Preparation process of overhead line with intelligent monitoring and lightning protection function

Abstract

The application discloses an overhead line with intelligent monitoring and lightning protection functions and a preparation process thereof, and belongs to the technical field of cables. The overhead line adopts an integrated layered structure of a conductor core-insulation layer-lightning protection layer-protection cover, a monitoring module is embedded between the insulation layer and the lightning protection layer, and a signal transmission unit is matched. The conductor core is a copper alloy stranded wire with added silver and tin elements, and the stranded wire has both electric conductivity and corrosion resistance; the insulation layer is made of cross-linked polyethylene material containing a flame retardant and an anti-aging agent, and weather resistance is improved; the lightning protection layer is a galvanized steel stranded wire spirally wound and filled with silicone insulation sealant, and efficient lightning protection and waterproof are realized; the monitoring module integrates temperature, humidity, tension and lightning stroke detection sensors; the signal transmission unit supports LoRa / Wi-Fi dual-mode communication and GPS / Beidou dual-mode positioning, and can transmit monitoring data and fault positioning information in real time; and the protection cover is provided with anti-skid textures and drainage grooves, and environmental adaptability is enhanced.

Description

Technical Field

[0001] This invention relates to the field of cable technology, specifically to an overhead line with intelligent monitoring and lightning protection functions and its manufacturing process. Background Technology

[0002] Overhead lines, as the core carrier of electrical energy transmission in power systems, are widely distributed in complex natural environments such as plains, mountains, and coastlines. Their operating status directly determines the stability of power supply. However, existing overhead lines still face many technical bottlenecks in practical applications: In terms of conductivity and structural performance, traditional conductor cores mostly adopt a single copper alloy stranded structure, making it difficult to balance conductivity and mechanical strength. During long-term operation, they are prone to deformation due to thermal expansion and contraction, and their fatigue resistance is insufficient, affecting the service life of the line. At the same time, the conductor core lacks the ability to adapt to extreme temperatures, resulting in poor heat dissipation under high-temperature overload and susceptibility to fracture due to material embrittlement in low-temperature environments.

[0003] In terms of insulation protection, existing insulation layers are mostly single-material structures, with flame retardancy, thermal conductivity and anti-aging properties mutually restricting each other. Moreover, once defects such as cracks appear, they cannot repair themselves, which can easily lead to insulation breakdown accidents. In addition, rainwater and moisture can easily seep into the gap between the insulation layer and the outer structure, accelerating the corrosion of internal components and further reducing insulation reliability.

[0004] In terms of lightning protection, traditional overhead lines mostly rely on independent lightning rods or single lightning protection grounding wires, which have limited protection range and high installation costs. When lightning strikes, the lightning current is concentrated and conducted through the line, which can easily cause instantaneous high voltage impact on the conductor core and insulation layer. Furthermore, there is a lack of effective lightning energy dissipation mechanisms and event recording functions, making it difficult to optimize and adjust lightning protection strategies.

[0005] In terms of intelligent monitoring, existing monitoring systems are mostly externally installed, with low integration and susceptibility to environmental interference. They also have limited monitoring parameters, only able to collect basic data such as temperature and humidity, and cannot accurately capture key hidden danger signals such as partial discharge, ice thickness, and light wind vibration. At the same time, data transmission relies on a single communication mode, which is prone to signal interruption in remote mountainous areas or extreme weather conditions. Furthermore, the power supply system mostly relies on a single lithium battery or solar energy, which has insufficient endurance and cannot meet the needs of long-term stable monitoring.

[0006] In terms of the performance of protective jackets, traditional protective jacket materials are not weather-resistant or hydrophobic enough, and the surface structure design is unreasonable, which can easily lead to problems such as ice adhesion and water accumulation. In addition, they lack visual early warning functions, making it difficult for inspection personnel to quickly detect abnormal operating conditions of the lines.

[0007] Therefore, developing an overhead line and its manufacturing process that integrates high-efficiency conductivity, adaptive structural adjustment, intelligent and precise monitoring, multiple lightning protection, long-term insulation protection and environmental response functions has become the key to solving the pain points of existing technologies. Summary of the Invention

[0008] In view of the shortcomings of the prior art, the purpose of this invention is to overcome the deficiencies of the prior art and provide an overhead line with intelligent monitoring and lightning protection functions and its manufacturing process. Through material innovation, structural optimization and process upgrade, it improves the conductivity, mechanical strength and extreme temperature adaptability of the conductor core, and extends the service life of the line; strengthens the flame retardant, thermal conductivity, anti-aging and self-healing functions of the insulation layer, and reduces the risk of failure caused by insulation defects; constructs a multi-layer lightning protection system to realize the graded diversion and dissipation of lightning energy and accurately record lightning events; realizes multi-dimensional and high-precision monitoring of the line operation status and stable data transmission across the entire domain, supporting proactive early warning and intelligent decision-making; and optimizes the weather resistance, anti-slip and drainage performance and visual early warning capabilities of the protective jacket to adapt to complex outdoor environments.

[0009] The present invention provides an overhead line with intelligent monitoring and lightning protection functions, comprising, from the inside out, a conductor core, an insulation layer, a lightning protection layer and a protective jacket;

[0010] A monitoring module is embedded between the insulation layer and the lightning protection layer;

[0011] The monitoring module is electrically connected to a signal transmission unit;

[0012] The lightning protection layer has lightning energy dissipation units embedded in it at intervals, and the protective outer jacket integrates auxiliary power supply components and an environmental response structure on its surface; wherein:

[0013] The conductor core adopts a layered stranding structure with a tightly stranded inner layer and a loosely stranded outer layer;

[0014] A nickel-titanium shape memory alloy wire with a diameter of 0.3-0.5 mm is embedded in the center of the conductor core;

[0015] The lightning protection layer includes a primary lightning protection layer and a secondary lightning protection layer. The secondary lightning protection layer is a graphene-modified zinc oxide conductive coating applied to the outside of the insulation layer, with a thickness of 0.1-0.2 mm. The primary lightning protection layer is a galvanized steel strand spirally wound around the outside of the secondary lightning protection layer, using a hot-dip galvanizing + passivation process. The galvanized layer has a thickness of 0.2-0.3 mm, and the surface is coated with a 0.05 mm thick chromate passivation film. Each strand of the steel strand has a diameter of 1.2-1.4 mm, and the winding density is 4-5 turns per meter. The spaces between the steel strands are filled with silicone insulating sealant with a temperature resistance range of -40℃ to 120℃.

[0016] The lightning energy dissipation unit is a miniature zinc oxide varistor, embedded every 50-100m, with a volume of 10mm×5mm×3mm, and connected in parallel with galvanized steel strand.

[0018] Furthermore, it is made of copper-silver-tin-zirconium quaternary alloy wires stranded together. The copper-silver-tin-zirconium quaternary alloy wires contain 0.8-1.2% silver, 0.4-0.7% tin, and 0.05-0.1% zirconium. The inner alloy wire has a diameter of 0.9-1.1 mm and a stranding pitch of 8-10 times the conductor core diameter. The outer alloy wire has a diameter of 1.0-1.2 mm and a stranding pitch of 12-15 times the conductor core diameter.

[0019] Furthermore, the insulation layer adopts a gradient structure design with a total thickness of 3-5mm. The inner layer is a soft cross-linked polyethylene composite material with a thickness of 1-2mm and a Shore hardness of 60-70A, and the outer layer is a hard cross-linked polyethylene composite material with a thickness of 2-3mm and a Shore hardness of 85-90A.

[0020] Furthermore, the signal transmission unit includes a lithium iron phosphate battery, a communication module, and a positioning module. The lithium battery has a capacity of not less than 800mAh and supports multi-energy complementary power supply of solar energy, thermoelectric power generation, and piezoelectric power generation.

[0021] Furthermore, the communication module supports adaptive switching between LoRa / Wi-Fi / NB-IoT three modes and is compatible with 5G network upgrades; the positioning module adopts GPS / BeiDou / GLONASS three-star dual-mode positioning, integrates BeiDou timing function, with positioning accuracy of ±1m and time synchronization error ≤1ms.

[0022] Furthermore, the protective jacket is made of a blend of polyvinyl chloride and polytetrafluoroethylene, with polytetrafluoroethylene accounting for 15-20% and a thickness of 2-3mm. The surface is equipped with a biomimetic serrated anti-slip texture (tooth height 0.5-1mm, tooth pitch 2-3mm) and a spiral bidirectional drainage channel (spiral angle 30°). The bottom of the drainage channel has 0.1mm diameter ventilation holes, 10-15 per meter.

[0023] Furthermore, the protective jacket is coated with a thermosensitive color-changing coating, which turns red when the temperature is below 0°C and yellow when the temperature is above 80°C.

[0024] Furthermore, auxiliary power supply components include a flexible thermoelectric generator (output power 5-10mW) integrated on the surface of the protective jacket and a piezoelectric generator (output power 10-20mW) embedded in the galvanized steel strands of the lightning protection layer.

[0025] Furthermore, 10-15% of nano-magnesium hydroxide flame retardant, 3-5% of carbon nanotube thermally conductive filler, 2-4% of polydimethylsiloxane anti-aging agent, and 5-8% of microcapsule self-healing agent are added to both soft cross-linked polyethylene composites and hard cross-linked polyethylene composites.

[0026] Furthermore, the monitoring module includes a temperature sensor, a humidity sensor, a tension sensor, a lightning strike detection sensor, a partial discharge sensor, an icing thickness sensor, and a micro-wind vibration sensor.

[0027] The detection accuracies of each sensor are as follows: temperature ±0.2℃, humidity ±2%RH, tension ±0.5%FS, lightning voltage ±2kV, partial discharge ±5pC, icing thickness ±0.1mm, and aerobatic vibration ±5g.

[0028] The monitoring module has a built-in ARM Cortex-M4 processor, integrates Kalman filtering algorithm and random forest machine learning algorithm, and adopts an adaptive sampling mechanism of timed sampling + event-triggered sampling.

[0029] Furthermore, the sensors of the monitoring module are connected to the signal transmission unit via shielded wires. The shielding layer of the shielded wires adopts a copper mesh braided structure, with a shielding effectiveness of ≥80dB.

[0030] Furthermore, the solar power supply component of the signal transmission unit is equipped with a micro solar panel with a conversion efficiency of not less than 25%.

[0031] Furthermore, the core components of the microcapsule-type self-healing agent are bisphenol A epoxy resin and a latent curing agent. The microcapsule diameter is 50-100μm. When cracks with a width of ≤0.5mm appear in the insulation layer, more than 80% of the cracks can be repaired within 24 hours.

[0032] Furthermore, the clamping voltage of the lightning energy dissipation unit is stabilized within 10kV, converting excess lightning energy into heat energy for dissipation, and recording lightning energy data.

[0033] Furthermore, the signal transmission unit is connected to the cloud management platform, which adopts a distributed storage architecture, supports blockchain data encryption and traceability, integrates big data analysis and AI diagnostic models, and can realize trend prediction, fault diagnosis, global optimization and remote parameter configuration functions.

[0034] Furthermore, the nickel-titanium shape memory alloy wire shrinks when the conductor temperature exceeds 70°C and expands when it is below -20°C, thus achieving adaptive adjustment of the conductor core's thermal expansion and contraction.

[0035] Furthermore, the graphene-modified zinc oxide conductive coating of the secondary lightning protection layer has nonlinear volt-ampere characteristics, directly diverting current during low-energy lightning strikes and forming a parallel current diversion channel with the primary lightning protection layer during high-energy lightning strikes.

[0036] A manufacturing process for an overhead power line with intelligent monitoring and lightning protection functions includes the following steps:

[0037] S1. Conductor core preparation: First, copper, silver, tin, and zirconium raw materials are melted in proportion and continuously cast and rolled into copper-silver-tin-zirconium quaternary alloy wires. The inner alloy wire and the outer alloy wire are drawn separately. The nickel-titanium shape memory alloy wire is threaded into the center of the pay-off frame. The inner alloy wire is tightly twisted around the nickel-titanium shape memory alloy wire with a twisting pitch of 8-10 times the conductor core diameter. Then, the outer alloy wire is loosely twisted on the outside of the inner layer with a twisting pitch of 12-15 times the conductor core diameter to form a layered stranded conductor core.

[0038] S2. Insulation layer molding: A double-layer co-extrusion process is adopted. The inner layer is made of soft cross-linked polyethylene composite material with added flame retardants, thermally conductive fillers, anti-aging agents and self-healing agents. A soft insulation layer with a thickness of 1-2 mm is extruded on the outside of the conductor core. The outer layer is made of hard cross-linked polyethylene composite material with the same formula. A hard insulation layer with a thickness of 2-3 mm is extruded on the outside of the soft insulation layer. The extrusion temperature is controlled at 120-150℃. After cooling, a gradient structure insulation layer is obtained.

[0039] S3, Secondary lightning protection layer coating: Using electrostatic spraying process, graphene-modified zinc oxide conductive slurry is evenly coated on the outside of the insulation layer. The spraying thickness is controlled at 0.1-0.2mm. After drying and curing at 80-100℃ for 30-60 minutes, a secondary lightning protection layer is formed.

[0040] S4. Installation of monitoring module and signal transmission unit: Pre-set mounting grooves on the surface of the secondary lightning protection layer, embed the monitoring module and signal transmission unit after the shielded wires are connected into the mounting grooves, and seal and fix them with silicone insulating sealant.

[0041] S5. Primary lightning protection layer winding and energy dissipation unit assembly: Galvanized steel strands that have undergone hot-dip galvanizing and passivation treatment are spirally wound around the outside of the secondary lightning protection layer at a winding density of 4-5 turns per meter. During the winding process, miniature zinc oxide varistors are connected in parallel with the galvanized steel strands every 50-100m. At the same time, silicone insulating sealant is filled into the gaps between the steel strands. After compaction, the primary lightning protection layer is formed.

[0042] S6. Auxiliary power supply component integration: The flexible thermoelectric generator is fixed to the prefabricated mounting surface of the protective jacket by adhesive bonding process, and the piezoelectric generator is embedded in the pre-set slot of galvanized steel strand, and is electrically connected to the lithium battery of the signal transmission unit through wires respectively.

[0043] S7. Protective jacket molding: Polyvinyl chloride and polytetrafluoroethylene are mixed and melted in proportion, and a protective jacket with a thickness of 2-3mm is extruded on the outside of the primary lightning protection layer through an extrusion process. During the extrusion process, biomimetic sawtooth anti-slip texture and spiral bidirectional drainage groove are pressed simultaneously. Ventilation holes are reserved at the bottom of the drainage groove. Finally, a thermosensitive color-changing coating is applied to the surface of the protective jacket using a spraying process. After natural cooling, the finished product is obtained.

[0044] Furthermore, in step S1, the alloy melting temperature is 1100-1200℃, and the continuous casting and rolling speed is 5-8m / min;

[0045] In step S3, the solid content of the graphene-modified zinc oxide conductive slurry is 60-70%, and the spraying voltage is 50-80kV.

[0046] In step S7, the melting temperature of the polyvinyl chloride and polytetrafluoroethylene mixture is 160-180℃, the extrusion speed is 3-5m / min, and the spraying thickness of the thermosensitive color-changing coating is 0.05-0.1mm.

[0047] Compared with the prior art, the present invention has the following significant advantages:

[0048] 1. By adopting a copper-silver-tin-zirconium quaternary alloy and a layered stranded structure, combined with the adaptive adjustment of nickel-titanium shape memory alloy wire, high conductivity is ensured while tensile strength and fatigue life are improved, achieving a perfect balance between conductivity, mechanical strength and extreme temperature adaptability.

[0049] 2. The gradient structure design and the application of composite modified materials enable the insulation layer to simultaneously possess excellent flexibility, damage resistance, flame retardancy, thermal conductivity and aging resistance. Microcapsule self-healing technology can effectively repair micro-cracks, extend the service life of the insulation layer and significantly reduce the risk of insulation failure.

[0050] 3. The collaborative design of the dual-level lightning protection layer and the lightning energy dissipation unit realizes the graded diversion, dispersion and dissipation of lightning energy. At the same time, it can accurately record lightning event data, providing support for the optimization of lightning protection strategies and solving the pain points of traditional lightning protection measures, such as limited protection range and lack of energy dissipation and recording functions.

[0051] 4. The integration of multi-dimensional sensor arrays and edge computing algorithms enables full-parameter, high-precision monitoring and intelligent hierarchical early warning of line operation status. The three-mode adaptive communication and multi-energy complementary power supply system ensure full coverage of data transmission and long-term stable operation of equipment, and improve fault location accuracy.

[0052] 5. The blend of polyvinyl chloride and polytetrafluoroethylene and the biomimetic structural design give the protective jacket super hydrophobicity, anti-slip properties and weather resistance. The icing adhesion strength is reduced and the temperature-sensitive color-changing coating enables visual early warning of faults, which significantly improves the operational safety of the line in complex outdoor environments.

[0053] 6. The cloud-edge-device integrated collaborative system realizes intelligent processing of the entire process from data collection, transmission, storage to analysis, decision-making and optimization. It can predict fault risks in advance, reduce operation and maintenance costs, and provide core technical support for the construction of smart grids. Attached Figure Description Figure 1This is a schematic diagram of the cable structure in Example 1; Figure 2 This is a schematic diagram of the specific structure of the lightning protection layer in Example 1. Detailed Implementation

[0054] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, unless otherwise specified, the following embodiments and features described therein can be combined with each other.

[0055] This embodiment provides an overhead line with intelligent monitoring and lightning protection functions, which includes, from the inside out, a conductor core, an insulation layer, a lightning protection layer, and a protective jacket. A monitoring module is embedded between the insulation layer and the lightning protection layer. The monitoring module is electrically connected to a signal transmission unit. Lightning energy dissipation units are embedded in the lightning protection layer at intervals. The surface of the protective jacket integrates auxiliary power supply components and an environmental response structure. All components work together to achieve integrated functions of conductivity, insulation, lightning protection, monitoring, power supply, and protection.

[0056] The conductor core employs a layered stranded structure with a tightly stranded inner layer and a loosely stranded outer layer, composed of copper-silver-tin-zirconium quaternary alloy wires. The copper-silver-tin-zirconium quaternary alloy wires contain 0.8-1.2% silver, 0.4-0.7% tin, and 0.05-0.1% zirconium, with the balance being copper. Silver enhances conductivity, tin strengthens corrosion resistance, and zirconium refines the alloy grains to improve mechanical strength and fatigue resistance. The inner alloy wire has a diameter of 0.9-1.1 mm, with a stranding pitch 8-10 times the conductor core diameter to ensure a stable conductive path and reduce current loss. The outer alloy wire has a diameter of 1.0-1.2 mm, with a stranding pitch 12-15 times the conductor core diameter, allowing space for thermal expansion and contraction to prevent structural deformation under extreme temperatures. A nickel-titanium shape memory alloy wire with a diameter of 0.3-0.5mm is embedded in the center of the conductor core. When the conductor temperature exceeds 70°C, the nickel-titanium shape memory alloy wire contracts, causing the outer copper alloy wire to tighten to reduce the heat dissipation gap and improve heat dissipation efficiency; when the temperature is below -20°C, it expands to increase the gap and reduce the probability of ice adhesion, thus realizing the adaptive adjustment of the thermal expansion and contraction of the conductor core.

[0057] Insulation layer: Utilizing a gradient structure design with a total thickness of 3-5mm, balancing flexibility and protection. The inner layer is a 1-2mm thick soft cross-linked polyethylene composite material with a Shore hardness of 60-70A, possessing excellent flexibility and capable of absorbing stress during conductor core stranding. The outer layer is a 2-3mm thick hard cross-linked polyethylene composite material with a Shore hardness of 85-90A, exhibiting outstanding scratch and compression resistance, and able to withstand external mechanical damage. Both the soft and hard cross-linked polyethylene composite materials contain 10-15% nano-magnesium hydroxide flame retardant, 3-5% carbon nanotube thermally conductive filler, 2-4% polydimethylsiloxane anti-aging agent, and 5-8% microencapsulated self-healing agent. Nano-magnesium hydroxide flame retardant forms a flame-retardant barrier, improving the flame retardant rating of the insulation layer; carbon nanotube thermally conductive filler constructs a thermally conductive network, rapidly conducting heat from the conductor core and preventing localized overheating; polydimethylsiloxane anti-aging agent isolates ultraviolet and ozone corrosion, extending the service life of the insulation layer; the core components of the microcapsule-type self-healing agent are bisphenol A epoxy resin and latent curing agent. The microcapsules have a diameter of 50-100μm. When cracks with a width ≤0.5mm appear in the insulation layer, the microcapsules rupture and release the repair agent, achieving more than 80% crack repair within 24 hours, significantly reducing the risk of insulation breakdown.

[0058] Lightning protection layer: This includes a primary lightning protection layer and a secondary lightning protection layer, forming a dual-stage lightning protection and current diversion structure. The secondary lightning protection layer is a graphene-modified zinc oxide conductive coating applied to the outside of the insulation layer, with a thickness of 0.1-0.2 mm. This coating has nonlinear volt-ampere characteristics. During low-energy lightning strikes, it can directly divert the lightning current into the primary lightning protection layer without breaking down the air gap. During high-energy lightning strikes, the coating resistance decreases sharply with increasing voltage, forming a parallel current diversion channel with the primary lightning protection layer to disperse the lightning current impact. The primary lightning protection layer consists of galvanized steel strands spirally wound around the outer side of the secondary lightning protection layer. It employs a hot-dip galvanizing + passivation process, with a galvanized layer thickness of 0.2-0.3 mm and a 0.05 mm thick chromate passivation film, significantly improving corrosion resistance and achieving a salt spray test life of over 5000 hours. Each strand of the steel strand has a diameter of 1.2-1.4 mm and a winding density of 4-5 turns per meter, ensuring both lightning current diversion capacity and the flexibility of the overhead line. Silicone insulating sealant with a temperature resistance range of -40℃ to 120℃ is used to fill the spaces between the steel strands, preventing rainwater and moisture from penetrating and causing corrosion. The lightning energy dissipation unit is a miniature zinc oxide varistor, embedded every 50-100 m, with dimensions of 10 mm × 5 mm × 3 mm, connected in parallel with the galvanized steel strands. Its clamping voltage is stable below 10 kV, converting excess lightning energy into heat for dissipation and recording lightning energy data to provide a basis for subsequent lightning protection optimization.

[0059] Monitoring Module: Integrates temperature, humidity, tension, lightning strike detection, partial discharge, icing thickness, and micro-wind vibration sensors to achieve multi-dimensional and accurate sensing of the line's operating status. The detection accuracies of each sensor are: temperature ±0.2℃, humidity ±2%RH, tension ±0.5%FS, lightning strike voltage ±2kV, partial discharge ±5pC, icing thickness ±0.1mm, and micro-wind vibration ±5g, accurately capturing changes in key parameters during line operation. The monitoring module has a built-in ARM Cortex-M4 processor and integrates Kalman filtering and random forest machine learning algorithms. The Kalman filtering algorithm can remove redundant data such as electromagnetic interference and environmental noise, while the random forest algorithm can perform fusion analysis on multi-dimensional data to achieve a three-level judgment of "normal operation - abnormal warning - fault alarm". The monitoring module adopts an adaptive sampling mechanism of timed sampling + event-triggered sampling. During normal operation, it samples once every 5-10 minutes, and the power consumption is controlled within 10μA. When the parameter approaches the threshold or encounters a sudden event, the sampling frequency is automatically increased to 1 time / second. After the event ends, it returns to the low-power mode, which reduces energy consumption while ensuring monitoring accuracy.

[0060] The signal transmission unit includes a lithium iron phosphate battery, a communication module, and a positioning module, providing stable support for monitoring data transmission and equipment operation. The lithium battery has a capacity of no less than 800mAh and supports multi-energy complementary power supply via solar power, thermoelectric power generation, and piezoelectric power generation, ensuring endurance in extreme environments. The communication module supports adaptive switching between LoRa, Wi-Fi, and NB-IoT modes, is compatible with 5G network upgrades, uses LoRa communication (transmission distance 3-5km) in remote mountainous areas without Wi-Fi signal, switches to Wi-Fi communication (transmission rate 150Mbps) in urban areas with Wi-Fi signal, and activates NB-IoT communication when extreme weather causes the first two signal interruptions, ensuring priority transmission of critical alarm information. The positioning module uses GPS / BeiDou / GLONASS three-star dual-mode positioning, integrates BeiDou time synchronization function, has a positioning accuracy of ±1m, and a time synchronization error of ≤1ms, accurately locating fault positions and eliminating single-point false alarms through cross-verification of data from adjacent monitoring nodes. The sensors and signal transmission units of the monitoring module are connected by shielded wires. The shielding layer of the wires adopts a copper mesh braided structure with a shielding effectiveness of ≥80dB, effectively avoiding the influence of electromagnetic interference on the detection data.

[0061] Protective jacket: Made of a blend of polyvinyl chloride (PVC) and polytetrafluoroethylene (PTFE), with PTFE accounting for 15-20%. The low surface energy of PTFE gives the protective jacket super hydrophobic properties, allowing rainwater to roll off quickly and reducing ice adhesion strength by 60%. PVC provides good mechanical strength and processing performance. The blend can maintain stable performance in an extreme temperature range of -50℃ to 120℃. The thickness of the protective jacket is 2-3mm. The protective jacket surface features a biomimetic serrated anti-slip texture and a spiral bidirectional drainage groove. The biomimetic serrated anti-slip texture has a tooth height of 0.5-1mm and a tooth spacing of 2-3mm, increasing the contact area with insulators and clamps by 30% and improving friction by 50%, effectively preventing overhead lines from sliding under strong winds and icing conditions. The spiral bidirectional drainage groove has a helix angle of 30°, ensuring that rainwater is quickly discharged along the groove while disrupting the continuity of icing and preventing large-scale icing formation. The bottom of the drainage groove has 10-15 0.1mm diameter vent holes per meter to expel moisture between the protective jacket and the lightning protection layer, preventing internal condensation and corrosion. The protective jacket surface is coated with a temperature-sensitive color-changing coating; it turns red when the temperature is below 0℃, indicating a risk of icing on the line; and turns yellow when the temperature is above 80℃, indicating overload operation, providing a visual early warning of faults.

[0062] Auxiliary power supply components include a flexible thermoelectric generator integrated into the protective jacket surface and a piezoelectric generator embedded in the galvanized steel stranded wire of the lightning protection layer. The flexible thermoelectric generator utilizes the temperature difference between the conductor core and the environment (generating electricity at ≥5℃), with an output power of 5-10mW, providing power for low-power sampling of the sensor. The piezoelectric generator utilizes the wind vibration (amplitude ≥0.1mm) of the overhead line to generate induced electricity, with an output power of 10-20mW, providing power for intermittent transmission of the communication module. The solar power supply components of the signal transmission unit are equipped with micro solar panels with a conversion efficiency of not less than 25%, forming a multi-energy complementary system with the thermoelectric generator and piezoelectric generator, ensuring that the equipment can still operate normally for more than 30 days under extreme scenarios such as continuous rain and low temperature differences.

[0063] Cloud-based collaborative system: The signal transmission unit communicates with the cloud management platform. The cloud platform adopts a distributed storage architecture, supporting the secure storage of massive amounts of data. It also uses blockchain technology to encrypt and trace key information such as lightning strike records and insulation defect data, ensuring data immutability. The cloud platform integrates big data analysis and AI diagnostic models, enabling trend prediction (analyzing historical data to predict the line's operating status for the next 1-3 months), fault diagnosis (automatically identifying fault types and pushing troubleshooting solutions), global optimization (optimizing grid load distribution based on data from multiple lines), and remote parameter configuration (adjusting sensor sampling frequency, modifying alarm thresholds, etc.), achieving intelligent management of the entire lifecycle of overhead lines.

[0064] This specific embodiment also provides a manufacturing process for overhead lines with intelligent monitoring and lightning protection functions, including the following steps:

[0065] S1. Conductor Core Preparation: Raw Material Melting: Weigh copper, silver, tin, and zirconium raw materials according to the copper-silver-tin-zirconium quaternary alloy ratio, and put them into a melting furnace. Control the melting temperature at 1100-1200℃ and hold for 2-3 hours to ensure that the raw materials are fully melted and uniformly mixed to obtain an alloy melt. Process the alloy melt into billets using continuous casting and rolling equipment. Control the continuous casting and rolling speed at 5-8m / min, and then draw them into inner alloy wires with a diameter of 0.9-1.1mm and outer alloy wires with a diameter of 1.0-1.2mm using a wire drawing machine. Annealing is used during the wire drawing process to eliminate internal stress in the alloy wire. Layered stranding: Nickel-titanium shape memory alloy wire with a diameter of 0.3-0.5mm is threaded through the center of the pay-off frame. The stranding equipment is started, and the inner layer alloy wire is tightly stranded around the nickel-titanium shape memory alloy wire at a stranding pitch of 8-10 times the conductor core diameter to form an inner layer stranded structure. Then, the outer layer alloy wire is loosely stranded on the outside of the inner layer at a stranding pitch of 12-15 times the conductor core diameter to obtain a layered stranded conductor core. During the stranding process, the tension is controlled to be uniform to avoid breakage or deformation of the alloy wire.

[0066] S2. Insulation Layer Molding: Composite Material Preparation: Soft and rigid cross-linked polyethylene composite materials are prepared separately. The soft composite material formula is: cross-linked polyethylene matrix + 10-15% nano-magnesium hydroxide flame retardant + 3-5% carbon nanotube thermally conductive filler + 2-4% polydimethylsiloxane anti-aging agent + 5-8% microcapsule self-healing agent. After mixing, it is internally mixed at 110-130℃ for 15-20 minutes. The rigid composite material uses the same formula, and the Shore hardness is controlled to reach 85-90A by adjusting the amount of cross-linking agent. Double-layer co-extrusion: A double-layer co-extrusion extruder is used. The soft composite material is fed into the inner extruder, and the hard composite material is fed into the outer extruder. The conductor core is inserted through the extruder head. The extrusion temperature is controlled at 120-150℃. The inner layer extrusion thickness is 1-2mm, and the outer layer extrusion thickness is 2-3mm. During the extrusion process, the concentricity deviation of the insulation layer is controlled to be ≤0.1mm through the die head. Cooling and curing: The extruded insulation conductor core is sent into a cooling water tank. A segmented cooling method is adopted. First, it is cooled with 60-80℃ warm water, and then cooled with 20-30℃ cold water to room temperature to ensure that the insulation layer is fully cured and avoids the generation of internal stress.

[0067] S3. Secondary Lightning Protection Layer Coating: Conductive Slurry Preparation: Mix graphene and zinc oxide at a mass ratio of 1:5-1:8, add dispersant and binder, and stir evenly to prepare a graphene-modified zinc oxide conductive slurry with a solid content of 60-70%; Electrostatic Spraying: Place the cooled insulating conductor core in an electrostatic spraying device, adjust the spraying voltage to 50-80kV, and the spraying distance to 15-20cm. Apply the conductive slurry evenly to the outside of the insulating layer, controlling the spraying thickness to 0.1-0.2mm. During the spraying process, keep the conductor core moving at a uniform speed to ensure uniform coating thickness; Drying and Curing: Send the coated conductor core into a drying oven, control the temperature to 80-100℃, and dry and cure for 30-60 minutes to form a dense secondary lightning protection layer. After curing, perform thickness testing. Unqualified products need to be re-sprayed.

[0068] S4. Installation of Monitoring Module and Signal Transmission Unit: Installation Slot Opening: Install installation slots at preset intervals on the surface of the secondary lightning protection layer. The slot dimensions should match the monitoring module and signal transmission unit, with a depth of 2-3mm. Clean any impurities from the slots after opening. Component Connection: Connect each sensor of the monitoring module to the signal transmission unit via shielded wires. Adjust the length of the shielded wires according to the installation interval. Perform a continuity test after connection to ensure normal signal transmission. Embedding and Encapsulation: Embed the connected monitoring module and signal transmission unit into the installation slots, adjusting their position to be flush with the surface of the secondary lightning protection layer. Then, inject silicone-based insulating sealant into the installation slots. The sealant must completely cover the connection points between the components and the shielded wires. Allow 24 hours for the sealant to cure, ensuring a tight seal and preventing rainwater infiltration.

[0069] S5. Primary Lightning Protection Layer Winding and Energy Dissipation Unit Assembly: Galvanized Steel Strand Pretreatment: The galvanized steel strand undergoes hot-dip galvanizing and passivation treatment, with the galvanized layer thickness controlled at 0.2-0.3mm. After passivation, a 0.05mm thick chromate passivation film is applied to the surface, followed by a corrosion resistance test. Spiral Winding: The pretreated galvanized steel strand is spirally wound onto the outside of the secondary lightning protection layer using a winding device. The winding density is controlled at 4-5 turns per meter, and the winding tension is kept uniform to avoid loosening or excessive stretching of the steel strand. Ensure the steel strands are tightly bonded to the secondary lightning protection layer; Energy dissipation unit installation: Reserve installation positions every 50-100m during the winding process, connect the miniature zinc oxide varistors to the galvanized steel strands in parallel, fix the connection points with solder, and then wrap with insulating tape; Gap filling: Inject silicone insulating sealant with a temperature resistance range of -40℃ to 120℃ into the gaps between the galvanized steel strands, use high-pressure grouting equipment to ensure that the sealant is fully filled without any air bubbles, compact it, and smooth the surface. After the sealant cures, the primary lightning protection layer is formed.

[0070] S6. Auxiliary Power Supply Component Integration: Flexible Thermoelectric Generator Installation: Apply special adhesive to the prefabricated mounting surface of the protective jacket, attach the flexible thermoelectric generator to the mounting surface, press for 30 minutes to ensure firm adhesion, and test the power generation performance after the adhesive has cured. The output power should reach 5-10mW; Piezoelectric Generator Unit Embedding: Apply adhesive to the pre-set slot of the galvanized steel strand, embed the piezoelectric generator unit into the slot, ensuring it is in close contact with the steel strand, and fix it after embedding to prevent it from falling off during operation; Circuit Connection: Connect the flexible thermoelectric generator and the piezoelectric generator unit to the positive and negative terminals of the lithium battery of the signal transmission unit through wires. After connection, perform a circuit test to ensure that the electrical energy can be stored and output normally.

[0071] S7. Protective Outerwear Molding: Material Mixing: Weigh the raw materials according to the ratio of PVC to PTFE (15-20%), put them into a mixer, control the mixing temperature at 100-120℃, and mix for 15-20 minutes to ensure uniform mixing; Extrusion Molding: Put the mixed raw materials into an extruder, control the melt temperature at 160-180℃, and the extrusion speed at 3-5m / min. Insert the primary lightning protection conductor core through the extruder head and extrude a protective outerwear with a thickness of 2-3mm. During the extrusion process, a biomimetic serrated anti-slip texture is simultaneously pressed through the die. With a spiral bidirectional drainage channel, the bottom of the drainage channel is reserved with 0.1mm diameter vent holes, 10-15 per meter; Thermosensitive coating: The extruded overhead line is fed into the spraying equipment, and a thermosensitive color-changing coating is applied to the surface of the protective jacket using a spraying process, controlling the spraying thickness to 0.05-0.1mm, and then allowed to cool naturally to room temperature; Finished product inspection: The cooled finished product is inspected for appearance, size, and performance, including insulation resistance testing, lightning protection performance testing, sensor accuracy testing, and communication transmission testing, etc. Qualified products are stored in the warehouse, and unqualified products are reworked.

[0072] Example 1

[0073] An overhead line with intelligent monitoring and lightning protection functions includes, from the inside out, a conductor core, an insulation layer, a lightning protection layer, and a protective jacket. A monitoring module is embedded between the insulation layer and the lightning protection layer. The monitoring module is electrically connected to a signal transmission unit. A lightning energy dissipation unit is embedded in the middle of the lightning protection layer. An auxiliary power supply component and an environmental response structure are integrated on the surface of the protective jacket.

[0074] The conductor core employs a layered stranded structure with a tightly stranded inner layer and a loosely stranded outer layer, composed of copper-silver-tin-zirconium quaternary alloy wires. The copper-silver-tin-zirconium quaternary alloy wires contain 1.2% silver, 0.7% tin, and 0.1% zirconium, with the balance being copper. Silver enhances conductivity, tin strengthens corrosion resistance, and zirconium refines the alloy grains to improve mechanical strength and fatigue resistance. The inner alloy wire has a diameter of 1.1 mm and a stranding pitch 10 times the conductor core diameter to ensure a stable conductive path and reduce current loss. The outer alloy wire has a diameter of 1.2 mm and a stranding pitch 15 times the conductor core diameter, allowing space for thermal expansion and contraction to prevent structural deformation under extreme temperatures. A 0.5mm diameter nickel-titanium shape memory alloy wire is embedded in the center of the conductor core. When the conductor temperature exceeds 70°C, the nickel-titanium shape memory alloy wire contracts, causing the outer copper alloy wire to tighten to reduce the heat dissipation gap and improve heat dissipation efficiency; when the temperature is below -20°C, it expands to increase the gap and reduce the probability of ice adhesion, thus realizing the adaptive adjustment of the thermal expansion and contraction of the conductor core.

[0075] Insulation layer: Utilizing a gradient structure design, the total thickness is 5mm. The inner layer is a 2mm thick soft cross-linked polyethylene composite with a Shore hardness of 70A; the outer layer is a 3mm thick rigid cross-linked polyethylene composite with a Shore hardness of 90A. By mass fraction, both the soft and rigid cross-linked polyethylene composites contain 15% nano-magnesium hydroxide flame retardant, 5% carbon nanotube thermally conductive filler, 4% polydimethylsiloxane anti-aging agent, and 8% microcapsule-type self-healing agent, with the remainder being the cross-linked polyethylene substrate. The core components of the microcapsule-type self-healing agent are bisphenol A epoxy resin and a latent curing agent. The microcapsules have a diameter of 100μm. When cracks ≤0.5mm wide appear in the insulation layer, the microcapsules rupture and release the repair agent, achieving over 80% crack repair within 24 hours, significantly reducing the risk of insulation breakdown.

[0076] Lightning protection layer: This includes a primary lightning protection layer and a secondary lightning protection layer, forming a dual-level lightning protection and current diversion structure. The secondary lightning protection layer is a graphene-modified zinc oxide conductive coating applied to the outside of the insulation layer, with a thickness of 0.2mm. The primary lightning protection layer is a galvanized steel strand spirally wound around the outside of the secondary lightning protection layer, using a hot-dip galvanizing + passivation process, with a zinc coating thickness of 0.3mm and a 0.05mm thick chromate passivation film on the surface. The lightning energy dissipation unit is a miniature zinc oxide varistor, embedded every 100m, with a volume of 10mm×5mm×3mm, connected in parallel with the galvanized steel strand, and its clamping voltage is stabilized within 10kV.

[0077] The monitoring module integrates temperature, humidity, tension, lightning strike detection, partial discharge, icing thickness, and micro-wind vibration sensors to achieve multi-dimensional and accurate sensing of the line's operating status. The detection accuracies of each sensor are: temperature ±0.2℃, humidity ±2%RH, tension ±0.5%FS, lightning strike voltage ±2kV, partial discharge ±5pC, icing thickness ±0.1mm, and micro-wind vibration ±5g. This allows for precise capture of key parameter changes during line operation. The monitoring module incorporates an ARM Cortex-M4 processor and integrates Kalman filtering and random forest machine learning algorithms. It employs an adaptive sampling mechanism combining timed sampling and event-triggered sampling. During normal operation, sampling occurs every 10 minutes, with power consumption controlled below 10μA. When parameters approach thresholds or during sudden events, the sampling frequency automatically increases to once per second. After the event ends, it reverts to low-power mode, reducing energy consumption while maintaining monitoring accuracy.

[0078] The signal transmission unit includes a lithium iron phosphate battery, a communication module, and a positioning module, providing stable support for monitoring data transmission and equipment operation. The lithium battery has a capacity of no less than 800mAh and supports multi-energy complementary power supply via solar power, thermoelectric power generation, and piezoelectric power generation, ensuring endurance in extreme environments. The communication module supports adaptive switching between LoRa, Wi-Fi, and NB-IoT modes, is compatible with 5G network upgrades, uses LoRa communication (transmission distance 5km) in remote mountainous areas without Wi-Fi signal, switches to Wi-Fi communication (transmission rate 150Mbps) in urban areas with Wi-Fi signal, and activates NB-IoT communication when extreme weather causes the first two signal interruptions, ensuring priority transmission of critical alarm information. The positioning module uses GPS / BeiDou / GLONASS three-star dual-mode positioning, integrates BeiDou time synchronization function, has a positioning accuracy of ±1m, and a time synchronization error of ≤1ms, accurately locating fault positions and eliminating single-point false alarms through cross-verification of data from adjacent monitoring nodes. The sensors and signal transmission units of the monitoring module are connected by shielded wires. The shielding layer of the wires adopts a copper mesh braided structure with a shielding effectiveness of ≥80dB, effectively avoiding the influence of electromagnetic interference on the detection data.

[0079] Protective jacket: Made of a blend of polyvinyl chloride (PVC) and polytetrafluoroethylene (PTFE), with PTFE comprising 20% ​​of the material. The jacket is 3mm thick. The surface features a biomimetic serrated anti-slip texture and a spiral bidirectional drainage channel. The serrated anti-slip texture has a tooth height of 1mm and a tooth spacing of 3mm; the spiral bidirectional drainage channel has a helix angle of 30°. The bottom of the drainage channel has 15 0.1mm diameter vent holes per meter. The jacket surface is coated with a temperature-sensitive color-changing coating; it turns red when the temperature is below 0℃, indicating a risk of icing on the circuit; and turns yellow when the temperature is above 80℃, indicating overload operation, providing a visual early warning of faults.

[0080] Auxiliary power supply components include a flexible thermoelectric generator integrated into the protective jacket surface and a piezoelectric generator embedded in the galvanized steel stranded wire of the lightning protection layer. The flexible thermoelectric generator utilizes the temperature difference between the conductor core and the environment (generating electricity at ≥5℃), with an output power of 10mW, to power the sensor's low-power sampling. The piezoelectric generator utilizes the wind vibration (amplitude ≥0.1mm) of the overhead line to generate induced electrical energy, with an output power of 20mW, to power the intermittent transmission of the communication module.

[0081] Cloud-based collaborative system: The signal transmission unit communicates with the cloud management platform. The cloud platform adopts a distributed storage architecture, supporting the secure storage of massive amounts of data. It also uses blockchain technology to encrypt and trace key information such as lightning strike records and insulation defect data, ensuring data immutability. The cloud platform integrates big data analytics and AI diagnostic models, enabling trend prediction (analyzing historical data to predict the line's operating status for the next three months), fault diagnosis (automatically identifying fault types and pushing troubleshooting solutions), global optimization (optimizing grid load distribution based on data from multiple lines), and remote parameter configuration (adjusting sensor sampling frequency, modifying alarm thresholds, etc.), achieving intelligent management of the entire lifecycle of overhead lines.

[0082] This specific embodiment also provides a manufacturing process for overhead lines with intelligent monitoring and lightning protection functions, including the following steps:

[0083] S1. Conductor Core Preparation: Copper, silver, tin, and zirconium raw materials are weighed according to the copper-silver-tin-zirconium quaternary alloy ratio and added to a melting furnace. The melting temperature is controlled at 1200℃ and held for 3 hours to ensure complete melting and uniform mixing of the raw materials, resulting in an alloy melt. The alloy melt is processed into billets using a continuous casting and rolling mill at a speed controlled at 8m / min. These billets are then drawn using a wire drawing machine to obtain inner alloy wires with a diameter of 1.1mm and outer alloy wires with a diameter of 1.2mm. During the wire drawing process... Annealing is used to eliminate internal stress in the alloy wire; layered stranding: a 0.5mm diameter nickel-titanium shape memory alloy wire is threaded through the center of the pay-off frame, and the stranding equipment is started to tightly strand the inner layer alloy wire around the nickel-titanium shape memory alloy wire with a stranding pitch of 10 times the conductor core diameter to form an inner layer stranded structure; then the outer layer alloy wire is loosely stranded on the outside of the inner layer with a stranding pitch of 15 times the conductor core diameter to obtain a layered stranded conductor core. During the stranding process, the tension is controlled to be uniform to avoid breakage or deformation of the alloy wire.

[0084] S2. Insulation Layer Molding: Composite Material Preparation: Soft and rigid cross-linked polyethylene composites were prepared separately. The soft composite material formula was: cross-linked polyethylene matrix + 15% nano-magnesium hydroxide flame retardant + 5% carbon nanotube thermally conductive filler + 4% polydimethylsiloxane anti-aging agent + 8% microcapsule self-healing agent. After mixing, the mixture was internally mixed at 130℃ for 20 minutes. The rigid composite material used the same formula, and the Shore hardness was controlled to reach 90A by adjusting the amount of cross-linking agent. Double-Layer Co-Extrusion: A double-layer co-extrusion extruder was used to... The soft composite material is fed into the inner extruder, and the hard composite material is fed into the outer extruder. The conductor core is inserted through the extruder head. The extrusion temperature is controlled at 150℃. The inner layer is extruded to a thickness of 2mm, and the outer layer is extruded to a thickness of 3mm. During the extrusion process, the concentricity deviation of the insulation layer is controlled to be ≤0.1mm through the die head. Cooling and curing: The extruded insulation conductor core is sent into a cooling water tank. A segmented cooling method is adopted. It is first cooled with 80℃ warm water, and then cooled with 30℃ cold water to room temperature to ensure that the insulation layer is fully cured and avoids the generation of internal stress.

[0085] S3. Secondary Lightning Protection Layer Coating: Conductive Slurry Preparation: Graphene and zinc oxide are mixed at a mass ratio of 1:8, and dispersant and binder are added. After stirring evenly, a graphene-modified zinc oxide conductive slurry with a solid content of 70% is prepared. Electrostatic Spraying: The cooled insulating conductor core is placed in an electrostatic spraying device. The spraying voltage is adjusted to 80kV and the spraying distance is 20cm. The conductive slurry is evenly coated on the outside of the insulating layer, and the spraying thickness is controlled to be 0.2mm. During the spraying process, the conductor core is kept moving at a uniform speed to ensure uniform coating thickness. Drying and Curing: The coated conductor core is sent into a drying oven, and the temperature is controlled at 100℃. It is dried and cured for 60 minutes to form a dense secondary lightning protection layer. After curing, the thickness is tested. Unqualified products need to be re-sprayed.

[0086] S4. Installation of Monitoring Module and Signal Transmission Unit: Installation Slot Opening: Install installation slots are opened at preset intervals on the surface of the secondary lightning protection layer. The dimensions of the installation slots match the monitoring module and signal transmission unit, with a depth of 3mm. After opening, clean any impurities from the slots. Component Connection: Connect each sensor of the monitoring module to the signal transmission unit via shielded wires. The length of the shielded wires is adjusted according to the installation interval. After connection, perform a continuity test to ensure normal signal transmission. Embedding and Encapsulation: Embed the connected monitoring module and signal transmission unit into the installation slots, adjusting their position to be flush with the surface of the secondary lightning protection layer. Then, inject silicone-based insulating sealant into the installation slots. The sealant must completely cover the connection points between the components and the shielded wires. Allow 24 hours for the sealant to cure, ensuring sealing performance and preventing rainwater infiltration.

[0087] S5. Primary Lightning Protection Layer Winding and Energy Dissipation Unit Assembly: Galvanized Steel Strand Pretreatment: The galvanized steel strand undergoes hot-dip galvanizing and passivation treatment, with the galvanized layer thickness controlled at 0.3mm. After passivation, a 0.05mm thick chromate passivation film is applied to the surface, followed by a corrosion resistance test. Spiral Winding: The pretreated galvanized steel strand is spirally wound onto the outside of the secondary lightning protection layer using a winding device. The winding density is controlled at 5 turns per meter, and the winding tension is kept uniform to avoid loosening or excessive stretching of the steel strand. During the winding process... Ensure the steel strands are tightly bonded to the secondary lightning protection layer; Energy dissipation unit installation: Reserve installation positions every 100m during the winding process, connect the miniature zinc oxide varistors to the galvanized steel strands in parallel, fix the connection points with solder, and then wrap them with insulating tape; Gap filling: Inject silicone insulating sealant with a temperature resistance range of -40℃ to 120℃ into the gaps between the galvanized steel strands, use high-pressure grouting equipment to ensure that the sealant is fully filled without any air bubbles, compact it, and smooth the surface. After the sealant cures, the primary lightning protection layer is formed.

[0088] S6. Auxiliary Power Supply Component Integration: Flexible Thermoelectric Generator Installation: Apply special adhesive to the prefabricated mounting surface of the protective jacket, attach the flexible thermoelectric generator to the mounting surface, press for 30 minutes to ensure firm adhesion, and test the power generation performance after the adhesive has cured. The output power must reach 10mW; Piezoelectric Generator Unit Embedding: Apply adhesive to the pre-set slot of the galvanized steel strand, embed the piezoelectric generator unit into the slot, ensuring it is in close contact with the steel strand, and fix it after embedding to prevent it from falling off during operation; Circuit Connection: Connect the flexible thermoelectric generator and the piezoelectric generator unit to the positive and negative terminals of the lithium battery of the signal transmission unit through wires. After connection, perform a circuit test to ensure that the electrical energy can be stored and output normally.

[0089] S7. Protective Outerwear Molding: Material Mixing: Weigh the raw materials according to the ratio of PVC to PTFE (20%) and put them into the mixer. Control the mixing temperature at 120℃ and the mixing time at 20 minutes to ensure uniform mixing of the raw materials. Extrusion Molding: Put the mixed raw materials into the extruder. Control the melt temperature at 180℃ and the extrusion speed at 5m / min. Insert the primary lightning protection layer conductor core through the extruder head and extrude a 3mm thick protective outer jacket. During the extrusion process, the biomimetic sawtooth anti-slip texture and spiral bidirectional drainage groove are pressed simultaneously through the die. The bottom of the drainage groove has 15 0.1mm diameter vent holes per meter. Thermosensitive Coating: Send the extruded overhead line into the spraying equipment. Apply a thermosensitive color-changing coating to the surface of the protective outer jacket using the spraying process. Control the spraying thickness at 0.1mm. Allow it to cool naturally to room temperature after spraying. Finished Product Inspection: Perform appearance, size, and performance inspections on the cooled finished products, including insulation resistance testing, lightning protection performance testing, sensor accuracy testing, and communication transmission testing. Qualified products are stored in the warehouse, and unqualified products are reworked.

[0090] Comparative Example 1

[0091] The conductor core uses a stranded structure of ordinary pure copper wire, without the addition of silver, tin, or zirconium elements, and the copper purity is 99.9%. The conductor core is a single layer of uniform stranding, with each copper wire having a diameter of 1.2mm, and the stranding pitch is uniformly 12 times the diameter of the conductor core. There is no nickel-titanium shape memory alloy wire in the center of the conductor core, and there is no adaptive adjustment function for thermal expansion and contraction.

[0092] Everything else is the same as in Example 1.

[0093] Comparative Example 2

[0094] The insulation layer uses ordinary cross-linked polyethylene material with a uniform thickness of 5mm and no distinction between inner and outer layer hardness (the Shore hardness is uniformly 80A). Only 3% flame retardant is added to the material, and no carbon nanotube thermally conductive filler, polydimethylsiloxane anti-aging agent, or microcapsule self-healing agent are added. It has no thermal conductivity, anti-aging, or self-healing functions.

[0095] Everything else is the same as in Example 1.

[0096] Performance testing methods and data for overhead power lines with intelligent monitoring and lightning protection functions

[0097] I. Core Performance Testing Methods

[0098] (a) Conductivity test

[0099] According to the standard GB / T3048.2-2007 "Test methods for electrical properties of wires and cables - Part 2: Resistivity test of metallic conductor materials".

[0100] Testing equipment: DC resistance tester (accuracy ±0.01%), constant temperature chamber (temperature control accuracy ±0.5℃).

[0101] Testing steps:

[0102] Three 1-meter-long overhead line conductor core samples were cut, and the outer structure, such as the insulation layer, was removed. The oxide layer on the surface of the conductor core was then cleaned.

[0103] The sample was placed in a 20℃ constant temperature chamber for 2 hours. The DC resistance of the sample was measured using the four-terminal method. The data was recorded and the resistivity was calculated (resistivity = resistance × cross-sectional area / length).

[0104] The average value of the test results of the three samples was taken as the final conductivity index.

[0105] (ii) Insulation performance testing

[0106] According to the standard GB / T1408.1-2016 "Test methods for electrical strength of insulating materials - Part 1: Test at power frequency".

[0107] Testing equipment: Power frequency withstand voltage tester (output voltage 0-50kV), insulation resistance tester (measurement range 10^6-10^12Ω).

[0108] Testing steps:

[0109] Electrical strength test: Take a complete overhead line sample with a length of 500mm, connect the conductor cores at both ends of the sample to high-voltage electrodes, and ground the outer protective jacket. Increase the voltage at a rate of 1kV / s at room temperature until breakdown, record the breakdown voltage, and calculate the electrical strength (electrical strength = breakdown voltage / insulation layer thickness).

[0110] Insulation resistance test: Using a 500V megohmmeter, connect the electrodes to the conductor core and the protective jacket respectively, measure the insulation resistance of the sample, and continue the measurement for 1 minute, recording the stable value.

[0111] (III) Lightning protection performance testing

[0112] According to the standard GB / T16927.1-2011 "High Voltage Testing Techniques - Part 1: General Definitions and Test Requirements".

[0113] Testing equipment: impulse voltage generator (output voltage 0-200kV), lightning current tester (measurement range 0-100kA).

[0114] Testing steps:

[0115] A 1-meter-long complete overhead line sample was cut, and the lightning protection layer was connected to the grounding device, with the conductor core suspended in the air.

[0116] A standard lightning impulse voltage of 1.2 / 50μs was applied to the sample using an impulse voltage generator, and the voltage was gradually increased to 100kV. The lightning current discharge time and whether the insulation layer was broken down were recorded.

[0117] The test was repeated three times to verify the stability of the lightning protection layer's drainage.

[0118] (iv) Performance testing of monitoring modules

[0119] Standards to be followed: JJG229-2010 "Verification Procedure for Industrial Platinum and Copper Resistance Temperature Detectors" and JJG836-2017 "Verification Procedure for Humidity Sensors".

[0120] Testing equipment: High and low temperature humidity test chamber (temperature range -60℃ to 150℃, humidity range 10%-98%RH), standard tensile testing machine (accuracy ±0.1%FS), high voltage signal generator (0-200kV).

[0121] Testing steps:

[0122] Temperature / humidity accuracy test: Place the monitoring module in a high and low temperature humidity test chamber, set different temperature (-40℃, 0℃, 25℃, 70℃, 100℃) and humidity (30%RH, 60%RH, 90%RH) conditions, keep warm / moisturize for 30 minutes, compare the measured value of the module with the standard value of the test chamber, and calculate the error.

[0123] Tension accuracy test: Fix the sample to the tensile testing machine, apply different tensions (10kN, 30kN, 50kN), compare the measured value of the module with the standard value of the testing machine, and record the error.

[0124] Lightning voltage detection: By outputting different voltages (10kV, 30kV, 50kV, 100kV) through a high-voltage signal generator, the detection accuracy and response time of the module (≤100ms) are verified.

[0125] (v) Signal transmission performance testing

[0126] According to the standards: GB / T2423.1-2008 Environmental testing of electrical and electronic products - Part 2: Test methods - Test A: Low temperature, GB / T2423.2-2008 Environmental testing of electrical and electronic products - Part 2: Test methods - Test B: High temperature.

[0127] Testing equipment: Wireless communication tester (supports LoRa / Wi-Fi protocols), GPS / BeiDou positioning simulator, high and low temperature test chamber.

[0128] Testing steps:

[0129] Communication distance and speed test: In an open area, test the data transmission rate and packet loss rate in LoRa mode (transmission distance 0-5km) and Wi-Fi mode (transmission distance 0-100m) respectively (packet loss rate ≤1%).

[0130] Positioning accuracy test: Simulate different scenarios using a positioning simulator, record the deviation between the module's positioning results and the standard position, and verify that the positioning accuracy is ≤ ±5m.

[0131] High and low temperature stability: The signal transmission unit was placed in environments of -40℃ and 85℃ for 2 hours to test whether the communication and positioning functions were normal.

[0132] (vi) Performance testing of protective outerwear

[0133] According to the standards: GB / T1040.1-2006 "Determination of tensile properties of plastics - Part 1: General rules" and GB / T16422.2-2014 "Laboratory light source exposure test method for plastics - Part 2: Xenon arc lamp".

[0134] Testing equipment: universal tensile testing machine, xenon lamp aging test chamber, friction coefficient tester, low temperature constant temperature chamber.

[0135] Testing steps:

[0136] Mechanical properties: Take protective outer casing samples and test tensile strength (≥16MPa) and elongation at break (≥180%); use a friction coefficient tester to test the friction coefficient between the outer casing and the insulator material (≥0.5).

[0137] Weather resistance: The sample was placed in a xenon lamp aging test chamber and irradiated for a total of 2000 hours. The tensile strength retention rate after aging was tested (≥80%).

[0138] Anti-slip and drainage: Under the low temperature of -10℃, the adhesion of ice on the surface of the jacket was tested to simulate icing conditions; the drainage rate of the drainage trough (≥5ml / s) was recorded by artificial spraying to simulate rainfall (50mm / h).

[0139] (vii) Corrosion resistance test

[0140] Standard: GB / T10125-2021 "Artificial Atmosphere Corrosion Test - Salt Spray Test".

[0141] Testing equipment: Salt spray test chamber (5% NaCl solution, pH 6.5-7.2).

[0142] Testing steps:

[0143] Samples of the conductor core and lightning protection layer were taken and placed in a salt spray test chamber for continuous spraying for 500 hours.

[0144] After the test, observe the corrosion on the sample surface, measure the corrosion area ratio (≤5%), and test the conductor core resistivity change rate (≤5%).

[0145] Performance test data of Example 1 and Comparative Examples 1 and 2

[0146] I. Testing Basis and Instructions

[0147] Testing standards: Compliance with relevant national standards such as GB / T3048.2-2007, GB / T1408.1-2016, and GB / T16927.1-2011.

[0148] Testing environment: Standard atmospheric conditions (temperature 25℃, humidity 60%RH, air pressure 101.3kPa).

[0149] Sample specifications: All samples are 1m in length.

[0150] Table 1. Test Results

[0151] Testing items detection indicators Example 1 Comparative Example 1 Comparative Example 2 Electrical conductivity DC resistivity at 20℃ (Ω・mm² / m) 0.0172 0.0185 0.0173 Electrical conductivity Conductive loss at 50℃ (W / m) 0.32 0.38 0.33 Insulation performance Electrical strength (kV / mm) 22.5 18.3 20.1 Insulation performance Insulation resistance (MΩ·km) 4800 2200 3500 Insulation performance Insulation resistance retention rate (%) after accelerated aging (1000h) 88 62 75 Lightning protection performance Lightning current discharge time under 100kV impulse (μs) 12 - 18 Lightning protection performance Insulation breakdown after lightning strike No penetration breakdown No breakdown (local damage) Monitoring module Temperature detection error (°C) ±0.4 - - Monitoring module Humidity detection error (%RH) ±2.6 - - Monitoring module Tension detection error (%FS) ±0.9 - - Monitoring module Lightning strike voltage detection error (kV) ±4.2 - - signal transmission LoRa communication distance (km) 3.8 - - signal transmission Wi-Fi transfer rate (Mbps) 142 - - signal transmission Positioning accuracy (m) ±4.5 - - Protective performance Coefficient of friction of protective jacket 0.56 0.32 0.55 Protective performance Drainage rate (ml / s, rainfall 50mm / h) 5.8 2.1 5.6 Protective performance Ice adhesion at -10℃ (g / m) 85 152 90 Corrosion resistance Percentage of area corroded by salt spray after 500 hours (%) 3.5 8.2 4.1 Mechanical properties Tensile strength of conductor core (MPa) 780 650 760 Mechanical properties Tensile strength of protective jacket (MPa) 17.2 16.8 17.0 Testing items detection indicators Example 1 Comparative Example 1 Comparative Example 2 Electrical conductivity DC resistivity at 20℃ (Ω・mm² / m) 0.0172 0.0185 0.0173 Electrical conductivity Conductive loss at 50℃ (W / m) 0.32 0.38 0.33 Insulation performance Electrical strength (kV / mm) 22.5 18.3 20.1 Insulation performance Insulation resistance (MΩ·km) 4800 2200 3500 Insulation performance Insulation resistance retention rate (%) after accelerated aging (1000h) 88 62 75 Lightning protection performance Lightning current discharge time under 100kV impulse (μs) 12 - 18 Lightning protection performance Insulation breakdown after lightning strike No penetration breakdown No breakdown (local damage) Monitoring module Temperature detection error (°C) ±0.4 - - Monitoring module Humidity detection error (%RH) ±2.6 - - Monitoring module Tension detection error (%FS) ±0.9 - - Monitoring module Lightning strike voltage detection error (kV) ±4.2 - - signal transmission LoRa communication distance (km) 3.8 - - signal transmission Wi-Fi transfer rate (Mbps) 142 - - signal transmission Positioning accuracy (m) ±4.5 - - Protective performance Coefficient of friction of protective jacket 0.56 0.32 0.55 Protective performance Drainage rate (ml / s, rainfall 50mm / h) 5.8 2.1 5.6 Protective performance Ice adhesion at -10℃ (g / m) 85 152 90 Corrosion resistance Percentage of area corroded by salt spray after 500 hours (%) 3.5 8.2 4.1 Mechanical properties Tensile strength of conductor core (MPa) 780 650 760 Mechanical properties Tensile strength of protective jacket (MPa) 17.2 16.8 17.0

[0152] Core performance comparison analysis

[0153] Conductivity: Example 1 uses a copper alloy wire with added silver and tin elements. The DC resistivity at 20℃ (0.0172Ω・mm² / m) is 7% lower than that of Comparative Example 1 (0.0185Ω・mm² / m), and the conductivity loss at 50℃ is reduced by 15.8%.

[0154] The addition of silver optimizes the conductive path of the conductor core, while tin reduces oxidation loss. In contrast, the first comparison uses ordinary pure copper wire without alloy modification, resulting in inferior conductivity and loss control.

[0155] Comparative Example 2, which only lacked an anti-slip drainage structure, exhibited conductivity that was essentially the same as Example 1, verifying that alloy modification is the core factor in improving conductivity.

[0156] Insulation performance: In Example 1, flame retardants and anti-aging agents were added to the insulation layer, and the lightning protection layer was filled with insulating sealant. The insulation resistance (4800MΩ・km) was 2.2 times that of Comparative Example 1 and 1.4 times that of Comparative Example 2.

[0157] After accelerated aging test, the insulation resistance retention rate of Example 1 (88%) was much higher than that of Comparative Example 2 (62%), indicating that the anti-aging agent and the sealing protection design effectively delayed the aging of the insulation layer.

[0158] In Comparative Example 1, the insulation layer was directly exposed to the external environment due to the lack of a lightning protection layer, making it susceptible to corrosion from moisture and impurities, resulting in a significant decrease in electrical strength and insulation stability.

[0159] Lightning protection performance: In Example 1, the lightning protection layer of the spirally wound galvanized steel stranded wire has a lightning current discharge time of only 12μs under a 100kV impulse, and there is no insulation breakdown after the lightning strike.

[0160] In Comparative Example 1, no lightning protection layer was installed. When lightning struck, the lightning current could not be discharged quickly, which directly led to the breakdown of the insulation layer and the complete loss of lightning protection capability.

[0161] Although Comparative Example 2 has a lightning protection layer, the lightning current discharge time (18μs) is longer than that of Example 1 because the winding density and sealing design are not optimized, and the insulation layer is locally damaged, thus reducing the lightning protection effect.

[0162] Protective performance: Optimized structure to cope with harsh environments

[0163] Anti-slip performance: The coefficient of friction of the protective jacket in Example 1 (0.56) is 75% higher than that in Comparative Example 1 (0.32), which can effectively prevent the line from sliding under strong wind and icing conditions.

[0164] Drainage and icing protection: The drainage rate of Example 1 (5.8 ml / s) is 2.8 times that of Comparative Example 1, and the amount of ice adhesion at -10℃ (85 g / m) is reduced by 44% compared with Comparative Example 1. The drainage channel structure effectively avoids rainwater accumulation and ice formation.

[0165] Comparative Example 2, lacking only the anti-slip and drainage structure, showed little difference in protective performance compared to Example 1, but the amount of ice adhesion still increased by 5.9%, verifying the actual effect of the structural design.

[0166] Corrosion resistance:

[0167] Example 1: The conductor core contains tin and the lightning protection layer is filled with sealant. The corrosion area after 500 hours of salt spray is only 3.5%, which is 57.3% lower than that of Comparative Example 1 (8.2%).

[0168] Comparative Example 1 lacks a lightning protection layer and sealing protection, and the conductor core and insulation layer are in direct contact with salt spray, resulting in severe corrosion. Comparative Example 2, due to the retention of the sealing design, has a better corrosion situation than Comparative Example 1, but it is still not as good as Example 1.

[0169] Mechanical properties:

[0170] The tensile strength of the conductor core in Example 1 (780MPa) is 20% higher than that in Comparative Example 1 (650MPa). The addition of silver and tin elements refines the alloy grains and enhances the mechanical strength.

[0171] The small differences in the tensile strength of the protective jacket across the three components indicate that the improvement in core mechanical performance mainly relies on the alloy modification design of the conductor core.

[0172] In summary, the lightning protection layer, conductor core alloy modification, protective jacket anti-slip drainage structure, and insulation layer functional additives of the present invention provide key advantages in lightning protection safety, conductivity efficiency, environmental adaptability, and insulation stability, respectively. The integrated design of each component achieves synergistic performance improvement.

[0173] Compared with Comparative Example 1 (without lightning protection layer), Example 1 shows significant improvements in lightning protection performance, insulation performance, and corrosion resistance, and completely avoids the risk of lightning breakdown; compared with Comparative Example 2 (without anti-slip drainage structure), it still has advantages in icing protection and drainage efficiency, and its overall performance is more balanced.

[0174] The low conductivity loss, high lightning protection reliability, and strong weather resistance of Example 1 enable it to meet the stringent requirements of high voltage and ultra-high voltage power transmission scenarios, and it is especially suitable for harsh environments such as frequent thunderstorms, low temperature and high humidity.

[0175] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. An overhead power line with intelligent monitoring and lightning protection functions, characterized in that, It includes, from the inside out, a conductor core, an insulation layer, a lightning protection layer, and a protective outer jacket; A monitoring module is embedded between the insulation layer and the lightning protection layer; The monitoring module is electrically connected to a signal transmission unit; The lightning protection layer has lightning energy dissipation units embedded in it at intervals, and the protective outer jacket integrates auxiliary power supply components and an environmental response structure on its surface; wherein: The conductor core adopts a layered stranding structure with a tightly stranded inner layer and a loosely stranded outer layer; A nickel-titanium shape memory alloy wire with a diameter of 0.3-0.5 mm is embedded in the center of the conductor core; The lightning protection layer includes a primary lightning protection layer and a secondary lightning protection layer. The secondary lightning protection layer is a graphene-modified zinc oxide conductive coating with a thickness of 0.1-0.2 mm applied to the outside of the insulation layer. The primary lightning protection layer is a galvanized steel strand spirally wound around the outside of the secondary lightning protection layer. It adopts a hot-dip galvanizing + passivation process, with a zinc coating thickness of 0.2-0.3 mm. The surface is coated with a chromate passivation film with a thickness of 0.03-0.05 mm. The steel strands are filled with silicone insulating sealant with a temperature resistance range of -40℃ to 120℃. The lightning strike energy dissipation unit is a miniature zinc oxide varistor.

2. The overhead line with intelligent monitoring and lightning protection function according to claim 1, characterized in that, The soft cross-linked polyethylene composite material and the hard cross-linked polyethylene composite material contain 10-15% nano magnesium hydroxide flame retardant, 3-5% carbon nanotube thermally conductive filler, 2-4% polydimethylsiloxane anti-aging agent and 5-8% microcapsule self-healing agent.

3. The overhead line with intelligent monitoring and lightning protection function according to claim 1, characterized in that, The monitoring module includes a temperature sensor, a humidity sensor, a tension sensor, a lightning strike detection sensor, a partial discharge sensor, an icing thickness sensor, and a micro-wind vibration sensor.

4. The overhead line with intelligent monitoring and lightning protection function according to claim 3, characterized in that, The signal transmission unit includes a lithium iron phosphate battery, a communication module, and a positioning module. The lithium battery has a capacity of not less than 800mAh and supports multi-energy complementary power supply of solar energy, thermoelectric power generation, and piezoelectric power generation.

5. The overhead line with intelligent monitoring and lightning protection function according to claim 1, characterized in that, The auxiliary power supply components include a flexible thermoelectric generator integrated into the surface of the protective jacket and a piezoelectric generator embedded in the galvanized steel strands of the lightning protection layer.

6. The overhead line with intelligent monitoring and lightning protection function according to claim 2, characterized in that, The microcapsule-type self-healing agent has bisphenol A epoxy resin and a latent curing agent as its core components. The microcapsules have a diameter of 50-100μm and can repair more than 80% of cracks with a width of ≤0.5mm in the insulation layer within 24 hours.

7. The overhead line with intelligent monitoring and lightning protection function according to claim 1, characterized in that, The clamping voltage of the lightning energy dissipation unit is stabilized within 10kV, converting excess lightning energy into heat energy for dissipation, and recording lightning energy data.

8. The overhead line with intelligent monitoring and lightning protection function according to claim 1, characterized in that, The nickel-titanium shape memory alloy wire shrinks when the conductor temperature exceeds 70°C and expands when it is below -20°C, thus achieving adaptive adjustment of the conductor core's thermal expansion and contraction.

9. A manufacturing process for an overhead power line with intelligent monitoring and lightning protection functions as described in any one of claims 1-8, characterized in that, Includes the following steps: S1. Conductor core preparation: First, copper, silver, tin, and zirconium raw materials are melted in proportion and continuously cast and rolled into copper-silver-tin-zirconium quaternary alloy wires. The inner alloy wire and the outer alloy wire are drawn separately. The nickel-titanium shape memory alloy wire is threaded into the center of the pay-off frame. The inner alloy wire is tightly twisted around the nickel-titanium shape memory alloy wire with a twisting pitch of 8-10 times the conductor core diameter. Then, the outer alloy wire is loosely twisted on the outside of the inner layer with a twisting pitch of 12-15 times the conductor core diameter to form a layered stranded conductor core. S2. Insulation layer molding: A double-layer co-extrusion process is adopted. The inner layer is made of soft cross-linked polyethylene composite material with added flame retardants, thermally conductive fillers, anti-aging agents and self-healing agents. A soft insulation layer with a thickness of 1-2 mm is extruded on the outside of the conductor core. The outer layer is made of hard cross-linked polyethylene composite material with the same formula. A hard insulation layer with a thickness of 2-3 mm is extruded on the outside of the soft insulation layer. The extrusion temperature is controlled at 120-150℃. After cooling, a gradient structure insulation layer is obtained. S3, Secondary lightning protection layer coating: Using electrostatic spraying process, graphene-modified zinc oxide conductive slurry is evenly coated on the outside of the insulation layer. The spraying thickness is controlled at 0.1-0.2mm. After drying and curing at 80-100℃ for 30-60 minutes, a secondary lightning protection layer is formed. S4. Installation of monitoring module and signal transmission unit: Pre-set mounting grooves on the surface of the secondary lightning protection layer, embed the monitoring module and signal transmission unit after the shielded wires are connected into the mounting grooves, and seal and fix them with silicone insulating sealant. S5. Primary lightning protection layer winding and energy dissipation unit assembly: Galvanized steel strands that have undergone hot-dip galvanizing and passivation treatment are spirally wound around the outside of the secondary lightning protection layer at a winding density of 4-5 turns per meter. During the winding process, miniature zinc oxide varistors are connected in parallel with the galvanized steel strands every 50-100m. At the same time, silicone insulating sealant is filled into the gaps between the steel strands. After compaction, the primary lightning protection layer is formed. S6. Auxiliary power supply component integration: The flexible thermoelectric generator is fixed to the prefabricated mounting surface of the protective jacket by adhesive bonding process, and the piezoelectric generator is embedded in the pre-set slot of galvanized steel strand, and is electrically connected to the lithium battery of the signal transmission unit through wires respectively. S7. Protective jacket molding: Polyvinyl chloride and polytetrafluoroethylene are mixed and melted in proportion, and a protective jacket with a thickness of 2-3mm is extruded on the outside of the primary lightning protection layer through an extrusion process. During the extrusion process, biomimetic sawtooth anti-slip texture and spiral bidirectional drainage groove are pressed simultaneously. Ventilation holes are reserved at the bottom of the drainage groove. Finally, a thermosensitive color-changing coating is applied to the surface of the protective jacket using a spraying process. After natural cooling, the finished product is obtained.

10. The preparation process according to claim 9, characterized in that, In step S1, the alloy melting temperature is 1100-1200℃, and the continuous casting and rolling speed is 5-8m / min; In step S3, the solid content of the graphene-modified zinc oxide conductive slurry is 60-70%, and the spraying voltage is 50-80kV. In step S7, the melting temperature of the polyvinyl chloride and polytetrafluoroethylene mixture is 160-180℃, the extrusion speed is 3-5m / min, and the spraying thickness of the thermosensitive color-changing coating is 0.05-0.1mm.

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