Method for manufacturing a tensioned anchoring integrated flexible photovoltaic cable

Abstract

The application discloses a kind of production methods of tensioning anchoring integrated flexible photovoltaic cable, belong to photovoltaic cable production technical field, solve the adaptability problem of photovoltaic cable cable length.The production method is first in factory prefabricated cable one end of fixed end anchor head, then the cable is moved to site construction site, then the fixed end anchor head is anchored and the other end of the cable is tensioned in place, finally the tensioning end anchor head of the other end of the cable is produced.The production method of the application combines the tensioning process of the cable with the anchoring process on the construction site, which can greatly improve the construction efficiency of the photovoltaic cable, so that the cable length is not affected by the precision, while reducing the difficulty of corrosion prevention and on-site construction difficulty.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, and more specifically, to a method for manufacturing a tensioned and anchored integrated flexible photovoltaic cable. Background Technology

[0002] In current flexible photovoltaic (PV) support structures, the flexible PV cables used are divided into load-bearing cables and module cables. Load-bearing cables are mainly installed between two adjacent support steel frames, connected to the PV panel triangular frame to support the weight of the PV panel; their length is approximately 30-40 meters. Module cables are installed between the first and last support steel frames, typically two cables, one high and one low. The cables are connected to the lower plane of the PV panel via steel hoops and are used to tension the PV panel's installation angle; their length is approximately 100-600 meters.

[0003] Currently, there are two main methods for anchoring flexible photovoltaic cables: 1. On-site installation using clamps at both ends. This method has lower requirements for cable length accuracy, allowing for on-site cutting to the actual length. However, exposed steel strands are difficult to protect against corrosion on-site. To meet the 25-year service life requirement, additional sealing cylinders, protective covers, and grease injection are necessary. 2. Extrusion anchoring of pre-fabricated cables. These cables are manufactured to a fixed length in the factory, offering good corrosion resistance. However, high cable length accuracy is required. A cable tensioning mechanism needs to be added at one or both ends. These tensioning mechanisms are made of steel, increasing the overall weight and cost of the cable net.

[0004] Because photovoltaic power plants are often built in terrains such as oceans, lakes, deserts, and mountains, the positional errors of the on-site pre-embedded steel frame can be significant. The inability to provide accurate cable length information may lead to the risk of finished cables being unable to be installed and ultimately needing to be scrapped and remade. For example, the cable length of the module ranges from 100 to 600 meters, making scrapping extremely costly. Furthermore, with longer cables, if finished cables are used, the tensile elongation is substantial, approximately 2‰ of the cable length, making the installation and traction process more difficult, and on-site tensioning also presents significant challenges.

[0005] At the same time, such as Figure 1 As shown, the current support steel frame 9 has welded ear plates a on both sides and is anchored by connecting the pin shaft to the cable fork ear b. The connection structure is complex and has high requirements for the welding quality of the ear plates, which also increases the construction difficulty. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to address the above-mentioned shortcomings of the prior art. The purpose of the present invention is to provide a method for manufacturing a tensioned and anchored integrated flexible photovoltaic cable, so that the cable length is not affected by precision, while reducing the difficulty of corrosion prevention and on-site construction.

[0007] To achieve the above objectives, the present invention provides a method for manufacturing a tensioned and anchored integrated flexible photovoltaic cable. The method involves first prefabricating a fixed end anchor head at one end of the cable in a factory, then moving the cable to the construction site, anchoring the fixed end anchor head, tensioning the other end of the cable, and finally manufacturing the tensioned end anchor head at the other end of the cable.

[0008] As a further improvement, the method includes the following steps:

[0009] S1: The fixed-end anchor head is manufactured in the factory by extrusion molding;

[0010] S2: Pack the cables from step S1 and ship them to the construction site;

[0011] S3: On the construction site, the fixed end anchor of one end of the cable is anchored to one of the supporting steel frames, and the other end is pulled to the anchor point of another supporting steel frame.

[0012] S4: At the anchor point, tension the cable to exceed the design force value, and then clamp and fix the cable.

[0013] S5: The tensioning end anchor head is processed by extrusion molding on the cable after the anchor point;

[0014] S6: Release the cable and lower it into place.

[0015] Furthermore, step S1 includes the following specific steps:

[0016] S1.1: Remove the HDPE layer at one end of the cable body, and insert the fixed end extrusion sleeve into the cable body to the bottom of the inner hole, ensuring that the fixed end extrusion sleeve covers a section of the HDPE layer of the cable body.

[0017] S1.2: Push the extrusion plate into the gap between the fixed end extrusion sleeve and the cable body;

[0018] S1.3: Pour sealant into the fixed end extrusion sleeve until the gap of the fixed end extrusion sleeve is filled;

[0019] S1.4: The fixed end extrusion sleeve is extruded and formed using an extrusion device to obtain the fixed end extrusion anchor head.

[0020] Further, in step S3, the fixed end anchor head is passed through one of the supporting steel frames and connected to the fixed end anchor head using a fixed end locking member to anchor the fixed end anchor head on the supporting steel frame, and then the other end of the cable body is passed through another supporting steel frame.

[0021] Furthermore, step S4 includes the following specific steps:

[0022] S4.1: Remove the HDPE layer at the other end of the cable to the process length for tensioning and the working length for anchoring;

[0023] S4.2: Install an integrated tensioning and extrusion device on the outside of another supporting steel frame, and connect the other end of the cable to the output end of the integrated tensioning device;

[0024] S4.3: Start the tensioning and extrusion integrated equipment, tension the cable to exceed the design force value, and then fix the cable.

[0025] Furthermore, step S4.2 also includes the following specific steps:

[0026] S4.2.1: First, turn one of the locking nuts into the support rod, and then pass one of the locking plates through the support rod;

[0027] S4.2.2: Place the support rod on the support steel frame, then pass another locking plate through the support rod, and then turn another locking nut into the support rod. Use the locking plate to hold the support steel frame in place, and then lock it in place with the two locking nuts.

[0028] S4.2.3: Pass the extrusion die through the support rod. At this time, align the inner hole of the extrusion die core with the cable hole on the support steel frame. Then mark the position where the extrusion jack needs to be installed on one side of the extrusion die sleeve.

[0029] S4.2.4: Remove the extrusion die and install the extrusion die, extrusion jack, and support plate into the marked positions to form the assembly;

[0030] S4.2.5: Insert the components connected in step S4.2.4 into the support rods respectively, so that the limiting step of the support rods contacts the support plate, and then tighten the lock nut on the support rods to fix the components;

[0031] S4.2.6: Install the tensioning jack and rear clamping assembly onto the support plate;

[0032] S4.2.7: Pass the cable body through the pad ring, extrusion die, tension end extrusion sleeve, support plate, tension jack, sensor, and rear clamping assembly in sequence;

[0033] S4.2.8: Install the tool clamp into the conical clamp hole of the tension jack piston to clamp and fix the cable.

[0034] Furthermore, step S4.2 also includes the following specific steps:

[0035] S4.2.1: Assemble the roller assembly and install it on the support plate;

[0036] S4.2.2: Install the extrusion die on the output end of the extrusion jack, and then install the extrusion jack on the support plate;

[0037] S4.2.3: Install the tensioning jack and rear clamping assembly onto the support plate;

[0038] S4.2.4: Hoist the components installed in step S4.2.3 to the cable installation position, install the clamping plates on the support plate, and clamp the two clamping plates on the support steel frame;

[0039] S4.2.5: Pass the cable body through the pad ring, extrusion die, tension end extrusion sleeve, extrusion jack, support plate, tension jack, sensor, and rear clamping assembly in sequence;

[0040] S4.2.6: Install the tool clamp into the conical clamp hole of the tension jack piston to clamp and fix the cable.

[0041] Furthermore, step S4.3 also includes the following specific steps:

[0042] S4.3.1: Start the extension of the tension jack piston to tension the cable to the piston stroke of the tension jack;

[0043] S4.3.2: Install the tool clamp into the corresponding conical clamp hole of the rear clamping assembly to clamp and fix the cable body, and at the same time loosen the tool clamp corresponding to the tensioning jack, and the piston of the tensioning jack retracts;

[0044] S4.3.3: Repeat steps S4.3.1 and S4.3.2 above, tension the cable to exceed the design force value, and then install the tool clamp into the corresponding conical clamp hole of the rear clamping assembly to clamp and fix the cable.

[0045] Furthermore, the steps include the following specific steps:

[0046] S5.1: Push the extrusion plate into the gap between the tensioning end extrusion sleeve and the cable body;

[0047] S5.2: Pour sealant into the tensioning end extrusion sleeve until the gap of the tensioning end extrusion sleeve is filled;

[0048] S5.3: Install a U-shaped insert after the tensioning end extrusion sleeve, so that one end of the tensioning end extrusion sleeve is locked in the slot of one end of the U-shaped insert, and the other end of the U-shaped insert is locked in the slot of the support plate.

[0049] S5.4: Start the extrusion jack piston to retract, drive the extrusion die core of the extrusion mold to move, and extrude the tension end extrusion sleeve to form the tension end anchor head.

[0050] Furthermore, step S6 includes the following specific steps:

[0051] S6.1: Move the washer and insert it into the cable hole of the supporting steel frame;

[0052] S6.2: After loosening the clamping component, retract the piston of the tensioning jack and move the tensioning end compression sleeve so that its end face is lowered into the centering step of the pad ring.

[0053] Furthermore, the manufacturing method also includes step S7: cutting off the excess cable body at the end face of the tensioning end anchor head, filling the cover plate with sealant, and then covering and fixing the cover plate to one end of the tensioning end extrusion sleeve.

[0054] Beneficial effects

[0055] Compared with the prior art, the advantages of this invention are as follows:

[0056] 1. The manufacturing method of this invention, by prefabricating the fixed end anchor head of one end of the cable in the factory, anchoring it after it arrives at the construction site, and then tensioning the cable into place and making the tensioning end anchor head on site, solves the problem of adaptability of photovoltaic cable length. Combining the cable tensioning process and the anchoring process on site can greatly improve the construction efficiency of photovoltaic cables, so that the cable length is not affected by accuracy. At the same time, only the cable body corresponding to the tensioning end anchor head needs to be tensioned and protected against corrosion on site, reducing the difficulty of corrosion protection and on-site construction.

[0057] 2. The manufacturing method of the present invention changes the anchoring method from welding ear plates on the supporting steel frame and connecting them to the fork ears of the cable through pin shafts to opening extrusion sleeve mounting holes on the supporting steel frame and using nuts or washers for pressure anchoring. This simplifies the connection method between the cable and the supporting steel frame, makes the cable structure simple, facilitates cable installation and adjustment, and reduces the cost of the cable.

[0058] 3. The manufacturing method of the present invention uses an integrated tensioning and extrusion equipment to tension and extrude the anchor head at the tensioning end. After the cable body is tensioned in place, the tensioning end extrusion sleeve can be extruded and anchored by extrusion jacks and extrusion molds. There is no need to replace the extrusion equipment, realizing integrated tensioning and extrusion operation, reducing construction difficulty and improving construction efficiency. Attached Figure Description

[0059] Figure 1 This is a schematic diagram of the anchoring structure of cables in the prior art;

[0060] Figure 2 This is a schematic diagram of the integrated tensioning and anchoring flexible photovoltaic cable in this invention;

[0061] Figure 3 This is an enlarged schematic diagram of the connection between the fixed end extrusion sleeve and the cable body in this invention;

[0062] Figure 4 This is an enlarged schematic diagram of the connection between the tensioning end extrusion sleeve and the cable body in this invention;

[0063] Figure 5 This is an enlarged schematic diagram of the fixed-end extrusion sleeve in this invention;

[0064] Figure 6 This is an enlarged schematic diagram of the tensioning end extrusion sleeve in this invention;

[0065] Figure 7 This is an enlarged side view of the anti-slip component in this invention;

[0066] Figure 8 This is an enlarged schematic diagram of the extrusion sheet structure in this invention;

[0067] Figure 9 This is a schematic diagram of the anchoring structure of the tensioned and anchored integrated flexible photovoltaic cable in this invention;

[0068] Figure 10 This is an enlarged schematic diagram of the gasket structure in this invention;

[0069] Figure 11 This is a schematic diagram of the integrated tensioning and extrusion device in Embodiment 1 of the present invention;

[0070] Figure 12 This is an enlarged schematic diagram of the extrusion die structure in Embodiment 1 of the present invention;

[0071] Figure 13 This is an enlarged side view of the extrusion die in Embodiment 1 of the present invention;

[0072] Figure 14 This is an enlarged schematic diagram of the support plate and tool anchor plate in Embodiment 1 of the present invention;

[0073] Figure 15 This is an enlarged schematic diagram of the support rod structure in Embodiment 1 of the present invention;

[0074] Figure 16 This is a schematic diagram of the structure when applied in Embodiment 1 of the present invention;

[0075] Figure 17 This is a schematic diagram of the integrated tensioning and extrusion device in Embodiment 2 of the present invention;

[0076] Figure 18 This is an enlarged schematic diagram of the extrusion die structure in Embodiment 2 of the present invention;

[0077] Figure 19 This is an enlarged schematic diagram of the support plate structure in Embodiment 2 of the present invention;

[0078] Figure 20This is an enlarged side view of the support plate structure in Embodiment 2 of the present invention;

[0079] Figure 21 This is an enlarged schematic diagram of the roller assembly in Embodiment 2 of the present invention;

[0080] Figure 22 This is a schematic diagram of the structure when applied in Embodiment 2 of the present invention;

[0081] Figure 23 This is an enlarged side view of the U-shaped insert structure in this invention;

[0082] Figure 24 This is an enlarged schematic diagram of a steel bracket opening structure according to the present invention;

[0083] Figure 25 This is an enlarged schematic diagram of another steel bracket opening structure in this invention;

[0084] Figure 26 This is a schematic diagram of a steel support and cable connection structure according to the present invention.

[0085] The components are: 1-fixed end extrusion sleeve, 2-cable body, 3-tensioning end extrusion sleeve, 4-extrusion plate, 5-sealant, 6-cover plate, 7-fixed end locking component, 8-wash ring, 9-support steel frame, 4a-protrusion, 4b-recess, 4c-step ring, a-ear plate, b-fork ear, 10-extrusion die, 101-extrusion die sleeve, 102-extrusion die core, 11-support plate, 12-extrusion jack, 13-tensioning jack, 14-tool clamping plate, 15-conical clamping plate hole, 16-tool anchor plate, 17-sensor, 18-U-shaped insert, 19-support rod, 191-limiting step, 20-locking nut, 21-locking plate, 22-plane, 23-U-shaped groove, 24-roller assembly, 25-clamping plate, 91-cable threading hole. Detailed Implementation

[0086] The present invention will be further described below with reference to specific embodiments shown in the accompanying drawings.

[0087] A method for manufacturing a tensioned and anchored integrated flexible photovoltaic cable is characterized by the following steps: First, a fixed-end anchor head at one end of the cable is prefabricated in a factory. Then, the cable is moved to the construction site, the fixed-end anchor head is anchored, and the other end of the cable is tensioned into place. Finally, the tensioned-end anchor head at the other end of the cable is manufactured.

[0088] S1: The fixed-end anchor head is manufactured in the factory by extrusion molding;

[0089] S2: Pack the cables from step S1 and ship them to the construction site;

[0090] S3: On the construction site, the fixed end anchor of one end of the cable is anchored to one of the supporting steel frames, and the other end is pulled to the anchor point of another supporting steel frame.

[0091] S4: At the anchor point, tension the cable to exceed the design force value, and then clamp and fix the cable.

[0092] S5: The tensioning end anchor head is processed by extrusion molding on the cable after the anchor point;

[0093] S6: Release the cable and lower it into place.

[0094] The manufacturing method of this invention solves the problem of adaptability of photovoltaic cables by prefabricating the fixed end anchor head of one end of the cable in the factory, anchoring it after it arrives at the construction site, and then tensioning the cable into place and making the tensioning end anchor head on site. Combining the cable tensioning process and the anchoring process on site can greatly improve the construction efficiency of photovoltaic cables, so that the cable length is not affected by accuracy. At the same time, only the cable body corresponding to the tensioning end anchor head needs to be tensioned and protected against corrosion on site, reducing the difficulty of corrosion protection and on-site construction.

[0095] like Figure 2-10 As shown in Figures 24-26, a 15.2mm diameter HDPE sheathed monofilament epoxy-coated steel stranded integral photovoltaic cable is used as an example.

[0096] The photovoltaic cable includes a fixed-end extrusion sleeve 1, a cable body 2, a tension-end extrusion sleeve 3, an extrusion plate 4, sealant 5, and a cover plate 6.

[0097] The fixed-end extrusion sleeve 1 includes a solid section, an intermediate extrusion section, and a micro-extrusion section. The inner hole of the fixed-end extrusion sleeve 1 is a stepped blind hole with the inner diameter decreasing from the micro-extrusion section to the solid section. The outer diameter of the intermediate extrusion section of the fixed-end extrusion sleeve 1 is larger than the outer diameter of the end furthest from the cable body 2, that is, the outer diameter of the intermediate extrusion section of the fixed-end extrusion sleeve 1 is larger than the outer diameter of the solid section. In addition to the reserved extrusion allowance, the outer diameter after extrusion is also larger than the outer diameter of the solid section, which is beneficial for demolding after extrusion. The inner diameter of the corresponding inner hole of the intermediate extrusion section is larger than the outer diameter of the cable body, and a reserved installation allowance is made. The position of the extrusion piece 4 facilitates its installation. A transition cone is set in the micro-extrusion section of the fixed end extrusion sleeve 1. The outer diameter of the tapered section is consistent with the inner diameter of the extrusion core 102 of the extrusion die 10, which is beneficial for centering during extrusion. The outer diameter of the micro-extrusion section is smaller than that of the middle extrusion section, that is, the reserved extrusion amount is smaller. The reserved extrusion amount in this section is not enough for anchoring and only serves as a sealing function. The inner diameter of the micro-extrusion section is larger than that of the middle extrusion section because the cable body installed in this section does not have the HDPE layer removed.

[0098] The tensioning end extrusion sleeve 3 includes a hollow threaded section, an intermediate extrusion section, and a micro-extrusion section. The inner hole of the tensioning end extrusion sleeve 3 is a stepped through hole with the inner diameter decreasing from the micro-extrusion section to the hollow threaded section. The outer diameter of the intermediate extrusion section of the tensioning end extrusion sleeve 3 is larger than the outer diameter of the end away from the cable body 2, that is, the outer diameter of the intermediate extrusion section is larger than the outer diameter of the hollow threaded section. In addition to the reserved extrusion allowance, the outer diameter after extrusion is also larger than the outer diameter of the hollow threaded section, which is beneficial for demolding after extrusion. The inner hole corresponding to the intermediate extrusion section has a reserved position for installing the extrusion plate 4, which is larger than the outer diameter of the cable body 2, to facilitate the installation of the extrusion plate 4. Installation; The micro-extrusion section is equipped with a transition cone, the outer diameter of which is consistent with the inner diameter of the extrusion core 102 of the extrusion die 10, which is beneficial for centering during extrusion. The outer diameter of the micro-extrusion section is smaller than that of the intermediate extrusion section, that is, the reserved extrusion amount is smaller. The reserved extrusion amount in this section is insufficient for anchoring and only serves as a sealing function. The inner diameter of the micro-extrusion section is larger than that of the intermediate extrusion section because the HDPE layer is not removed from the cable body at this position. The outer diameter of the tension end extrusion sleeve 3 after extrusion is larger than that of the fixed end extrusion sleeve 1 because the tension end extrusion sleeve 3 uses the end face to bear the pressure.

[0099] The extrusion piece 4 is an arc-shaped strip, cut from a single ring into several pieces. The inner diameter of the arc is designed according to the diameter of the steel strand used, and the outer diameter is designed according to the inner diameter of the extrusion sleeve. The width of the extrusion piece 4 can also be cut according to the specifications of the steel strand. The cut extrusion pieces 4 can be finally assembled into a ring to form an anti-slip component, which can provide a larger deformation space and further improve the connection firmness. The inner and outer arc surfaces of the extrusion piece 4 are provided with protrusions 4a and pits 4b of different shapes. The protrusions 4a and pits 4b increase the friction, which greatly improves the tensile strength between the fixed end extrusion sleeve 1 and the tensioning end extrusion sleeve 3 and the cable body 2, further preventing the problem of loosening. One end is provided with a stepped ring 4c. After the extrusion piece 4 is inserted into the fixed end extrusion sleeve 1 or the tensioning end extrusion sleeve 3, the stepped ring 4c contacts the step inside the extrusion sleeve to form a seal and limit, realizing rapid positioning and installation.

[0100] The manufacturing method of this photovoltaic cable includes the following specific steps in step S1:

[0101] S1.1: Remove the HDPE layer from one end of the cable body 2, and fit the fixed end extrusion sleeve 1 into the cable body 2 to the bottom of the inner hole. Check whether the fixed end extrusion sleeve 1 covers a sufficiently long section of the cable body HDPE layer. If not, it means that the HDPE layer has been peeled off too long. The cable body 2 can be shortened to ensure that the fixed end extrusion sleeve 1 covers a section of the cable body 2 HDPE layer to ensure the sealing performance of the cable.

[0102] S1.2: Push the extrusion plate 4 into the gap between the fixed end extrusion sleeve 1 and the cable body 2. The stepped ring 4c of the extrusion plate 4 rests on the step of the inner hole of the fixed end extrusion sleeve 1. Repeat this action to push in several extrusion plates 4 and ensure that the extrusion plates 4 are evenly distributed in the fixed end extrusion sleeve 1.

[0103] S1.3: Pour sealant 5 into the fixed end extrusion sleeve 1 until the gap of the fixed end extrusion sleeve 1 is filled;

[0104] S1.4: The fixed end extrusion sleeve 1 is extruded and formed using an extrusion device to obtain the fixed end extrusion anchor head.

[0105] In step S1.4 above, after the extrusion is completed, the surface of the fixed end extrusion sleeve 1 is wiped clean, the seal between the fixed end extrusion sleeve 1 and the transition section of the cable body 2 is checked to ensure it is tight, and then the surface of the fixed end extrusion sleeve 1 is painted for corrosion protection.

[0106] Step S3 of the photovoltaic cable manufacturing method involves passing the fixed-end anchor head through one of the supporting steel frames 9 and connecting it to the fixed-end anchor head using the fixed-end locking member 7, thus anchoring the fixed-end anchor head onto the supporting steel frame 9. Then, the other end of the cable body 2 is passed through the other supporting steel frame 9. In this embodiment, during construction, cable holes 91 are first drilled at the same position on both supporting steel frames 9 to allow the fixed-end anchor head and cable body 2 to pass through. The fixed-end locking member 7 is a fixed-end nut, which is threadedly connected to the threaded section on the outer wall of the solid section of the fixed-end compression sleeve 1, thereby anchoring the fixed-end anchor head onto the supporting steel frame 9. Obviously, in other embodiments, the fixed-end locking member 7 can also be a fixed-end bolt, in which case the thread on the solid section of the fixed-end compression sleeve 1 is an internal thread.

[0107] Step S4 of the photovoltaic cable manufacturing method includes the following specific steps:

[0108] S4.1: Remove the HDPE layer at the other end of cable 2 to the process length for construction tensioning and the working length for anchoring. This length is the distance between the anchoring points under stress-free conditions calculated based on the actual cable length on site.

[0109] S4.2: Install a tensioning and extrusion integrated device on the outside of another supporting steel frame 9, and connect the other end of the cable body 2 to the output end of the tensioning integrated device;

[0110] S4.3: Start the tensioning and extrusion integrated equipment, tension the cable body 2 to a value exceeding the design force, and then fix the cable body 2. Because after the tensioning end anchor head is made, the tensioning end anchor head will be lowered onto the support steel frame 9. Therefore, when performing the extrusion action of the tensioning end extrusion sleeve 3, the tensioning force of the cable body 2 must be set to a value greater than the design required force.

[0111] Example 1

[0112] like Figure 11-16 As shown in Figure 23, the tensioning and extrusion integrated device used in the invention includes an extrusion mold 10 and a support plate 11. Two extrusion jacks 12 are connected to both sides of the extrusion mold 10 and the support plate 11, meaning there are two extrusion jacks 12 in total. The two extrusion jacks 12 are offset from the center of the extrusion mold 10 and the support plate 11. Both ends of the two extrusion jacks 12 are connected and fixed to the extrusion mold 10 and the support plate 11 respectively by bolts. A tensioning jack 13 is provided on the outside of the support plate 11. The base of the tensioning jack 13 is connected and fixed to the support plate 11 by bolts. Both the extrusion jack 12 and the tensioning jack 13 are through-type jacks. A front clamping assembly for clamping the cable body 2 is provided at the output end of the tensioning jack 13. A rear clamping assembly for clamping the cable body 2 is also provided on the support plate 11 outside the tensioning jack 13. The extrusion mold 10, the front clamping assembly, and the rear clamping assembly have the same axis, facilitating the cable body 2 to pass through in a straight line.

[0113] Both the front clamping assembly and the rear clamping assembly include tool clamping plates 14. The tool clamping plate 14 of the front clamping assembly is movably installed in the conical clamping plate hole 15 inside the piston of the tensioning jack 13. A tool anchor plate 16 is provided on the support plate 11 on the outside of the tensioning jack 13. The tool anchor plate 16 has a U-shaped support leg, which is fixed to the support plate 11 by welding. The bottom of the support leg has a through hole that passes through the tool anchor plate. The through hole on the anchor plate is a conical clamping plate hole 15. The tool clamping plate 14 of the rear clamping assembly is movably installed in the conical clamping plate hole 15 inside the tool anchor plate 16. The axis of the extrusion die 10, the conical clamping plate hole 15 inside the piston, and the conical clamping plate hole 15 inside the tool anchor plate 16 are the same, ensuring that the cable 2 can pass through.

[0114] The extrusion die 10 is a special die for making extruded anchor heads. It includes an extrusion die sleeve 101 and an extrusion die core 102. The extrusion die sleeve 101 is connected to the extrusion jack 12. The extrusion die core 102 is embedded in the center of the extrusion die sleeve 101. The extrusion die core 102 has a structure with a central through hole. The inner diameter of the central through hole is set according to the outer diameter of the extrusion sleeve to be extruded. The two side openings of the extrusion die core 102 are flared to facilitate centering during extrusion and demolding after extrusion. The extrusion die core 102 is made of hard alloy steel. The axis of the extrusion die core 102, the front clamping assembly, and the rear clamping assembly are the same. That is, the axis of the extrusion die core 102, the conical clamping plate hole 15 in the piston, and the conical clamping plate hole 15 in the tool anchor plate 16 are the same, ensuring that the cable body 2 can pass through them in a straight line.

[0115] A sensor 17 for detecting the tension of the cable body 2 is provided between the front clamping assembly and the rear clamping assembly. This sensor 17 is a tension sensor and is sleeved on the cable body 2. A movable U-shaped insert 18 is also provided between the extrusion die 10 and the support plate 11. The U-shaped insert 18 consists of a U-shaped strip and a handle. The opening size of the U-shaped strip is determined according to the size of the cable body and can be inserted into the cable body 2. The handle is T-shaped and has a thread at one end that connects to the thread on the U-shaped strip, serving as a tooling for inserting into the cable body during extrusion. The support plate 11 has a slot in which the U-shaped strip of the U-shaped insert 18 is engaged, serving as a positioning function for the U-shaped insert 18. At the same time, a slot is also provided at the end of the U-shaped insert 18 away from the support plate 11, where the tensioning end extrusion sleeve 3 is engaged, serving as a positioning function for the tensioning end extrusion sleeve 3.

[0116] Support rods 19 are provided on both sides between the extrusion die 10 and the support plate 11. These support rods 19 pass through the extrusion jack 12 and the extrusion die 10, guiding the movement of the extrusion die 10 and reducing the impact of the extrusion die 10's sway on the extrusion jack 12. One end of the support rod 19 passes through the support plate 11 and is threadedly connected to a locking nut 20. The other end passes through the extrusion die 10 and is detachably connected to the support steel frame 9 via a fastening device. The fastening device includes two locking plates 21 and a locking nut 20. The locking plates 21 are U-shaped square plates with through holes at the bottom. A flat surface 22 is provided on the support rod 19 near the support steel frame 9. This flat surface 22 fits against the outer end face of the support steel frame 9. The flat surface of the support rod 19 in contact with the support steel frame 9 increases the stress area and effectively fixes it. A limiting step 191 is provided on one end of the support rod 19 near the support plate 11. The limiting step 191 contacts the side of the support plate 11 to form a limit, so that the support plate 11 can be clamped and fixed between the limiting step 191 and the locking nut 20 by using the locking nut 20. U-shaped grooves 23 are provided on both sides of the extrusion die 10 and the support plate 11. The U-shaped groove 23 corresponding to the extrusion die 10 is opened on the extrusion die sleeve 101. The support rod 19 is movably inserted into the U-shaped groove 23, so that the support rod 19 can be pulled out from both sides of the extrusion die 10 and the support plate 11, making it more convenient to use.

[0117] When the aforementioned integrated tensioning and extrusion equipment is used for tensioning and extruding photovoltaic cables, step S4.2 further includes the following specific steps:

[0118] S4.2.1: Tighten a locking nut 20 into the support rod 19 in advance, and then pass one of the locking plates 21 through the support rod 19, with the slot of the locking plate 21 facing the support steel frame 9;

[0119] S4.2.2: Place the support rod 19 on the support steel frame 9, and make contact with the support steel frame 9 using the plane 22. Then pass another locking plate 21 through the support rod 19, with the slot of the locking plate 21 also facing the support steel frame 9. Then turn another locking nut 20 into the support rod 19, use the locking plate 21 to lock the support steel frame 9, and lock it with the two locking nuts 20.

[0120] S4.2.3: Pass the extrusion die 10 through the support rod 19. At this time, align the inner hole of the extrusion die core 102 of the extrusion die 10 with the cable hole 91 on the support steel frame 9. Then mark the position where the extrusion jack 12 needs to be installed on one side of the extrusion die sleeve 101 of the extrusion die 10.

[0121] S4.2.4: Remove the extrusion die 10 and install the extrusion die 10, extrusion jack 12, and support plate 11 in the marked positions to form an assembly;

[0122] S4.2.5: Insert the components connected in step S4.2.4 into the support rod 19 respectively, so that the limiting step 191 of the support rod 19 contacts the support plate 11, and then tighten the locking nut 20 on the support rod 19 to fix the components.

[0123] S4.2.6: Install the tensioning jack 13 and the rear clamping assembly onto the support plate 11;

[0124] S4.2.7: Pass the cable body 2 through the pad ring 8, extrusion mold 10, tension end extrusion sleeve 3, support plate 11, tension jack 13, sensor 17, and rear clamping assembly in sequence;

[0125] S4.2.8: Install the tool clamp 14 into the conical clamp hole 15 of the piston of the tension jack 13 to clamp and fix the cable body 2.

[0126] When tensioning the cable, step S4.3 also includes the following specific steps:

[0127] S4.3.1: Start the tensioning jack 13 piston to extend, tensioning cable 2 to the stroke of tensioning jack 13;

[0128] S4.3.2: Install the tool clamp 14 into the corresponding conical clamp hole 15 of the rear clamping assembly to clamp and fix the cable body 2, and at the same time loosen the tool clamp 14 corresponding to the tension jack 13, and the piston of the tension jack 13 retracts.

[0129] S4.3.3: Repeat steps S4.3.1 and S4.3.2 above, tension the cable body 2 to exceed the design force value, and then install the tool clamp 14 into the corresponding conical clamp hole 15 of the rear clamping assembly to clamp and fix the cable body 2.

[0130] When compressing the cable 2, step S5 includes the following specific steps:

[0131] S5.1: Push the extrusion plate 4 into the gap between the tension end extrusion sleeve 3 and the cable body 2. The stepped ring 4c of the extrusion plate 4 rests on the step of the inner hole of the tension end extrusion sleeve 3. Repeat this action to push in several extrusion plates 4 and ensure that the extrusion plates 4 are evenly distributed in the tension end extrusion sleeve 3.

[0132] S5.2: Pour sealant 5 into the tensioning end extrusion sleeve 3 until the gap of the tensioning end extrusion sleeve 3 is filled;

[0133] S5.3: Install a U-shaped insert 18 after the tensioning end extrusion sleeve 3, so that one end of the tensioning end extrusion sleeve 3 is stuck in the slot of one end of the U-shaped insert 18, and the other end of the U-shaped insert 18 is stuck in the slot of the support plate 11.

[0134] S5.4: Start the extrusion jack 12 piston retracts, driving the extrusion die core 102 of the extrusion die 10 to move, extruding and forming the tension end extrusion sleeve 3 to obtain the tension end anchor head.

[0135] In step S5.4 above, after the extrusion is completed, wipe the surface of the tension end extrusion sleeve 3 clean, check whether the seal between the tension end extrusion sleeve 3 and the transition section of the cable body 2 is tight, and then apply anti-corrosion paint to the surface of the tension end extrusion sleeve 3.

[0136] In the method for manufacturing photovoltaic cables, step S6 includes the following specific steps:

[0137] S6.1: Move the pad ring 8 and insert the pad ring 8 into the cable hole 91 of the supporting steel frame 9;

[0138] S6.2: After loosening the clamping assembly, the corresponding tool clamp 14 is released, the piston of the tensioning jack 13 is retracted, and the tensioning end compression sleeve 3 is moved so that its end face is lowered into the centering step 82 of the pad ring 8.

[0139] In step S6.2 above, if the tensioning end compression sleeve 3 cannot be lowered into the centering step 82 of the washer ring 8 after the piston stroke of the tensioning jack 13 is in place, then the tool clamp 14 is installed into the conical clamp hole 15 corresponding to the rear clamping assembly. Then the tensioning jack 13 extends, and the tool clamp 14 is installed into the conical clamp hole 15 corresponding to the tensioning jack 13. Step S6.2 is repeated to move the tensioning end compression sleeve 3 until its end face is lowered into the centering step 82 of the washer ring 8.

[0140] The manufacturing method of photovoltaic cable also includes step S7: cut off the cable body 2 that is not in the end face of the tensioning end anchor head, fill the cover plate 6 with sealant 5, and then cover and fix the cover plate 6 to one end of the tensioning end extrusion sleeve 3. Specifically, the cover plate 6 is connected to the threaded end of the tensioning end extrusion sleeve 3 by thread.

[0141] Example 2

[0142] like Figure 17-23 As shown, another tensioning and extrusion integrated device used in the invention includes an extrusion mold 10 and a support plate 11. An extrusion jack 12 is connected to one side of the support plate 11. The extrusion jack 12 is a through-hole jack to facilitate the passage of the cable 2. It is fixed to the support plate 11 by bolts. The extrusion mold 10 is installed at the output end of the extrusion jack 12. The extrusion mold 10 is installed on the piston of the extrusion jack 12 by bolts. A tensioning jack 13 is provided on the other side of the support plate 11. The tensioning jack is a through-hole jack to facilitate the passage of the cable 2. It is fixed to the support plate 11 by bolts. A front clamping assembly for clamping the cable 2 is provided at the output end of the tensioning jack 13. A rear clamping assembly for clamping the cable 2 is also provided on the support plate 11 outside the tensioning jack 13. The centerlines of the extrusion mold 10, the extrusion jack 12, the front clamping assembly, and the rear clamping assembly are the same, which facilitates the cable 2 to pass through in a straight line.

[0143] Both the front clamping assembly and the rear clamping assembly include tool clamping plates 14. The tool clamping plate 14 of the front clamping assembly is movably installed in the conical clamping plate hole 15 inside the piston of the tensioning jack 13. A tool anchor plate 16 is provided on the support plate 11 on the outside of the tensioning jack 13. The tool anchor plate 16 has a U-shaped support leg, which is fixed to the support plate 11 by welding. The bottom of the support leg has a through hole that passes through the tool anchor plate. The through hole on the anchor plate is a conical clamping plate hole 15. The tool clamping plate 14 of the rear clamping assembly is movably installed in the conical clamping plate hole 15 inside the tool anchor plate 16. The conical clamping plate holes 15 inside the piston of the extrusion die 10, the extrusion jack 12, and the tensioning jack 13, and the conical clamping plate holes 15 inside the tool anchor plate 16 are on the same axis, ensuring that the cable 2 can pass through.

[0144] The extrusion die 10, as a special die for making extruded anchor heads, includes an extrusion die sleeve 101 and an extrusion die core 102. One end of the extrusion die sleeve 101 is fixedly connected to the extrusion jack 12, and the other end is fixedly connected to the extrusion die core 102. The extrusion die core 102 has a structure with a through hole in the middle. The inner diameter of the through hole is set according to the outer diameter of the extrusion sleeve to be extruded. The center lines of the extrusion die core 102, the extrusion die sleeve 101, the extrusion jack 12, the front clamping assembly, and the rear clamping assembly are the same. That is, the center lines of the conical clamping hole 15 in the piston of the extrusion die core 102, the extrusion die sleeve 101, the extrusion jack 12, and the conical clamping hole 15 in the tool anchor plate 16 are the same, ensuring that the cable body 2 can pass through them in a straight line.

[0145] The extrusion die sleeve 101 has a hollow frame structure to facilitate the insertion of the U-shaped insert 18. The U-shaped insert 18 is movably placed inside the extrusion die sleeve 101. This U-shaped insert 18 consists of a U-shaped strip and a handle. The opening size of the U-shaped strip is determined according to the size of the cable body 2 and can be inserted into the cable body 2. The handle is T-shaped, and one end is threaded to connect with the thread on the U-shaped strip, serving as a tooling for inserting the cable body during extrusion. The extrusion die sleeve 101 has a slot where the U-shaped strip of the U-shaped insert 18 is engaged, providing positioning for the U-shaped insert 18. Simultaneously, a slot is also provided at the end of the U-shaped insert 18 furthest from the support plate 11, where the tensioning end extrusion sleeve 3 is engaged, providing positioning for the tensioning end extrusion sleeve 3.

[0146] The extrusion die core 102 is made of hard alloy steel, and the two side openings of the extrusion die core 102 are funnel-shaped to facilitate centering during extrusion and demolding after extrusion. Furthermore, a sensor 17 for detecting the tension of the cable body 2 is provided between the front clamping assembly and the rear clamping assembly. This sensor 17 is a tension sensor and is sleeved on the cable body 2. Even further, the support plate 11 is an L-shaped plate with reinforcing ribs at the corners. The tension jack 13, extrusion jack 12, and rear clamping assembly are all installed on one side of the L-shaped plate, and a U-shaped groove 23 is formed on one side of the L-shaped plate. The corresponding axis lines of the extrusion die 10, extrusion jack 12, front clamping assembly, and rear clamping assembly pass through the U-shaped groove 23 to facilitate the passage of the cable body 2.

[0147] The other side of the L-shaped plate is detachably connected to the supporting steel frame via a fastening device. Specifically, the fastening device includes a roller assembly 24 and two clamping plates 25. The roller assembly 24 can be configured in one or more sets as needed, including rollers and two connecting plates. The two connecting plates are bolted to the supporting plate 11. The rollers are mounted on a connecting shaft via bearings, and the two ends of the connecting shaft are connected to the two connecting plates. The two clamping plates 25 are symmetrically clamped on both sides of the supporting steel frame 9, and both clamping plates 25 are detachably connected to the supporting plate 11. Specifically, the clamping plates 25 are connected to the supporting plate 11 via bolt pairs. The roller assembly 24 is installed on the supporting plate 11 between the two clamping plates 25, and the roller assembly 24 is in contact with the supporting steel frame 9, that is, the rollers of the roller assembly 24 are in contact with the supporting steel frame 9. Using the roller assembly 24 in contact with the supporting steel frame 9 facilitates the movement of the tensioning and compression integrated mechanism to the position of the next cable. Furthermore, the shape of the clamping plate 25 is adapted to the side of the supporting steel frame 9, increasing the contact area between the clamping plate 25 and the supporting steel frame 9 and improving the fastening stability.

[0148] The aforementioned integrated tensioning and extrusion equipment is used for tensioning and extruding photovoltaic cables. The tensioning and extrusion process of the cable body is basically the same, except that step S4.2 is different. In this embodiment, step S4.2 further includes the following specific steps:

[0149] S4.2.1: Assemble the roller assembly 24 and install it on the support plate 11;

[0150] S4.2.2: Install the extrusion die 10 on the output end of the extrusion jack 12, and then install the extrusion jack 12 on the support plate 11;

[0151] S4.2.3: Install the tensioning jack 13 and the rear clamping assembly onto the support plate 11;

[0152] S4.2.4: Hoist the components installed in step S4.2.3 to the cable installation position, install the clamping plate 25 on the support plate 11, and clamp the two clamping plates 25 on the support steel frame 9;

[0153] S4.2.5: Pass the cable body 2 through the pad ring 8, extrusion mold 10, tension end extrusion sleeve 3, extrusion jack 12, support plate 11, tension jack 13, sensor 17, and rear clamping assembly in sequence;

[0154] S4.2.6: Install the tool clamp 14 into the conical clamp hole 15 of the piston of the tension jack 13 to clamp and fix the cable body 2.

[0155] The manufacturing method of the present invention uses an integrated tensioning and extrusion equipment to tension and extrude the anchor head at the tensioning end. After the cable body 2 is tensioned in place, the tensioning end extrusion sleeve 3 can be extruded and anchored by the extrusion jack 12 and the extrusion mold 10. There is no need to replace the extrusion equipment, realizing the integrated tensioning and extrusion operation, reducing construction difficulty and improving construction efficiency.

[0156] Meanwhile, the manufacturing method has been changed from the anchoring method of welding ear plates a on the support steel frame 9 and connecting them to the fork ears b of the cable through pins to the support steel frame 9 with extrusion sleeve installation holes and nut or washer pressure anchoring method. This simplifies the connection method between the cable and the support steel frame, makes the cable structure simple, and makes cable installation and adjustment convenient, thereby reducing the cost of the cable.

[0157] like Figure 2-10 As shown, the tensioned and anchored integrated flexible photovoltaic cable manufactured using the manufacturing method of the present invention includes a cable body 2, a fixed end compression sleeve 1, and a tensioning end compression sleeve 3. The fixed end compression sleeve 1 covers one end of the cable body 2 and is fixed to one end of the cable body 2 by compression to form a fixed end anchor head. The other end of the cable body 2 passes through the tensioning end compression sleeve 3 and is fixed to the other end of the cable body 2 by compression to form a tensioning end anchor head. An anti-corrosion component is provided at one end of the tensioning end compression sleeve 3 to cover the other end of the cable body 2.

[0158] Anti-slip components are provided between the cable body 2 and the tension end compression sleeve 3 and the fixed end compression sleeve 1, which can improve the connection between the fixed end compression sleeve 1 and the tension end compression sleeve 3 and the cable body 2.

[0159] A sealant 5 is provided between the end of the tension end extrusion sleeve 3 and the fixed end extrusion sleeve 1 near the cable body 2 and the cable body 2. Specifically, the sealant 5 is formed by injecting glue into the end of the tension end extrusion sleeve 3 and the fixed end extrusion sleeve 1 with the largest diameter, so as to seal the cable body inside the extrusion sleeve.

[0160] The anti-corrosion component includes a cover plate 6 and a sealant 5. The cover plate 6 is threaded to one end of the tensioning end extrusion sleeve 3 to cover the cable body 2, and the sealant 5 is filled in the cover plate 6 on one side of the tensioning end extrusion sleeve 3 to achieve the purpose of sealing and anti-corrosion of the other end of the cable body 2.

[0161] The fixed end compression sleeve 1 has a thread at the end away from the cable body 2, that is, the thread is opened on the solid section of the fixed end compression sleeve 1, which facilitates the connection with the fixed end locking member 7 to achieve anchoring.

[0162] The photovoltaic cable also includes a fixed-end locking member 7 and a washer 8. The fixed-end locking member 7 is a fixed-end nut. Correspondingly, the thread on the end of the fixed-end compression sleeve 1 away from the cable body 2 is an external thread (in other embodiments, the fixed-end locking member 7 can also be a fixed-end bolt, in which case the thread on the end of the fixed-end compression sleeve 1 away from the cable body 2 is an internal thread). The fixed-end compression sleeve 1 passes through one of the support steel frames 9 and is threadedly connected to the fixed-end locking member 7. One side of the fixed-end locking member 7 is pressed against the support steel frame 9, thereby anchoring the fixed-end anchor head to one of the support steel frames 9. The tensioning end compression sleeve 3 passes through another support steel frame 9 and the washer 8 in sequence. One side of the washer 8 is pressed against the support steel frame 9, and the tensioning end compression sleeve 3 is pressed against the other side of the washer 8, thereby anchoring the tensioning end anchor head to the other support steel frame 9, thus anchoring the cable between the two support steel frames 9.

[0163] A centering boss 81 is provided on one side of the washer 8. The centering boss 81 is engaged in the mounting hole of the supporting steel frame 9 to facilitate the installation of the washer 8 and at the same time serve to center the cable body 2. A centering step 82 is provided on the other side of the washer 8. The end of the tensioning end compression sleeve 3 is engaged in the centering step 82 to facilitate the insertion of the tensioning end compression sleeve 3 into the washer 8 and at the same time serve to center the cable body 2.

[0164] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention, and these will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.

Claims

1. A method for manufacturing an integrated tensioned and anchored flexible photovoltaic cable, characterized in that, The manufacturing method involves first prefabricating the fixed-end anchor head at one end of the cable in the factory, then moving the cable to the construction site, anchoring the fixed-end anchor head, and tensioning the other end of the cable into place. Finally, the tensioning-end anchor head at the other end of the cable is manufactured. The method includes the following steps: S1: The fixed-end anchor head is manufactured in the factory by extrusion molding; S2: Pack the cables from step S1 and ship them to the construction site; S3: On the construction site, the fixed end anchor of one end of the cable is anchored to one of the supporting steel frames, and the other end is pulled to the anchor point of another supporting steel frame. S4: At the anchor point, tension the cable to exceed the design force value, and then clamp and fix the cable. S5: The tensioning end anchor head is processed by extrusion molding on the cable after the anchor point; S6: Release the cable and lower it into place; Step S4 includes the following specific steps: S4.1: Remove the HDPE layer at the other end of the cable (2) to the construction tensioning process length and the anchoring working length; S4.2: Install a tensioning and extrusion integrated device on the outside of another supporting steel frame (9), and connect the other end of the cable (2) to the output end of the tensioning integrated device; S4.3: Start the tensioning and extrusion integrated equipment, tension the cable (2) to exceed the design force value, and then fix the cable (2); Step S4.2 further includes the following specific steps: S4.2.1: Beforehand, turn a locking nut (20) into the support rod (19), and then pass one of the locking plates (21) through the support rod (19). S4.2.2: Place the support rod (19) on the support steel frame (9), then pass another locking plate (21) through the support rod (19), and then turn another locking nut (20) into the support rod (19), using the locking plate (21) to hold the support steel frame (9), and lock it with the two locking nuts (20); S4.2.3: Pass the extrusion die (10) through the support rod (19). At this time, align the inner hole of the extrusion die core (102) of the extrusion die (10) with the cable hole (91) on the support steel frame (9). Then mark the position where the extrusion jack (12) needs to be installed on one side of the extrusion die sleeve (101) of the extrusion die (10). S4.2.4: Remove the extrusion die (10), and install the extrusion die (10), extrusion jack (12), and support plate (11) in the marked positions to form a component; S4.2.5: Insert the components connected in step S4.2.4 into the support rod (19) respectively, so that the limiting step (191) of the support rod (19) contacts the support plate (11), and then tighten the locking nut (20) on the support rod (19) to fix the components; S4.2.6: Install the tensioning jack (13) and the rear clamping assembly on the support plate (11); S4.2.7: Pass the cable body (2) through the pad ring (8), extrusion mold (10), tension end extrusion sleeve (3), support plate (11), tension jack (13), sensor (17), and rear clamping assembly in sequence; S4.2.8: Install the tool clamp (14) into the conical clamp hole (15) of the piston of the tension jack (13) to clamp and fix the cable body (2).

2. A method for manufacturing an integrated tensioned and anchored flexible photovoltaic cable, characterized in that, The manufacturing method involves first prefabricating the fixed-end anchor head at one end of the cable in the factory, then moving the cable to the construction site, anchoring the fixed-end anchor head, and tensioning the other end of the cable into place. Finally, the tensioning-end anchor head at the other end of the cable is manufactured. The method includes the following steps: S1: The fixed-end anchor head is manufactured in the factory by extrusion molding; S2: Pack the cables from step S1 and ship them to the construction site; S3: On the construction site, the fixed end anchor of one end of the cable is anchored to one of the supporting steel frames, and the other end is pulled to the anchor point of another supporting steel frame. S4: At the anchor point, tension the cable to exceed the design force value, and then clamp and fix the cable. S5: The tensioning end anchor head is processed by extrusion molding on the cable after the anchor point; S6: Release the cable and lower it into place; Step S4 includes the following specific steps: S4.1: Remove the HDPE layer at the other end of the cable (2) to the construction tensioning process length and the anchoring working length; S4.2: Install a tensioning and extrusion integrated device on the outside of another supporting steel frame (9), and connect the other end of the cable (2) to the output end of the tensioning integrated device; S4.3: Start the tensioning and extrusion integrated equipment, tension the cable (2) to exceed the design force value, and then fix the cable (2); Step S4.2 further includes the following specific steps: S4.2.1: Assemble the roller assembly (24) and install it on the support plate (11); S4.2.2: Install the extrusion die (10) at the output end of the extrusion jack (12), and then install the extrusion jack (12) on the support plate (11); S4.2.3: Install the tensioning jack (13) and the rear clamping assembly on the support plate (11); S4.2.4: Hoist the components installed in step S4.2.3 to the cable installation position, install the clamping plate (25) on the support plate (11), and clamp the two clamping plates (25) on the support steel frame (9); S4.2.5: Pass the cable body (2) through the pad ring (8), extrusion mold (10), tension end extrusion sleeve (3), extrusion jack (12), support plate (11), tension jack (13), sensor (17), and rear clamping assembly in sequence; S4.2.6: Install the tool clamp (14) into the conical clamp hole (15) of the piston of the tension jack (13) to clamp and fix the cable body (2).

3. A method for manufacturing an integrated tensioned and anchored flexible photovoltaic cable according to claim 1 or 2, characterized in that, Step S1 includes the following specific steps: S1.1: Remove the HDPE layer from one end of the cable body (2), and fit the fixed end extrusion sleeve (1) into the cable body (2) to the bottom of the inner hole, so as to ensure that the fixed end extrusion sleeve (1) covers a section of the HDPE layer of the cable body (2); S1.2: Push the extrusion plate (4) into the gap between the fixed end extrusion sleeve (1) and the cable body (2); S1.3: Pour sealant (5) into the fixed end extrusion sleeve (1) until the gap of the fixed end extrusion sleeve (1) is filled; S1.4: The fixed end extrusion sleeve (1) is extruded using an extrusion device to obtain the fixed end extrusion anchor head.

4. A method for manufacturing a tensioned and anchored integrated flexible photovoltaic cable according to claim 1 or 2, characterized in that, Step S3 involves passing the fixed end anchor head through one of the supporting steel frames (9) and connecting it with the fixed end locking member (7) to anchor the fixed end anchor head onto the supporting steel frame (9), and then passing the other end of the cable body (2) through another supporting steel frame (9).

5. A method for manufacturing a tensioned and anchored integrated flexible photovoltaic cable according to claim 1 or 2, characterized in that, Step S4.3 further includes the following specific steps: S4.3.1: Start the tensioning jack (13) piston extension to tension the cable (2) to the piston stroke of the tensioning jack (13); S4.3.2: Install the tool clamp (14) into the corresponding conical clamp hole (15) of the rear clamping assembly to clamp and fix the cable body (2), and at the same time loosen the tool clamp (14) corresponding to the tension jack (13), and the piston of the tension jack (13) retracts; S4.3.3: Repeat steps S4.3.1 and S4.3.2 above, tension the cable (2) to exceed the design force value, and then install the tool clamp (14) into the corresponding conical clamp hole (15) of the rear clamping assembly to clamp and fix the cable (2).

6. A method for manufacturing a tensioned and anchored integrated flexible photovoltaic cable according to claim 1 or 2, characterized in that, Step S5 includes the following specific steps: S5.1: Push the extrusion plate (4) into the gap between the tension end extrusion sleeve (3) and the cable body (2); S5.2: Pour sealant (5) into the tension end extrusion sleeve (3) until the gap of the tension end extrusion sleeve (3) is filled; S5.3: Install a U-shaped insert (18) after the tensioning end extrusion sleeve (3), so that one end of the tensioning end extrusion sleeve (3) is stuck in the slot of one end of the U-shaped insert (18), and the other end of the U-shaped insert (18) is stuck in the slot of the support plate (11); S5.4: Start the extrusion jack (12) piston retracts, driving the extrusion die core (102) of the extrusion die (10) to move, extruding the tension end extrusion sleeve (3) to obtain the tension end anchor head.

7. A method for manufacturing a tensioned and anchored integrated flexible photovoltaic cable according to claim 1 or 2, characterized in that, Step S6 includes the following specific steps: S6.1: Move the pad ring (8) and insert the pad ring (8) into the cable hole (91) of the support steel frame (9); S6.2: After loosening the clamping component, the corresponding tool clamp (14) is released, the piston of the tensioning jack (13) is started to retract, and the tensioning end compression sleeve (3) is moved so that its end face is lowered into the centering step (82) of the pad ring (8).

8. A method for manufacturing a tensioned and anchored integrated flexible photovoltaic cable according to claim 1 or 2, characterized in that, The manufacturing method further includes step S7: cutting off the excess cable body (2) on the end face of the tensioning end anchor head, filling the cover plate (6) with sealant (5), and then covering and fixing the cover plate (6) to one end of the tensioning end extrusion sleeve (3).

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