WO2022052520A1 - 地上采矿工程用卷绕拖拽电缆及生产工艺 - Google Patents

地上采矿工程用卷绕拖拽电缆及生产工艺 Download PDF

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Publication number
WO2022052520A1
WO2022052520A1 PCT/CN2021/097175 CN2021097175W WO2022052520A1 WO 2022052520 A1 WO2022052520 A1 WO 2022052520A1 CN 2021097175 W CN2021097175 W CN 2021097175W WO 2022052520 A1 WO2022052520 A1 WO 2022052520A1
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Prior art keywords
core
braided
conductor
main
shielding layer
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PCT/CN2021/097175
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English (en)
French (fr)
Inventor
刘焱鑫
隋明辉
任帅
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常州船用电缆有限责任公司
江苏中利集团股份有限公司
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Publication of WO2022052520A1 publication Critical patent/WO2022052520A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
    • H01B7/041—Flexible cables, conductors, or cords, e.g. trailing cables attached to mobile objects, e.g. portable tools, elevators, mining equipment, hoisting cables
    • 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
    • H01B13/02—Stranding-up
    • 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
    • H01B13/02—Stranding-up
    • H01B13/0207—Details; Auxiliary devices
    • 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
    • H01B13/24—Sheathing; Armouring; Screening; Applying other protective layers by extrusion
    • 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
    • H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
    • H01B13/2606—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by braiding
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/0009—Details relating to the conductive cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/1895—Internal space filling-up means
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
    • H01B7/22—Metal wires or tapes, e.g. made of steel
    • H01B7/228—Metal braid
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/36—Insulated conductors or cables characterised by their form with distinguishing or length marks

Definitions

  • the invention relates to the technical field of electric power cables, in particular to a winding and dragging cable for ground mining engineering and a production process.
  • the purpose of the present invention is to provide a winding towing cable and a production process for the above-ground mining engineering with a simple structure, which is beneficial to prolong the service life.
  • the basic technical scheme for realizing the purpose of the present invention is: a winding and dragging cable for above-ground mining engineering, which is structurally characterized by including a main wire core, a monitoring wire core, a center filling and an outer sheath.
  • the three main wire cores have the same structure, and are provided with main wire core conductors, main wire core insulating layers and shielding layers in sequence from the inside to the outside along their respective radial directions.
  • the main wire core insulation layer is extruded and wrapped by ethylene propylene rubber outside the main wire core conductor.
  • the shielding layer includes a braided shielding layer and a wrapping shielding layer.
  • the braided shielding layer is braided outside the main core insulation layer with a braided conductor as one strand of braided wire and nylon yarn.
  • Braided conductors are made of twisted metal monofilaments.
  • Semi-conductive nylon tape is wrapped around the braided shield to form a wrap shield.
  • the monitoring wire core is sequentially provided with a monitoring wire core conductor and a monitoring wire core insulating layer from the inside to the outside along its radial direction.
  • the monitoring core conductor is made of nylon rope and conductor twisted together.
  • the center is filled with a saddle core pad, and the saddle core pad is made of semi-conductive rubber or neoprene material extruded outside the monitoring wire core. Center fill and 3 main cores twisted into a cable.
  • the outer sheath is extruded with neoprene rubber material outside the 3 main cores and center filling of the twisted cable.
  • the braided conductor of the braided shielding layer is formed by twisting seven 0.25mm metal monofilaments.
  • the nylon yarn of the braided shielding layer is made of 2/240D.
  • the monitoring core conductor is made up of 1 nylon rope and 4 conductors twisted together;
  • the rope is arranged in 4 conductors in a 1+4 structure.
  • the technical solutions based on the above-mentioned corresponding technical solutions are: the four conductors of the monitoring wire core conductors are all stranded by six tinned copper wires.
  • the nylon rope is made of 3/5/210D nylon wire, that is, each nylon rope is twisted by 5 pieces of 210D nylon wire, and then 3 strands are twisted to form a nylon rope.
  • the outer surface of the monitoring wire core is coated with talcum powder.
  • the monitoring wire core insulating layer is made by continuous vulcanization of ethylene-propylene rubber with a hardness of 60A to 80A.
  • a production process for winding and dragging cables for ground mining engineering comprising the following steps:
  • the braided conductor is used as one strand of braided yarn and is combined with nylon yarn to form a braided shielding layer outside the insulating layer of the main core.
  • the semi-conductive nylon tape is wrapped around the braided shielding layer to form a wrapping shielding layer.
  • the monitoring core conductor is made of 1 nylon rope and 4 conductors twisted together. When twisted, the nylon rope in the center of the pay-off tension is larger than the conductor, and the extension of the tension is controlled within 3%.
  • the conductors are stranded with 6 tinned copper wires of 0.2mm.
  • the 4 conductors use a 4/6/0.2 complex structure, that is, each conductor is stranded by 6 tinned copper wires of 0.2mm, and then 4 strands are stranded.
  • the twisted pitch ratio is 8 times.
  • the nylon rope adopts 3/5/210D, that is, each nylon rope is twisted by 5 210D nylon wires, and then 3 strands are twisted to form a nylon rope, and placed in a 1+4 structure when 4 conductors are twisted together. in the center of the 4 conductors.
  • the ethylene-propylene rubber is extruded out of the conductor of the monitoring wire, and then continuously vulcanized to form the insulating layer of the monitoring wire.
  • the semi-conductive rubber or neoprene rubber material is extruded out of the monitoring wire core to form a saddle-shaped cushion, so as to make a center filling, and talcum powder is coated on the surface of the monitoring wire core before extrusion.
  • the saddle type cushion core is carried out by tank type vulcanization equipment or horizontal drying pipeline. When extruding, a large amount of talcum powder should be placed in the cooling water tank to make the surface of the saddle type cushion core fully adhere to the talcum powder.
  • the neoprene rubber material is extruded and wrapped around the 3 main cores and the center filling of the twisted cable to form an outer sheath.
  • step 3 The technical scheme based on the above-mentioned corresponding technical scheme is: in step 3):
  • the braided conductor is made by twisting seven 0.25mm metal monofilaments, and the braided wire is braided with 2/240D nylon yarn and a corresponding braided conductor of 7/0.25.
  • the braided conductor is welded as a whole, and the single bundle of strands in each ingot should be welded at least 3mm apart, and the overall replacement distance of the coil should not be less than 1m.
  • step 7 The technical scheme based on above-mentioned each corresponding technical scheme is: in step 7):
  • the feeding end and the discharging end of the two ends of the central hollow tube of the feeding device of the saddle-shaped core pad are respectively provided with a first positioning die and a second positioning die.
  • the saddle-shaped core pad is guided by the first positioning die and the second positioning die so as to be coaxial with it when entering the cage cable forming machine.
  • the first positioning mold is in the shape of a disc, and the center thereof is provided with through holes corresponding to the shape of the saddle-shaped core pad through both ends of the center along its axial direction.
  • the second positioning die is an integral piece, including a cylindrical feed end and a conical discharge end, and the center is provided with a wire passage corresponding to the shape of the saddle-shaped core pad running through its two ends along its axial direction. hole.
  • the invention has the following beneficial effects: (1) At present, the mechanical life of common mining cables in China is generally 6-10 months, and the mechanical life of the winding and dragging cables for aboveground mining engineering using this structure can be increased by at least one time.
  • the monitoring core conductor of the present invention is made of nylon rope and conductors twisted together.
  • the nylon rope at the center of the pay-off tension is required to be larger than the conductor strand, and its extension under tension should be controlled within 3%.
  • the 4/6/0.2 double-stranded structure is adopted, and the twisted pitch ratio is 8 times.
  • the 3/5/210D nylon rope is selected as the reinforcing element, and the 1+4 structure is used when the conductor is twisted. Placed in the center of the conductor, the test shows that the nylon wire with an elongation greater than 25% can meet the problem that the conductor is stretched by 15% without breaking.
  • the surface of the monitoring wire core of the present invention is coated with talcum powder before the center is filled before being extruded, and the cable can be freely adapted when it is used and bent.
  • the twisted braided conductor of the braided shielding layer of the shielding layer of the present invention is used as one of the parallel wires to be woven together with the nylon yarn. It is separated from the outer sheath, which is beneficial to bending, and the shielding reliability is good, and the braided shielding layer is beneficial to improve the mechanical strength.
  • Nylon yarn material can enhance mechanical strength, and because nylon yarn material can be made of different colors, it can also play the role of core identification.
  • the braiding machine can not store enough length of the braided conductor, so the welding of the braided conductor will be involved.
  • the braided wire is welded as a whole.
  • the single bundle of strands in each spindle needs to be welded at least 3mm apart, and the overall replacement distance of the braid is not less than 1m, so as to ensure the conductor joint The distance is not too close so as not to affect the overall mechanical strength.
  • a first positioning mold and a second positioning mold are respectively provided at the feeding end and the discharging end of the two ends of the central hollow tube of the feeding device of the saddle-shaped core pad, and the first positioning mold and the second positioning mold are paired with each other.
  • the saddle-shaped core pad is guided so that it is coaxial with it when entering the cage cable forming machine; the discharge end of the second positioning die adopts a conical shape, so that the saddle-shaped core pad can be closer to the cage type cable forming machine when it is discharged, and the positioning is more accurate.
  • each arc surface is fitted to the surface of the main wire core through the die during stranding, and the cable tension is uniform and consistent.
  • FIG. 1 is a schematic structural diagram of the coiled towing cable for above-ground mining engineering of the present invention.
  • FIG. 2 is a schematic structural diagram of a first positioning mold.
  • FIG. 3 is a schematic structural diagram of a second positioning mold.
  • FIG. 4 is a schematic view when viewed from the rear of FIG. 3 .
  • Main Core 1 Main Core Conductor 1-1, Main Core Insulation Layer 1-2, Shielding Layer 1-3, Braided Shielding Layer 1-31, Braided Conductor 1-31-1, Nylon Yarn 1-31-2, Wrapped Shields 1-32,
  • Monitor core 2 monitor core conductor 2-1, monitor core insulation 2-2,
  • Center fill 3 outer sheath 4, first positioning mold 51, second positioning mold 52.
  • the coiled towing cable for aboveground mining engineering of the present invention comprises a main core 1, a monitoring core 2, a center filling 3 and an outer sheath 4.
  • main wire cores 1 there are three main wire cores 1, and the three main wire cores 1 have the same structure, and are provided with main wire core conductors 1-1, main wire core insulating layers 1-2 and shielding layers 1-1 in sequence from the inside to the outside along their respective radial directions. 3.
  • the main core conductor 1-1 is formed by twisting a plurality of tinned copper wire bundles.
  • the main wire core insulating layer 1-2 is made by continuous vulcanization of ethylene-propylene rubber with a hardness of 60A to 80A, and the main wire core insulating layer 1-2 is extruded and wrapped outside the main wire core conductor 1-1.
  • the shielding layer 1-3 includes a braided shielding layer 1-31 and a wrapping shielding layer 1-32.
  • the braided shielding layer 1-31 is compositely braided outside the main core insulation layer 1-2 with the braided conductor 1-31-1 as one strand of braided silk and the nylon yarn 1-31-2.
  • Nylon yarn 1-31-2 is made of 2/240D, that is, each nylon yarn is made of 2 240D nylon filaments twisted together.
  • the braided conductor 1-31-1 is formed by twisting seven 0.25mm metal monofilaments, which are copper monofilaments in this embodiment.
  • the semi-conductive nylon tape is wrapped around the braided shielding layer 1-31 to form a wrapping shielding layer 1-32.
  • the monitoring wire core 2 is provided with a monitoring wire core conductor 2-1 and a monitoring wire core insulating layer 2-2 in turn from the inside to the outside along its radial direction.
  • the monitoring core conductor 2-1 is made of 1 nylon rope and 4 conductors twisted together. The twisted pitch ratio is 8 times.
  • the conductors are twisted by 6 tinned copper wires, and 1 nylon rope. It is arranged in 4 conductors in a 1+4 structure.
  • the monitoring wire core insulating layer 2-2 is made of continuous vulcanization of ethylene-propylene rubber with a hardness of 60A to 80A.
  • the nylon rope is made of 3/5/210D nylon wire, that is, each nylon rope is twisted by 5 pieces of 210D nylon wire, and then 3 strands are twisted to form a nylon rope.
  • Center fill 3 uses saddle core pads.
  • the saddle core pad is made of semi-conductive rubber or neoprene material extruded and wrapped outside the monitoring wire core 2, and the outer surface of the monitoring wire core 2 is coated with talcum powder.
  • Center fills 3 and 3 main cores 1 are twisted into a cable.
  • the outer sheath 4 is extruded and wrapped around the three main cores 1 and the center filling 3 of the twisted cable by using neoprene material.
  • the production process of the coiled towing cable for aboveground mining engineering of the present invention comprises the following steps:
  • the ethylene-propylene rubber is extruded out of the main core conductor 1-1 by an extruder to form the main core insulation layer 1-2, and then the ethylene-propylene rubber of the main core insulation layer 1-2 is vulcanized by vulcanization equipment.
  • the braided conductor 1-31-1 is used as one strand of braided yarn and the nylon yarn 1-31-2 is compositely braided outside the main core insulation layer 1-2 to form a braided shield layer 1-31.
  • the braided conductor 1-31-1 is formed by twisting seven 0.25mm metal monofilaments, which are copper monofilaments in this embodiment. Braided filaments are braided with 2/240D nylon yarn and a corresponding strand of 7/0.25 braided conductor 1-31-1.
  • Braided conductors 1-31-1 are welded as a whole, and the single bundle of strands in each ingot should be welded at least 3mm apart, and the overall replacement distance of the coil should not be less than 1m.
  • the semi-conductive nylon tape is wrapped around the braided shielding layer 1-31 to form a wrapping shielding layer 1-32.
  • the monitoring core conductor 2-1 is made of 1 nylon rope and 4 conductors twisted together. When twisting, the nylon rope at the center of the pay-off tension is larger than the conductor, and the extension of the tension is controlled within 3%.
  • the conductors are stranded with 6 tinned copper wires of 0.2mm.
  • the 4 conductors use a 4/6/0.2 complex structure, that is, each conductor is stranded by 6 tinned copper wires of 0.2mm, and then 4 strands are stranded.
  • the twisted pitch ratio is 8 times.
  • the nylon rope adopts 3/5/210D, that is, each nylon rope is twisted by 5 210D nylon wires, and then 3 strands are twisted to form a nylon rope, and placed in a 1+4 structure when 4 conductors are twisted together. in the center of the 4 conductors.
  • the monitoring wire core 2 is made by extruding the ethylene-propylene rubber around the monitoring wire core conductor 2-1, and then performing continuous vulcanization to form the monitoring wire core insulating layer 2-2.
  • the semi-conductive rubber or neoprene material is extruded out of the monitoring wire core 2 to form a saddle-shaped cushion, thereby making the center filling 3, and the outer surface of the monitoring wire core 2 is coated with talcum powder before extrusion.
  • the saddle type cushion core is carried out by tank type vulcanization equipment or horizontal drying pipeline. When extruding, a large amount of talcum powder should be placed in the cooling water tank to make the surface of the saddle type cushion core fully adhere to the talcum powder.
  • a first positioning mold 51 and a second positioning mold 52 are respectively provided at the feeding end and the discharging end of the two ends of the central hollow tube of the feeding device of the saddle-shaped core pad.
  • the saddle-shaped core pad is guided by the first positioning die 51 and the second positioning die 52 so as to be coaxial with it when entering the cage cable forming machine.
  • the first positioning mold 51 is in the shape of a disk, and the center thereof is provided with through holes corresponding to the shape of the saddle-shaped core pad through the two ends of the center along its axial direction.
  • the second positioning die 52 is an integral piece, including a cylindrical feed end and a conical discharge end, and the center along its axial direction is provided with a pass line corresponding to the shape of the saddle-shaped core pad running through its two ends.
  • the through hole and the conical shape of the discharge end can make the saddle-shaped core pad closer to the stranding die of the cage cable forming machine when discharging, and the positioning is more accurate.

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  • Manufacturing & Machinery (AREA)
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Abstract

一种地上采矿工程用卷绕拖拽电缆及生产工艺，该电缆包括主线芯（1）、监视线芯（2）、中心填充（3）和外护套（4），主线芯沿其各自径向由内向外依次设有主线芯导体（1-1）、主线芯绝缘层（1-2）和屏蔽层（1-3），屏蔽层包括编织屏蔽层（1-31）和绕包屏蔽层（1-32），编织屏蔽层由编织导体（1-31-1）作为编织丝的一股与尼龙纱（1-31-2）一起复合编织在主线芯绝缘层外，半导电尼龙带绕包在编织屏蔽层外形成绕包屏蔽层，监视线芯沿其径向由内向外依次设有监视线芯导体（2-1）和监视线芯绝缘层（2-2），监视线芯导体由尼龙绳和导体复绞而成，中心填充采用马鞍型芯垫，马鞍型芯垫采用半导电橡皮或氯丁橡皮材料挤包在监视线芯外，中心填充和3根主线芯绞合成缆，外护套采用氯丁橡皮材料挤包在绞合成缆的3根主线芯和中心填充外。将编织屏蔽层与外护套隔开，有利于弯曲，屏蔽可靠性好，编织屏蔽层有利于提高机械强度，马鞍形芯垫的每个弧面均贴合在主线芯的表面，成缆张力均匀一致好。

Description

地上采矿工程用卷绕拖拽电缆及生产工艺 技术领域
本发明涉及电力电缆技术领域，具体是一种地上采矿工程用卷绕拖拽电缆及生产工艺。
背景技术
目前，随着煤矿机械化、自动化程度不断提高，电气控制技术在煤矿生产中有着非常重要的意义。地上采矿工程用卷绕拖拽电缆，由于使用工况的复杂性，电缆长期处于移动弯曲状态，因此电缆机械寿命非常短，通常寿命在6-10个月。而且作为矿用电缆、港机电缆等需要长期频繁移动的电缆，因此电缆中都会设置马鞍型垫心，避免线芯之间相互摩擦造成损伤。而在电缆的生产工艺中，如何保证马鞍型垫心与各绞合单元的位置固定最为关键。
发明内容
本发明的目的是提供一种结构简单，有利于延长使用寿命的地上采矿工程用卷绕拖拽电缆及生产工艺。
实现本发明目的的基本技术方案是：一种地上采矿工程用卷绕拖拽电缆，其结构特点是：包括主线芯、监视线芯、中心填充和外护套。主线芯有3根。3根主线芯结构相同，均沿其各自径向由内向外依次设有主线芯导体、主线芯绝缘层和屏蔽层。主线芯绝缘层由乙丙橡胶挤包在主线芯导体外。屏蔽层包括编织屏蔽层和绕包屏蔽层。
编织屏蔽层由编织导体作为编织丝的一股与尼龙纱一起复合编织在主线芯绝缘层外。编织导体由金属单丝绞合而成。半导电尼龙带绕包在编织屏蔽层外形成绕包屏蔽层。
监视线芯沿其径向由内向外依次设有监视线芯导体和监视线芯绝缘层。监视线芯导体由尼龙绳和导体复绞而成。
中心填充采用马鞍型芯垫，马鞍型芯垫采用半导电橡皮或氯丁橡皮材料挤包在监视线芯外。中心填充和3根主线芯绞合成缆。
外护套采用氯丁橡皮材料挤包在绞合成缆的3根主线芯和中心填充外。
以上述基本技术方案为基础的技术方案是：编织屏蔽层的编织导体由7根0.25mm的金属单丝绞合而成。
以上述各相应技术方案为基础的技术方案是：编织屏蔽层的尼龙纱采用2/240D 制成。
以上述各相应技术方案为基础的技术方案是：监视线芯导体由1根尼龙绳和4根导体复绞而成，监视线芯导体复绞时绞合节径比为8倍，1根尼龙绳采用1+4的结构设置在4根导体中。
以上述各相应技术方案为基础的技术方案是：监视线芯导体的4个导体均由6根镀锡铜丝绞合而成。尼龙绳采用3/5/210D尼龙丝制成，即每股尼龙绳由5根210D尼龙丝绞合，再3股进行绞合形成尼龙绳。
以上述各相应技术方案为基础的技术方案是：监视线芯外表涂覆滑石粉。
以上述各相应技术方案为基础的技术方案是：监视线芯绝缘层由硬度为60A至80A的乙丙橡胶连续硫化制作而成。
一种地上采矿工程用卷绕拖拽电缆的生产工艺，包括以下步骤：
1)将若干镀锡铜线束绞后复绞，形成主线芯导体。
2)通过挤塑机将乙丙橡胶挤包在主线芯导体外形成主线芯绝缘层，然后通过硫化设备对主线芯绝缘层的乙丙橡胶进行硫化处理。
3)将编织导体作为编织丝的一股与尼龙纱一起复合编织在主线芯绝缘层外形成编织屏蔽层。
4)半导电尼龙带绕包在编织屏蔽层外形成绕包屏蔽层。
5)监视线芯导体采用1根尼龙绳和4根导体复绞而成，在绞合时放线张力中心尼龙绳大于导体，其受张力的延伸控制在3％以内。导体采用6根0.2mm的镀锡铜丝绞合而成。4根导体采用了4/6/0.2的复绞结构，即每根导体由6根0.2mm的镀锡铜丝绞合，再4股进行复绞，复绞时绞合节径比为8倍，尼龙绳采用3/5/210D，即每股尼龙绳由5根210D尼龙丝绞合，再3股进行绞合形成尼龙绳，并在4根导体复绞时以1+4的结构形式放置在4根导体中心。将乙丙橡胶挤包在监视线芯导体外，然后进行连续硫化形成监视线芯绝缘层。
6)将半导电橡皮或氯丁橡皮材料挤包在监视线芯外形成马鞍型垫心，从而制成中心填充，挤包前在监视线芯外表涂覆滑石粉。
马鞍型垫心采用罐式硫化设备或水平干烘管道进行，挤包时在冷却水槽中应放入大量滑石粉，使马鞍型垫心表面充分粘连滑石粉。
7)使用笼式成缆机对3根主线芯和中心填充进行绞合，主线芯在成缆转动的同时中心填充的马鞍型垫心的送料装置与绞笼转动方向同步转动，保证马鞍型垫心的每个弧面均贴合在相应的主线芯的表面。
8)将氯丁橡皮材料挤包在绞合成缆的3根主线芯和中心填充外形成外护套。
以上述相应技术方案为基础的技术方案是：步骤3)中：
3.1)编织导体由7根0.25mm的金属单丝绞合而成，编织丝采用2/240D尼龙纱与相应的一股7/0.25的编织导体一起进行编织。
3.2)编织导体采用整体焊接，每锭纡子中的单束股线之间需间隔至少3mm进行焊接，纡子整体更换距离不小于1m。
以上述各相应技术方案为基础的技术方案是：步骤7)中：
所述马鞍形芯垫的送料装置的中心空管两端的进料端和出料端分别设有第一定位模具和第二定位模具。通过第一定位模具和第二定位模具对马鞍形芯垫进行导向，使其进入笼式成缆机时与其同轴。
所述第一定位模具为圆盘形，中央沿其轴向设有贯穿其两端的与马鞍形芯垫形状相对应的过线通孔。
所述第二定位模具为一体件，包括呈圆柱状的进料端和呈圆锥状的出料端，中央沿其轴向设有贯穿其两端的与马鞍形芯垫形状相对应的过线通孔。
本发明具有以下的有益效果：(1)目前国内普通矿用电缆机械寿命一般在6-10个月，而采用此结构的地上采矿工程用卷绕拖拽电缆，机械寿命可提高至少一倍。
(2)本发明的监视线芯导体采用尼龙绳及导体复绞而成，绞合时要求放线张力中心尼龙绳大于导体股线，而其受张力的延伸应控制在3％以内，导体采用了4/6/0.2的复绞结构，复绞时绞合节径比为8倍，选择了3/5/210D的尼龙绳作为加强元件，并在导体复绞时以1+4的结构形式放置在导体中心，试验表明伸长率大于25％的尼龙丝能满足导体拉伸15％不产生断裂的问题。
(3)本发明的监视线芯挤包前中心填充前表面涂覆滑石粉，电缆使用弯曲时能够自由适应。
(4)本发明的屏蔽层的编织屏蔽层的绞合后的编织导体作为并丝中的一股，与尼龙纱一起进行编织，编织后再绕包一层半导电尼龙带，将编织屏蔽层与外护套隔开，有利于弯曲，屏蔽可靠性好，编织屏蔽层有利于提高机械强度。尼龙纱材料能起到加强机械强度作用，而且尼龙纱材料由于可以做不同颜色，还可以起到线芯识别的效果。
(5)由于编织屏蔽层的作为编织丝的一股的编织导体的外径较大，编织机纡子无法储存足够长度的编织导体，所以会涉及到编织导体的焊接。为防止焊点过于密集而影响编织层强度，编织丝采用整体焊接，每锭纡子中的单束股线之间需间隔至少3mm进行焊接，纡子整体更换距离不小于1m，从而保证导体接头距离不会太近以免 影响整体机械强度。
(6)本发明通过在马鞍形芯垫的送料装置的中心空管两端的进料端和出料端分别设置第一定位模具和第二定位模具，通过第一定位模具和第二定位模具对马鞍形芯垫进行导向，使其进入笼式成缆机时与其同轴；第二定位模具的出料端采用圆锥状能使马鞍形芯垫出料时更接近笼式成缆机，定位更加精确，绞合时通过模具使其每个弧面均贴合在主线芯的表面，成缆张力均匀一致好。
附图说明
图1为本发明的地上采矿工程用卷绕拖拽电缆的结构示意图。
图2为第一定位模具的结构示意图。
图3为第二定位模具的结构示意图。
图4为从图3的后方观察时的示意图。
附图中的标号为：
主线芯1，主线芯导体1-1，主线芯绝缘层1-2，屏蔽层1-3，编织屏蔽层1-31，编织导体1-31-1，尼龙纱1-31-2，绕包屏蔽层1-32，
监视线芯2，监视线芯导体2-1，监视线芯绝缘层2-2，
中心填充3，外护套4，第一定位模具51，第二定位模具52。
具体实施方式
为了使本发明的内容更容易被清楚地理解，下面根据具体实施例并结合附图，对本发明作进一步详细的说明。本发明的方位的描述按照图1所示的方位进行，也即图1所示的上下左右方向即为描述的上下左右方向，图1所朝的一方为前方，背离图1的一方为后方。
应注意到：相似的标号和字母在下面的附图中表示类似项，因此，一旦某一项在一个附图中被定义，则在随后的附图中不需要对其进行进一步定义和解释。同时，在本发明的描述中，术语“第一”、“第二”等仅用于区分描述，而不能理解为指示或暗示相对重要性。
需要理解的是，术语“上”、“下”、“内”、“外”等指示方位或位置关系是基于附图所述的位置关系，仅是为了便于描述本发明或简化描述，而不是指示必须具有的特定的方位。
(实施例1)
见图1，本发明的地上采矿工程用卷绕拖拽电缆包括主线芯1、监视线芯2、中 心填充3和外护套4。
见图1，主线芯1有3根，3根主线芯1结构相同，均沿其各自径向由内向外依次设有主线芯导体1-1、主线芯绝缘层1-2和屏蔽层1-3。
所述的主线芯导体1-1由若干镀锡铜线束绞后复绞而成。主线芯绝缘层1-2由硬度为60A至80A的乙丙橡胶连续硫化制作而成，主线芯绝缘层1-2挤包在主线芯导体1-1外。
见图1，屏蔽层1-3包括编织屏蔽层1-31和绕包屏蔽层1-32。
编织屏蔽层1-31由编织导体1-31-1作为编织丝的一股与尼龙纱1-31-2一起复合编织在主线芯绝缘层1-2外。
尼龙纱1-31-2采用2/240D制成，即每股尼龙纱由2根240D尼龙丝绞合而成。
编织导体1-31-1由7根0.25mm的金属单丝绞合而成，本实施例为铜单丝。
半导电尼龙带绕包在编织屏蔽层1-31外形成绕包屏蔽层1-32。
见图1，监视线芯2沿其径向由内向外依次设有监视线芯导体2-1和监视线芯绝缘层2-2。监视线芯导体2-1由1根尼龙绳和4根导体复绞而成，复绞时绞合节径比为8倍，导体由6根镀锡铜丝绞合而成，1根尼龙绳采用1+4的结构设置在4根导体中。监视线芯绝缘层2-2由硬度为60A至80A的乙丙橡胶连续硫化制作而成。尼龙绳采用3/5/210D尼龙丝制成，即每股尼龙绳由5根210D尼龙丝绞合，再3股进行绞合形成尼龙绳。
中心填充3采用马鞍型芯垫。马鞍型芯垫采用半导电橡皮或氯丁橡皮材料挤包在监视线芯2外，监视线芯2外表涂覆滑石粉。
中心填充3和3根主线芯1绞合成缆。
外护套4采用氯丁橡皮材料挤包在绞合成缆的3根主线芯1和中心填充3外。
见图1至图4，本发明的地上采矿工程用卷绕拖拽电缆的生产工艺包括以下步骤：
1)将若干镀锡铜线束绞后复绞，形成主线芯导体1-1。
2)通过挤塑机将乙丙橡胶挤包在主线芯导体1-1外形成主线芯绝缘层1-2，然后通过硫化设备对主线芯绝缘层1-2的乙丙橡胶进行硫化处理。
3)将编织导体1-31-1作为编织丝的一股与尼龙纱1-31-2一起复合编织在主线芯绝缘层1-2外形成编织屏蔽层1-31。
3.1)编织导体1-31-1由7根0.25mm的金属单丝绞合而成，本实施例为铜单丝。编织丝采用2/240D尼龙纱与相应的一股7/0.25的编织导体1-31-1一起进行编织。
3.2)编织导体1-31-1采用整体焊接，每锭纡子中的单束股线之间需间隔至少3mm 进行焊接，纡子整体更换距离不小于1m。
4)半导电尼龙带绕包在编织屏蔽层1-31外形成绕包屏蔽层1-32。
5)监视线芯导体2-1采用1根尼龙绳和4根导体复绞而成，在绞合时放线张力中心尼龙绳大于导体，其受张力的延伸控制在3％以内。导体采用6根0.2mm的镀锡铜丝绞合而成。4根导体采用了4/6/0.2的复绞结构，即每根导体由6根0.2mm的镀锡铜丝绞合，再4股进行复绞，复绞时绞合节径比为8倍，尼龙绳采用3/5/210D，即每股尼龙绳由5根210D尼龙丝绞合，再3股进行绞合形成尼龙绳，并在4根导体复绞时以1+4的结构形式放置在4根导体中心。将乙丙橡胶挤包在监视线芯导体2-1外，然后进行连续硫化形成监视线芯绝缘层2-2，从而制成监视线芯2。
6)将半导电橡皮或氯丁橡皮材料挤包在监视线芯2外形成马鞍型垫心，从而制成中心填充3，挤包前在监视线芯2外表涂覆滑石粉。
马鞍型垫心采用罐式硫化设备或水平干烘管道进行，挤包时在冷却水槽中应放入大量滑石粉，使马鞍型垫心表面充分粘连滑石粉。
7)使用笼式成缆机对3根主线芯1和中心填充3进行绞合，主线芯1在成缆转动的同时中心填充3的马鞍型垫心的送料装置与绞笼转动方向同步转动，保证马鞍型垫心的每个弧面均贴合在相应的主线芯1的表面。
所述马鞍形芯垫的送料装置的中心空管两端的进料端和出料端分别设有第一定位模具51和第二定位模具52。通过第一定位模具51和第二定位模具52对马鞍形芯垫进行导向，使其进入笼式成缆机时与其同轴。
所述第一定位模具51为圆盘形，中央沿其轴向设有贯穿其两端的与马鞍形芯垫形状相对应的过线通孔。
所述第二定位模具52为一体件，包括呈圆柱状的进料端和呈圆锥状的出料端，中央沿其轴向设有贯穿其两端的与马鞍形芯垫形状相对应的过线通孔，出料端采用圆锥状能使马鞍形芯垫出料时更接近笼式成缆机的绞合模具，定位更加精确。
8)将氯丁橡皮材料挤包在绞合成缆的3根主线芯1和中心填充3外形成外护套4。
以上所述的具体实施例，对本发明的目的、技术方案和有益效果进行了进一步详细说明，所应理解的是，以上所述仅为本发明的具体实施例而已，并不用于限制本发明，凡在本发明的精神和原则之内，所做的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

  1. 一种地上采矿工程用卷绕拖拽电缆，其特征在于：包括主线芯、监视线芯、中心填充和外护套；主线芯有3根；3根主线芯结构相同，均沿其各自径向由内向外依次设有主线芯导体、主线芯绝缘层和屏蔽层；主线芯绝缘层由乙丙橡胶挤包在主线芯导体外；屏蔽层包括编织屏蔽层和绕包屏蔽层；
    编织屏蔽层由编织导体作为编织丝的一股与尼龙纱一起复合编织在主线芯绝缘层外；编织导体由金属单丝绞合而成；
    半导电尼龙带绕包在编织屏蔽层外形成绕包屏蔽层；
    监视线芯沿其径向由内向外依次设有监视线芯导体和监视线芯绝缘层；监视线芯导体由尼龙绳和导体复绞而成；
    中心填充采用马鞍型芯垫，马鞍型芯垫采用半导电橡皮或氯丁橡皮材料挤包在监视线芯外；中心填充和3根主线芯绞合成缆；
    外护套采用氯丁橡皮材料挤包在绞合成缆的3根主线芯和中心填充外。
  2. 根据权利要求1所述的地上采矿工程用卷绕拖拽电缆，其特征在于：编织屏蔽层的编织导体由7根0.25mm的金属单丝绞合而成。
  3. 根据权利要求1所述的地上采矿工程用卷绕拖拽电缆，其特征在于：编织屏蔽层的尼龙纱采用2/240D制成。
  4. 根据权利要求1至3之一所述的地上采矿工程用卷绕拖拽电缆，其特征在于：监视线芯导体由1根尼龙绳和4根导体复绞而成，监视线芯导体复绞时绞合节径比为8倍，1根尼龙绳采用1+4的结构设置在4根导体中。
  5. 根据权利要求4所述的地上采矿工程用卷绕拖拽电缆，其特征在于：监视线芯导体的4个导体均由6根镀锡铜丝绞合而成；尼龙绳采用3/5/210D尼龙丝制成，即每股尼龙绳由5根210D尼龙丝绞合，再3股进行绞合形成尼龙绳。
  6. 根据权利要求4所述的地上采矿工程用卷绕拖拽电缆，其特征在于：监视线芯外表涂覆滑石粉。
  7. 根据权利要求4所述的地上采矿工程用卷绕拖拽电缆，其特征在于：监视线芯绝缘层由硬度为60A至80A的乙丙橡胶连续硫化制作而成。
  8. 一种地上采矿工程用卷绕拖拽电缆的生产工艺，其特征是，包括以下步骤：
    1)将若干镀锡铜线束绞后复绞，形成主线芯导体；
    2)通过挤塑机将乙丙橡胶挤包在主线芯导体外形成主线芯绝缘层，然后通过硫化设备对主线芯绝缘层的乙丙橡胶进行硫化处理；
    3)将编织导体作为编织丝的一股与尼龙纱一起复合编织在主线芯绝缘层外形成编织屏蔽层；
    4)半导电尼龙带绕包在编织屏蔽层外形成绕包屏蔽层；
    5)监视线芯导体采用1根尼龙绳和4根导体复绞而成，在绞合时放线张力中心尼龙绳大于导体，其受张力的延伸控制在3％以内；导体采用6根0.2mm的镀锡铜丝绞合而成；4根导体采用了4/6/0.2的复绞结构，即每根导体由6根0.2mm的镀锡铜丝绞合，再4股进行复绞，复绞时绞合节径比为8倍，尼龙绳采用3/5/210D，即每股尼龙绳由5根210D尼龙丝绞合，再3股进行绞合形成尼龙绳，并在4根导体复绞时以1+4的结构形式放置在4根导体中心；将乙丙橡胶挤包在监视线芯导体外，然后进行连续硫化形成监视线芯绝缘层；
    6)将半导电橡皮或氯丁橡皮材料挤包在监视线芯外形成马鞍型垫心，从而制成中心填充，挤包前在监视线芯外表涂覆滑石粉；
    马鞍型垫心采用罐式硫化设备或水平干烘管道进行，挤包时在冷却水槽中应放入大量滑石粉，使马鞍型垫心表面充分粘连滑石粉；
    7)使用笼式成缆机对3根主线芯和中心填充进行绞合，主线芯在成缆转动的同时中心填充的马鞍型垫心的送料装置与绞笼转动方向同步转动，保证马鞍型垫心的每个弧面均贴合在相应的主线芯的表面；
    8)将氯丁橡皮材料挤包在绞合成缆的3根主线芯和中心填充外形成外护套。
  9. 根据权利要求8所述的地上采矿工程用卷绕拖拽电缆的生产工艺，其特征是，步骤3)中：
    3.1)编织导体由7根0.25mm的金属单丝绞合而成，编织丝采用2/240D尼龙纱与相应的一股7/0.25的编织导体一起进行编织；
    3.2)编织导体采用整体焊接，每锭纡子中的单束股线之间需间隔至少3mm进行焊接，纡子整体更换距离不小于1m。
  10. 根据权利要求8所述的地上采矿工程用卷绕拖拽电缆的生产工艺，其特征是，步骤7)中：
    所述马鞍形芯垫的送料装置的中心空管两端的进料端和出料端分别设有第一定位模具和第二定位模具；通过第一定位模具和第二定位模具对马鞍形芯垫进行导向，使其进入笼式成缆机时与其同轴；
    所述第一定位模具为圆盘形，中央沿其轴向设有贯穿其两端的与马鞍形芯垫形状相对应的过线通孔；
    所述第二定位模具为一体件，包括呈圆柱状的进料端和呈圆锥状的出料端，中央沿其轴向设有贯穿其两端的与马鞍形芯垫形状相对应的过线通孔。
PCT/CN2021/097175 2020-09-14 2021-05-31 地上采矿工程用卷绕拖拽电缆及生产工艺 WO2022052520A1 (zh)

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