High-strength cable for industrial robot and preparation process of high-strength cable

Abstract

The invention discloses a high-strength cable for an industrial robot and a preparation process of the high-strength cable. The preparation process comprises the following steps: selecting a high-strength conductor material, performing multi-pass wire drawing processing on the conductor material, and twisting a plurality of fine copper wires according to a preset pitch and direction to form a conductor core; fluoroplastic is selected as a first layer of insulating material to coat the conductor core to form a first insulating layer, and modified thermoplastic elastomer particles coat the first insulating layer to form a second insulating layer; wrapping a wrapping material outside the second insulating layer by using a wrapping machine to form a wrapping layer; a sheath material extruder is provided to wrap the wrapping layer to form an outer sheath, and then cutting is carried out to obtain the high-strength cable. According to the process, material selection and structural design are innovatively combined, the double-layer insulation structure provides excellent high-temperature resistance and electrical insulation performance, friction between the inner layer and the outer sheath is effectively reduced due to application of the wrapping layer, the service life of the cable is prolonged, and therefore the high-strength cable is prepared.

Description

Technical Field

[0001] The present invention relates to the technical field of cables, and in particular to a high-strength cable for an industrial robot and a preparation process thereof. Background Art

[0002] In recent years, with the rapid development of industrial automation and intelligent manufacturing, industrial robots have been increasingly used in various industries. Industrial robots play a vital role in the fields of automobile manufacturing, electronic assembly, metal processing, food packaging, etc. Their working environment is usually characterized by high intensity, high frequency and high precision, requiring robots to have the ability to move at high speed, accurately position and work continuously for a long time. In this case, all kinds of cables connecting the robot, such as power cables, signal cables and control cables, must have good mechanical and electrical properties, be able to withstand frequent bending, torsion and drag chain movement, and ensure stable signal transmission and reliable operation of the system.

[0003] Existing industrial robot-specific cables usually use ordinary conductor materials and conventional insulation structures. These cables have acceptable performance during initial use, but are prone to some problems in long-term high-intensity working environments. For example, the conductor material has insufficient mechanical strength, which causes fatigue damage to the cable during frequent bending and twisting; traditional insulation materials have poor resistance to high temperatures, wear and chemical corrosion, and cannot meet the requirements of complex industrial environments; the cable structure design lacks targeted protective measures, which leads to increased friction between the inner conductor and the outer sheath, accelerating the aging and damage of the cable. These defects shorten the service life of the cable, increase maintenance and replacement costs, and affect the overall efficiency and reliability of the industrial robot.

[0004] Therefore, it is necessary to improve the special cables for industrial robots in the prior art to solve the technical problem of low industrial strength. Summary of the invention

[0005] The purpose of the present invention is to provide a high-strength cable for an industrial robot and a preparation process thereof to solve the above technical problems.

[0006] To achieve this object, the present invention adopts the following technical solutions: A preparation process for a high-strength cable for an industrial robot, comprising: Step S1: selecting a high-strength conductor material, performing multiple wire drawing processes on the conductor material to obtain a thin copper wire of a required diameter, and twisting a plurality of the thin copper wires according to a preset pitch and direction to form a conductor core; Step S2: selecting fluoroplastic as the first layer of insulating material, using a continuous extrusion process to melt the fluoroplastic and evenly coat it on the conductor core to form a first insulating layer; Step S3: preparing modified thermoplastic elastomer particles, and coating the modified thermoplastic elastomer particles on the first insulating layer to form a second insulating layer through an extrusion process; Step S4: selecting a preset wrapping material, and using a wrapping machine to spirally wrap the wrapping material around the second insulating layer at a preset overlap rate to form a wrapping layer; Step S5: providing a pre-prepared sheath material, and wrapping the sheath material around the wrapping layer through an extruder to form an outer sheath, rapidly solidifying the outer sheath by cooling, and then cutting to obtain a high-strength cable.

[0007] Optionally, the step S1 specifically includes: Step S11: selecting a high-strength conductor material, wherein the conductor material is a high-strength copper alloy rod material containing trace alloy elements; Step S12: performing multiple wire drawing processes on the high-strength copper alloy rod material, using wire drawing equipment, using a wire drawing die made of nano-diamond material, controlling the wire drawing speed to be 300 m / min to 600 m / min, and gradually drawing the copper alloy rod material into a thin copper wire; Step S13: performing continuous annealing treatment on the thin copper wire, controlling the annealing temperature to be 250° C. to 400° C.; Step S14: twisting the annealed thin copper wires according to a preset pitch and direction, with the twisting method being a multi-layer concentric twisting or a bundle twisting structure, to form a conductor core; Optionally, after step S14, the following steps are further included: Step S15: The conductor core is cleaned and dried by ultrasonic cleaning.

[0008] Optionally, the step S2 specifically includes: Step S21: selecting fluoroplastic as the first layer of insulating material, wherein the fluoroplastic is selected from any one of polytetrafluoroethylene, soluble polytetrafluoroethylene or perfluoroethylene propylene; Step S22: preheating the conductor core at a temperature of 80° C. to 120° C. for a time of 1 minute to 3 minutes; Step S23: drying the fluoroplastic insulating material at a temperature of 120° C. to 150° C. for 4 to 8 hours.

[0009] Optionally, after step S23, the following steps are further included: Step S24: setting extrusion process parameters, adding the dried fluoroplastic particles into the hopper of the screw extruder, and setting the temperature of each temperature zone of the extruder to: Barrel zone temperature: 260°C to 300°C; Screw zone temperature: 280℃ to 320℃; Head zone temperature: 300℃ to 340℃; At the same time, the screw speed of the extruder is set to 15 rpm to 30 rpm, and the extrusion speed is controlled between 5 m / min and 15 m / min; Step S25: performing continuous extrusion coating, passing the preheated conductor core through the die core of the extruder, and extruding the molten fluoroplastic from the die core and uniformly coating the outer surface of the conductor core to form a first insulating layer; Step S26: Cooling and shaping, cooling the conductor core coated with the fluoroplastic insulation layer through a cooling water tank, and controlling the temperature of the cooling water between 10°C and 25°C.

[0010] Optionally, the modified thermoplastic elastomer particles include the following components: 20 to 30 parts of an elastomer resin, wherein the elastomer resin is a thermoplastic polyolefin elastomer or a thermoplastic polyurethane; 20 parts of a functionalized elastomer, wherein the functionalized elastomer is a polyolefin elastomer or an elastomer copolymer grafted with maleic anhydride; 5-10 parts of stabilizer, zinc oxide, hindered phenol antioxidant or hydroxylamine stabilizer; 5-15 parts of plasticizer, using environmentally friendly plasticizers such as citric acid esters or epoxidized vegetable oils; 5-10 parts of reinforcing filler, glass microspheres, modified kaolin or calcium carbonate; 10-20 parts of flame retardant, using phosphorus nitrogen series or expansion type flame retardant; 0.5 to 2 parts of nano additives, such as nano titanium dioxide, graphene or carbon nanotubes, are used to enhance the mechanical properties and thermal conductivity of the material.

[0011] Optionally, the step S4 specifically includes: Step S41: selecting a wrapping material, wherein the thickness of the wrapping material is 0.02 mm to 0.05 mm, and the wrapping material is a polyimide film, a polytetrafluoroethylene film or a high-strength fiber fabric; Step S42: pre-treating the wrapping material by means of tension adjustment and surface treatment; Step S43: setting wrapping process parameters according to cable specifications and performance requirements.

[0012] Optionally, after step S43, the following steps are further included: Step S44: performing a wrapping operation according to set wrapping process parameters, using a multi-head high-speed wrapping machine to wrap the pre-treated wrapping material around the second insulating layer at a preset overlap rate and spiral angle; Step S45: After wrapping is completed, the wrapping layer is heat-set to stabilize the structure and size of the wrapping layer. The heat-setting temperature is controlled at 80°C to 120°C. Step S46: Quality inspection of the wrapping layer, performing quality inspection on the cables that have completed wrapping and heat setting treatment, wherein the quality inspection includes appearance inspection and size measurement.

[0013] Optionally, the step S5 specifically includes: Step S51: providing sheath material; Step S52: adding the sheath material into an extruder, and setting the temperature and pressure parameters of the extruder so that the sheath material is fully plasticized into a molten state in the extruder; Step S53: the cable passes through the center of the die core of the extruder, and the molten sheath material is evenly extruded from the die sleeve and coated outside the wrapping layer to form an outer sheath; Step S54: rapidly solidifying the outer sheath by cooling, and performing size and appearance inspection on the cooled cable; the cooling method includes water cooling or air cooling, and the cooling temperature is controlled at room temperature to 25° C.; Step S56: cutting the cable according to work requirements to obtain a high-strength cable that meets specification requirements.

[0014] The present invention further provides a high-strength cable for an industrial robot, which is prepared by the above-mentioned preparation process of the high-strength cable for an industrial robot, and the high-strength cable comprises: The conductor core is formed by twisting a number of thin copper wires according to a preset pitch and direction; A first insulating layer, covering the conductor core, is made of fluoroplastics by continuous extrusion process; The second insulating layer is formed by coating the first insulating layer with modified thermoplastic elastomer particles by extrusion process; A wrapping layer is formed by spirally wrapping a wrapping material at a preset overlap rate outside the second insulating layer; The outer sheath is formed by coating the outer cladding layer with an extruder, and then the outer sheath is rapidly solidified by cooling.

[0015] Compared with the prior art, the present invention has the following beneficial effects: during processing, a high-strength conductor material, such as a high-strength copper alloy wire, is selected, and multiple passes of wire drawing are performed on the wire to obtain a thin copper wire of a desired diameter, and then the wire is twisted according to a preset pitch and direction to form a conductor core with excellent mechanical properties and conductive properties, and a continuous extrusion process is adopted to uniformly coat the molten fluoroplastic on the conductor core to form a first insulating layer; modified thermoplastic elastomer particles are prepared, and a second insulating layer is formed outside the first insulating layer through an extrusion process, and a suitable wrapping material is selected, and a wrapping machine is used to spirally wrap the second insulating layer at a preset overlap rate to form a wrapping layer, and the pre-prepared The sheath material is coated on the outside of the winding layer by an extruder to form an outer sheath, and is solidified by rapid cooling. After cutting, a cable with high strength and high durability is obtained. This process makes an innovative combination in material selection and structural design. The high-strength conductor core ensures the conductive reliability and mechanical strength of the cable. The double-layer insulation structure provides excellent high temperature resistance and electrical insulation performance, and enhances the flexibility and fatigue resistance of the cable. The application of the winding layer effectively reduces the friction between the inner layer and the outer sheath, and extends the service life of the cable. The prepared high-strength cable has good mechanical and electrical properties, and can meet the requirements of industrial robots in high-intensity working environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0017] The structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with this technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantive technical significance. Any structural modification, change in proportion or adjustment of size, without affecting the effects and purposes that can be achieved by the present invention, should still fall within the scope of the technical contents disclosed by the present invention.

[0018] Figure 1 This is one of the flow diagrams of the preparation process of the high-strength cable of the first embodiment; Figure 2 This is the second schematic flow chart of the process for preparing the high-strength cable of the first embodiment. DETAILED DESCRIPTION

[0019] In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below 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.

[0020] In the description of the present invention, it should be understood that the terms "upper", "lower", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. It should be noted that when a component is considered to be "connected" to another component, it may be directly connected to the other component or there may be a centrally arranged component at the same time.

[0021] The technical solution of the present invention is further described below with reference to the accompanying drawings and through specific implementation methods.

[0022] Embodiment 1: Combination Figure 1 to Figure 2 As shown, an embodiment of the present invention provides a preparation process of a high-strength cable for an industrial robot, comprising: Step S1: selecting a high-strength conductor material, performing multiple wire drawing processes on the conductor material to obtain a thin copper wire of a required diameter, and twisting a plurality of thin copper wires according to a preset pitch and direction to form a conductor core; Select high-strength conductor materials, such as high-purity copper alloys containing trace alloying elements, to improve the mechanical strength and fatigue resistance of the conductor. The conductor material is subjected to multiple wire drawing processes to gradually draw it into thin copper wires of the required diameter. The multi-pass wire drawing process can refine the grains and improve the flexibility and strength of the copper wire. Then, multiple thin copper wires are twisted according to the preset pitch and direction to form a conductor core. During the twisting process, the twisting pitch and twisting direction need to be precisely controlled to ensure that the conductor core has good flexibility, conductivity and torsion resistance to meet the use requirements of industrial robots in high-frequency bending and torsional movements.

[0023] Step S2: Select fluoroplastic as the first layer of insulating material, adopt a continuous extrusion process, melt the fluoroplastic and evenly coat it on the conductor core to form the first insulating layer; the fluoroplastic is polytetrafluoroethylene (PTFE), perfluoroethylene propylene (FEP) or soluble polytetrafluoroethylene (PFA).

[0024] Fluoroplastic is selected as the first layer of insulation material, which has excellent high temperature resistance, chemical corrosion resistance and electrical insulation performance. The continuous extrusion process is used to heat and melt the fluoroplastic, and then evenly coat the conductor core to form the first layer of insulation. The extrusion process requires strict control of the extrusion temperature, screw speed and line speed to ensure that the thickness of the insulation layer is uniform and the surface is smooth and defect-free. During cooling and shaping, the insulation layer is quickly solidified through water cooling or air cooling to maintain dimensional stability and electrical performance.

[0025] Step S3: preparing modified thermoplastic elastomer particles, and extruding the modified thermoplastic elastomer particles to coat the first insulating layer to form a second insulating layer; To prepare modified thermoplastic elastomer particles, a thermoplastic elastomer material with a specific formula is selected, and plasticizers, flame retardants, reinforcing fillers and nano additives are added to improve the flexibility, heat resistance, flame retardancy and mechanical strength of the material. The prepared mixture is extruded and granulated by melt blending to obtain modified thermoplastic elastomer particles. Then, these particles are extruded to form a second insulating layer outside the first insulating layer. During extrusion, the extrusion temperature, pressure and speed need to be controlled to ensure the stability of the extrudate and the uniformity of the thickness of the second insulating layer. This layer further enhances the flexibility and bending resistance of the cable to meet the requirements of high-frequency movement of industrial robots.

[0026] Step S4: Select a preset wrapping material, and use a wrapping machine to spirally wrap the wrapping material around the second insulating layer at a preset overlap rate to form a wrapping layer; the wrapping material is a material with a low friction coefficient and high wear resistance, and the wrapping material is a polyimide film, a polytetrafluoroethylene film or a high-strength fiber fabric.

[0027] The function of the wrapping layer is to reduce the friction between the outer sheath and the internal structure, prevent wear caused by bending and torsion, and extend the service life of the cable.

[0028] Step S5: providing a pre-prepared sheath material, and wrapping the sheath material around the wrapping layer through an extruder to form an outer sheath, rapidly solidifying the outer sheath by cooling, and then cutting to obtain a high-strength cable.

[0029] Provide pre-prepared sheath materials, select materials with high wear resistance, oil resistance, chemical corrosion resistance and weather resistance, such as modified polyurethane (PU), thermoplastic polyether ester elastomer (TPEE) or modified polyolefin, and add nano-enhancers and anti-aging agents to improve performance. Add the sheath material to the extruder, control the extrusion temperature, screw speed and extrusion speed to fully plasticize and evenly melt it. Then, the molten sheath material is wrapped around the wrapping layer through the extruder to form an outer sheath. During the extrusion process, it is necessary to ensure that the thickness of the outer sheath is uniform and the surface is smooth and defect-free. Subsequently, the outer sheath is quickly solidified by cooling methods (such as water cooling or air cooling). Finally, the cooled cable is inspected for size and appearance. After ensuring the quality is qualified, it is cut to the required length to produce a high-strength cable that meets the specification requirements.

[0030] The working principle of the present invention is as follows: during processing, a high-strength conductor material, such as a high-strength copper alloy wire, is selected, and multiple wire drawing processes are performed on the wire to obtain a thin copper wire of a desired diameter, and then the wire is twisted according to a preset pitch and direction to form a conductor core with excellent mechanical properties and conductive properties, and a continuous extrusion process is adopted to evenly coat the molten fluoroplastic on the conductor core to form a first insulating layer; modified thermoplastic elastomer particles are prepared, and a second insulating layer is formed outside the first insulating layer through an extrusion process, and a suitable wrapping material is selected, and a wrapping machine is used to spirally wrap the second insulating layer at a preset overlap rate to form a wrapping layer, and the pre-prepared sheath material is An outer sheath is formed by coating the wrapping layer through an extruder, and solidified by rapid cooling. After cutting, a cable with high strength and high durability is obtained. This process makes an innovative combination in material selection and structural design. The high-strength conductor core ensures the conductive reliability and mechanical strength of the cable. The double-layer insulation structure provides excellent high temperature resistance and electrical insulation performance, and enhances the flexibility and fatigue resistance of the cable. The application of the wrapping layer effectively reduces the friction between the inner layer and the outer sheath, and extends the service life of the cable. The prepared high-strength cable has good mechanical and electrical properties, and can meet the requirements of industrial robots in high-intensity working environments.

[0031] In this embodiment, it is specifically explained that step S1 specifically includes: Step S11: selecting a high-strength conductor material, the conductor material being a high-strength copper alloy rod material containing trace alloy elements; the alloy elements include magnesium, tin or zirconium to improve the mechanical strength and fatigue resistance of the conductor; In order to improve the mechanical strength and fatigue resistance of the cable, high-strength copper alloy rods containing trace alloy elements are selected as conductor materials. The added trace alloy elements (such as silver Ag, magnesium Mg, tin Sn, etc.) can refine the copper grain structure, enhance the strength, toughness and oxidation resistance of the material, and maintain excellent conductivity.

[0032] Step S12: performing multiple wire drawing processes on the high-strength copper alloy rod material, using wire drawing equipment, using a wire drawing die made of nano-diamond material, controlling the wire drawing speed to be 300 m / min to 600 m / min, and gradually drawing the copper alloy rod material into a thin copper wire; The selected copper alloy rods are subjected to multiple wire drawing processes using wire drawing equipment. The wire drawing dies are made of nano-diamond material because of their ultra-high hardness and finish, which can reduce die wear and ensure that the copper wire surface is smooth, scratch-free and defect-free during the wire drawing process. The wire drawing speed is controlled between 300 m / min and 600 m / min, which not only improves production efficiency but also avoids copper wire breakage or performance degradation caused by excessive speed. Through multiple wire drawing processes, the diameter of the rod is gradually reduced to make it a thin copper wire that meets the specification requirements. At the same time, the grains are refined, and the mechanical properties and flexibility of the copper wire are improved.

[0033] Step S13: performing continuous annealing treatment on the thin copper wire, controlling the annealing temperature to be 250° C. to 400° C. and the annealing time to be 1 second to 10 seconds, so as to eliminate the internal stress generated during the wire drawing process and enhance the conductivity and flexibility of the thin copper wire.

[0034] Step S14: Twisting the annealed thin copper wires according to a preset pitch and direction, with the twisting method being a multi-layer concentric twisting or a bundle twisting structure, to form a conductor core; wherein the twisting pitch is controlled to be 8 to 16 times the outer diameter of the conductor, and the twisting direction is alternating; The annealed fine copper wire is combined into a conductor core according to a specific twisting process. The twisting method uses multi-layer concentric twisting or bundle twisting structure. Multi-layer concentric twisting can improve the roundness and flexibility of the conductor core, and the bundle twisting structure increases the softness and fatigue resistance of the conductor. The twisting pitch (i.e. the length required to complete a circle of twisting) is controlled between 8 and 16 times the outer diameter of the conductor. A smaller pitch improves flexibility, and a larger pitch enhances stability. The twisting direction is changed alternately (alternating between positive twisting and reverse twisting), which can offset the stress generated during the twisting process, prevent the conductor core from twisting and deformation, and improve the mechanical properties and service life of the cable.

[0035] Step S15: The conductor core is cleaned and dried by ultrasonic cleaning to remove oil, oxides and impurities on the surface of the conductor core. In addition, a nano-scale anti-oxidation protective film can be coated on the surface in an inert gas protection environment to improve the adhesion of the subsequent insulation layer and the anti-oxidation performance of the conductor.

[0036] In this embodiment, it is specifically described that step S2 specifically includes: Step S21: Select fluoroplastic as the first layer of insulating material, the fluoroplastic is selected from any one of polytetrafluoroethylene, soluble polytetrafluoroethylene or perfluoroethylene propylene; according to the use environment and performance requirements of the cable, perfluoroethylene propylene (FEP) is preferred to take into account both high temperature resistance and good mechanical properties; 0.5% to 2% of nano-aluminum oxide (Al2O3) or nano-silicon oxide (SiO2) is added to the fluoroplastic as a filler to improve the mechanical strength and wear resistance of the insulating layer.

[0037] Step S22: preheating the conductor core at a temperature of 80° C. to 120° C. for a time of 1 minute to 3 minutes to remove moisture and impurities on the conductor surface and improve the adhesion of the fluoroplastic insulation layer.

[0038] Step S23: Drying the fluoroplastics, drying the fluoroplastics insulating material at a temperature of 120° C. to 150° C. for 4 to 8 hours; ensuring that the moisture content of the material is less than 0.02% to prevent bubbles and defects during extrusion.

[0039] Step S24: setting extrusion process parameters, adding the dried fluoroplastic particles into the hopper of the screw extruder, and setting the temperature of each temperature zone of the extruder to: Barrel zone temperature: 260°C to 300°C; Screw zone temperature: 280℃ to 320℃; Head zone temperature: 300℃ to 340℃; At the same time, the screw speed of the extruder is set to 15 rpm to 30 rpm, and the extrusion speed is controlled between 5 m / min and 15 m / min to ensure the stable flow and uniform extrusion of the molten fluoroplastic; Step S25: Perform continuous extrusion coating, pass the preheated conductor core through the die core of the extruder, and extrude the molten fluoroplastic from the die sleeve and evenly coat the outer surface of the conductor core to form the first insulating layer; by adjusting the gap between the die core and the die sleeve, control the thickness of the insulating layer to be between 0.2 mm and 0.5 mm to ensure the thickness uniformity and roundness of the insulating layer.

[0040] Step S26: Cooling and shaping, cooling the conductor core coated with the fluoroplastic insulation layer through a cooling water tank, the temperature of the cooling water is controlled between 10° C. and 25° C. The cooling length is 2 meters to 5 meters, so that the fluoroplastic insulation layer is quickly solidified to prevent internal stress and deformation.

[0041] Surface inspection and pretreatment: perform surface inspection on the cooled insulated wire to ensure that there are no defects such as bubbles, impurities, scratches and burrs. At the same time, online spark detection can be performed on the insulation layer with a test voltage of 5kV to 10kV to ensure that the integrity of the insulation layer and the electrical performance meet the requirements.

[0042] As a preferred embodiment of this embodiment, the modified thermoplastic elastomer particles include the following components: 20 to 30 parts of the elastomer resin, which is a thermoplastic polyolefin elastomer or a thermoplastic polyurethane and has excellent flexibility and fatigue resistance.

[0043] 20 parts of functionalized elastomer, which is a polyolefin elastomer or elastomer copolymer grafted with maleic anhydride; used to improve the compatibility with other components.

[0044] 5-10 parts of stabilizer, zinc oxide, hindered phenol antioxidant or hydroxylamine stabilizer are selected to enhance the material's resistance to heat and oxygen aging.

[0045] 5 to 15 parts of plasticizer, using environmentally friendly plasticizers such as citrate or epoxidized vegetable oil; improve the flexibility and low-temperature performance of the material.

[0046] 5 to 10 parts of reinforcing filler, such as glass beads, modified kaolin or calcium carbonate, are used to improve the mechanical strength and dimensional stability of the material.

[0047] 10-20 parts of flame retardant, using phosphorus nitrogen series or intumescent flame retardant; providing good flame retardant performance and environmentally friendly halogen-free.

[0048] 0.5 to 2 parts of nano additives, such as nano titanium dioxide, graphene or carbon nanotubes, are used to enhance the mechanical properties and thermal conductivity of the material.

[0049] In this embodiment, it is specifically described that step S4 specifically includes: Step S41: selecting a wrapping material, wherein the thickness of the wrapping material is 0.02 mm to 0.05 mm, and the wrapping material is a polyimide film, a polytetrafluoroethylene film or a high-strength fiber fabric; The fiber material or film material with high strength and low friction coefficient is selected. The thickness of the wrapping material is 0.02 mm to 0.05 mm and the width is 5 mm to 20 mm. It has excellent wear resistance, heat resistance and chemical corrosion resistance.

[0050] Step S42: pre-treating the wrapping material by means of tension adjustment and surface treatment; Tension adjustment: Unfold the wrapping material at a constant tension to eliminate internal stress and prevent wrinkles or loosening during wrapping; Surface treatment: Plasma surface activation treatment or coating of low friction coefficient lubricant, such as molybdenum disulfide (MoS2) or polytetrafluoroethylene emulsion, on the wrapping material to reduce the friction coefficient between the wrapping layer and other layers.

[0051] Step S43: setting wrapping process parameters according to cable specifications and performance requirements.

[0052] Wrapping angle: controlled between 20° and 45° to ensure the overlap rate and uniformity of the wrapping layer; Overlap rate: set to 30% to 70%, preferably 50%, to enhance the integrity and mechanical strength of the wrapping layer; Wrapping tension: Adjust to 5N to 15N to ensure that the wrapping material fits tightly without damaging the second insulation layer; Wrapping speed: set to 20m / min to 60m / min, select the appropriate speed according to production efficiency and product quality requirements.

[0053] Step S44: performing a wrapping operation according to the set wrapping process parameters, using a multi-head high-speed wrapping machine to wrap the pre-treated wrapping material around the second insulating layer at a preset overlap rate and spiral angle; The specific steps are: Cable introduction: introduce the prepared cables from the cable inlet of the taping machine to ensure constant cable tension; Synchronous control: The electrical control system is used to synchronously adjust the supply speed of the wrapping material and the forward speed of the cable to ensure the uniformity of the wrapping layer; Wrapping path: According to the set wrapping angle, the wrapping material is wrapped on the outer surface of the cable in a spiral manner, and the overlapping parts are uniform.

[0054] Step S45: After wrapping is completed, the wrapping layer is heat-set to stabilize the structure and size of the wrapping layer. The heat-setting temperature is controlled at 80°C to 120°C. Treatment time: Keep for 1 to 5 minutes to rearrange the molecular chains of the wrapping material and increase the interlayer adhesion and stability; Cooling method: After heat setting, natural cooling or forced air cooling is used to reduce the cable temperature to room temperature to prevent deformation caused by thermal stress.

[0055] Step S46: Quality inspection of the wrapping layer, performing quality inspection on the cables that have completed wrapping and heat setting treatment, the quality inspection includes appearance inspection and size measurement.

[0056] Appearance inspection: Check the surface of the wrapping layer to ensure there are no wrinkles, bubbles, damage or contamination; Dimension measurement: Use a laser diameter gauge to measure the cable outer diameter and the thickness of the sheath, with a tolerance of ±0.1 mm.

[0057] In this embodiment, it is specifically described that step S5 specifically includes: Step S51: providing a sheath material; the sheath material is a material with high wear resistance, oil resistance, chemical corrosion resistance and weather resistance, and is selected from modified polyurethane, thermoplastic polyether ester elastomer (TPEE) or modified polyolefin.

[0058] Step S52: adding the sheath material into the extruder, and setting the temperature and pressure parameters of the extruder so that the sheath material is fully plasticized into a molten state in the extruder; Add the selected jacket material into the hopper of the extruder in the form of granules or powder. In order to ensure that the jacket material is fully plasticized in the extruder, the process parameters of the extruder need to be set reasonably. In general, the temperature setting of the extruder should be adjusted according to the characteristics of the jacket material, such as the barrel temperature is set to 150℃ to 190℃, and the head temperature is set to 160℃ to 200℃. At the same time, adjust the screw speed and back pressure of the extruder so that the jacket material is evenly heated and fully melted during the extrusion process to achieve a good plasticization effect.

[0059] Step S53: the cable passes through the center of the die core of the extruder, and the molten sheath material is evenly extruded from the die sleeve and coated on the outer side of the wrapping layer to form an outer sheath; The processed cable (with a wrapping layer formed) is introduced into the center of the die core of the extruder to keep the cable tension stable. The molten sheath material is evenly extruded from the die sleeve and coated on the outside of the cable wrapping layer to form an outer sheath. In order to ensure that the thickness of the outer sheath is uniform and the surface is smooth, the extrusion speed of the extruder, the die gap and the pulling speed of the cable need to be precisely controlled to ensure that the sheath material is evenly coated on the outside of the cable without defects such as bubbles, stretching or shrinkage.

[0060] Step S54: the outer sheath is rapidly solidified by cooling, and the size and appearance of the cable after cooling are inspected; the cooling method includes water cooling or air cooling, and the cooling temperature is controlled at room temperature to 25°C; It needs to be cooled to solidify quickly. Common cooling methods include water cooling and air cooling. Water cooling usually uses a cooling water tank, and the water temperature is controlled at room temperature to 25°C. When the cable passes through the water tank, the outer sheath is quickly cooled and shaped. Air cooling uses a cold air blower or natural ventilation to remove the heat from the cable surface. After cooling, the cable needs to be inspected for size and appearance, including measuring the outer diameter of the cable, the thickness of the sheath, and checking whether the sheath surface is smooth, free of bubbles, impurities, and mechanical damage, to ensure that the quality of the cable meets the requirements.

[0061] Step S56: cutting the cable according to work requirements to obtain a high-strength cable that meets specification requirements.

[0062] After the cable is cooled and quality tested, it is cut according to the actual work requirements. The cutting length can be based on customer requirements or standard lengths (such as 100 meters, 500 meters, 1000 meters, etc.). When cutting, professional wire cutting equipment is required to ensure that the cut is smooth and does not damage the internal structure of the cable. The cut cables can be coiled or wound for easy storage, transportation and subsequent use.

[0063] Embodiment 2: The present invention further provides a high-strength cable for an industrial robot, which is prepared by the preparation process of the high-strength cable for an industrial robot as in Example 1. The high-strength cable comprises: The conductor core is formed by twisting a plurality of thin copper wires according to a preset pitch and direction; during the twisting process, the twisting pitch and twisting direction are controlled so that the conductor core has good flexibility and fatigue resistance.

[0064] The first insulating layer is coated on the outside of the conductor core and is made of fluoroplastic using a continuous extrusion process; the first insulating layer provides reliable electrical insulation and environmental protection for the conductor core, prevents the external environment from affecting the conductor core, and extends the service life of the cable.

[0065] The second insulation layer is formed by extruding modified thermoplastic elastomer particles over the first insulation layer; the second insulation layer has excellent flexibility, bending resistance and wear resistance, which can effectively improve the mechanical properties of the cable under frequent bending and complex movement environments. The second insulation layer and the first insulation layer together form a double-layer insulation structure, providing higher electrical safety and mechanical protection.

[0066] The wrapping layer is formed by spirally wrapping the wrapping material on the outside of the second insulating layer at a preset overlap rate; the function of the wrapping layer is to reduce the friction between the outer sheath and the inner structure, prevent the wear of the internal structure of the cable during bending and torsion, and enhance the fatigue resistance and bending resistance of the cable.

[0067] The outer sheath is formed by coating the outer layer of the winding layer through an extruder, and then the outer sheath is quickly solidified by cooling; the outer sheath provides comprehensive mechanical protection and environmental barrier for the cable, and can resist external mechanical damage, chemical corrosion and climate influences, ensuring long-term and reliable operation of the cable in harsh industrial environments.

[0068] As described above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features thereof may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A process for preparing a high-strength cable for an industrial robot, characterized in that: include: Step S1: selecting a high-strength conductor material, performing multiple wire drawing processes on the conductor material to obtain a thin copper wire of a required diameter, and twisting a plurality of the thin copper wires according to a preset pitch and direction to form a conductor core; Step S2: selecting fluoroplastic as the first layer of insulating material, using a continuous extrusion process to melt the fluoroplastic and evenly coat it on the conductor core to form a first insulating layer; Step S3: preparing modified thermoplastic elastomer particles, and coating the modified thermoplastic elastomer particles on the first insulating layer to form a second insulating layer through an extrusion process; Step S4: selecting a preset wrapping material, and using a wrapping machine to spirally wrap the wrapping material around the second insulating layer at a preset overlap rate to form a wrapping layer; Step S5: providing a pre-prepared sheath material, and wrapping the sheath material around the wrapping layer through an extruder to form an outer sheath, rapidly solidifying the outer sheath by cooling, and then cutting to obtain a high-strength cable.

2. The process for preparing a high-strength cable for an industrial robot according to claim 1, characterized in that: The step S1 specifically includes: Step S11: selecting a high-strength conductor material, wherein the conductor material is a high-strength copper alloy rod material containing trace alloy elements; Step S12: performing multiple wire drawing processes on the high-strength copper alloy rod material, using wire drawing equipment, using a wire drawing die made of nano-diamond material, controlling the wire drawing speed to be 300 m / min to 600 m / min, and gradually drawing the copper alloy rod material into a thin copper wire; Step S13: performing continuous annealing treatment on the thin copper wire, controlling the annealing temperature to be 250° C. to 400° C.; Step S14: Twisting the annealed thin copper wires according to a preset pitch and direction in a multi-layer concentric twisting or bundle twisting structure to form a conductor core.

3. The process for preparing a high-strength cable for an industrial robot according to claim 2, characterized in that: After step S14, the following steps are also included: Step S15: The conductor core is cleaned and dried by ultrasonic cleaning.

4. The preparation process of the high-strength cable for industrial robots according to claim 1, characterized in that: The step S2 specifically includes: Step S21: selecting fluoroplastic as the first layer of insulating material, wherein the fluoroplastic is selected from any one of polytetrafluoroethylene, soluble polytetrafluoroethylene or perfluoroethylene propylene; Step S22: preheating the conductor core at a temperature of 80° C. to 120° C. for a time of 1 minute to 3 minutes; Step S23: drying the fluoroplastic insulating material at a temperature of 120° C. to 150° C. for 4 to 8 hours.

5. The process for preparing a high-strength cable for an industrial robot according to claim 4, characterized in that: After step S23, the following steps are also included: Step S24: setting extrusion process parameters, adding the dried fluoroplastic particles into the hopper of the screw extruder, and setting the temperature of each temperature zone of the extruder to: Barrel zone temperature: 260°C to 300°C; Screw zone temperature: 280℃ to 320℃; Head zone temperature: 300℃ to 340℃; At the same time, the screw speed of the extruder is set to 15 rpm to 30 rpm, and the extrusion speed is controlled between 5 m / min and 15 m / min; Step S25: performing continuous extrusion coating, passing the preheated conductor core through the die core of the extruder, and extruding the molten fluoroplastic from the die core and uniformly coating the outer surface of the conductor core to form a first insulating layer; Step S26: Cooling and shaping, cooling the conductor core coated with the fluoroplastic insulation layer through a cooling water tank, and controlling the temperature of the cooling water between 10°C and 25°C.

6. The process for preparing a high-strength cable for an industrial robot according to claim 1, characterized in that: The modified thermoplastic elastomer particles include the following components: 20 to 30 parts of an elastomer resin, wherein the elastomer resin is a thermoplastic polyolefin elastomer or a thermoplastic polyurethane; 20 parts of a functionalized elastomer, wherein the functionalized elastomer is a polyolefin elastomer or an elastomer copolymer grafted with maleic anhydride; 5-10 parts of stabilizer, zinc oxide, hindered phenol antioxidant or hydroxylamine stabilizer; 5-15 parts of plasticizer, using environmentally friendly plasticizers such as citric acid esters or epoxidized vegetable oils; 5-10 parts of reinforcing filler, glass microspheres, modified kaolin or calcium carbonate; 10-20 parts of flame retardant, using phosphorus nitrogen series or expansion type flame retardant; 0.5 to 2 parts of nano additives, such as nano titanium dioxide, graphene or carbon nanotubes, are used to enhance the mechanical properties and thermal conductivity of the material.

7. The process for preparing a high-strength cable for an industrial robot according to claim 1, characterized in that: The step S4 specifically includes: Step S41: selecting a wrapping material, wherein the thickness of the wrapping material is 0.02 mm to 0.05 mm, and the wrapping material is a polyimide film, a polytetrafluoroethylene film or a high-strength fiber fabric; Step S42: pre-treating the wrapping material by means of tension adjustment and surface treatment; Step S43: setting wrapping process parameters according to cable specifications and performance requirements.

8. The process for preparing a high-strength cable for an industrial robot according to claim 7, characterized in that: After step S43, the following steps are further included: Step S44: performing a wrapping operation according to set wrapping process parameters, using a multi-head high-speed wrapping machine to wrap the pre-treated wrapping material around the second insulating layer at a preset overlap rate and spiral angle; Step S45: After wrapping is completed, the wrapping layer is heat-set to stabilize the structure and size of the wrapping layer. The heat-setting temperature is controlled at 80°C to 120°C. Step S46: Quality inspection of the wrapping layer, performing quality inspection on the cables that have completed wrapping and heat setting treatment, wherein the quality inspection includes appearance inspection and size measurement.

9. The process for preparing a high-strength cable for an industrial robot according to claim 1, characterized in that: The step S5 specifically includes: Step S51: providing sheath material; Step S52: adding the sheath material into an extruder, and setting the temperature and pressure parameters of the extruder so that the sheath material is fully plasticized into a molten state in the extruder; Step S53: the cable passes through the center of the die core of the extruder, and the molten sheath material is evenly extruded from the die sleeve and coated outside the wrapping layer to form an outer sheath; Step S54: rapidly solidifying the outer sheath by cooling, and performing size and appearance inspection on the cooled cable; the cooling method includes water cooling or air cooling, and the cooling temperature is controlled at room temperature to 25° C.; Step S56: cutting the cable according to work requirements to obtain a high-strength cable that meets specification requirements.

10. A high-strength cable for an industrial robot, characterized in that: The high-strength cable is manufactured by the preparation process of the high-strength cable for industrial robots according to any one of claims 1 to 9, wherein the high-strength cable comprises: The conductor core is formed by twisting a number of thin copper wires according to a preset pitch and direction; A first insulating layer, covering the conductor core, is made of fluoroplastics by continuous extrusion process; The second insulating layer is formed by coating the first insulating layer with modified thermoplastic elastomer particles by extrusion process; A wrapping layer is formed by spirally wrapping a wrapping material at a preset overlap rate outside the second insulating layer; The outer sheath is formed by coating the outer cladding layer with an extruder, and then the outer sheath is rapidly solidified by cooling.

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