector. 72.
  • the deflector roller 73 functions as a limit and guide to prevent the aramid and stainless steel wire from shaking greatly due to external forces during the twisting process.
  • the two-way drive cylinder 74 controls the coordination between the locking block 75 and the locking hole to limit the aramid and stainless steel wire during the stranding process, and increase the friction between the aramid and the stainless steel wire and the deflector 72, thereby enabling Efficiently twist aramid and stainless steel wire.
  • a telescopic tube 76 is installed on the side wall of the deflector 71, and a telescopic hole is provided on the telescopic tube 76, and a telescopic frame 77 is provided in the telescopic hole through a sliding fit.
  • a telescopic spring 78 is sleeved between the inner walls of the hole.
  • An actuator motor 79 is installed in the telescopic tube 76 through a motor seat.
  • An actuator cam 710 is provided on the output shaft of the actuator motor 79. The actuator cam 710 abuts on the telescopic frame 77 to expand and contract.
  • the rack 77 is provided with an execution work block 7a.
  • the execution work block 7a is a truncated cone-shaped structure with a diameter increasing from left to right.
  • the execution work block 7a is uniformly provided with a buffer groove along its circumferential direction, and a buffer plate 7b is provided in the buffer groove through a spring, and the execution motor 79
  • the execution cam 710 is controlled to rotate, the execution cam 710 and the telescopic spring 78 cooperate with each other to control the execution block 7a for reciprocating operation, the execution block 7a can cooperate with the guide frame 6, and the execution block 7a in motion can be inserted
  • the twisting point between the aramid fiber and the stainless steel wire is beaten to ensure the tightness of the aramid fiber and the stainless steel wire.
  • the stainless steel wire part can be guided. With the assistance of the buffer plate 7b and the spring, it can reduce the friction between the aramid fiber and the stainless steel wire and the execution block 7a while ensuring the tightness of the aramid fiber and the stainless steel wire. Ensure that the aramid and stainless steel wires in operation will not be affected by external forces and cause their own wear, thereby improving the linear quality of the strong electric core.

Abstract

本发明提供一种用于电动汽车充电桩的电缆、制备方法及弱电柔性线芯的绞合装置,柔性线芯由芳纶与不锈钢丝混杂同心绞合形成,其中含芳纶80%-90%,节距倍数为5-10倍。本发明的电缆屏蔽性优良,并具有良好耐弯折和耐热性能。

Description

用于电动汽车充电桩的电缆、制备方法及弱电柔性线芯的绞合装置 技术领域
本发明涉及新能源汽车技术领域,尤其是充电桩上使用的充电电缆。
背景技术
随着新能源汽车尤其是插电式以及纯电动汽车的普及使用,需要像传统燃油汽车的加油站一样地布设充电桩,充电桩作为电动汽车最直接的配套得到了大力发展,其涉及到电源转换、充电控制、计费以及线缆,电源转换、充电控制、计费均为软件设计问题,只有线缆设计属于硬件设计问题。充电桩的线缆既需要进行电能的传输,也需要进行数据信息的传输,其中包括电能动力线芯(强电线芯)以及弱电线芯,在实际充电使用的过程,经常收到拖拉、弯折、汽车碾压,甚至对折,容易对线缆造成损害,尤其是在碾压时对较细的弱电线芯造成的损害以及弯曲对折时对强电线芯的损害,因而对线缆的延展性、耐折弯、耐热、耐压等多方面提出较高的要求。
技术问题
现有技术对线缆的弯曲性能进行了比较多的研究,例如采用强电线芯采用编制铜网和复绞单丝相结合的方式,提高耐弯折性能,或者采用单独的多股软铜丝绞合的导体,并在导体外挤包弹性体绝缘层;但这些方式虽然对耐弯折性能有所建树,能够起到一定的改善,但从充电线缆的弱电、强电线芯本身角度出发,仍有改善空间和必要性,以在屏蔽性能、耐弯折以及耐高温等性能上得到提升。柔性线芯对线缆的质量有着重要的影响,柔性线芯的传统的制作方式需要人工控制对原料进行混杂绞合,无法保证柔性线芯的绞合的紧密度,直接影响线缆的使用效果。
技术解决方案
本发明目的在于提供一种屏蔽优良并具有良好耐弯折性能的用于电动汽车充电桩的电缆。
为达成上述目的,本发明提出如下技术方案:
用于电动汽车充电桩的电缆,包括:具有充电电芯以及弱电电芯的电芯,所述充电电芯,构造为在充电桩与电动汽车之间的电能传输媒介;所述弱电电芯构造为具有相同结构的信号电芯和控制电芯;多个充电电芯与多个弱电电芯之间两两相切地分布;
绕包在所述电芯外的聚酯带外护层;
绕包在聚酯带外护层外的总屏蔽层;
绕包在总屏蔽层外的隔离层;
绕包在隔离层外的编织层; 
设置在编织层外的外护套层;以及填充在充电电芯与弱电电芯之间的、并由所述聚酯带层包覆的填充层;
其中,所述弱电电芯包括柔性线芯以及绕制在柔性线芯上的铜丝,所述柔性线芯由芳纶与不锈钢丝混杂同心绞合形成,其中含芳纶80%-90%,节距倍数为5-10倍;
铜丝外挤包有绝缘层;
绝缘层外绕包有金属丝与纤维编织形成的复合屏蔽层;
复合屏蔽层外包覆聚酯带层;
并且,所述复合屏蔽层包含金属丝60%-70%,编织角度控制在45±5°, 编织密度大于80%,屏蔽层厚度为0.3mm-0.5mm;
所述充电电芯由多根镀银铜丝或镀锡铜丝绞合后额外再编织一层镀银铜丝或镀锡铜丝组成。
优选地,所述聚酯带外护层的厚度为0.04-0.2mm 。
优选地,所述弱电电芯的绝缘层包括高抗撕裂性硅橡胶绝缘层,厚度为0.5-1mm。
优选地,所述隔离层包括聚氯乙烯、聚乙烯或者聚烯烃隔离层,厚度为0.8-2mm。
优选地,所述编织层包括芳纶编织层,厚度在0.3-0.5mm,编制密度大于80%。
优选地,所述外护套层采用聚氯乙烯-橡胶混合物挤包在编织层上形成,厚度在1-3mm;
所述外护套层在挤包过程中,所述聚氯乙烯-橡胶混合物中掺杂有氧化铝或者碳化硅耐磨颗粒以及石墨粉,耐磨颗粒粒径在40-60nm,石墨粉粒径30-40nm。
根据本发明的公开的改进方案,还提出一种用于电动汽车充电桩的电缆的制作方法,包括以下步骤:
步骤1、充电电芯制备
采用多根镀银铜丝或镀锡铜丝绞合后额外再编织一层镀银铜丝或镀锡铜丝组成作为导电芯,分别在其外部绕包绝缘层,再在绝缘层外绕包纤维与金属丝复合编织的复合屏蔽层,其中绝缘层为硅橡胶绝缘层,厚度为1-2.4mm;复合屏蔽层中包含金属丝60%-70%,编织角度控制在45±5°,编织密度大于80%,屏蔽层厚度为0.3mm-0.8mm;在复合屏蔽层外表面绕包聚酯带层;
步骤2、弱电电芯制备
采用多根不锈钢丝与芳纶混杂同心绞合,制成柔性线芯,其中含芳纶80%-90%,节距倍数为5-10倍,线芯截面为圆形;然后在柔性线芯上绕制铜丝,铜丝为退火铜丝,直径为0.12-0.3mm,节距倍数为5-10倍;然后在铜丝外挤包绝缘层,绝缘层为硅橡胶绝缘层,厚度为0.5-1mm;再在绝缘层外包覆复合屏蔽层,复合屏蔽层中包含金属丝60%-70%和30%-40%的纤维,编织角度控制在45±5°, 编织密度大于80%,厚度为0.3mm-0.8mm;在复合屏蔽层外表面绕包聚酯带层;
步骤3、组合成缆
将步骤1和步骤2制备的电芯组合成缆,其中三个充电电芯形成正立的正三角形分布并两两相切,三个弱电电芯形成倒立的正三角形分布并位于充电电芯相切的空隙位置;在六个电芯的外部绕包聚酯带聚酯带层,厚度0.3-0.4mm;在六个电芯之间的空隙位置使用填充料进行填充;
步骤4、成缆后,在聚酯带层聚酯带层的外部绕包总屏蔽层,采用复合屏蔽层,其中包含金属丝60%-70%和30%-40%的纤维,编织角度控制在45±5°, 编织密度大于80%,厚度为0.04mm-0.2mm;
步骤5、在复合屏蔽层外包覆隔离层,隔离层为聚氯乙烯隔离层或者交联聚乙烯隔离层,0.8-2mm;
步骤6、在隔离层外包覆编织层,编织层为芳纶编织层,其厚度在0.05-0.2mm,编制密度大于80%。
步骤7、在编织层外采用聚氯乙烯-橡胶混合物挤包以在编织层上形成外护套层,厚度在1-3mm,其中挤包过程中,聚氯乙烯-橡胶混合物中掺杂有氧化铝或者碳化硅耐磨颗粒以及石墨粉,耐磨颗粒粒径在40-60nm,石墨粉粒径30-40nm。
优选地,所述步骤2中,所述柔性线芯采用一体式绞合装置制备,一体式绞合装置具有底板,底板上安装有电动滑块,电动滑块上安装有移动架,移动架上通过电机座安装有转动电机,转动电机的输出轴上设置有绞合机构,底板的中部设置有导引架,底板的后端设置有导流机构;导引架为空腔结构,且导引架为直径沿着轴向为逐渐增加的喇叭状结构;
绞合机构包括安装在转动电机输出轴上的绞合转动架,绞合转动架上设置有绞合套环,绞合转动架的上下两侧对称设置有绞合锁紧槽,绞合套环的侧壁上对称设置有穿插孔,绞合套环上设置有扣紧盖,扣紧盖的外壁上对称设置有扣紧块,扣紧盖的中部设置有通孔,扣紧盖的外壁的厚度从左往右为逐渐加大;
导流机构包括安装在底板上的导流板,导流板上对称设置有导流孔,导流板上设置有与导流孔相互配合的导流架,导流架的前端下侧通过轴承设置有导流辊,导流架的上侧设置有锁定孔;导流板的侧壁上安装有双向驱动气缸,双向驱动气缸上设置有锁定块,锁定块上设置有绞合槽;
导流板的侧壁上安装有伸缩管,伸缩管上设置有伸缩孔,伸缩孔内通过滑动配合方式设置有伸缩架,伸缩架与伸缩孔的内壁之间套设有伸缩弹簧,伸缩管内通过电机座安装有执行电机,执行电机的输出轴上设置有执行凸轮,执行凸轮抵靠在伸缩架上,伸缩架上设置有执行作业块,并执行作业块为直径从左往右依次增加的圆台状结构;执行作业块上沿其周向方向均匀设置有缓冲槽,缓冲槽内通过弹簧设置有缓冲板;
其中绞合过程包括以下步骤:芳纶与不锈钢丝从后往前依次串扰经过导流孔、导流架、导引架、穿插孔与绞合锁紧槽,通过导引架减少绞合前芳纶与不锈钢丝之间的距离,使芳纶与不锈钢丝的绞合点控制在导引架内;然后将扣紧盖扣紧,扣紧盖与绞合锁紧槽之间相互配合分别对芳纶与不锈钢丝的左端进行锁紧;通过转动电机控制绞合转动架旋转,绞合转动架使得芳纶与不锈钢丝绞合作业;同时,通过电动滑块控制绞合作业中的移动架从右往左匀速的移动,带动芳纶与不锈钢丝从右往左同步运动;
绞合过程中,执行电机控制执行凸轮转动,执行凸轮与伸缩弹簧之间相互配合控制执行作业块进行往复作业,执行作业块与导引架之间相互动作,使得运动中的执行作业块可插入到导引架内部,从而对芳纶与不锈钢丝之间的绞合点进行击打,从而保证芳纶与不锈钢丝之间绞合的紧密程度。
优选地,所述一体式绞合装置制备中,执行作业块上沿其周向方向均匀设置有缓冲槽,缓冲槽内通过弹簧设置有缓冲板;其中,在绞合过程中,缓冲槽在作业中对待绞合的芳纶与不锈钢丝部分进行导引,使得在缓冲板与弹簧的辅助下击打芳纶与不锈钢丝时降低与执行作业块之间的摩擦力。
根据本发明公开的方案还提出一种弱电柔性线芯的绞合装置,包括底板、电动滑块、移动架、导引架、转动电机、绞合机构、导流机构以及执行电机,其中:
电动滑块安装在所述底板上,电动滑块上安装有移动架,移动架上通过电机座安装转动电机;转动电机的输出轴上设置绞合机构;
导引架设置在底板的中部;导流机构设置在底板的后端;导引架为空腔结构,且导引架为直径沿着轴向为逐渐增加的喇叭状结构;
绞合机构包括安装在转动电机输出轴上的绞合转动架,绞合转动架上设置有绞合套环,绞合转动架的上下两侧对称设置有绞合锁紧槽,绞合套环的侧壁上对称设置有穿插孔,绞合套环上设置有扣紧盖,扣紧盖的外壁上对称设置有扣紧块,扣紧盖的中部设置有通孔,扣紧盖的外壁的厚度从左往右为逐渐加大;
导流机构包括安装在底板上的导流板,导流板上对称设置有导流孔,导流板上设置有与导流孔相互配合的导流架,导流架的前端下侧通过轴承设置有导流辊,导流架的上侧设置有锁定孔;导流板的侧壁上安装有双向驱动气缸,双向驱动气缸上设置有锁定块,锁定块上设置有绞合槽;
导流板的侧壁上安装有伸缩管,伸缩管上设置有伸缩孔,伸缩孔内通过滑动配合方式设置有伸缩架,伸缩架与伸缩孔的内壁之间套设有伸缩弹簧,伸缩管内通过电机座安装有执行电机,执行电机的输出轴上设置有执行凸轮,执行凸轮抵靠在伸缩架上,伸缩架上设置有执行作业块,并执行作业块为直径从左往右依次增加的圆台状结构;执行作业块上沿其周向方向均匀设置有缓冲槽,缓冲槽内通过弹簧设置有缓冲板;
执行作业块上沿其周向方向均匀设置有缓冲槽,缓冲槽内通过弹簧设置有缓冲板;其中,在绞合过程中,缓冲槽在作业中对待绞合的芳纶与不锈钢丝部分进行导引,使得在缓冲板与弹簧的辅助下击打芳纶与不锈钢丝时降低与执行作业块之间的摩擦力。
有益效果
由以上本发明的技术方案可见,本发明的有益效果在于:
1、由于传统的线缆中使用芳纶作为柔性中心,是因为芳纶的拉伸强度和初始模量高,但其延伸率较低,耐热性不好,而且柔性线芯质量直接影响线缆的质量,选择传统的方法制备对芳纶与不锈钢丝混杂绞合,无法保证柔性线芯的绞合的紧密度,直接影响线缆的使用效果,本发明使用芳纶与不锈钢的复合材料绞合,利于芳纶高强度、高韧性的特点,同时利于不锈钢丝的耐热性优良,而且高模量的特点,形成的柔性中心带的耐温好、模量高且延伸率效果优良,提高抗弯折性能;
2、在柔性中心的基础上进行金属铜丝的绕制,控制以小节距规则绞合,进一步提高弱电电芯抗弯折性能;
3、弱电电芯以及总屏蔽层中使用复合屏蔽器,实现信号干扰屏蔽,同时利用金属与纤维的编织进一步增强抗弯折性能;
4、外护套层使用复合混合物,其中掺杂的颗粒增强线缆的耐磨和拉伸性能,提高线缆的使用寿命;
5、对于传统充电铜导体的过硬问题,采用多根镀银铜丝或镀锡铜丝绞合后额外再编织一层镀银铜丝或镀锡铜丝,防止该导体松散和提高柔性;
6、相比传统的柔性线芯的芳纶编织结构,本发明采用高效的绞合装置,确保线芯中芳纶与不锈钢丝之间绞合的紧密程度;同时在确保芳纶与不锈钢丝绞合紧密度的同时保证作业中的芳纶与不锈钢丝不会受外力影响造成自身的磨损。
应当理解,前述构思以及在下面更加详细地描述的额外构思的所有组合只要在这样的构思不相互矛盾的情况下都可以被视为本公开的发明主题的一部分。
结合附图从下面的描述中可以更加全面地理解本发明教导的前述和其他方面、实施例和特征。本发明的其他附加方面例如示例性实施方式的特征和/或有益效果将在下面的描述中显见,或通过根据本发明教导的具体实施方式的实践中得知。
附图说明
附图不意在按比例绘制。在附图中,在各个图中示出的每个相同或近似相同的组成部分可以用相同的标号表示。为了清晰起见,在每个图中,并非每个组成部分均被标记。现在,将通过例子并参考附图来描述本发明的各个方面的实施例,其中
图1是本发明的用于电动汽车充电桩的电缆的截面示意图。
图2是本发明的用于电动汽车充电桩的电缆的弱电线缆的示意图。
图3是本发明电动汽车充电桩的电缆的制备流程图;
图4是本发明绞合装置的剖视图;   
图5是本发明绞合装置的结构图;
图6是本发明绞合装置中执行作业块的剖视图。
本发明的实施方式
为了更了解本发明的技术内容,特举具体实施例并配合上述附图1-6说明如下。
在本公开中参照附图来描述本发明的各方面,附图中示出了许多说明的实施例。本公开的实施例不必定意在包括本发明的所有方面。应当理解,上面介绍的多种构思和实施例,以及下面更加详细地描述的那些构思和实施方式可以以很多方式中任意一种来实施,这是因为本发明所公开的构思和实施例并不限于任何实施方式。另外,本发明公开的一些方面可以单独使用,或者与本发明公开的其他方面的任何适当组合来使用。
【实施例 1- 电缆及电缆制备】
结合图1、2所示,本发明的第一方面公开一种用于电动汽车充电桩的电缆,包括电芯、绕包在电芯外的聚酯带层30、绕包在聚酯带层30外的总屏蔽层40、绕包在复合屏蔽层40外的隔离层50、绕包在隔离层50外的编织层60、设置在编织层60外的外护套层80和填充在充电电芯10与弱电电芯20之间的、并由聚酯带层30包覆的填充层90。
外护套层80采用聚氯乙烯-橡胶混合物挤包在编织层上形成,厚度在1-3mm。填充层90采用尼龙填充料进行填充。
结合图1、2所示,电芯具有充电电芯10(强电电芯)以及弱电电芯20,充电电芯10,构造为在充电桩与电动汽车之间的电能传输媒介。弱电电芯20具有相同结构的信号电芯和控制电芯;多个充电电芯10与多个弱电电芯20之间两两相切地分布。
结合图1、2,三个充电电芯形成正立的正三角形分布,并两两相切,三个弱电电芯形成倒立的正三角形分布并位于充电电芯相切的空隙位置,形成对称结构。
优选的例子中,弱电电芯20包括柔性线芯21以及绕制在柔性线芯21上的铜丝22,柔性线芯21由芳纶与不锈钢丝混杂同心绞合形成,其中含芳纶80%-90%,节距倍数为5-10倍。铜丝22外挤包有绝缘层23。绝缘层外绕包有金属丝与纤维编织形成的复合屏蔽层24。复合屏蔽层24外包覆聚酯带层25。如此,形成的弱电电芯通过柔性线芯(柔性中心)结合铜丝的绕制实现优异的抗弯折性能。
在尤其优选的例子中,复合屏蔽层24中包含金属丝60%-70%,编织角度控制在45±5°, 编织密度大于80%,厚度为0.3mm-0.5mm。在试验过程中,通过上述实施例的弱电电芯20以及采用这样的电芯20的线缆在25摄氏度环境温度下,经过5000次的弯折试验后,仍然保持良好状态,电性接触良好,而且外护套层表面无裂痕,具有良好的耐热性和抗弯折性能。
同时,我们在试验过程中,分别采用1T(对应于A0、A1等微型、紧凑型电动汽车、混动车)和2T(对应于中高档电动汽车、混动汽车)的压力负载对线缆分别进行模拟压力测试,在测试10000次后,线缆仍能够保持在压力释放后恢复原型,并能够保证电接触良好。
在优选的实施例中,外护层30为聚酯带绕包层,聚酯带绕包层的厚度为0.04-0.2mm。
在优选的实施例中,弱电电芯20的绝缘层包括硅橡胶绝缘层,厚度为0.5-1mm。
在优选的实施例中,隔离层50包括聚氯乙烯隔离层或者聚乙烯或聚烯烃隔离层,厚度为0.8-2mm。
在优选的实施例中,编织层60包括芳纶编织层,厚度在0.05-0.2mm,编制密度大于80%。
在优选的实施例中,外护套层80在挤包过程中,聚氯乙烯-橡胶混合物中掺杂有氧化铝或者碳化硅耐磨颗粒以及石墨粉,耐磨颗粒粒径在40-60nm,石墨粉粒径30-40nm,如此本发明的实施例采用复合混合物掺杂的外护套层,掺杂的颗粒增强线缆的耐磨和拉伸性能,提高线缆的使用寿命。
【实施例 2- 电缆制备工艺】
结合图1和图3所示,在本发明公开的实施例中还提出一种用于电动汽车充电桩的电缆的制备方法,包括以下步骤:
步骤1、充电电芯制备
采用多根镀银铜丝或镀锡铜丝绞合后额外再编织一层镀银铜丝或镀锡铜丝组成作为导电芯,分别在其外部绕包绝缘层,再在绝缘层外绕包纤维与金属丝复合编织的复合屏蔽层,其中绝缘层为硅橡胶绝缘层,厚度为1-2.4mm;复合屏蔽层中包含金属丝60%-70%,编织角度控制在45±5°,编织密度大于80%,屏蔽层厚度为0.3mm-0.8mm;在复合屏蔽层外表面绕包聚酯带层;
步骤2、弱电电芯制备
采用多根不锈钢丝与芳纶混杂同心绞合,其中含芳纶80%-90%,节距倍数为5-10倍,制成柔性线芯,截面为圆形;然后在柔性线芯上绕制铜丝,铜丝为退火铜丝,直径为0.12-0.3mm,节距倍数为5-10倍;然后在铜丝外挤包绝缘层,绝缘层为硅橡胶绝缘层,厚度为0.5-1mm;再在绝缘层外包覆复合屏蔽层,复合屏蔽层中包含金属丝60%-70%和30%-40%的纤维,编织角度控制在45±5°, 编织密度大于80%,厚度为0.3mm-0.8mm;在复合屏蔽层外表面绕包聚酯带层;
步骤3、组合成缆
将步骤1和步骤2制备的电芯组合成缆,其中三个充电电芯形成正立的正三角形分布并两两相切,三个弱电电芯形成倒立的正三角形分布并位于充电电芯相切的空隙位置;在六个电芯的外部绕包聚酯带聚酯带层,厚度0.3-0.4mm;在六个电芯之间的空隙位置使用填充料进行填充;
步骤4、成缆后,在聚酯带层聚酯带层的外部绕包总屏蔽层40,采用复合屏蔽层,其中包含金属丝60%-70%和30%-40%的纤维,编织角度控制在45±5°, 编织密度大于80%,厚度为0.04mm-0.2mm;
步骤5、在复合屏蔽层外包覆隔离层,隔离层为聚氯乙烯隔离层或者交联聚乙烯隔离层,0.8-2mm;
步骤6、在隔离层外包覆编织层,编织层为芳纶编织层,其厚度在0.05-0.2mm,编制密度大于80%。
步骤7、在编织层外采用聚氯乙烯-橡胶混合物挤包以在编织层上形成外护套层,厚度在1-3mm,其中挤包过程中,聚氯乙烯-橡胶混合物中掺杂有氧化铝或者碳化硅耐磨颗粒以及石墨粉,耐磨颗粒粒径在40-60nm,石墨粉粒径30-40nm。
【实施例 3- 柔性线芯制备】
结合图3-6所示,本发明的电缆制备过程中,为了提高核心充电线缆的线缆的耐磨和拉伸性能,在制备复合的柔性线芯时采用专用的一体化绞合装置进行绞合,结合图4-6示例性的表示了绞合装置的结构示意。
结合图3-6,绞合装置包括作为绞合基底的底板1,底板1上安装有电动滑块2,电动滑块2上安装有移动架3,移动架3上通过电机座安装有转动电机4,转动电机4的输出轴上设置有绞合机构5。
底板1的中部设置有导引架6,底板1的后端设置有导流机构7。
绞合机构5包括安装在转动电机4输出轴上的绞合转动架51,绞合转动架51上设置有绞合套环52,绞合转动架51的上下两侧对称设置有绞合锁紧槽,绞合套环52的侧壁上对称设置有穿插孔。
绞合套环52上设置有扣紧盖53,扣紧盖53的中部设置有通孔,扣紧盖53的外壁的厚度从左往右为逐渐加大。
扣紧盖53的外壁上对称设置有扣紧块54,可选的,扣紧块54由塑料材质组成。
结合图3,再绞合时,将芳纶与不锈钢丝从后往前依次串扰经过导流孔、导流架72、导引架6、穿插孔与绞合锁紧槽。通过导引架6可以减少绞合前芳纶与不锈钢丝之间的距离,使芳纶与不锈钢丝的绞合点控制在导引架6内,从而提高芳纶与不锈钢丝在绞合作业中的紧密程度。
然后将扣紧盖53扣紧,扣紧盖53与绞合锁紧槽之间相互配合分别对芳纶与不锈钢丝的左端进行锁紧,确保两者能够顺利的进行绞合作业。转动电机4控制绞合转动架51旋转,绞合转动架51带动芳纶与不锈钢丝绞合作业,电动滑块2控制绞合作业中的移动架3从右往左匀速的移动,从而带动芳纶与不锈钢丝从右往左同步运动。
导引架6为空腔结构,且导引架6为直径从左往右逐渐增加的喇叭状结构;
导流机构7包括安装在底板1上的导流板71,导流板71上对称设置有导流孔,导流板71上设置有与导流孔相互配合的导流架72,导流架72的前端下侧通过轴承设置有导流辊73,导流架72的上侧设置有锁定孔。
结合图4,导流板71的侧壁上安装有双向驱动气缸74,双向驱动气缸74上设置有锁定块75,锁定块75上设置有绞合槽,芳纶与不锈钢丝穿过导流架72,导流辊73起到了限位与导向的作用,防止芳纶与不锈钢丝在绞合过程中因外力的作用大幅度的晃动。
双向驱动气缸74控制锁定块75与锁定孔之间相互配合可以对绞合过程中的芳纶与不锈钢丝进行限位,增加芳纶与不锈钢丝和导流架72之间的摩擦力,从而能够高效的对芳纶与不锈钢丝进行绞合作业。
优选地,结合图4、5,导流板71的侧壁上安装有伸缩管76,伸缩管76上设置有伸缩孔,伸缩孔内通过滑动配合方式设置有伸缩架77,伸缩架77与伸缩孔的内壁之间套设有伸缩弹簧78,伸缩管76内通过电机座安装有执行电机79,执行电机79的输出轴上设置有执行凸轮710,执行凸轮710抵靠在伸缩架77上,伸缩架77上设置有执行作业块7a。
优选的,执行作业块7a为直径从左往右依次增加的圆台状结构,执行作业块7a上沿其周向方向均匀设置有缓冲槽,缓冲槽内通过弹簧设置有缓冲板7b,执行电机79控制执行凸轮710转动,执行凸轮710与伸缩弹簧78之间相互配合控制执行作业块7a进行往复作业,执行作业块7a能够与导引架6之间相互配合,运动中的执行作业块7a可以插入到导引架6内部,从而对芳纶与不锈钢丝之间的绞合点进行敲打,从而保证芳纶与不锈钢丝之间绞合的紧密程度,而缓冲槽在作业中对待绞合的芳纶与不锈钢丝部分可以进行导引,缓冲板7b与弹簧的辅助下能够在敲打芳纶与不锈钢丝时降低与执行作业块7a之间的摩擦力,在确保芳纶与不锈钢丝绞合紧密度的同时保证作业中的芳纶与不锈钢丝不会受外力影响造成自身的磨损,从而提高强电核心的线性的质量。
虽然本发明已以较佳实施例揭露如上,然其并非用以限定本发明。本发明所属技术领域中具有通常知识者,在不脱离本发明的精神和范围内,当可作各种的更动与润饰。因此,本发明的保护范围当视权利要求书所界定者为准。

Claims (10)

  1. 用于电动汽车充电桩的电缆,其特征在于,包括:具有充电电芯(10)以及弱电电芯(20)的电芯,所述充电电芯(10),构造为在充电桩与电动汽车之间的电能传输媒介;所述弱电电芯(20)构造为具有相同结构的信号电芯和控制电芯;多个充电电芯(10)与多个弱电电芯(20)之间两两相切地分布;
    绕包在所述电芯外的聚酯带外护层(30);
    绕包在聚酯带外护层(30)外的总屏蔽层(40);
    绕包在总屏蔽层(40)外的隔离层(50);
    绕包在隔离层(50)外的编织层(60); 
    设置在编织层(60)外的外护套层(80);以及填充在充电电芯(10)与弱电电芯(20)之间的、并由所述聚酯带层(30)包覆的填充层(90);
    其中,所述弱电电芯(20)包括柔性线芯(21)以及绕制在柔性线芯(21)上的铜丝(22),所述柔性线芯(21)由芳纶与不锈钢丝混杂同心绞合形成,其中含芳纶80%-90%,节距倍数为5-10倍;
    铜丝(22)外挤包有绝缘层(23);
    绝缘层外绕包有金属丝与纤维编织形成的复合屏蔽层(24);
    复合屏蔽层(24)外包覆聚酯带层(25);
    并且,所述复合屏蔽层(24)包含金属丝60%-70%,编织角度控制在45±5°, 编织密度大于80%,屏蔽层厚度为0.3mm-0.5mm;
    所述充电电芯(10)由多根镀银铜丝或镀锡铜丝绞合后额外再编织一层镀银铜丝或镀锡铜丝组成。
  2. 根据权利要求1所述的用于电动汽车充电桩的电缆,其特征在于,所述聚酯带外护层(30)的厚度为0.04-0.2mm 。
  3. 根据权利要求1所述的用于电动汽车充电桩的电缆,其特征在于,弱电电芯(20)的绝缘层包括高抗撕裂性硅橡胶绝缘层,厚度为0.5-1mm。
  4. 根据权利要求1所述的用于电动汽车充电桩的电缆,其特征在于,所述隔离层(50)包括聚氯乙烯、聚乙烯或者聚烯烃隔离层,厚度为0.8-2mm。
  5. 根据权利要求1所述的用于电动汽车充电桩的电缆,其特征在于,所述编织层(60)包括芳纶编织层,厚度在0.3-0.5mm,编制密度大于80%。
  6. 根据权利要求1所述的用于电动汽车充电桩的电缆,其特征在于,所述外护套层(80)采用聚氯乙烯-橡胶混合物挤包在编织层上形成,厚度在1-3mm;
    所述外护套层(80)在挤包过程中,所述聚氯乙烯-橡胶混合物中掺杂有氧化铝或者碳化硅耐磨颗粒以及石墨粉,耐磨颗粒粒径在40-60nm,石墨粉粒径30-40nm。
  7. 一种用于电动汽车充电桩的电缆的制作方法,其特征在于,包括以下步骤:
    步骤1、充电电芯制备
    采用多根镀银铜丝或镀锡铜丝绞合后额外再编织一层镀银铜丝或镀锡铜丝组成作为导电芯,分别在其外部绕包绝缘层,再在绝缘层外绕包纤维与金属丝复合编织的复合屏蔽层,其中绝缘层为硅橡胶绝缘层,厚度为1-2.4mm;复合屏蔽层中包含金属丝60%-70%,编织角度控制在45±5°,编织密度大于80%,屏蔽层厚度为0.3mm-0.8mm;在复合屏蔽层外表面绕包聚酯带层;
    步骤2、弱电电芯制备
    采用多根不锈钢丝与芳纶混杂同心绞合,制成柔性线芯,其中含芳纶80%-90%,节距倍数为5-10倍,线芯截面为圆形;然后在柔性线芯上绕制铜丝,铜丝为退火铜丝,直径为0.12-0.3mm,节距倍数为5-10倍;然后在铜丝外挤包绝缘层,绝缘层为硅橡胶绝缘层,厚度为0.5-1mm;再在绝缘层外包覆复合屏蔽层,复合屏蔽层中包含金属丝60%-70%和30%-40%的纤维,编织角度控制在45±5°, 编织密度大于80%,厚度为0.3mm-0.8mm;在复合屏蔽层外表面绕包聚酯带层;
    步骤3、组合成缆
    将步骤1和步骤2制备的电芯组合成缆,其中三个充电电芯形成正立的正三角形分布并两两相切,三个弱电电芯形成倒立的正三角形分布并位于充电电芯相切的空隙位置;在六个电芯的外部绕包聚酯带聚酯带层,厚度0.3-0.4mm;在六个电芯之间的空隙位置使用填充料进行填充;
    步骤4、成缆后,在聚酯带层聚酯带层的外部绕包总屏蔽层,采用复合屏蔽层,其中包含金属丝60%-70%和30%-40%的纤维,编织角度控制在45±5°, 编织密度大于80%,厚度为0.04mm-0.2mm;
    步骤5、在复合屏蔽层外包覆隔离层,隔离层为聚氯乙烯隔离层或者交联聚乙烯隔离层,0.8-2mm;
    步骤6、在隔离层外包覆编织层,编织层为芳纶编织层,其厚度在0.05-0.2mm,编制密度大于80%。
    步骤7、在编织层外采用聚氯乙烯-橡胶混合物挤包以在编织层上形成外护套层,厚度在1-3mm,其中挤包过程中,聚氯乙烯-橡胶混合物中掺杂有氧化铝或者碳化硅耐磨颗粒以及石墨粉,耐磨颗粒粒径在40-60nm,石墨粉粒径30-40nm。
  8. 根据权利要求7所述的用于电动汽车充电桩的电缆的制作方法,其特征在于,所述步骤2中,所述柔性线芯采用一体式绞合装置制备,一体式绞合装置具有底板,底板上安装有电动滑块,电动滑块上安装有移动架,移动架上通过电机座安装有转动电机,转动电机的输出轴上设置有绞合机构,底板的中部设置有导引架,底板的后端设置有导流机构;导引架为空腔结构,且导引架为直径沿着轴向为逐渐增加的喇叭状结构;
    绞合机构包括安装在转动电机输出轴上的绞合转动架,绞合转动架上设置有绞合套环,绞合转动架的上下两侧对称设置有绞合锁紧槽,绞合套环的侧壁上对称设置有穿插孔,绞合套环上设置有扣紧盖,扣紧盖的外壁上对称设置有扣紧块,扣紧盖的中部设置有通孔,扣紧盖的外壁的厚度从左往右为逐渐加大;
    导流机构包括安装在底板上的导流板,导流板上对称设置有导流孔,导流板上设置有与导流孔相互配合的导流架,导流架的前端下侧通过轴承设置有导流辊,导流架的上侧设置有锁定孔;导流板的侧壁上安装有双向驱动气缸,双向驱动气缸上设置有锁定块,锁定块上设置有绞合槽;
    导流板的侧壁上安装有伸缩管,伸缩管上设置有伸缩孔,伸缩孔内通过滑动配合方式设置有伸缩架,伸缩架与伸缩孔的内壁之间套设有伸缩弹簧,伸缩管内通过电机座安装有执行电机,执行电机的输出轴上设置有执行凸轮,执行凸轮抵靠在伸缩架上,伸缩架上设置有执行作业块,并执行作业块为直径从左往右依次增加的圆台状结构;执行作业块上沿其周向方向均匀设置有缓冲槽,缓冲槽内通过弹簧设置有缓冲板;
    其中绞合过程包括以下步骤:芳纶与不锈钢丝从后往前依次串扰经过导流孔、导流架、导引架、穿插孔与绞合锁紧槽,通过导引架减少绞合前芳纶与不锈钢丝之间的距离,使芳纶与不锈钢丝的绞合点控制在导引架内;然后将扣紧盖扣紧,扣紧盖与绞合锁紧槽之间相互配合分别对芳纶与不锈钢丝的左端进行锁紧;通过转动电机控制绞合转动架旋转,绞合转动架使得芳纶与不锈钢丝绞合作业;同时,通过电动滑块控制绞合作业中的移动架从右往左匀速的移动,带动芳纶与不锈钢丝从右往左同步运动;
    绞合过程中,执行电机控制执行凸轮转动,执行凸轮与伸缩弹簧之间相互配合控制执行作业块进行往复作业,执行作业块与导引架之间相互动作,使得运动中的执行作业块可插入到导引架内部,从而对芳纶与不锈钢丝之间的绞合点进行击打,从而保证芳纶与不锈钢丝之间绞合的紧密程度。
  9. 根据权利要求8所述的用于电动汽车充电桩的电缆的制作方法,其特征在于,所述一体式绞合装置制备中,执行作业块上沿其周向方向均匀设置有缓冲槽,缓冲槽内通过弹簧设置有缓冲板;其中,在绞合过程中,缓冲槽在作业中对待绞合的芳纶与不锈钢丝部分进行导引,使得在缓冲板与弹簧的辅助下击打芳纶与不锈钢丝时降低与执行作业块之间的摩擦力。
  10. 一种用于电动汽车充电桩电缆的弱电柔性线芯的绞合装置,其特征在于,包括底板、电动滑块、移动架、导引架、转动电机、绞合机构、导流机构以及执行电机,其中:
    电动滑块安装在所述底板上,电动滑块上安装有移动架,移动架上通过电机座安装转动电机;转动电机的输出轴上设置绞合机构;
    导引架设置在底板的中部;导流机构设置在底板的后端;导引架为空腔结构,且导引架为直径沿着轴向为逐渐增加的喇叭状结构;
    绞合机构包括安装在转动电机输出轴上的绞合转动架,绞合转动架上设置有绞合套环,绞合转动架的上下两侧对称设置有绞合锁紧槽,绞合套环的侧壁上对称设置有穿插孔,绞合套环上设置有扣紧盖,扣紧盖的外壁上对称设置有扣紧块,扣紧盖的中部设置有通孔,扣紧盖的外壁的厚度从左往右为逐渐加大;
    导流机构包括安装在底板上的导流板,导流板上对称设置有导流孔,导流板上设置有与导流孔相互配合的导流架,导流架的前端下侧通过轴承设置有导流辊,导流架的上侧设置有锁定孔;导流板的侧壁上安装有双向驱动气缸,双向驱动气缸上设置有锁定块,锁定块上设置有绞合槽;
    导流板的侧壁上安装有伸缩管,伸缩管上设置有伸缩孔,伸缩孔内通过滑动配合方式设置有伸缩架,伸缩架与伸缩孔的内壁之间套设有伸缩弹簧,伸缩管内通过电机座安装有执行电机,执行电机的输出轴上设置有执行凸轮,执行凸轮抵靠在伸缩架上,伸缩架上设置有执行作业块,并执行作业块为直径从左往右依次增加的圆台状结构;执行作业块上沿其周向方向均匀设置有缓冲槽,缓冲槽内通过弹簧设置有缓冲板;
    执行作业块上沿其周向方向均匀设置有缓冲槽,缓冲槽内通过弹簧设置有缓冲板;其中,在绞合过程中,缓冲槽在作业中对待绞合的芳纶与不锈钢丝部分进行导引,使得在缓冲板与弹簧的辅助下击打芳纶与不锈钢丝时降低与执行作业块之间的摩擦力。
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