WO2022120905A1 - Method for producing high-precision special-shaped strand small-diameter cable - Google Patents

Method for producing high-precision special-shaped strand small-diameter cable Download PDF

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WO2022120905A1
WO2022120905A1 PCT/CN2020/136651 CN2020136651W WO2022120905A1 WO 2022120905 A1 WO2022120905 A1 WO 2022120905A1 CN 2020136651 W CN2020136651 W CN 2020136651W WO 2022120905 A1 WO2022120905 A1 WO 2022120905A1
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zone
cable
conductor
semi
speed
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PCT/CN2020/136651
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French (fr)
Chinese (zh)
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汤陈旦
夏正军
李斌
祝军
梁福才
袁杰
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江苏上上电缆集团有限公司
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Publication of WO2022120905A1 publication Critical patent/WO2022120905A1/en

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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
    • H01B7/0009—Details relating to the conductive cores
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • 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
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/141—Insulating conductors or cables by extrusion of two or more insulating layers
    • 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
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • H01B13/148—Selection of the insulating material therefor
    • 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
    • H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
    • H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
    • H01B3/28—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances natural or synthetic rubbers
    • 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
    • H01B7/02—Disposition of insulation
    • H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
    • 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
    • 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

Definitions

  • the invention relates to a high-precision small-diameter cable production method for special-shaped strands of high-speed rail transit, and belongs to the technical field of cable manufacturing.
  • Cables for high-speed rail transit are used for power transmission in train operation.
  • the supply cable along the line is used to supply the long stator of the traction motor.
  • Each single-track railway has two sets of independent three-phase cables to supply power to the long stators of the motors on both sides of the high-speed railway.
  • Each phase consists of stranded conductors to reduce cable reactance. Due to the special design, the cable presents an "S"-shaped wiring in the track, which needs to meet the characteristics of small bending radius, UV resistance, corrosion resistance, vibration resistance, aging resistance, flame retardant, and light weight.
  • the outer diameter of the cable is required to be small, it can be laid in the stator slot without falling off, and the overall structure of the cable is relatively fixed, so it is difficult to use additional function/performance layers to the cable to improve the applicable performance of the cable. Therefore, it is necessary to improve the accuracy of the product through technological methods in the production process.
  • the "a kind of transportation cable" with the announcement number of CN210667842U in order to ensure the use, it is necessary to control the outer diameter of the finished cable to be as small as possible to ensure that the cable can be laid in the stator slot and not fall off.
  • the present invention proposes a method for producing high-precision special-shaped strands and small-diameter cables.
  • the method can realize high-precision production of cable products based on existing equipment and molds through the control of the production process. Specifically:
  • a method for producing high-precision special-shaped strand small-diameter cables comprising the steps of:
  • Described step 1) comprises:
  • the aluminum alloy rod is drawn into fan-shaped monofilament, Z-shaped monofilament and S-shaped monofilament by corresponding wire drawing dies;
  • Wire drawing process The aluminum rod is passed through 11 wire drawing dies in sequence, and the arc surface of the single wire corresponds to the arc groove of the die hole, so as to ensure the stable force of the aluminum wire and no deviation of the cross section of the single wire;
  • step 1.2) Take the three kinds of monofilaments obtained in step 1.1) and twist them to form a conductor, and the fan-shaped monofilament is made into the inner layer of the conductor; the Z-shaped monofilament and the S-shaped monofilament are sequentially wrapped outside the inner layer of the conductor;
  • n there are n layers of conductors from the inside to the outside, the inner layer of the conductor is the first layer, and n is a natural number; the twisting directions of the conductors of the adjacent layers are opposite; from the second layer, the cross-section of the monofilament of the conductors of the adjacent layers is a mirror image Symmetrical, and finally the nth layer conductor is made to obtain the cable conductor;
  • the aluminum rod is drawn into a special-shaped monofilament, and then the special-shaped monofilament is twisted into a circular shape in sequence through the twisting process. Explosion occurs, ensuring the tightness of the conductor.
  • the inner layer of the conductor is made of 4 fan-shaped monofilaments
  • the middle layer of the conductor is composed of multiple Z-shaped monofilaments
  • the outer conductor layer is composed of multiple S-shaped monofilaments
  • the fan-shaped monofilament, the Z-shaped monofilament and the S-shaped monofilament are all the aluminum rods are sequentially inserted into 11 corresponding wire drawing dies according to the sequence, and the monofilament arc surfaces are corresponding to the arc grooves of the die holes.
  • the parameters of the wire drawing machine include:
  • Fan-shaped monofilament the speed ratio of the constant speed wheel is 1.19, the diameter of the finished die is 4.20mm, the wire pitch is 0.1mm, and the wire drawing speed is 8m/s;
  • the speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.30mm, the wire pitch is 0.1mm, and the wire drawing speed is 10m/s;
  • the speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.29mm, the wire pitch is 0.1mm, and the wire drawing speed is 12m/s;
  • the parameters of the stranding machine include: the rotational speed of the inner layer of the stranded conductor is 40 ⁇ 45r/min; the rotational speed of the middle layer of the stranded conductor is 30 ⁇ 45 r/min. 35r/min; the rotational speed of the outer layer of the stranded conductor is 30-33r/min; the line speed of the finished product is 7-8m/min;
  • the temperature in the heating stage is 500°C, and the heating time is 30-40min;
  • the temperature in the heat preservation stage is 500°C, and the heat preservation time is 3h;
  • the cooling rate in the cooling stage is 40°C/h, and the cooling time is 12h.
  • the steps 2) to 4) are realized by a three-layer co-extrusion process:
  • the temperature zone of the first extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100°C; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
  • the temperature zone of the second extruder for extruding ethylene-propylene rubber is controlled as follows: 50-60°C for the first zone, 55-65°C for the second zone, 65-70°C for the third zone, 65-75°C for the fourth zone, and 75-80°C for the fifth zone ;
  • the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
  • the temperature zone of the third extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100°C; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
  • the steam pressure during production is 8-12 bar
  • the production speed is 5-6 m/min
  • the screw speed of the first extruder is 15-20 r/min
  • the screw speed of the second extruder is 8-12 r/min
  • the third The screw speed of the extruder is 8 to 12 r/min.
  • water is cooled in a cold water tank, and the cooling time is 15 minutes; the water temperature of the cold water tank is controlled to be 5-10°C.
  • the semi-conductive neoprene rubber is extruded in the fourth rubber extruder, and the temperature zone of the fourth rubber extrusion machine is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, and the third zone is 55-65°C. Zone 65 ⁇ 70°C, zone 4 65 ⁇ 75°C, zone 5 75 ⁇ 80°C; Zone 1 is feeding section, Zone 2 and Zone 3 are plasticizing section, Zone 4 and Zone 5 are homogenizing section;
  • the steam pressure is 7 ⁇ 8bar
  • the production speed is 5 ⁇ 6m/min
  • the screw speed of the fourth extruder is 18 ⁇ 20r/min;
  • the cooling time is 20min; the water temperature of the cold water tank is controlled to 5 ⁇ 10 °C.
  • the nanoscale semi-conductive glue is applied online, and the coating step is: the cable is routed on the coating machine, the semi-conductive glue is sprayed, and the infrared heating tube is heated and dried cured.
  • the traditional semi-conductive layers of cables are mostly made of films or tapes covered with nano-scale semi-conductive layers (such as polyester films, semi-conductive non-woven fabrics), which are wrapped outside the cables by wrapping.
  • nano-scale semi-conductive layers such as polyester films, semi-conductive non-woven fabrics
  • this method increases the outer diameter of the cable.
  • the method of directly coating the nanoscale semiconducting glue is adopted.
  • glue products are used to manufacture nanoscale semi-conductive films, and are mainly mixtures of oily acrylic emulsion and ethyl ester containing nanocarbon black or carbon pipes.
  • the linear speed of the cable is 4-5m/min, and the curing time of the glue is 5min.
  • the thickness of the semi-conductive nano-coating obtained by this process can reach 5-50 ⁇ m, which is very thin and has good firmness.
  • the viscosity of the semi-conductive glue is controlled within 15 to 18 seconds (Enzl viscosity), and the electric pressure cylinder is used to stir evenly at a uniform speed;
  • the cable conveying speed is synchronized with the spraying pressure, the cable conveying speed is 4-5m/min, and the spraying pressure is 0.8-1MPa, to ensure that the glue thickness of each surface of the cable is uniform;
  • Control of drying temperature The infrared heating tube is heated and dried, and the curing heating temperature is 200 °C, and the surface temperature of the cable cross section is uniform.
  • Cable conveying During the spraying process, the cable is always located in the center of the sprayer to prevent the coating from being scratched and the thickness is uniform.
  • the aluminum alloy used for the conductor is AA8000 series aluminum alloy. Used to improve mechanical strength and creep resistance.
  • the control deviation of the outer diameter of the cable conductor is ⁇ 0.1mm
  • the control deviation of the outer diameter of the insulated core is ⁇ 0.2mm
  • the control deviation of the outer diameter of the finished cable is ⁇ 0.2mm, which ensures that the cable can be laid in the stator slot. Does not fall off.
  • the conductor By controlling the annealing process of the conductor, the conductor has the advantages of high flexibility, small bending stress, no deformation, no looseness, and creep resistance after laying. Moreover, after testing, the elongation at break of the center conductor is 25% to 35%.
  • the cable produced by the production method of the high-precision special-shaped strand small-diameter cable is used for power supply of the long stator of the traction motor of the high-speed rail transit.
  • the cable prepared by this method is suitable for power transmission of high-speed rail transit. It not only strictly controls the outer diameter, but also has reliable electrical properties (such as insulation properties such as voltage resistance), and also has excellent bending properties, weather resistance, flame retardancy, etc. Features.
  • the insulating shielding layer, semi-conducting sheath layer and semi-conducting nano-coating are integrated into one structure, and the surface resistance of the finished cable is not more than 200 ⁇ . It can effectively reduce the induced current, capacitive current and leakage current of the cable during operation, and ensure the safety of the cable during long-term operation.
  • the cable In order to meet the special application environment of high-speed rail transit line track laying, the cable needs to meet the requirements of excellent electrical performance, weather resistance, and easy bending performance.
  • This special cable adopts special-shaped annealed aluminum conductor, and the central layer is composed of four 90° fan-shaped monofilament strands; the secondary inner layer is composed of Z-shaped monofilament stranding; the outer layer is composed of S-shaped monofilament stranding; Annealed, the conductor has high flexibility, low bending stress, no deformation, no looseness, creep resistance, etc. Because the material can meet the requirements of high voltage performance, it can meet the low temperature resistance of -40 °C and the high temperature resistance of 105 °C.
  • the high-strength rubber is used as the sheath material and adopts a single-layer structure, which can meet the requirements of weather resistance and semi-conductivity under the condition of high mechanical properties.
  • the special application environment has high requirements on the outer diameter of the cable, and at the same time, in order to meet the requirements of the embedded part of the cable embedded in the stator core, the requirement of minimum deviation of the outer diameter of the cable is required.
  • the method and the prepared cable have excellent outer diameter consistency.
  • the control deviation of the outer diameter of the cable conductor is ⁇ 0.1mm
  • the control deviation of the outer diameter of the insulated core is ⁇ 0.2mm
  • the outer diameter of the finished cable is ⁇ 0.2mm.
  • the control deviation is ⁇ 0.2mm, which ensures that the cable can be laid in the stator slot without falling off.
  • FIG. 1 is a schematic diagram of a radial cross-sectional view of the conductor of the cable of this embodiment.
  • FIG. 2 is a schematic diagram of the cross-sectional structure of the cable of this embodiment.
  • conductor inner layer 1 conductor middle layer 2, conductor outer layer 3, Z-shaped monofilament 4, sector-shaped monofilament 5, S-shaped monofilament 6, conductor 7, conductor shielding layer 8, insulating layer 9, insulating shielding layer 10.
  • Semi-conductive sheath layer 11 semi-conductive nano-coating layer 12 .
  • the high-precision special-shaped strand small-diameter cable obtained by this manufacturing method has a structure as follows: conductor 7 and conductor shielding layer 8 wrapped around conductor 7, insulating layer 9, insulating shielding layer 10, semiconducting A cable composed of a sheath layer 11 and a semiconducting nanocoating 12 .
  • This cable is used to supply power to the long stator of traction motors used in high-speed rail transit.
  • the diameter of the conductor 7 is in the range of 19.5-20.5 mm; the thickness of the insulating layer 9 is in the range of 5.2-5.8 mm; the thickness of the semi-conductive sheath layer 11 is in the range of 1.8-2.4 mm; The thickness of layer 12 is in the range of 5-50 ⁇ m;
  • the conductor 7 is made of aluminum alloy; the conductor shielding layer 8 is made of semiconductive neoprene; the insulating layer 9 is made of ethylene propylene rubber; the insulating shielding layer 10 is made of semiconductive neoprene. It is composed of rubber; the sheath material of the semi-conductive sheath layer 11 is composed of semi-conductive neoprene rubber extruded;
  • the conductor 7 is divided into layers 1 to n from the inside to the outside, and n is a natural number (three layers in this example);
  • They are composed of a plurality of identical monofilaments with a "Z"-shaped or "S"-shaped cross-section, which are spliced and twisted with each other; the stranding directions of the monofilaments of the adjacent conductors are opposite; the monofilaments of the adjacent conductors are mirror images Symmetrical;
  • any special-shaped monofilament is extruded from aluminum alloy monofilament.
  • the pitch-to-diameter ratio of the monofilament strands that constitute each layer of conductors is 10 to 18 times, (the outermost layer has the smallest pitch-to-diameter ratio to ensure that the conductors are tight and not loose).
  • the conductor 7 is a conductor made of an aluminum alloy rod by drawing, twisting and annealing.
  • the conductor shielding layer 8 is a shielding layer made of semi-conductive material (semi-conductive chloroprene rubber) through the process of extruding rubber and vulcanizing.
  • the insulating layer 9 is an insulating layer made of insulating material (ethylene propylene rubber) through the process of extruding rubber and vulcanizing.
  • the insulating shielding layer 10 is an insulating shielding layer made of semi-conductive material (semi-conductive chloroprene rubber) through the process of extruding rubber and vulcanizing.
  • the semi-conductive sheath layer 11 is a sheath layer obtained from a sheath material (semi-conductive neoprene) through a process of extruding rubber and vulcanizing.
  • the semi-conductive nano-coating layer 12 is a nano-scale coating made of semi-conductive glue through a spraying process.
  • the cable produced by the production method of the high-precision special-shaped strand small-diameter cable is used for power supply of the long stator of the traction motor of the high-speed rail transit.
  • the method for producing a high-precision special-shaped strand small-diameter cable includes the following steps: 1) manufacturing a conductor 7 of the cable; 2) extruding semiconducting neoprene rubber to make a conductor shielding layer 8; 3) extruding ethylene-propylene rubber to make an insulating layer 9; 4)
  • the insulating shielding layer 10 is made by extruding semiconducting neoprene; 5)
  • the semiconducting sheath layer 11 is made by extruding semiconducting neoprene; Coating 12.
  • Described step 1) comprises:
  • the aluminum alloy rod is drawn into fan-shaped monofilament 5, Z-shaped monofilament 4 and S-shaped monofilament 6 by using corresponding wire-drawing dies;
  • Wire drawing process The aluminum rod is passed through 11 wire drawing dies in sequence, and the arc surface of the single wire corresponds to the arc groove of the die hole, so as to ensure the stable force of the aluminum wire and no deviation of the cross section of the single wire;
  • step 1.2) Three kinds of monofilaments obtained in step 1.1) are twisted to form conductor 7, and sector-shaped monofilament 5 is made into conductor inner layer 1; Z-shaped monofilament 4 and S-shaped monofilament 6 are sequentially wrapped outside conductor inner layer 1;
  • the conductor 7 has n layers from the inside to the outside, the inner layer 1 of the conductor is the first layer, and n is a natural number; the stranding directions of the monofilaments of the adjacent conductors are opposite; from the second layer, the monofilaments of the adjacent conductors
  • the cross section of the cable is mirror-symmetrical, and finally the nth layer conductor is made to obtain the conductor 7 of the cable;
  • step 1.2 On the metal wire continuous annealing production line, anneal the cable conductor obtained in step 1.2), wherein: the temperature in the heating stage is 500°C, and the heating time is 30-40min; the temperature in the heat preservation stage is 500°C, and the holding time is 3h ; The cooling rate in the cooling stage is 40°C/h, and the cooling time is 12h;
  • the steps 2) to 4) are realized by a three-layer co-extrusion process:
  • the temperature zone of the first extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100°C; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
  • the temperature zone of the second extruder for extruding ethylene-propylene rubber is controlled as follows: 50-60°C for the first zone, 55-65°C for the second zone, 65-70°C for the third zone, 65-75°C for the fourth zone, and 75-80°C for the fifth zone ;
  • the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
  • the temperature zone of the third extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100°C; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
  • the steam pressure during production is 8 ⁇ 12bar
  • the production speed is 5 ⁇ 6m/min
  • the screw speed of the first extruder is 15 ⁇ 20r/min
  • the screw speed of the second extruder is 8 ⁇ 12r/min
  • the third extruder screw speed is 8 ⁇ 12r/min. Rubber machine screw speed 8 ⁇ 12r/min;
  • the cooling time is 15min; the water temperature of the cold water tank is controlled to 5 ⁇ 10 °C.
  • the semi-conductive chloroprene rubber is extruded to make the semi-conductive sheath layer 11;
  • the semi-conductive neoprene rubber is extruded in the fourth rubber extruder, and the temperature zone of the fourth rubber extrusion machine is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, and the third zone is 55-65°C. Zone 65 ⁇ 70°C, zone 4 65 ⁇ 75°C, zone 5 75 ⁇ 80°C; Zone 1 is feeding section, Zone 2 and Zone 3 are plasticizing section, Zone 4 and Zone 5 are homogenizing section;
  • the steam pressure is 7 ⁇ 8bar
  • the production speed is 5 ⁇ 6m/min
  • the screw speed of the fourth extruder is 18 ⁇ 20r/min;
  • the cooling time is 20min; the water temperature of the cold water tank is controlled to 5 ⁇ 10 °C.
  • the nanoscale semi-conductive glue is applied online, and the coating step is: the cable is routed on the coating machine, the semi-conductive glue is sprayed, and the infrared heating tube is heated and dried ; When gluing, the linear speed of the cable is 4 ⁇ 5m/min; the curing time of the glue is 5min.
  • the thickness of the semi-conductive nano-coating 12 is in the range of 5 to 50 ⁇ m, and is heated and dried by an infrared heating tube at 200 degrees Celsius;
  • Coating configuration adopt a two-component system, add curing agent and diluent to the coating, control the viscosity of the coating within 15-18 seconds, and use an electric pressure cylinder to stir evenly at a uniform speed;
  • the cable conveying speed is synchronized with the spraying pressure (the cable conveying speed is 4 ⁇ 5m/min, and the spraying pressure is 0.8 ⁇ 1MPa) to ensure that the glue thickness of each surface of the cable is uniform;
  • Cable conveying During the spraying process, the cable is always located in the center of the sprayer to prevent the coating from being scratched, and the thickness is uniform.
  • the fan-shaped monofilament 5, the Z-shaped monofilament 4 and the S-shaped monofilament 6 all pass the aluminum rods into 11 corresponding wire drawing dies according to the sequence, and the monofilament arc surface and the die hole arc are connected.
  • the parameters of the wire drawing machine include:
  • Fan-shaped monofilament 5 the speed ratio of the constant speed wheel is 1.19, the diameter of the finished die is 4.20mm, the wire pitch is 0.1mm, and the wire drawing speed is 8m/s;
  • Z-shaped monofilament 4 The speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.30mm, the wire pitch is 0.1mm, and the wire drawing speed is 10m/s;
  • S-shaped monofilament 6 The speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.29mm, the wire pitch is 0.1mm, and the wire drawing speed is 12m/s.
  • step 1.2 three kinds of monofilaments are twisted on the stranding machine, and the parameters of the stranding machine include:
  • the rotational speed of the inner layer 1 of the stranded conductor is 40 to 45 r/min; the rotational speed of the middle layer 2 of the stranded conductor is 30 to 35 r/min; the rotational speed of the outer layer 3 of the stranded conductor is 30 to 33 r/min;
  • the line speed of the finished product is 7-8m/min.
  • the control deviation of the outer diameter of the cable conductor is ⁇ 0.1mm
  • the control deviation of the outer diameter of the insulated core is ⁇ 0.2mm
  • the control deviation of the outer diameter of the finished cable is ⁇ 0.2mm, which ensures that the cable can be laid in the stator slot without falling off.
  • Softness control The hardness of the material is controlled, in which the hardness of the insulation and sheath material is ⁇ 70A.

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Abstract

A method for producing a high-precision special-shaped strand small-diameter cable, comprising the following steps: 1) fabricating a cable conductor; 2) extruding semi-conductive neoprene to form a conductor shielding layer; 3) extruding an ethylene-propylene rubber to form an insulating layer; 4) extruding the semi-conductive neoprene to form an insulating shielding layer; 5) extruding the semi-conductive neoprene to form a semi-conductive sheath layer; and 6) coating nanoscale semi-conductive glue to form a semi-conductive nano-coating. In the method, by means of a specific conductor machining process, an extrusion process of each functional layer and the like, the prepared cable has the feature of high precision; meanwhile, the performance thereof can satisfy laying requirements of cables for high-speed rail transit. Thus, the technical problem of improving product precision by means of a process method during production is solved.

Description

高精度异形股线小直径电缆生产方法Production method of high-precision special-shaped strand small-diameter cable 技术领域technical field
本发明涉及一种可用于高速轨道交通的异形股线的高精度小直径电缆生产方法，属于电缆制造技术领域。The invention relates to a high-precision small-diameter cable production method for special-shaped strands of high-speed rail transit, and belongs to the technical field of cable manufacturing.
背景技术Background technique
高速轨道交通用电缆用于列车运行的电力传输。沿线路的供电电缆用于对牵引电机的长定子供电。每条单线铁路有两组相互独立的三相电缆分别对高速铁路的两侧电机长定子供电。每一相都由多股导线组成，以降低电缆电抗。由于设计特殊，电缆在轨道中呈现“S”型布线，需满足弯曲半径小，防紫外线、耐腐蚀、抗震动、抗老化、阻燃、质量轻等特点。由于电缆要求外径小，可敷设在定子槽并不脱落，电缆的整体结构较为固定，很难采用对电缆附加功能/性能层来提高电缆的适用性能。所以，要在生产过程中通过工艺方法来提高产品的精度。如公告号为CN210667842U的“一种交通用电缆”，在为了保证使用，需要控制成品电缆外径尺寸尽可能小，以确保电缆能敷设在定子槽中不脱落。Cables for high-speed rail transit are used for power transmission in train operation. The supply cable along the line is used to supply the long stator of the traction motor. Each single-track railway has two sets of independent three-phase cables to supply power to the long stators of the motors on both sides of the high-speed railway. Each phase consists of stranded conductors to reduce cable reactance. Due to the special design, the cable presents an "S"-shaped wiring in the track, which needs to meet the characteristics of small bending radius, UV resistance, corrosion resistance, vibration resistance, aging resistance, flame retardant, and light weight. Since the outer diameter of the cable is required to be small, it can be laid in the stator slot without falling off, and the overall structure of the cable is relatively fixed, so it is difficult to use additional function/performance layers to the cable to improve the applicable performance of the cable. Therefore, it is necessary to improve the accuracy of the product through technological methods in the production process. For example, the "a kind of transportation cable" with the announcement number of CN210667842U, in order to ensure the use, it is necessary to control the outer diameter of the finished cable to be as small as possible to ensure that the cable can be laid in the stator slot and not fall off.
发明内容SUMMARY OF THE INVENTION
为了解决上述技术问题，本发明提出一种高精度异形股线小直径电缆生产方法，本方法通过生产工艺的控制，基于现有的设备以及模具，可实现电缆产品的高精度生产。具体来说：In order to solve the above technical problems, the present invention proposes a method for producing high-precision special-shaped strands and small-diameter cables. The method can realize high-precision production of cable products based on existing equipment and molds through the control of the production process. Specifically:
一种高精度异形股线小直径电缆生产方法，包括步骤：A method for producing high-precision special-shaped strand small-diameter cables, comprising the steps of:
1)制造电缆导体；1) Manufacturing cable conductors;
2)挤包半导电氯丁橡胶制成导体屏蔽层；2) Extruded semi-conductive neoprene to make conductor shielding layer;
3)挤包乙丙橡胶制成绝缘层；3) Extruded ethylene-propylene rubber to make insulation layer;
4)挤包半导电氯丁橡胶制成绝缘屏蔽层；4) Extruded semi-conductive neoprene to make insulating shielding layer;
5)挤包半导电氯丁橡胶制成半导电护套层；5) Extruding semi-conductive neoprene rubber to make semi-conductive sheath layer;
6)涂覆纳米级半导电胶水制成半导电纳米涂层。6) Coating nanoscale semiconducting glue to make semiconducting nanocoating.
所述步骤1)包括：Described step 1) comprises:
1.1)预制单丝：1.1) Prefabricated monofilament:
拉丝：将铝合金杆采用相应拉丝模具分别拉制成扇形单丝、Z形单丝和S形单丝；Drawing: The aluminum alloy rod is drawn into fan-shaped monofilament, Z-shaped monofilament and S-shaped monofilament by corresponding wire drawing dies;
拉丝工艺：将铝杆按道次依次穿入11个拉丝模，将单丝弧面与模孔弧槽相对应，确保铝丝受力稳定，单丝截面无偏差；Wire drawing process: The aluminum rod is passed through 11 wire drawing dies in sequence, and the arc surface of the single wire corresponds to the arc groove of the die hole, so as to ensure the stable force of the aluminum wire and no deviation of the cross section of the single wire;
1.2)取步骤1.1)制得的三种单丝绞合构成导体，扇形单丝制成导体内层；Z形单丝和S形单丝依次包裹在导体内层外；1.2) Take the three kinds of monofilaments obtained in step 1.1) and twist them to form a conductor, and the fan-shaped monofilament is made into the inner layer of the conductor; the Z-shaped monofilament and the S-shaped monofilament are sequentially wrapped outside the inner layer of the conductor;
设导体自内而外有n层，导体内层为第1层，n为自然数；相邻层导体的绞合方向相反；从第2层起，相邻层导体的单丝的断面是成镜像对称的，最终制成第n层导体，得到电缆导体；It is assumed that there are n layers of conductors from the inside to the outside, the inner layer of the conductor is the first layer, and n is a natural number; the twisting directions of the conductors of the adjacent layers are opposite; from the second layer, the cross-section of the monofilament of the conductors of the adjacent layers is a mirror image Symmetrical, and finally the nth layer conductor is made to obtain the cable conductor;
该工艺要求的技术原理以及效果为：将铝杆拉制成异型单丝，然后通过绞合工艺使异型单丝按序绞合成圆形，效果是导体弯曲时，单丝由于互相嵌合，不会出现炸开现象，确保了导体的紧密性。The technical principle and effect required by this process are as follows: the aluminum rod is drawn into a special-shaped monofilament, and then the special-shaped monofilament is twisted into a circular shape in sequence through the twisting process. Explosion occurs, ensuring the tightness of the conductor.
在具体实施时候，导体共三层，导体内层是由4根扇形单丝制成，导体中间层是由多根Z形单丝构成，导体外层是由多根S形单丝构成；In the specific implementation, there are three layers of conductors, the inner layer of the conductor is made of 4 fan-shaped monofilaments, the middle layer of the conductor is composed of multiple Z-shaped monofilaments, and the outer conductor layer is composed of multiple S-shaped monofilaments;
所述步骤1.1)中，扇形单丝、Z形单丝和S形单丝都是将铝杆按道次依次穿入11个对应的拉丝模，将单丝弧面与模孔弧槽相对应，拉丝机的参数包括：In the step 1.1), the fan-shaped monofilament, the Z-shaped monofilament and the S-shaped monofilament are all the aluminum rods are sequentially inserted into 11 corresponding wire drawing dies according to the sequence, and the monofilament arc surfaces are corresponding to the arc grooves of the die holes. , the parameters of the wire drawing machine include:
扇形单丝：定速轮的速比为1.19，成品模直径4.20mm，排线节距0.1mm，拉丝速度8m/s；Fan-shaped monofilament: the speed ratio of the constant speed wheel is 1.19, the diameter of the finished die is 4.20mm, the wire pitch is 0.1mm, and the wire drawing speed is 8m/s;
Z形单丝：定速轮的速比为1.16，成品模直径3.30mm，排线节距0.1mm，拉丝速度10m/s；Z-shaped monofilament: the speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.30mm, the wire pitch is 0.1mm, and the wire drawing speed is 10m/s;
S形单丝：定速轮的速比为1.16，成品模直径3.29mm，排线节距0.1mm，拉丝速度12m/s；S-shaped monofilament: the speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.29mm, the wire pitch is 0.1mm, and the wire drawing speed is 12m/s;
所述步骤1.2)中，把三种单丝在绞线机上绞合，绞线机的参数包括：绞合导体内层的转速是40～45r/min；绞合导体中间层的转速是30～35r/min；绞合导体外层的转速是30～33r/min；成品的线速度是7～8m/min；In the step 1.2), three kinds of monofilaments are twisted on a stranding machine, and the parameters of the stranding machine include: the rotational speed of the inner layer of the stranded conductor is 40～45r/min; the rotational speed of the middle layer of the stranded conductor is 30～45 r/min. 35r/min; the rotational speed of the outer layer of the stranded conductor is 30-33r/min; the line speed of the finished product is 7-8m/min;
1.3)在金属线材连续退火生产线上，对步骤1.2)制得的电缆导体进行退火处理，其中：1.3) On the metal wire continuous annealing production line, anneal the cable conductor obtained in step 1.2), wherein:
加热阶段温度为500℃，加热时间为30～40min；The temperature in the heating stage is 500℃, and the heating time is 30-40min;
保温阶段温度为500℃，保温时间为3h；The temperature in the heat preservation stage is 500℃, and the heat preservation time is 3h;
降温阶段的降温速度为40℃/h，降温时间为12h。The cooling rate in the cooling stage is 40℃/h, and the cooling time is 12h.
所述步骤2)～4)是三层共挤工艺实现：The steps 2) to 4) are realized by a three-layer co-extrusion process:
挤包半导电氯丁橡胶的第一挤橡机温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、 四区80～90℃、五区90～100℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；The temperature zone of the first extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100℃; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
挤包乙丙橡胶的第二挤橡机温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区65～75℃、五区75～80℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；The temperature zone of the second extruder for extruding ethylene-propylene rubber is controlled as follows: 50-60°C for the first zone, 55-65°C for the second zone, 65-70°C for the third zone, 65-75°C for the fourth zone, and 75-80°C for the fifth zone ; The first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
挤包半导电氯丁橡胶的第三挤橡机温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区80～90℃、五区90～100℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；The temperature zone of the third extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100℃; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
机头温度设定：110℃；Head temperature setting: 110℃;
上述挤包过程中，生产时蒸汽压力8～12bar，生产速度5～6m/min，第一挤橡机螺杆转速15～20r/min，第二挤橡机螺杆转速8～12r/min，第三挤橡机螺杆转速8～12r/min。In the above-mentioned extrusion process, the steam pressure during production is 8-12 bar, the production speed is 5-6 m/min, the screw speed of the first extruder is 15-20 r/min, the screw speed of the second extruder is 8-12 r/min, and the third The screw speed of the extruder is 8 to 12 r/min.
上述步骤完成后，在冷水槽中水冷，冷却时间为15min；冷水槽的水温控制为5～10℃。After the above steps are completed, water is cooled in a cold water tank, and the cooling time is 15 minutes; the water temperature of the cold water tank is controlled to be 5-10°C.
所述步骤5)挤包半导电氯丁橡胶制成半导电护套层：The step 5) extruding semi-conductive neoprene rubber to make a semi-conductive sheath layer:
对步骤4)制得线缆，在第四挤橡机中挤包半导电氯丁橡胶，第四挤橡机的温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区65～75℃、五区75～80℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；For the cable obtained in step 4), the semi-conductive neoprene rubber is extruded in the fourth rubber extruder, and the temperature zone of the fourth rubber extrusion machine is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, and the third zone is 55-65°C. Zone 65～70℃, zone 4 65～75℃, zone 5 75～80℃; Zone 1 is feeding section, Zone 2 and Zone 3 are plasticizing section, Zone 4 and Zone 5 are homogenizing section;
生产时蒸汽压力7～8bar，生产速度5～6m/min，第四挤橡机螺杆转速18～20r/min；During production, the steam pressure is 7~8bar, the production speed is 5~6m/min, and the screw speed of the fourth extruder is 18~20r/min;
在冷水槽中水冷，冷却时间为20min；冷水槽的水温控制为5～10℃。Water cooling in the cold water tank, the cooling time is 20min; the water temperature of the cold water tank is controlled to 5 ~ 10 ℃.
所述步骤6)在步骤5)制得线缆外，在线涂覆纳米级半导电胶水，涂覆步骤为：电缆在涂覆机上走线，半导电胶进行喷涂，红外加热管进行加热烘干固化。In the step 6), in addition to the cable obtained in step 5), the nanoscale semi-conductive glue is applied online, and the coating step is: the cable is routed on the coating machine, the semi-conductive glue is sprayed, and the infrared heating tube is heated and dried cured.
传统的电缆半导电层多是采用覆有纳米级半导电层的薄膜或带制品(如聚酯薄膜、半导电无纺布)，这类薄膜是采用绕包方式包裹在线缆外。对于本电缆来说，这种方式增加了线缆外径。为了进一步减少线缆外径，特采用直接涂覆纳米级半导电胶水的方式。现有技术中，这类胶水产品是用于制造纳米级半导电薄膜，主要是包含有纳米碳黑或碳管道的油性丙烯酸乳液和乙脂等混合物。The traditional semi-conductive layers of cables are mostly made of films or tapes covered with nano-scale semi-conductive layers (such as polyester films, semi-conductive non-woven fabrics), which are wrapped outside the cables by wrapping. For this cable, this method increases the outer diameter of the cable. In order to further reduce the outer diameter of the cable, the method of directly coating the nanoscale semiconducting glue is adopted. In the prior art, such glue products are used to manufacture nanoscale semi-conductive films, and are mainly mixtures of oily acrylic emulsion and ethyl ester containing nanocarbon black or carbon pipes.
涂胶时，线缆的线速度是4～5m/min，胶水固化时间为5min，本工艺制得的半导电纳米涂层的厚度范围可达5～50μm，非常薄，并且牢固程度好。When applying glue, the linear speed of the cable is 4-5m/min, and the curing time of the glue is 5min. The thickness of the semi-conductive nano-coating obtained by this process can reach 5-50μm, which is very thin and has good firmness.
半导电胶水的粘度控制在15～18秒(恩氏粘度)，采用电压力筒匀速搅拌均匀；The viscosity of the semi-conductive glue is controlled within 15 to 18 seconds (Enzl viscosity), and the electric pressure cylinder is used to stir evenly at a uniform speed;
涂层厚度的调节：电缆输送速度与喷涂压力同步，电缆输送速度是4～5m/min，喷涂压力是0.8～1MPa，确保电缆每个面的胶水厚度均匀；Adjustment of coating thickness: the cable conveying speed is synchronized with the spraying pressure, the cable conveying speed is 4-5m/min, and the spraying pressure is 0.8-1MPa, to ensure that the glue thickness of each surface of the cable is uniform;
烘干温度的控制：红外加热管加热烘干，固化加热温度是200℃，电缆横截面表面温度均匀一致。Control of drying temperature: The infrared heating tube is heated and dried, and the curing heating temperature is 200 ℃, and the surface temperature of the cable cross section is uniform.
电缆输送：电缆在喷涂过程中，始终位于喷涂机中央，防止涂层被刮伤，并且厚度均匀。Cable conveying: During the spraying process, the cable is always located in the center of the sprayer to prevent the coating from being scratched and the thickness is uniform.
所述步骤1)中，导体采用的铝合金是AA8000系列铝合金。用来提高机械强度及抗蠕变性能。In the step 1), the aluminum alloy used for the conductor is AA8000 series aluminum alloy. Used to improve mechanical strength and creep resistance.
通过本生产工艺，在产品精度上，电缆导体外径控制偏差±0.1mm，绝缘线芯外径控制偏差±0.2mm，成品电缆外径控制偏差±0.2mm，确保了电缆能敷设在定子槽中不脱落。Through this production process, in terms of product accuracy, the control deviation of the outer diameter of the cable conductor is ±0.1mm, the control deviation of the outer diameter of the insulated core is ±0.2mm, and the control deviation of the outer diameter of the finished cable is ±0.2mm, which ensures that the cable can be laid in the stator slot. Does not fall off.
通过对导体的退火工艺控制，使导体具有柔软度高，曲折应力小，敷设后不变形、不松散、抗蠕变等优点。而且，经检测，中心导体的断裂伸长率在25％～35％。By controlling the annealing process of the conductor, the conductor has the advantages of high flexibility, small bending stress, no deformation, no looseness, and creep resistance after laying. Moreover, after testing, the elongation at break of the center conductor is 25% to 35%.
本高精度异形股线小直径电缆生产方法制得电缆是用于高速轨道交通的牵引电机的长定子供电。The cable produced by the production method of the high-precision special-shaped strand small-diameter cable is used for power supply of the long stator of the traction motor of the high-speed rail transit.
本方法制得的电缆适用于高速轨道交通的电力传输，其不仅严格控制外径，具有可靠的电气性能(如耐压等绝缘性能)，同时还具有优异的弯曲性能、耐候性能、阻燃等特点。The cable prepared by this method is suitable for power transmission of high-speed rail transit. It not only strictly controls the outer diameter, but also has reliable electrical properties (such as insulation properties such as voltage resistance), and also has excellent bending properties, weather resistance, flame retardancy, etc. Features.
通过生产控制，绝缘屏蔽层、半导电护套层、半导电纳米涂层为一体式结构，成品电缆表面电阻不大于200Ω。可以有效降低电缆运行时的感应电流、电容电流和泄漏电流，确保电缆长期运行时的使用安全。Through production control, the insulating shielding layer, semi-conducting sheath layer and semi-conducting nano-coating are integrated into one structure, and the surface resistance of the finished cable is not more than 200Ω. It can effectively reduce the induced current, capacitive current and leakage current of the cable during operation, and ensure the safety of the cable during long-term operation.
本技术方案的原理以及有益效果说明如下：The principle and beneficial effects of this technical solution are described as follows:
1、为了满足高速轨道交通线路轨道敷设的特种应用环境，则需要电缆满足优异的电气性能、耐候性能、易弯曲性能等要求。1. In order to meet the special application environment of high-speed rail transit line track laying, the cable needs to meet the requirements of excellent electrical performance, weather resistance, and easy bending performance.
本特种电缆采用异型退火铝导体，中心层由4根90°扇形单丝绞合构成；次内层采用Z字形单丝绞合构成；外层采用S字形单丝绞合构成；再进行导体整体退火，导体柔软度高，曲折应力小，敷设后不变形、不松散、抗蠕变等优点；乙丙橡胶作为绝缘料，采用三层共挤工艺加工绝缘层。由于该材料在满足高电压性能的要求下能够满足耐-40℃低温性能、耐105℃高温性能。This special cable adopts special-shaped annealed aluminum conductor, and the central layer is composed of four 90° fan-shaped monofilament strands; the secondary inner layer is composed of Z-shaped monofilament stranding; the outer layer is composed of S-shaped monofilament stranding; Annealed, the conductor has high flexibility, low bending stress, no deformation, no looseness, creep resistance, etc. Because the material can meet the requirements of high voltage performance, it can meet the low temperature resistance of -40 °C and the high temperature resistance of 105 °C.
高强度橡皮作为护套材料，采用单层结构，在满足高机械性能的情况下能够满足耐气候、半导电要求。The high-strength rubber is used as the sheath material and adopts a single-layer structure, which can meet the requirements of weather resistance and semi-conductivity under the condition of high mechanical properties.
2、特种应用环境对电缆的外径有很高要求，同时为了电缆嵌在定子铁芯上的嵌入部的要求，则需要电缆外径偏差极小的要求。2. The special application environment has high requirements on the outer diameter of the cable, and at the same time, in order to meet the requirements of the embedded part of the cable embedded in the stator core, the requirement of minimum deviation of the outer diameter of the cable is required.
本方法及其制得电缆具有优秀的外径一致性，通过本生产工艺，在产品精度上，电缆导体外径控制偏差±0.1mm，绝缘线芯外径控制偏差±0.2mm，成品电缆外径控制偏差±0.2mm，确保了电缆能 敷设在定子槽中不脱落。The method and the prepared cable have excellent outer diameter consistency. Through the production process, in terms of product accuracy, the control deviation of the outer diameter of the cable conductor is ±0.1mm, the control deviation of the outer diameter of the insulated core is ±0.2mm, and the outer diameter of the finished cable is ±0.2mm. The control deviation is ±0.2mm, which ensures that the cable can be laid in the stator slot without falling off.
附图说明Description of drawings
图1是本实施例电缆的导体径向截面示意图。FIG. 1 is a schematic diagram of a radial cross-sectional view of the conductor of the cable of this embodiment.
图2为本实施例电缆截面结构示意图。FIG. 2 is a schematic diagram of the cross-sectional structure of the cable of this embodiment.
图中：导体内层1、导体中间层2、导体外层3、Z形单丝4、扇形单丝5、S形单丝6、导体7、导体屏蔽层8、绝缘层9、绝缘屏蔽层10、半导电护套层11、半导电纳米涂层12。In the figure: conductor inner layer 1, conductor middle layer 2, conductor outer layer 3, Z-shaped monofilament 4, sector-shaped monofilament 5, S-shaped monofilament 6, conductor 7, conductor shielding layer 8, insulating layer 9, insulating shielding layer 10. Semi-conductive sheath layer 11 , semi-conductive nano-coating layer 12 .
具体实施方式Detailed ways
下面结合附图和具体实施例，对本技术方案进一步说明：Below in conjunction with the accompanying drawings and specific embodiments, the technical solution is further described:
参考附图1和2，本制造方法制得的高精度异形股线小直径电缆，其结构为：导体7以及导体7外包裹的导体屏蔽层8、绝缘层9、绝缘屏蔽层10、半导电护套层11和半导电纳米涂层12构成的电缆。该电缆是用于高速轨道交通的牵引电机的长定子供电。Referring to the accompanying drawings 1 and 2, the high-precision special-shaped strand small-diameter cable obtained by this manufacturing method has a structure as follows: conductor 7 and conductor shielding layer 8 wrapped around conductor 7, insulating layer 9, insulating shielding layer 10, semiconducting A cable composed of a sheath layer 11 and a semiconducting nanocoating 12 . This cable is used to supply power to the long stator of traction motors used in high-speed rail transit.
所述导体7的直径范围是19.5-20.5mm；所述绝缘层9的厚度范围是5.2-5.8mm；所述半导电护套层11的厚度范围是1.8-2.4mm；所述半导电纳米涂层12的厚度范围是5-50μm；The diameter of the conductor 7 is in the range of 19.5-20.5 mm; the thickness of the insulating layer 9 is in the range of 5.2-5.8 mm; the thickness of the semi-conductive sheath layer 11 is in the range of 1.8-2.4 mm; The thickness of layer 12 is in the range of 5-50 μm;
所述导体7的材质是铝合金材质；所述导体屏蔽层8是由半导电氯丁橡胶构成；所述绝缘层9是由乙丙橡胶构成；所述绝缘屏蔽层10是由半导电氯丁橡胶构成；所述半导电护套层11的护套料是半导电氯丁橡胶经挤橡构成；The conductor 7 is made of aluminum alloy; the conductor shielding layer 8 is made of semiconductive neoprene; the insulating layer 9 is made of ethylene propylene rubber; the insulating shielding layer 10 is made of semiconductive neoprene. It is composed of rubber; the sheath material of the semi-conductive sheath layer 11 is composed of semi-conductive neoprene rubber extruded;
导体7由内而外分为第1～n层，n为自然数(本例为3层)；The conductor 7 is divided into layers 1 to n from the inside to the outside, and n is a natural number (three layers in this example);
——对于第1层导体：- for layer 1 conductors:
它由多根成轴对称的扇形单丝绞合构成，绞合的节径比是20～25倍；It is composed of multiple axisymmetric fan-shaped monofilaments twisted, and the twisted pitch ratio is 20 to 25 times;
——对于第2～n层导体7：- For the second to nth layer conductors 7:
它们分别由多个相同的、截面是“Z”字形或“S”字形的单丝相互拼接绞合构成；相邻层导体的单丝绞合方向相反；相邻层导体的单丝是成镜像对称的；They are composed of a plurality of identical monofilaments with a "Z"-shaped or "S"-shaped cross-section, which are spliced and twisted with each other; the stranding directions of the monofilaments of the adjacent conductors are opposite; the monofilaments of the adjacent conductors are mirror images Symmetrical;
任一异形单丝是由铝合金单丝挤压成型。构成各层导体的单丝绞合的节径比是10～18倍，(最外层节径比最小，确保导体紧密、不松散)。Any special-shaped monofilament is extruded from aluminum alloy monofilament. The pitch-to-diameter ratio of the monofilament strands that constitute each layer of conductors is 10 to 18 times, (the outermost layer has the smallest pitch-to-diameter ratio to ensure that the conductors are tight and not loose).
所述导体7是由铝合金杆经拉制、绞合及退火工艺制得的导体。所述导体屏蔽层8是由半导电料(半导电氯丁橡胶)经挤橡连硫工艺制得的屏蔽层。所述绝缘层9是由绝缘料(乙丙橡胶)经挤橡连硫工艺制得的绝缘层。所述绝缘屏蔽层10是由半导电料(半导电氯丁橡胶)经挤橡连硫工艺制得的绝缘屏蔽层。所述半导电护套层11是由护套料(半导电氯丁橡胶)经挤橡连硫工艺制得的护套层。所述半导电纳米涂层12是由半导电胶经喷涂工艺制得的纳米级涂层。The conductor 7 is a conductor made of an aluminum alloy rod by drawing, twisting and annealing. The conductor shielding layer 8 is a shielding layer made of semi-conductive material (semi-conductive chloroprene rubber) through the process of extruding rubber and vulcanizing. The insulating layer 9 is an insulating layer made of insulating material (ethylene propylene rubber) through the process of extruding rubber and vulcanizing. The insulating shielding layer 10 is an insulating shielding layer made of semi-conductive material (semi-conductive chloroprene rubber) through the process of extruding rubber and vulcanizing. The semi-conductive sheath layer 11 is a sheath layer obtained from a sheath material (semi-conductive neoprene) through a process of extruding rubber and vulcanizing. The semi-conductive nano-coating layer 12 is a nano-scale coating made of semi-conductive glue through a spraying process.
本高精度异形股线小直径电缆生产方法制得电缆是用于高速轨道交通的牵引电机的长定子供电。The cable produced by the production method of the high-precision special-shaped strand small-diameter cable is used for power supply of the long stator of the traction motor of the high-speed rail transit.
本高精度异形股线小直径电缆生产方法，包括步骤：1)制造电缆的导体7；2)挤包半导电氯丁橡胶制成导体屏蔽层8；3)挤包乙丙橡胶制成绝缘层9；4)挤包半导电氯丁橡胶制成绝缘屏蔽层10；5)挤包半导电氯丁橡胶制成半导电护套层11；6)涂覆纳米级半导电胶水制成半导电纳米涂层12。The method for producing a high-precision special-shaped strand small-diameter cable includes the following steps: 1) manufacturing a conductor 7 of the cable; 2) extruding semiconducting neoprene rubber to make a conductor shielding layer 8; 3) extruding ethylene-propylene rubber to make an insulating layer 9; 4) The insulating shielding layer 10 is made by extruding semiconducting neoprene; 5) The semiconducting sheath layer 11 is made by extruding semiconducting neoprene; Coating 12.
所述步骤1)包括：Described step 1) comprises:
1.1)预制单丝：1.1) Prefabricated monofilament:
拉丝：将铝合金杆采用相应拉丝模具分别拉制成扇形单丝5、Z形单丝4和S形单丝6；Drawing: The aluminum alloy rod is drawn into fan-shaped monofilament 5, Z-shaped monofilament 4 and S-shaped monofilament 6 by using corresponding wire-drawing dies;
拉丝工艺：将铝杆按道次依次穿入11个拉丝模，将单丝弧面与模孔弧槽相对应，确保铝丝受力稳定，单丝截面无偏差；Wire drawing process: The aluminum rod is passed through 11 wire drawing dies in sequence, and the arc surface of the single wire corresponds to the arc groove of the die hole, so as to ensure the stable force of the aluminum wire and no deviation of the cross section of the single wire;
1.2)取步骤1.1)制得的三种单丝绞合构成导体7，扇形单丝5制成导体内层1；Z形单丝4和S形单丝6依次包裹在导体内层1外；1.2) Three kinds of monofilaments obtained in step 1.1) are twisted to form conductor 7, and sector-shaped monofilament 5 is made into conductor inner layer 1; Z-shaped monofilament 4 and S-shaped monofilament 6 are sequentially wrapped outside conductor inner layer 1;
设导体7自内而外有n层，导体内层1为第1层，n为自然数；相邻层导体的单丝的绞合方向相反；从第2层起，相邻层导体的单丝的断面是成镜像对称的，最终制成第n层导体，得到电缆的导体7；It is assumed that the conductor 7 has n layers from the inside to the outside, the inner layer 1 of the conductor is the first layer, and n is a natural number; the stranding directions of the monofilaments of the adjacent conductors are opposite; from the second layer, the monofilaments of the adjacent conductors The cross section of the cable is mirror-symmetrical, and finally the nth layer conductor is made to obtain the conductor 7 of the cable;
1.3)在金属线材连续退火生产线上，对步骤1.2)制得的电缆导体进行退火处理，其中：加热阶段温度为500℃，加热时间为30～40min；保温阶段温度为500℃，保温时间为3h；降温阶段的降温速度为40℃/h，降温时间为12h；1.3) On the metal wire continuous annealing production line, anneal the cable conductor obtained in step 1.2), wherein: the temperature in the heating stage is 500°C, and the heating time is 30-40min; the temperature in the heat preservation stage is 500°C, and the holding time is 3h ; The cooling rate in the cooling stage is 40℃/h, and the cooling time is 12h;
所述步骤2)～4)是三层共挤工艺实现：The steps 2) to 4) are realized by a three-layer co-extrusion process:
挤包半导电氯丁橡胶的第一挤橡机温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区80～90℃、五区90～100℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；The temperature zone of the first extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100℃; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
挤包乙丙橡胶的第二挤橡机温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区65～75℃、五区75～80℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；The temperature zone of the second extruder for extruding ethylene-propylene rubber is controlled as follows: 50-60°C for the first zone, 55-65°C for the second zone, 65-70°C for the third zone, 65-75°C for the fourth zone, and 75-80°C for the fifth zone ; The first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
挤包半导电氯丁橡胶的第三挤橡机温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、 四区80～90℃、五区90～100℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；The temperature zone of the third extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100℃; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
机头温度设定：110℃；Head temperature setting: 110℃;
挤包过程中，生产时蒸汽压力8～12bar，生产速度5～6m/min，第一挤橡机螺杆转速15～20r/min，第二挤橡机螺杆转速8～12r/min，第三挤橡机螺杆转速8～12r/min；During the extrusion process, the steam pressure during production is 8~12bar, the production speed is 5~6m/min, the screw speed of the first extruder is 15~20r/min, the screw speed of the second extruder is 8~12r/min, and the third extruder screw speed is 8~12r/min. Rubber machine screw speed 8 ~ 12r/min;
在冷水槽中水冷，冷却时间为15min；冷水槽的水温控制为5～10℃。Water cooling in a cold water tank, the cooling time is 15min; the water temperature of the cold water tank is controlled to 5 ~ 10 ℃.
所述步骤5)挤包半导电氯丁橡胶制成半导电护套层11；In the step 5), the semi-conductive chloroprene rubber is extruded to make the semi-conductive sheath layer 11;
对步骤4)制得线缆，在第四挤橡机中挤包半导电氯丁橡胶，第四挤橡机的温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区65～75℃、五区75～80℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；For the cable obtained in step 4), the semi-conductive neoprene rubber is extruded in the fourth rubber extruder, and the temperature zone of the fourth rubber extrusion machine is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, and the third zone is 55-65°C. Zone 65～70℃, zone 4 65～75℃, zone 5 75～80℃; Zone 1 is feeding section, Zone 2 and Zone 3 are plasticizing section, Zone 4 and Zone 5 are homogenizing section;
生产时蒸汽压力7～8bar，生产速度5～6m/min，第四挤橡机螺杆转速18～20r/min；During production, the steam pressure is 7~8bar, the production speed is 5~6m/min, and the screw speed of the fourth extruder is 18~20r/min;
在冷水槽中水冷，冷却时间为20min；冷水槽的水温控制为5～10℃。Water cooling in the cold water tank, the cooling time is 20min; the water temperature of the cold water tank is controlled to 5 ~ 10 ℃.
所述步骤6)在步骤5)制得线缆外，在线涂覆纳米级半导电胶水，涂覆步骤为：电缆在涂覆机上走线，半导电胶进行喷涂，红外加热管进行加热烘干；涂胶时，线缆的线速度是4～5m/min；胶水固化时间为5min。In the step 6), in addition to the cable obtained in step 5), the nanoscale semi-conductive glue is applied online, and the coating step is: the cable is routed on the coating machine, the semi-conductive glue is sprayed, and the infrared heating tube is heated and dried ; When gluing, the linear speed of the cable is 4 ~ 5m/min; the curing time of the glue is 5min.
半导电纳米涂层12的厚度范围是5～50μm，采用红外加热管200摄氏度加热烘干；The thickness of the semi-conductive nano-coating 12 is in the range of 5 to 50 μm, and is heated and dried by an infrared heating tube at 200 degrees Celsius;
1)涂料的配置：采用双组分体系，在涂料中加入固化剂及稀释剂，涂料的粘度控制在15～18秒，采用电压力筒匀速搅拌均匀；1) Coating configuration: adopt a two-component system, add curing agent and diluent to the coating, control the viscosity of the coating within 15-18 seconds, and use an electric pressure cylinder to stir evenly at a uniform speed;
2)涂层厚度的调节：电缆输送速度与喷涂压力同步(电缆输送速度为4～5m/min，喷涂压力为0.8～1MPa)，确保电缆每个面的胶水厚度均匀；2) Adjustment of coating thickness: The cable conveying speed is synchronized with the spraying pressure (the cable conveying speed is 4~5m/min, and the spraying pressure is 0.8~1MPa) to ensure that the glue thickness of each surface of the cable is uniform;
3)烘干温度的控制：红外加热管加热烘干，电缆横截面表面温度均匀一致；3) Control of drying temperature: The infrared heating tube is heated and dried, and the surface temperature of the cross section of the cable is uniform;
4)电缆输送：电缆在喷涂过程中，始终位于喷涂机中央，防止涂层被刮伤，并且厚度均匀。4) Cable conveying: During the spraying process, the cable is always located in the center of the sprayer to prevent the coating from being scratched, and the thickness is uniform.
本例中，导体7共三层(即n＝3)，导体内层1是由4根扇形单丝5制成，导体中间层2是由多根Z形单丝4构成，导体外层3是由多根S形单丝6构成；In this example, there are three layers of conductors 7 (that is, n=3). It is composed of a plurality of S-shaped monofilaments 6;
所述步骤1.1)中，扇形单丝5、Z形单丝4和S形单丝6都是将铝杆按道次依次穿入11个对应的拉丝模，将单丝弧面与模孔弧槽相对应，拉丝机的参数包括：In the step 1.1), the fan-shaped monofilament 5, the Z-shaped monofilament 4 and the S-shaped monofilament 6 all pass the aluminum rods into 11 corresponding wire drawing dies according to the sequence, and the monofilament arc surface and the die hole arc are connected. Corresponding to the groove, the parameters of the wire drawing machine include:
扇形单丝5：定速轮的速比为1.19，成品模直径4.20mm，排线节距0.1mm，拉丝速度8m/s；Fan-shaped monofilament 5: the speed ratio of the constant speed wheel is 1.19, the diameter of the finished die is 4.20mm, the wire pitch is 0.1mm, and the wire drawing speed is 8m/s;
Z形单丝4：定速轮的速比为1.16，成品模直径3.30mm，排线节距0.1mm，拉丝速度10m/s；Z-shaped monofilament 4: The speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.30mm, the wire pitch is 0.1mm, and the wire drawing speed is 10m/s;
S形单丝6：定速轮的速比为1.16，成品模直径3.29mm，排线节距0.1mm，拉丝速度12m/s。S-shaped monofilament 6: The speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.29mm, the wire pitch is 0.1mm, and the wire drawing speed is 12m/s.
所述步骤1.2)中，把三种单丝在绞线机上绞合，绞线机的参数包括：In the described step 1.2), three kinds of monofilaments are twisted on the stranding machine, and the parameters of the stranding machine include:
绞合导体内层1的转速是40～45r/min；绞合导体中间层2的转速是30～35r/min；绞合导体外层3的转速是30～33r/min；The rotational speed of the inner layer 1 of the stranded conductor is 40 to 45 r/min; the rotational speed of the middle layer 2 of the stranded conductor is 30 to 35 r/min; the rotational speed of the outer layer 3 of the stranded conductor is 30 to 33 r/min;
成品的线速度是7～8m/min。The line speed of the finished product is 7-8m/min.
挤包工艺对电缆的成品率有一定影响，经比对，本例制得电缆良品率最高的最优挤包工艺是例2工艺：The extrusion process has a certain influence on the yield of the cable. After comparison, the optimal extrusion process with the highest cable yield in this example is the process of Example 2:
Figure PCTCN2020136651-appb-000001
Figure PCTCN2020136651-appb-000001
Figure PCTCN2020136651-appb-000002
Figure PCTCN2020136651-appb-000002
Figure PCTCN2020136651-appb-000003
Figure PCTCN2020136651-appb-000003
经破坏性解剖实验检测：电缆导体外径控制偏差±0.1mm，绝缘线芯外径控制偏差±0.2mm，成品电缆外径控制偏差±0.2mm，确保了电缆能敷设在定子槽中不脱落。柔软度控制：材料的硬度进行控制，其中绝缘、护套料硬度≤70A。Tested by destructive anatomy experiments: the control deviation of the outer diameter of the cable conductor is ±0.1mm, the control deviation of the outer diameter of the insulated core is ±0.2mm, and the control deviation of the outer diameter of the finished cable is ±0.2mm, which ensures that the cable can be laid in the stator slot without falling off. Softness control: The hardness of the material is controlled, in which the hardness of the insulation and sheath material is ≤70A.
经检测，本电缆的电性能、机械性能的检测全要求如下表，在下表的检测项目中，结果均为合格：After testing, the electrical properties and mechanical properties of this cable are all tested as follows:
Figure PCTCN2020136651-appb-000004
Figure PCTCN2020136651-appb-000004
本发明不限于上述实施例，凡采用等同或等效替换形成的技术方案均落入本发明要求的保护范围。The present invention is not limited to the above-mentioned embodiments, and all technical solutions formed by adopting equivalents or equivalent replacements fall into the protection scope required by the present invention.

Claims (4)

  1. 一种高精度异形股线小直径电缆生产方法，包括步骤：1)制造电缆导体；2)挤包半导电氯丁橡胶制成导体屏蔽层；3)挤包乙丙橡胶制成绝缘层；4)挤包半导电氯丁橡胶制成绝缘屏蔽层；5)挤包半导电氯丁橡胶制成半导电护套层；6)涂覆纳米级半导电胶水制成半导电纳米涂层，其特征是A method for producing a high-precision special-shaped stranded small-diameter cable, comprising the steps of: 1) manufacturing a cable conductor; 2) extruding semiconducting neoprene rubber to make a conductor shielding layer; 3) extruding ethylene-propylene rubber to make an insulating layer; 4) ) extruding semi-conductive chloroprene rubber to make an insulating shielding layer; 5) extruding semi-conducting chloroprene rubber to make a semi-conducting sheath layer; 6) coating nano-scale semi-conductive glue to make a semi-conductive nano-coating, which features Yes
    所述步骤1)包括：Described step 1) comprises:
    1.1)预制单丝：1.1) Prefabricated monofilament:
    拉丝：将铝合金杆采用相应拉丝模具分别拉制成扇形单丝、Z形单丝和S形单丝；Drawing: The aluminum alloy rod is drawn into fan-shaped monofilament, Z-shaped monofilament and S-shaped monofilament by corresponding wire drawing dies;
    拉丝工艺：将铝杆按道次依次穿入11个拉丝模，将单丝弧面与模孔弧槽相对应，确保铝丝受力稳定，单丝截面无偏差；Wire drawing process: The aluminum rod is passed through 11 wire drawing dies in sequence, and the arc surface of the single wire corresponds to the arc groove of the die hole, so as to ensure the stable force of the aluminum wire and no deviation of the cross section of the single wire;
    1.2)取步骤1.1)制得的三种单丝绞合构成导体，1.2) Take the three monofilaments obtained in step 1.1) and twist them to form conductors,
    扇形单丝制成导体内层；Z形单丝和S形单丝依次包裹在导体内层外；The fan-shaped monofilament is made into the inner layer of the conductor; the Z-shaped monofilament and the S-shaped monofilament are sequentially wrapped outside the inner layer of the conductor;
    设导体自内而外有n层，导体内层为第1层，n为自然数；相邻层导体的绞合方向相反；从第2层起，相邻层导体的单丝的断面是成镜像对称的，最终制成第n层导体，得到电缆导体；Suppose the conductor has n layers from the inside to the outside, the inner layer of the conductor is the first layer, and n is a natural number; the twisting directions of the conductors of the adjacent layers are opposite; from the second layer, the cross-section of the monofilament of the conductors of the adjacent layers is a mirror image Symmetrical, and finally the nth layer conductor is made to obtain the cable conductor;
    1.3)在金属线材连续退火生产线上，对步骤1.2)制得的电缆导体进行退火处理，其中：加热阶段温度为500℃，加热时间为30～40min；保温阶段温度为500℃，保温时间为3h；降温阶段的降温速度为40℃/h，降温时间为12h；1.3) On the metal wire continuous annealing production line, anneal the cable conductor obtained in step 1.2), wherein: the temperature in the heating stage is 500°C, and the heating time is 30-40min; the temperature in the heat preservation stage is 500°C, and the holding time is 3h ; The cooling rate in the cooling stage is 40℃/h, and the cooling time is 12h;
    所述步骤2)～4)是三层共挤工艺实现：The steps 2) to 4) are realized by a three-layer co-extrusion process:
    挤包半导电氯丁橡胶的第一挤橡机温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区80～90℃、五区90～100℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；The temperature zone of the first extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100℃; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
    挤包乙丙橡胶的第二挤橡机温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区65～75℃、五区75～80℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；The temperature zone control of the second extruder for extruding ethylene-propylene rubber is: 50-60°C in the first zone, 55-65°C in the second zone, 65-70°C in the third zone, 65-75°C in the fourth zone, and 75-80°C in the fifth zone ; The first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
    挤包半导电氯丁橡胶的第三挤橡机温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区80～90℃、五区90～100℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；The temperature zone of the third extruder extruding semi-conductive chloroprene rubber is controlled as follows: the first zone is 50-60°C, the second zone is 55-65°C, the third zone is 65-70°C, the fourth zone is 80-90°C, and the fifth zone is 90-90°C. 100℃; the first zone is the feeding section, the second and third zones are the plasticizing section, and the fourth and fifth zones are the homogenizing section;
    机头温度设定：110℃Head temperature setting: 110℃
    挤包过程中，生产时蒸汽压力8～12bar，生产速度5～6m/min，第一挤橡机螺杆转速15～20r/min，第二挤橡机螺杆转速8～12r/min，第三挤橡机螺杆转速8～12r/min；During the extrusion process, the steam pressure during production is 8~12bar, the production speed is 5~6m/min, the screw speed of the first extruder is 15~20r/min, the screw speed of the second extruder is 8~12r/min, and the third extruder screw speed is 8~12r/min. Rubber machine screw speed 8 ~ 12r/min;
    在冷水槽中水冷，冷却时间为15min；冷水槽的水温控制为5～10℃；Water cooling in the cold water tank, the cooling time is 15min; the water temperature of the cold water tank is controlled to 5 ~ 10 ℃;
    所述步骤5)挤包半导电氯丁橡胶制成半导电护套层；Described step 5) extruding semi-conductive chloroprene rubber to make semi-conductive sheath layer;
    对步骤4)制得线缆，在第四挤橡机中挤包半导电氯丁橡胶，第四挤橡机的温区控制为：一区50～60℃、二区55～65℃、三区65～70℃、四区65～75℃、五区75～80℃；一区为入料段，二区和三区为塑化段，四区和五区为均化段；For the cable prepared in step 4), the semi-conductive neoprene rubber is extruded in the fourth extruder, and the temperature zone of the fourth extruder is controlled as follows: 50 to 60° C. in the first zone, 55 to 65° C. in the second zone, and 3 Zone 65～70℃, fourth zone 65～75℃, fifth zone 75～80℃; zone one is feeding section, zone two and three are plasticizing section, zone four and five are homogenizing section;
    生产时蒸汽压力7～8bar，生产速度5～6m/min，第四挤橡机螺杆转速18～20r/min；The steam pressure during production is 7~8bar, the production speed is 5~6m/min, and the screw speed of the fourth extruder is 18~20r/min;
    在冷水槽中水冷，冷却时间为20min；冷水槽的水温控制为5～10℃；Water cooling in the cold water tank, the cooling time is 20min; the water temperature of the cold water tank is controlled to 5 ~ 10 ℃;
    所述步骤6)在步骤5)制得线缆外，在线涂覆纳米级半导电胶水，涂覆步骤为：电缆在涂覆机上走线，半导电胶水进行喷涂，红外加热管进行加热烘干；涂胶时，线缆的线速度是4～5m/min；胶水固化时间为5min。In the step 6), in addition to the cable obtained in step 5), the nanoscale semi-conductive glue is applied online, and the coating step is: the cable is routed on the coating machine, the semi-conductive glue is sprayed, and the infrared heating tube is heated and dried ; When gluing, the linear speed of the cable is 4 ~ 5m/min; the curing time of the glue is 5min.
  2. 根据权利要求1所述的高精度异形股线小直径电缆生产方法，其特征是半导电纳米涂层的厚度范围是5～50μm，采用红外加热管加热烘干，加热温度是200℃；The method for producing high-precision special-shaped strand small-diameter cables according to claim 1, wherein the thickness of the semiconductive nano-coating is in the range of 5 to 50 μm, and is heated and dried by an infrared heating tube, and the heating temperature is 200 ° C;
    1)纳米级半导电胶水的粘度为15～18秒；1) The viscosity of the nanoscale semi-conductive glue is 15-18 seconds;
    2)涂层厚度的调节：电缆输送速度与喷涂压力同步，电缆输送速度是4～5m/min，喷涂压力是0.8～1MPa，确保电缆每个面的胶水厚度均匀；2) Adjustment of coating thickness: the cable conveying speed is synchronized with the spraying pressure, the cable conveying speed is 4-5m/min, and the spraying pressure is 0.8-1MPa to ensure that the glue thickness of each surface of the cable is uniform;
    3)烘干温度的控制：红外加热管加热烘干，电缆横截面表面温度均匀一致；3) Control of drying temperature: The infrared heating tube is heated and dried, and the surface temperature of the cross section of the cable is uniform;
    4)电缆输送：电缆在喷涂过程中，始终位于喷涂机中央，防止涂层被刮伤，并且厚度均匀。4) Cable conveying: During the spraying process, the cable is always located in the center of the sprayer to prevent the coating from being scratched, and the thickness is uniform.
  3. 根据权利要求1所述的高精度异形股线小直径电缆生产方法，其特征是导体共三层，导体内层是由4根扇形单丝制成，导体中间层是由多根Z形单丝构成，导体外层是由多根S形单丝构成；The method for producing high-precision special-shaped strand small-diameter cables according to claim 1, characterized in that the conductor has three layers in total, the inner layer of the conductor is made of 4 fan-shaped monofilaments, and the middle layer of the conductor is composed of a plurality of Z-shaped monofilaments The outer layer of the conductor is composed of a plurality of S-shaped monofilaments;
    所述步骤1.1)中，In the step 1.1),
    扇形单丝、Z形单丝和S形单丝都是将铝杆按道次依次穿入11个对应的拉丝模，将单丝弧面与模孔弧槽相对应，拉丝机的参数包括：For fan-shaped monofilament, Z-shaped monofilament and S-shaped monofilament, aluminum rods are passed through 11 corresponding wire drawing dies in sequence, and the arc surface of the monofilament corresponds to the arc groove of the die hole. The parameters of the wire drawing machine include:
    扇形单丝：定速轮的速比为1.19，成品模直径4.20mm，排线节距0.1mm，拉丝速度8m/s；Fan-shaped monofilament: the speed ratio of the constant speed wheel is 1.19, the diameter of the finished die is 4.20mm, the wire pitch is 0.1mm, and the wire drawing speed is 8m/s;
    Z形单丝：定速轮的速比为1.16，成品模直径3.30mm，排线节距0.1mm，拉丝速度10m/s；Z-shaped monofilament: the speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.30mm, the wire pitch is 0.1mm, and the wire drawing speed is 10m/s;
    S形单丝：定速轮的速比为1.16，成品模直径3.29mm，排线节距0.1mm，拉丝速度12m/s；S-shaped monofilament: the speed ratio of the constant speed wheel is 1.16, the diameter of the finished die is 3.29mm, the wire pitch is 0.1mm, and the wire drawing speed is 12m/s;
    所述步骤1.2)中，把三种单丝在绞线机上绞合，绞线机的参数包括：In the described step 1.2), three kinds of monofilaments are twisted on the stranding machine, and the parameters of the stranding machine include:
    绞合导体内层的转速是40～45r/min；绞合导体中间层的转速是30～35r/min；绞合导体外层的转速是30～33r/min；The rotational speed of the inner layer of the stranded conductor is 40-45r/min; the rotational speed of the middle layer of the stranded conductor is 30-35r/min; the rotational speed of the outer layer of the stranded conductor is 30-33r/min;
    成品的线速度是7～8m/min。The line speed of the finished product is 7-8m/min.
  4. 根据权利要求1所述的高精度异形股线小直径电缆生产方法，其特征是所述高精度异形股线小直径电缆生产方法制得电缆是用于高速轨道交通的牵引电机的长定子供电。The method for producing high-precision special-shaped strand small-diameter cables according to claim 1, wherein the cables produced by the high-precision special-shaped small-diameter cable production method are used for long stator power supply of traction motors of high-speed rail transit .
PCT/CN2020/136651 2020-12-07 2020-12-16 Method for producing high-precision special-shaped strand small-diameter cable WO2022120905A1 (en)

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