A manufacturing system for light weight high strength cables for automotive applications

Abstract

The application provides a light high-strength cable for automobile application, and a manufacturing system thereof, compared with the prior art, the manufacturing system comprises a plurality of extruders respectively used for applying an insulation layer and a sheath to the outside of a conductor, a stranding machine used for applying a shielding layer to the outside of the conductor, a winding device used for winding and recycling the manufactured light high-strength cable, two sleeving modules used for sleeving to the outside of the light high-strength cable to fix and arrange the light high-strength cable during the winding and recycling process, and a cutting module used for cutting the light high-strength cable matched between the two sleeving modules. The application integrates the multifunctional extruder, the stranding machine, the winding device and the cutting module, realizes the automatic production process from the conductor to the finished product, guarantees the high quality and consistency of the structure of the light high-strength cable, and improves the production efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of cable production, and in particular to a production system for lightweight and high-strength cables for automotive applications. Background Art

[0002] Cables used in new energy vehicles must be capable of carrying high voltage and current, and be resistant to high temperatures, chemicals, grease, and oils. They must also possess excellent mechanical strength to withstand the vibration and shock experienced during vehicle operation. These cables must also be lightweight and flexible to facilitate installation and reduce vehicle weight, while also exhibiting excellent electromagnetic compatibility to minimize electromagnetic interference. They are widely used in power transmission, charging, signal transmission, and vehicle auxiliary systems, encompassing everything from power cables connecting battery packs to electric motors, charging cables supporting fast charging technologies, and signal cables for data transmission and signal control.

[0003] This experimental team has been browsing and studying a large amount of relevant records and materials on the relevant technologies of new energy vehicle cables for a long time. At the same time, relying on relevant resources and conducting a large number of relevant experiments, after a large number of searches, it was found that there are existing technologies such as CN107039117B, CN111370161B, CN111768911B, and CN112331400B disclosed in the prior art. For example, the prior art discloses a high-voltage cable for new energy vehicles. The preparation of the high-voltage cable is to sheath a silicone rubber insulation layer on the outer surface of a tinned copper stranded conductor, and to sheath a tinned copper wire shielding layer on the silicone rubber insulation layer. A sheath is provided on the tinned copper wire shielding layer to obtain a high-voltage cable body, and the high-voltage cable body is introduced into the cleaning chamber through the left guide frame on the workbench, and the cleaned high-voltage cable body is introduced into the winding frame through the right guide frame, and the high-voltage cable body is wound up by the winding roller on the winding frame to obtain a finished product. In the winding process of the high-voltage cable body, the cleaned high-voltage cable body is wound up by the winding roller 1 on the winding frame. After the winding roller 1 is wound up, the high-voltage cable body is introduced into the winding roller 2 for re-winding the high-voltage cable body, and the winding rollers 1, 2 and 3 are used to realize non-stop winding of the high-voltage cable body in turn.

[0004] The present invention is made in order to solve the common problems in the field such as low cable production efficiency. Summary of the Invention

[0005] The purpose of the present invention is to address the deficiencies in the current art and to provide a system for manufacturing lightweight, high-strength cables for automotive applications.

[0006] In order to overcome the deficiencies of the prior art, the present invention adopts the following technical solutions:

[0007] A system for manufacturing a lightweight, high-strength cable for automotive applications, the lightweight, high-strength cable for automotive applications comprising a conductor formed by twisting a plurality of cable cores, an insulating layer laid outside the conductor, a shielding layer laid outside the insulating layer, and a sheath laid outside the shielding layer.

[0008] The cable core at least comprises a copper conductor, a mica tape laid outside the copper conductor, and an insulating layer laid outside the mica tape.

[0009] The insulating layer is made of at least cross-linked polyethylene and polyvinyl chloride.

[0010] The shielding layer is made of at least copper tape and aluminum tape.

[0011] The sheath is made of at least polyvinyl chloride and polyethylene.

[0012] The production system includes several extruders for laying the insulation layer and the sheath outside the conductor, a stranding machine for laying the shielding layer outside the conductor, a winding device for recycling the finished lightweight high-strength cable, two sheathing modules for sheathing the outside of the lightweight high-strength cable to fix and organize the lightweight high-strength cable during the winding and recycling process, and a cutting module for cutting the lightweight high-strength cable fitted between the two sheathing modules.

[0013] Furthermore, each sleeve module includes a connecting tubular matching tube, a CNC robot arm that supports and fixes the matching tube, a guide unit arranged inside the matching tube, and a clamping unit arranged inside the matching tube.

[0014] Furthermore, the interior of the mating tube is a cavity, and the lightweight and high-strength cable passes through the mating tubes of the two sleeve modules in sequence. Taking the center line of the mating tube perpendicular to its axis as a reference, the area on the left side of the center line is the left area of ​​the mating tube, and the area on the right side of the center line is the right area of ​​the mating tube. The guide unit is arranged in the left area, and the clamping unit is arranged in the right area.

[0015] Furthermore, the inner wall of the matching tube is respectively provided with opening grooves in a ring-shaped distribution, and the opening grooves are recessed from the inner tube wall of the matching tube relative to the outer tube wall of the matching tube. The groove wall of the opening groove opposite to its opening is the groove bottom wall, and the opening grooves are distributed in the left area around the tube axis of the matching tube as the center.

[0016] Furthermore, the clamping unit includes an air bag laid in the matching tube, several pressure sensors laid on the inner wall of the matching tube, an air tube one end of which is connected to the air bag and the other end extends to the outside of the matching tube, and an air pump fixedly connected to the air tube for controlling gas transmission in the air tube.

[0017] Furthermore, the airbag is strip-shaped and is laid on the inner wall of the matching tube. The airbag and the pressure sensor are arranged opposite to each other, and the airbag and the tube axis of the matching tube are arranged parallel.

[0018] Furthermore, the guide unit includes a plurality of rolling elements which are respectively and sequentially fitted into the opening grooves.

[0019] Each of the rolling elements includes a left spring element with one end vertically fixed to the bottom wall of the open groove, a right spring element with one end vertically fixed to the bottom wall of the open groove, a left fixed block fixed to the other end of the left spring element, a right fixed block fixed to the other end of the right spring element, a left bearing ring embedded in the left fixed block, a right bearing ring embedded in the right fixed block, a roller coaxially arranged horizontally between the left bearing ring and the right bearing ring, a left roller shaft with one end sleeved on the inner ring of the left bearing ring and the other end fixed to one side of the roller, a right roller shaft with one end sleeved on the inner ring of the right bearing ring and the other end fixed to the other side of the roller, a permanent magnet embedded in the roller, an electromagnetic coil embedded in the bottom wall of the open groove, and a controller for controlling the electromagnetic strength of the electromagnetic coil.

[0020] Furthermore, the cutting module includes a fixed column, a support plate fixed to the top of the fixed column and used to support the cutting section, a laser cutting knife, a balance beam plate horizontally arranged above the fixed column, and a telescopic driving member whose top is fixed to the balance beam plate and whose bottom is fixedly connected to the laser cutting knife to drive the laser cutting knife to perform lifting and moving operations. The laser cutting knife is driven to extend by the telescopic driving member to achieve cutting of the lightweight and high-strength cable fixed on the support plate.

[0021] The beneficial effects achieved by the present invention are:

[0022] 1. This invention realizes an automated production process from conductor to finished product by integrating a multifunctional extruder, stranding machine, winding equipment and cutting module, ensuring the high quality and consistency of the lightweight and high-strength cable structure. The advanced CNC robot arm and dedicated sleeve module effectively fix and shape the lightweight and high-strength cable, improving production efficiency while ensuring cutting accuracy and reducing material waste.

[0023] 2. The clamping unit of the present invention achieves efficient, uniform and safe fixation of lightweight and high-strength cables by using strip-shaped airbags, pressure sensors and precisely controlled air pumps. The strip-shaped design of the airbags and the laying method parallel to the pipe axis ensure uniform contact and compression of the outer wall of the lightweight and high-strength cable, avoiding local damage to the lightweight and high-strength cable. The real-time monitoring and intelligent feedback mechanism of the pressure sensor allow precise control of the clamping force, ensuring that the lightweight and high-strength cables are fixed while preventing excessive compression, thereby improving the production efficiency and operational flexibility of the lightweight and high-strength cables, and enhancing the safety and reliability of the production process.

[0024] 3. The present invention realizes precise guidance, quick fixation and accurate cutting of cables by integrating an electromagnetically controlled guiding unit, an automated clamping and cutting module, adjusts the position of the roller to adapt to different cable diameters, ensures efficient and continuous production process, improves safety and reliability, and has flexibility in handling various cable types. BRIEF DESCRIPTION OF DRAWINGS

[0025] The present invention can be further understood from the following description in conjunction with the drawings. The components in the drawings are not necessarily drawn to scale, but emphasis is placed on illustrating the principles of the embodiments. In different views, the same reference numerals designate corresponding parts.

[0026] Figure 1 A modular schematic diagram of the manufacturing system for lightweight high-strength cables for automotive applications of the present invention.

[0027] Figure 2 A partial structural schematic diagram of the guiding unit of the present invention.

[0028] Figure 3 A partial structural schematic diagram of the sleeving module of the present invention.

[0029] Figure 4 A partial structural schematic diagram of the rolling member of the present invention.

[0030] BRIEF DESCRIPTION OF DRAWINGS: 1 - opening; 2 - groove bottom wall; 3 - inner tube wall; 4 - outer tube wall; 5 - opening groove; 6 - fitting tube; 7 - air bag; 8 - pressure sensor; 9 - left fixed block; 10 - left spring member; 11 - right spring member; 12 - right fixed block; 13 - right roller shaft; 14 - roller; 15 - left roller shaft. DETAILED DESCRIPTION

[0031] In order to make the purpose, technical solutions and advantages of the present invention clearer and more apparent, the present invention will be further described in detail below in conjunction with its embodiments; it should be pointed out that the specific embodiments described here are only used to explain the present invention and do not limit the case. For those skilled in the art, other systems, methods and / or features of the present embodiment will become apparent after reviewing the following detailed description. And the terms used to describe the positional relationship in the drawings are only used for illustrative description, and cannot be understood as a limitation of the present patent. For those skilled in the art, the specific meanings of the above terms can be understood according to the specific circumstances.

[0032] Embodiment one: in conjunction with Figure 1 , attached Figure 2 , attached Figure 3 , attached Figure 4The embodiment constructs a light high-strength cable for automobile application. 1. A manufacturing system of a light high-strength cable for automobile application, characterized in that the light high-strength cable for automobile application comprises a conductor twisted by a plurality of cable cores, an insulation layer applied outside the conductor, a shielding layer applied outside the insulation layer, and a sheath applied outside the shielding layer,

[0033] The cable core comprises at least a copper conductor, a mica tape applied outside the copper conductor, and an insulation layer applied outside the mica tape,

[0034] The manufacturing material of the insulation layer comprises at least cross-linked polyethylene and polyvinyl chloride,

[0035] The manufacturing material of the shielding layer comprises at least a copper tape and an aluminum tape,

[0036] The manufacturing material of the sheath comprises at least polyvinyl chloride and polyethylene,

[0037] The manufacturing system comprises a plurality of extruders respectively used for applying the insulation layer and the sheath outside the conductor, a twisting machine used for applying the shielding layer outside the conductor, a winding device for winding and recycling the manufactured light high-strength cable, two sleeving modules used for sleeving outside the light high-strength cable to fix and arrange the light high-strength cable during the winding and recycling process, and a cutting module used for cutting the light high-strength cable matched between the two sleeving modules,

[0038] The winding device is a prior art and will not be described here,

[0039] Each sleeving module comprises a matching pipe in communication with a tubular shape, a numerical control mechanical arm used for supporting and fixing the matching pipe, a guide unit arranged inside the matching pipe, and a clamping unit arranged inside the matching pipe,

[0040] The inside of the matching pipe is a cavity, the light high-strength cable sequentially penetrates the matching pipes of the two sleeving modules, and the center line perpendicular to the axis of the matching pipe is taken as a reference, the left area of the matching pipe is located on the left side of the center line, and the right area of the matching pipe is located on the right side of the center line, the guide unit is arranged in the left area, and the clamping unit is arranged in the right area,

[0041] The inner wall of the matching pipe is respectively provided with an open groove in a ring distribution, the open groove is arranged to be recessed from the inner pipe wall of the matching pipe relative to the outer pipe wall of the matching pipe, the groove wall opposite to the opening of the open groove is a groove bottom wall, and the open groove is distributed in the left area with the pipe axis of the matching pipe as the center,

[0042] The present invention realizes an automated production process from conductor to finished product by integrating a multifunctional extruder, stranding machine, winding equipment and cutting module, ensuring the high quality and consistency of the lightweight and high-strength cable structure. The advanced CNC robot arm and dedicated sleeve module effectively fix and shape the lightweight and high-strength cable, improving production efficiency while ensuring cutting accuracy and reducing material waste.

[0043] Example 2: Combined with the attached Figure 1 , Attachment Figure 2 , Attachment Figure 3 and attached Figure 4 In addition to the contents of the above embodiments, the clamping unit includes an airbag installed in the mating tube, a plurality of pressure sensors installed on the inner wall of the mating tube, an air tube with one end connected to the airbag and the other end extending out of the mating tube, and an air pump fixedly connected to the air tube for controlling gas transmission in the air tube. The strip-shaped airbag effectively and evenly contacts the outer wall of the lightweight and high-strength cable.

[0044] The airbag is strip-shaped and is laid on the inner wall of the matching tube. The airbag and the pressure sensor are arranged opposite to each other and are arranged parallel to the axis of the matching tube.

[0045] When the air pump inflates the airbag, the airbag expands and pushes the lightweight high-strength cable against the inner wall of the matching tube, so as to evenly compress and fix the lightweight high-strength cable in the matching tube.

[0046] At the same time, the pressure sensor monitors the contact pressure of the lightweight high-strength cable in real time until the pressure sensor monitoring value reaches its preset threshold value, and further feeds back a signal to the air pump through communication technology to stop the inflation operation of the airbag, so as to ensure that the lightweight high-strength cable is clamped tightly enough to prevent the lightweight high-strength cable from moving, and at the same time prevent the airbag from squeezing the lightweight high-strength cable too tightly to avoid damaging the lightweight high-strength cable.

[0047] When it is necessary to release or readjust the position of the lightweight high-strength cable, the air pump works in reverse to discharge the gas in the airbag, reducing the volume of the airbag, thereby loosening the clamping of the lightweight high-strength cable and allowing the lightweight high-strength cable to move in the matching tube.

[0048] The clamping unit of the present invention achieves efficient, uniform and safe fixation of lightweight high-strength cables by using strip-shaped airbags, pressure sensors and precisely controlled air pumps. The strip-shaped design of the airbags and the laying method parallel to the pipe axis ensure uniform contact and compression of the outer wall of the lightweight high-strength cable, avoiding local damage to the lightweight high-strength cable. The real-time monitoring and intelligent feedback mechanism of the pressure sensor allow precise control of the clamping force, ensuring that the lightweight high-strength cable is fixed while preventing excessive compression, thereby improving the production efficiency and operational flexibility of the lightweight high-strength cable, and enhancing the safety and reliability of the production process.

[0049] Example 3: Combined with the Figure 1 , Attachment Figure 2 , Attachment Figure 3 and attached Figure 4 In addition to the contents of the above embodiments, the guide unit includes a plurality of rolling elements that are respectively and sequentially matched in the opening grooves.

[0050] Each of the rolling elements comprises a left spring element with one end vertically fixed to the bottom wall of the open groove, a right spring element with one end vertically fixed to the bottom wall of the open groove, a left fixed block fixed to the other end of the left spring element, a right fixed block fixed to the other end of the right spring element, a left bearing ring embedded in the left fixed block, a right bearing ring embedded in the right fixed block, a roller coaxially arranged between the left bearing ring and the right bearing ring, a left roller shaft with one end sleeved on the inner ring of the left bearing ring and the other end fixed to one side of the roller, a right roller shaft with one end sleeved on the inner ring of the right bearing ring and the other end fixed to the other side of the roller, a permanent magnet embedded in the roller, an electromagnetic coil embedded in the bottom wall of the open groove, and a controller for controlling the electromagnetic strength of the electromagnetic coil.

[0051] When the direction of the magnetic field generated by the electromagnetic coil is opposite to the direction of the magnetic field of the permanent magnet, the permanent magnet and the electromagnetic coil attract each other, thereby driving the roller to move toward the electromagnetic coil.

[0052] When the magnetic field direction of the electromagnetic coil is the same as that of the permanent magnet, the permanent magnet and the electromagnetic coil will generate a repulsive force, further pushing the roller away from the electromagnetic coil.

[0053] The controller accurately adjusts the size and direction of the current in the electromagnetic coil to control the attraction and repulsion as well as the size of the attraction and repulsion, thereby adjusting the position of the roller in the opening groove, thereby achieving adaptive abutment transmission operations for lightweight and high-strength cables of different diameters.

[0054] The two sheathing modules are configured to coaxially fix the lightweight high-strength cable at a preset interval, and the lightweight high-strength cable segment located between the two sheathing modules is defined as a cutting segment.

[0055] The cutting module comprises a fixed column, a support plate fixed to the top of the fixed column and used for supporting a cutting section, a laser cutting knife, a beam plate horizontally arranged above the fixed column, and a telescopic driving member fixed to the top of the beam plate and fixedly connected with the laser cutting knife at the bottom to drive the laser cutting knife to move up and down, the laser cutting knife is driven to extend by the telescopic driving member to cut the lightweight high-strength cable fixed to the support plate,

[0056] In the production system of the present application, the cutting and transferring steps of the lightweight high-strength cable are as follows:

[0057] S101: The two cooperating pipes of the sleeving module are coaxially arranged at a preset interval,

[0058] S102: The produced lightweight high-strength cable is sequentially fed into the cooperating pipes of the two sleeving modules, and the lightweight high-strength cable is sequentially transported and arranged by the guiding unit in the sleeving module, so that the lightweight high-strength cable can be kept horizontal during the transmission and winding,

[0059] S103: After the winding device winds the lightweight high-strength cable of a preset length, the winding device stops working, at this time, the clamping unit in the sleeving module realizes the fastening and clamping of the lightweight high-strength cable by the inflated air bag, so as to keep the position of the lightweight high-strength cable stable,

[0060] S104: The cutting module cuts the cutting section between the two winding devices,

[0061] S105: After cutting, one of the clamping units continues to be fixed, and the other clamping unit moves synchronously with the lightweight high-strength cable to ensure that the cut lightweight high-strength cable section is continuously fixed and pulled to the winding device, so that the lightweight high-strength cable is stably fed into the winding device until the winding of the lightweight high-strength cable is completed,

[0062] The present application realizes accurate guidance, rapid fixation and precise cutting of the cable by integrating the electromagnetic control guiding unit, the automatic clamping and cutting module, adjusts the position of the roller to adapt to different cable diameters, ensures efficient and continuous production process, improves safety and reliability, and has flexibility in processing various cable types.

[0063] While the application has been described with reference to various embodiments, it will be understood that many modifications and variations of the present application are possible. It is therefore understood that within the scope of the application, that the application can be practiced otherwise than as specifically described. That is, the methods, systems and devices discussed above are examples. Various configurations can omit, substitute, or add various procedures or components as appropriate. For instance, the methods described can be performed in an order different from that described, and / or various steps can be added, omitted or combined. Also, features described with respect to certain configurations can be combined in other configurations, for example, features described with respect to one configuration can be combined with features described with respect to a different configuration. Also, control and signal lines can be conveyed by a variety of means known in the art and the example embodiment, such as a bus, a signal path, a wired connection, wireless connection, etc. Additionally, a plurality of different creative synthesis mechanisms can be employed. Also, the word "comprising" does not exclude the presence of elements or steps other than those listed and the word "a" or "an" preceding the name of an element does not exclude the presence of a plurality of such elements or steps. It is further understood that devices of the present application can optionally include one or more elements, features or steps described herein.

Claims

1. A system for producing lightweight, high-strength cables for automotive applications, characterized in that: The lightweight and high-strength cable for automotive applications includes a conductor formed by twisting a plurality of cable cores, an insulating layer laid outside the conductor, a shielding layer laid outside the insulating layer, and a sheath laid outside the shielding layer. The cable core at least comprises a copper conductor, a mica tape laid outside the copper conductor, and an insulating layer laid outside the mica tape. The insulating layer is made of at least cross-linked polyethylene and polyvinyl chloride. The shielding layer is made of at least copper tape and aluminum tape. The sheath is made of at least polyvinyl chloride and polyethylene. The production system includes several extruders for laying the insulation layer and the sheath on the outside of the conductor, a stranding machine for laying the shielding layer on the outside of the conductor, a winding device for winding and recycling the finished lightweight high-strength cable, two sheathing modules for sheathing the outside of the lightweight high-strength cable to fix and organize the lightweight high-strength cable during the winding and recycling process, and a cutting module for cutting the lightweight high-strength cable fitted between the two sheathing modules; Each sleeve module includes a connecting tubular matching tube, a CNC robot arm for supporting and fixing the matching tube, a guide unit arranged inside the matching tube, and a clamping unit arranged inside the matching tube; The interior of the matching tube is a cavity, and the lightweight and high-strength cable passes through the matching tubes of the two sheathed modules in sequence. With the center line of the matching tube perpendicular to its axis as a reference, the area to the left of the center line is the left area of ​​the matching tube, and the area to the right of the center line is the right area of ​​the matching tube. The guide unit is arranged in the left area, and the clamping unit is arranged in the right area. The inner wall of the matching tube is respectively provided with opening grooves in a ring-shaped distribution. The opening grooves are recessed from the inner tube wall of the matching tube relative to the outer tube wall of the matching tube. The groove wall of the opening groove opposite to its opening is the groove bottom wall, and the opening grooves are distributed around the tube axis of the matching tube in the left area. The clamping unit includes an air bag installed in the matching tube, a plurality of pressure sensors installed on the inner wall of the matching tube, an air tube with one end connected to the air bag and the other end extending out of the matching tube, and an air pump fixedly connected to the air tube for controlling gas transmission in the air tube; The airbag is strip-shaped and is laid on the inner wall of the matching tube. The airbag and the pressure sensor are arranged opposite to each other, and the airbag and the tube axis of the matching tube are arranged parallel.

2. The manufacturing system of the lightweight and high-strength cable according to claim 1, characterized in that: The guide unit includes a plurality of rolling elements which are respectively and sequentially fitted into the opening grooves. Each of the rolling elements includes a left spring element with one end vertically fixed to the bottom wall of the open groove, a right spring element with one end vertically fixed to the bottom wall of the open groove, a left fixed block fixed to the other end of the left spring element, a right fixed block fixed to the other end of the right spring element, a left bearing ring embedded in the left fixed block, a right bearing ring embedded in the right fixed block, a roller coaxially arranged horizontally between the left bearing ring and the right bearing ring, a left roller shaft with one end sleeved on the inner ring of the left bearing ring and the other end fixed to one side of the roller, a right roller shaft with one end sleeved on the inner ring of the right bearing ring and the other end fixed to the other side of the roller, a permanent magnet embedded in the roller, an electromagnetic coil embedded in the bottom wall of the open groove, and a controller for controlling the electromagnetic strength of the electromagnetic coil.

3. The manufacturing system of the lightweight and high-strength cable according to claim 2, characterized in that: The cutting module includes a fixed column, a support plate fixed to the top of the fixed column and used to support the cutting section, a laser cutting knife, a balance beam plate arranged horizontally above the fixed column, and a telescopic drive member whose top is fixed to the balance beam plate and whose bottom is fixedly connected to the laser cutting knife to drive the laser cutting knife to perform lifting and moving operations. The laser cutting knife is driven to extend by the telescopic drive member to cut the lightweight and high-strength cable fixed on the support plate.

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