A high-voltage cable continuous production line and a cable production process using the same

Abstract

The application relates to a high-voltage cable continuous production line which comprises a machine body, a plurality of unwinding rollers arranged at one end of the machine body in the length direction, a winding roller arranged at the other end of the machine body in the length direction, a pouring mold arranged between the unwinding rollers and the winding roller, a mold cavity formed in the side of the pouring mold facing the winding roller, a plurality of wire core holes formed in the side of the pouring mold facing the unwinding rollers, the wire core holes being communicated with the mold cavity, an insulation layer flow channel, an aluminum liquid flow channel and a protective layer flow channel formed in the side wall of the pouring mold, and the insulation layer flow channel, the aluminum liquid flow channel and the protective layer flow channel being communicated with the mold cavity. The application has the effect of reducing the crack probability in the aluminum sleeve.

Description

Technical Field

[0001] This application relates to the field of cable manufacturing, and in particular to a continuous production line for high-voltage cables and a cable manufacturing process using the production line. Background Technology

[0002] High-voltage cables are a type of power cable, referring to power cables used to transmit power between 1kV and 1000kV. They are mostly used for power transmission and distribution. From the inside out, a high-voltage cable consists of a conductive core, an insulation layer covering the conductor core, an aluminum sheath covering the insulation layer, and a wear-resistant protective layer covering the aluminum sheath.

[0003] In existing high-voltage cables, the aluminum sleeve is formed by bending and welding aluminum plates to create an aluminum ring that is fitted over the insulation layer. Then, a diameter reduction device is used to reduce the diameter of the aluminum ring, so that the inner wall of the aluminum ring fits against the outer wall of the insulation layer and covers the outside of the insulation layer to form the aluminum sleeve. During the production process, the aluminum ring needs to be squeezed to reduce its diameter. This process can easily lead to the aluminum ring breaking, resulting in cracks in the formed aluminum sleeve and affecting its performance. Summary of the Invention

[0004] To reduce the probability of cracks forming in the aluminum sheath, this application provides a continuous production line for high-voltage cables.

[0005] The high-voltage cable continuous production line provided in this application adopts the following technical solution:

[0006] A high-voltage cable continuous production line includes a machine body. A plurality of unwinding rollers are arranged at one end of the machine body along its length, and a winding roller is arranged at the other end of the machine body along its length. A casting mold is arranged between the unwinding rollers and the winding rollers. The casting mold has a cavity on the side facing the winding rollers, and a plurality of wire core holes are formed on the side facing the unwinding rollers. All wire core holes are connected to the cavity. An insulation layer flow channel, an aluminum liquid flow channel, and a protective layer flow channel are formed on the side wall of the casting mold, and all three flow channels are connected to the cavity.

[0007] By adopting the above technical solution, molten aluminum liquid is poured into an aluminum sleeve through a casting mold, thereby reducing the probability of cracks in the aluminum sleeve caused by diameter reduction.

[0008] Optionally, the aluminum liquid flow channel includes an inlet section and a forming section both opened on the casting mold. One end of the inlet section passes through the casting mold and connects to the outside of the casting mold. One end of the forming section is connected to the inlet section, and the other end is connected to the mold cavity.

[0009] By adopting the above technical solution, the forming part can be set so that the aluminum liquid is formed and then wrapped around the wire core.

[0010] Optionally, the insulating layer flow channel includes an injection section, an annular flow channel, and branch flow channels all formed on the casting mold. One end of the injection section penetrates the casting mold and connects to the outside of the casting mold. The annular flow channel is formed at the end of the injection section away from penetrating the casting mold and is distributed in a ring along the cross-section of the casting mold. There are several branch flow channels, which are evenly distributed around the annular flow channel. One end of the branch flow channel connects to the annular flow channel and the other end connects to the mold cavity.

[0011] By adopting the above technical solution, molten insulating liquid is injected into the annular flow channel through the injection section, and then the insulating liquid is injected between the wire core and the aluminum sleeve through multiple branch channels to complete the casting of the insulation layer.

[0012] Optionally, the casting mold is provided with a first cooling cavity, which is located around the molding part.

[0013] By adopting the above technical solution, the first cooling chamber can accelerate the cooling and forming of molten aluminum.

[0014] Optionally, the casting mold is provided with a second cooling cavity, which is located around the mold cavity.

[0015] By adopting the above technical solution, the second cooling chamber can accelerate the cooling and forming of the insulation layer and the protective layer.

[0016] Optionally, the casting mold is provided with a winding assembly at the end facing the unwinding roller. The winding assembly includes a winding gear, a winding gear ring, and a power component. There are several winding gears, and several wire-passing holes are opened on the winding gears. The winding gears are rotatably mounted on the casting mold corresponding to the wire core holes. The winding gear ring is sleeved on the winding gears and is rotatably mounted on the casting mold. The winding gear ring meshes with several winding gears. The power component is mounted on the machine body and drives the winding gear ring to rotate.

[0017] By adopting the above technical solution, the winding assembly can be used to wind multiple strands of copper wire, which facilitates the winding of copper wire during cable production.

[0018] Optionally, the winding assembly can be detachably mounted on the casting mold.

[0019] By adopting the above technical solution, the detachable winding assembly can be replaced with a suitable winding assembly according to the required number of copper wires.

[0020] Optionally, a mounting platform is fixed on the machine body, and the casting mold can be detachably mounted on the mounting platform.

[0021] By adopting the above technical solution, the detachable casting mold enables the production line to produce high-voltage cables of different sizes.

[0022] A high-voltage cable manufacturing process using a continuous high-voltage cable production line includes the following steps:

[0023] S1: Uncoiling, the steel wire coil is installed on the uncoiling roller for uncoiling;

[0024] S2: Winding, the uncoiled steel wires are divided into multiple equal parts, and each part is wound to form a wire core. The wound wire cores enter the mold cavity of the casting mold through the wire core hole.

[0025] S3: Casting aluminum sleeve. Molten aluminum is fed from the inlet to the forming part. After cooling and forming into an aluminum sleeve in the forming part, it enters the mold cavity and covers the outside of the wire core.

[0026] S4: Casting the insulation layer, molten PVC polyethylene is introduced into the mold cavity through the insulation layer flow channel, the molten PVC polyethylene fills between the wire core and the aluminum sleeve and cools to form the insulation layer;

[0027] S5: Casting the protective layer involves passing molten rubber through the protective layer channel into the mold cavity, allowing the molten rubber to cool outside the aluminum sleeve and form a protective layer.

[0028] S6: Rewinding, the formed cable is wound up on the winding roller to complete the cable processing.

[0029] By adopting the above technical solution, the temperature of aluminum is much higher than the temperature at which the protective layer and insulation layer melt. Since the cable production process is usually carried out from the inside out, the existing cables are produced by shrinking the diameter of the aluminum sleeve after it is fitted with a large diameter aluminum sleeve. During this production process, the aluminum sleeve is prone to cracks and can also be damaged by extrusion, thus affecting the function of the aluminum sleeve. This application avoids the step of extruding and shrinking the diameter of the aluminum sleeve by changing the traditional inside-out processing sequence, reducing the probability of hidden damage to the aluminum sleeve. At the same time, it improves production efficiency by using a single mold for joint casting, and reduces the equipment required for production and the space required for placing the equipment.

[0030] In summary, this application includes at least one of the following beneficial technical effects:

[0031] 1. Molten aluminum is poured into an aluminum sleeve using a casting mold, thereby reducing the probability of cracks in the aluminum sleeve caused by diameter reduction;

[0032] 2. The first cooling chamber can accelerate the cooling and forming of molten aluminum;

[0033] 3. The second cooling chamber can accelerate the cooling and forming of the insulation layer and the protective layer;

[0034] 4. The winding assembly allows for the winding of multiple copper wires, facilitating the winding of copper wires during cable production. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the overall structure of this embodiment.

[0036] Figure 2 This is a cross-sectional structural diagram of the casting mold in this embodiment.

[0037] Figure 3 yes Figure 1 A magnified view of section A in the middle.

[0038] Explanation of reference numerals in the attached drawings: 1. Machine body; 2. Unwinding roller; 3. Rewinding roller; 4. Casting mold; 5. Mold cavity; 6. Core hole; 7. Insulation layer flow channel; 71. Injection section; 72. Annular flow channel; 73. Branch flow channel; 8. Aluminum liquid flow channel; 81. Liquid inlet section; 82. Forming section; 9. Protective layer flow channel; 10. First cooling chamber; 11. Second cooling chamber; 12. Winding assembly; 121. Winding gear; 122. Winding gear ring; 123. Power component; 13. Mounting platform; 14. Mounting plate; 15. First liquid inlet pipe; 16. First liquid outlet pipe; 17. Second liquid inlet pipe; 18. Second liquid outlet pipe; 19. Wire threading hole. Detailed Implementation

[0039] The following is in conjunction with the appendix Figure 1-3 This application will be described in further detail.

[0040] This application discloses a continuous high-voltage cable production line, referring to... Figure 1 and Figure 2 The system includes a rectangular body 1. Several unwinding rollers 2 are rotatably mounted at one end of the body 1 along its length, and a winding roller 3 is rotatably mounted at the other end. A casting mold 4 is positioned between the unwinding rollers 2 and the winding roller 3. The casting mold 4 has a cavity 5 facing the winding roller 3, and several wire core holes 6 are formed on the side of the casting mold 4 facing the unwinding rollers 2. In this embodiment, three wire core holes 6 are formed, penetrating both ends of the casting mold 4 along its length and connecting to the cavity 5. An insulating layer flow channel 7, an aluminum liquid flow channel 8, and a protective layer are formed on the side wall of the casting mold 4. The flow channel 9, the insulating layer flow channel 7, the aluminum liquid flow channel 8, and the protective layer flow channel 9 are all connected to the mold cavity 5. The insulating layer flow channel 7 is used to introduce molten PVC polyethylene. After the molten PVC polyethylene enters the mold cavity 5, it forms an insulating layer outside the core. The aluminum liquid flow channel 8 is used to introduce molten aluminum liquid, so that the aluminum liquid can enter the mold cavity 5 and form an aluminum sleeve outside the insulating layer. The protective layer flow channel 9 is used to introduce molten rubber, so that the molten rubber forms a protective layer covering the aluminum sleeve inside the mold cavity 5. The molten aluminum liquid is poured into the aluminum sleeve through the casting mold 4, thereby reducing the probability of cracks in the aluminum sleeve caused by diameter reduction.

[0041] Reference Figure 2The aluminum liquid flow channel 8 includes an inlet section 81 and a forming section 82, both of which are formed on the casting mold 4. The inlet section 81 is a single flow channel, with one end penetrating through the casting mold 4 and connecting to the outside of the casting mold 4. The inlet section 81 is used to connect to the equipment for manufacturing molten aluminum liquid so that the molten aluminum liquid can be introduced into the casting mold 4. The forming section 82 is an annular flow channel 72. The inner and outer diameters of the forming section 82 are set according to the required aluminum sleeve. One end of the forming section 82 is connected to the inlet section 81, and the other end is connected to the mold cavity 5. The molten aluminum liquid enters the forming section 82 through the inlet section 81, cools in the forming section 82, and then enters the mold cavity 5 and is sleeved around the core. The insulation layer flow channel 7 includes an injection section 71, an annular flow channel 72, and a branch flow channel, both of which are formed on the casting mold 4. The injection section 71 penetrates the casting mold 4 at one end and connects to the outside of the casting mold 4. The injection section 71 is connected to the equipment for manufacturing molten PVC polyethylene. The annular flow channel 72 is opened at the end of the injection section 71 away from the end that penetrates the casting mold 4. The annular flow channel 72 is distributed in a ring shape along the cross section of the casting mold 4. There are several branch channels 73, which are evenly distributed around the annular flow channel 72. One end of the branch channel 73 is connected to the annular flow channel 72 and the other end is connected to the mold cavity 5. Molten PVC polyethylene enters the annular flow channel 72 through the injection section, and then enters the mold cavity 5 through the branch channels 73 around the annular flow channel 72, so that the molten PVC polyethylene fills the space between the wire core and the aluminum sleeve. After the molten PVC polyethylene cools, it forms an insulating layer.

[0042] Reference Figure 2 The casting mold 4 has a first cooling chamber 10, which is located around the forming part 82. The casting mold 4 has a first liquid inlet pipe 15 and a first liquid outlet pipe 16, which are respectively connected to the two ends of the first cooling chamber 10 along its length. Coolant enters the first cooling chamber 10 through the first liquid inlet pipe 15 and exchanges heat with the aluminum liquid in the forming part 82 in the first cooling chamber 10, thereby increasing the cooling and forming speed of the aluminum liquid. After heat exchange in the first cooling chamber 10, the coolant is discharged through the first liquid outlet pipe 16 and circulated back in, realizing the continuous production of high-voltage cables. The casting mold 4 is provided with a second cooling chamber 11, which is located around the mold cavity 5. The casting mold 4 is provided with a second liquid inlet pipe 17 and a second liquid outlet pipe 18, which are respectively connected to the two ends of the length direction of the second cooling chamber 11. The coolant enters the second cooling chamber 11 from the second liquid inlet pipe 17 and exchanges heat with the high-voltage cable in the mold cavity 5 in the second cooling chamber 11, thereby improving the cooling and molding speed of the high-voltage cable. After the coolant exchanges heat in the second cooling chamber 11, it is discharged from the second liquid outlet pipe 18. The coolant is circulated in to realize the continuous production of high-voltage cables.

[0043] Reference Figure 1 and Figure 3A winding assembly 12 is detachably mounted on one end of the casting mold 4 facing the unwinding roller 2. The winding assembly 12 includes several winding gears 121 rotatably mounted on the casting mold 4 corresponding to the wire core holes 6, a winding gear ring 122 sleeved on the winding gears 121, and a power component 123 mounted on the machine body 1. The winding gears 121 have several wire-passing holes 19, the number of which is the number of steel wires required for each wire core. The winding gear ring 122 is rotatably mounted on the casting mold 4, and the winding gear ring 122 meshes with several winding gears 121. The power component 123... 23. A power motor is selected and installed on the machine body 1. A drive gear is installed on the shaft of the power motor. An external gear is sleeved on the outer surface of the winding gear ring 122. The drive gear and the external gear mesh with each other. When the drive motor starts, it drives the drive gear to rotate. The rotation of the drive gear drives the winding gear ring 122 to rotate. The rotation of the winding gear ring 122 drives the winding gear 121. The unwound copper wire passes through the wire hole 19 and is wound to form a wire core under the rotation of the winding gear 121. The wound wire core enters the casting mold 4 through the wire core hole 6 for subsequent processing.

[0044] Reference Figure 1 and Figure 2 A mounting platform 13 is fixed on the machine body 1. A mounting plate 14 is provided on the casting mold 4. Bolts are threaded through the mounting plate 14 and connected to the mounting platform 13. The casting mold 4 is detachably mounted on the mounting platform 13 by means of bolts. The casting mold 4 is a mold made of asbestos. The casting mold 4 is divided into an upper mold and a lower mold. The upper mold and the lower mold are each provided with a half of the mounting plate 14. The bolts are used to install the casting mold 4 and also to fix the upper mold and the lower mold to each other. The connection part of the casting mold 4 between the first cooling chamber 10 and the forming part 82 and the second cooling chamber 11 and the mold cavity 5. Copper is used because asbestos has poor heat transfer properties, ensuring that the temperature of the molten aluminum does not affect PVC, polyethylene, and rubber. The connection between the first cooling chamber 10 and the molding part 82, as well as the second cooling chamber 11 and the mold cavity 5, is made of copper, which allows for faster heat transfer between the first cooling chamber 10 and the molding part 82, as well as the second cooling chamber 11 and the mold cavity 5, thus accelerating the cooling speed. The detachable casting mold 4 allows the production line to produce high-voltage cables of different sizes. The detachable winding assembly 12 allows for the selection of a suitable winding assembly 12 based on the required number of copper wires.

[0045] A high-voltage cable production process using a continuous high-voltage cable production line includes the following steps: S1: Uncoiling, where a steel wire coil is installed on an uncoiling roller for uncoiling; S2: Winding, where the uncoiled steel wire is divided into multiple equal portions, and each portion is wound to form a wire core, the wound wire core entering the mold cavity of a casting mold through a wire core hole; S3: Casting an aluminum sheath, where molten aluminum is fed from the inlet to the forming section, cooled and formed into an aluminum sheath in the forming section, and then enters the mold cavity to cover the wire core; S4: Casting an insulation layer, where molten PVC polyethylene is introduced into the mold cavity through an insulation layer flow channel, filling and cooling between the wire core and the aluminum sheath to form an insulation layer; S5: Casting a protective layer, where molten rubber is introduced into the mold cavity through a protective layer flow channel, allowing the molten rubber to fill the space between the aluminum sheath and the insulation layer. External cooling forms a protective layer; S6: winding, the formed cable is wound on the winding roller to complete the cable processing; the temperature of aluminum is much higher than the melting temperature of the protective layer and the insulation layer, and the cable production process is usually carried out from the inside to the outside. Therefore, the existing cables are produced by using a large-diameter aluminum sleeve and then reducing the diameter of the aluminum sleeve. During this production process, the aluminum sleeve is prone to cracks and can also be damaged by extrusion, thus affecting the function of the aluminum sleeve. This application avoids the step of extruding and reducing the diameter of the aluminum sleeve by changing the traditional inside-out processing sequence, reducing the probability of hidden damage to the aluminum sleeve. At the same time, it improves production efficiency by using a single mold for joint casting, and reduces the equipment required for production and the space required for placing the equipment.

[0046] The implementation principle of this application embodiment is as follows: the wire coil is placed on the unwinding roller 2 and unwound. The unwound wire passes through the wire threading hole 19 and enters the wire core hole 6. Then it passes through the casting mold and is installed on the winding roller 3. The motor drives the winding roller 3 to rotate and wind it. During this period, the winding gear 121 rotates to wind the wire into a wire core. When the wire core passes through the mold cavity 5, an aluminum sleeve is fitted on it, and an insulating layer is cast between the aluminum sleeve and the wire core. A protective layer is cast on the outside of the aluminum sleeve to form a high-voltage cable and wind it on the winding roller 3 to complete the continuous production of the high-voltage cable.

[0047] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A continuous high-voltage cable production line, comprising a machine body (1), wherein a plurality of unwinding rollers (2) are arranged at one end of the machine body (1) along its length, and a winding roller (3) is arranged at the other end of the machine body (1) along its length, characterized in that: The machine body (1) is provided with a casting mold (4) between the unwinding roller (2) and the winding roller (3). The casting mold (4) has a mold cavity (5) on the side facing the winding roller (3). The casting mold (4) has a plurality of wire core holes (6) on the side facing the unwinding roller (2). The wire core holes (6) are all connected to the mold cavity (5). The side wall of the casting mold (4) is provided with an insulating layer flow channel (7), an aluminum liquid flow channel (8) and a protective layer flow channel (9). The insulating layer flow channel (7), the aluminum liquid flow channel (8) and the protective layer flow channel (9) are all connected to the mold cavity (5). The aluminum liquid flow channel (8) includes an inlet section (81) and a forming section (82) both opened on the casting mold (4). One end of the inlet section (81) passes through the casting mold (4) and connects to the outside of the casting mold (4). One end of the forming section (82) is connected to the inlet section (81), and the other end is connected to the mold cavity (5). The insulating layer flow channel (7) includes an injection section (71), an annular flow channel (72), and a branch flow channel (73) all opened on the casting mold (4). One end of the injection section (71) penetrates the casting mold (4) and connects to the outside of the casting mold (4). The annular flow channel (72) is opened at the end of the injection section (71) away from penetrating the casting mold (4). The annular flow channel (72) is distributed in an annular shape along the cross section of the casting mold (4). There are several branch flow channels (73). Several branch flow channels (73) are evenly distributed around the annular flow channel (72). One end of the branch flow channel (73) connects to the annular flow channel (72) and the other end connects to the mold cavity (5). The casting mold (4) is provided with a first cooling cavity (10), which is located around the molding part (82); The casting mold (4) is provided with a second cooling cavity (11), which is located around the mold cavity (5).

2. The high-voltage cable continuous production line according to claim 1, characterized in that: The casting mold (4) is provided with a winding assembly (12) facing the unwinding roller (2). The winding assembly (12) includes a winding gear (121), a winding gear ring (122), and a power component (123). There are several winding gears (121), and several wire holes (19) are opened on the winding gears (121). The winding gears (121) are rotatably mounted on the casting mold (4) corresponding to the wire core holes (6). The winding gear ring (122) is sleeved on the winding gears (121) and rotatably mounted on the casting mold (4). The winding gear ring (122) meshes with several winding gears (121). The power component (123) is mounted on the machine body (1) and drives the winding gear ring (122) to rotate.

3. The high-voltage cable continuous production line according to claim 2, characterized in that: The winding assembly (12) is detachably mounted on the casting mold (4).

4. A continuous high-voltage cable production line according to claim 1, characterized in that: The machine body (1) is fixedly provided with an installation platform (13), and the casting mold (4) is detachably installed on the installation platform (13).

5. A high-voltage cable production process using the high-voltage cable continuous production line of claim 1, comprising the following steps: S1: Unwinding, the wire coil is installed on the unwinding roller (2) for unwinding; S2: Winding, the uncoiled steel wires are divided into multiple equal parts, and each part is wound to form a wire core. The wound wire core enters the mold cavity (5) of the casting mold (4) through the wire core hole (6). S3: Casting aluminum sleeve, the aluminum liquid is sent from the liquid inlet (81) into the forming part (82), and after cooling and forming into an aluminum sleeve in the forming part (82), it enters the mold cavity (5) and covers the outside of the wire core; S4: Cast the insulation layer by passing molten PVC polyethylene through the insulation layer flow channel (7) into the mold cavity (5). The molten PVC polyethylene fills the space between the wire core and the aluminum sleeve and cools to form the insulation layer. S5: Casting the protective layer, the molten rubber is introduced into the mold cavity (5) through the protective layer flow channel (9), so that the molten rubber cools outside the aluminum sleeve to form a protective layer; S6: Rewinding, the formed cable is wound on the winding roller (3) to complete the cable processing.

Images