A 10kV high-performance cable for coal mining machines and its manufacturing process

Abstract

The present invention discloses a 10kV high-performance cable for coal mining machines, comprising an internal wire core assembly and a sheath assembly coated on the outside of the internal wire core assembly, wherein the sheath assembly comprises an inner sheath, a braided layer and an outer sheath sequentially arranged from the inside to the outside; the internal wire core assembly comprises a plurality of power wire core units, a plurality of control wire core units and an optical fiber. The present invention provides a 10kV high-performance cable for coal mining machines, which is suitable for use in coal mining machines and has the characteristics of being not easy to be punctured, having strong anti-aging performance and having a long service life.

Description

Technical Field

[0001] The invention belongs to the technical field of cables, and in particular relates to a 10kV high-performance cable for coal mining machines and a manufacturing process thereof. Background Art

[0002] At present, the highest voltage level of domestic coal mining machine cables is 1.9 / 3.3kV. The coal mining machine cables are in a reciprocating motion with a bending radius of 2-3 times during operation. During the bending motion, the coal mining machine cables rub against the cable clamps, and the cable sheath layer is easily worn. At the same time, the cables may be squeezed by coal blocks in the cable clamps, and the cable sheath is further damaged, which in turn affects the cable insulation layer, causing cable short circuits, equipment shutdowns, and safety accidents. The service life of the cables is not long, and it is almost difficult to achieve continuous use of multiple coal mining faces.

[0003] Coal mining machine cables are always in a dynamic bending state during operation. As the voltage level increases, the performance requirements for insulation materials are higher. Conventional materials will be greatly deformed when subjected to external impact, which may lead to electrical breakdown, local discharge-induced heating, accelerated aging, and rapid performance degradation, resulting in a short service life of the cable. At the same time, in order to protect the long-term reliability of the insulation core, the external protective layer is also crucial. Summary of the invention

[0004] The purpose of the present invention is to overcome the above problems existing in the prior art and to provide a 10kV high-performance coal mining machine cable suitable for use in coal mining machines, which has the characteristics of impact resistance, not easy to be punctured, strong anti-aging performance and long service life.

[0005] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions:

[0006] In a first aspect, a 10 kV high-performance coal mining machine cable comprises an internal wire core component and a sheath component coated on the outside of the internal wire core component, wherein the sheath component comprises an inner sheath, a braided layer and an outer sheath sequentially arranged from the inside to the outside;

[0007] The internal wire core assembly includes a plurality of power wire core units, a plurality of control wire core units and optical fibers;

[0008] The power core unit includes multiple power conductors and a conductor insulation layer group coated on the outside of the multiple power conductors. The conductor insulation layer group includes a conductor shielding layer, a power insulation layer and an insulation shielding layer arranged in sequence from the inside to the outside. The outside of the insulation shielding layer is coated with a conductor metal shielding layer.

[0009] Preferably, the control wire core unit comprises a plurality of control wire cores and a control metal shielding layer coated on the outside of the plurality of control wire cores;

[0010] The control core includes a plurality of control conductors and a control insulation layer group wrapped around the plurality of control conductors;

[0011] The control insulation layer group has the same structure as the conductor insulation layer group, and the control insulation layer group adopts the same structure as the conductor insulation layer group.

[0012] In a second aspect, a manufacturing process of a 10 kV high performance coal mining machine cable is provided, the manufacturing process comprising the following steps:

[0013] S01: Power conductor twisting

[0014] Twisting a plurality of power conductors, after twisting, subjecting the twisted power conductors to a primary annealing treatment in a nitrogen atmosphere, placing them aside for 1-2 days after the primary annealing treatment, and then subjecting them to a secondary annealing treatment, to prepare a flexible conductor after the secondary annealing treatment, wherein the annealing temperatures of the primary annealing treatment and the secondary annealing treatment are both 230-280° C., and the time is both 3-5 hours;

[0015] S02: Preparation of power line core unit

[0016] The internal insulating material, the rubber material and the external insulating material are respectively sent to three extruders for plasticization, and the plasticized products are respectively sent to three extruder heads of a three-layer co-extruder, and the flexible conductor is placed in the three-layer co-extruder, and a conductor shielding layer, a power insulating layer and an insulating shielding layer are formed on the outside of the flexible conductor by a three-layer co-extrusion process, and then a conductor metal shielding layer is woven outside the insulating shielding layer to prepare a power core unit, wherein the conductor insulating layer group is made by extruding the internal insulating material through the extruder head after being plasticized by the extruder, the power insulating layer is made by extruding the rubber material through the extruder head after being plasticized by the extruder, and the insulating shielding layer is made by extruding the external insulating material through the extruder head after being plasticized by the extruder;

[0017] Among them, this step is carried out in a dust-free workshop;

[0018] S03: Control conductor twisting

[0019] Twisting a plurality of control conductors to prepare a control harness;

[0020] S04: Prepare control core unit

[0021] According to the operation method of step S02, a control insulation layer group is formed on the outside of the control wire harness to prepare a control wire core, and after multiple control wire cores are twisted, a control metal shielding layer is braided on the outside of the twisted multiple control wire cores to prepare a control wire core unit;

[0022] Among them, this step is carried out in a dust-free workshop;

[0023] S05: Cable

[0024] A cage stranding machine is used to prepare multiple power core units, multiple control core units and optical fibers into internal core components;

[0025] S06: Sheath extrusion

[0026] A cable is prepared by sequentially coating an inner sheath on the outside of an internal core component with a series of extrusion equipment, weaving a braided layer on the outside of the inner sheath, coating the outside of the braided layer with an outer sheath, and then subjecting the cable to thermal cross-linking. The series of extrusion equipment comprises a first rubber extruder, a braiding machine, a second rubber extruder, and a vulcanization pipeline sequentially arranged along the moving direction of the internal core component. The inner sheath is extruded by the first rubber extruder, the braided layer is braided by the braiding machine, and the outer sheath is extruded by the second rubber extruder.

[0027] Preferably, the rubber material comprises the following raw materials in parts by weight: 8-12 parts of EPDM 4770, 35-45 parts of POE 8150, 30-40 parts of EPDM 2504, 8-12 parts of paraffin oil, 20-30 parts of talc, 70-80 parts of calcined clay, 1-2 parts of paraffin, 1.0-1.4 parts of antioxidant RD, 0.5-1.5 parts of antioxidant MB, 0.4-0.6 parts of coupling agent A-172, 0.4-0.6 parts of stearic acid, 2-3 parts of polyethylene, 3-5 parts of zinc oxide, 2-4 parts of carbon black N330, 2-4 parts of vulcanizing agent DCP, and 1-3 parts of vulcanizing aid TAIC.

[0028] More preferably, the rubber material comprises the following raw materials in parts by weight: 10 parts of EPDM 4770, 40 parts of POE 8150, 35 parts of EPDM 2504, 10 parts of paraffin oil, 25 parts of talc, 75 parts of calcined clay, 1.5 parts of paraffin, 1.2 parts of antioxidant RD, 1 part of antioxidant MB, 0.5 parts of coupling agent A-172, 0.5 parts of stearic acid, 2.5 parts of polyethylene, 4 parts of zinc oxide, 3 parts of carbon black N330, 3.2 parts of vulcanizing agent DCP, and 2 parts of vulcanizing aid TAIC.

[0029] Preferably, the preparation process of the rubber material is carried out in a dust-free workshop, and the preparation process of the rubber material includes the following steps:

[0030] Step a: weigh the raw materials of the rubber material according to the formula;

[0031] Step b: mixing the raw materials at 110-120° C. to prepare a rubber compound, wherein no vulcanizing agent or vulcanizing aid is added during the mixing process;

[0032] Step c: filtering the rubber material once using a primary filter at 120-130° C.; wherein the primary filter comprises a first filter layer, a second filter layer, a third filter layer, a fourth filter layer and a fifth filter layer which are stacked in sequence, the apertures of the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are 40 mesh, 80 mesh, 100 mesh, 80 mesh and 40 mesh respectively, and the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are all made of stainless steel;

[0033] Step d: performing secondary filtration on the rubber material after the primary filtration at 110-130° C. using a secondary filter screen; wherein the secondary filter screen comprises a sixth filter layer, a seventh filter layer, an eighth filter layer, a ninth filter layer and a tenth filter layer which are stacked in sequence, and the apertures of the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are 40 meshes, 100 meshes, 100 meshes, 80 meshes and 40 meshes respectively, and the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are all made of stainless steel;

[0034] Step e: adding a vulcanizing agent and a vulcanizing aid to the rubber material after the secondary filtration, granulating the rubber material with a granulator and then cooling the granulator to prepare a rubber material;

[0035] Step f: placing the prepared rubber material in a hanging bag and sealing it for storage; wherein the hanging bag is made of PP material;

[0036] Among them, after the rubber material is prepared, it is placed in a PP hanging bag for use to ensure the cleanliness of the rubber material.

[0037] Preferably, the raw material components and weight ratios of the internal insulating material and the external insulating material are the same;

[0038] The internal insulating material comprises the following raw materials in parts by weight: 30-40 parts of chlorinated polyethylene, 30-40 parts of ethylene vinyl acetate copolymer, 7-8 parts of magnesium oxide, 12-18 parts of chlorinated paraffin, 3-5 parts of dioctyl phthalate, 6-8 parts of paraffin oil, 6-10 parts of vaseline, 60-68 parts of conductive carbon black, 1-3 parts of polyethylene wax, 0.5-1.5 parts of carbon black dispersant, 1-3 parts of antioxidant RD, 1-2 parts of antioxidant MB, 2-2.6 parts of crosslinking agent DCP, and 0.5-0.9 parts of accelerator TAC.

[0039] More preferably, the internal insulating material includes the following raw materials in parts by weight: 35 parts of chlorinated polyethylene, 35 parts of ethylene vinyl acetate copolymer, 7.2 parts of magnesium oxide, 15 parts of chlorinated paraffin, 4 parts of dioctyl phthalate, 7 parts of paraffin oil, 8 parts of vaseline, 64 parts of conductive carbon black, 2 parts of polyethylene wax, 1 part of carbon black dispersant, 2 parts of antioxidant RD, 1.5 parts of antioxidant MB, 2.3 parts of crosslinking agent DCP, and 0.7 parts of accelerator TAC.

[0040] Preferably, the raw material components and weight ratios of the inner sheath and the outer sheath are the same;

[0041] The inner sheath comprises the following raw materials in parts by weight: 70-90 parts of chlorinated polyethylene, 4-6 parts of calcium carbonate, 16-20 parts of talc, 2-8 parts of white carbon black, 1-2 parts of microcrystalline wax, 6-10 parts of plasticizer DOP, 15-30 parts of chlorinated paraffin, 4-6 parts of magnesium oxide, 1-2 parts of calcium zinc stabilizer, 10-20 parts of GLC250, 5-15 parts of GZRY-1, 1-2 parts of DCP, and 2-3 parts of TAIC powder.

[0042] More preferably, the inner sheath comprises the following raw materials in parts by weight: 80 parts of chlorinated polyethylene, 5 parts of calcium carbonate, 18 parts of talc, 5 parts of white carbon black, 1.7 parts of microcrystalline wax, 8 parts of plasticizer DOP, 19 parts of chlorinated paraffin, 5.2 parts of magnesium oxide, 1.5 parts of calcium zinc stabilizer, 15 parts of GLC250, 10 parts of GZRY-1, 1.75 parts of DCP, and 2.6 parts of TAIC powder.

[0043] Compared with the prior art, the present invention has the following beneficial effects:

[0044] 1. The 10kV high-performance coal mining machine cable provided by the present invention is suitable for use in coal mining machines, is not easy to be broken down, has strong anti-aging performance and long service life.

[0045] 2. The present invention provides a 10kV high-performance cable for coal mining machines and its manufacturing process, which adopts multiple power conductors twisted together, and the conductors have high roundness, softness and good tensile resistance; the conductors are subjected to secondary annealing after twisting, and the elongation at break of the single wire is improved, so that it can show greater deformation ability, thereby improving its applicability and durability during use, so that it is more suitable for use in the production environment of coal mining machines.

[0046] 3. The present invention provides a 10kV high-performance cable for coal mining machines and a manufacturing process thereof. The conductor insulation layer group and the control insulation layer group both adopt the same structure, and are both composed of a conductor shielding layer, a power insulation layer and an insulation shielding layer. The conductor shielding layer and the insulation shielding layer connected to the power insulation layer have the same formula composition, can be tightly fitted with the power insulation layer and can be subsequently peeled off, and no residue is left and no insulation is lost during peeling; through the formula composition of the rubber material used in the power insulation layer, a power insulation layer with good anti-extrusion and anti-deformation capabilities can be prepared, and the rubber materials used in the power insulation layer are all made in a dust-free workshop, reducing the probability of dust and impurity pollution, thereby avoiding voltage breakdown.

[0047] 4. The conductor insulation layer group and the control insulation layer group both adopt the same structure, and are both composed of a conductor shielding layer, a power insulation layer and an insulation shielding layer. Among them, the conductor shielding layer, the power insulation layer and the insulation shielding layer are prepared by a three-layer co-extrusion process, thereby ensuring the reliability of the insulation layer during movement.

[0048] 5. The present invention provides a 10kV high-performance cable for coal mining machines, in which an inner sheath, a braided layer and an outer sheath are sequentially coated on the outside of the internal core assembly, wherein the inner sheath and the outer sheath are composed of the same formula. The inner sheath and the outer sheath prepared by the formula have high strength and high wear resistance and other properties, which can meet the use of coal mining machines.

[0049] 6. The present invention provides a manufacturing process for a 10kV high-performance cable for coal mining machines, which adopts a series extrusion device to cover the inner wire core component with an inner sheath, a braided layer and an outer sheath. The series extrusion device is composed of a first rubber extruder, a braiding machine, a second rubber extruder and a vulcanization pipeline which are sequentially arranged along the moving direction of the internal wire core component. During the movement, the internal wire core component first passes through the first rubber extruder, and the part of the internal wire core component located in the first rubber extruder is covered with a layer of inner sheath. Then the internal wire core component is continuously transmitted to the braiding machine, and the braiding machine braids a layer of braided layer on the outside of the internal wire core component covered with the inner sheath. After that, the internal wire core component is continuously transmitted to the second rubber extruder, and a layer of outer sheath is covered on the outside of the internal wire core component covered with a layer of braided layer. Finally, the internal wire core component covered with the outer sheath is continuously transmitted to the vulcanization pipeline for heat cross-linking to achieve molecular-level bonding, thereby making the braided layer form an integral whole with the inner and outer sheaths respectively. This structure can resist cable torsion, improve the stability of the structure, and the bending performance of the cable is not affected; moreover, the traditional outer sheath process generally first passes through an extruder unit to process the first layer of inner sheath, which is heated in a vulcanization pipeline, and the material of the inner sheath is cross-linked and formed. After cooling by circulating water, the second layer, i.e., the braided layer, is woven. After the braiding is completed, it passes through an extruder unit again, is heated in a vulcanization pipeline, and the outer sheath material is cross-linked and formed. The inner sheath and the outer sheath are in contact with each other through the gaps in the braided layer. In this process, when processing the first layer of inner sheath, the cable is inevitably contaminated after being cooled and packaged by cooling water, which seriously affects the bonding of the inner sheath and the outer sheath, and even causes bulging of the inner sheath and the outer sheath. When used, the outer sheath is separated from the layer and loses its tear and crack resistance. The serial extrusion process of the present application can solve this problem. The inner sheath and the outer sheath are heated and cross-linked in a vulcanization pipeline at the same time, thereby achieving molecular-level bonding to ensure the bending performance of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0051] Figure 1 It is a structural schematic diagram provided by the present invention;

[0052] Figure 2 It is a structural schematic diagram of the internal wire core assembly provided by the present invention;

[0053] Figure 3 It is a flow chart of the preparation process of the 10kV high-performance cable for coal mining machines provided by the present invention;

[0054] Figure 4 It is a structural schematic diagram of the string extrusion equipment provided by the present invention. DETAILED DESCRIPTION

[0055] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0056] In the description of the present invention, it should be understood that the terms "opening", "upper", "lower", "thickness", "top", "middle", "length", "inside", "all around" and the like indicating orientation or positional relationship are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the components or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as limiting the present invention.

[0057] like Figure 1 to Figure 2 As shown, as an embodiment of the first aspect of the present invention, a 10kV high-performance coal mining machine cable is provided, which is composed of an internal wire core component 1 and a sheath component 20 coated on the outside of the internal wire core component 1, wherein the sheath component 20 includes an inner sheath 2, a braided layer 3 and an outer sheath 4 sequentially arranged from the inside to the outside, and the inner sheath 2 is coated on the outside of the internal wire core component 1;

[0058] Braided layer 3 is made of Kevlar fiber, which has a tensile strength of 2.5 GPa, effectively preventing the cable from twisting during installation and use, thus extending the service life of the cable;

[0059] The internal core assembly 1 is composed of a plurality of power core units 11, a plurality of control core units 12 and optical fibers 13, wherein the optical fibers 13 are composed of 8 single-mode optical fibers and are reinforced with high-strength fibers;

[0060] Among them, in the internal wire core assembly 1, the optical fiber 13 is arranged between the multiple power wire core units 11; the multiple control wire core units 12 form a wire bundle, and the multiple control wire core units 12 are located outside the wire bundle;

[0061] In the internal wire core assembly 1, the number of the power wire core units 11 and the control wire core units 12 is the same;

[0062] The power line core unit 11 includes a plurality of power conductors 5 and a conductor insulation layer group 6 covering the outside of the plurality of power conductors 5, wherein the conductor insulation layer group 6 includes a conductor shielding layer 61, a power insulation layer 62 and an insulation shielding layer 63 which are sequentially arranged from the inside to the outside;

[0063] The cross-sectional area of ​​the multiple power conductors 5 after twisting is 25-185mm 2 ;

[0064] In the conductor insulation layer group 6, the thickness of the conductor shielding layer 61 is 0.5-1 mm, the thickness of the power insulation layer 62 is 5.5-6.5 mm, and the thickness of the insulation shielding layer 63 is 0.5-1.0 mm;

[0065] The material of the power conductor 5 is tinned soft copper, which has better performance. In the power core unit 11, the number of the power conductors 5 is 3-4;

[0066] The outside of the insulating shielding layer 63 is coated with a conductor metal shielding layer 7 with a thickness of 0.2-0.4 mm;

[0067] The control core unit 12 includes a plurality of control cores 8 and a control metal shielding layer 9 covering the plurality of control cores 8;

[0068] The control core 8 includes a plurality of control conductors 81 and a control insulation layer group 10 covering the plurality of control conductors 81;

[0069] The material of the control conductor 81 is tinned soft copper with a cross-sectional area of ​​2.5 mm 2 -10mm 2 , the number is 3-10, the optimal number is 6;

[0070] The control insulation layer group 10 has the same structure as the conductor insulation layer group 6;

[0071] In the control insulation layer group 10, it adopts the same three-layer structure as the conductor insulation layer group 6, including a control shielding layer, a control insulation layer and a control insulation shielding layer, wherein the control shielding layer is made of the same material as the conductor shielding layer 61, the control insulation layer is made of the same material as the power insulation layer 62, and the control insulation shielding layer is made of the same material as the insulation shielding layer 63; the thickness of the control shielding layer is 0.1-0.2mm, the thickness of the control insulation layer is 0.8-2.0mm, and the thickness of the control insulation shielding layer is 0.15-0.3mm.

[0072] like Figure 3 As shown, as an embodiment of the second aspect of the present invention, a preparation process of a 10kV high-performance coal mining machine cable is provided, and the manufacturing process comprises the following steps:

[0073] S01: Power conductor twisting

[0074] The plurality of power conductors 5 are twisted together, and the processing parameters are: the bundle twisting pitch diameter ratio is 14-20, the re-twisting inner layer pitch diameter ratio is 14-16, and the re-twisting outer layer pitch diameter ratio is 12-14;

[0075] After the twisting is completed, the twisted power conductor 5 is subjected to a primary annealing treatment in a nitrogen atmosphere, and after the primary annealing treatment, it is left for 1-2 days and then subjected to a secondary annealing treatment, and after the secondary annealing treatment, a flexible conductor is prepared;

[0076] The annealing temperature of the first annealing treatment and the second annealing treatment is 230-280°C, and the time is 3-5h;

[0077] According to the test, after the secondary annealing treatment, the elongation at break of the single wire of the flexible conductor increased from 18-20% before annealing to 28-31%;

[0078] S02: Preparation of power line core unit

[0079] After the internal insulating material, the rubber material and the external insulating material are respectively sent to three extruders for plasticization, the plasticized products are respectively sent to three extruder heads of a three-layer co-extruder, and the flexible conductor is placed in the three-layer co-extruder. A conductor shielding layer 61, a power insulating layer 62 and an insulating shielding layer 63 are formed on the outside of the flexible conductor by a three-layer co-extrusion process, and then a conductor metal shielding layer 7 is woven outside the insulating shielding layer 63 to prepare a power line core unit 11;

[0080] In step S02, the conductor insulation layer group 6 is made by extruding the internal insulation material through the extruder head after being plasticized by the extruder, the power insulation layer 7 is made by extruding the rubber material through the extruder head after being plasticized by the extruder, and the insulation shielding layer 71 is made by extruding the external insulation material through the extruder head after being plasticized by the extruder;

[0081] In step S02, the rubber material includes the following raw materials in parts by weight: 8-12 parts of EPDM 4770, 35-45 parts of POE 8150, 30-40 parts of EPDM 2504, 8-12 parts of paraffin oil, 20-30 parts of talc, 70-80 parts of calcined clay, 1-2 parts of paraffin, 1.0-1.4 parts of antioxidant RD, 0.5-1.5 parts of antioxidant MB, 0.4-0.6 parts of coupling agent A-172, 0.4-0.6 parts of stearic acid, 2-3 parts of polyethylene, 3-5 parts of zinc oxide, 2-4 parts of carbon black N330, 2-4 parts of vulcanizing agent DCP, and 1-3 parts of vulcanizing aid TAIC;

[0082] The production process of rubber materials is as follows, and all production is carried out in a dust-free workshop:

[0083] Step a: weigh the raw materials of the rubber material according to the formula;

[0084] Step b: mixing the raw materials at 110-120° C. to prepare a rubber compound, wherein no vulcanizing agent or vulcanizing aid is added during the mixing process;

[0085] Step c: filtering the rubber material once using a primary filter at 120-130° C.; wherein the primary filter comprises a first filter layer, a second filter layer, a third filter layer, a fourth filter layer and a fifth filter layer which are stacked in sequence, the apertures of the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are 40 mesh, 80 mesh, 100 mesh, 80 mesh and 40 mesh respectively, and the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are all made of stainless steel;

[0086] Step d: performing secondary filtration on the rubber material after the primary filtration at 110-130° C. using a secondary filter screen; wherein the secondary filter screen comprises a sixth filter layer, a seventh filter layer, an eighth filter layer, a ninth filter layer and a tenth filter layer which are stacked in sequence, and the apertures of the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are 40 meshes, 100 meshes, 100 meshes, 80 meshes and 40 meshes respectively, and the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are all made of stainless steel;

[0087] Through two filtrations, the quality and performance of the rubber material prepared later can be ensured;

[0088] During the two filtration processes, the primary filter screen used needs to be replaced when the total mass of the filtered rubber material filtered by the primary filter screen reaches 400-500kg;

[0089] The secondary filter used needs to be replaced when the total mass of the rubber material filtered by the secondary filter reaches 400-500kg;

[0090] During the two filtration processes, the primary filter and the secondary filter are both made of multi-layer stainless steel filters with different apertures to remove impurities, which have the characteristics of high filtration efficiency, high flexibility and improved product quality. The rubber material prepared after the two filtrations does not contain large impurities or substances that are difficult to remove, thereby preventing the presence of impurities from damaging subsequent processing equipment;

[0091] Step e: adding a vulcanizing agent and a vulcanizing aid to the rubber material after the secondary filtration, granulating the rubber material with a granulator and then cooling the granulator to prepare a rubber material;

[0092] Step f: placing the prepared rubber material in a hanging bag and sealing it for storage; wherein the hanging bag is made of PP material;

[0093] In actual use, the hanging bag can be hung at a high place, and the discharge port at the bottom of the hanging bag is located at the feed port of the extruder. When the discharge port at the bottom of the hanging bag is opened, the material automatically falls into the feed port of the extruder, thereby reducing the time that the rubber material in the hanging bag is exposed to the external environment, ensuring the cleanliness of the rubber material, reducing the probability of dust and impurity contamination, and avoiding voltage breakdown.

[0094] In step S02, the raw material composition and weight ratio of the internal insulating material and the external insulating material are the same;

[0095] In step S02, the internal insulating material includes the following raw materials in parts by weight: 30-40 parts of chlorinated polyethylene, 30-40 parts of ethylene vinyl acetate copolymer, 7-8 parts of magnesium oxide, 12-18 parts of chlorinated paraffin, 3-5 parts of dioctyl phthalate, 6-8 parts of paraffin oil, 6-10 parts of vaseline, 60-68 parts of conductive carbon black, 1-3 parts of polyethylene wax, 0.5-1.5 parts of carbon black dispersant, 1-3 parts of antioxidant RD, 1-2 parts of antioxidant MB, 2-2.6 parts of crosslinking agent DCP, and 0.5-0.9 parts of accelerator TAC;

[0096] S03: Control conductor twisting

[0097] Twisting a plurality of control conductors 81 to prepare a control harness;

[0098] The control conductor 81 adopts a double-layer twisting process: the first layer has a bundle twisting ratio of 4-8, and the second layer has a bundle twisting ratio of 3-6;

[0099] S04: Prepare control core unit

[0100] According to the operation mode of step S02, a control insulating layer group 10 is formed on the outside of the control wire harness to prepare a control wire core 8. After a plurality of control wire cores 8 are twisted, a control metal shielding layer 9 is woven outside the twisted plurality of control wire cores 8 to prepare a control wire core unit 12.

[0101] S05: Cable

[0102] A cage stranding machine is used to prepare multiple power core units 11, multiple control core units 12 and optical fibers 13 into an internal core assembly, wherein in this process, the parameters of the cage stranding machine are set as follows: a pitch-diameter ratio of 5-8 times;

[0103] Wherein, the optical fiber 13 is located between the multiple power line core units 11;

[0104] S06: Sheath extrusion

[0105] An inner sheath 2 is coated on the outside of the inner core component 1 by using a serial extrusion device, a braided layer 3 is braided on the outside of the inner sheath 2, and an outer sheath 4 is coated on the outside of the braided layer 3 to prepare a cable.

[0106] In step S06, the raw material components and weight ratios of the inner sheath 2 and the outer sheath 4 are the same;

[0107] The inner sheath 2 comprises the following raw materials in parts by weight: 70-90 parts of chlorinated polyethylene, 4-6 parts of calcium carbonate, 16-20 parts of talc, 2-8 parts of white carbon black, 1-2 parts of microcrystalline wax, 6-10 parts of plasticizer DOP, 15-30 parts of chlorinated paraffin, 4-6 parts of magnesium oxide, 1-2 parts of calcium zinc stabilizer, 10-20 parts of GLC250, 5-15 parts of GZRY-1, 1-2 parts of DCP, and 2-3 parts of TAIC powder;

[0108] like Figure 4 As shown, the string extrusion equipment includes a first rubber extruder 100, a braiding machine 200, a second rubber extruder 300 and a vulcanization pipe 400 which are sequentially set up along the moving direction of the internal wire core component 1, the inner sheath 2 is extruded by the first rubber extruder 100, the braided layer 3 is braided by the braiding machine 200, and the outer sheath 4 is extruded by the second rubber extruder 300;

[0109] The specific process of step S06 is as follows: the head of the internal wire core component is first transmitted to the first rubber extruder 100, the part of the internal wire core component located in the first rubber extruder 100 is coated with an inner sheath 2, and then is continuously transmitted to the braiding machine 200, and a braided layer 3 is braided by the braiding machine 200, and then is continuously transmitted to the second rubber extruder 300 for coating with an outer sheath 4, and finally is heated and cross-linked through the vulcanization pipe 400, and the internal wire core component is continuously transmitted, and after all the wire core components are extruded along the length direction, a cable is prepared.

[0110] The following description is made in conjunction with a specific 10kV high-performance coal mining machine cable and its production process to further explain the contents of the embodiments of the first aspect and the second aspect of the present invention.

[0111] Example 1

[0112] This embodiment provides a 10kV high-performance coal mining machine cable, which is composed of an internal wire core component 1 and a sheath component 20 coated on the outside of the internal wire core component 1, wherein the sheath component 20 includes an inner sheath 2, a braided layer 3 and an outer sheath 4 which are sequentially arranged from the inside to the outside, and the inner sheath 2 is coated on the outside of the internal wire core component 1;

[0113] The internal core assembly 1 is composed of three power core units 11, three control core units 12 and optical fibers 13, wherein the optical fibers 13 are composed of 8 single-mode optical fibers and reinforced with high-strength fibers; the optical fibers 13 are arranged between the three power core units 11;

[0114] The power line core unit 11 includes three power conductors 5 and a conductor insulation layer group 6 covering the outside of the three power conductors 5. The conductor insulation layer group 6 includes a conductor shielding layer 61, a power insulation layer 62 and an insulation shielding layer 63 which are sequentially arranged from the inside to the outside. The power conductor 5 is made of tinned soft copper. The cross-sectional area of ​​the three power conductors 5 after twisting is 100 mm. 2 , in the conductor insulation layer group 6, the thickness of the conductor shielding layer 61 is 0.75 mm, the thickness of the power insulation layer 62 is 6.0 mm, and the thickness of the insulation shielding layer 63 is 0.75 mm;

[0115] The outside of the insulating shielding layer 63 is coated with a conductor metal shielding layer 7;

[0116] The control core unit 12 includes three control cores 8 and a control metal shielding layer 9 wrapped around the three control cores 8. The control core 8 includes six control conductors 81 and a control insulation layer group 10 wrapped around the six control conductors 81. The control conductors 81 are made of tinned soft copper with a cross-sectional area of ​​2.5 mm. 2 ;

[0117] The control insulation layer group 10 has the same structure as the conductor insulation layer group 6. In the control insulation layer group 10, it adopts the same three-layer structure as the conductor insulation layer group 6, including a control shielding layer, a control insulation layer and a control insulation shielding layer; wherein, the control line conductor shielding thickness is 0.15mm, the insulation layer thickness is 1.4mm, and the control line insulation shielding layer thickness is 0.20mm.

[0118] This embodiment also provides a manufacturing process for a 10 kV high performance coal mining machine cable, the manufacturing process comprising the following steps:

[0119] S01: Power conductor twisting

[0120] The three power conductors 5 are twisted together, and the processing parameters are: the bundle twisting pitch diameter ratio is 17, the inner layer pitch diameter ratio of the double twisting is 15, and the outer layer pitch diameter ratio of the double twisting is 13;

[0121] After the twisting is completed, the twisted power conductor 5 is subjected to a primary annealing treatment in a nitrogen atmosphere, and after the primary annealing treatment, it is left for 1.5 days and then subjected to a secondary annealing treatment. After the secondary annealing treatment, a flexible conductor is prepared;

[0122] Among them, the annealing temperature of the first annealing treatment and the second annealing treatment is 255℃, and the time is 4h;

[0123] S02: Preparation of power line core unit

[0124] After the internal insulating material, the rubber material and the external insulating material are respectively sent to three extruders for plasticization, the plasticized products are respectively sent to three extruder heads of a three-layer co-extruder, and the flexible conductor is placed in the three-layer co-extruder. A conductor shielding layer 61, a power insulating layer 62 and an insulating shielding layer 63 are formed on the outside of the flexible conductor by a three-layer co-extrusion process, and then a conductor metal shielding layer 7 is woven outside the insulating shielding layer 63 to prepare a power line core unit 11;

[0125] In step S02, the conductor insulation layer group 6 is made by extruding the internal insulation material through the extruder head after being plasticized by the extruder, the power insulation layer 7 is made by extruding the rubber material through the extruder head after being plasticized by the extruder, and the insulation shielding layer 71 is made by extruding the external insulation material through the extruder head after being plasticized by the extruder;

[0126] In step S02, the rubber material includes the following raw materials in parts by weight: 477010 parts of EPDM, 815040 parts of POE, 250435 parts of EPDM, 10 parts of paraffin oil, 25 parts of talc, 75 parts of calcined clay, 1.5 parts of paraffin, 1.2 parts of antioxidant RD, 1 part of antioxidant MB, 20.5 parts of coupling agent A-172, 0.5 parts of stearic acid, 2.5 parts of polyethylene, 4 parts of zinc oxide, 3 parts of carbon black N330, 3.2 parts of vulcanizing agent DCP, and 2 parts of vulcanizing aid TAIC;

[0127] The production process of rubber materials is as follows, and the production process is carried out in a dust-free workshop:

[0128] Step a: weighing the raw materials of the rubber material according to the formula of the rubber material;

[0129] Step b: mixing the raw materials at 115° C., without adding a vulcanizing agent or a vulcanizing aid during the mixing process, and preparing a rubber compound after mixing;

[0130] Step c: filtering the rubber material once using a primary filter screen at 125°C;

[0131] Step d: performing a secondary filtration on the rubber material after the primary filtration at 120° C. using a secondary filter screen;

[0132] Step e: adding a vulcanizing agent and a vulcanizing aid to the rubber material after the secondary filtration, granulating the rubber material with a granulator and then cooling the granulator to prepare a rubber material;

[0133] Step f: placing the prepared rubber material in a hanging bag and sealing it for storage.

[0134] After the rubber material is produced, its anti-extrusion and anti-deformation properties are tested. Its performance parameters are shown in Table 1. The specific measurement method is as follows:

[0135] The fully vulcanized rubber material is made into a sample with a length, width and height of 10mm±0.5mm, put into an oven and apply a pressure of 1.0MPa, let it stand at 180℃±3℃ for 30min, take it out, remove the external pressure and cool it naturally to room temperature, measure the dimensional change in the compressive direction, the change value / original value is the deformation rate, and it is qualified if the deformation rate is less than 15%.

[0136] Table 1

[0137] project unit Typical Value Tensile Strength MPa 9.0 Elongation at break ％ 210 hardness Shao A 78 Dielectric strength kV / mm 32 Deformation rate ％ 6

[0138] In step S02, the raw material composition and weight ratio of the internal insulating material and the external insulating material are the same;

[0139] In step S02, the internal insulating material includes the following raw materials in parts by weight: 35 parts of chlorinated polyethylene, 35 parts of ethylene vinyl acetate copolymer, 7.2 parts of magnesium oxide, 15 parts of chlorinated paraffin, 4 parts of dioctyl phthalate, 7 parts of paraffin oil, 8 parts of vaseline, 64 parts of conductive carbon black, 2 parts of polyethylene wax, 1 part of carbon black dispersant, 2 parts of antioxidant RD, 1.5 parts of antioxidant MB, 2.3 parts of cross-linking agent DCP, and 0.7 parts of accelerator TAC;

[0140] S03: Control conductor twisting

[0141] The six control conductors 81 are twisted together to prepare a control harness;

[0142] The control conductor 81 adopts a double-layer twisting process: the first layer has a bundle twisting ratio of 6, and the second layer has a bundle twisting ratio of 4;

[0143] S04: Prepare control core unit

[0144] According to the operation mode of step S02, a control insulating layer group 10 is formed on the outside of the control wire harness to prepare a control wire core 8. After three control wire cores 8 are twisted, a control metal shielding layer 9 is braided outside the three twisted control wire cores 8 to prepare a control wire core unit 12.

[0145] S05: Cable

[0146] The three power core units 11, the three control core units 12 and the optical fiber 13 are prepared into an internal core assembly by using a cage stranding machine, wherein in this process, the parameters of the cage stranding machine are set as follows: the pitch diameter ratio is 6 times; the optical fiber 13 is located between the three power core units 11;

[0147] S06: Sheath extrusion

[0148] An inner sheath 2 is coated on the outside of the inner core component by using a string extrusion device, a braided layer 3 is braided on the outside of the inner sheath 2, and an outer sheath 4 is coated on the outside of the braided layer 3 to prepare a cable;

[0149] In step S06, the raw material components and weight ratios of the inner sheath 2 and the outer sheath 4 are the same;

[0150] The inner sheath 2 includes the following raw materials in parts by weight: 80 parts of chlorinated polyethylene, 5 parts of calcium carbonate, 18 parts of talc, 5 parts of white carbon black, 1.7 parts of microcrystalline wax, 8 parts of plasticizer DOP, 19 parts of chlorinated paraffin, 5.2 parts of magnesium oxide, 1.5 parts of calcium zinc stabilizer, 15 parts of GLC250, 10 parts of GZRY-1, 1.75 parts of DCP, and 2.6 parts of TAIC powder.

[0151] Among them, the performance of the inner sheath 2 and the outer sheath 4 is tested, and their performance parameters are shown in Table 2;

[0152] Table 2

[0153] project unit Typical Value Tensile Strength MPa 21.0 Elongation at break ％ 380 hardness Shao A 80 Tear strength N / mm 8.0 Volumetric wear <![CDATA[mm 3 ]]> 0.98

[0154] The inner sheath 2 and the outer sheath 4 are resistant to aging at 100°C x 10 days with a performance retention rate of 72%.

[0155] The specific process of step S06 and the specific composition of the string extrusion equipment are all referred to the embodiment of the second aspect of the present invention.

[0156] Example 2

[0157] This embodiment provides a 10kV high-performance coal mining machine cable, which is composed of an internal wire core component 1 and a sheath component 20 coated on the outside of the internal wire core component 1, wherein the sheath component 20 includes an inner sheath 2, a braided layer 3 and an outer sheath 4 which are sequentially arranged from the inside to the outside, and the inner sheath 2 is coated on the outside of the internal wire core component 1;

[0158] The internal core assembly 1 is composed of three power core units 11, three control core units 12 and optical fibers 13, wherein the optical fibers 13 are composed of 8 single-mode optical fibers and reinforced with high-strength fibers; the optical fibers 13 are arranged between the three power core units 11;

[0159] The power core unit 11 includes four power conductors 5 and a conductor insulation layer group 6 wrapped around the four power conductors 5. The conductor insulation layer group 6 includes a conductor shielding layer 61, a power insulation layer 62 and an insulation shielding layer 63 which are sequentially arranged from the inside to the outside. The power conductor 5 is made of tinned soft copper. The cross-sectional area of ​​the four power conductors 5 after twisting is 25 mm. 2 , in the conductor insulation layer group 6, the thickness of the conductor shielding layer 61 is 0.5 mm, the thickness of the power insulation layer 62 is 5.5 mm, and the thickness of the insulation shielding layer 63 is 0.5 mm;

[0160] The outside of the insulating shielding layer 63 is coated with a conductor metal shielding layer 7;

[0161] The control core unit 12 includes two control cores 8 and a control metal shielding layer 9 wrapped around the two control cores 8. The control core 8 includes three control conductors 81 and a control insulation layer group 10 wrapped around the three control conductors 81. The control conductors 81 are made of tinned soft copper with a cross-sectional area of ​​2.5 mm. 2 ;

[0162] The control insulation layer group 10 has the same structure as the conductor insulation layer group 6. In the control insulation layer group 10, it adopts the same three-layer structure as the conductor insulation layer group 6, including a control shielding layer, a control insulation layer and a control insulation shielding layer; wherein, the control line conductor shielding thickness is 0.1mm, the insulation layer thickness is 0.8mm, and the control line insulation shielding layer thickness is 0.3mm.

[0163] This embodiment also provides a manufacturing process for a 10 kV high performance coal mining machine cable, the manufacturing process comprising the following steps:

[0164] S01: Power conductor twisting

[0165] The four power conductors 5 are twisted together, and the processing parameters are: the bundle twisting pitch diameter ratio is 14, the inner layer pitch diameter ratio of the multiple twisting is 14, and the outer layer pitch diameter ratio of the multiple twisting is 12;

[0166] After the twisting is completed, the twisted power conductor 5 is subjected to a primary annealing treatment in a nitrogen atmosphere, and after the primary annealing treatment, it is left for 1 day and then subjected to a secondary annealing treatment. After the secondary annealing treatment, a flexible conductor is prepared;

[0167] The annealing temperature of the first annealing treatment and the second annealing treatment is 230°C, and the time is 3h;

[0168] S02: Preparation of power line core unit

[0169] After the internal insulating material, the rubber material and the external insulating material are respectively sent to three extruders for plasticization, the plasticized products are respectively sent to three extruder heads of a three-layer co-extruder, and the flexible conductor is placed in the three-layer co-extruder. A conductor shielding layer 61, a power insulating layer 62 and an insulating shielding layer 63 are formed on the outside of the flexible conductor by a three-layer co-extrusion process, and then a conductor metal shielding layer 7 is woven outside the insulating shielding layer 63 to prepare a power line core unit 11;

[0170] In step S02, the conductor insulation layer group 6 is made by extruding the internal insulation material through the extruder head after being plasticized by the extruder, the power insulation layer 7 is made by extruding the rubber material through the extruder head after being plasticized by the extruder, and the insulation shielding layer 71 is made by extruding the external insulation material through the extruder head after being plasticized by the extruder;

[0171] In step S02, the rubber material includes the following raw materials in parts by weight: 477012 parts of EPDM, 815045 parts of POE, 250430 parts of EPDM, 8 parts of paraffin oil, 20 parts of talc, 70 parts of calcined clay, 1 part of paraffin, 1 part of antioxidant RD, 0.5 parts of antioxidant MB, 0.4 parts of coupling agent A-172, 0.4 parts of stearic acid, 2 parts of polyethylene, 3 parts of zinc oxide, 2 parts of carbon black N330, 2 parts of vulcanizing agent DCP, and 1 part of vulcanizing aid TAIC;

[0172] The production process of rubber materials is as follows, and the production process is carried out in a dust-free workshop:

[0173] Step a: weighing the raw materials of the rubber material according to the formula of the rubber material;

[0174] Step b: mixing the raw materials at 110° C., without adding a vulcanizing agent or a vulcanizing aid during the mixing process, and preparing a rubber compound after mixing;

[0175] Step c: filtering the rubber material once using a primary filter screen at 120°C;

[0176] Step d: performing a secondary filtration on the rubber material after the primary filtration at 110° C. using a secondary filter screen;

[0177] Step e: adding a vulcanizing agent and a vulcanizing aid to the rubber material after the secondary filtration, granulating the rubber material with a granulator and then cooling the granulator to prepare a rubber material;

[0178] Step f: placing the prepared rubber material in a hanging bag and sealing it for storage.

[0179] In step S02, the raw material composition and weight ratio of the internal insulating material and the external insulating material are the same;

[0180] In step S02, the internal insulating material includes the following raw materials in parts by weight: 40 parts of chlorinated polyethylene, 30 parts of ethylene vinyl acetate copolymer, 7 parts of magnesium oxide, 12 parts of chlorinated paraffin, 3 parts of dioctyl phthalate, 6 parts of paraffin oil, 6 parts of vaseline, 60 parts of conductive carbon black, 1 part of polyethylene wax, 0.5 parts of carbon black dispersant, 1 part of antioxidant RD, 1 part of antioxidant MB, 2.6 parts of crosslinking agent DCP, and 0.9 parts of accelerator TAC;

[0181] S03: Control conductor twisting

[0182] The three control conductors 81 are twisted together to prepare a control harness;

[0183] The control conductor 81 adopts a double-layer twisting process: the first layer has a bundle pitch ratio of 4, and the second layer has a bundle pitch ratio of 6;

[0184] S04: Prepare control core unit

[0185] According to the operation mode of step S02, a control insulating layer group 10 is formed on the outside of the control wire harness to prepare a control wire core 8. After two control wire cores 8 are twisted, a control metal shielding layer 9 is braided outside the two twisted control wire cores 8 to prepare a control wire core unit 12.

[0186] S05: Cable

[0187] The three power core units 11, the three control core units 12 and the optical fiber 13 are prepared into an internal core assembly by using a cage stranding machine, wherein in this process, the parameters of the cage stranding machine are set as follows: the pitch diameter ratio is 5 times; the optical fiber 13 is located between the three power core units 11;

[0188] S06: Sheath extrusion

[0189] An inner sheath 2 is coated on the outside of the inner core component by using a string extrusion device, a braided layer 3 is braided on the outside of the inner sheath 2, and an outer sheath 4 is coated on the outside of the braided layer 3 to prepare a cable;

[0190] The raw material components and weight ratios of the inner sheath 2 and the outer sheath 4 are the same;

[0191] The inner sheath 2 includes the following raw materials in parts by weight: 90 parts of chlorinated polyethylene, 4 parts of calcium carbonate, 16 parts of talc, 2 parts of white carbon black, 1 part of microcrystalline wax, 6 parts of plasticizer DOP, 15 parts of chlorinated paraffin, 4 parts of magnesium oxide, 1 part of calcium zinc stabilizer, 10 parts of GLC250, 15 parts of GZRY-, 1 part of DCP, and 2 parts of TAIC powder.

[0192] The specific process of step S06 and the specific composition of the string extrusion equipment are all referred to the embodiment of the second aspect of the present invention.

[0193] Example 3

[0194] This embodiment provides a 10kV high-performance coal mining machine cable, which is composed of an internal wire core component 1 and a sheath component 20 coated on the outside of the internal wire core component 1, wherein the sheath component 20 includes an inner sheath 2, a braided layer 3 and an outer sheath 4 which are sequentially arranged from the inside to the outside, and the inner sheath 2 is coated on the outside of the internal wire core component 1;

[0195] The internal core assembly 1 is composed of three power core units 11, three control core units 12 and optical fibers 13, wherein the optical fibers 13 are composed of 8 single-mode optical fibers and reinforced with high-strength fibers; the optical fibers 13 are arranged between the four power core units 11;

[0196] The power line core unit 11 includes three power conductors 5 and a conductor insulation layer group 6 covering the outside of the three power conductors 5. The conductor insulation layer group 6 includes a conductor shielding layer 61, a power insulation layer 62 and an insulation shielding layer 63 which are sequentially arranged from the inside to the outside. The power conductor 5 is made of tinned soft copper, and the cross-sectional area of ​​the multiple power conductors 5 after being twisted is 185 mm 2 , in the conductor insulation layer group 6, the thickness of the conductor shielding layer 61 is 1 mm, the thickness of the power insulation layer 62 is 6.5 mm, and the thickness of the insulation shielding layer 63 is 1.0 mm;

[0197] The outside of the insulating shielding layer 63 is coated with a conductor metal shielding layer 7;

[0198] The control core unit 12 includes three control cores 8 and a control metal shielding layer 9 wrapped around the three control cores 8. The control core 8 includes four control conductors 81 and a control insulation layer group 10 wrapped around the four control conductors 81. The control conductors 81 are made of tinned soft copper with a cross-sectional area of ​​2.5 mm. 2 ;

[0199] The control insulation layer group 10 has the same structure as the conductor insulation layer group 6. In the control insulation layer group 10, it adopts the same three-layer structure as the conductor insulation layer group 6, including a control shielding layer, a control insulation layer and a control insulation shielding layer; wherein, the control line conductor shielding thickness is 0.2mm, the insulation layer thickness is 2.0mm, and the control line insulation shielding layer thickness is 0.15mm.

[0200] This embodiment also provides a manufacturing process for a 10 kV high performance coal mining machine cable, the manufacturing process comprising the following steps:

[0201] S01: Power conductor twisting

[0202] The three power conductors 5 are twisted together, and the processing parameters are: the bundle twisting pitch diameter ratio is 20, the inner layer pitch diameter ratio of the double twisting is 16, and the outer layer pitch diameter ratio of the double twisting is 14;

[0203] After the twisting is completed, the twisted power conductor 5 is subjected to a primary annealing treatment in a nitrogen atmosphere, and after the primary annealing treatment, it is left for 2 days and then subjected to a secondary annealing treatment. After the secondary annealing treatment, a flexible conductor is prepared;

[0204] The annealing temperature of the first annealing treatment and the second annealing treatment is 280°C, and the time is 5h;

[0205] S02: Preparation of power line core unit

[0206] After the internal insulating material, the rubber material and the external insulating material are respectively sent to three extruders for plasticization, the plasticized products are respectively sent to three extruder heads of a three-layer co-extruder, and the flexible conductor is placed in the three-layer co-extruder. A conductor shielding layer 61, a power insulating layer 62 and an insulating shielding layer 63 are formed on the outside of the flexible conductor by a three-layer co-extrusion process, and then a conductor metal shielding layer 7 is woven outside the insulating shielding layer 63 to prepare a power line core unit 11;

[0207] In step S02, the conductor insulation layer group 6 is made by extruding the internal insulation material through the extruder head after being plasticized by the extruder, the power insulation layer 7 is made by extruding the rubber material through the extruder head after being plasticized by the extruder, and the insulation shielding layer 71 is made by extruding the external insulation material through the extruder head after being plasticized by the extruder;

[0208] In step S02, the rubber material includes the following raw materials in parts by weight: 47708 parts of EPDM, 35 parts of POE 8150, 440 parts of EPDM 250, 12 parts of paraffin oil, 30 parts of talc, 80 parts of calcined clay, 2 parts of paraffin, 1.4 parts of antioxidant RD, 1.5 parts of antioxidant MB, 0.6 parts of coupling agent A-172, 0.6 parts of stearic acid, 3 parts of polyethylene, 5 parts of zinc oxide, 4 parts of carbon black N330, 4 parts of vulcanizing agent DCP, and 3 parts of vulcanizing aid TAIC;

[0209] The production process of rubber materials is as follows, and the production process is carried out in a dust-free workshop:

[0210] Step a: weighing the raw materials of the rubber material according to the formula of the rubber material;

[0211] Step b: mixing the raw materials at 120° C., without adding a vulcanizing agent or a vulcanizing aid during the mixing process, and preparing a rubber compound after mixing;

[0212] Step c: filtering the rubber material once using a primary filter screen at 130° C.;

[0213] Step d: performing a secondary filtration on the rubber material after the primary filtration at 130° C. using a secondary filter screen;

[0214] Step e: adding a vulcanizing agent and a vulcanizing aid to the rubber material after the secondary filtration, granulating the rubber material with a granulator and then cooling the granulator to prepare a rubber material;

[0215] Step f: placing the prepared rubber material in a hanging bag and sealing it for storage.

[0216] In step S02, the raw material composition and weight ratio of the internal insulating material and the external insulating material are the same;

[0217] In step S02, the internal insulating material includes the following raw materials in parts by weight: 40 parts of chlorinated polyethylene, 40 parts of ethylene vinyl acetate copolymer, 8 parts of magnesium oxide, 18 parts of chlorinated paraffin, 5 parts of dioctyl phthalate, 8 parts of paraffin oil, 10 parts of vaseline, 68 parts of conductive carbon black, 3 parts of polyethylene wax, 1.5 parts of carbon black dispersant, 3 parts of antioxidant RD, 2 parts of antioxidant MB, 2 parts of cross-linking agent DCP, and 0.5 parts of accelerator TAC;

[0218] S03: Control conductor twisting

[0219] The four control conductors 81 are twisted together to prepare a control harness;

[0220] The control conductor 81 adopts a double-layer twisting process: the first layer has a bundle pitch ratio of 8, and the second layer has a bundle pitch ratio of 3;

[0221] S04: Prepare control core unit

[0222] According to the operation mode of step S02, a control insulating layer group 10 is formed on the outside of the control wire harness to prepare a control wire core 8. After three control wire cores 8 are twisted, a control metal shielding layer 9 is braided outside the three twisted control wire cores 8 to prepare a control wire core unit 12.

[0223] S05: Cable

[0224] The three power core units 11, the three control core units 12 and the optical fiber 13 are prepared into an internal core assembly by using a cage stranding machine, wherein in this process, the parameters of the cage stranding machine are set as follows: the pitch diameter ratio is 5 times; the optical fiber 13 is located between the multiple power core units 11;

[0225] S06: Sheath extrusion

[0226] An inner sheath 2 is coated on the outside of the inner core component by using a string extrusion device, a braided layer 3 is braided on the outside of the inner sheath 2, and an outer sheath 4 is coated on the outside of the braided layer 3 to prepare a cable;

[0227] The raw material components and weight ratios of the inner sheath 2 and the outer sheath 4 are the same;

[0228] The inner sheath 2 includes the following raw materials in parts by weight: 70 parts of chlorinated polyethylene, 6 parts of calcium carbonate, 20 parts of talc, 8 parts of white carbon black, 2 parts of microcrystalline wax, 10 parts of plasticizer DOP, 30 parts of chlorinated paraffin, 6 parts of magnesium oxide, 2 parts of calcium zinc stabilizer, 20 parts of GLC250, 15 parts of GZRY-1, 2 parts of DCP, and 3 parts of TAIC powder.

[0229] The specific process of step S06 and the specific composition of the string extrusion equipment are all referred to the embodiment of the second aspect of the present invention.

[0230] Comparative Example

[0231] The comparative example uses an existing coal mining machine cable, model MCPT.

[0232] Experimental example

[0233] The cables prepared in Examples 1-3 and the cables in the comparative example were tested using the test method specified in MT818. The cables prepared in Examples 1-3 were bent 120,000 times, and the control core unit and the optical fiber were not broken. The cables in the comparative example were bent 120,000 times, and the control core unit and the optical fiber were damaged.

[0234] The cables prepared in Examples 1-3 were subjected to a power frequency voltage test. The test results showed that the cables prepared in Examples 1-3 could withstand 40 kV / 5 min without breakdown. However, the cables in the comparative example had a large leakage current, a withstand voltage of less than 10 kV, and obvious damage to the insulation layer.

[0235] The performance of the conductor insulation layer group 6, the control insulation layer group 10, the inner sheath 2 and the outer sheath 4 of the cables prepared in Examples 1-3 were tested. The test results are shown in Table 3.

[0236] Table 3

[0237]

[0238] It can be seen from the data in Table 3 that the performance of the conductor insulation layer group 6, the control insulation layer group 10, the inner sheath 2 and the outer sheath 4 provided in Examples 1-3 are better than the performance of the cable with model MCPT provided in the comparative example, indicating that the performance of the 10kV high-performance coal mining machine cable provided by the present invention is better than that of the cable with model MCPT.

[0239] The present invention provides a 10kV high-performance coal mining machine cable, which is suitable for use in coal mining machines and has the advantages of being impact-resistant, not prone to breakdown, having strong anti-aging performance and long service life.

[0240] In the description of this specification, the description with reference to the terms "one embodiment", "example", "specific example", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0241] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the present invention to be protected.

Claims

1. A manufacturing process for a 10kV high-performance coal mining machine cable, characterized in that: The manufacturing process includes the following steps: S01: Power conductor twisting Twisting a plurality of power conductors (5), and after the twisting is completed, performing a primary annealing treatment on the twisted power conductors (5) in a nitrogen atmosphere, and after the primary annealing treatment, leaving the conductors for 1-2 days, and then performing a secondary annealing treatment, and after the secondary annealing treatment, a flexible conductor is prepared, wherein the annealing temperatures of the primary annealing treatment and the secondary annealing treatment are both 230-280° C., and the time is both 3-5 hours; S02: Preparation of power line core unit The internal insulating material, the rubber material and the external insulating material are respectively sent to three extruders for plasticization, and the plasticized products are respectively sent to three extruder heads of a three-layer co-extruder, and a flexible conductor is placed in the three-layer co-extruder. A conductor shielding layer (61), a power insulating layer (62) and an insulating shielding layer (63) are formed on the outside of the flexible conductor by a three-layer co-extrusion process, and then a conductor metal shielding layer (7) is braided outside the insulating shielding layer (63) to prepare a power line core unit (11), wherein the conductor insulating layer group (6) is formed by plasticizing the internal insulating material in an extruder and then extruding it through the extruder head of the three-layer co-extruder, the power insulating layer (7) is formed by plasticizing the rubber material in an extruder and then extruding it through the extruder head of the three-layer co-extruder, and the insulating shielding layer (71) is formed by plasticizing the external insulating material in an extruder and then extruding it through the extruder head of the three-layer co-extruder; The preparation process of the rubber material is carried out in a dust-free workshop, and the preparation process of the rubber material includes the following steps: Step a: weigh the raw materials of the rubber material according to the formula; Step b: mixing the raw materials at 110-120° C. to prepare a rubber compound, wherein no vulcanizing agent or vulcanizing aid is added during the mixing process; Step c: filtering the rubber material once using a primary filter at 120-130° C.; wherein the primary filter comprises a first filter layer, a second filter layer, a third filter layer, a fourth filter layer and a fifth filter layer which are stacked in sequence, the apertures of the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are 40 mesh, 80 mesh, 100 mesh, 80 mesh and 40 mesh respectively, and the first filter layer, the second filter layer, the third filter layer, the fourth filter layer and the fifth filter layer are all made of stainless steel; Step d: performing secondary filtration on the rubber material after the primary filtration at 110-130° C. using a secondary filter screen; wherein the secondary filter screen comprises a sixth filter layer, a seventh filter layer, an eighth filter layer, a ninth filter layer and a tenth filter layer which are stacked in sequence, and the apertures of the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are 40 meshes, 100 meshes, 100 meshes, 80 meshes and 40 meshes respectively, and the sixth filter layer, the seventh filter layer, the eighth filter layer, the ninth filter layer and the tenth filter layer are all made of stainless steel; Step e: adding a vulcanizing agent and a vulcanizing aid to the rubber material after the secondary filtration, granulating the rubber material with a granulator and then cooling the granulator to prepare a rubber material; Step f: placing the prepared rubber material in a hanging bag and sealing it for storage; wherein the hanging bag is made of PP material; S03: Control conductor twisting Twisting a plurality of control conductors (81) to prepare a control harness; S04: Prepare control core unit According to the operation method of step S02, a control insulation layer group (10) is formed on the outside of the control wire harness to prepare a control wire core (8); after a plurality of control wire cores (8) are twisted, a control metal shielding layer (9) is braided on the outside of the twisted plurality of control wire cores (8) to prepare a control wire core unit (12); S05: Cable A cage stranding machine is used to prepare a plurality of power core units (11), a plurality of control core units (12) and optical fibers (13) into an internal core assembly (1); S06: Sheath extrusion A cable is prepared by sequentially coating an inner core component (1) with an inner sheath (2), braiding a braided layer (3) on the outer side of the inner sheath (2), and coating the outer side of the braided layer (3) with an outer sheath (4), and then subjecting the cable to thermal cross-linking. The cable comprises a first rubber extruder, a braiding machine, a second rubber extruder, and a vulcanization pipeline, which are sequentially arranged along the moving direction of the inner core component (1). The inner sheath (2) is extruded by the first rubber extruder, the braided layer (3) is braided by the braiding machine, and the outer sheath (4) is extruded by the second rubber extruder.

2. The manufacturing process of a 10kV high-performance coal mining machine cable according to claim 1 is characterized in that: The rubber material comprises the following raw materials in parts by weight: 8-12 parts of EPDM 4770, 35-45 parts of POE 8150, 30-40 parts of EPDM 2504, 8-12 parts of paraffin oil, 20-30 parts of talc, 70-80 parts of calcined clay, 1-2 parts of paraffin, 1.0-1.4 parts of antioxidant RD, 0.5-1.5 parts of antioxidant MB, 0.4-0.6 parts of coupling agent A-172, 0.4-0.6 parts of stearic acid, 2-3 parts of polyethylene, 3-5 parts of zinc oxide, 2-4 parts of carbon black N330, 2-4 parts of vulcanizing agent DCP, and 1-3 parts of vulcanizing aid TAIC.

3. The manufacturing process of a 10kV high-performance coal mining machine cable according to claim 2 is characterized in that: The rubber material includes the following raw materials in parts by weight: 10 parts of EPDM 4770, 40 parts of POE 8150, 35 parts of EPDM 2504, 10 parts of paraffin oil, 25 parts of talc, 75 parts of calcined clay, 1.5 parts of paraffin, 1.2 parts of antioxidant RD, 1 part of antioxidant MB, 0.5 parts of coupling agent A-172, 0.5 parts of stearic acid, 2.5 parts of polyethylene, 4 parts of zinc oxide, 3 parts of carbon black N330, 3.2 parts of vulcanizing agent DCP, and 2 parts of vulcanizing aid TAIC.

4. The manufacturing process of a 10kV high-performance coal mining machine cable according to claim 1, characterized in that: The raw material components and weight ratios of the internal insulating material and the external insulating material are the same; The internal insulating material comprises the following raw materials in parts by weight: 30-40 parts of chlorinated polyethylene, 30-40 parts of ethylene vinyl acetate copolymer, 7-8 parts of magnesium oxide, 12-18 parts of chlorinated paraffin, 3-5 parts of dioctyl phthalate, 6-8 parts of paraffin oil, 6-10 parts of vaseline, 60-68 parts of conductive carbon black, 1-3 parts of polyethylene wax, 0.5-1.5 parts of carbon black dispersant, 1-3 parts of antioxidant RD, 1-2 parts of antioxidant MB, 2-2.6 parts of crosslinking agent DCP, and 0.5-0.9 parts of accelerator TAC.

5. The manufacturing process of a 10kV high-performance coal mining machine cable according to claim 4, characterized in that: The internal insulating material includes the following raw materials in parts by weight: 35 parts of chlorinated polyethylene, 35 parts of ethylene vinyl acetate copolymer, 7.2 parts of magnesium oxide, 15 parts of chlorinated paraffin, 4 parts of dioctyl phthalate, 7 parts of paraffin oil, 8 parts of vaseline, 64 parts of conductive carbon black, 2 parts of polyethylene wax, 1 part of carbon black dispersant, 2 parts of antioxidant RD, 1.5 parts of antioxidant MB, 2.3 parts of crosslinking agent DCP, and 0.7 part of accelerator TAC.

6. The manufacturing process of a 10kV high-performance coal mining machine cable according to claim 1, characterized in that: The raw material components and weight ratios of the inner sheath (2) and the outer sheath (4) are the same; The inner sheath (2) comprises the following raw materials in parts by weight: 70-90 parts of chlorinated polyethylene, 4-6 parts of calcium carbonate, 16-20 parts of talc, 2-8 parts of white carbon black, 1-2 parts of microcrystalline wax, 6-10 parts of plasticizer DOP, 15-30 parts of chlorinated paraffin, 4-6 parts of magnesium oxide, 1-2 parts of calcium zinc stabilizer, 10-20 parts of GLC250, 5-15 parts of GZRY-1, 1-2 parts of DCP, and 2-3 parts of TAIC powder.

7. The manufacturing process of a 10kV high performance cable for coal mining machines according to claim 6, characterized in that: The inner sheath (2) comprises the following raw materials in parts by weight: 80 parts of chlorinated polyethylene, 5 parts of calcium carbonate, 18 parts of talc, 5 parts of white carbon black, 1.7 parts of microcrystalline wax, 8 parts of plasticizer DOP, 19 parts of chlorinated paraffin, 5.2 parts of magnesium oxide, 1.5 parts of calcium zinc stabilizer, 15 parts of GLC250, 10 parts of GZRY-1, 1.75 parts of DCP, and 2.6 parts of TAIC powder.

8. A 10kV high-performance coal mining machine cable made by the manufacturing process according to any one of claims 1 to 7, characterized in that: It comprises an internal wire core component (1) and a sheath component (20) covering the outside of the internal wire core component (1), wherein the sheath component (20) comprises an inner sheath (2), a braided layer (3) and an outer sheath (4) which are arranged in order from the inside to the outside; The internal wire core assembly (1) comprises a plurality of power wire core units (11), a plurality of control wire core units (12) and optical fibers (13); The power line core unit (11) comprises a plurality of power conductors (5) and a conductor insulation layer group (6) coated on the outside of the plurality of power conductors (5); the conductor insulation layer group (6) comprises a conductor shielding layer (61), a power insulation layer (62) and an insulation shielding layer (63) arranged in sequence from the inside to the outside; the insulation shielding layer (63) is coated on the outside with a conductor metal shielding layer (7).

9. A 10kV high performance coal mining machine cable according to claim 8, characterized in that: The control wire core unit (12) comprises a plurality of control wire cores (8) and a control metal shielding layer (9) coated on the outside of the plurality of control wire cores (8); The control core (8) comprises a plurality of control conductors (81) and a control insulation layer group (10) coated on the outside of the plurality of control conductors (81); The control insulation layer group (10) has the same structure as the conductor insulation layer group (6).

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