WO2022048463A1 - 一种铝护套电缆的生产系统 - Google Patents

一种铝护套电缆的生产系统 Download PDF

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Publication number
WO2022048463A1
WO2022048463A1 PCT/CN2021/113934 CN2021113934W WO2022048463A1 WO 2022048463 A1 WO2022048463 A1 WO 2022048463A1 CN 2021113934 W CN2021113934 W CN 2021113934W WO 2022048463 A1 WO2022048463 A1 WO 2022048463A1
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Prior art keywords
assembly
extrusion
aluminum
welding
production system
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Ceased
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PCT/CN2021/113934
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English (en)
French (fr)
Inventor
王国权
陆春良
张波
王惠兵
姜勤荣
刘党荣
孙明华
席娇娜
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Jiangsu Hengtong Wire and Cable Technology Co Ltd
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Jiangsu Hengtong Wire and Cable Technology Co Ltd
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Publication of WO2022048463A1 publication Critical patent/WO2022048463A1/zh
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Ceased legal-status Critical Current

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K13/00—Welding by high-frequency current heating
    • B23K13/01—Welding by high-frequency current heating by induction heating
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/0036—Details
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • H01B13/228—After-treatment

Definitions

  • the invention relates to the technical field of cable production, in particular to a production system for aluminum sheathed cables.
  • the cable is usually twisted by several or several groups of wires (at least two in each group), each group of wires is insulated from each other, and often twisted around a center, and the entire outer layer is covered with a highly insulating coating,
  • the cable has the characteristics of inner energization and outer insulation.
  • aluminum sheathed cables are more and more used in various industries.
  • the difficulty of processing aluminum sheathed cables is mainly the welding of aluminum sheaths.
  • aluminum materials are easy to oxidize, argon is mostly used to solve this problem.
  • the arc welding process is protected by inert gas, but the disadvantage of the argon arc welding process is that the production speed is slow and the efficiency is low, only about 10 meters per minute.
  • the use of inert gas produces a lot of waste, because each cable has thousands of
  • the welding quality control of the argon arc welding process is difficult, and when defects occur, the loss is large; the above problems can be solved by the high-frequency welding process at present.
  • the extrusion assembly adopts two opposite rollers and sets a forming surface on the rollers.
  • the aluminum strip is extruded and welded by the rotation of the rollers and the friction can be reduced.
  • the extrusion point that is, the welding point
  • the high-frequency welding coil is located in the middle of the connection line, and the high-frequency welding coil is located at the front end of the extrusion assembly. Due to the rotation of the roller, the high-frequency welding coil is at least the distance of the roller radius from the welding point, resulting in the welding point after the heating is completed. It can be closed in time, so the welding quality will be reduced; at the same time, if the welding quality needs to be increased, the power of the high-frequency welding machine will increase, resulting in waste.
  • the technical problem to be solved by the present invention is to provide a production system for aluminum sheathed cables, which no longer uses inert gas, and at the same time shortens the distance between the high-frequency welding coil and the welding point, improves welding quality and reduces power.
  • a production system for aluminum sheathed cables including a cable core discharging component, an aluminum tape discharging component, an aluminum sheath forming component, a high-frequency welding component, a diameter reducing and shaping component assembly and winding assembly, the cable core is pulled out from the cable core unwinding assembly, and the aluminum strip is pulled out from the aluminum strip unloading assembly, merged into the aluminum sheath forming assembly for forming, and then enters the high-frequency welding assembly to The aluminum sheath is welded, and after the welding is completed, the external shaping is carried out through the reducing and shaping component, and finally the aluminum sheathed cable is wound through the winding component.
  • a pressing assembly and a high-frequency induction welding machine for heating both sides of an aluminum strip the extrusion assembly includes an extrusion bracket and a pair of extrusion dies arranged on the extrusion bracket for merging the two sides of the aluminum strip , a fixed component is arranged between the extrusion die and the extrusion bracket, and the extrusion die is made of graphene material.
  • the fixing assembly includes a fixing base arranged on the extrusion bracket, a pressure plate arranged above the fixing base, and a baffle plate arranged behind the fixing base, and the fixing base, the pressure plate and the baffle are formed.
  • the cavity includes a top surface, a bottom surface and a side surface, and an elastic member is arranged between the side surface and the extrusion die.
  • the elastic member is rubber.
  • an adjustment assembly for adjusting the distance between the two extrusion dies is provided between the fixing assembly and the extrusion bracket.
  • the adjustment assembly includes a movable member that can move on the extrusion bracket and a power source for driving the movable member to move, and the fixed assembly is disposed on the movable member.
  • the moving member is a guide rail pair
  • the power source is a hydraulic cylinder
  • the hydraulic cylinder drives the fixed component to move on the guide rail pair.
  • the moving piece includes two fixed seats arranged on the extrusion bracket, a screw rod arranged between the two fixed seats, and two moving sliders arranged on the screw rod.
  • the fixed components are arranged on the two moving sliders in one-to-one correspondence, the screw rod has two threads with opposite directions, and the two moving sliders are respectively located on the threads in different directions.
  • the rotation drives the two moving sliders to move toward or away from each other.
  • the aluminum sheath forming assembly includes a flattening device for flattening the aluminum strip, a hemming device for bending both sides of the aluminum strip, and wrapping the cable core and closing the two sides of the aluminum strip. Aluminium strip side concentrator with direction concentration.
  • the reducing and shaping assembly includes a glue tank located behind the extrusion assembly, and a reducing die disposed on the glue tank and away from the extrusion assembly, and the forming hole of the reducing mold is close to
  • One side of the extrusion component is a large circle
  • the side away from the extrusion component is a small circle
  • a slope is formed between the large circle and the small circle.
  • the beneficial effects of the present invention are: through the above-mentioned system, the aluminum sheathed cable can be automatically produced from raw material to forming, and high-frequency welding technology is adopted, so that inert gas can no longer be used for protection, and the production cost can be reduced; at the same time, graphene material is used.
  • Making the extrusion die can prevent the deformation of the extrusion die, and use the self-lubricating function of graphene, so that the extrusion die no longer adopts a roller structure but adopts a fixed structure, shortening the position of the high-frequency welding coil and the welding point, and improving the welding performance. At the same time, it can reduce the power of high-frequency welding and reduce energy consumption.
  • Fig. 1 is the structural representation of the production system of the aluminum sheathed cable of the present invention
  • Fig. 2 is the structural schematic diagram of the aluminum sheath forming assembly of the present invention
  • FIG. 3 is a cross-sectional structural schematic diagram of the hemming fixing roller in the aluminum sheath forming assembly of the present invention
  • Figure 4 is a schematic cross-sectional view of the folding movable roller in the aluminum sheath forming assembly of the present invention
  • FIG. 5 is a cross-sectional structural schematic diagram of the anti-shake roller in the aluminum sheath forming assembly of the present invention.
  • Fig. 6 is the sectional structure schematic diagram of the centralized mold in the aluminum sheath forming assembly of the present invention.
  • FIG. 7 is a schematic view of the structure of the extrusion assembly of the present invention.
  • a production system for aluminum sheathed cables includes a cable core discharging component 1, an aluminum tape discharging component 2, an aluminum sheath forming component 3, a high-frequency welding component 4, a diameter reducing and shaping component 5, and a receiving component 5.
  • Coil assembly 6 the cable core is drawn out from the cable core unwinding assembly, and the aluminum strip is drawn out from the aluminum strip unloading assembly, and after merging and keeping the cable core on the top and the aluminum tape on the bottom, it enters the aluminum sheath forming assembly 3
  • the two sides of the aluminum strip in the aluminum sheath forming assembly 3 are gradually folded upward to finally form a circular arc structure with an open upper end, and the aluminum strip after folding and forming enters the high-frequency welding assembly 4 to weld the aluminum sheath.
  • the high-frequency welding assembly 4 includes an extrusion assembly 42 for merging and welding both sides of the aluminum strip and a high-frequency induction welding machine 41 for heating both sides of the aluminum strip.
  • the two sides of the strip are heated to make it in a molten state, and then enter the extrusion assembly 42, and the extrusion assembly 42 makes the two sides of the aluminum strip meet, wherein the meeting point is a welding point and is welded and formed here, and after the welding is completed, it is shaped by reducing the diameter
  • the component 5 performs external shaping of the aluminum sheath, reducing the diameter of the aluminum sheath and making the shape round, and finally winding the aluminum sheath cable through the winding component 6 to complete the entire forming work.
  • the aluminum sheath forming assembly 3 includes a flattening device 31 for flattening the aluminum strip, a hemming device 32 for bending the two sides of the aluminum strip, and for wrapping the cable core and turning the two sides of the aluminum strip toward the aluminum strip.
  • the aluminum strip side concentrating device 34 concentrated in the closing direction; since the aluminum strip may be deformed during transportation and unloading, in order to make the subsequent process normal, it is necessary to use a flattening device 31 to flatten the aluminum strip.
  • the flattening device 31 includes Two leveling brackets 311 arranged vertically, a leveling fixed roller 312 and a leveling movable roller 313 are arranged between the two leveling brackets 311, and a leveling adjusting device 314 is arranged on the top of the two leveling brackets 311 to adjust the leveling.
  • the device 314 can make the leveling movable roller 313 move up and down, so as to adjust the distance between the leveling fixed roller 312 and the leveling movable roller 313, which needs to be done according to the thickness of the aluminum strip; the two leveling adjustment devices 314 can be linked by the linkage assembly, and the operation When there is a single leveling adjusting device 314, the two leveling adjusting devices 314 move at the same time, which can ensure that the distance between the leveling fixed roller 312 and the leveling movable roller 313 is the same;
  • the operation with the side concentrating device 34, the hemming device 32 includes two hemming brackets 321 arranged vertically, a hemming fixed roller 322 and a hemming movable roller 323 are arranged between the two hemming brackets 321, Both the hemming fixed roller 322 and the hemming movable roller 323 can rotate around their axis of rotation.
  • a hemming adjusting device 324 is provided on the two hemming brackets 321, and the two hemming adjusting devices 324 are also It can be connected by a linkage assembly, which is convenient for adjustment.
  • the hemming fixing roller 322 includes a first roller body and forms a hemming fixing arc on both sides of the first roller body along the radial direction, as shown in the figure.
  • the hemming movable roller 323 shown in 4 includes a second roller body and forms a hemming movable arc inward along the radial direction on both sides of the second roller body, and the hemming fixed arc and the hemming movable arc cooperate to realize the Folding operation with both sides, at the same time, an annular groove 3231 is formed inward in the radial direction on the central cylindrical surface of the second roller body, and the cable core is combined with the aluminum strip through the annular groove 3231;
  • the concentration device 34 is located in front of the high-frequency welding assembly 4, and its main purpose is to concentrate the sides of the folded aluminum strip in the closing direction again, and then heat the two sides of the aluminum strip through the high-frequency welding assembly 4, and the sides of the aluminum strip are concentrated.
  • the device 34 includes a vertically arranged centralized fixing bracket 341, and a centralized mold 342 is set on the centralized fixed bracket 341.
  • the cavity of the centralized mold 342 is a trapezoidal hole (as shown in FIG. 6), and the small The circle is close to the high-frequency welding component 4, and the large circle of the trapezoidal hole is far away from the high-frequency welding component 4.
  • the aluminum strip enters the trapezoidal hole from the large circle. Due to the inclined plane in the trapezoidal hole, the two sides of the aluminum strip are concentrated upward and the distance between the two sides is close. , and then come out from the small circle and enter the high-frequency welding assembly 4 .
  • an anti-shake device 33 is provided between the edge folding device 32 and the aluminum tape concentration device 34, and the anti-shake device 33 includes a vertically arranged anti-shake device 33
  • the anti-shake bracket 331, a rotating beam extending from the anti-shake bracket 331, an anti-shake roller 332 is arranged on the rotating beam, the anti-shake roller 332 is arranged above the aluminum sheathed cable and is in contact with it, the anti-shake roller
  • the roller surface of 332 is provided with a concave (as shown in Figure 5), which is matched with the aluminum strip.
  • the extrusion assembly 42 includes an extrusion bracket 421 and a pair of extrusion dies 422 arranged on the extrusion bracket 421 for merging two sides of the aluminum strip.
  • a fixed component 423 is arranged between the brackets 421, and the extrusion die 422 is made of graphene material. According to the nature of the graphene material itself, it has heat resistance, which can improve the service life of the extrusion die 422, while working The surface has a lubricating effect, and the aluminum sheath slides in the extrusion die 422 to improve the smoothness of sliding, and the roller structure is no longer used; the welding points of the two sides of the aluminum strip at the extrusion assembly 42 meet to form a welding convergence angle.
  • the welding point can be set at the position of the extrusion die 422 close to the welding coil side of the high-frequency induction welding machine 41, so that the The distance between the welding coil of the high-frequency induction welding machine 41 and the welding point can be reduced, and when the distance is reduced, both sides of the aluminum strip can quickly enter the welding point after heating and melting, so the two sides of the aluminum strip can be Welding is carried out at high temperature to ensure the quality of the welding seam on the aluminum strip.
  • the heating temperature can be appropriately reduced, thereby reducing the power of the high-frequency induction welding machine 41. If the heating temperature does not decrease, it can be accelerated by The movement speed of the aluminum sheath improves production efficiency. This structure can not only improve welding quality, but also reduce energy and speed up production.
  • the fixing assembly 423 includes a fixing base 4231 arranged on the pressing bracket 421, a pressing plate 4232 arranged above the fixing base 4231, and a baffle plate arranged behind the fixing base 4231.
  • the fixing base 4231, the pressing plate 4232 and the baffle plate A cavity for accommodating the extrusion die 422 is formed.
  • the extrusion die 422 is arranged in the cavity.
  • the fixed base 4231 is L-shaped and includes a bottom plate and a vertical plate.
  • the rear end of the bottom plate and the vertical plate is the position after the advancing direction of the aluminum sheathed cable; the pressing plate 4232 restricts the movement of the extrusion die 422 in the vertical direction, and the baffle restricts the movement of the extrusion die 422 in the advancing direction of the aluminum sheathed cable.
  • the bottom surface of the pressing plate 4232 is the top surface of the chamber
  • the side of the riser close to the extrusion die 422 is the side surface of the chamber
  • the top surface of the bottom plate is the bottom surface of the chamber
  • the front of the chamber and the other The side is open
  • the cavity of the extrusion die 422 is set on one side of the opening; in order to ensure the quality of the aluminum sheath molding, and to ensure that the aluminum strip is in contact with the extrusion die 422 to reduce damage caused by rigid contact, the cavity is
  • An elastic piece 4233 is arranged between the side of the chamber and the extrusion die 422 (ie, the vertical plate and the extrusion die 422).
  • the elastic piece 4233 has a buffering effect.
  • the elastic piece 4233 can buffer such impact and displacement and can keep the extrusion die 422 in contact with the aluminum strip all the time.
  • the elastic piece 4233 is made of heat-resistant rubber material;
  • the two fixing components 423 are one Two extrusion dies 422 are fixed correspondingly, and the cavities of the two extrusion dies 422 are arranged opposite to each other to form a complete cavity structure for extruding the aluminum sheath; since during use, both sides of the aluminum strip have Therefore, the strength between the two extrusion dies 422 can be increased to extrude the oxide layers on both sides of the aluminum strip during the merging process, so that the mutual bonding between the aluminum materials located in the oxide layer can improve the welding quality;
  • the extruded oxide layer forms a bulge on the outside of the formed aluminum jacket.
  • An adjustment assembly 424 for adjusting the distance between the two extrusion dies 422 is provided between the fixing assembly 423 and the extrusion bracket 421.
  • the adjustment assembly 424 is used to facilitate the processing and production of aluminum sheathed cables with different diameters.
  • the adjustment assembly 424 It includes a movable member that can move on the extrusion bracket 421 and a power source that drives the movable member to move.
  • the fixed component 423 is arranged on the movable member, and the power source drives the movable member to move to adjust the distance between the extrusion dies 422;
  • the adjustment assembly 424 mainly has two design forms in this scheme. The first one is that the moving part is the guide rail pair 4243, and the power source is the hydraulic cylinder.
  • the component includes two fixed seats arranged on the extrusion bracket 421, a screw rod 4242 arranged between the two fixed seats, and two moving sliders 4241 arranged on the screw rod 4242.
  • the two fixed components 423 The fixed bases 4231 are set on the two moving sliders 4241 in one-to-one correspondence, the screw rod 4242 is composed of two threads with opposite directions, and the two moving sliders 4241 are respectively located on the threads in different directions,
  • the screw rod 4242 rotates and drives the two moving sliders 4241 to move toward or away from each other, and two sets of guide rail pairs 4243 are arranged on both sides of the screw rod 4242, and the moving sliders 4241 straddle the two sets of guide rail pairs 4243 to ensure smooth operation.
  • the power source adopts a motor, and the forward or reverse rotation of the motor drives the screw 4241 to rotate forward or reversely, so as to realize the movement toward or away from the two extrusion dies 422 .
  • the reducing and shaping assembly 5 includes a glue tank 51 located behind the extrusion assembly 42, and a reducing die 52 disposed on the glue tank 51 and away from the extrusion assembly 42.
  • the reducing die The side of the forming hole of 52 close to the extrusion assembly 42 is a large circle, the side away from the extrusion assembly 42 is a small circle, and there is an inclined plane between the large circle and the small circle, that is, the forming hole is a trapezoidal hole, and the aluminum sheath is welded after completion.
  • Hot melt glue is applied in the glue tank 51, and then the aluminum sheath is micro-shaped through the trapezoidal hole, and the protrusion of the extruded oxide layer during the extrusion welding process of the extrusion assembly 42 is removed to ensure its roundness.
  • the cable core and the aluminum strip are simultaneously discharged into the aluminum sheath forming component 3 through the cable core discharging assembly 1 and the aluminum strip discharging assembly 2, and the aluminum strip passes through the leveling device 31 and the cable core in the folding device.
  • the 32 meeting points enter the aluminum strip concentration device 34.
  • the anti-shake device 33 ensures the smooth movement of the aluminum strip and the cable core, and then enters the welding coil of the high-frequency welding machine 41 for heating, so that both sides of the aluminum strip are in a molten state.
  • the extrusion die 422 in the extrusion assembly 42 is made of graphene material, which can prevent the extrusion die 422 from deforming and use the graphene self-lubricating function, so that the extrusion die 422 is no longer
  • the roller structure is adopted and the fixed structure is adopted, and then hot melt adhesive is applied into the glue tank 51, and the aluminum sheath is micro-shaped by the reducing die 52 to ensure its roundness, and finally is wound by the winding assembly 6;
  • the system integrates automatic production from raw materials to molding, adopts high-frequency welding technology, can no longer use inert gas for protection, and reduces production costs;
  • the self-lubricating function of graphene makes the extrusion die 422 no longer use a roller structure but a fixed structure, shortening the position of the high-frequency welding coil and the welding point, improving the welding quality and reducing the power of high-frequency welding. energy consumption.

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  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing Of Electric Cables (AREA)

Abstract

本发明涉及一种铝护套电缆的生产系统，包括电缆芯放料组件、铝带放料组件、铝护套成型组件、高频焊接组件、减径整形组件以及收卷组件，高频焊接组件包括挤压组件以及高频感应焊接机，挤压组件包括挤压支架以及一对挤压模具，在挤压模具与挤压支架之间设置固定组件，挤压模具采用石墨烯材料制作而成。通过上述系统，将铝护套线缆从原料到成型一体自动化生产，采用高频焊接技术，不再使用惰性气体进行保护，降低生产成本；同时，采用石墨烯材料制作挤压模具，能够防止挤压模具变形，使用石墨烯自润滑的功能，使得挤压模具不再采用滚轮式结构而采用固定式结构，将高频焊接线圈位置与焊接点位置缩短，提高焊接质量的同时能够降低高频焊接的功率。

Description

一种铝护套电缆的生产系统 技术领域
本发明涉及电缆的生产技术领域，尤其是涉及一种铝护套电缆的生产系统。
背景技术
电缆通常是由几根或几组导线(每组至少两根)绞合而成，每组导线之间相互绝缘，并常围绕着一根中心扭成，整个外面包有高度绝缘的覆盖层，电缆具有内通电，外绝缘的特征。
铝护套电缆依据其本身特性，越来越多被应用于各种行业，铝护套电缆的加工过程的难度主要是铝护套的焊接，由于铝材料易氧化，为解决此问题大多采用氩弧焊工艺并采用惰性气体进行保护，但是氩弧焊工艺的缺点是生产速度慢、效率低，每分钟仅为10米左右，同时使用惰性气体较多产生大量浪费，由于电缆每根都有千米的长度，而氩弧焊工艺的焊接质量控制较难，当发生缺陷时，损失较大；目前采用高频焊接工艺可以解决上述问题，目前高频焊接工艺与挤压组件配合实现焊接操作，而挤压组件采用两个相对的滚轮并在滚轮上设置成型面，通过滚轮转动实现将铝带挤压焊接并且能够减小摩擦，然而这种方式挤压点即焊接点位于两个滚轮轴芯的连线的中部，而高频焊接线圈位于挤压组件前端，由于滚轮的转动使得高频焊接线圈距离焊接点至少需要滚轮半径的距离，从而导致在加热完成后焊接点的位置靠后，不能够及时合拢，从而焊接质量会降低；同时若保证焊接质量需要提高温度，从而导致高频焊接机的功率增加，造成浪费。
发明内容
本发明所要解决的技术问题是提供一种铝护套电缆的生产系统，不再使用惰性气体，同时缩短高频焊接线圈与焊接点的距离提升焊接质量，降低功率。
本发明解决其技术问题所采取的技术方案是：一种铝护套电缆的生产系统，包括电缆芯放料组件、铝带放料组件、铝护套成型组件、高频焊接组件、减径整形组件以及收卷组件，所述的电缆芯从电缆芯放料组件抽出，所述的铝带从铝带放料组件抽出，合并后进入铝护套成型组件进行成型，之后进入高频焊接组件对铝护套进行焊接，焊接完成之后通过减径整形组件进行外部整形，最后通过收卷组件收卷铝护套电缆，所述的高频焊接组件包括用于将铝带两侧边合并焊接的挤压组件以及用于对铝带两侧加热的高频感应焊接机，所述的挤压组件包括挤压支架以及设置于挤压支架上用于将铝带两侧边合并的一对挤压模具，在所述的挤压模具与挤压支架之间设置固定组件，所述的挤压模具采用石墨烯材料制作而成。
进一步具体的，所述的固定组件包括设置于挤压支架上的固定底座、设置于固定底座上方的压板以及设置于固定底座后方的挡板，所述的固定底座、压板以及挡板之间形成一容纳挤压模具的腔室。
进一步具体的，所述的腔室包括顶面、底面以及一个侧面，在所述的侧面与挤压模具之间设置弹性件。
进一步具体的，所述的弹性件为橡胶。
进一步具体的，在所述的固定组件与挤压支架之间设置用于调整两个挤压模具之间距离的调整组件。
进一步具体的，所述的调整组件包括可在挤压支架上移动的移动件以及驱动移动件运动的动力源，所述的固定组件设置于移动件上。
进一步具体的，所述的移动件为导轨副，所述的动力源为液压缸，所述的液压缸驱动固定组件在导轨副上运动。
进一步具体的，所述的移动件包括设置在挤压支架上的两个固定座、设置于两个固定座之间的丝杆以及设置于丝杆上的两个移动滑块，两个所述的固定组件一一对应设置于两个移动滑块上，所述的丝杆上有两段方向相反的螺纹，两个所述的移动滑块分别位于不同方向的螺纹上，所述的丝杆转动驱动两个移动滑块作相向或者背离运动。
进一步具体的，所述的铝护套成型组件包括用于平整铝带的平整装置、用于折弯铝带两侧边的折边装置以及用于将电缆芯包裹并将铝带两侧向闭合方向集中的铝带侧边集中装置。
进一步具体的，所述的减径整形组件包括位于挤压组件后方的胶液箱、设置于胶液箱上且远离挤压组件一侧的减径模具，所述的减径模具的成型孔靠近挤压组件的一侧为大圆，远离挤压组件的一侧为小圆，大圆与小圆之间为斜面。
本发明的有益效果是：通过上述系统，将铝护套线缆从原料到成型一体自动化生产，采用高频焊接技术，能够不再使用惰性气体进行保护，降低生产成本；同时，采用石墨烯材料制作挤压模具，能够防止挤压模具变形，使用石墨烯自润滑的功能，使得挤压模具不再采用滚轮式结构而采用固定式结构，将高频焊接线圈位置与焊接点位置缩短，提高焊接质量的同时能够降低高频焊接的功率，降低能量消耗。
附图说明
图1是本发明铝护套电缆的生产系统的结构示意图；
图2是本发明铝护套成型组件的结构示意图；
图3是本发明铝护套成型组件内折边固定辊的剖视结构示意图；
图4是本发明铝护套成型组件内折边活动辊的剖视结构示意图；
图5是本发明铝护套成型组件内防抖辊的剖视结构示意图；
图6是本发明铝护套成型组件内集中模具的剖视结构示意图；
图7是本发明挤压组件的结构示意图。
图中：1、电缆芯放料组件；2、铝带放料组件；3、铝护套成型组件；4、高频焊接组件；5、减径整形组件；6、收卷组件；31、平整装置；32、折边装置；33、防抖装置；34、铝带侧边集中装置；311、平整支架；312、平整固定辊；313、平整活动辊；314、平整调节装置；321、折边支架；322、折边固定辊；323、折边活动辊；3231、环状槽；324、折边调节装置；331、防抖支架；332、防抖辊；341、集中固定支架；342、集中模具；41、高频感应焊接机；42、挤压组件；421、挤压支架；422、挤压模具；423、固定组件；424、调整组件；4231、固定底座；4232、压板；4233、弹性件；4241、滑块；4242、丝杆；4243、导轨副；51、胶液箱；52、减径模具。
具体实施方式
下面结合附图及具体实施方式对本发明进行详细描述：
如图1所示一种铝护套电缆的生产系统，包括电缆芯放料组件1、铝带放料组件2、铝护套成型组件3、高频焊接组件4、减径整形组件5以及收卷组件6，所述的电缆芯从电缆芯放料组件抽出，所述的铝带从铝带放料组件抽出，合并后并保持电缆芯在上铝带在下的方式进入铝护套成型组件3进行成型，在铝护套成型组件3内铝带的两侧边逐步向上折起最终形成上端开口的圆弧形结构，折边成型之后的铝带进入高频焊接组件4对铝护套进行焊接，而高频焊接组件4包括用于将铝带两侧边合并焊接的挤压组件42以及用于对铝带两侧加热的高频感应焊接机41，在高频感应焊接机41内将铝带两侧边加热使其处于熔融状态，之后进入挤压组件42内而挤压组件42使得铝带两边汇合，其中汇合点为焊接点并在此处焊接成型，在焊接完成之后通过减径整形组件5进行铝护套的外部整形，减小铝护套直径并且外形整圆，最后通过收卷组件6收卷铝护套电缆，完成整个成型工作。
如图2所示铝护套成型组件3包括用于平整铝带的平整装置31、用于折弯铝带两侧边的折边装置32以及用于将电缆芯包裹并将铝带两侧向闭合方向集中的铝带侧边集中装置34；由于铝带可能在运输以及放料过程中发生变形，为了后续工序正常，故需要采用平整装置31对铝带进行压平操作，该平整装置31包括两根竖向设置的平整支架311，在两根平整支架311之间设置一个平整固定辊312与一个平整活动辊313，同时在两根平整支架311的顶部均设置一平整调节装置314该平整调节装置314可以使得平整活动辊313上下移动，从而调整平整固定辊312与平整活动辊313之间的间距，需要根据铝带的厚度进行；两个平整调节装置314可以通过联动组件进行联动，在操作单个平整调节装置314时，两个平整调节装置314同时运动，能够保证平整固定辊312与平整活动辊313之间的距离相同；折边装置32是将铝带两侧向上弯曲，以方便后续铝带侧边集中装置34的操作，该折边装置32包括两根竖向设置的折边支架321，在两个折边支架321之间设置一折边固定辊322与一折边活动辊323，折边固定辊322与折边活动辊323均可围绕其转轴进行自转，同时根据铝带的厚度在两个折边支架321上均设置一折边调节装置324，两个折边调节装置324也可以通过联动组件进行连接，方便调整的时候同步，如图3所示折边固定辊322包括第一辊本体并在第一辊本体的两侧沿径向方向形成折边固定弧形，如图4所示折边活动辊323包括第二辊本体并在第二辊本体的两侧沿径向方向向内形成折边活动弧形，折边固定弧形与折边活动弧形配合实现对铝带两侧边的折边操作，同时在第二辊本体的中部柱面沿径向方向向内形成一环状槽3231，电缆芯通过该环状槽3231与铝带进行组合；铝带侧边集中装置34位于高频焊接组件4之前，其主要目的将已经折边的铝带两侧再次向闭合方向集中，之后通过高频焊接组件4对铝带两侧进行加热，该铝带侧边集中装置34包括一竖向设置的集中固定支架341，并在该集中固定支架341上设置一集中模具342，该集中模具342的型腔为一梯形孔(如图6所示)，梯形孔的小圆靠近高频焊接组件4，梯形孔的大圆远离高频焊接组件4，铝带从大圆处进入梯形孔内，由于梯形孔内的斜面使得铝带两侧边向上集中且两侧边的距离靠近，之后从小圆处出来进入高频焊接组件4内。由于铝带包裹电缆芯运动时会发生抖动现象，为了不影响焊接质量，故在折边装置32与铝带集中装置34之间设置一防抖装置33，该防抖装置33包括竖向设置的防抖支架331，从该防抖支架331上伸出的一旋转梁，在该旋转梁上设置一防抖辊332，防抖辊332设置于铝护套电缆的上方并与其接触，防抖辊332的辊面上设置内凹(如图5 所示)，该内凹与铝带配合。
如图7所示挤压组件42包括挤压支架421以及设置于挤压支架421上用于将铝带两侧边合并的一对挤压模具422，在所述的挤压模具422与挤压支架421之间设置固定组件423，所述的挤压模具422采用石墨烯材料制作而成，根据石墨烯材料本身的性质，具有耐热性，能够提高挤压模具422的使用寿命，同时在工作面具有润滑效果，铝护套在挤压模具422内滑动，提高滑动的顺畅性，不再使用滚轮结构；铝带两侧边在挤压组件42处的焊接点汇合形成焊接汇合角，该角度控制在5°～10°，由于挤压模具422采用块状的固定形式(不需要转动)，焊接点可以设置于挤压模具422靠近高频感应焊接机41焊接线圈一侧的位置，故使得高频感应焊接机41的焊接线圈与焊接点之间距离可以缩小，而当该距离缩小后，铝带两侧边在加热熔融之后能够很快进入焊接点，所以铝带两侧边能够在很高的温度时进行焊接，保证铝带上焊缝的质量，由于距离缩小后，其加热温度可适当降低，从而降低高频感应焊接机41的功率，而若加热温度不降低时，可以通过加快铝护套的运动速度来提高生产效率，该种结构既能够提高焊接质量，又能够降低能源及加快生产速度。
固定组件423包括设置于挤压支架421上的固定底座4231、设置于固定底座4231上方的压板4232以及设置于固定底座4231后方的挡板，所述的固定底座4231、压板4232以及挡板之间形成一容纳挤压模具422的腔室，挤压模具422设置在该腔室内，固定底座4231呈L型包括底板及竖板，压板4232通过螺钉固定在竖板的顶部，挡板通过螺钉固定在底板及竖板的后端即铝护套电缆前进方向后到达的位置；压板4232限制挤压模具422在竖直方向上的运动，挡板限制挤压模具422在铝护套电缆前进方向上的运动；压板4232的底面为该腔室的顶面，竖板靠近挤压模具422的一面为该腔室的侧面，底板的顶面为该腔室的底面，而该腔室的前面以及另一个侧面为开口状，而挤压模具422的型腔设置于开口的一侧面；为了保证铝护套成型的质量，并且保证铝带与挤压模具422接触时减少刚性接触造成的损害，在该腔室的侧面与挤压模具422(即竖板与挤压模具422)之间设置弹性件4233，弹性件4233具有缓冲作用，铝带在进行焊接时，会将挤压模具422向外侧推出产生微小的冲击与位移，而弹性件4233能够缓冲这种冲击及位移同时能够使得挤压模具422始终与铝带接触，该弹性件4233选择耐热的橡胶材料制作而成；两个固定组件423分别一一对应固定两个挤压模具422，而两个挤压模具422的型腔相对设置组成用于挤压铝护套的完整的型腔结构；由于在使用过程中，铝带两侧边均有氧化层，故可以增加两个挤压模具422之间的力度在汇合过程中将铝带两侧边的氧化层挤出，使得位于氧化层内部的铝材料之间相互结合能够提高焊接质量；而被挤出的氧化层会在成型的铝护套外侧形成一块凸起。
在固定组件423与挤压支架421之间设置用于调整两个挤压模具422之间距离的调整组件424，此调整组件424是为了方便不同直径铝护套电缆的加工生产，该调整组件424包括可在挤压支架421上移动的移动件以及驱动移动件运动的动力源，所述的固定组件423设置于移动件上，动力源驱动移动件运动调整挤压模具422之间的距离；而调整组件424在本方案中主要有两种设计形式，第一种，移动件为导轨副4243，而动力源为液压缸，为了保持平衡，导轨副4243设置两组，固定组件423的固定底座4231横跨在两组导轨副4243上，液压缸设置两个，分别一一对应与两个固定底座4231，液压缸推动固定底座4231带动挤压模具422在导轨副4243上运动；第二种，移动件包括设置在挤压支架421上的两个固定座、设置于两个固定座之间的丝杆4242以及设置于丝杆4242上的两个移动滑块4241，两个所述的固定 组件423的固定底座4231一一对应设置于两个移动滑块4241上，所述的丝杆4242上由两段方向相反的螺纹组成，两个所述的移动滑块4241分别位于不同方向的螺纹上，所述的丝杆4242转动驱动两个移动滑块4241作相向或者背离运动，同时在丝杆4242两侧设置两组导轨副4243，移动滑块4241横跨在两组导轨副4243上保证运行平稳，动力源采用电机，而电机的正转或者反转驱动丝杆4241正转或者反转，实现两个挤压模具422之间相向或者背离运动。
如图1所示减径整形组件5包括位于挤压组件42后方的胶液箱51、设置于胶液箱51上且远离挤压组件42一侧的减径模具52，所述的减径模具52的成型孔靠近挤压组件42的一侧为大圆，远离挤压组件42的一侧为小圆，大圆与小圆之间为斜面，即成型孔为梯形孔，铝护套在完成焊接后在胶液箱51内涂附热熔胶，之后通过梯形孔对铝护套进行微整形，并去除挤压组件42挤压焊接过程中挤出氧化层的凸起，保证其圆度。
综上，通过电缆芯放料组件1、铝带放料组件2将电缆芯以及铝带同时放料进入铝护套成型组件3内，而铝带通过平整装置31后与电缆芯在折边装置32处汇合同时进入铝带集中装置34内，此时通过防抖装置33保证铝带及电缆芯运动平稳，之后进入高频焊接机41的焊接线圈进行加热使得铝带两侧边处于熔融状态，进入挤压组件42内，而在挤压组件42内的挤压模具422采用石墨烯材料制作而成，能够防止挤压模具422变形并使用石墨烯自润滑的功能，使得挤压模具422不再采用滚轮式结构而采用固定式结构，之后进入胶液箱51内涂附热熔胶，通过减径模具52对铝护套进行微整形，保证其圆度，最后通过收卷组件6收卷；该系统从原料到成型一体自动化生产，采用高频焊接技术，能够不再使用惰性气体进行保护，降低生产成本；同时，采用石墨烯材料制作挤压模具422，能够防止挤压模具422变形，使用石墨烯自润滑的功能，使得挤压模具422不再采用滚轮式结构而采用固定式结构，将高频焊接线圈位置与焊接点位置缩短，提高焊接质量的同时能够降低高频焊接的功率，降低能量消耗。
需要强调的是：以上仅是本发明的较佳实施例而已，并非对本发明作任何形式上的限制，凡是依据本发明的技术实质对以上实施例所作的任何简单修改、等同变化与修饰，均仍属于本发明技术方案的范围内。

Claims (10)

  1. 一种铝护套电缆的生产系统，包括电缆芯放料组件(1)、铝带放料组件(2)、铝护套成型组件(3)、高频焊接组件(4)、减径整形组件(5)以及收卷组件(6)，所述的电缆芯从电缆芯放料组件(1)抽出，所述的铝带从铝带放料组件(2)抽出，合并后进入铝护套成型组件(3)进行成型，之后进入高频焊接组件(4)对铝护套进行焊接，焊接完成之后通过减径整形组件(5)进行外部整形，最后通过收卷组件(6)收卷铝护套电缆，其特征在于，所述的高频焊接组件(4)包括用于将铝带两侧边合并焊接的挤压组件(42)以及用于对铝带两侧加热的高频感应焊接机(41)，所述的挤压组件(42)包括挤压支架(421)以及设置于挤压支架(421)上用于将铝带两侧边合并的一对挤压模具(422)，在所述的挤压模具(422)与挤压支架(421)之间设置固定组件(423)，所述的挤压模具(422)采用石墨烯材料制作而成。
  2. 根据权利要求1所述的铝护套电缆的生产系统，其特征在于，所述的固定组件(423)包括设置于挤压支架(421)上的固定底座(4231)、设置于固定底座(4231)上方的压板(4232)以及设置于固定底座(4231)后方的挡板，所述的固定底座(4231)、压板(4232)以及挡板之间形成一容纳挤压模具(422)的腔室。
  3. 根据权利要求2所述的铝护套电缆的生产系统，其特征在于，所述的腔室包括顶面、底面以及一个侧面，在所述的侧面与挤压模具(422)之间设置弹性件(4233)。
  4. 根据权利要求3所述的铝护套电缆的生产系统，其特征在于，所述的弹性件(4233)为橡胶。
  5. 根据权利要求1所述的铝护套电缆的生产系统，其特征在于，在所述的固定组件(423)与挤压支架(421)之间设置用于调整两个挤压模具(422)之间距离的调整组件(424)。
  6. 根据权利要求5所述的铝护套电缆的生产系统，其特征在于，所述的调整组件(424)包括可在挤压支架(421)上移动的移动件以及驱动移动件运动的动力源，所述的固定组件(423)设置于移动件上。
  7. 根据权利要求6所述的铝护套电缆的生产系统，其特征在于，所述的移动件为导轨副(4243)，所述的动力源为液压缸，所述的液压缸驱动固定组件(423)在导轨副(4243)上运动。
  8. 根据权利要求6所述的铝护套电缆的生产系统，其特征在于，所述的移动件包括设置在挤压支架(421)上的两个固定座、设置于两个固定座之间的丝杆(4242)以及设置于丝杆(4242)上的两个移动滑块(4241)，两个所述的固定组件(423)一一对应设置于两个移动滑块(4241)上，所述的丝杆(4242)上有两段方向相反的螺纹，两个所述的移动滑块(4241)分别位于不同方向的螺纹上，所述的丝杆(4242)转动驱动两个移动滑块(4241)作相向或者背离运动。
  9. 根据权利要求1所述的铝护套电缆的生产系统，其特征在于，所述的铝护套成型组件(3)包括用于平整铝带的平整装置(31)、用于折弯铝带两侧边的折边装置(32)以及用于将电缆芯包裹并将铝带两侧向闭合方向集中的铝带侧边集中装置(34)。
  10. 根据权利要求1所述的铝护套电缆的生产系统，其特征在于，所述的减径整形组件(5)包括位于挤压组件(42)后方的胶液箱(51)、设置于胶液箱(51)上且远离挤压组件(42)一侧的减径模具(52)，所述的减径模具(52)的成型孔靠近挤压组件(42)的一侧为大圆，远离挤压组件(42)的一侧为小圆，大圆与小圆之间为斜面。
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