High-power intelligent temperature control cable

Abstract

The invention, which relates to the technical field of power transmission, discloses a high-power intelligent temperature control cable comprising a conductor, a first insulating layer, a temperature control system, an early warning system and a protective sleeve. The conductor is made of a high-conductivity material, and the conductor is coated with a first insulating layer; the temperature control system comprises a liquid cooling pipe and a plurality of temperature sensors, and cooling liquid is suitable for flowing in the liquid cooling pipe; the early warning system comprises a temperature sensing optical fiber which is distributed along the axial direction of the conductor, and the temperature sensing optical fiber is connected with a fault early warning module; the protection sleeve wraps the conductor, the temperature control system and the temperature sensing optical fiber and comprises an electromagnetic shielding layer, a mechanical protection layer and a safety protection layer. The temperature sensor and the fault early warning module are used for connecting the control unit. The operating temperature of the cable is adjusted in real time through the temperature control system, and thermal fatigue of the conductor is effectively inhibited; high-strength electromagnetic shielding, mechanical tensile strength and bending resistance are provided through the protective sleeve; and the temperature and strain states of the cable are monitored in real time through the early warning system, so that the operation safety is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power transmission, in particular to a high-power intelligent temperature control cable. BACKGROUND

[0002] In high-power cables, temperature control, protection system and fault monitoring are the key to ensure reliable operation. However, existing cable technology usually relies on passive heat dissipation methods (such as natural convection or simple air cooling) and basic insulation and shielding structure, which may lead to the following problems: Dependence on passive heat dissipation or simple air cooling leads to large temperature fluctuations, resulting in accelerated conductor thermal fatigue.

[0003] The electromagnetic shielding, mechanical strength and flame retardant performance of existing cables are difficult to balance, especially in high-frequency electromagnetic interference or extreme mechanical stress environment.

[0004] Conventional cables rely on regular manual detection and lack real-time distributed monitoring capability, which cannot provide early warning of latent defects.

[0005] In view of the above problems, there is an urgent need for a high-power intelligent temperature control cable that integrates efficient temperature control, composite protection and real-time fault monitoring to meet the high reliability requirements in extreme environments. SUMMARY

[0006] To solve the above technical problems, the present application provides a high-power intelligent temperature control cable, and the specific technical scheme is as follows: A high-power intelligent temperature control cable, comprising a conductor, a first insulation layer, a temperature control system, an early warning system and a protective sleeve.

[0007] The conductor is made of high-conductivity material, and the conductor is coated with a first insulation layer.

[0008] The temperature control system comprises a liquid cooling pipe and a plurality of temperature sensors distributed axially along the conductor, and the liquid cooling pipe is adapted to flow cooling liquid.

[0009] The early warning system comprises a temperature sensing optical fiber distributed axially along the conductor, and the temperature sensing optical fiber is connected with a fault early warning module.

[0010] The protective sleeve covers the conductor, temperature control system and temperature sensing optical fiber, and comprises an electromagnetic shielding layer, a mechanical protection layer and a safety protection layer.

[0011] The temperature sensor and the fault early warning module are used to connect a control unit.

[0012] Preferably, the liquid cooling pipe is distributed in a spiral manner; and / or the temperature sensing optical fiber is laid in an S shape.

[0013] Preferably, the conductor is a copper strand or a silver-plated copper strand; and / or the cooling liquid comprises an aqueous ethylene glycol solution; and / or the liquid cooling pipe is made of stainless steel.

[0014] Preferably: The electromagnetic shielding layer comprises an aluminum foil layer, a copper wire braided mesh layer, and a red copper chain armor layer.

[0015] The mechanical protection layer comprises an aramid composite tape layer formed by spirally winding aramid fiber composite tape at an angle of 40-50°.

[0016] The safety protection layer comprises a halogen-free low-smoke flame-retardant sheath layer and a polytetrafluoroethylene sheath layer.

[0017] Preferably: The aluminum foil layer, copper wire braided mesh layer, red copper chain armor layer, aramid composite tape layer, halogen-free low-smoke flame-retardant sheath layer, and polytetrafluoroethylene sheath layer are sequentially fitted from the inside out.

[0018] It also includes a polyester film layer fitted inside the aluminum foil layer, an inner lining protection layer disposed between the copper wire braided mesh layer and the red copper chain armor layer, and a nano-silver heat-conducting paste filled between the polyester film layer and the conductor, temperature control system, and temperature-sensitive optical fiber.

[0019] Preferably: The control unit uses a PID algorithm to dynamically adjust the flow rate or flow of the cooling liquid based on the temperature sensor data.

[0020] The fault warning module uses a Bayesian algorithm to fuse temperature and strain data and generate a fault warning signal by analyzing temperature gradients and impedance spectra.

[0021] Preferably, the temperature control system further comprises a segmented temperature control assembly, and the liquid cooling pipe is coated with a second insulating layer; the segmented temperature control assembly comprises a dielectric layer, a positive electrode strip, a wire, and a negative electrode strip.

[0022] The dielectric layer is provided on the inner wall of the liquid cooling pipe.

[0023] The positive electrode strip is provided on the outer wall of the second insulating layer and is provided with multiple segments along the length direction of the liquid cooling pipe, and each segment of the positive electrode strip is connected to the wire through a thermosensitive semiconductor material, and the wire is connected to the control unit.

[0024] The negative electrode strip is provided on the outer wall of the second insulating layer and is laid along the length direction of the liquid cooling pipe and opposite to the positive electrode strip.

[0025] Preferably, the dielectric layer is a poly-p-xylylene coating prepared by chemical vapor deposition; or the dielectric layer is a preformed polytetrafluoroethylene lining fixed to the inner wall of the liquid cooling pipe by a heat shrink process.

[0026] Preferably, the heat-sensitive semiconductor material is a doped silicon semiconductor; and / or the second insulating layer is a polyimide film coated on the outer wall of the liquid cooling pipe through a heat shrink process; and / or the negative electrode strip is a copper foil.

[0027] Preferably, the prefabricated polytetrafluoroethylene lining is prepared from modified polytetrafluoroethylene, and the preparation process comprises the following steps: The polytetrafluoroethylene powder and the nano-aluminum oxide particles are mixed in a mass ratio of 100: (5-10), and 1-2% of a silane coupling agent based on the total mass of the two is added to form a modified polytetrafluoroethylene mixture.

[0028] The modified polytetrafluoroethylene mixture is prepared after extrusion molding.

[0029] The high-power intelligent temperature control cable provided by the application has the following beneficial effects: 1. Efficient temperature control: The temperature control system adopts liquid cooling pipes and multiple temperature sensors distributed along the conductor axis, combined with flowing coolant, to adjust the cable operating temperature in real time, effectively inhibit conductor thermal fatigue, and improve the current-carrying capacity and service life of the cable.

[0030] 2. Comprehensive protection performance: The protective sleeve includes an electromagnetic shielding layer, a mechanical protection layer, and a safety protection layer, which respectively provide high-strength electromagnetic shielding, mechanical tensile and bending resistance, and flame retardant and chemical corrosion resistance, significantly enhancing the adaptability of the cable in extreme environments (such as high temperature, strong acid and alkali, electromagnetic interference).

[0031] 3. Real-time fault early warning: The early warning system can monitor the temperature and strain state of the cable in real time through the temperature-sensitive optical fiber and fault early warning module distributed along the conductor axis, timely detect latent defects and generate early warning signals, reduce the risk of failure, and improve the operation safety.

[0032] 4. System integration and intelligentization: Through the communication connection between the temperature sensor and the fault early warning module and the control unit, the temperature control and fault monitoring are cooperatively managed, the cable operation efficiency is optimized, and the cable is suitable for high-reliability scenarios such as nuclear power, deep sea, aerospace, and polar exploration. BRIEF DESCRIPTION OF DRAWINGS

[0033] In order to more clearly illustrate the technical solutions in the embodiments of the application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiments or prior art description. Obviously, the drawings in the following description are only some embodiments described in the application, and for those skilled in the art, other drawings can also be obtained without creative labor on the basis of these drawings.

[0034] Figure 1A cross-sectional view of a high-power intelligent temperature control cable according to an embodiment of the present application; Figure 2 A side view of a liquid cooling tube according to another embodiment of the present application.

[0035] Reference signs Conductor First insulating layer Temperature control system; 31-liquid cooling tube; 32-temperature sensor; 33-positive electrode belt; 34-conductor; 35-negative electrode belt Early warning system Protective sleeve; 51-electromagnetic shielding layer; 511-aluminum foil layer; 512-copper wire braid layer; 513-copper chain mail layer; 52-mechanical protection layer; 521-aramid composite belt layer; 53-safety protection layer; 531-halogen-free low-smoke flame-retardant sheath layer; 532-polytetrafluoroethylene sheath layer; 54-polyester film layer; 55-inner lining protection layer; 56-nano-silver heat-conducting paste DETAILED DESCRIPTION

[0036] In order for those skilled in the art to better understand the technical solutions of the present application, the present application will be described in detail below in conjunction with the drawings, and the description in this part is only exemplary and explanatory, and should not have any limiting effect on the protection scope of the present application.

[0037] It should be noted that: similar reference numerals in the following drawings represent similar items, and therefore, once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0038] It should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. indicate the orientation or positional relationship shown in the drawings, or the orientation or positional relationship when the product of the present application is used, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the indicated device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", etc. are only used for differentiation and cannot be understood as indicating or implying relative importance.

[0039] In addition, the terms "horizontal", "vertical", "overhanging", etc. do not mean that the components must be absolutely horizontal or overhanging, but can be slightly inclined. For example, "horizontal" only means that its direction is relatively more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly inclined.

[0040] In the description of the present application, it is also necessary to explain that, unless otherwise explicitly specified and limited, the terms "set", "install", "connect", "connect" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium, or it can be connected inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0041] Please refer to Figure 1 and Figure 2 The present embodiment provides a high-power intelligent temperature control cable, which comprises a conductor 1, a first insulation layer 2, a temperature control system 3, a warning system 4 and a protective sleeve 5.

[0042] The conductor 1 is made of high-conductivity material, and the conductor 1 is coated with the first insulation layer 2.

[0043] The temperature control system 3 comprises a liquid cooling pipe 31 distributed along the axis of the conductor 1 and a plurality of temperature sensors 32, and the liquid cooling pipe 31 is adapted to flow cooling liquid.

[0044] The warning system 4 comprises a temperature sensing optical fiber distributed along the axis of the conductor 1, and the temperature sensing optical fiber is connected with a fault warning module.

[0045] The protective sleeve 5 covers the conductor 1, the temperature control system 3 and the temperature sensing optical fiber, and comprises an electromagnetic shielding layer 51, a mechanical protection layer 52 and a safety protection layer 53.

[0046] The temperature sensor 32 and the fault warning module are used to connect a control unit.

[0047] Wherein, the conductor 1 adopts high conductivity material, such as 99.99% oxygen-free copper or silver-plated copper wire, conductivity ≥58MS / m, to ensure efficient current transmission. The silver plating thickness can be selected from 1 to 5 μm to achieve equipotential connection and reduce contact resistance; the first insulation layer 2 can adopt cross-linked polyethylene or polytetrafluoroethylene, thickness 1-2 mm, to provide electrical insulation and uniformly cover the conductor; the temperature control system 3 includes a liquid cooling pipe 31 and a temperature sensor 32, the liquid cooling pipe 31 can be made of 316L stainless steel or high thermal conductivity polyimide, pipe diameter 1.5-2.5 mm, wall thickness 0.1-0.3 mm; the cooling liquid can be selected from 50% ethylene glycol aqueous solution, silicon oil or low conductivity fluorinated liquid, flow rate 8-15 L / min; the temperature sensor 32 can be selected from PT1000 or thermocouple, accuracy ±0.5℃, one every 0.5-1 m; the temperature sensing optical fiber can adopt single-mode or multi-mode optical fiber, based on Raman scattering principle, spatial resolution 0.1-0.5 m; the fault warning module is based on embedded processor, running Bayesian algorithm, fusing temperature and strain data; the control unit can adopt PLC or embedded controller, communicating with the temperature sensor and the fault warning module through RS485 or CAN bus, running PID and Bayesian algorithms.

[0048] The number of liquid cooling pipes 31 and temperature sensing optical fibers can be multiple, the multiple liquid cooling pipes 31 can be distributed in a spiral along the conductor axis, with a spacing of 10-15 mm to ensure uniform heat dissipation; the temperature sensing optical fiber can be laid in an S shape or a straight line, adhering to the outer wall of the conductor 1 or the liquid cooling pipe 31. The protective sleeve 5 is fitted from the inside out, and the inside can be filled with nano-silver thermal paste (thermal conductivity 5-10 W / m·K) to enhance heat conduction.

[0049] The preparation process can specifically include the following steps: S1. Conductor processing: copper wire is cleaned by ultrasonic wave, silver plated (electroplating or chemical plating), vacuum annealed (300-400℃, 1-3h).

[0050] S2. Insulation layer coating: XLPE uniformly coats the conductor by extrusion molding, curing temperature 150-200℃.

[0051] S3. Liquid cooling pipe integration: laser welding the liquid cooling pipe to the conductor, pressure test (2-4 MPa, 20-40 min), filling cooling liquid.

[0052] S4. Temperature sensing optical fiber laying: S-shaped winding and fixing, interval 0.1-0.5 m, connecting OTDR host.

[0053] S5. Protective sleeve preparation: layer-by-layer winding or extruding electromagnetic shielding layer, mechanical protection layer and safety protection layer, filling thermal paste.

[0054] Specifically, the conductor 1 is used to transmit high-voltage current, the temperature control system 3 dissipates heat through the circulation of cooling liquid (pump set driving) by the liquid cooling pipe 31, the temperature sensor 32 can monitor the temperature in real time, and the data is transmitted to the control unit; the early warning system 4 detects temperature and strain through the temperature sensing optical fiber, and the fault early warning module analyzes the abnormality and generates a warning; the protective sleeve 5 provides electromagnetic, mechanical and chemical protection to ensure the stable operation of the cable in extreme environments (such as -40~120℃).

[0055] The high-power intelligent temperature control cable provided by the embodiment has the following beneficial effects: Efficient temperature control: The temperature control system adopts liquid cooling pipes and multiple temperature sensors distributed along the conductor axis, cooperates with the flowing cooling liquid, can adjust the cable operating temperature in real time, effectively suppresses the conductor thermal fatigue, and improves the current carrying capacity and service life of the cable.

[0056] Comprehensive protection performance: The protective sleeve includes an electromagnetic shielding layer, a mechanical protection layer and a safety protection layer, which respectively provide high-strength electromagnetic shielding, mechanical tensile and bending resistance, and flame retardant and chemical corrosion resistance, significantly enhancing the adaptability of the cable in extreme environments (such as high temperature, strong acid and alkali, electromagnetic interference).

[0057] Real-time fault early warning: The early warning system can monitor the temperature and strain state of the cable in real time through the temperature sensing optical fiber and the fault early warning module distributed along the conductor axis, discover latent defects in time and generate early warning signals, reduce the risk of failure, and improve the operation safety.

[0058] System integration and intelligentization: Through the communication connection of the temperature sensor and the fault early warning module with the control unit, the temperature control and fault monitoring are cooperatively managed, the cable operation efficiency is optimized, and the cable is suitable for high-reliability scenes such as nuclear power, deep sea, aerospace, polar exploration, etc.

[0059] Further, the liquid cooling pipe 31 is spirally distributed; and / or the temperature sensing optical fiber is laid in an S shape.

[0060] The temperature sensing optical fiber can be a high-temperature resistant single-mode optical fiber with a core diameter of 8~10μm and a cladding diameter of 125μm; the liquid cooling pipe 31 can be spirally wound along the conductor 1 in an axial direction, with a pitch of 10~15mm and an angle of 30~60°, to ensure that the cooling liquid uniformly covers the conductor 1 and enhances the heat dissipation efficiency; the spiral can be a single spiral or a double spiral, which can be adjusted according to the heat dissipation requirement; the temperature sensing optical fiber can be laid in an S-shaped curve along the outer wall of the conductor 1 or the liquid cooling pipe 31, with a spacing of 0.1~0.5m, and the fixing method is high-temperature resistant ribbon or adhesive, to ensure high spatial resolution monitoring.

[0061] In preparation, the liquid cooling tube 31 can be fixed around the conductor 1 by an automatic winding device with a set pitch, and the fixed points are laser welded; the temperature sensing fiber can be manually or mechanically S-shapedly wound, and fixed every 0.1-0.5 m with a ribbon, and the terminal is connected to an OTDR host.

[0062] Beneficially, the spiral liquid cooling tube 31 can increase the heat conduction area of the cooling liquid and the conductor, and optimize heat transfer; the S-shaped temperature sensing fiber detects temperature and strain through Raman scattering, and realizes 0.1-0.5 m spatial resolution combined with OTDR technology, thereby improving fault positioning accuracy.

[0063] Further, the conductor 1 is a copper strand or a silver-plated copper strand; and / or the cooling liquid comprises an aqueous ethylene glycol solution; and / or the liquid cooling tube 31 is made of stainless steel.

[0064] Further: The electromagnetic shielding layer 51 comprises an aluminum foil layer 511, a copper wire braid layer 512, and a red copper chain armor layer 513.

[0065] The mechanical protection layer 52 comprises an aramid composite tape layer 521 formed by 40-50° spiral winding of aramid fiber composite tape.

[0066] The safety protection layer 53 comprises a halogen-free low-smoke flame-retardant sheath layer 531 and a polytetrafluoroethylene protective layer 532.

[0067] The aluminum foil layer 511 has a thickness of 0.1-0.3 mm and a shielding effectiveness of 100-120 dB@10 MHz; the copper wire braid layer 512 has a copper wire diameter of 0.1-0.2 mm, a coverage rate of 90%-95%, and a shielding effectiveness of 120-140 dB@10 MHz; the red copper chain armor layer 513 has a thickness of 0.5-1 mm and a shielding effectiveness of 140-150 dB@10 MHz; the aramid fiber composite tape (EPDM substrate) has a thickness of 1-2 mm, a tensile strength of 150-200 MPa, and a bending radius of 4D; the halogen-free low-smoke flame-retardant sheath 531 meets the UL94 V-0 standard, has a smoke density of <100, and has a temperature resistance of -40-120°C; and the polytetrafluoroethylene protective layer 532 has a thickness of 0.5-1 mm and is resistant to strong acid and alkali and ultraviolet aging.

[0068] The layers are sequentially sleeved from the inside to the outside: aluminum foil → copper wire braid → red copper armor → aramid composite tape → halogen-free flame-retardant sheath → PTFE protective layer, and are fixed by conductive adhesive or mechanical pressing between layers.

[0069] The preparation process can comprise: Aluminum foil layer: winding 0.2 mm aluminum foil with a lap rate of 20%-30%.

[0070] Copper wire braid: automatic braiding machine braiding, coverage rate ≥90%.

[0071] Red copper armor: chain type compression molding, ensure the contact resistance ≤0.1Ω.

[0072] Aramid composite tape: 45° spiral winding, winding speed 0.5~1m / min.

[0073] Halogen-free flame-retardant sheath and PTFE sheath: extrusion molding, curing temperature 150~200℃.

[0074] Beneficially, the aluminum foil and copper wire braid provide high-frequency electromagnetic shielding, the red copper armor enhances low-frequency shielding and mechanical strength; the aramid composite tape improves tensile and bending performance, and the halogen-free flame-retardant sheath and PTFE sheath ensure fire safety and chemical stability.

[0075] Further: The aluminum foil layer 511, the copper wire braid layer 512, the red copper chain armor layer 513, the aramid composite tape layer 521, the halogen-free low-smoke flame-retardant sheath layer 531 and the polytetrafluoroethylene sheath layer 532 are sequentially sleeved from inside to outside.

[0076] It also includes a polyester film layer 54 arranged in the aluminum foil layer 511, an inner lining protective layer 55 arranged between the copper wire braid layer 512 and the red copper chain armor layer 513, and a nano-silver heat-conducting paste 56 filled between the polyester film layer 54 and the conductor 1, the temperature control system 3 and the temperature-sensitive optical fiber.

[0077] Among them, the polyester film layer 54 is specifically polyethylene terephthalate (PET) with a thickness of 0.05~0.1mm, providing inner layer insulation; the inner lining protective layer 55 can be made of polyethylene (PE) or polyvinyl chloride (PVC) with a thickness of 0.5~1mm, buffering the mechanical stress between the copper wire braid and the armor; the nano-silver heat-conducting paste 56 has a thermal conductivity of 5~10W / m·K, filling the gap between the conductor 1, the liquid cooling pipe 31 and the temperature-sensitive optical fiber, enhancing heat conduction.

[0078] When arranged, the polyester film layer 54 is tightly attached to the inner side of the aluminum foil layer 511, the inner lining protective layer 55 is located between the copper wire braid and the red copper armor, and the nano-silver heat-conducting paste 56 fills the internal gap, ensuring that heat is quickly transferred to the liquid cooling pipe 31.

[0079] When prepared, the polyester film layer 54 is made by winding 0.05mm PET film with a lap rate of 10%~20%; the inner lining protective layer 55 is made by extrusion molding PE or PVC with uniform thickness; the nano-silver heat-conducting paste 56 can be filled by injection equipment, and the thermal conductivity is tested after curing.

[0080] Further: The control unit adopts PID algorithm to dynamically adjust the cooling liquid flow rate or flow according to the data of the temperature sensor 32.

[0081] The fault early warning module adopts a Bayesian algorithm, fuses temperature and strain data, and generates a fault early warning signal by analyzing temperature gradient and impedance spectrum.

[0082] The control unit can be a PLC or an embedded controller, runs a PID algorithm, has a processing capacity of ≥100 MHz, and has a communication interface of RS485 or CAN; the fault early warning module is an embedded processor, runs a Bayesian algorithm, has a memory of ≥512 MB, and fuses temperature (accuracy ±0.5℃) and strain (accuracy ±5) data; the temperature sensor 32 can be a PT1000, has a resistance of 1000Ω@0℃, and is arranged every 0.5-1 m.

[0083] In arrangement, the temperature sensor 32 is uniformly distributed along the axial direction of the conductor 1, is fixed to the outer wall of the liquid cooling pipe 31 or the conductor 1, and transmits data through an RS485 bus. The fault early warning module is integrated in the control unit or is a separate module, and the temperature sensing fiber terminal is connected to an OTDR host.

[0084] In preparation, the temperature sensor PT1000 is fixed by welding or bonding and is connected to an RS485 bus; the control unit is embedded with a PID algorithm, sets temperature threshold and flow adjustment parameters; and the fault early warning module is programmed with a Bayesian algorithm and calibrates temperature and strain data processing logic.

[0085] The PID algorithm calculates deviation according to temperature sensor data, dynamically adjusts pump group flow (8-15 L / min), and stabilizes cable temperature. The Bayesian algorithm analyzes temperature gradient and impedance spectrum of the temperature sensing fiber, identifies latent defects (such as buffer layer ablation), and generates an early warning signal.

[0086] Further, the temperature control system 3 further comprises a segmented temperature control assembly, and the liquid cooling pipe 31 is wrapped with a second insulation layer; the segmented temperature control assembly comprises a dielectric layer, a positive electrode belt 33, a wire 34, and a negative electrode belt 35.

[0087] The dielectric layer is arranged on the inner wall of the liquid cooling pipe 31.

[0088] The positive electrode belt 33 is arranged on the outer wall of the second insulation layer, is provided with multiple segments along the length direction of the liquid cooling pipe 31, each segment of the positive electrode belt 33 is connected to the wire 34 through a thermosensitive semiconductor material, and the wire 34 is connected to the control unit.

[0089] The negative electrode belt 35 is arranged on the outer wall of the second insulation layer, is laid along the length direction of the liquid cooling pipe 31, and is arranged opposite to the positive electrode belt 33.

[0090] The dielectric layer can be selected from poly-p-xylylene (0.05-0.1 mm in thickness) or polytetrafluoroethylene (0.1-0.2 mm in thickness), and the dielectric strength is greater than 10 kV / mm; the second insulating layer can be selected from a polyimide film, 0.05-0.1 mm in thickness; the positive electrode strip 33 can be a copper foil, 1-3 mm in width, 0.3-0.6 mm in thickness, 0.5-2 m in length, and the thermosensitive semiconductor material is a doped silicon semiconductor; the negative electrode strip 35 can be a copper foil, 0.5-1.5 mm in width, 0.05-0.2 mm in thickness, and grounded; and the wire 34 can be a copper wire, 0.1-0.3 mm in diameter, and the withstand voltage is greater than 500 V.

[0091] In the arrangement, the second insulating layer covers the outer wall of the liquid cooling pipe, the positive electrode strip 33 and the negative electrode strip 35 are arranged in parallel along the axial direction on the insulating layer, the positive electrode strip is segmented (0.5-2 m), and the side part is connected with the thermosensitive semiconductor material. Each segment of the semiconductor is connected with the control unit through the wire 34, and the negative electrode strip 35 is continuously grounded.

[0092] In the preparation, the outer wall of the liquid cooling pipe 31 is heat-shrunk with a PI film (150-200 ℃, 20-30 min); the positive electrode strip 33 is segmented and pasted, the negative electrode strip 35 (copper foil) is continuously pasted, and the wire 34 is welded and then encapsulated with insulating glue.

[0093] When the temperature of a certain segment is greater than 60 ℃, the thermosensitive semiconductor material becomes conductive, the positive electrode strip 33 and the wire 34 are conductive, the control unit applies a voltage of 10-30 V, and an electric field (10-50 V / cm) is formed between the positive and negative electrode strips. The dielectric layer isolates the electric field, triggers the electro-wetting effect, changes the contact angle of the cooling liquid, increases the pipe wall heat exchange area, and enhances the local heat dissipation.

[0094] Further, the dielectric layer is a poly-p-xylylene coating prepared by chemical vapor deposition; or the dielectric layer is a pre-prepared polytetrafluoroethylene lining fixed to the inner wall of the liquid cooling pipe 31 by a heat-shrinking process.

[0095] Further, the thermosensitive semiconductor material is a doped silicon semiconductor; and / or the second insulating layer is a polyimide film, which is wrapped on the outer wall of the liquid cooling pipe 31 by a heat-shrinking process; and / or the negative electrode strip 35 is a copper foil.

[0096] Further, the pre-prepared polytetrafluoroethylene lining is prepared from modified polytetrafluoroethylene, and the preparation process includes the following steps: The polytetrafluoroethylene powder and the nano-aluminum oxide particles are mixed in a mass ratio of 100:(5-10), and 1%-2% of a silane coupling agent is added to the total mass of the two, and stirred to form a modified polytetrafluoroethylene mixture.

[0097] The modified polytetrafluoroethylene mixture is prepared by extrusion molding.

[0098] Beneficially, nano-alumina can improve the thermal conductivity of PTFE, and silane coupling agent can enhance the adhesion to the inner wall of stainless steel; plasma treatment activates the surface, further improves the bonding strength, and ensures long-term operation without peeling.

[0099] The following provides specific examples, which can make those skilled in the art more fully understand the present application, but in no way limit the present application.

[0100] Examples Copper material wire drawing (wire speed 10 m / s, 6 mm diameter), cleaning (ultrasonic wave, 40 kHz, 10 min); silver electroplating (50 g / L silver sulfate, 3.2 A / dm 2 , 25℃, 15 min), coating thickness 3.1 μm; vacuum annealing (350℃, 2h, heating rate 5℃ / min). XLPE particles (5 kg) are added to the extruder (180℃, screw 50 rpm), extruded to a thickness of 1.52 mm, cooled in a water tank (20℃, 5 min). 316L stainless steel tube (3, Φ2.0 mm, wall thickness 0.2 mm) is laser welded (2 kW, speed 1 m / min) to the conductor, with a spiral spacing of 12.3 mm and an angle of 45°; 50% ethylene glycol aqueous solution (10 L) is injected, and pressure testing (3.02 MPa, 30 min, no leakage) is performed. PT1000 sensors (10) are bonded to the outer wall of the liquid-cooled tube (spacing 1.01 m) and connected to the RS485 bus. Single-mode optical fiber (12 m) is wrapped in an S shape and fixed with high-temperature-resistant tape, and the terminal is connected to the OTDR host. Wrap 0.05 mm polyester film, 0.2 mm aluminum foil; copper wire weaving (0.15 mm), red copper armor (0.5 mm); aramid composite tape (1.5 mm, 45° winding, speed 0.82 m / min); extruded halogen-free flame-retardant sheath (180℃, 3 kg) and PTFE sheath (0.5 mm, 2 kg); fill nano-silver thermal paste (0.5 kg, injection pressure 0.1 MPa).

[0101] PLC burns PID algorithm (target temperature 40℃, proportional coefficient Kp=0.8, integral time Ti=10s), connected to the RS485 bus; burn Bayesian algorithm, calibrate temperature (±0.5℃) and strain (±5με) threshold.

[0102] At an ambient temperature of 25.3℃, use an infrared thermal imager and a thermocouple temperature meter to test the temperature rise, run the cable at 1200A load for 1h, record the liquid-cooled tube inlet (T1) / outlet (T2) temperature and the conductor surface temperature (T3); calculate the temperature rise: ΔT = max(T3) - 25.3℃; measure the temperature distribution at 5 points (0m, 2.5m, 5m, 7.5m, 10m), and calculate the standard deviation σ.

[0103] Simulate local temperature rise (60℃, 5cm area), record OTDR signal positioning accuracy, test 5 times, take average value.

[0104] Simulate local temperature rise (65℃) and strain mutation (100με), record the time of generating early warning signal by Bayesian algorithm, test 5 times, take average value.

[0105] Test data is shown in the following table: Comparative example Copper material drawing (wire speed 10m / s, 6mm diameter), ultrasonic cleaning (40kHz, 10min); vacuum annealing (350℃, 2h, heating rate 5℃ / min), no silver plating treatment; XLPE particles (5kg) are added to the extruder (180℃, 50rpm), the extrusion thickness is 1.51mm, cooling water tank (20℃, 5min); copper wire weaving (0.15mm); extrusion halogen-free flame-retardant sheath (180℃, 3kg, screw 60rpm).

[0106] Temperature rise and temperature uniformity test method is the same as the example, test data is shown in the following table: It should be noted that in this text, the term "includes", "contains" or any other variant thereof is intended to cover non-exclusive inclusion, so that the process, method, article or equipment including a series of elements not only includes those elements, but also includes other elements not explicitly listed, or includes elements inherent to such process, method, article or equipment.

[0107] The principles and implementation modes of the present application are described by applying specific examples in this text, and the above example description is only used to help understand the method of the present application and its core idea. The above is only the preferred embodiment of the present application, it should be pointed out that due to the limitation of language expression, there are infinite specific structures objectively, for ordinary skilled person in the art, on the premise of not departing from the principle of the present application, can make several improvements, decoration or changes, also can combine the above technical features in appropriate way; these improvements, decoration, changes or combinations, or without improvement, directly apply the concept and technical scheme of the present application to other occasions, should be regarded as the protection scope of the present application.

Claims

1. A high power intelligent temperature control cable, characterized in that, It comprises: a conductor (1) made of high-conductivity material, which is coated with a first insulation layer (2); a temperature control system (3) comprising liquid cooling pipes (31) and a plurality of temperature sensors (32) distributed axially along the conductor (1), the liquid cooling pipes (31) being adapted to flow cooling liquid; a pre-warning system (4) comprising temperature sensing optical fibers distributed axially along the conductor (1), the temperature sensing optical fibers being connected with a fault pre-warning module; a protective sleeve (5) covering the conductor (1), the temperature control system (3) and the temperature sensing optical fibers, the protective sleeve (5) comprising an electromagnetic shielding layer (51), a mechanical protection layer (52) and a safety protection layer (53); the temperature sensors (32) and the fault pre-warning module being used to connect a control unit.

2. The high-power intelligent temperature control cable according to claim 1, wherein: the liquid cooling pipes (31) are distributed in a spiral manner; and / or the temperature sensing optical fibers are laid in an S shape.

3. The high-power intelligent temperature control cable according to claim 1, wherein: the conductor (1) is a copper strand or a silver-plated copper strand; and / or the cooling liquid comprises an aqueous ethylene glycol solution; and / or the liquid cooling pipes (31) are made of stainless steel.

4. The high-power intelligent temperature control cable according to claim 1, wherein: the electromagnetic shielding layer (51) comprises an aluminum foil layer (511), a copper wire braided mesh layer (512) and a red copper interlocking armor layer (513); the mechanical protection layer (52) comprises an aramid composite tape layer (521) formed by 40-50° spiral winding of aramid fiber composite tape; the safety protection layer (53) comprises a halogen-free low-smoke flame-retardant sheath layer (531) and a polytetrafluoroethylene sheath layer (532).

5. The high-power intelligent temperature control cable according to claim 4, wherein: the aluminum foil layer (511), the copper wire braided mesh layer (512), the red copper interlocking armor layer (513), the aramid composite tape layer (521), the halogen-free low-smoke flame-retardant sheath layer (531) and the polytetrafluoroethylene sheath layer (532) are successively sleeved from inside to outside; further comprising a polyester film layer (54) attached to the inside of the aluminum foil layer (511), an inner lining protection layer (55) arranged between the copper wire braided mesh layer (512) and the red copper interlocking armor layer (513), and a nano-silver heat-conducting paste (56) filled between the polyester film layer (54) and the conductor (1), the temperature control system (3) and the temperature sensing optical fibers.

6. The high-power intelligent temperature control cable according to any one of claims 1 to 5, wherein: the control unit adopts a PID algorithm to dynamically adjust the flow rate or flow volume of the cooling liquid according to the data of the temperature sensors (32); the fault pre-warning module adopts a Bayesian algorithm to fuse temperature and strain data and generate a fault pre-warning signal by analyzing temperature gradient and impedance spectrum.

7. The high power intelligent temperature controlled cable of claim 1, wherein, The temperature control system (3) further comprises a segmented temperature control assembly, and the liquid cooling pipes (31) are coated with a second insulation layer; the segmented temperature control assembly comprises: a dielectric layer arranged on the inner wall of the liquid cooling pipes (31); A positive electrode strip (33) is arranged on the outer wall of the second insulation layer and is arranged in multiple sections along the length direction of the liquid cooling pipe (31). Each section of the positive electrode strip (33) is connected to a wire (34) through a thermosensitive semiconductor material, and the wire (34) is connected to the control unit. A negative electrode strip (35) is arranged on the outer wall of the second insulation layer and is arranged along the length direction of the liquid cooling pipe (31) and opposite to the positive electrode strip (33).

8. The high-power intelligent temperature control cable according to claim 7, characterized in that: the dielectric layer is a poly-p-xylylene coating prepared by chemical vapor deposition; or the dielectric layer is a prefabricated polytetrafluoroethylene lining fixed to the inner wall of the liquid cooling pipe (31) through a heat shrink process.

9. The high-power intelligent temperature control cable according to claim 7, characterized in that: the thermosensitive semiconductor material is a doped silicon semiconductor; and / or the second insulation layer is a polyimide film coated on the outer wall of the liquid cooling pipe (31) through a heat shrink process; and / or the negative electrode strip (35) is a copper foil.

10. The high power intelligent temperature controlled cable of claim 8, wherein, The prefabricated polytetrafluoroethylene lining is prepared from modified polytetrafluoroethylene, and the preparation process includes the following steps: polytetrafluoroethylene powder and nano-aluminum oxide particles are mixed in a mass ratio of 100:(5-10), and 1%-2% of the total mass of the two is added to a silane coupling agent, and stirred to form a modified polytetrafluoroethylene mixture; the modified polytetrafluoroethylene mixture is formed by extrusion molding.

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