Integrated cable for electric welding machine and preparation method thereof

Abstract

The invention relates to the technical field of cables for high-end equipment manufacturing, and particularly discloses an integrated cable for an electric welding machine and a preparation method of the integrated cable. The integrated cable comprises a breather pipe, a braided reinforcing layer, a conductor twisting layer, a flame-retardant insulating layer and a sheath layer which are sequentially arranged from inside to outside. And the power wire cores in the conductor stranded layer are annularly divided into a positive electrode group and a negative electrode group. According to the particularity of the working condition environment of the electric welding machine, the ventilating pipe, the positive electrode power line, the negative electrode power line and the control signal line are integrated, the technical characteristics of being good in integrity and compactness and convenient to use are achieved, and meanwhile the technical characteristics of being good in flexibility, high in structural strength and good in insulation and flame retardance are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of cables for high-end equipment manufacturing, and in particular to an integrated cable for an electric welding machine and a preparation method thereof. Background Art

[0002] The electric welder is mainly composed of a welder, a welding gun and the functional pipelines between them. It uses the high-temperature arc generated when the positive and negative poles are short-circuited to melt the solder on the welding rod and the material to be welded, so that the contacted objects are combined. The traditional functional pipelines used between the welder and the welding gun of the electric welder are split structures, that is, the positive power line, the negative power line, the control signal line and the ventilation pipe are dispersed and relatively independent structures, which requires the electric welder to be individually connected in steps during manufacturing, resulting in low manufacturing efficiency and high cost; and the functional pipelines are relatively scattered during use, which is inconvenient to use. In view of this, the industry has disclosed various special cables for electric welders that integrate ventilation pipes, positive power lines, negative power lines and control signal lines. For example, the Chinese patent literature discloses a technology named "inert gas shielded electric welder cable", publication number CN2454870Y, publication date October 17, 2001, a technology named "a combination cable for gas shielded welding", publication number CN202736525U, publication date February 13, 2013, a technology named "a method for preparing an integrated electric welder cable and the cable obtained therefrom", publication number CN107993769A, publication date May 4, 2018, and a technology named "an integrated electric welder cable and its preparation method", publication number CN103137246A, publication date June 5, 2013, etc.

[0003] This type of integrated cable is basically composed of an internal ventilation tube, a conductor layer twisted outside the ventilation tube, and a sheath layer extruded outside the conductor layer. Although it has a simple structure, it has technical problems such as easy deformation and poor flame retardancy. This is because: 1. The ventilation pipe is a hollow tube structure extruded from plastic. In order to meet the flexibility in the working environment, it needs to be soft. However, this also leads to low structural strength of the ventilation pipe, poor resistance to bending deformation and external impact extrusion, and the ventilation pipe is prone to deformation and interruption, affecting the welding quality of the electric welder; 2. The working environment of the electric welding machine is low voltage, high current, and spark splashing, which is directly affected by ignition factors. However, the sheath layer outside the conductor layer is more responsible for insulation, solvent resistance and wear resistance, and has poor flame retardant properties.

[0004] Therefore, in view of the particularity of the working environment of the electric welding machine, it is necessary to design a special cable with good softness and flexibility, high structural strength and good insulation flame retardancy. Summary of the invention

[0005] The technical purpose of the present invention is to provide an integrated cable for an electric welder which integrates a ventilation pipe, a positive power line, a negative power line and a control signal line, and has good softness and flexibility, high structural strength and good insulation and flame retardancy, in view of the particularity of the working environment of the above-mentioned electric welder and the shortcomings of the prior art, and a preparation method of the integrated cable.

[0006] The technical purpose of the present invention is achieved by the following technical solution: an integrated cable for an electric welding machine, the integrated cable comprising a vent pipe, a braided reinforcement layer, a conductor stranding layer, a flame-retardant insulation layer and a sheath layer arranged in sequence from the inside to the outside; The power cores in the conductor twisted layer are divided into a positive electrode group and a negative electrode group in the annular direction.

[0007] As one of the preferred technical solutions, the ventilation pipe is a hollow tube structure formed by extrusion of hard EPDM rubber.

[0008] As one of the preferred technical solutions, the braided reinforcement layer is a braided structure of aramid yarns on the outside of the ventilation pipe, and the braiding density is ≥85%.

[0009] As one of the preferred technical solutions, the conductor twisted layer is a spirally twisted structure of multiple power cores and two control cores outside the braided reinforcement layer; The power line core is a bare conductor structure; multiple power line cores are divided into two groups in the circumferential direction, multiple power line cores in one group form a positive electrode group arranged in parallel, and multiple power line cores in the other group form a negative electrode group arranged in parallel; The control wire core has a sheath layer of an insulating structure; the two control wire cores are circumferentially symmetrically arranged between the positive electrode group power wire core and the negative electrode group power wire core to separate the positive electrode group power wire core from the negative electrode group power wire core.

[0010] Furthermore, the power line core is a concentrically twisted structure of multiple copper conductors.

[0011] Furthermore, the control line core has two insulating cores twisted together, and a fluoroplastic sheath layer extruded outside the twisted insulating cores; Each insulating core is composed of a copper conductor and an EPDM rubber insulation layer extruded outside.

[0012] As one of the preferred technical solutions, the flame retardant insulating layer is an overlapping winding structure of a ceramic silicone rubber composite tape outside the conductor twisted layer, and the winding overlap rate is ≥30%.

[0013] As one of the preferred technical solutions, the sheath layer is an extruded structure of an easily strippable sheath material outside the flame-retardant insulating layer; The easy-to-peel sheath material is composed of the following raw materials in weight ratio: 100 parts of chlorinated polyethylene rubber, 1 part of coupling agent, 2.5 parts of calcium zinc stabilizer, 10 parts of light magnesium oxide, 8 parts of phosphorus flame retardant, 2 parts of calcium stearate, 6 parts of chlorinated paraffin, 18 parts of plasticizer, 6 parts of environmentally friendly semi-reinforced carbon black powder, 14 parts of light calcium, 50 parts of calcined kaolin, 25 parts of talc, 6 parts of precipitated white carbon black, 3.8 parts of BIBP crosslinking agent, and 5.2 parts of TMPTA crosslinking aid; The chlorinated polyethylene rubber is CM135B type; The coupling agent is coupling agent KH-402; The chlorinated paraffin adopts chlorinated paraffin 52#; The talcum powder is 2500 mesh talcum powder.

[0014] Furthermore, the easily strippable sheath material is prepared according to the following process flow: Step 1. Add the formula amount of chlorinated polyethylene rubber, calcined kaolin, talcum powder, environmentally friendly semi-reinforced carbon black powder, light calcium, precipitated white carbon black, light magnesium oxide, calcium zinc stabilizer, phosphorus flame retardant, calcium stearate, plasticizer, chlorinated paraffin, and coupling agent into an internal mixer in sequence, mix for 6 minutes to 7 minutes at a working temperature of 110° C. to 115° C., and produce the rubber; Step 2. The rubber compound is rolled on an open mixing mill for three times, and the strip is left to stand for at least 24 hours to obtain a mixed rubber compound; Step 3. Add a section of mixed rubber material into an internal mixer, and add the formulated amount of BIBP crosslinking agent and TMPTA crosslinking aid in the internal mixer in sequence, mix for 0.5min to 2min in an operating temperature environment of 100°C to 105°C, and discharge the rubber; Step 4. The rubber material is pressed into sheets on an open mixing mill, turned over and rolled; Step 5: The film is rolled out on a calender to obtain a sheath material with low elongation at break, low tear strength and easy peeling.

[0015] A method for preparing the above-mentioned integrated cable for electric welding machine, wherein the integrated cable is prepared according to the following process steps: Step 1. In an extruder, a hollow structure ventilation tube is extruded from hard EPDM rubber; Step 2. Install the ventilation pipe in a braiding machine, take the ventilation pipe as the center, and braid the aramid yarn on the outside of the ventilation pipe to obtain a braided reinforcement layer on the outside of the ventilation pipe; Step 3. Install the ventilation pipe with the braided reinforcement layer in a twisting machine, arrange multiple power cores outside the braided reinforcement layer, and make two control cores evenly separate the multiple power cores in the circumferential direction, and spirally twist the power cores and the control cores outside the braided reinforcement layer according to the designed pitch diameter ratio to obtain a conductor twisted layer; Step 4. Install the ventilation pipe with the conductor twisted layer in a wrapping machine, and wrap the ceramic silicone rubber composite tape on the outside of the conductor twisted layer in an overlapping manner to obtain a flame retardant insulation layer; Step 5. Install the ventilation pipe with the flame-retardant insulation layer in an extruder, and extrude the easily strippable sheath material on the outside of the flame-retardant insulation layer to obtain a sheath layer.

[0016] The beneficial technical effect of the present invention is: the above technical measures are aimed at the particularity of the working environment of the above electric welding machine, and integrate the ventilation pipe, positive power line, negative power line and control signal line into one, and have the technical characteristics of integrity, good compactness and easy use. Under the premise of basically not affecting the soft bending performance, the braided reinforcement layer woven outside the ventilation pipe can effectively improve the structural strength of the ventilation pipe, and has good resistance to bending deformation, external impact extrusion and dragging. In the working environment, it can effectively adapt to the flexible change of the welding gun position and keep the ventilation pipeline in the ventilation pipe unobstructed and uninterrupted; by wrapping the ceramic silicone rubber composite tape with insulation and flame retardant properties on the outside of the twisted conductor layer, on the one hand, it can effectively constrain and tighten the cores of the twisted conductor layer, on the other hand, it has good insulation performance, on the third hand, it has good flame retardant performance, and on the fourth hand, the ceramic silicone rubber composite tape wrapped with overlapping wrapping will basically not hinder the soft bending performance of the entire cable. Therefore, the integrated cable of the above technical measures also has the technical characteristics of good soft bending, high structural strength and good insulation and flame retardancy.

[0017] In the above technical measures, the sheath layer is extruded with a sheath material with low elongation at break and low tear strength. It has the properties of insulation, wear resistance, flame retardancy, solvent resistance, low temperature resistance, etc., and also has good stripping properties, which is conducive to the wiring operation of the welding machine during manufacturing and later maintenance, especially the robot automatic stripping and wiring operation of the welding machine in automated manufacturing operations. Specifically, the sheath material is based on chlorinated polyethylene rubber, and the components produce the following coordinated and compatible mechanism characteristics: The CM135B chlorinated polyethylene rubber used has the technical characteristics of low viscosity, and has excellent aging resistance, ozone resistance, flame retardancy, corona resistance, oil resistance and other properties, as well as unique non-flammability performance; The BIBP cross-linking agent and TMPTA cross-linking aid used meet the process performance requirements and are both odorless and environmentally friendly. The coupling agent KH-402 used can couple the interfaces of various materials with greatly different properties, thereby improving the properties of the rubber and increasing the bonding strength; The light magnesium oxide used can effectively neutralize the dehydrochlorination (HCl) reaction of CM135B caused by heating. If it is not neutralized, the dehydrochlorination will prevent the cross-linking reaction of the BIBP cross-linking agent, and ultimately affect the cross-linking performance of the entire rubber compound. The calcium zinc stabilizer used can effectively absorb harmful substances such as free radicals, preventing them from causing degradation of materials and loss of physical properties. Moreover, calcium zinc stabilizers are different from traditional lead salt heat stabilizers and have the technical characteristics of environmental protection and good stability. The phosphorus flame retardant used has the advantages of low smoke, non-toxicity, and low halogen, meeting the environmental protection requirements of the rubber compound; The calcium stearate used has a good lubricating effect on the entire formula system to achieve better processing performance; The chlorinated paraffin and DOS (plasticizer) used increase the plasticizing flow processing performance of the rubber compound. The simultaneous use of the two materials can play a good synergistic role. Among them, chlorinated paraffin also has better flame retardant properties; DOS has a smaller molecular weight and can increase the low temperature resistance of the rubber compound. The environmentally friendly semi-reinforced carbon black powder used has strong mechanical reinforcement performance and generates less heat during the processing of the rubber compound, which can effectively prevent the rubber compound from scorching; The calcined kaolin, talcum powder and precipitated silica used together produce a synergistic reinforcing effect to achieve the reinforcement of the rubber compound; among them, the calcined kaolin is alkaline, which can cooperate with light magnesium oxide to effectively neutralize the HCl gas produced by the dehydrochlorination (HCl) reaction; talcum powder is beneficial to improving the processing performance of the rubber compound, and the particle fineness of talcum powder above 2000 mesh is smaller and the reinforcing effect is obvious. The 2500 talcum powder selected in the formula is the best choice for comprehensive performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 A structural schematic diagram of the present invention.

[0019] The meaning of the codes in the figure are: 1—ventilation pipe; 2—braided reinforcement layer; 3—conductor twisted layer; 31—power line core; 32—control line core; 4—flame retardant insulation layer; 5—sheath layer. DETAILED DESCRIPTION

[0020] The present invention relates to the field of cable technology for high-end equipment manufacturing, specifically an integrated cable for electric welding machines, and a method for preparing the integrated cable. The main technical solution of the present invention is specifically described below in conjunction with multiple embodiments. Figure 1 The technical solution of the present invention is explained clearly and in detail; although other embodiments are not separately drawn with drawings, their main structures can still refer to the drawings of embodiment 1.

[0021] It should be noted that the drawings of the present invention are schematic, and unnecessary details have been simplified to clarify the technical purpose of the present invention, so as to avoid blurring the technical solution of the present invention that contributes to the prior art. In addition, the expressions "approximately", "substantially" and the like regarding quantity or matching relationship in the following text mean that reasonable assembly errors and processing errors in the industry are allowed to exist, and do not literally express absolute quantities or matching relationships.

[0022] Example 1 See also Figure 1 As shown, the present invention is an integrated cable for electric welding machines, which includes a vent 1, a braided reinforcement layer 2, a conductor twisted layer 3, a flame retardant insulation layer 4 and a sheath layer 5 arranged in sequence from the inside to the outside. The conductor twisted layer 3 is a spirally twisted structure of multiple power cores 31 and two control cores 32. Under the separation of the two control cores 32, the power cores in the conductor twisted layer 3 are divided into a positive electrode group and a negative electrode group in the annular direction, that is, a positive power line and a negative power line are formed, so that the entire cable integrates a vent, a positive power line, a negative power line and a control signal line, and has the technical characteristics of being integral, compact and easy to use.

[0023] Specifically, the ventilation pipe 1 is a hollow tube structure formed by extrusion of hard EPDM rubber with excellent airtightness and flexibility.

[0024] The braided reinforcement layer 2 is a braided structure of aramid yarn with excellent flexibility, tensile strength and compressive strength on the outside of the ventilation pipe 1, and the braiding density is about 95%.

[0025] The conductor twisted layer 3 is a spiral twisted structure of multiple power cores 31 and two control cores 32 outside the braided reinforcement layer 2. Among them, the power core 31 is a bare conductor structure, which is a concentric twisted structure of multiple fifth-category soft copper conductors; the multiple power cores 31 are divided into two groups in the circumferential direction, and the multiple power cores 31 in one group form a positive electrode group arranged in parallel, and the multiple power cores 31 in the other group form a negative electrode group arranged in parallel. The control core 32 has two insulating cores twisted together, and a fluoroplastic sheath layer extruded on the outside of the twisted insulating core. Each insulating core is composed of a fifth-category soft copper conductor and an EPDM rubber insulation layer extruded outside; the two control cores 32 are symmetrically arranged between the positive electrode group power core and the negative electrode group power core in the circumferential direction, separating the positive electrode group power core from the negative electrode group power core, so as to ensure that the positive electrode group power core and the negative electrode group power core in the same structural layer do not interfere with each other while satisfying their control signal transmission instinct.

[0026] The flame retardant insulating layer 4 is an overlapping structure of ceramic silicone rubber composite tape wrapped outside the conductor twisted layer 3, and the wrapping overlap rate is about 50%.

[0027] The sheath layer 5 is an extruded structure of a low elongation at break, low tear strength, and easy-to-peel sheath material outside the flame-retardant insulating layer 4 to adapt to the wire stripping operation, especially the wire stripping operation in automated operation. Among them, the low elongation at break, low tear strength, and easy-to-peel sheath material is composed of the following raw materials in weight ratio: 100 parts of chlorinated polyethylene rubber, 1 part of coupling agent, 2.5 parts of calcium zinc stabilizer, 10 parts of light magnesium oxide, 8 parts of phosphorus flame retardant, 2 parts of calcium stearate, 6 parts of chlorinated paraffin, 18 parts of plasticizer, 6 parts of environmentally friendly semi-reinforced carbon black powder, 14 parts of light calcium, 50 parts of calcined kaolin, 25 parts of talc, 6 parts of precipitated white carbon black, 3.8 parts of BIBP crosslinking agent, and 5.2 parts of TMPTA crosslinking aid; the chlorinated polyethylene rubber adopts CM135B type; the coupling agent adopts coupling agent KH-402 type; the chlorinated paraffin adopts chlorinated paraffin 52# ​​type; and the talc adopts 2500 mesh talc.The aforementioned low elongation at break, low tear strength, and easy-to-peel sheath material is based on chlorinated polyethylene rubber. The CM135B chlorinated polyethylene rubber used has the technical characteristics of low viscosity, and has excellent aging resistance, ozone resistance, flame retardancy, corona resistance, oil resistance and other properties, as well as unique non-flammability performance; the BIBP cross-linking agent and TMPTA cross-linking aid used are both odorless and environmentally friendly while meeting the process performance requirements; the coupling agent KH-402 used can couple the interfaces of various materials with very different properties, thereby improving the performance of the rubber and increasing the bonding strength; the lightweight magnesium oxide in the formula can effectively neutralize the dehydrochlorination (HCl) reaction of CM135B caused by heating. If it is not neutralized, the dehydrochlorination will prevent the cross-linking reaction of the BIBP cross-linking agent, and ultimately affect the cross-linking performance of the entire rubber; the calcium zinc stabilizer in the formula can effectively absorb harmful substances such as free radicals to prevent the degradation of materials and loss of physical properties caused by free radicals and other harmful substances, and the calcium zinc stabilizer is different from the traditional lead salt heat stabilizer and has the technical characteristics of environmental protection and good stability. Points; Phosphorus flame retardants have the advantages of low smoke, non-toxicity, and low halogen, meeting the environmental protection requirements of rubber; Calcium stearate has a good lubricating effect on the entire formula system to achieve better processing performance; Chlorinated paraffin and DOS (plasticizer) increase the plasticizing flow processing performance of the rubber. The simultaneous use of the two materials can play a good synergistic role. Chlorinated paraffin also has better flame retardant properties, and DOS has a smaller molecular weight, which can increase the low temperature resistance of the rubber; Environmentally friendly semi-reinforced carbon black powder has strong mechanical reinforcement properties , and it can generate less heat during the processing of the rubber, which can effectively prevent the rubber from scorching; calcined kaolin, talcum powder and precipitated silica work together to produce a synergistic reinforcement effect to achieve the reinforcement of the rubber. Among them, calcined kaolin is alkaline, which can cooperate with light magnesium oxide to effectively neutralize the HCl gas produced by the dehydrochlorination (HCl) reaction. Talc powder is beneficial to improving the processing performance of the rubber. The particle fineness of talcum powder above 2000 mesh is small and the reinforcement effect is obvious. Therefore, the 2500 talc powder selected in the formula is the best choice for comprehensive performance.

[0028] The above-mentioned low elongation at break, low tear strength, and easy-to-peel sheath material is prepared according to the following process flow: Step 1. Add the formulated amount of chlorinated polyethylene rubber, calcined kaolin, talcum powder, environmentally friendly semi-reinforced carbon black powder, light calcium, precipitated white carbon black, light magnesium oxide, calcium zinc stabilizer, phosphorus flame retardant, calcium stearate, plasticizer, chlorinated paraffin, and coupling agent into an internal mixer in sequence, mix for about 7 minutes at a working temperature of about 112°C, and produce the rubber; Step 2. The rubber compound is rolled on an open mixing mill for three times, and the strip is left to stand for about 24 hours to obtain a mixed rubber compound; Step 3. Add a section of mixed rubber material into an internal mixer, and add the formulated amount of BIBP crosslinking agent and TMPTA crosslinking aid in the internal mixer in sequence, mix for about 1 minute at a working temperature of about 103°C, and discharge the rubber; Step 4. The rubber material is pressed into sheets on an open mixing mill, turned over and rolled; Step 5: The film is rolled out on a calender to obtain a sheath material with low elongation at break, low tear strength and easy peeling.

[0029] The sheath material prepared according to the above formula and preparation process has the physical properties listed in Table 1 below after testing.

[0030] Table 1 Test physical properties of the above sheath materials

[0031] It can be seen from Table 1 above that the sheath material obtained by the above formula and preparation process has the technical characteristics of low elongation at break and low tear strength while meeting the technical requirements of the industry, and has the technical characteristic of good stripping property in the later application of the formed cable.

[0032] The above-mentioned integrated cable is manufactured according to the following process steps: Step 1. In an extruder, a hollow structure ventilation tube is extruded from hard EPDM rubber; Step 2. Install the ventilation pipe in a braiding machine, take the ventilation pipe as the center, and braid the aramid yarn on the outside of the ventilation pipe to obtain a braided reinforcement layer on the outside of the ventilation pipe; Step 3. Install the ventilation pipe with the braided reinforcement layer in a twisting machine, arrange multiple power cores outside the braided reinforcement layer, and make two control cores evenly separate the multiple power cores in the circumferential direction, and spirally twist the power cores and the control cores outside the braided reinforcement layer according to the designed pitch diameter ratio to obtain a conductor twisted layer; Step 4. Install the ventilation pipe with the conductor twisted layer in a wrapping machine, and wrap the ceramic silicone rubber composite tape on the outside of the conductor twisted layer in an overlapping manner to obtain a flame retardant insulation layer; Step 5. Install the ventilation pipe with the flame-retardant insulation layer in an extruder, and extrude the easily strippable sheath material on the outside of the flame-retardant insulation layer to obtain a sheath layer.

[0033] Example 2 The present invention is an integrated cable for electric welding machines, which includes a vent pipe, a braided reinforcement layer, a conductor twisted layer, a flame retardant insulation layer and a sheath layer arranged in sequence from the inside to the outside. The conductor twisted layer is a spiral twisted structure of multiple power cores and two control cores. Under the separation of the two control cores, the power cores in the conductor twisted layer are circumferentially separated into a positive electrode group and a negative electrode group, that is, a positive power line and a negative power line are formed, so that the entire cable integrates the vent pipe, the positive power line, the negative power line and the control signal line, and has the technical characteristics of being integral, compact and easy to use.

[0034] Specifically, the ventilation pipe is a hollow tube structure formed by extrusion of hard EPDM rubber with excellent airtightness and flexibility.

[0035] The braided reinforcement layer is a double-layer braided structure of aramid yarn with excellent flexibility, tensile strength and compressive resistance on the outside of the ventilation pipe, and the braiding density of each layer is about 85%.

[0036] The conductor twisted layer is a spiral twisted structure of multiple power cores and two control cores outside the braided reinforcement layer. Among them, the power core is a bare conductor structure, which is a concentric twisted structure of multiple fifth-category soft copper conductors; multiple power cores are divided into two groups in the circumferential direction, and multiple power cores in one group form a positive electrode group arranged in parallel, and multiple power cores in the other group form a negative electrode group arranged in parallel. The control core has two insulating cores twisted together, and a fluoroplastic sheath layer extruded on the outside of the twisted insulating core. Each insulating core is composed of a fifth-category soft copper conductor and an EPDM rubber insulation layer extruded outside; the two control cores are symmetrically placed between the positive electrode group power core and the negative electrode group power core in the circumferential direction, separating the positive electrode group power core from the negative electrode group power core, so as to ensure that the positive electrode group power core and the negative electrode group power core in the same structural layer do not interfere with each other while satisfying their control signal transmission instinct.

[0037] The flame retardant insulating layer is an overlapping wrapping structure of a ceramic silicone rubber composite tape outside the conductor twisted layer, and the wrapping overlap rate is about 45%.

[0038] The sheath layer is an extruded structure of a low elongation at break, low tear strength, and easy-to-strip sheath material outside the flame-retardant insulation layer to adapt to wire stripping operations, especially wire stripping operations in automated operations. Among them, the low elongation at break, low tear strength, and easy-to-strip sheath material is composed of the following raw materials in weight ratio: 100 parts of chlorinated polyethylene rubber, 1 part of coupling agent, 2.5 parts of calcium zinc stabilizer, 10 parts of light magnesium oxide, 8 parts of phosphorus flame retardant, 2 parts of calcium stearate, 6 parts of chlorinated paraffin, 18 parts of plasticizer, 6 parts of environmentally friendly semi-reinforced carbon black powder, 14 parts of light calcium, 50 parts of calcined kaolin, 25 parts of talc, 6 parts of precipitated white carbon black, 3.8 parts of BIBP crosslinking agent, and 5.2 parts of TMPTA crosslinking aid; the chlorinated polyethylene rubber adopts CM135B type; the coupling agent adopts coupling agent KH-402 type; the chlorinated paraffin adopts chlorinated paraffin 52# ​​type; and the talc adopts 2500 mesh talc.

[0039] The above-mentioned low elongation at break, low tear strength, and easy-to-peel sheath material is prepared according to the following process flow: Step 1. Add the formulated amount of chlorinated polyethylene rubber, calcined kaolin, talcum powder, environmentally friendly semi-reinforced carbon black powder, light calcium, precipitated white carbon black, light magnesium oxide, calcium zinc stabilizer, phosphorus flame retardant, calcium stearate, plasticizer, chlorinated paraffin, and coupling agent into an internal mixer in sequence, mix for about 7 minutes at a working temperature of about 110° C., and produce the rubber; Step 2. The rubber compound is rolled on an open mixer for three times, and the rolled rubber compound is left to stand for about 25 hours to obtain a mixed rubber compound; Step 3. Add a section of mixed rubber material into an internal mixer, and add the formulated amount of BIBP crosslinking agent and TMPTA crosslinking aid in the internal mixer in sequence, mix for about 0.5 minutes at a working temperature of about 105°C, and discharge the rubber; Step 4. The rubber material is pressed into sheets on an open mixing mill, turned over and rolled; Step 5: The film is rolled out on a calender to obtain a sheath material with low elongation at break, low tear strength and easy peeling.

[0040] The above-mentioned integrated cable is manufactured according to the following process steps: Step 1. In an extruder, a hollow structure ventilation tube is extruded from hard EPDM rubber; Step 2. Install the ventilation pipe in a braiding machine, take the ventilation pipe as the center, and braid the aramid yarn on the outside of the ventilation pipe to obtain a braided reinforcement layer on the outside of the ventilation pipe; Step 3. Install the ventilation pipe with the braided reinforcement layer in a twisting machine, arrange multiple power cores outside the braided reinforcement layer, and make two control cores evenly separate the multiple power cores in the circumferential direction, and spirally twist the power cores and the control cores outside the braided reinforcement layer according to the designed pitch diameter ratio to obtain a conductor twisted layer; Step 4. Install the ventilation pipe with the conductor twisted layer in a wrapping machine, and wrap the ceramic silicone rubber composite tape on the outside of the conductor twisted layer in an overlapping manner to obtain a flame retardant insulation layer; Step 5. Install the ventilation pipe with the flame-retardant insulation layer in an extruder, and extrude the easily strippable sheath material on the outside of the flame-retardant insulation layer to obtain a sheath layer.

[0041] Example 3 The present invention is an integrated cable for electric welding machines, which includes a vent pipe, a braided reinforcement layer, a conductor twisted layer, a flame retardant insulation layer and a sheath layer arranged in sequence from the inside to the outside. The conductor twisted layer is a spiral twisted structure of multiple power cores and two control cores. Under the separation of the two control cores, the power cores in the conductor twisted layer are circumferentially separated into a positive electrode group and a negative electrode group, that is, a positive power line and a negative power line are formed, so that the entire cable integrates the vent pipe, the positive power line, the negative power line and the control signal line, and has the technical characteristics of being integral, compact and easy to use.

[0042] Specifically, the ventilation pipe is a hollow tube structure formed by extrusion of hard EPDM rubber with excellent airtightness and flexibility.

[0043] The braided reinforcement layer is a braided structure of aramid yarn with excellent flexibility, tensile strength and compressive resistance on the outside of the ventilation pipe, and the braiding density is about 97%.

[0044] The conductor twisted layer is a spiral twisted structure of multiple power cores and two control cores outside the braided reinforcement layer. Among them, the power core is a bare conductor structure, which is a concentric twisted structure of multiple fifth-category soft copper conductors; multiple power cores are divided into two groups in the circumferential direction, and multiple power cores in one group form a positive electrode group arranged in parallel, and multiple power cores in the other group form a negative electrode group arranged in parallel. The control core has two insulating cores twisted together, and a fluoroplastic sheath layer extruded on the outside of the twisted insulating core. Each insulating core is composed of a fifth-category soft copper conductor and an EPDM rubber insulation layer extruded outside; the two control cores are symmetrically placed between the positive electrode group power core and the negative electrode group power core in the circumferential direction, separating the positive electrode group power core from the negative electrode group power core, so as to ensure that the positive electrode group power core and the negative electrode group power core in the same structural layer do not interfere with each other while satisfying their control signal transmission instinct.

[0045] The flame retardant insulation layer is a double-layer overlapping wrapping structure of a ceramic silicone rubber composite tape outside the conductor twisted layer, and the wrapping overlap rate of each layer is about 30%.

[0046] The sheath layer is an extruded structure of a low elongation at break, low tear strength, and easy-to-strip sheath material outside the flame-retardant insulation layer to adapt to wire stripping operations, especially wire stripping operations in automated operations. Among them, the low elongation at break, low tear strength, and easy-to-strip sheath material is composed of the following raw materials in weight ratio: 100 parts of chlorinated polyethylene rubber, 1 part of coupling agent, 2.5 parts of calcium zinc stabilizer, 10 parts of light magnesium oxide, 8 parts of phosphorus flame retardant, 2 parts of calcium stearate, 6 parts of chlorinated paraffin, 18 parts of plasticizer, 6 parts of environmentally friendly semi-reinforced carbon black powder, 14 parts of light calcium, 50 parts of calcined kaolin, 25 parts of talc, 6 parts of precipitated white carbon black, 3.8 parts of BIBP crosslinking agent, and 5.2 parts of TMPTA crosslinking aid; the chlorinated polyethylene rubber adopts CM135B type; the coupling agent adopts coupling agent KH-402 type; the chlorinated paraffin adopts chlorinated paraffin 52# ​​type; and the talc adopts 2500 mesh talc.

[0047] The above-mentioned low elongation at break, low tear strength, and easy-to-peel sheath material is prepared according to the following process flow: Step 1. Add the formulated amount of chlorinated polyethylene rubber, calcined kaolin, talcum powder, environmentally friendly semi-reinforced carbon black powder, light calcium, precipitated white carbon black, light magnesium oxide, calcium zinc stabilizer, phosphorus flame retardant, calcium stearate, plasticizer, chlorinated paraffin, and coupling agent into an internal mixer in sequence, mix for about 6 minutes at a working temperature of about 115°C, and produce the rubber; Step 2. The rubber compound is rolled on an open mixing mill for three times, and the strip is left to stand for about 24 hours to obtain a mixed rubber compound; Step 3. Add a section of mixed rubber material into an internal mixer, and add the formulated amount of BIBP crosslinking agent and TMPTA crosslinking aid in the internal mixer in sequence, mix for 2 minutes at a working temperature of about 100° C., and discharge the rubber; Step 4. The rubber material is pressed into sheets on an open mixing mill, turned over and rolled; Step 5: The film is rolled out on a calender to obtain a sheath material with low elongation at break, low tear strength and easy peeling.

[0048] The above-mentioned integrated cable is manufactured according to the following process steps: Step 1. In an extruder, a hollow structure ventilation tube is extruded from hard EPDM rubber; Step 2. Install the ventilation pipe in a braiding machine, take the ventilation pipe as the center, and braid the aramid yarn on the outside of the ventilation pipe to obtain a braided reinforcement layer on the outside of the ventilation pipe; Step 3. Install the ventilation pipe with the braided reinforcement layer in a twisting machine, arrange multiple power cores outside the braided reinforcement layer, and make two control cores evenly separate the multiple power cores in the circumferential direction, and spirally twist the power cores and the control cores outside the braided reinforcement layer according to the designed pitch diameter ratio to obtain a conductor twisted layer; Step 4. Install the ventilation pipe with the conductor twisted layer in a wrapping machine, and wrap the ceramic silicone rubber composite tape on the outside of the conductor twisted layer in an overlapping manner to obtain a flame retardant insulation layer; Step 5. Install the ventilation pipe with the flame-retardant insulation layer in an extruder, and extrude the easily strippable sheath material on the outside of the flame-retardant insulation layer to obtain a sheath layer.

[0049] The above embodiments are only used to illustrate the present invention, but not to limit it.

[0050] Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the above embodiments or make equivalent substitutions for some of the technical features therein; and these modifications or substitutions do not deviate the essence of the corresponding technical solutions from the spirit and scope of the present invention.

Claims

1. An integrated cable for an electric welding machine, characterized in that: The integrated cable comprises a ventilation tube (1), a braided reinforcement layer (2), a conductor twisted layer (3), a flame-retardant insulation layer (4) and a sheath layer (5) which are arranged in sequence from the inside to the outside; The power line core in the conductor twisted layer (3) is divided into a positive electrode group and a negative electrode group in the annular direction.

2. The integrated cable for welding machine according to claim 1, characterized in that: The ventilation pipe (1) is a hollow tube structure formed by extrusion of hard EPDM rubber.

3. The integrated cable for electric welding machine according to claim 1, characterized in that: The braided reinforcement layer (2) is a braided structure of aramid yarns on the outside of the ventilation pipe (1), with a braiding density of ≥85%.

4. The integrated cable for electric welding machine according to claim 1, characterized in that: The conductor twisted layer (3) is a spirally twisted structure of a plurality of power wire cores (31) and two control wire cores (32) outside the braided reinforcement layer (2); The power line core (31) is a bare conductor structure; the multiple power line cores (31) are evenly divided into two groups in the circumferential direction, the multiple power line cores (31) in one group form a positive electrode group arranged in parallel, and the multiple power line cores (31) in the other group form a negative electrode group arranged in parallel; The control wire core (32) has a sheath layer of an insulating structure; the two control wire cores (32) are circumferentially symmetrically arranged between the positive electrode group power wire core and the negative electrode group power wire core, separating the positive electrode group power wire core from the negative electrode group power wire core.

5. The integrated cable for electric welding machine according to claim 4, characterized in that: The power line core (31) is a concentrically twisted structure of multiple copper conductors.

6. The integrated cable for welding machine according to claim 4, characterized in that: The control wire core (32) comprises two insulating cores twisted together, and a fluoroplastic sheath layer extruded outside the twisted insulating cores; Each insulating core is composed of a copper conductor and an EPDM rubber insulation layer extruded outside.

7. The integrated cable for electric welding machine according to claim 1, characterized in that: The flame-retardant insulating layer (4) is an overlapping structure of ceramic silicone rubber composite tape wrapped outside the conductor twisted layer (3), and the wrapping overlap rate is ≥30%.

8. The integrated cable for electric welding machine according to claim 1, characterized in that: The sheath layer (5) is an extruded structure of an easily strippable sheath material outside the flame-retardant insulating layer (4); The easy-to-peel sheath material is composed of the following raw materials in weight ratio: 100 parts of chlorinated polyethylene rubber, 1 part of coupling agent, 2.5 parts of calcium zinc stabilizer, 10 parts of light magnesium oxide, 8 parts of phosphorus flame retardant, 2 parts of calcium stearate, 6 parts of chlorinated paraffin, 18 parts of plasticizer, 6 parts of environmentally friendly semi-reinforced carbon black powder, 14 parts of light calcium, 50 parts of calcined kaolin, 25 parts of talc, 6 parts of precipitated white carbon black, 3.8 parts of BIBP crosslinking agent, and 5.2 parts of TMPTA crosslinking aid; The chlorinated polyethylene rubber is CM135B type; The coupling agent is coupling agent KH-402; The chlorinated paraffin adopts chlorinated paraffin 52#; The talcum powder is 2500 mesh talcum powder.

9. The integrated cable for electric welding machine according to claim 8, characterized in that: The easily strippable sheath material is prepared according to the following process flow: Step 1. Add the formula amount of chlorinated polyethylene rubber, calcined kaolin, talcum powder, environmentally friendly semi-reinforced carbon black powder, light calcium, precipitated white carbon black, light magnesium oxide, calcium zinc stabilizer, phosphorus flame retardant, calcium stearate, plasticizer, chlorinated paraffin, and coupling agent into an internal mixer in sequence, mix for 6 minutes to 7 minutes at a working temperature of 110° C. to 115° C., and produce the rubber; Step 2. The rubber compound is rolled on an open mixing mill for three times, and the strip is left to stand for at least 24 hours to obtain a mixed rubber compound; Step 3. Add a section of mixed rubber material into an internal mixer, and add the formulated amount of BIBP crosslinking agent and TMPTA crosslinking aid in the internal mixer in sequence, mix for 0.5min to 2min in an operating temperature environment of 100°C to 105°C, and discharge the rubber; Step 4. The rubber material is pressed into sheets on an open mixing mill, turned over and rolled; Step 5: The film is rolled out on a calender to obtain a sheath material with low elongation at break, low tear strength and easy peeling.

10. A method for preparing the integrated cable for welding machine according to any one of claims 1 to 9, characterized in that: The integrated cable is manufactured according to the following process steps: Step 1. In an extruder, a hollow structure ventilation tube is extruded from hard EPDM rubber; Step 2. Install the ventilation pipe in a braiding machine, take the ventilation pipe as the center, and braid the aramid yarn on the outside of the ventilation pipe to obtain a braided reinforcement layer on the outside of the ventilation pipe; Step 3. Install the ventilation pipe with the braided reinforcement layer in a twisting machine, arrange multiple power cores outside the braided reinforcement layer, and make two control cores evenly separate the multiple power cores in the circumferential direction, and spirally twist the power cores and the control cores outside the braided reinforcement layer according to the designed pitch diameter ratio to obtain a conductor twisted layer; Step 4. Install the ventilation pipe with the conductor twisted layer in a wrapping machine, and wrap the ceramic silicone rubber composite tape on the outside of the conductor twisted layer in an overlapping manner to obtain a flame retardant insulation layer; Step 5. Install the ventilation pipe with the flame-retardant insulation layer in an extruder, and extrude the easily strippable sheath material on the outside of the flame-retardant insulation layer to obtain a sheath layer.

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