Cable fusion operation process

Abstract

This invention discloses a cable fusion splicing process, comprising the following steps: S1, aligning the cable to be processed and measuring the stripping dimensions; S2, sequentially stripping the outer sheath, outer shielding layer, insulation layer, and inner shielding layer of the cable, and machining the stripped ends into a pencil-tip shape; S3, fitting outer and inner insulating heat-shrink tubing onto the cable to be processed; S4, mounting the two cables to be processed on a mold and pouring welding powder into the mold for fusion splicing; S5, polishing the outer surface of the welding position until smooth; S6, wrapping the inner semi-conductive shielding tape around the cable core and the outer perimeter of the welding position; S7, heating the inner insulating heat-shrink tubing; S8, wrapping the outer semi-conductive shielding tape around the outer perimeter of the inner insulating heat-shrink tubing; S9, heating the outer insulating heat-shrink tubing. This invention has the following advantages and effects: the cables processed by this process have stable transmission and a longer service life.

Description

Technical Field

[0001] This invention relates to the field of power technology, and in particular to a cable splicing process. Background Technology

[0002] Due to limitations in production equipment, related technologies, and transportation conditions, cable joints are indispensable in current urban power distribution networks and long-distance cables. As a crucial connection point in the entire power supply network, the stability of cable joints directly impacts the overall operational quality of the power supply system. Traditional power cable connections are made by crimping or screwing the metal cores of two cables to extend the connection. Crimping or screwing is a traditional contact connection method. Because cable loads and temperatures constantly change, continuous thermal expansion and contraction can easily cause the crimped joints to loosen and gaps to widen, leading to partial discharge or inadequate insulation recovery. Over time, this can result in insulation failure, breakdown, and even cable bursts, posing a series of safety hazards and accidents.

[0003] Through the continuous efforts of industry professionals, cable fusion technology has been developed. As a novel technology, cable fusion technology offers numerous advantages over conventional cable joint manufacturing methods. This technology restores the cable to its original factory condition through multiple processes, including core welding, core grinding, melting of the inner semiconductor layer, melting and restoration of the main insulation layer, grinding of the main insulation layer, equal-diameter restoration, melting of the outer semiconductor layer, and restoration of the outer sheath. The greatest advantage of this technology lies in its ability to fuse the copper core, inner shield, main insulation, and outer shield into a single unit, enhancing the cable's waterproof, explosion-proof, and insulation properties, and extending the cable joint's lifespan. During the fusion process, molten copper solution is poured into a mold to fuse the two cores. However, this operation is affected by factors such as the mold and the flow rate of the copper solution, making it impossible to manually control the flow rate. This can easily lead to uneven flow, resulting in uneven molecular distribution, endogenous porosity, and uneven stress. Partial discharge can occur in these areas, directly causing insulation breakdown and shortening insulation life. The present invention was conceived in response to the above problems. Summary of the Invention

[0004] The purpose of this invention is to provide a cable splicing process that provides stable transmission and a longer service life.

[0005] The above-mentioned technical objective of the present invention is achieved through the following technical solution: a cable splicing operation process, comprising the following steps;

[0006] S1. Position the cable to be processed correctly and measure the stripping dimensions of the cable;

[0007] S2. Sequentially strip the outer sheath, outer shielding layer, insulation layer and inner shielding layer of the cable, and process the stripped tail into a pencil tip shape;

[0008] S3. Install outer insulation heat shrink tubing and inner insulation heat shrink tubing on the cable to be processed;

[0009] S4. Install the two cables to be processed onto the mold and pour welding powder into the mold for welding.

[0010] S5. Grind the outer surface of the welding position until smooth;

[0011] S6. Wrap the inner semiconducting shielding tape around the cable core and the outer periphery of the welding position;

[0012] S7. Move the inner insulation heat shrink tubing to the position corresponding to the cable core and the welding position and heat and shrink it.

[0013] S8. Wrap an outer semi-conductive shielding tape around the outer circumference of the inner insulating heat shrink tubing.

[0014] S9. Move the outer insulating heat shrink tubing to the corresponding outer semiconductive shielding strip and heat it to shrink it.

[0015] By adopting the above technical solution, the pencil-tip shaped stripping tail enables a tight connection between the cable outer sheath and the newly wrapped outer sheath during the subsequent wrapping process, increasing the contact area for a more robust fusion weld. Ignition of the welding powder melts the copper powder within through an instantaneous burst of temperature, thus achieving fusion between the two cable cores. This method avoids many problems caused by uneven solution flow rates, thereby improving fusion quality and ensuring stable cable transmission and extended service life. The heat-shrink tubing combined with the shielding tape structure is not limited by the construction environment, offering convenient operation and good versatility.

[0016] Further settings include: controlling the temperature of the inner and outer insulating heat shrink tubing between 160-180 degrees Celsius and the time between 45-50 minutes.

[0017] By adopting the above technical solution, the control of temperature and time, combined with the material properties of the heat shrink tubing, can tightly fuse the outer insulating heat shrink tubing, the outer semiconductive shielding tape, the inner insulating heat shrink tubing, and the inner semiconductive shielding tape into one piece without damaging the material properties of the heat shrink tubing itself, avoiding gaps, and providing better protection.

[0018] Further configured as follows: the mold includes a left mold body, a right mold body, and a mold cavity formed between the left mold body and the right mold body. A docking channel for placing cables is formed on both sides of the mold cavity between the left mold body and the right mold body, and the two docking channels are coaxially arranged. An opening communicating with the outside is formed above the mold cavity, and an elongated ignition port extending along the axis of the docking channel is formed below the mold cavity. A layer of ignition powder extending to the ignition port is attached to the inner peripheral wall of the mold cavity.

[0019] By adopting the above technical solution, a layer of ignition powder is pre-attached to the inner wall of the mold cavity, and then welding powder for fusion is filled inside the ignition powder layer. The ignition powder layer is ignited through an ignition port located below it. The ignited ignition powder layer burns violently, and the resulting flame has an upward burning tendency, thus enabling rapid ignition of the entire ignition powder layer. The burning ignition powder layer evenly ignites the solder on the outer wall and then spreads the burning evenly into the interior of the solder. This structure allows the later-burning solder powder inside to evenly heat the earlier-burning solder powder on the outside, making the fusion temperature more uniform and the copper powder melted more evenly, thereby avoiding the phenomenon of inconsistent stress. This structure also avoids the phenomenon that the first-burning position cools down before the later-burning position cools down slowly during the process of the solder spreading from one side to the other, resulting in a large difference in curing efficiency and cooling temperature difference between different positions. Ultimately, this affects the linkage between the material molecular chains, affects the overall structural strength after molding, and prevents the occurrence of uneven stress.

[0020] The mold cavity is further configured such that: an isolation layer with an opening is provided on the inner peripheral wall of the mold cavity; a blocking part is formed on both sides of the opening of the isolation layer; a cooling channel is formed between the isolation layer and the inner peripheral wall of the mold cavity; air inlet channels communicating with the cooling channel are formed on the left and right mold bodies; a number of cooling micro-holes are distributed on the isolation layer and the cooling micro-holes cannot be supplied with solder; and the ignition powder layer is provided inside the isolation layer.

[0021] By employing the above technical solution, the isolation layer, combined with the ignition powder layer, uniformly ignites the welding powder. The integrated air inlet and cooling channels ensure that the cooling airflow acts evenly on the outer wall of the weld joint, achieving uniform cooling from the outside in. This avoids inconsistent stress at the weld joint caused by uneven cooling temperatures or large temperature differences. The distribution of micropores allows for better heat exchange between the airflow within the cooling channels and the weld joint, improving cooling efficiency. Since molten copper is a viscous fluid with high density and surface tension, the molten copper will not enter the micropores and cause blockage, thus ensuring efficient heat dissipation.

[0022] Further configured as follows: the isolation layer includes a left block disposed inside the left mold body and a right block disposed inside the right mold body. The left block and the right block are provided with several grid strips extending in opposite directions at the positions corresponding to the ignition port, and the two sets of several grid strips are arranged alternately. The ignition powder layer extends outward through the two adjacent sets of several grid strips.

[0023] By employing the above technical solution, the gaps between the staggered grid strips allow the ignition powder layer to pass through, ensuring its proper ignition. Separating the left and right blocks allows for the separation of several adjacent grid strips, facilitating subsequent cleaning even if a small amount of copper solution enters between adjacent grid strips.

[0024] The further configuration is as follows: a sealing strip is inserted at the inlet of each of the air inlet channels, and each sealing strip is provided with a pull ring.

[0025] By adopting the above technical solution, the sealing strip is designed to ensure uniform temperature during the welding process, thereby guaranteeing the welding quality. When cooling is required, the sealing strip can be opened via the pull ring for better cooling of the weld joint.

[0026] The material of the ignition powder layer includes gunpowder, fiber, and beeswax in a ratio of 8:2:4.

[0027] By adopting the above technical solution, gunpowder is used to provide open flame ignition, and the combination of fiber and beeswax can solidify and shape the gunpowder, so that the solidified and shaped ignition powder layer can be firmly fixed on the isolation layer.

[0028] Further configured as follows: the cable core is composed of several lines, the several lines including several protruding lines and several recessed lines, the several protruding lines and several recessed lines are arranged alternately.

[0029] By adopting the above technical solution, this method increases the contact area with the wire core during welding, improves the structural strength, and can better weld the wire into a whole. In addition, this structure can increase the radial load at the weld point, so that the cable can be bent and laid without breaking at the weld point.

[0030] In summary, the present invention has the following advantages: the cables processed by this process have stable transmission and a longer service life. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the cable fusion splicing structure in the embodiment;

[0032] Figure 2 This is a schematic diagram of the mold structure in the embodiment;

[0033] Figure 3This is a cross-sectional view of the mold in the embodiment;

[0034] Figure 4 This is a partial exploded view of the mold in the embodiment;

[0035] Figure 5 This is a partial structural diagram of an embodiment.

[0036] In the diagram: 1. Left mold body; 2. Right mold body; 3. Mold cavity; 4. Docking channel; 5. Ignition port; 6. Ignition powder layer; 7. Welding powder; 8. Blocking part; 9. Cooling channel; 10. Air inlet channel; 11. Cooling micropores; 12. Left block; 13. Right block; 14. Grille strip; 15. Sealing strip; 16. Pull ring; 17. Protruding line; 18. Recessed line; 19. Outer insulating heat shrink tubing; 20. Inner insulating heat shrink tubing; 21. Outer semi-conductive shielding tape; 22. Inner semi-conductive shielding tape. Detailed Implementation

[0037] The present invention will be further described in detail below with reference to the accompanying drawings.

[0038] refer to Figures 1 to 5 A cable fusion splicing process includes the following steps;

[0039] S1. Position the cable to be processed correctly and measure the stripping dimensions of the cable;

[0040] S2. Sequentially strip the outer sheath, outer shielding layer, insulation layer and inner shielding layer of the cable, and process the stripped tail into a pencil tip shape;

[0041] S3. Install the outer insulation heat shrink tubing 19 and the inner insulation heat shrink tubing 20 on the cable to be processed.

[0042] S4. Install the two cables to be processed onto the mold and pour welding powder 7 into the mold;

[0043] S5. Grind the outer surface of the welding position until smooth;

[0044] S6. Wrap the inner semiconducting shielding tape 22 around the cable core and the outer periphery of the welding position;

[0045] S7. Move the inner insulation heat shrink tubing 20 to the position corresponding to the cable core and the welding position and heat and shrink it.

[0046] S8. Wrap an outer semi-conductive shielding tape 21 around the outer periphery of the inner insulating heat shrink tubing 20;

[0047] S9. Move the outer insulating heat shrink tubing 19 to the corresponding outer semiconductive shielding strip 21 and heat and shrink it.

[0048] The temperature of the inner insulating heat shrink tubing 20 and the outer insulating heat shrink tubing 19 is controlled between 160 and 180 degrees Celsius and the time is controlled between 45 and 50 minutes, with the preferred temperature being 170 degrees Celsius.

[0049] The mold includes a left mold body 1, a right mold body 2, and a mold cavity 3 formed between the left mold body 1 and the right mold body 2. Bolts pass through the left mold body 1 and the right mold body 2 in sequence and are threadedly connected to nuts to assemble the mold. A docking channel 4 for placing cables and communicating with the mold cavity 3 is formed on both opposite sides of the mold cavity 3 between the left mold body 1 and the right mold body 2, and the two docking channels 4 are coaxially arranged. An opening communicating with the outside is formed at the top of the mold cavity 3, and an elongated ignition port 5 extending along the axis of the docking channel 4 is formed at the bottom of the mold cavity 3.

[0050] An isolation layer with an opening is fixedly installed on the inner peripheral wall of the mold cavity 3. The opening of the isolation layer extends upward on both sides to form a blocking part 8. A cooling channel 9 is formed between the isolation layer and the inner peripheral wall of the mold cavity 3. Air inlet channels 10 communicating with the cooling channel 9 are opened on both the left mold body 1 and the right mold body 2. A number of cooling micro holes 11 are distributed on the isolation layer, and the cooling micro holes 11 cannot be supplied with solder. A layer of ignition powder 6 extending to the ignition port 5 is attached to the inner peripheral wall of the isolation layer.

[0051] The isolation layer includes a left block 12 fixedly disposed inside the left mold body 1 and a right block 13 fixedly disposed inside the right mold body 2. Both the left block 12 and the right block 13 have integrally formed, oppositely extending grid strips 14 at positions corresponding to the ignition port 5, with the grid strips 14 arranged in an alternating pattern. The ignition powder layer 6 extends outward through the gap between two adjacent grid strips 14. A sealing strip 15 is inserted at the inlet of the air inlet channel 10, and a pull ring 16 is fixed to each sealing strip 15.

[0052] The ignition powder layer 6 is made of gunpowder, fiber, and beeswax in a ratio of 8:2:4. The cable core is composed of several lines, including several protruding lines 17 and several recessed lines 18, which are arranged alternately.

[0053] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. A cable splicing process, characterized in that: Includes the following steps; S1. Position the cable to be processed correctly and measure the stripping dimensions of the cable; S2. Sequentially strip the outer sheath, outer shielding layer, insulation layer and inner shielding layer of the cable, and process the stripped tail into a pencil tip shape; S3. Install the outer insulation heat shrink tubing (19) and the inner insulation heat shrink tubing (20) on the cable to be processed; S4. Install the two cables to be processed on the mold and pour welding powder (7) into the mold for welding. S5. Grind the outer surface of the welding position until smooth; S6. Wrap the inner semiconductive shielding tape (22) around the cable core and the outer periphery of the welding position; S7. Move the inner insulation heat shrink tubing (20) to the position corresponding to the cable core and the welding position and heat and shrink it; S8. Wrap an outer semi-conductive shielding tape (21) around the outer periphery of the inner insulating heat shrink tubing (20); S9. Move the outer insulating heat shrink tubing (19) to the corresponding outer semiconductive shielding strip (21) and heat it to shrink it; The mold includes a left mold body (1), a right mold body (2), and a mold cavity (3) formed between the left mold body (1) and the right mold body (2). A docking channel (4) for placing cables is formed on both sides of the mold cavity (3) between the left mold body (1) and the right mold body (2), and the two docking channels (4) are coaxially arranged. An opening communicating with the outside is formed above the mold cavity (3), and a long strip-shaped ignition port (5) extending along the axis of the docking channel (4) is formed below the mold cavity (3). A layer of ignition powder (6) extending to the ignition port (5) is attached to the inner peripheral wall of the mold cavity (3). An isolation layer with an opening is provided on the inner peripheral wall of the mold cavity (3). A blocking part (8) is formed on both sides of the opening of the isolation layer. A cooling channel (9) is formed between the isolation layer and the inner peripheral wall of the mold cavity (3). An air inlet channel (10) communicating with the cooling channel (9) is formed on both the left mold body (1) and the right mold body (2). A number of cooling micro holes (11) are distributed on the isolation layer and the cooling micro holes (11) cannot be used for the welding liquid to pass through. The ignition powder layer (6) is set inside the isolation layer. The isolation layer includes a left block (12) disposed inside the left module (1) and a right block (13) disposed inside the right module (2). The left block (12) and the right block (13) are provided with several grid strips (14) extending in opposite directions at the positions corresponding to the ignition port (5), and the two sets of several grid strips (14) are arranged alternately. The ignition powder layer (6) extends outward through the two adjacent sets of several grid strips (14).

2. The cable splicing process according to claim 1, characterized in that: The temperature of the inner insulating heat shrink tubing (20) and the outer insulating heat shrink tubing (19) is controlled between 160-180 degrees Celsius and the time is controlled between 45-50 minutes.

3. The cable splicing process according to claim 1, characterized in that: Each of the air inlet channels (10) is provided with a sealing strip (15) at its entrance and each sealing strip (15) is provided with a pull ring (16).

4. The cable splicing process according to claim 1, characterized in that: The ignition powder layer (6) is made of gunpowder, fiber and beeswax in a ratio of 8:2:

4.

5. The cable splicing process according to claim 1, characterized in that: The cable core is composed of several lines, including several protruding lines (17) and several recessed lines (18), which are arranged in an alternating pattern.

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