A bend-resistant high voltage cable

Abstract

This invention relates to the field of power cable technology and proposes a bend-resistant high-voltage cable, comprising several stranded multi-core conductors, each multi-core conductor being covered with an insulation layer, and further comprising a flexible tube, a filler layer, a wrapping layer, a buffer layer, a sheath layer, and end positioning components. The flexible tube is disposed between the multiple multi-core conductors and abuts against the insulation layer of each multi-core conductor. The multiple multi-core conductors are sequentially covered with the filler layer, wrapping layer, buffer layer, and sheath layer. When the cable is bent, the filler layer can deform to create space for the multi-core conductors. End positioning components are installed at both ends of the cable, and several support components are disposed between the two end positioning components. Through the above technical solution, the problem of bending stress concentration easily occurring in the prior art due to the frequent bending of drag chain cables, which easily leads to damage to the insulation layer and sheath layer, is solved.

Description

Technical Field

[0001] This invention relates to the field of power cable technology, specifically to a high-voltage cable that is resistant to bending. Background Technology

[0002] Bending-resistant cables are widely used in factories and enterprises due to their strong bending resistance and durability. At present, bending-resistant cables have become a common type of cable in industrial production industries. They are widely used in the metallurgical industry and automation equipment field, and are required to have extremely strong bending resistance, acid and alkali resistance, wear resistance, moisture resistance, and the ability to work in humid environments for a long time.

[0003] In industrial and daily applications, cables are often used in conjunction with cable chains in dynamic environments. To meet the requirements of cable chain operation, a multi-core conductor stranded structure is usually adopted, with an insulation layer, a filler layer, a wrapping layer, and a sheath layer set in sequence on the outside. By selecting flexible insulation and sheath materials and optimizing conductor stranding density, the basic bending resistance of the cable is improved, enabling it to adapt to repeated bending and movement conditions to a certain extent and ensuring the stability of high-voltage power supply.

[0004] In existing technologies, cables often employ solid or integral filled structures internally, resulting in relatively limited deformation of the filling layer during bending. This makes it difficult to proactively provide sufficient deformation space for the conductor when the cable is bent, leading to conductor compression and insulation wear. Furthermore, because multiple conductors are twisted together, they are prone to unraveling and positional shifts after repeated bending over a long period. In addition, the cable-cable coupling structure is relatively simple, often using a direct rigid fixation at both ends. This structure easily causes rigid compression damage to the cable sheath. During bending, the middle section of the cable is also prone to excessive friction with the inner wall of the cable chain, resulting in sagging due to its own weight and further cable damage. Especially under high-voltage operating conditions, the stress concentration caused by these problems is more pronounced, resulting in a relatively low repeated bending life of existing cables, making it difficult to balance high-voltage insulation and mechanical service life. Summary of the Invention

[0005] This invention proposes a bend-resistant high-voltage cable to solve the problem in the prior art where the frequent bending of drag chain cables easily leads to stress concentration during bending, which in turn easily causes damage to the insulation and sheath layers.

[0006] The technical solution of the present invention is as follows: A bend-resistant high-voltage cable includes several stranded multi-core conductors, each of which is covered with an insulation layer, and further includes: A flexible tube is disposed between multiple multi-core conductors, and the flexible tube abuts against the insulation layer outside the multiple multi-core conductors respectively; A filler layer, a wrapping layer, a buffer layer, and a sheath layer are sequentially provided on the outside of several multi-core conductors. When the cable is bent, the filler layer can deform to make room for deformation of the multi-core conductors. An end positioning assembly is provided, wherein the end positioning assembly is installed at both ends of the cable, and a plurality of supporting assemblies are provided between the two end positioning assemblies. The end positioning structure is used to fix the relative position of the two ends of the cable and the drag chain, wherein the drag chain is composed of a plurality of chain links. The end positioning components are installed on the chain links at both ends of the cable chain via positioning brackets. Support brackets are installed on the remaining chain links. Each of the support brackets is connected to a support component. The support components can slide on the sheath layer along the length of the cable.

[0007] Furthermore, the filling layer is composed of several filling strips, and tensile ropes are provided inside each of the several filling strips along the length direction. Elliptical filling ropes are provided inside each of the filling strips along its length.

[0008] Furthermore, each of the elliptical filling ropes is composed of two flexible filling ropes. Each flexible filling rope has several insertion protrusions arranged at equal intervals. The insertion protrusions on each pair of matching flexible filling ropes are arranged alternately. Each flexible filling rope has an insertion groove, which is adapted to the corresponding insertion protrusion.

[0009] To secure the cable within the cable chain, the end positioning assembly includes: The lower arc-shaped positioning frame is installed on each of the positioning brackets, and each of the lower arc-shaped positioning frames is provided with a matching upper arc-shaped positioning frame. The upper arc-shaped positioning frame is installed on the positioning bracket by fasteners. The arc-shaped pad is installed inside each of the lower arc-shaped positioning frames and each of the upper arc-shaped positioning frames.

[0010] The arc-shaped pad has a hollow structure that is thin in the middle and thick at both ends.

[0011] To avoid excessive friction between the cable and the inner wall of the cable chain links, the support assembly includes: Support ring, each of the support brackets is provided with a support ring inside; An annular protrusion is provided on the outer side of each of the supporting rings. A snap-fit ​​ring is provided at the position corresponding to the supporting bracket of the annular protrusion, and the snap-fit ​​ring is adapted to the annular protrusion. Sliding rings are installed inside each of the supporting rings.

[0012] Furthermore, the structure of the hole in the middle of the sliding ring is set as an arc-shaped structure with the middle dimension smaller than the dimensions at both ends, and there is a gap between the sliding ring and the sheath layer, and the sheath layer slides in fit with the sliding ring.

[0013] The working principle and beneficial effects of this invention are as follows: 1. In this invention, a flexible tube is set in the middle of the multi-core conductor, and a flexible filling layer is formed by plug-in elliptical filling rope. The flexible tube continuously abuts the insulation layer radially, firmly constraining the position of the stranded multi-core conductor, avoiding conductor stranding and displacement problems caused by long-term frequent bending. The filling layer can adaptively deform with the bending of the cable, actively reserving sufficient deformation space for the multi-core conductor, relieving bending pressure from the inside, and preventing conductor from squeezing and wearing the insulation layer. At the same time, the filling strip has built-in anti-tensile rope, which takes into account the axial tensile performance of the cable, ensuring the stability of the internal structure of the cable and adapting to the insulation protection requirements under high-voltage conditions.

[0014] 2. In this invention, a hollow arc-shaped pad that is thin in the middle and thick at both ends is used in conjunction with upper and lower arc-shaped positioning frames to achieve flexible locking of the cable and the cable chain. This can not only firmly fix the cable end and prevent excessive relative slippage between the cable and the cable chain, ensuring that the movement of the cable chain and the bending of the cable are synchronized, but also use the elastic deformation of the arc-shaped pad to buffer the rigid compression of the cable end during the movement of the cable chain, preventing the sheath layer and insulation layer from being damaged by pressure.

[0015] 3. In this invention, the sliding ring and the sheath layer slide together to stably support the cable, preventing the middle section of the cable from sagging due to its own weight and generating excessive friction with the inner wall of the cable chain. At the same time, it does not restrict the axial expansion and contraction and bending deformation of the cable. With the buffer layer and the wrapping layer dispersing the bending stress layer by layer, it completely alleviates the stress concentration problem caused by the frequent bending of the cable chain, greatly improves the cable's lifespan against repeated bending, and truly takes into account both the high voltage insulation reliability and mechanical service life, making it suitable for various dynamic high voltage power supply scenarios of cable chains. Attached Figure Description

[0016] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0017] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a cross-sectional three-dimensional structural schematic diagram of the present invention; Figure 3 This is a schematic diagram of the overall separable structure in this invention; Figure 4This is a schematic diagram of the structure of the multi-core conductor, insulating layer, flexible tube, wrapping layer, buffer layer, sheath layer, filling tape, tensile rope, and elliptical filling rope in this invention. Figure 5 This is a cross-sectional view of the flexible filling rope, the insertion protrusion, and the insertion groove in this invention. Figure 6 This is a cross-sectional view of the end positioning component in this invention; Figure 7 This is a schematic diagram of the cross-sectional structure of the separated cross-sectional positioning components in this invention; Figure 8 This is a cross-sectional view of the support component in this invention; Figure 9 This is a cross-sectional view of the support bracket and the snap ring in this invention.

[0018] In the diagram: 1. Multi-core conductor; 2. Insulation layer; 3. Flexible tube; 4. Wrapping layer; 5. Buffer layer; 6. Sheath layer; 7. Positioning bracket; 8. Support bracket; 9. Filler tape; 10. Tensile rope; 11. Elliptical filler rope; 1101. Flexible filler rope; 1102. Insertion protrusion; 1103. Insertion groove; 12. Lower arc-shaped positioning frame; 13. Upper arc-shaped positioning frame; 14. Fastener; 15. Arc-shaped pad; 16. Support ring; 17. Annular protrusion; 18. Snap-fit ​​ring; 19. Sliding ring; 20. Unit link. Detailed Implementation

[0019] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0020] like Figures 1 to 9 As shown, this embodiment proposes a bend-resistant high-voltage cable, including several stranded multi-core conductors 1. Each multi-core conductor 1 is covered with an insulation layer 2, which is made of cross-linked polyethylene. The cable also includes a flexible tube 3, a filling layer, a wrapping layer 4, a buffer layer 5, a sheath layer 6, and an end positioning component. The flexible tube 3 is disposed in the middle of the multi-core conductors 1 and abuts against the insulation layer 2 on the outside of each multi-core conductor 1. The multi-core conductors 1 are sequentially covered with a filling layer, a wrapping layer 4, a buffer layer 5, and a sheath layer 6. When the cable is bent, the filling layer can deform to make room for the multi-core conductors 1. The filling layer is composed of several filling strips 9. Each filling strip 9 has a tensile rope 10 made of several tensile filaments twisted together along its length. Each filling strip 9 has an elliptical filling rope 11 along its length.

[0021] Each elliptical filling rope 11 is composed of two flexible filling ropes 1101. Each flexible filling rope 1101 has several insertion protrusions 1102 arranged at equal intervals. The insertion protrusions 1102 on each pair of matching flexible filling ropes 1101 are arranged alternately. Each flexible filling rope 1101 has an insertion groove 1103, which is adapted to the corresponding insertion protrusion 1102.

[0022] It should be added that the flexible tube 3 is recommended to be made of flexible rubber or flexible plastic, the wrapping layer 4 can be made of non-woven fabric or polyester tape, the sheath layer 6 can be made of materials such as bend-resistant polyurethane, and the buffer layer 5 can be made of foamed rubber or foamed polyethylene tape, so as to meet the usage requirements.

[0023] When the cable is frequently bent, the centrally located flexible tube 3 continuously radially abuts against the outer insulation layer 2 of the multi-core conductor 1, constraining the position of the stranded conductor, preventing the conductor from unraveling or shifting, maintaining the regularity of the internal structure of the cable, and reducing the situation of the conductor squeezing the insulation layer 2 from the source. At the same time, when the cable is bent and generates extrusion pressure, the elliptical filling rope 11, which is composed of two flexible filling ropes 1101 inserted together, can adapt to the extrusion pressure and deform accordingly. It works in conjunction with the overall deformation of the filling tape 9 to actively provide sufficient deformation space for the multi-core conductor 1, avoiding damage to the conductor due to pressure. The built-in tensile rope 10 simultaneously ensures the axial tensile strength of the cable to play a tensile role.

[0024] When installing the cable in the cable carrier, first install both ends of the cable in front of the unit links 20 at both ends of the cable carrier using the end positioning components. Then, let the cable pass through all the supporting components in sequence, and then fix both ends of the cable to install the cable on the cable carrier.

[0025] When the cable needs to be bent, the end positioning components at both ends can undergo elastic deformation, thereby preventing excessive relative slippage between the cable and the cable chain. At the same time, it buffers the squeezing force on the cable during the movement of the cable chain. The buffer layer 5 is made of several foamed tapes wound in a spiral shape. Together with the flexible tube 3 and the filler tape 9, it prevents the sheath layer 6 and the insulation layer 2 from being crushed. Furthermore, during the bending process of the cable, the middle section of the cable can slide relative to the supporting components, preserving the deformation space for axial sliding and bending of the cable.

[0026] Both ends of the cable are equipped with end positioning components, and several support components are arranged between the two end positioning components. The end positioning structure is used to fix the relative position of the cable ends and the cable chain. The cable chain consists of several links. The links at both ends of the cable chain are equipped with end positioning components through positioning brackets 7, and the remaining links are equipped with support brackets 8. The support brackets 8 are connected to the support components one by one. The support components can slide on the sheath layer 6 along the length of the cable. The end positioning component includes a lower arc-shaped positioning frame 12 and an arc-shaped pad 15. Each positioning bracket 7 is equipped with a lower arc-shaped positioning frame 12, and each lower arc-shaped positioning frame 12 is equipped with a matching upper arc-shaped positioning frame 13. The upper arc-shaped positioning bracket 13 is installed on the positioning bracket 7 by fasteners 14. The fasteners 14 are preferably matched screws and nuts. The nuts are installed on the positioning bracket 7. Mounting holes are opened at both ends of the upper arc-shaped positioning bracket 13. When the upper arc-shaped positioning bracket 13 is placed on the lower arc-shaped positioning bracket 12, the position of the mounting hole corresponds to the position of the nut. At this time, the matching screw is screwed into the corresponding nut through the mounting hole to complete the installation of the upper arc-shaped positioning bracket 13 and the positioning bracket 7. Each lower arc-shaped positioning bracket 12 and each upper arc-shaped positioning bracket 13 are equipped with an arc-shaped pad 15. The arc-shaped pad 15 is designed as a hollow structure with a thin middle and thick ends. The material of the arc-shaped pad 15 can be elastic rubber or silicone.

[0027] When installing the cable in the cable carrier, first thread the cable through the corresponding support components in sequence. Then, when it is necessary to fix the end of the cable to the unit link 20 at the end of the cable carrier, place the end of the cable on the corresponding positioning bracket 7. At this time, the sheath layer 6 of the cable end abuts against the arc pad 15 on the corresponding lower arc positioning frame 12. Then, install the upper arc positioning frame 13 on the corresponding lower arc positioning frame 12. At this time, the arc pad 15 on the upper arc positioning frame 13 also abuts against the sheath layer 6 of the cable end. Finally, fix the position of the cable by setting the fastener 14.

[0028] Because the arc-shaped pad 15 has a hollow structure that is thin in the middle and thick at both ends (as shown in the image). Figure 7 As shown, while clamping the cable, elastic deformation can occur, thereby reducing the occurrence of relative slippage between the cable and the two ends of the drag chain. This buffers the compressive stress on the cable ends during drag chain movement, preventing damage to the sheath layer 6 and insulation layer 2. The middle section of the cable retains space for axial sliding and bending deformation.

[0029] The support assembly includes a support ring 16, an annular protrusion 17, and a sliding ring 19. Each support bracket 8 has a support ring 16 inside, and an annular protrusion 17 is provided on the outer side of each support ring 16. A snap-fit ​​ring 18 is provided at the position corresponding to the annular protrusion 17 and the support bracket 8. The snap-fit ​​ring 18 is adapted to the annular protrusion 17. A sliding ring 19 is installed inside each support ring 16. The structure of the hole in the middle of the sliding ring 19 is set as an arc structure with the middle dimension smaller than the dimensions at both ends. There is a gap between the sliding ring 19 and the sheath layer 6, and the sheath layer 6 and the sliding ring 19 are in sliding fit.

[0030] It should be added that the sliding ring 19 can be made of stainless steel. The side of the sliding ring 19 that contacts the sheath layer 6 is polished. Relying on the high hardness, wear resistance, corrosion resistance and moderate rigidity of stainless steel, it can ensure that the sliding ring 19 will not deform or break during long-term use, and is suitable for humid and dusty industrial conditions. At the same time, the polished surface can greatly reduce the sliding friction, avoid scratching or damaging the sheath layer 6, ensure smooth cable sliding and no damage to the outer layer, and further improve the overall service life of the cable.

[0031] When installing the cable, first select a suitable cable chain, fix the positioning bracket 7 on the unit chain links 20 at both ends of the cable chain, install the support bracket 8 on the remaining intermediate chain links one by one, and then fix the support ring 16 to the snap ring 18 on the support bracket 8 through the outer annular protrusion 17, thus completing the pre-installation of the cable chain side supporting components.

[0032] The support ring 16 is engaged with the snap ring 18 via the annular protrusion 17 on the support bracket 8, achieving synchronous movement with the chain links. The sliding ring 19 has an arc-shaped inner hole with a small middle and large ends that fits with the sheath. When the cable bends or expands, the cable can slide freely inside the sliding ring 19 along the length of the cable, which not only supports the cable to prevent it from sagging or rubbing against the inner wall of the drag chain, but also does not restrict the cable's own bending deformation resistance.

[0033] The working principle or usage process of this invention is as follows: When installing the cable, first select a suitable cable chain, fix the positioning bracket 7 on the unit chain links 20 at both ends of the cable chain, and install the support bracket 8 on the remaining intermediate chain links one by one. Then, the support ring 16 is fixed to the snap ring 18 on the support bracket 8 through the outer annular protrusion 17, thus completing the pre-installation of the cable chain side components. Then, the cable passes through the sliding ring 19 inside all the support components in sequence along the length of the cable chain, ensuring that the cable is straight, without twisting, and centered in the inner cavity of the cable chain, avoiding contact and friction between the cable and the side wall of the cable chain.

[0034] Then, place both ends of the cable on the corresponding positioning brackets 7. At this time, the sheath layer 6 at the end of the cable abuts against the arc pad 15 on the corresponding lower arc positioning bracket 12. Then, install the upper arc positioning bracket 13 on the corresponding lower arc positioning bracket 12. At this time, the arc pad 15 on the upper arc positioning bracket 13 also abuts against the sheath layer 6 at the end of the cable. Then, fix the position of the cable by setting the fasteners 14.

[0035] Finally, install both ends of the cable chain onto the fixed end and the moving end of the equipment, respectively. Check whether the cable bends smoothly and without jamming during operation, and then it can be put into use.

[0036] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A bend-resistant high-voltage cable, comprising a plurality of stranded multi-core conductors (1), each of the multi-core conductors (1) being covered with an insulation layer (2), characterized in that, Also includes: A flexible tube (3) is disposed between multiple multi-core conductors (1), and the flexible tube (3) abuts against the insulation layer (2) outside the multiple multi-core conductors (1); A filler layer, a wrapping layer (4), a buffer layer (5) and a sheath layer (6) are sequentially wrapped around the outside of several multi-core conductors (1). When the cable is bent, the filler layer can deform to make room for deformation of the multi-core conductors (1). An end positioning assembly is provided, wherein the end positioning assembly is installed at both ends of the cable, and a plurality of supporting assemblies are provided between the two end positioning assemblies. The end positioning structure is used to fix the relative position of the two ends of the cable and the drag chain, wherein the drag chain is composed of a plurality of chain links. The end positioning components are installed on the chain links at both ends of the cable chain via positioning brackets (7), and the remaining chain links are each equipped with a support bracket (8). The support brackets (8) are connected to the support components one by one, and the support components can slide on the sheath layer (6) along the cable length direction.

2. The high-voltage cable with bending resistance according to claim 1, characterized in that, The filling layer is composed of several filling strips (9), and tensile ropes (10) are provided inside each of the several filling strips (9) along the length direction. Each filling strip (9) is provided with an elliptical filling rope (11) along the length direction.

3. The high-voltage cable with bending resistance according to claim 2, characterized in that, Each of the elliptical filling ropes (11) is composed of two flexible filling ropes (1101). Each flexible filling rope (1101) has several insertion protrusions (1102) arranged at equal intervals. The insertion protrusions (1102) on each pair of matching flexible filling ropes (1101) are arranged alternately. Each flexible filling rope (1101) has an insertion groove (1103) that is adapted to the corresponding insertion protrusion (1102).

4. A bend-resistant high-voltage cable according to claim 1, characterized in that, The end positioning component includes: The lower arc-shaped positioning frame (12) is installed on each of the positioning brackets (7), and each of the lower arc-shaped positioning frames (12) is provided with a matching upper arc-shaped positioning frame (13). The upper arc-shaped positioning frame (13) is installed on the positioning bracket (7) by fasteners (14). The arc-shaped pad (15) is installed inside each of the lower arc-shaped positioning frames (12) and each of the upper arc-shaped positioning frames (13).

5. A bend-resistant high-voltage cable according to claim 4, characterized in that, The arc-shaped pad (15) is internally configured as a hollow structure that is thin in the middle and thick at both ends.

6. A bend-resistant high-voltage cable according to claim 1, characterized in that, The support component includes: Support ring (16), each of the support brackets (8) is provided with the support ring (16). An annular protrusion (17) is provided on the outer side of each of the supporting rings (16). A snap ring (18) is provided at the position corresponding to the annular protrusion (17) and the supporting bracket (8). The snap ring (18) is adapted to the annular protrusion (17). Sliding ring (19), each of the supporting rings (16) is equipped with a sliding ring (19).

7. A bend-resistant high-voltage cable according to claim 6, characterized in that, The structure of the hole in the middle of the sliding ring (19) is an arc-shaped structure with the middle dimension smaller than the dimensions at both ends. There is a gap between the sliding ring (19) and the sheath layer (6), and the sheath layer (6) and the sliding ring (19) are in sliding fit.

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