A lightweight large-section conductor and a manufacturing method thereof

Abstract

A lightweight large-section conductor is composed of a compressed and twisted layer of a trapezoidal copper-clad aluminum alloy wire, a compressed and twisted layer of a trapezoidal copper conductor enameled wire, and a compressed and twisted layer of a round copper-clad aluminum alloy wire, from the inside to the outside, and a semi-conductive nylon tape is coated on the surface of the trapezoidal copper conductor enameled wire. The manufacturing method thereof comprises the following steps: Step 1, concentrically coating a pure copper tape with equal thickness on a high-performance aluminum alloy rod, and performing argon arc welding with a coating welding machine to obtain a wire; Step 2, selecting a wire drawing die set to anneal the wire in the wire drawing machine during the drawing process to form a metallurgical bond and obtain the processed wire. Step 3, after the wire is twisted by a frame twisting machine, it is compressed and formed by a die, and the semi-conductive tape is coated on the outer surface. The outer layer of the present invention adopts copper conductor monofilaments coated with insulating varnish to achieve mutual insulation between monofilaments, greatly increase the surface area, reduce the AC resistance of the conductor, and increase the current carrying capacity; the inner layer uses copper-clad aluminum alloy to replace copper, which reduces the cost.

Description

Technical Field

[0001] The invention relates to a cable conductor and a manufacturing method thereof, in particular to a lightweight large-section conductor and a manufacturing method thereof, and belongs to the field of electric power. Background Art

[0002] The conductor of AC cable is usually copper conductor, accounting for 50~70% of the total cable cost. In recent years, the price of copper has increased dramatically, which has brought great challenges to the control of project cost. Due to the skin effect and proximity effect of copper conductor in power cable, the AC resistance will increase significantly as long as the diameter of the conductor is greater than 16mm, thereby increasing the loss of the cable and causing the conductor to heat up. In addition, copper core cable has a large specific gravity, especially large-section power cable is difficult to construct. If aluminum core conductor is used as a substitute, although the cost can be reduced, it is easy to corrode, has poor oxidation resistance, and poor tensile strength and fatigue resistance. Summary of the invention

[0003] In order to solve the above problems, save costs and reduce the weight of cable conductors, a lightweight large-section conductor and a manufacturing method thereof are provided, and the technical solution is as follows:

[0004] A lightweight large-section conductor, which is composed of a compressed and twisted layer of a trapezoidal copper-clad aluminum alloy wire, a compressed and twisted layer of a trapezoidal copper conductor enameled wire coated with a compressed and twisted layer of a round copper-clad aluminum alloy wire from the inside to the outside, and a semi-conductive nylon tape is coated on the surface of the trapezoidal copper conductor enameled wire.

[0005] The thickness of the tightly twisted layer of the trapezoidal copper conductor enameled wire is 8~10mm.

[0006] The volume ratio of the copper layer in the round copper clad aluminum alloy wire and the trapezoidal copper clad aluminum alloy wire is 10~20%.

[0007] The side edges of the trapezoidal copper-clad aluminum alloy wire and the trapezoidal copper conductor enameled wire are chamfered with a radius of 0.3~0.6mm.

[0008] The surface of the trapezoidal copper conductor enameled wire is coated with insulating varnish.

[0009] A method for manufacturing a lightweight large-section conductor comprises the following steps:

[0010] Step 1: Concentrically wrap a pure copper strip with equal thickness on a high-performance aluminum alloy rod, and perform argon arc welding with a wrap welding machine to obtain a wire;

[0011] Step 2: Use a wire drawing die set to anneal the wire in the wire drawing machine during the drawing process to form a metallurgical bond and obtain the processed wire.

[0012] Step 3: After the wires are twisted by a frame twisting machine, they are pressed into shape by a mold and coated with a semi-conductive tape on the outside.

[0013] In step 2, the wire drawing die set is a circular wire drawing die set, and the wire obtained after processing is a circular copper-clad aluminum alloy wire.

[0014] In step 2, the wire drawing die set is a trapezoidal wire drawing die set, and the wire obtained after processing is a trapezoidal copper-clad aluminum alloy wire.

[0015] In step 2, the wire drawing die set is a trapezoidal wire drawing die set, the wire material is a pure copper rod, and the wire material after processing is a trapezoidal copper conductor single wire.

[0016] The trapezoidal copper conductor single wire is evenly sprayed with insulating paint to obtain the trapezoidal copper conductor enameled wire.

[0017] The thickness of the insulating paint is 2~10μm, and the material can be polyurethane paint, polyester imide paint or acetal paint.

[0018] The wire drawing die set can be a cemented carbide die, a polycrystalline die, a diamond coating die or a combination thereof.

[0019] Compared with the prior art, the beneficial effects of the present invention are: 1. Due to the skin effect, the current tends to flow on the surface. The outer layer adopts copper conductor monofilaments coated with insulating paint to achieve mutual insulation between the monofilaments, which greatly increases the surface area, reduces the AC resistance of the conductor, and increases the current carrying capacity; 2. The inner layer uses copper-clad aluminum alloy instead of copper, which has a similar conductive effect but reduces the cost; 3. The compression coefficient of the trapezoidal compressed conductor is greater than 99%, and the size is reduced. Compared with the split conductor, the outer diameter of the conductor is reduced, and the eccentricity of the cross-linked core insulation layer is easier to control, thereby improving the quality of the cable. At the same time, the use of materials such as insulating materials, shielding materials, armor layers and sheath materials in subsequent processes is saved, and the manufacturing cost is reduced; 4. The compressed and twisted cable is easier to process and manufacture than the conventional large-section split conductor; 5. The lightweight of the power cable is achieved, which is convenient for cable installation and laying. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 It is a schematic diagram of the cross-sectional structure of the present invention;

[0021] In the figure: 1. Semi-conductive nylon tape, 2. Round copper-clad aluminum alloy wire, 3. Trapezoidal copper-clad aluminum alloy wire, 4. Trapezoidal copper conductor enameled wire. DETAILED DESCRIPTION

[0022] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0023] Example 1

[0024] A lightweight large-section conductor comprises a compressed and twisted layer of round copper-clad aluminum alloy wires, a compressed and twisted layer of trapezoidal copper-clad aluminum alloy wires and a compressed and twisted layer of trapezoidal copper conductor enameled wires, wherein the trapezoidal copper conductor enameled wires are wrapped with a semi-conductive tape. The compressed and twisted layer of round copper-clad aluminum alloy wires, the compressed and twisted layer of trapezoidal copper-clad aluminum alloy wires and the compressed and twisted layer of trapezoidal copper conductor enameled wires are compressed and formed by a frame stranding machine. The compressed and twisted layer of the trapezoidal copper conductor enameled wires has a thickness of 8 to 10 mm. The semi-conductive tape is a semi-conductive nylon tape.

[0025] Example 2

[0026] Round copper-clad aluminum alloy wire is obtained by the following steps:

[0027] 1) Concentrically wrap the T2 pure copper strip with equal thickness on the high-performance aluminum alloy rod, and perform argon arc welding with a wrap welding machine;

[0028] 2) Select a suitable round wire drawing die set to continuously draw and anneal the wire in the wire drawing machine, that is, annealing is performed simultaneously during the drawing process to form a metallurgical bond and obtain a round copper-clad aluminum alloy wire.

[0029] Example 3

[0030] Trapezoidal copper-clad aluminum alloy wire is obtained by the following steps:

[0031] 1) Concentrically wrap the T2 pure copper strip with equal thickness on the high-performance aluminum alloy rod, and perform argon arc welding with a wrap welding machine;

[0032] 2) Select a suitable trapezoidal wire drawing die set to continuously draw and anneal the wire in the wire drawing machine, that is, annealing is performed simultaneously during the drawing process to form a metallurgical bond and obtain a trapezoidal copper-clad aluminum alloy wire.

[0033] Example 4

[0034] The trapezoidal copper conductor enameled wire is obtained by the following steps:

[0035] 1) Select a suitable trapezoidal wire drawing die set to continuously draw and anneal the T2 pure copper rod in the wire drawing machine, that is, anneal it simultaneously during the drawing process to obtain a trapezoidal copper conductor single wire;

[0036] 2) Spray insulating paint evenly on the trapezoidal copper conductor single wire;

[0037] 3) The sprayed wire is continuously dried in a tube furnace to obtain a trapezoidal copper conductor enameled wire.

[0038] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and range of equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A lightweight large-section conductor, characterized in that The device is composed of, from the inside to the outside, a tightly twisted layer of a round copper-clad aluminum alloy wire (2), a tightly twisted layer of a trapezoidal copper-clad aluminum alloy wire (3), and a tightly twisted layer of a trapezoidal copper conductor enameled wire (4), and a semi-conductive nylon tape (1) is wrapped around the surface of the trapezoidal copper conductor enameled wire (4); The thickness of the compressed and stranded layer of the trapezoidal copper conductor enameled wire (4) is 8-10 mm; The volume of the copper layer in the round copper-clad aluminum alloy wire (2) and the trapezoidal copper-clad aluminum alloy wire (3) is 10-20%; The side edges of the trapezoidal copper-clad aluminum alloy wire (3) and the trapezoidal copper conductor enameled wire (4) are chamfered with a radius of 0.3-0.6 mm; The surface of the trapezoidal copper conductor enameled wire (4) is coated with insulating varnish.

2. A method for manufacturing a lightweight large-section conductor according to claim 1, characterized in that The steps include: Step 1: Concentrically wrap a pure copper strip with equal thickness on a high-performance aluminum alloy rod, and perform argon arc welding with a wrap welding machine to obtain a wire; Step 2: using a wire drawing die set to anneal the wire obtained in step 1 in a wire drawing machine during the drawing process to form a metallurgical bond and obtain a processed copper-clad aluminum alloy wire; A wire drawing die set is selected to anneal the pure copper rod in the wire drawing machine during the drawing process to obtain a single copper conductor wire; Step 3: The copper-clad aluminum alloy wire obtained in step 2 and the copper conductor single wire are twisted together by a frame twisting machine, and then pressed into shape by a mold, and the outer surface is coated with a semi-conductive tape.

3. A method for manufacturing a lightweight large-section conductor according to claim 2, characterized in that The wire drawing die set described in step 2 is a circular wire drawing die set and a trapezoidal wire drawing die set.

4. A method for manufacturing a lightweight large-section conductor according to claim 2, characterized in that The insulating varnish is evenly sprayed on the copper conductor single wire, and the sprayed copper conductor single wire is continuously dried in a tube furnace to obtain the copper conductor enameled wire.

Images