A method for processing a liquid-cooled cable conductor structure and a liquid-cooled cable conductor structure

Abstract

The present disclosure relates to a liquid-cooled cable conductor structure processing method and a liquid-cooled cable conductor structure. The processing method comprises the following steps: S01, according to the conductor cross-sectional area S 导 Calculate the area of ​​the annular region S 环 ; S02, according to the conductor cross-sectional area S 导 and the single wire diameter d 丝 Calculate the number of conductor single wires Z 计 ; S03, according to the obtained annular area S 环 and the diameter of the liquid cooling tube d 管 Calculate the number of strands n; S04. Calculate the number of strands Z based on the obtained conductor monofilaments 计 The number of single strands Z per strand is calculated by the number of strands n 股 ; S05, according to the number of strands n and the number of single strands Z 股 Correct the calculation to obtain the actual number of conductor single wires Z 实 ; S06, forming a liquid cooling cable conductor structure according to the obtained parameters. The liquid cooling cable conductor structure is formed by the above-mentioned processing method. The present disclosure can ensure that the conductor structure meets the requirements of small size and high roundness, and is helpful to improve the production efficiency of the liquid cooling cable, reduce material costs, and improve the appearance quality.

Description

Technical Field

[0001] The present disclosure relates to the technical field of cable processing, and in particular to a method for processing a liquid-cooled cable conductor structure and a liquid-cooled cable conductor structure. Background Art

[0002] Liquid-cooled cables have liquid cooling tubes inside, which can remove the heat generated by the conductor during operation through the circulation of coolant, thereby achieving rapid cooling. Their current carrying capacity is greatly increased compared to ordinary cables, and they are widely used in charging pile equipment.

[0003] To facilitate user use, liquid-cooled cables must not only have a large current-carrying capacity, but also meet requirements such as softness, small size and round appearance. Therefore, the conductor structure of liquid-cooled cables is usually the conventional 5th or 6th structure, that is, the conductor is made of thin single wires (usually the single wire diameter is 0.5mm or less) which are first bundled into strands, and then the strands are evenly twisted together outside the liquid cooling tube through a stranding machine.

[0004] When designing the liquid cooling cable conductor structure, it is necessary to consider the conductor cross-sectional area S required by the liquid cooling cable conductor structure. 导 To design the number of conductor single wires, the number of strands n and the number of single strands Z 股 The key parameters of the conductor structure of liquid-cooled cables, such as too many or too few strands, will affect the outer diameter and appearance of the cable products, and even affect the production efficiency of the cable, such as:

[0005] When the number of strands is designed to be too large, some strands will not have enough space when twisting, and the number of layers of the conductor structure must be increased to place them, which will cause the outer diameter of the twisted conductor structure to be large and not round.

[0006] When the number of strands is designed to be too small, on the one hand, the number of single wires in each strand will increase, the outer diameter of the strand will be larger, and the outer diameter of the conductor structure formed by the twisted wire will be large. On the other hand, there will be a large gap between two adjacent strands, which will cause the outer side of the conductor structure to easily become concave at the gap position, resulting in an irregular shape of the conductor structure.

[0007] In summary, in the process of processing the liquid-cooled cable conductor structure, according to the required conductor cross-sectional area S 导 To reasonably design the number of conductor single wires, the number of strands n and the number of single strands Z 股 Parameters such as diameter and roundness are of great significance to the outer diameter and roundness of the conductor structure.

[0008] At present, the existing technology lacks a method for reasonably designing the above parameters. In actual processing, the design is mostly based on the processing experience of the processing personnel. Whether the size and roundness of the conductor structure meet the standards depends entirely on the processing experience of the processing personnel. The dependence on processing experience is large, and it is difficult to ensure that the size and roundness of the liquid-cooled cable products have a high compliance rate, which affects the material cost, production efficiency and product appearance quality during the liquid-cooled cable processing. Summary of the invention

[0009] In order to solve the problems existing in the above-mentioned prior art, one of the purposes of the present disclosure is to provide a method for processing a liquid-cooled cable conductor structure, and the second purpose is to provide a liquid-cooled cable conductor structure. 导 and the single wire diameter d 丝 To determine the reasonable actual number of monofilaments Z 实 , the number of strands n and the number of single strands Z 股 , which can ensure that the conductor structure meets the requirements of small size and high roundness, and helps to improve the production efficiency of liquid-cooled cables, reduce material costs and improve appearance quality.

[0010] A method for processing a liquid-cooled cable conductor structure disclosed in the present invention comprises the following steps:

[0011] S01, according to the conductor cross-sectional area S 导 Calculate the annular area S outside the liquid cooling tube in the conductor structure 环 ;

[0012] S02, according to the conductor cross-sectional area S 导 and the single wire diameter d 丝 Calculate the number of conductor single wires Z 计 ;

[0013] S03, according to the obtained annular area S 环 and the diameter of the liquid cooling tube d 管 Calculate the number of strands n;

[0014] S04. Calculate the number of conductor monofilaments Z based on the obtained 计 The number of single strands Z per strand is calculated by the number of strands n 股 ;

[0015] S05, according to the obtained strand number n and the number of single strands Z 股 Correct the calculation to obtain the actual number of conductor single wires Z 实 ;

[0016] S06, according to the actual number of conductor monofilaments Z 实 , the number of strands n and the number of single strands Z 股 Processing to form a liquid-cooled cable conductor structure.

[0017] Preferably, in step S01, according to the conductor cross-sectional area S 导 Calculate the annular area S outside the liquid cooling tube in the conductor structure 环 Specifically:

[0018] S 环 =1.7*S 导 .

[0019] Preferably, in step S02, according to the conductor cross-sectional area S 导 and the single wire diameter d 丝 Calculate the number of conductor single wires Z 计 Specifically:

[0020] Z 计 =4S 导 / (π*d 丝 2 ).

[0021] Preferably, in step S03, according to the obtained annular area S 环 and the diameter of the liquid cooling tube d 管 The number of strands n is calculated as follows:

[0022] d 环 =(4 / π*S 环 +d 管 2 ) 1 / 2 ;

[0023] d 股 =(d 环 -d 管 ) / 2;

[0024] a=arcsin[d 股 / (d 管 +d 股 )];

[0025] n = ROUND (π / a);

[0026] Where, d 环 Indicates the outer diameter of the conductor structure, d 股 It represents the outer diameter of a single strand of wire, and a represents 1 / 2 of the angle between the centers of two adjacent strands of wire.

[0027] Preferably, in step S04, the number Z of conductor monofilaments is calculated according to the obtained conductor monofilaments. 计 The number of single strands Z per strand is calculated by the number of strands n 股 Specifically:

[0028] Z 股 =ROUND(Z计 / n).

[0029] Preferably, in step S05, according to the obtained strand number n and the number of single strands Z 股 Correct the calculation to obtain the actual number of conductor single wires Z 实 Specifically:

[0030] Z 实 =n*Z 股 .

[0031] Preferably, in step S06, according to the actual number Z of the obtained conductor monofilaments 实 , the number of strands n and the number of single strands Z 股 The structure of the liquid-cooled cable conductor is as follows:

[0032] Take Z 实 The root diameter is d 丝 The number of strands per strand is Z 股 Dividing into n strands, processing the monofilaments of each strand by a bundled wire method to form n strands of wire;

[0033] The obtained n strands of wire are twisted at equal angles and intervals on the outside of the liquid cooling tube by twisting, so as to obtain the liquid cooling cable conductor structure.

[0034] The present disclosure also provides a liquid-cooled cable conductor structure, which is formed by processing using the liquid-cooled cable conductor structure processing method as described above.

[0035] The advantages of the liquid-cooled cable conductor structure processing method and the liquid-cooled cable conductor structure disclosed in the present invention are that the present invention is based on the conductor cross-sectional area S 导 Calculate the area S of the annular region outside the liquid cooling tube 环 , and then according to the conductor cross-sectional area S 导 and the single wire diameter d 丝 Calculate the number of conductor single wires Z 计 , and according to the obtained annular area S 环 and the diameter of the liquid cooling tube d 管 Calculate the number of strands n and the number of strands Z based on the conductor single wire 计 The number of single strands Z per strand is calculated by the number of strands n 股 Then according to the number of single strands Z 股 Correct the calculation to obtain the actual number of conductor single wires Z 实 Finally, according to the actual number of conductor monofilaments Z 实 , the number of strands n and the number of single strands Z 股 The liquid-cooled cable conductor structure is formed by processing. 导 and the single wire diameter d 丝 To determine the reasonable actual number of monofilaments Z实 , the number of strands n and the number of single strands Z 股 , so that the number of strands n and the number of single strands Z 股 The design is accurate and reasonable. It can meet the requirements of the cross-sectional size of the liquid-cooled cable conductor while also meeting the requirements of small size and high roundness. It also helps to improve the production efficiency of the liquid-cooled cable, reduce material costs, and improve appearance quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 is a flow chart of steps of a method for processing a liquid-cooled cable conductor structure disclosed in the present invention;

[0037] Figure 2 is a structural schematic diagram of a liquid-cooled cable conductor structure disclosed in the present invention;

[0038] Figure 3 It is a method model diagram of a liquid-cooled cable conductor structure processing method disclosed in the present invention.

[0039] Explanation of the reference numerals: 1-liquid cooling tube, 2-strand, 3-annular area. DETAILED DESCRIPTION

[0040] like Figure 1 As shown, a method for processing a liquid-cooled cable conductor structure disclosed in the present invention comprises the following steps:

[0041] S01, according to the conductor cross-sectional area S 导 Calculate the annular area S outside the liquid cooling tube in the conductor structure 环 ;

[0042] S02, according to the conductor cross-sectional area S 导 and the single wire diameter d 丝 Calculate the number of conductor single wires Z 计 ;

[0043] S03, according to the obtained annular area S 环 and the diameter of the liquid cooling tube d 管 Calculate the number of strands n;

[0044] S04. Calculate the number of conductor monofilaments Z based on the obtained 计 The number of single strands Z per strand is calculated by the number of strands n 股 ;

[0045] S05, according to the obtained strand number n and the number of single strands Z 股 Correct the calculation to obtain the actual number of conductor single wires Z 实 ;

[0046] S06, according to the actual number of conductor monofilaments Z 实, the number of strands n and the number of single strands Z 股 Processing to form a liquid-cooled cable conductor structure.

[0047] The present disclosure is based on the conductor cross-sectional area S 导 Calculate the area S of the annular region outside the liquid cooling tube 环 , and then according to the conductor cross-sectional area S 导 and the single wire diameter d 丝 Calculate the number of conductor single wires Z 计 , and according to the obtained annular area S 环 and the diameter of the liquid cooling tube d 管 Calculate the number of strands n and the number of strands Z based on the conductor single wire 计 The number of single strands Z per strand is calculated by the number of strands n 股 Then according to the number of single strands Z 股 Correct the calculation to obtain the actual number of conductor single wires Z 实 Finally, according to the actual number of conductor monofilaments Z 实 , the number of strands n and the number of single strands Z 股 The liquid-cooled cable conductor structure is formed by processing. 导 and the single wire diameter d 丝 To determine the reasonable actual number of monofilaments Z 实 , the number of strands n and the number of single strands Z 股 , so that the number of strands n and the number of single strands Z 股 The design is accurate and reasonable. It can meet the requirements of the cross-sectional size of the liquid-cooled cable conductor while also meeting the requirements of small size and high roundness. It also helps to improve the production efficiency of the liquid-cooled cable, reduce material costs, and improve appearance quality.

[0048] Furthermore, in this embodiment, in step S01, according to the conductor cross-sectional area S 导 Calculate the annular area S outside the liquid cooling tube in the conductor structure 环 Specifically:

[0049] S 环 =1.7*S 导 .

[0050] The derivation process of the above formula is as follows:

[0051] According to the calculation formula of the outer diameter of the strand:

[0052] d 股 =[(4z-1) / 3] 1 / 2 *d 丝 ; (1)

[0053] Where, d 股represents the outer diameter of the strand, z represents the number of monofilaments in the strand, d 丝 Indicates the diameter of the single filament.

[0054] Then we have:

[0055] S 股 =π / 4*d 股 2 =π / 12*(4z-1)*d 丝 2 ; (2)

[0056] Where S 股 is the outline area of ​​the strand.

[0057] S 丝实 =z*π / 4*d 丝 2 ; (3)

[0058] Where S 丝实 Represents the actual area of ​​the monofilaments in the strand.

[0059] From formula (2) and (3), we can get:

[0060] S 丝实 / S 股 =3z / (4z-1); (4)

[0061] Since z>>1, we have:

[0062] S 丝实 / S 股 =3z / 4z=0.75; (5)

[0063] Right now:

[0064] S 导 / S 股和 =(n*S 丝实 ) / (n*S 股 )=0.75;(6)

[0065] In the formula, S 导 Represents the cross-sectional area of ​​the conductor, S 股和 is the sum of the contour areas of all strands.

[0066] like Figure 3 As shown:

[0067] a=π / n;(7)

[0068] Where a is the angle and n is the number of strands.

[0069] Sina=AP / (OB+BP)=r 股 / (r 管 +r 股 ); (8)

[0070] In the formula, r 股 is the strand radius, r 管 is the radius of the liquid cooling tube.

[0071] S 环 =π(r 管 +2r 股 ) 2 -π*r 管 2 =π(4*r 管 *r 股 +r 股 2 );(9)

[0072] In the formula, S 环 is the area of ​​the annular region in the conductor structure.

[0073] S 股和 =n*S 股 =n*π*r 股 2 ; (10)

[0074] From formula (7) and (8), we can get:

[0075] S 股和 / S 环 =n*r 股 / (4r 管 +r 股 );(11)

[0076] When 管>> r 股 When , we can get from formula (8):

[0077] S 股和 / S 环 =n*r 股 / (4r 管 +4r 股 ) = n / 4*sinα; (12)

[0078] like Figure 3 As shown, in △OBD, there are:

[0079] sinα=BD / OB;(13)

[0080] When 管>> r 股 , BD≈arc BF=π / n*OB, then:

[0081] S 股和 / S 环 =n / 4*sinα=n / 4*(π / n*OB) / OB=π / 4; (14)

[0082] From formula (6) and (14), we can get:

[0083] S 环 =4 / π*S 股和 =4 / π*S 导 / 0.75=1.7S 导 (15)

[0084] Furthermore, in this embodiment, in step S02, according to the conductor cross-sectional area S 导 and the single wire diameter d 丝 Calculate the number of conductor single wires Z 计 Specifically:

[0085] Z 计 =4S 导 / (π*d 丝 2 ). (16)

[0086] Furthermore, in this embodiment, in step S03, according to the obtained annular area S 环 and the diameter of the liquid cooling tube d 管 The number of strands n is calculated as follows:

[0087] Due to S 环 =π / 4(d 环 2 -d 管 2 ), (17)

[0088] Then we have:

[0089] d 环 =(4 / π*S 环 +d 管 2 ) 1 / 2 ; (18)

[0090] Then we can get:

[0091] d 股 =(d 环 -d 管 ) / 2; (19)

[0092] From formula (8), we can get:

[0093] Sina=r 股 / (r 管 +r 股 ) = d 股 / (d 管 +d 股 ); (20)

[0094] Then we can get:

[0095] a=arcsin[d 股 / (d 管 +d 股 )];(twenty one)

[0096] Then we have:

[0097] n=ROUND(π / a); (22)

[0098] Where, d 环 Indicates the outer diameter of the conductor structure, d 股 It represents the outer diameter of a single strand of wire, and a represents 1 / 2 of the angle between the centers of two adjacent strands of wire.

[0099] Furthermore, in this embodiment, in step S04, the number Z of conductor monofilaments is calculated based on the obtained conductor monofilaments. 计 The number of single strands Z per strand is calculated by the number of strands n 股 Specifically:

[0100] Z 股 =ROUND(Z 计 / n); (23)

[0101] Furthermore, in this embodiment, in step S05, according to the obtained number of strands n and the number of single strands Z 股 Correct the calculation to obtain the actual number of conductor single wires Z 实 Specifically:

[0102] Z 实 =n*Z 股 .(twenty four)

[0103] Furthermore, in this embodiment, in step S06, according to the actual number Z of the obtained conductor monofilaments 实 , the number of strands n and the number of single strands Z 股 The structure of the liquid-cooled cable conductor is as follows:

[0104] Take Z 实 The root diameter is d 丝 The number of strands per strand is Z 股 Dividing into n strands, processing the monofilaments of each strand by a bundled wire method to form n strands of wire;

[0105] The obtained n strands of wire are twisted at equal angles and intervals on the outside of the liquid cooling tube by twisting, so as to obtain the liquid cooling cable conductor structure.

[0106] Taking the actual liquid-cooled cable conductor structure processing process as an example, the conductor cross-sectional area S required for the liquid-cooled cable conductor structure is 导 25mm 2 , single wire diameter d丝 The diameter of the liquid cooling tube is 0.2 mm. 管 It is 4.5mm.

[0107] The conductor structure is designed by applying the liquid-cooled cable conductor structure processing method of this embodiment, as follows:

[0108] According to the above formula (15), S 环 =1.7*25mm 2 =42.5mm 2 .

[0109] From the above formula (16), we can get: 计 =4S 导 / (π*d 丝 2 )=4*25 / (3.14*0.2*0.2)=796.

[0110] From the above formula (18), we can get: 环 =(4 / π*S 环 +d 管 2 ) 1 / 2 =(4 / 3.14*42.5+4.5*4.5) 1 / 2 =8.6mm.

[0111] From the above formula (19), we can get: 股 =(d 环 -d 管 ) / 2=(8.6-4.5) / 2=2.1mm.

[0112] From the above formula (20), we can get Sina = r 股 / (r 管 +r 股 ) = d 股 / (d 管 +d 股 )=2.1 / (4.5+2.1)=0.31.

[0113] From the above formula (21), we can get: a = arcsin[d 股 / (d 管 +d 股 )]=arcsin0.31=18.2°.

[0114] From the above formula (22), n=ROUND(π / a)=ROUND(180° / 18.2°)=10.

[0115] From the above formula (23), we can get: 股 =ROUND(Z 计 / n)=ROUND(796 / 10)=80.

[0116] From the above formula (24), we can get: Z 实 =n*Z 股 =10*80=800.

[0117] 800 monofilaments with a diameter of 0.2 mm are taken, divided into 10 strands with 80 strands per strand, and the monofilaments of each strand are processed by a bundled wire method to form 10 strands of wire;

[0118] The 10 obtained strands of wire are twisted at equal angles and intervals on the outside of the liquid cooling tube by twisting, thereby obtaining the liquid cooling cable conductor structure.

[0119] The present disclosure can be based on the conductor cross-sectional area S 导 and the single wire diameter d 丝 To determine the reasonable actual number of monofilaments Z 实 , the number of strands n and the number of single strands Z 股 , which can ensure that the conductor structure meets the requirements of small size and high roundness, and helps to improve the production efficiency of liquid-cooled cables, reduce material costs and improve appearance quality.

[0120] The present embodiment also provides a liquid-cooled cable conductor structure, which is formed by the liquid-cooled cable conductor structure processing method as described above. The liquid-cooled cable conductor structure and the liquid-cooled cable conductor structure processing method as described above belong to the same inventive concept, and can be understood by referring to the above description, and will not be described again. The liquid-cooled cable conductor structure of the present embodiment is formed by the above processing method, and has the advantages of reasonable design of the number of strands and the number of single strands, small size, and high roundness.

[0121] In the description of the present disclosure, it is necessary to understand that the directions or positional relationships indicated by directional words such as "front, back, up, down, left, right", "lateral, vertical, horizontal" and "top, bottom" are usually based on the directions or positional relationships shown in the drawings, and are only for the convenience of describing the present disclosure and simplifying the description. Unless otherwise specified, these directional words do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the scope of protection of the present disclosure.

[0122] For those skilled in the art, various other corresponding changes and deformations can be made according to the technical solutions and concepts described above, and all of these changes and deformations should fall within the protection scope of the claims of the present disclosure.

Claims

1. A method for processing a liquid-cooled cable conductor structure, characterized in that: The following steps are involved: S01, according to the conductor cross-sectional area S 导 Calculate the annular area S outside the liquid cooling tube in the conductor structure 环 ; S02, according to the conductor cross-sectional area S 导 and the single wire diameter d 丝 Calculate the number of conductor single wires Z 计 ; S03, according to the obtained annular area S 环 and the diameter of the liquid cooling tube d 管 Calculate the number of strands n; S04. Calculate the number of conductor monofilaments Z based on the obtained 计 The number of single strands Z per strand is calculated by the number of strands n 股 ; S05, according to the obtained strand number n and the number of single strands Z 股 Correct the calculation to obtain the actual number of conductor single wires Z 实 ; S06, according to the actual number of conductor monofilaments Z 实 , the number of strands n and the number of single strands Z 股 Processing to form a liquid-cooled cable conductor structure.

2. The method for processing a liquid-cooled cable conductor structure according to claim 1, characterized in that: In step S01, according to the conductor cross-sectional area S 导 Calculate the annular area S outside the liquid cooling tube in the conductor structure 环 Specifically: S 环 =1.7*S 导 。 3. The method for processing a liquid-cooled cable conductor structure according to claim 2, characterized in that: In step S02, according to the conductor cross-sectional area S 导 and the single wire diameter d 丝 Calculate the number of conductor single wires Z 计 Specifically: Z 计 =4S 导 / (π*d 丝 2 )。 4. The method for processing a liquid-cooled cable conductor structure according to claim 3, characterized in that: In step S03, according to the obtained annular area S 环 and the diameter of the liquid cooling tube d 管 The number of strands n is calculated as follows: d 环 =(4 / π*S 环 +d 管 2 ) 1 / 2 ; d 股 =(d 环 -d 管 ) / 2; a=arcsin[d 股 / (d 管 +d 股 )]; n = ROUND (π / a); Where, d 环 Indicates the outer diameter of the conductor structure, d 股 It represents the outer diameter of a single strand of wire, and a represents 1 / 2 of the angle between the centers of two adjacent strands of wire.

5. The method for processing a liquid-cooled cable conductor structure according to claim 4, characterized in that: In step S04, the number Z of the conductor monofilaments is calculated based on the obtained conductor monofilaments. 计 The number of single strands Z per strand is calculated by the number of strands n 股 Specifically: Z 股 =ROUND(Z 计 / n)。 6. The method for processing a liquid-cooled cable conductor structure according to claim 5, characterized in that: In step S05, according to the obtained number of strands n and the number of single strands Z 股 Correct the calculation to obtain the actual number of conductor single wires Z 实 Specifically: WITH 实 =n*Z 股 。 7. The method for processing a liquid-cooled cable conductor structure according to claim 6, characterized in that: In step S06, the actual number of conductor monofilaments Z is obtained. 实 , the number of strands n and the number of single strands Z 股 The structure of the liquid-cooled cable conductor is as follows: Take Z 实 The root diameter is d 丝 The number of strands per strand is Z 股 Dividing into n strands, processing the monofilaments of each strand by a bundled wire method to form n strands of wire; The obtained n strands of wire are twisted at equal angles and intervals on the outside of the liquid cooling tube by twisting, so as to obtain the liquid cooling cable conductor structure.

8. A liquid-cooled cable conductor structure, characterized in that: The liquid-cooled cable conductor structure is formed by processing using the liquid-cooled cable conductor structure processing method as described in any one of claims 1 to 7.

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