A wear-resistant tensile cable specially used for pile foundation equipment and its preparation process

Abstract

The present invention discloses a special wear-resistant and tensile-resistant cable for pile foundation equipment and a preparation process thereof. The cable comprises a power cable core, a control cable core and a protective layer. The power cable core and the control cable core are wrapped in a cabling structure layer, and the protective layer is wrapped outside the cabling structure layer. The present invention improves the wear resistance and drag resistance of the cable by arranging a reinforcing element in the middle of the power cable core and in the cabling structure layer, and at the same time, the protective layer adopts a high-performance elastomeric material and is provided with a reinforcing structure. Through the close cooperation between the layers, the problem of the core twisting and the protective layer rupture caused by the different friction between the layers of materials due to the uneven force of the mining cable is solved, and the service life of the mining cable is improved. At the same time, its preparation process is simple, easy to operate and highly reliable.

Description

Technical Field

[0001] The invention belongs to the technical field of power cables, and in particular relates to a special wear-resistant tensile cable for pile foundation equipment and a preparation process thereof. Background Art

[0002] Cables for pile foundation equipment are mainly used for mining excavation equipment, drilling, shield machines and other mechanical equipment. They are one of the types of cables with higher performance requirements, greater technical difficulty and harsher use environment among the cables for pile foundation equipment in the mining industry. This type of drag cable is called "weekly cable" in the industry, which means that the service life is about seven days a week. Why is the service life so short? The main reason is that during the high-speed, violent and high-frequency reciprocating dragging of the cable in a harsh environment, the cable is very susceptible to lateral or longitudinal tension, resulting in the control core or monitoring core being broken. Sometimes, even the power core of the cable is directly broken. The main reason why the drag cables for pile foundations produced by most cable manufacturers have a low service life is that the cable materials and cable process design are unreasonable. Ultimately, the cables cannot withstand high-intensity operation, resulting in the failure to meet the specified cable service life.

[0003] The commonly used drag cable structure in special cables for pile foundation equipment is mainly composed of power core, control core (monitoring line), ground core, insulation and sheath. The control core and power core are the main soul of the cable. If the control core breaks, the cable will be out of control and the electrical equipment will malfunction. If the power core breaks, the entire cable will be scrapped.

[0004] Therefore, providing a cable for pile foundation equipment that is wear-resistant, tensile-resistant and has a long service life is a problem that needs to be solved by those skilled in the art. Summary of the invention

[0005] In view of the problem of short service life of existing special cables for pile foundation equipment, the purpose of the present invention is to provide a special wear-resistant tensile cable for pile foundation equipment and a preparation process thereof, which solves the problems of easy core breakage of cable conductors and control wire cores for pile foundation equipment and short service life of cables, and can meet the use requirements of cables for pile foundation equipment.

[0006] In order to achieve the above-mentioned object, the present invention provides a special wear-resistant tensile cable for pile foundation equipment, comprising a power cable core, a control cable core and a protective layer, wherein the power cable core and the control cable core are wrapped in a cabling structure layer, and the protective layer is wrapped outside the cabling structure layer;

[0007] The power cable core comprises a power core, which is composed of a high-flexibility main core conductor, a reinforcing element is arranged at the center of the high-flexibility main core conductor, a reinforced conductor sheath is arranged outside the high-flexibility main core conductor, and an elastic main core insulation layer is arranged outside the reinforced conductor sheath;

[0008] The control cable core comprises a control core, which is composed of a high-flexibility main core conductor, a reinforcing element is arranged at the center of the high-flexibility main core conductor, a reinforced conductor sheath is arranged outside the high-flexibility main core conductor, and an elastic control core insulation layer is arranged outside the reinforced conductor sheath;

[0009] The cabling structure layer is composed of a cabling braided reinforcement layer;

[0010] The protective layer comprises an elastomer inner lining layer, an aramid filament reinforcement layer and an elastomer outer protective layer, and the three are processed from inside to outside in a non-co-extrusion manner to form a three-layer bonding structure.

[0011] Furthermore, the highly flexible main line core conductor is made of the sixth type of ultra-fine soft copper conductor that is precisely twisted.

[0012] Furthermore, the reinforcing element is composed of an aramid reinforcing core.

[0013] Furthermore, the reinforced conductor wrapping layer is made of high-strength polyester tape.

[0014] Furthermore, the elastic main core insulation layer and the elastic control core insulation layer are both made of elastic plastic insulation material.

[0015] Furthermore, the cabled braided reinforcement layer is woven with high-strength steel wires, and a fiber wire structure is woven outside the steel wires.

[0016] Furthermore, the elastomer inner lining layer is made of elastomer plastic, the aramid filament reinforcement layer is woven from high-strength aramid filaments, and the elastomer outer sheath is made of high-strength and wear-resistant elastomer plastic.

[0017] The present invention also provides a preparation process for the above-mentioned wear-resistant and tension-resistant cable specially used for pile foundation equipment. First, a reinforcing element is set on the conductor during the process of bundling and twisting the conductor, and then the conductor is wrapped with an insulating layer. When the cable core is twisted into a cable, a braided reinforcement structure is set on the cabling structure layer. Finally, a wear-resistant and tension-resistant protective layer is set outside the cabling structure layer.

[0018] Furthermore, the wire bundling direction and the wire twisting direction of the conductor are arranged in different directions, the wire bundling pitch multiple of the conductor is controlled between 8-14 times, and the wire twisting pitch multiple is controlled between 10-16 times.

[0019] Furthermore, the protective layer includes an elastomer inner lining layer, an aramid filament reinforcement layer and an elastomer outer sheath, and the three are processed from the inside to the outside into a three-layer bonding structure in a non-co-extrusion manner. The elastomer inner lining layer is coated on the cable core using a full extrusion process, the weaving density of the aramid filament reinforcement layer is controlled at 40%-45%, and the elastomer outer sheath is coated on the aramid filament reinforcement layer in a full extrusion form. At the same time, the cable is heated before the elastomer outer sheath is extruded, and the heating temperature is between 60-65 degrees Celsius.

[0020] The wear-resistant and tensile-resistant cable specially used for pile foundation equipment provided by the present invention completely integrates the insulating layer, the cabling braided reinforcement layer, the elastomer inner lining layer, the tear-resistant aramid fiber reinforcement layer and the elastomer outer sheath together, thereby solving the problem of loose adhesion and easy delamination between the layers, so that the wire core, the cable core, the cabling braided reinforcement layer and the protective layer are twisted at the same time during the twisting process of the cable, fundamentally solving the problem of wire core breaking and protective layer rupture caused by different friction forces between the layers of materials due to uneven force for mining cables, thereby improving the service life of mining cables, and at the same time its preparation process is simple, easy to operate and highly reliable. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present invention is further described below in conjunction with the accompanying drawings and specific embodiments.

[0022] Figure 1 It is a schematic diagram of the cross-sectional structure of the wear-resistant tensile cable specially used for pile foundation equipment in this example;

[0023] Figure 2 This is a schematic diagram of the process flow of the wear-resistant tensile cable specially used for pile foundation equipment in this example.

[0024] Meaning of the symbols in the figure:

[0025] Aramid reinforcement core 1, high-flexible main core conductor 2, reinforced conductor sheath 3, elastomeric main core insulation layer 4, high-flexible control core conductor 5, elastomeric control core insulation layer 6, cabling braid reinforcement layer 7, elastomeric inner lining layer 8, aramid silk reinforcement layer 9, elastomeric outer sheath 10. DETAILED DESCRIPTION

[0026] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further explained below with reference to specific diagrams.

[0027] In view of the problem of short service life of existing cables dedicated to pile foundation equipment, this example provides a wear-resistant and tensile-resistant cable dedicated to pile foundation equipment, which solves the problem of easy breakage of cable conductors and control wire cores used in pile foundation equipment and short cable service life, and can meet the use requirements of cables for pile foundation equipment.

[0028] like Figure 1As shown, the wear-resistant tensile cable specially used for pile foundation equipment provided in this example includes: a power cable core, a control cable core and a protective layer, wherein the power cable core and the control cable core are wrapped in a cabling structure layer, and the protective layer is wrapped outside the cabling structure layer.

[0029] Specifically, the power cable core includes a power line core, which is composed of a highly flexible main line core conductor 2 for conducting electricity. The highly flexible main line core conductor 2 in this example is preferably made of the sixth type of ultra-fine soft copper conductor, which can effectively ensure the stable output of the cable's electrical performance.

[0030] At the same time, an aramid reinforcing core 1 is arranged in the center of the high-flexibility main core conductor 2 to improve the anti-twisting and anti-dragging capabilities of the conductor core and to improve the mechanical strength of the twisted conductor. In this example, high-strength aramid wires are preferably used for regular twisting.

[0031] Furthermore, a reinforced conductor wrapping layer 3 is provided outside the highly flexible main line core conductor 2, which is used to wrap the highly flexible main line core conductor 2 into an integral structure and play a role in heat insulation.

[0032] The reinforced conductor wrapping layer 3 in this example is preferably made of high-strength polyester tape, which can achieve good heat insulation and electrical insulation effects.

[0033] Furthermore, an elastomeric main core insulation layer 4 is provided on the outside of the reinforced conductor sheath 3 for insulation and heat insulation to prevent the high-flexibility main core conductor 2 from breaking through the external protective layer, which is made of an elastomeric material with higher purity, stronger mechanical properties and better dielectric properties.

[0034] The elastomeric main core insulation layer 4 in this example is preferably made of elastomeric plastic insulation material, which can not only provide insulation and heat insulation, but also improve the wear resistance and tensile resistance of the cable.

[0035] The control cable core in this example includes a control core, which is composed of a highly flexible control core conductor 5 for conducting electricity. The highly flexible control core conductor 5 in this example is preferably made of the sixth type of ultra-fine soft copper conductor, which can effectively ensure the stable output of the cable's electrical performance.

[0036] At the same time, an aramid reinforcing core 1 is arranged at the center of the high-flexibility control core conductor 5 to improve the anti-twisting and anti-dragging capabilities of the conductor core and to improve the mechanical strength of the twisted conductor. In this example, high-strength aramid wires are preferably used for regular twisting.

[0037] Furthermore, a reinforced conductor wrapping layer 3 is provided outside the highly flexible control core conductor 5, which is used to wrap the highly flexible main core conductor 2 into an integral structure and play a role in heat insulation.

[0038] The reinforced conductor wrapping layer 3 in this example is preferably wrapped with a high-strength polyester tape, which can achieve a good heat insulation effect.

[0039] Furthermore, an elastomeric control core insulation layer 6 is provided on the outside of the reinforced conductor sheath 3 for insulation and heat insulation to prevent the high-flexibility control core conductor 5 from breaking through the external protective layer, which is made of an elastomeric material with higher purity, stronger mechanical properties and better dielectric properties.

[0040] The elastomeric control core insulation layer 6 in this example is preferably made of elastomeric plastic insulation material, which can not only provide insulation and heat insulation, but also improve the wear resistance and tensile resistance of the cable.

[0041] Based on the above structure, multiple power cable cores and multiple control cable cores are twisted together and then wrapped in a cabling structure layer to form the overall structure of the cable.

[0042] In order to improve the cable's ability to withstand alternating stresses of reciprocating bending and dragging, the cabling structure layer in this example is preferably formed by a cabling braided reinforcement layer 7, which is preferably woven from high-strength steel wires.

[0043] Since the interaction force between the steel wire and the cable core insulation layer will increase the sliding friction between the steel wire and the insulation layer, the steel wire is prone to fatigue and aging, and the surface is scratched, resulting in uneven radial force on the steel wire, excessive local force, and steel wire breakage. In this example, a braided steel wire structure is preferably used. In the specific setting, a fiber wire structure can be woven outside the steel wire to make the force between the steel wire and the cable core uniform, reduce the sliding friction coefficient, improve the bearing capacity of the steel wire, and also enable the steel wire to withstand greater tension.

[0044] Furthermore, in order to improve the cable's anti-dragging performance, this example also provides a protective layer on the outside of the cable braided reinforcement layer 7, wherein the protective layer includes an elastomer inner lining layer 8, an aramid fiber reinforcement layer 9 and an elastomer outer sheath 10, and the three are processed from the inside to the outside in a non-co-extrusion manner to form a three-layer bonding structure.

[0045] Among them, the elastomeric inner lining layer 8 is used to form a tightly connected structure with the cable braided reinforcement layer 7. The elastomeric inner lining layer 8 in this example is preferably made of elastomeric plastic, which can have good bonding properties on the one hand and improve the cable's anti-drag performance on the other hand.

[0046] In the specific configuration, the elastomeric inner lining layer 8 in this example is preferably made of elastomeric plastic.

[0047] The aramid fiber reinforcement layer 9 is bonded outside the elastic inner lining layer 8 to disperse the local concentrated stress and greatly reduce the torsion of the cable core. In the specific setting, the aramid fiber reinforcement layer 9 in this example is preferably made of high-strength aramid fibers.

[0048] The elastomer outer sheath 10 is bonded and arranged outside the aramid fiber reinforcement layer 9 to improve the cable's drag resistance. In the specific arrangement, the elastomer outer sheath 10 in this example is preferably made of high-strength wear-resistant elastomer plastic.

[0049] The wear-resistant and tensile-resistant cable specially used for pile foundation equipment provided in this example solves the problem of loose adhesion and easy delamination between the layers by completely integrating the insulating layer, the cabling braided reinforcement layer 7, the elastomer inner lining layer 8, the tear-resistant aramid silk reinforcement layer 9 and the elastomer outer sheath 10. During the torsion process of the cable, the wire core, the cable braided reinforcement layer 7 and the protective layer are twisted at the same time, fundamentally solving the problem of wire core breaking and protective layer rupture due to different friction between the layers of materials caused by uneven force in mining cables, thereby improving the service life of mining cables.

[0050] like Figure 2 As shown, a wear-resistant and tensile-resistant cable specially used for pile foundation equipment is provided based on the above-mentioned structural setting. This example also provides a production process of the cable, including the following steps: first, a reinforcing element is arranged on the conductor during the process of bundling and twisting the wires, and then an insulating layer is wrapped around the conductor. When the cable core is twisted into a cable, a braided reinforcement structure is arranged on the cabling structure layer, and finally a wear-resistant and drag-resistant protective layer is arranged outside the cabling structure layer.

[0051] The production process of the above-mentioned wear-resistant tensile cable specially used for pile foundation equipment is described in detail below with reference to specific examples.

[0052] (1) Conductor bundles and twisted wires

[0053] In this example, the direction of the conductor wire bundle and the direction of the twisted wire are set in different directions, that is, the right-hand wire bundle and the left-hand twisted wire or the opposite direction are uniformly required. At the same time, in order to improve the tensile and torsional resistance of the wire core, the wire bundle pitch multiple is controlled between 10-12 times, and the twisted wire pitch multiple is controlled between 12-14 times. At the same time, the setting of the reinforcing element is increased during the twisting process to improve the tensile strength of the conductor. The reinforcing element in this example is preferably aramid wire reinforcing wire. Aramid wire is the main raw material for military bulletproof vests. Its excellent tensile strength is 5-6 times that of high-quality steel and can reach 4.0GPa. Therefore, placing aramid wire in the center and periphery of the twisted wire can greatly improve the conductor core's ability to resist torsion and dragging. While improving the mechanical strength of the twisted conductor, it can effectively ensure the stable output of the cable's electrical performance.

[0054] (2) Setting of insulation layer

[0055] This example aims to improve the stress and torsion resistance of pile foundation cables. On the one hand, the insulating material of the insulating layer adopts an elastomeric material with higher purity, stronger mechanical properties and better dielectric properties to improve the quality of raw materials. On the other hand, the insulating layer adopts a full extrusion method to prevent decoupling between the insulating layer and the conductor. The insulation performance indicators of the optimized and improved insulation are much higher than the standard requirements, with a tensile strength of 17MPa and an elongation of more than 400%.

[0056] (3) Optimization design of cabling process

[0057] In this example, the cabling process adds load-bearing components. Conventional products of cabling components use steel wire to strengthen the core. As the cable is subjected to alternating stress from reciprocating bending and dragging, the interaction between the steel wire and the insulation layer will increase the sliding friction between the steel wire and the insulation layer. The steel wire is prone to fatigue aging and scratching the surface, resulting in uneven radial force on the steel wire, excessive local force, and steel wire breakage. In order to overcome this problem, the new towing cable adopts a braided steel wire structure, that is, a fiber wire structure braided outside the steel wire, so that the force between the steel wire and the cable core is uniform, the sliding friction coefficient is reduced, the bearing capacity of the steel wire is improved, and the steel wire can also withstand greater tension.

[0058] (4) Setting of protective layer

[0059] The protective layer in this example includes an elastomeric inner lining layer 8, an aramid fiber reinforcement layer 9 and an elastomeric outer sheath 10 which are arranged in sequence from the inside to the outside. The three are processed into a three-layer bonding structure in a non-co-extrusion manner. This structure is an important part to ensure the good performance of the drag cable. The bonding structure between the elastomeric outer sheath 10, the aramid fiber reinforcement layer 9 and the elastomeric inner lining layer 8 enables the elastomeric inner lining layer 8 to bear the tension and torsion of the elastomeric outer sheath 10 after being reinforced by the aramid fiber reinforcement layer 9. The aramid fiber reinforcement layer 9 in the center can disperse the locally concentrated stress and greatly reduce the torsion exerted on the cable core.

[0060] Furthermore, the combination of the three layers of the protective layer should be able to adhere to each other and not be easy to delaminate. How to ensure the tight adhesion of the sheath layer requires optimization and improvement of the material formula. In general, materials with different molecular weights and different molecular structures are selected, and suitable materials are selected according to the principle of similar compatibility. Here, the elastomer inner lining layer 8 is preferably composed of elastomer polyvinyl chloride insulation or its equivalent synthetic high molecular polymer, and the elastomer outer sheath 10 is preferably composed of elastomer polyolefin material. The elastomer inner lining layer 8 here must be extruded by a full extrusion process to ensure the tight combination of the elastomer inner lining layer 8 and the cable core. The aramid fiber reinforcement layer 9 is made of high-strength aramid fiber material, and the braiding density is controlled at 40%-45%. The braiding mesh must be executed according to this process. The braiding density should not be too large to prevent the elastomer outer sheath 10 from being tightly clamped into the braiding gap. Before the aramid fiber reinforcement layer 9 is set, the elastomer inner lining layer 8 is heated at a heating temperature of 60-70 degrees Celsius. At this time, the material has excellent viscosity, otherwise it will not achieve the effect of mutual adhesion and not easy to delaminate. The setting of the elastomer outer sheath 10 should be in full extrusion form. At the same time, the cable is heated before extrusion of the elastomer outer sheath 10. The heating temperature is 60-65 degrees Celsius to ensure the close bonding between the elastomer inner lining 8, the aramid fiber reinforcement layer 9 and the elastomer outer sheath 10.

[0061] (5) Finished product inspection and warehousing

[0062] Finally, the finished products are tested and put into storage after confirming the composite requirements.

[0063] The above shows and describes the basic principles, main features and advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A wear-resistant tensile cable specially used for pile foundation equipment, characterized in that: It comprises a power cable core, a control cable core and a protective layer, wherein the power cable core and the control cable core are wrapped in a cabling structure layer, and the protective layer is wrapped outside the cabling structure layer; The power cable core comprises a power core, which is composed of a high-flexibility main core conductor, a reinforcing element is arranged at the center of the high-flexibility main core conductor, a reinforced conductor sheath is arranged outside the high-flexibility main core conductor, and an elastic main core insulation layer is arranged outside the reinforced conductor sheath; The control cable core comprises a control core, which is composed of a high-flexibility main core conductor, a reinforcing element is arranged at the center of the high-flexibility main core conductor, a reinforced conductor sheath is arranged outside the high-flexibility main core conductor, and an elastic control core insulation layer is arranged outside the reinforced conductor sheath; A plurality of power cable cores and a plurality of control cable cores are twisted together and then wrapped in a cabling structure layer to form the overall structure of the cable; the cabling structure layer is woven with high-strength steel wires, and a fiber wire structure is woven outside the steel wires; The protective layer comprises an elastomer inner lining layer, an aramid filament reinforcement layer and an elastomer outer protective layer, and the three are processed from inside to outside in a non-co-extrusion manner to form a three-layer bonding structure.

2. The wear-resistant tensile cable for pile foundation equipment according to claim 1 is characterized in that: The highly flexible main line core conductor is made of the sixth type of ultra-fine soft copper conductor finely twisted.

3. The wear-resistant tensile cable for pile foundation equipment according to claim 1, characterized in that: The reinforcing element is composed of an aramid reinforcing core.

4. The wear-resistant tensile cable for pile foundation equipment according to claim 1, characterized in that: The reinforced conductor wrapping layer is made of high-strength polyester tape.

5. The wear-resistant tensile cable for pile foundation equipment according to claim 1, characterized in that: The elastic main line core insulation layer and the elastic control line core insulation layer are both made of elastic plastic insulation material.

6. The wear-resistant tensile cable for pile foundation equipment according to claim 1, characterized in that: The elastomer inner lining layer is made of elastomer plastic, the aramid filament reinforcement layer is woven from high-strength aramid filaments, and the elastomer outer sheath is made of high-strength wear-resistant elastomer plastic.

7. A process for preparing the wear-resistant tensile cable for pile foundation equipment according to any one of claims 1 to 6, characterized in that: First, reinforcing elements are set on the conductor during the process of bundling and twisting the wires, and then the conductor is wrapped with an insulating layer. After the cable core is twisted into one, it is wrapped in a cabling structure layer with a braided reinforcement structure. Finally, a wear-resistant and drag-resistant protective layer is set outside the cabling structure layer.

8. The preparation process of the wear-resistant tensile cable for pile foundation equipment according to claim 7, characterized in that: The wire bundling direction and the wire twisting direction of the conductor are arranged in different directions, the wire bundling pitch multiple of the conductor is controlled between 8 and 14 times, and the wire twisting pitch multiple is controlled between 10 and 16 times.

9. The preparation process of the wear-resistant tensile cable for pile foundation equipment according to claim 7, characterized in that: The protective layer includes an elastomer inner lining layer, an aramid filament reinforcement layer and an elastomer outer sheath, and the three are processed from the inside to the outside into a three-layer bonding structure in a non-co-extrusion manner. The elastomer inner lining layer is coated on the cable core by a full extrusion process, the braiding density of the aramid filament reinforcement layer is controlled at 40%-45%, and the elastomer outer sheath is coated on the aramid filament reinforcement layer in a full extrusion form. At the same time, the cable is heated before the elastomer outer sheath is extruded, and the heating temperature is between 60 and 65 degrees Celsius.

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