Preparation method and system of wire and cable insulating layer

Abstract

The invention relates to the technical field of cable preparation, and particularly provides a preparation method and system of a wire and cable insulation layer, and the method comprises the steps: carrying out the wire drawing and extrusion of metal, obtaining metal wires, stranding a plurality of metal wires in opposite directions, obtaining a stranded conductor, and carrying out the compound stranding of a plurality of stranded conductors, and obtaining a cable conductor; wrapping a cable conductor with an insulating layer to obtain a wire core, collecting the real-time thickness H0 of the insulating layer, comparing the real-time thickness H0 with a preset thickness threshold Hmin, and judging whether the extrusion speed is adjusted or not; further detecting whether bubbles exist in the insulating layer, and adjusting the extrusion pressure when the bubbles exist; and after the final wire core is obtained, an isolating layer is woven by using annealed soft copper wires outside the wire core, and a heat-resistant mixing agent is added outside the isolating layer and is coated with a protective jacket to prepare the cable. According to the method, through automation and real-time quality control, the cable preparation process is more stable and controllable.

Description

Technical Field

[0001] The present invention relates to the technical field of cable preparation, and in particular to a method for preparing an insulating layer of a wire or cable. Background Art

[0002] Cable insulation is an important component in cable structure. Its main function is to provide insulation protection for cable conductors to prevent current leakage, arc discharge and other power problems. The insulation layer is usually made of insulating materials, which have high insulation properties and can effectively isolate electrical conductors to ensure the transmission of electrical signals and the delivery of electrical energy.

[0003] The main task of the insulation layer is to provide reliable electrical insulation to prevent current leakage, arc discharge and other power problems. Currently, in the cable manufacturing process, the insulation thickness is usually measured after the cable is prepared. The lack of real-time adaptive adjustment methods during the production process may lead to resource waste and difficulty in controlling product quality. If the thickness of the insulation layer is too low or there are bubbles, it will increase the risk of leakage in the cable system, which may cause danger to personnel and equipment.

[0004] Therefore, it is necessary to design a method and system for preparing the insulation layer of wires and cables to solve the problems existing in current cable production. Summary of the invention

[0005] In view of this, the present invention proposes a method and system for preparing the insulation layer of wires and cables, aiming to solve the problems of lack of adaptive adjustment in the current cable preparation process, delayed decision-making that easily leads to increased production costs, and low product quality consistency.

[0006] In one aspect, the present invention provides a method for preparing an insulating layer of a wire and cable, comprising: Drawing and extruding metal to obtain metal wire, twisting multiple strands of the metal wire in opposite directions to obtain a twisted conductor, and re-twisting the multiple strands of the twisted conductor to obtain a cable conductor; Based on the extruder wrapping the insulating layer outside the cable conductor to obtain the wire core, collecting image data of the insulating layer, obtaining the real-time thickness H0 of the insulating layer according to the image data, comparing the real-time thickness H0 with a preset thickness threshold Hmin, and judging whether to adjust the extrusion speed of the extruder to extrude the insulating layer according to the comparison result; When H0<0.9Hmin, it is determined that the extrusion speed is adjusted according to the thickness difference △H=Hmin-H0 between the real-time thickness H0 and the preset thickness threshold Hmin; When 0.9Hmin≤H0≤Hmin, it is determined that the extrusion speed is not adjusted; After determining whether the extrusion speed is adjusted and the thickness of the insulating layer meets the requirement, detecting whether there are bubbles in the insulating layer based on X-rays, and adjusting the extrusion pressure of the extruder when it is determined that there are bubbles in the insulating layer; After determining whether to adjust the extrusion pressure and obtain the final wire core, an isolation layer is woven outside the wire core using annealed soft copper wire, and a heat-resistant mixture is added outside the isolation layer and a protective jacket is coated to form a cable.

[0007] Further, when H0<0.9Hmin, it is determined that the thickness difference △H=Hmin-H0 between the real-time thickness H0 and the preset thickness threshold Hmin is adjusted, including: Preset a first preset thickness difference △H1, a second preset thickness difference △H2 and a third preset thickness difference △H3, and △H1<△H2<△H3; preset a first preset speed adjustment coefficient A1, a second preset speed adjustment coefficient A2 and a third preset speed adjustment coefficient A3, and A1<A2<A3; select a speed adjustment coefficient according to the size relationship between the thickness difference △H and each preset thickness difference to adjust the extrusion speed V0 of the extruder; When △H1≤△H<△H2, the third preset speed adjustment coefficient A3 is selected to adjust the extrusion speed V0 of the extruder, and the insulating layer is extruded at the adjusted extrusion speed V0·A3; When △H2≤△H<△H3, the second preset speed adjustment coefficient A2 is selected to adjust the extrusion speed V0 of the extruder, and the insulating layer is extruded at the adjusted extrusion speed V0·A2; When ΔH3≤ΔH, the first preset speed adjustment coefficient A1 is selected to adjust the extrusion speed V0 of the extruder, and the insulating layer is extruded at the adjusted extrusion speed V0·A1.

[0008] Further, when it is determined that the extrusion speed is adjusted, and the i-th preset speed adjustment coefficient is selected to adjust the extrusion speed V0, after obtaining the adjusted extrusion speed V0·Ai, i=1, 2, 3, it also includes: Collect image information of the insulating layer after the speed adjustment, obtain thickness data Hh0 of the insulating layer after the speed adjustment, compare the thickness data Hh0 of the insulating layer after the speed adjustment with a preset thickness threshold Hmin, and determine whether the thickness meets the requirement according to the comparison result; When Hh0<0.9Hmin, it is determined that the thickness data Hh0 of the insulating layer after the speed adjustment does not meet the requirement, and the extrusion temperature W0 of the extruder is collected to determine whether to adjust the extrusion temperature W0; When 0.9Hmin≤H0≤Hmin, it is determined that the thickness data Hh0 of the insulating layer after speed adjustment meets the requirement.

[0009] Further, when it is determined that the thickness data Hh0 of the insulating layer after the speed adjustment does not meet the requirement, the extrusion temperature W0 of the extruder is collected, and it is determined whether to adjust the extrusion temperature W0, including: Comparing the extrusion temperature W0 with a preset extrusion temperature threshold Wmax, and determining whether to adjust the extrusion temperature W0 according to the comparison result; When W0>Wmax, it is determined that the heating power P0 of the extruder is adjusted according to the magnitude relationship between the extrusion temperature W0 and the extrusion temperature threshold Wmax; When W0≤Wmax, it is determined that the extrusion temperature W0 does not need to be further adjusted, and an early warning is issued.

[0010] Further, when it is determined that the heating power P0 of the extruder is adjusted according to the magnitude relationship between the extrusion temperature W0 and the extrusion temperature threshold Wmax, it includes: Obtain a temperature difference △W=W0-Wmax between the extrusion temperature W0 and the set extrusion temperature threshold Wmax, pre-set a first preset temperature difference △W1, a second preset temperature difference △W2 and a third preset temperature difference △W3, and △W1<△W2<△W3; pre-set a first preset power adjustment coefficient B1, a second preset power adjustment coefficient B2 and a third preset power adjustment coefficient B3, and B1<B2<B3; select a power adjustment coefficient according to the size relationship between the temperature difference △W and each preset temperature difference to adjust the heating power P0, and heat with the adjusted heating power; When △W1≤△W<△W2, the third preset power adjustment coefficient B3 is selected to adjust the heating power P0 to obtain the adjusted heating power P0·B3; When △W2≤△W<△W3, the second preset power adjustment coefficient B2 is selected to adjust the heating power P0 to obtain the adjusted heating power P0·B2; When ΔW3≤ΔW, the first preset power adjustment coefficient B1 is selected to adjust the heating power P0 to obtain the adjusted heating power P0·B1.

[0011] Further, when it is determined that the heating power P0 is to be adjusted, and the i-th preset power adjustment coefficient Bi is selected to adjust the heating power P0, after obtaining the adjusted heating power P0·Bi, i=1, 2, 3, it also includes: The ambient temperature T is collected, and the ambient temperature change rate Tv is obtained according to the ambient temperature T. The temperature change rate Tv is calculated by the following formula: ; in, represents the ambient temperature at time t; represents the ambient temperature at time t-1; Presetting the ambient temperature change rate Tvmax, comparing the ambient temperature change rate Tv with the ambient temperature change rate Tvmax, and judging whether to make a secondary adjustment to the adjusted heating power P0·Bi according to the comparison result; When Tv>Tvmax, it is determined that the adjusted heating power P0·Bi is to be adjusted twice; When 0<Tv≤Tvmax, it is determined that the adjusted heating power P0·Bi is not to be adjusted a second time.

[0012] Further, when it is determined to make a secondary adjustment to the adjusted heating power P0·Bi, it includes: A first preset temperature change rate Tv1 and a second preset temperature change rate Tv2 are preset, and Tvmax<Tv1<Tv2, and a power adjustment coefficient is selected according to the magnitude relationship between the ambient temperature change rate Tv and each preset ambient temperature change rate to perform secondary adjustment on the adjusted heating power P0·Bi, and the heating power after secondary adjustment is operated; When Tvmax<Tv≤Tv1, the third preset power adjustment coefficient B3 is selected to perform secondary adjustment on the adjusted heating power P0·Bi to obtain the secondary adjusted heating power P0·Bi·B3; When Tv1<Tv≤Tv2, the second preset power adjustment coefficient B2 is selected to perform secondary adjustment on the adjusted heating power P0·Bi to obtain the secondary adjusted heating power P0·Bi·B2; When Tv2<Tv, the first preset power adjustment coefficient B1 is selected to perform a second adjustment on the adjusted heating power P0·Bi to obtain the second adjusted heating power P0·Bi·B1.

[0013] Further, based on X-ray detection, whether there are bubbles in the insulating layer, when it is determined that there are bubbles in the insulating layer, the extrusion pressure of the extruder is adjusted, including: Collecting the bubble content ratio E0 in the insulating layer, comparing the bubble content ratio E0 with a preset content threshold Emax, and determining whether to adjust the extrusion pressure of the extruder according to the comparison result; When E0>Emax, it is determined that the extrusion pressure of the extruder is adjusted; When E0≤Emax, it is determined that the extrusion pressure of the extruder is not adjusted.

[0014] Further, when it is determined that the extrusion pressure of the extruder is to be adjusted, it includes: Preset a first preset pressure adjustment coefficient C1, a second preset pressure adjustment coefficient C2 and a third preset pressure adjustment coefficient C3, and C1<C2<C3; preset a first preset bubble content ratio E1 and a second preset bubble content ratio E2, and Emax<E1<E2; select an adjustment coefficient according to the relationship between the bubble content ratio E0 and each preset bubble content ratio to adjust the extrusion pressure Y0 of the extruder, and complete the wire core production with the adjusted extrusion pressure; When Emax<E0≤E1, the first preset pressure adjustment coefficient C1 is selected to adjust the extrusion pressure Y0 of the extruder to obtain the adjusted extrusion pressure Y0·C1; When E1<E0≤E2, the second preset pressure adjustment coefficient C2 is selected to adjust the extrusion pressure Y0 of the extruder to obtain the adjusted extrusion pressure Y0·C2; When E2<E0, the third preset pressure adjustment coefficient C3 is selected to adjust the extrusion pressure Y0 of the extruder to obtain the adjusted extrusion pressure Y0·C3.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: by collecting image data of the insulating layer and comparing the actual thickness with the preset thickness threshold, it is possible to immediately detect whether the thickness of the insulating layer meets the requirements during the preparation process, thereby reducing resource waste and improving the efficiency of quality control. When there is a gap between the real-time thickness H0 and the preset thickness threshold Hmin, the extrusion speed is automatically adjusted to ensure that the thickness of the insulating layer meets the requirements. The insulation layer thickness is prevented from being too low, thereby reducing the risk of leakage. X-ray detection is introduced to detect whether there are bubbles in the insulating layer during the preparation process. If bubbles are found, the extrusion pressure of the extruder is automatically adjusted to eliminate the bubble problem, thereby improving the reliability of the cable. Through automation and real-time quality control, the dependence on workers' operating experience is reduced, making the cable preparation process more stable and controllable.

[0016] On the other hand, the present invention also provides a system for preparing an insulation layer of a wire and cable, comprising: A twisting unit is configured to draw and extrude metal to obtain metal wires, twist a plurality of strands of the metal wires in opposite directions to obtain a twisted conductor, and re-twist the plurality of strands of the twisted conductors to obtain a cable conductor; A collection unit is configured to obtain a core by wrapping an insulating layer outside the cable conductor by an extruder, collect image data of the insulating layer, obtain a real-time thickness H0 of the insulating layer according to the image data, compare the real-time thickness H0 with a preset thickness threshold Hmin, and determine whether to adjust an extrusion speed of the extruder to extrude the insulating layer according to the comparison result; When H0<0.9Hmin, it is determined that the extrusion speed is adjusted according to the thickness difference △H=Hmin-H0 between the real-time thickness H0 and the preset thickness threshold Hmin; When 0.9Hmin≤H0≤Hmin, it is determined that the extrusion speed is not adjusted; The detection unit is configured to, after determining whether the extrusion speed is adjusted and the thickness of the insulating layer meets the requirement, the acquisition unit detects whether there are bubbles in the insulating layer based on X-rays, and adjusts the extrusion pressure of the extruder when it is determined that there are bubbles in the insulating layer; The coating unit is configured to, after determining whether to adjust the extrusion pressure and obtain the final wire core, weave an isolation layer with annealed soft copper wire outside the wire core, add a heat-resistant mixture outside the isolation layer and coat it with a protective jacket to form a cable.

[0017] It is understandable that the above-mentioned method and system for preparing the insulation layer of the wire and cable have the same beneficial effects, which will not be repeated here. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Various other advantages and benefits will become apparent to those of ordinary skill in the art by reading the detailed description of the preferred embodiments below. The accompanying drawings are only for the purpose of illustrating the preferred embodiments and are not to be considered as limiting the present invention. Moreover, the same reference symbols are used throughout the accompanying drawings to represent the same components. In the accompanying drawings: Figure 1 A flow chart of a method for preparing an insulating layer of a wire and cable provided in an embodiment of the present invention; Figure 2 A structural block diagram of a system for preparing an insulating layer of a wire or cable provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0019] Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. Although exemplary embodiments of the present disclosure are shown in the accompanying drawings, it should be understood that the present disclosure can be implemented in various forms and should not be limited by the embodiments described herein. On the contrary, these embodiments are provided in order to enable a more thorough understanding of the present disclosure and to fully convey the scope of the present disclosure to those skilled in the art. It should be noted that, in the absence of conflict, the embodiments of the present invention and the features described in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in combination with the embodiments.

[0020] See also Figure 1 As shown, this embodiment provides a method for preparing an insulating layer of a wire and cable, comprising: Step S100: drawing and extruding metal to obtain metal wires, twisting multiple strands of metal wires in opposite directions to obtain a twisted conductor, and re-twisting the multiple twisted conductors to obtain a cable conductor.

[0021] Step S200: Obtain a wire core by wrapping an insulating layer around the cable conductor using an extruder, collect image data of the insulating layer, obtain a real-time thickness H0 of the insulating layer based on the image data, compare the real-time thickness H0 with a preset thickness threshold Hmin, and determine whether to adjust the extrusion speed of the insulating layer extruded by the extruder based on the comparison result.

[0022] When H0<0.9Hmin, it is determined that the extrusion speed is adjusted according to the thickness difference △H=Hmin-H0 between the real-time thickness H0 and the preset thickness threshold Hmin. When 0.9Hmin≤H0≤Hmin, it is determined that the extrusion speed is not adjusted.

[0023] Step S300: after determining whether the extrusion speed is adjusted and the thickness of the insulating layer meets the requirement, detecting whether there are bubbles in the insulating layer based on X-rays, and adjusting the extrusion pressure of the extruder when it is determined that there are bubbles in the insulating layer.

[0024] Step S400: After determining whether to adjust the extrusion pressure and obtain the final wire core, an isolation layer is woven outside the wire core using annealed soft copper wire, a heat-resistant mixture is added outside the isolation layer, and a protective jacket is coated to form a cable.

[0025] Specifically, the metal is drawn and extruded, and then multiple strands of metal wire are twisted into a stranded conductor, and then the stranded conductor is twisted again to obtain a cable conductor. After the insulation layer is wrapped around the cable conductor, the core is obtained, and the image data of the insulation layer is collected and the real-time thickness is compared with the preset thickness threshold. When collecting the image data of the insulation layer, a high-resolution camera can be used to shoot the surface of the cable, and the overall thickness can be determined by using image edge recognition. The thickness of the insulation layer is obtained based on the overall thickness and the thickness of the cable conductor. Since the metal wire stranded conductor is solid and tightly twisted, the size of the stranded conductor and the cable conductor is relatively fixed. The camera is usually installed near the extruder, and the surface of the insulation layer of the cable is monitored in real time through an imaging sensor. Or a CCD camera and parallel light are used to obtain the overall thickness. The parallel light illuminates the core. Since the core blocks the CCD surface to form a light spot, the overall thickness can be collected according to the light spot width. If the thickness of the insulation layer does not meet the requirements, the extrusion speed is automatically adjusted to ensure that the thickness of the insulation layer meets the standard. Too low insulation layer thickness is avoided, thereby reducing the risk of leakage. Preprocessing the image includes removing noise, enhancing contrast, smoothing the image, or calibrating to ensure good image quality. Edge detection algorithms detect discontinuities in brightness or color in the image, thereby identifying the outer boundaries of the insulation layer. Image processing tools are used to measure the distance between these boundaries. By measuring the distance between the outer boundaries of the insulation layer in the image, the thickness of the insulation layer can be calculated. The insulation layer is detected by X-rays to determine whether there are bubbles. If bubbles are detected, the extrusion pressure of the extruder is adjusted to eliminate the bubble problem. The X-ray source is turned on to generate X-ray radiation. These X-rays enter the interior through the cable insulation layer and are absorbed or scattered when passing through the insulation layer. On the opposite side of the X-ray source, an X-ray detector is installed. The detector is used to measure the intensity of the X-rays during the transmission process. When the X-rays pass through the insulation layer, bubbles or other inhomogeneities will cause the X-rays to be absorbed or scattered, which will affect the intensity of the X-rays received by the detector. The received X-ray intensity data is used to generate an image, usually an X-ray fluoroscopy or X-ray CT scan image. This image will show the structure inside the insulation layer, including the location and size of any bubbles. The generated image is transmitted to a computer system, analyzed and processed. The presence of bubbles in the insulation layer, as well as their size and distribution, can be detected.

[0026] It can be understood that based on image data acquisition and real-time thickness measurement, the thickness of the cable insulation layer is monitored in real time. If the thickness of the insulation layer does not meet the requirements, the extrusion conditions are adjusted to ensure that the standard is met. The production of insulation layers with unqualified thickness is avoided, and the risk of leakage is reduced. Based on X-ray detection, bubbles or other unevenness in the insulation layer can be detected early. If bubbles are detected, the system can automatically adjust the extrusion pressure of the extruder to eliminate the bubble problem. The reliability of the cable is improved.

[0027] In some embodiments of the present application, in S200, when H0 is less than 0.9Hmin, it is determined that the thickness difference △H=Hmin-H0 between the real-time thickness H0 and the preset thickness threshold Hmin is used to adjust the extrusion speed, including: presetting a first preset thickness difference △H1, a second preset thickness difference △H2, and a third preset thickness difference △H3, and △H1<△H2<△H3. Presetting a first preset speed adjustment coefficient A1, a second preset speed adjustment coefficient A2, and a third preset speed adjustment coefficient A3, and A1<A2<A3. According to the relationship between the thickness difference △H and each preset thickness difference, the speed adjustment coefficient is selected to adjust the extrusion speed V0 of the extruder. When △H1≤△H<△H2, the third preset speed adjustment coefficient A3 is selected to adjust the extrusion speed V0 of the extruder, and the insulating layer is extruded at the adjusted extrusion speed V0·A3. When △H2≤△H<△H3, the second preset speed adjustment coefficient A2 is selected to adjust the extrusion speed V0 of the extruder, and the insulation layer is extruded at the adjusted extrusion speed V0·A2. When △H3≤△H, the first preset speed adjustment coefficient A1 is selected to adjust the extrusion speed V0 of the extruder, and the insulation layer is extruded at the adjusted extrusion speed V0·A1.

[0028] Specifically, the real-time thickness of the insulation layer is obtained by collecting image data, and the thickness of the insulation layer is monitored in real time during the preparation process so as to detect any deviation from the specification as early as possible. The preset insulation layer thickness threshold is the minimum thickness expected when preparing the cable. The main function of the cable insulation layer is to provide electrical insulation, so it must be ensured that its thickness is sufficient to prevent current leakage and arc discharge. Different speed adjustment coefficients are selected according to different thickness differences to adjust the extrusion speed of the extruder. These speed adjustment coefficients correspond to different thickness difference ranges. This is to select an appropriate speed adjustment range according to the thickness deviation of the insulation layer.

[0029] It can be understood that this adaptive adjustment strategy ensures that the insulation layer is always maintained within a safe and qualified range, reducing the risk of leakage in the cable system and improving the reliability and performance of the cable. This also helps to reduce the risk of power problems and improve the efficiency and controllability of cable preparation.

[0030] In some embodiments of the present application, in S200, when it is determined that the extrusion speed is adjusted, and the i-th preset speed adjustment coefficient is selected to adjust the extrusion speed V0, after obtaining the adjusted extrusion speed V0·Ai, i=1, 2, 3, it also includes: collecting image information of the insulating layer after the speed adjustment, obtaining the thickness data Hh0 of the insulating layer after the speed adjustment, comparing the thickness data Hh0 of the insulating layer after the speed adjustment with the preset thickness threshold Hmin, and judging whether the thickness meets the requirement according to the comparison result. When Hh0<0.9Hmin, it is determined that the thickness data Hh0 of the insulating layer after the speed adjustment does not meet the requirement, and the extrusion temperature W0 of the extruder is collected to judge whether the extrusion temperature W0 is adjusted. When 0.9Hmin≤H0≤Hmin, it is determined that the thickness data Hh0 of the insulating layer after the speed adjustment meets the requirement.

[0031] Specifically, after the extrusion speed is adjusted, it is necessary to collect image information of the insulation layer again to obtain the thickness data of the insulation layer after the speed adjustment. This is because the speed adjustment will affect the thickness of the insulation layer. Compare the thickness data of the insulation layer after the speed adjustment with the preset thickness threshold to determine whether the thickness meets the requirements. If Hh0 is less than 90% of the preset thickness threshold, that is, 0.9Hmin, it means that the insulation layer is still thin and needs further adjustment. After the speed adjustment, if it is found that the thickness of the insulation layer does not meet the requirements, it is necessary to consider adjusting the extrusion temperature of the extruder. Because changes in extrusion temperature can affect the fluidity of the material and thickness control during the extrusion process.

[0032] It is understood that by constantly checking the insulation thickness after speed adjustment, any deviation is discovered in time and appropriate measures are taken to correct it to ensure that the insulation meets the required specifications. In addition, if the insulation thickness does not meet the requirements, the adjustment of extrusion temperature will be considered to further improve thickness control. This comprehensive monitoring and adjustment method helps to improve the performance, reliability and quality control of the cable and reduce the risk of power problems.

[0033] In some embodiments of the present application, when it is determined in S200 that the thickness data Hh0 of the insulating layer after speed adjustment does not meet the requirements, the extrusion temperature W0 of the extruder is collected, and it is determined whether to adjust the extrusion temperature W0, including: comparing the extrusion temperature W0 with the preset extrusion temperature threshold Wmax, and judging whether to adjust the extrusion temperature W0 according to the comparison result. When W0>Wmax, it is determined that the heating power P0 of the extruder is adjusted according to the size relationship between the extrusion temperature W0 and the set extrusion temperature threshold Wmax. When W0≤Wmax, it is determined not to continue to adjust the extrusion temperature W0, and an early warning is issued.

[0034] Specifically, the extrusion temperature is an important parameter that affects the formation and thickness of the insulation layer. When it is detected that the thickness of the insulation layer does not meet the requirements, the influence of the extrusion temperature needs to be further considered. If the extrusion temperature is too high, the insulation layer will be thin, so the extrusion temperature needs to be adjusted. When the temperature is lower than the threshold but the thickness is low, the extruder head will be further considered to be faulty, and an early warning will be issued in time to replace the extruder head or perform maintenance on the extruder head.

[0035] It is understandable that not only the speed adjustment is taken into account, but also the extrusion temperature adjustment. By comparing the extrusion temperature with the preset threshold, the temperature deviation can be discovered and corrected in time to ensure the uniformity and conformity of the insulation layer. It helps to improve the production quality of the cable insulation layer, reduce the risk of unqualified products, and increase the reliability and performance of the cable.

[0036] In some embodiments of the present application, when it is determined in S200 that the heating power P0 of the extruder is adjusted according to the size relationship between the extrusion temperature W0 and the set extrusion temperature threshold Wmax, it includes: obtaining the temperature difference △W=W0-Wmax between the extrusion temperature W0 and the set extrusion temperature threshold Wmax, presetting the first preset temperature difference △W1, the second preset temperature difference △W2 and the third preset temperature difference △W3, and △W1<△W2<△W3. Presetting the first preset power adjustment coefficient B1, the second preset power adjustment coefficient B2 and the third preset power adjustment coefficient B3, and B1<B2<B3. According to the size relationship between the temperature difference △W and each preset temperature difference, the power adjustment coefficient is selected to adjust the heating power P0, and heating is performed with the adjusted heating power. When △W1≤△W<△W2, the third preset power adjustment coefficient B3 is selected to adjust the heating power P0, and the adjusted heating power P0·B3 is obtained. When △W2≤△W<△W3, the second preset power adjustment coefficient B2 is selected to adjust the heating power P0 to obtain the adjusted heating power P0·B2. When △W3≤△W, the first preset power adjustment coefficient B1 is selected to adjust the heating power P0 to obtain the adjusted heating power P0·B1.

[0037] It is understandable that when the thickness of the insulation layer does not meet the requirements, the speed and temperature adjustments are considered, and the size of the temperature difference is also comprehensively considered. According to the comparison between the temperature difference and the preset temperature difference, the appropriate power adjustment coefficient is selected to accurately adjust the heating power to ensure the uniformity and qualification of the insulation layer. It helps to improve the production quality of the cable insulation layer and reduce the risk of unqualified products. By issuing early warnings, it can also alert operators in advance to help avoid potential problems in the production process.

[0038] In some embodiments of the present application, in S200, when it is determined that the heating power P0 is adjusted, and the i-th preset power adjustment coefficient Bi is selected to adjust the heating power P0, after obtaining the adjusted heating power P0·Bi, i=1, 2, 3, it also includes: collecting the ambient temperature T, and obtaining the ambient temperature change rate Tv according to the ambient temperature T, and the temperature change rate Tv is calculated by the following formula: ; in, Represents the ambient temperature at time t. Indicates the ambient temperature at time t-1. The ambient temperature change rate Tvmax is preset, and the ambient temperature change rate Tv is compared with the ambient temperature change rate Tvmax. According to the comparison result, it is determined whether to make a secondary adjustment to the adjusted heating power P0·Bi. When Tv>Tvmax, it is determined that the adjusted heating power P0·Bi is adjusted secondary. When 0<Tv≤Tvmax, it is determined that the adjusted heating power P0·Bi is not adjusted secondary.

[0039] Specifically, the extrusion temperature affects the formation of the insulation layer. Similarly, changes in ambient temperature can also affect the formation of the insulation layer during the extrusion process, especially in some complex industrial environments where temperature fluctuations may be common. Therefore, it is necessary to consider the potential impact of ambient temperature changes on the extrusion process and the quality of the insulation layer. Rapid changes in ambient temperature can be monitored by calculating the ambient temperature change rate. If the rate of change of the ambient temperature exceeds the preset ambient temperature change rate threshold, a secondary adjustment is made.

[0040] It is understandable that by monitoring the ambient temperature and its rate of change, secondary adjustments can be made when the ambient temperature fluctuates greatly to adapt to production requirements under different environmental conditions. Through secondary adjustments, the good performance of the cable insulation layer can be better maintained, reducing the rate of defective products.

[0041] In some embodiments of the present application, when it is determined in S200 that the adjusted heating power P0·Bi is to be adjusted for the second time, it includes: presetting a first preset temperature change rate Tv1 and a second preset temperature change rate Tv2, and Tvmax<Tv1<Tv2, selecting a power adjustment coefficient according to the magnitude relationship between the ambient temperature change rate Tv and each preset ambient temperature change rate to adjust the adjusted heating power P0·Bi for the second time, and operating with the heating power adjusted for the second time. When Tvmax<Tv≤Tv1, selecting a third preset power adjustment coefficient B3 to adjust the adjusted heating power P0·Bi for the second time, and obtaining the heating power P0·Bi·B3 after the second adjustment. When Tv1<Tv≤Tv2, selecting a second preset power adjustment coefficient B2 to adjust the adjusted heating power P0·Bi for the second time, and obtaining the heating power P0·Bi·B2 after the second adjustment. When Tv2<Tv, selecting a first preset power adjustment coefficient B1 to adjust the adjusted heating power P0·Bi for the second time, and obtaining the heating power P0·Bi·B1 after the second adjustment.

[0042] Specifically, the rate of change of ambient temperature is a measure of how much the ambient temperature changes over a short period of time. A higher rate of temperature change may require a secondary adjustment of the heating power to cope with rapidly changing ambient conditions. Different power adjustment factors are used based on the relationship between the rate of change of ambient temperature and different preset thresholds. This multi-level adjustment method makes the production process more refined to adapt to different degrees of temperature changes.

[0043] It is understandable that the influence of the rate of change of ambient temperature on the preparation process of cable insulation layer is fully considered. Through multi-level adjustment methods, it can respond more accurately to rapidly changing environmental conditions. It improves the preparation efficiency of cables, reduces the scrap rate, and ensures that cables produced in different environments can meet high quality requirements, improving the stability and controllability of the entire cable production process.

[0044] In some embodiments of the present application, in S300, whether there are bubbles in the insulating layer is detected based on X-rays, and when it is determined that there are bubbles in the insulating layer, the extrusion pressure of the extruder is adjusted, including: collecting the bubble content ratio E0 in the insulating layer, comparing the bubble content ratio E0 with the preset content threshold Emax, and judging whether to adjust the extrusion pressure of the extruder according to the comparison result. When E0>Emax, it is determined that the extrusion pressure of the extruder is adjusted. When E0≤Emax, it is determined that the extrusion pressure of the extruder is not adjusted.

[0045] Specifically, by measuring the percentage of bubbles in the insulation layer, we can understand whether there are bubbles in the insulation layer. If the percentage of bubbles exceeds the preset threshold, it means that there are too many bubbles in the insulation layer and measures need to be taken. By adjusting the extrusion pressure of the extruder, the bubbles in the insulation layer can be reduced or eliminated. Adjusting the extrusion pressure helps ensure that the insulation layer is uniform and free of bubbles, thereby improving the insulation performance and quality of the cable.

[0046] It is understandable that it helps to eliminate or reduce bubbles in the insulation layer, thereby ensuring that the quality and insulation performance of the cable insulation layer meet the standards. By real-time monitoring of the bubble content ratio and adjusting the extrusion pressure as needed, production waste in the cable preparation process can be reduced.

[0047] In some embodiments of the present application, when it is determined in S300 that the extrusion pressure of the extruder is adjusted, it includes: presetting a first preset pressure adjustment coefficient C1, a second preset pressure adjustment coefficient C2 and a third preset pressure adjustment coefficient C3, and C1<C2<C3. Preset a first preset bubble content ratio E1 and a second preset bubble content ratio E2, and Emax<E1<E2. According to the relationship between the bubble content ratio E0 and each preset bubble content ratio, an adjustment coefficient is selected to adjust the extrusion pressure Y0 of the extruder, and the wire core is produced with the adjusted extrusion pressure. When Emax<E0≤E1, the first preset pressure adjustment coefficient C1 is selected to adjust the extrusion pressure Y0 of the extruder, and the adjusted extrusion pressure Y0·C1 is obtained. When E1<E0≤E2, the second preset pressure adjustment coefficient C2 is selected to adjust the extrusion pressure Y0 of the extruder, and the adjusted extrusion pressure Y0·C2 is obtained. When E2<E0, the third preset pressure adjustment coefficient C3 is selected to adjust the extrusion pressure Y0 of the extruder to obtain the adjusted extrusion pressure Y0·C3.

[0048] Specifically, the bubble content ratio E0 reflects the number and distribution of bubbles in the insulation layer. If the bubble content ratio exceeds the preset threshold value E2, the cable insulation quality will be greatly damaged and the insulation performance will deteriorate during use. By adjusting the extrusion pressure of the extruder, the back pressure of the extruder head can be increased through the extruder control panel or the corresponding control system. Back pressure is a reverse force applied at the extruder head, which can help push the material through the extruder head, thereby increasing the pressure. Increasing the pressure of the extruder by adjusting or increasing the back pressure can usually affect the physical properties of the insulation layer, such as density and bubble distribution. When the bubble content ratio E0 is high, the bubble content can be reduced and the quality of the insulation layer can be improved by selecting an appropriate adjustment coefficient.

[0049] It can be understood that the bubble content in the insulation layer is monitored in real time, and the extrusion pressure is adjusted according to the actual situation to ensure that the bubbles in the insulation layer are maintained at a low level. By adjusting the extrusion pressure, the bubbles in the cable insulation layer are effectively reduced, and the insulation performance and quality of the cable are improved. It is beneficial to reduce the risk of cable failure and extend the service life of the cable. In addition, reducing waste in the cable preparation process helps to reduce costs.

[0050] In the above embodiment, by collecting image data of the insulating layer and comparing the actual thickness with the preset thickness threshold, it is possible to immediately detect whether the thickness of the insulating layer meets the requirements during the preparation process, thereby reducing resource waste and improving the efficiency of quality control. When there is a gap between the real-time thickness H0 and the preset thickness threshold Hmin, the extrusion speed is automatically adjusted to ensure that the thickness of the insulating layer meets the requirements. The thickness of the insulating layer is prevented from being too low, thereby reducing the risk of leakage. By introducing X-ray detection, it is possible to detect whether there are bubbles in the insulating layer during the preparation process. If bubbles are found, the extrusion pressure of the extruder is automatically adjusted to eliminate the bubble problem, thereby improving the reliability of the cable. Through automation and real-time quality control, the dependence on workers' operating experience is reduced, making the cable preparation process more stable and controllable.

[0051] In another preferred embodiment based on the above embodiment, refer to Figure 2 As shown, this embodiment provides a system for preparing an insulating layer of a wire and cable, applying the above method, including: The twisting unit is configured to draw and extrude the metal to obtain the metal wire, twist a plurality of metal wires in opposite directions to obtain the twisted conductor, and twist the plurality of twisted conductors to obtain the cable conductor; The acquisition unit is configured to obtain a core based on the insulation layer wrapped outside the cable conductor by the extruder, collect image data of the insulation layer, obtain a real-time thickness H0 of the insulation layer according to the image data, compare the real-time thickness H0 with a preset thickness threshold Hmin, and determine whether to adjust the extrusion speed of the insulation layer extruded by the extruder according to the comparison result; When H0<0.9Hmin, the thickness difference △H=Hmin-H0 between the real-time thickness H0 and the preset thickness threshold Hmin is determined, and the extrusion speed is adjusted; When 0.9Hmin≤H0≤Hmin, it is determined that the extrusion speed is not adjusted; The detection unit is configured to, after determining whether the extrusion speed is adjusted and the thickness of the insulating layer meets the requirement, detect whether there are bubbles in the insulating layer based on X-rays by the collection unit, and adjust the extrusion pressure of the extruder when it is determined that there are bubbles in the insulating layer; The coating unit is configured to, after determining whether to adjust the extrusion pressure and obtain the final wire core, weave an isolation layer using annealed soft copper wire outside the wire core, add a heat-resistant mixture outside the isolation layer and coat it with a protective jacket to make a cable.

[0052] It is understandable that the above-mentioned method and system for preparing the insulation layer of the wire and cable have the same beneficial effects, which will not be repeated here.

[0053] Those skilled in the art will appreciate that the embodiments of the present application may be provided as methods, systems or computer program products. Therefore, the present application may take the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present application may take the form of a computer program product implemented on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0054] The present application is described with reference to the flowcharts and / or block diagrams of the methods, devices (systems) and computer program products according to the embodiments of the present application. It should be understood that each process and / or box in the flowchart and / or block diagram, as well as the combination of processes and / or boxes in the flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, a special-purpose computer, an embedded processor or other programmable data processing device to produce a machine, so that the instructions executed by the processor of the computer or other programmable data processing device generate instructions for implementing the processes in the flowchart and / or block diagram. Figure 1 A process or multiple processes and / or boxes Figure 1 A device that provides the functions specified in a block or multiple blocks.

[0055] These computer program instructions may also be stored in a computer readable memory capable of directing a computer or other programmable data processing device to operate in a specific manner, so that the instructions stored in the computer readable memory produce an article of manufacture including an instruction device, which implements the process Figure 1 A process or multiple processes and / or boxes Figure 1 A function specified in one or more boxes.

[0056] These computer program instructions can also be loaded onto a computer or other programmable data processing device so that a series of operating steps are executed on the computer or other programmable device to produce a computer-implemented process, thereby providing instructions for implementing the process in the computer or other programmable device. Figure 1 A process or multiple processes and / or boxes Figure 1 The steps for the functions specified in one or more boxes.

[0057] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, ordinary technicians in the relevant field should understand that the specific implementation methods of the present invention can still be modified or replaced by equivalents. Any modification or equivalent replacement that does not depart from the spirit and scope of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A method for preparing an insulating layer of a wire and cable, characterized in that: include: Drawing and extruding metal to obtain metal wire, twisting multiple strands of the metal wire in opposite directions to obtain a twisted conductor, and re-twisting the multiple strands of the twisted conductor to obtain a cable conductor; Based on the extruder wrapping the insulating layer outside the cable conductor to obtain the wire core, collecting image data of the insulating layer, obtaining the real-time thickness H0 of the insulating layer according to the image data, comparing the real-time thickness H0 with a preset thickness threshold Hmin, and judging whether to adjust the extrusion speed of the extruder to extrude the insulating layer according to the comparison result; When H0<0.9Hmin, it is determined that the extrusion speed is adjusted according to the thickness difference △H=Hmin-H0 between the real-time thickness H0 and the preset thickness threshold Hmin; When 0.9Hmin≤H0≤Hmin, it is determined that the extrusion speed is not adjusted; After determining whether the extrusion speed is adjusted and the thickness of the insulating layer meets the requirement, detecting whether there are bubbles in the insulating layer based on X-rays, and adjusting the extrusion pressure of the extruder when it is determined that there are bubbles in the insulating layer; After determining whether to adjust the extrusion pressure and obtain the final wire core, an isolation layer is woven from annealed soft copper wire outside the wire core, a heat-resistant mixture is added outside the isolation layer, and a protective jacket is coated to form a cable.

2. The method for preparing the insulating layer of electric wire and cable according to claim 1, characterized in that: When H0<0.9Hmin, it is determined that the thickness difference △H=Hmin-H0 between the real-time thickness H0 and the preset thickness threshold Hmin, and the extrusion speed is adjusted, including: Preset a first preset thickness difference △H1, a second preset thickness difference △H2 and a third preset thickness difference △H3, and △H1<△H2<△H3; preset a first preset speed adjustment coefficient A1, a second preset speed adjustment coefficient A2 and a third preset speed adjustment coefficient A3, and A1<A2<A3; select a speed adjustment coefficient according to the size relationship between the thickness difference △H and each preset thickness difference to adjust the extrusion speed V0 of the extruder; When △H1≤△H<△H2, the third preset speed adjustment coefficient A3 is selected to adjust the extrusion speed V0 of the extruder, and the insulating layer is extruded at the adjusted extrusion speed V0·A3; When △H2≤△H<△H3, the second preset speed adjustment coefficient A2 is selected to adjust the extrusion speed V0 of the extruder, and the insulating layer is extruded at the adjusted extrusion speed V0·A2; When ΔH3≤ΔH, the first preset speed adjustment coefficient A1 is selected to adjust the extrusion speed V0 of the extruder, and the insulating layer is extruded at the adjusted extrusion speed V0·A1.

3. The method for preparing the insulating layer of the wire and cable according to claim 2, characterized in that: When it is determined that the extrusion speed is to be adjusted, and the i-th preset speed adjustment coefficient is selected to adjust the extrusion speed V0, after obtaining the adjusted extrusion speed V0·Ai, i=1, 2, 3, it also includes: Collect image information of the insulating layer after the speed adjustment, obtain thickness data Hh0 of the insulating layer after the speed adjustment, compare the thickness data Hh0 of the insulating layer after the speed adjustment with a preset thickness threshold Hmin, and determine whether the thickness meets the requirement according to the comparison result; When Hh0<0.9Hmin, it is determined that the thickness data Hh0 of the insulating layer after the speed adjustment does not meet the requirement, and the extrusion temperature W0 of the extruder is collected to determine whether to adjust the extrusion temperature W0; When 0.9Hmin≤H0≤Hmin, it is determined that the thickness data Hh0 of the insulating layer after speed adjustment meets the requirement.

4. The method for preparing the insulating layer of the wire and cable according to claim 3, characterized in that: When it is determined that the thickness data Hh0 of the insulating layer after the speed adjustment does not meet the requirement, the extrusion temperature W0 of the extruder is collected, and it is determined whether to adjust the extrusion temperature W0, including: Comparing the extrusion temperature W0 with a preset extrusion temperature threshold Wmax, and determining whether to adjust the extrusion temperature W0 according to the comparison result; When W0>Wmax, it is determined that the heating power P0 of the extruder is adjusted according to the magnitude relationship between the extrusion temperature W0 and the extrusion temperature threshold Wmax; When W0≤Wmax, it is determined that the extrusion temperature W0 is not to be further adjusted, and an early warning is issued.

5. The method for preparing the insulating layer of electric wire and cable according to claim 4, characterized in that: When it is determined that the heating power P0 of the extruder is adjusted according to the magnitude relationship between the extrusion temperature W0 and the extrusion temperature threshold Wmax, it includes: Obtain a temperature difference △W=W0-Wmax between the extrusion temperature W0 and the set extrusion temperature threshold Wmax, pre-set a first preset temperature difference △W1, a second preset temperature difference △W2 and a third preset temperature difference △W3, and △W1<△W2<△W3; pre-set a first preset power adjustment coefficient B1, a second preset power adjustment coefficient B2 and a third preset power adjustment coefficient B3, and B1<B2<B3; select a power adjustment coefficient according to the size relationship between the temperature difference △W and each preset temperature difference to adjust the heating power P0, and heat with the adjusted heating power; When △W1≤△W<△W2, the third preset power adjustment coefficient B3 is selected to adjust the heating power P0 to obtain the adjusted heating power P0·B3; When △W2≤△W<△W3, the second preset power adjustment coefficient B2 is selected to adjust the heating power P0 to obtain the adjusted heating power P0·B2; When ΔW3≤ΔW, the first preset power adjustment coefficient B1 is selected to adjust the heating power P0 to obtain the adjusted heating power P0·B1.

6. The method for preparing the insulating layer of electric wire and cable according to claim 5, characterized in that: When it is determined that the heating power P0 is to be adjusted, and the i-th preset power adjustment coefficient Bi is selected to adjust the heating power P0, after obtaining the adjusted heating power P0·Bi, i=1, 2, 3, it also includes: The ambient temperature T is collected, and the ambient temperature change rate Tv is obtained according to the ambient temperature T. The temperature change rate Tv is calculated by the following formula: ； in, represents the ambient temperature at time t; represents the ambient temperature at time t-1; Presetting the ambient temperature change rate Tvmax, comparing the ambient temperature change rate Tv with the ambient temperature change rate Tvmax, and judging whether to make a secondary adjustment to the adjusted heating power P0·Bi according to the comparison result; When Tv>Tvmax, it is determined that the adjusted heating power P0·Bi is to be adjusted twice; When 0<Tv≤Tvmax, it is determined that the adjusted heating power P0·Bi is not to be adjusted a second time.

7. The method for preparing the insulating layer of the wire and cable according to claim 6, characterized in that: When it is determined that the adjusted heating power P0·Bi is to be adjusted for the second time, it includes: A first preset temperature change rate Tv1 and a second preset temperature change rate Tv2 are preset, and Tvmax<Tv1<Tv2, and a power adjustment coefficient is selected according to the magnitude relationship between the ambient temperature change rate Tv and each preset ambient temperature change rate to perform secondary adjustment on the adjusted heating power P0·Bi, and the heating power after secondary adjustment is operated; When Tvmax<Tv≤Tv1, the third preset power adjustment coefficient B3 is selected to perform secondary adjustment on the adjusted heating power P0·Bi to obtain the secondary adjusted heating power P0·Bi·B3; When Tv1<Tv≤Tv2, the second preset power adjustment coefficient B2 is selected to perform secondary adjustment on the adjusted heating power P0·Bi to obtain the secondary adjusted heating power P0·Bi·B2; When Tv2<Tv, the first preset power adjustment coefficient B1 is selected to perform a secondary adjustment on the adjusted heating power P0·Bi to obtain the secondary adjusted heating power P0·Bi·B1.

8. The method for preparing the insulating layer of electric wire and cable according to claim 1, characterized in that: Detecting whether bubbles exist in the insulating layer based on X-rays, and adjusting the extrusion pressure of the extruder when it is determined that bubbles exist in the insulating layer, including: Collecting the bubble content ratio E0 in the insulating layer, comparing the bubble content ratio E0 with a preset content threshold Emax, and determining whether to adjust the extrusion pressure of the extruder according to the comparison result; When E0>Emax, it is determined that the extrusion pressure of the extruder is adjusted; When E0≤Emax, it is determined that the extrusion pressure of the extruder is not adjusted.

9. The method for preparing the insulating layer of electric wire and cable according to claim 8, characterized in that: When determining to adjust the extrusion pressure of the extruder, the method comprises: Preset a first preset pressure adjustment coefficient C1, a second preset pressure adjustment coefficient C2 and a third preset pressure adjustment coefficient C3, and C1<C2<C3; preset a first preset bubble content ratio E1 and a second preset bubble content ratio E2, and Emax<E1<E2; select an adjustment coefficient according to the relationship between the bubble content ratio E0 and each preset bubble content ratio to adjust the extrusion pressure Y0 of the extruder, and complete the wire core production with the adjusted extrusion pressure; When Emax<E0≤E1, the first preset pressure adjustment coefficient C1 is selected to adjust the extrusion pressure Y0 of the extruder to obtain the adjusted extrusion pressure Y0·C1; When E1<E0≤E2, the second preset pressure adjustment coefficient C2 is selected to adjust the extrusion pressure Y0 of the extruder to obtain the adjusted extrusion pressure Y0·C2; When E2<E0, the third preset pressure adjustment coefficient C3 is selected to adjust the extrusion pressure Y0 of the extruder to obtain the adjusted extrusion pressure Y0·C3.

10. A system for preparing an insulating layer of a wire and cable, using the method according to any one of claims 1 to 9, characterized in that: include: A twisting unit is configured to draw and extrude metal to obtain metal wires, twist a plurality of strands of the metal wires in opposite directions to obtain a twisted conductor, and re-twist the plurality of strands of the twisted conductors to obtain a cable conductor; A collection unit is configured to obtain a core by wrapping an insulating layer outside the cable conductor by an extruder, collect image data of the insulating layer, obtain a real-time thickness H0 of the insulating layer according to the image data, compare the real-time thickness H0 with a preset thickness threshold Hmin, and determine whether to adjust an extrusion speed of the extruder to extrude the insulating layer according to the comparison result; When H0<0.9Hmin, it is determined that the extrusion speed is adjusted according to the thickness difference △H=Hmin-H0 between the real-time thickness H0 and the preset thickness threshold Hmin; When 0.9Hmin≤H0≤Hmin, it is determined that the extrusion speed is not adjusted; The detection unit is configured to, after determining whether the extrusion speed is adjusted and the thickness of the insulating layer meets the requirement, the acquisition unit detects whether there are bubbles in the insulating layer based on X-rays, and adjusts the extrusion pressure of the extruder when it is determined that there are bubbles in the insulating layer; The coating unit is configured to, after determining whether to adjust the extrusion pressure and obtain the final wire core, weave an isolation layer with annealed soft copper wire outside the wire core, add a heat-resistant mixture outside the isolation layer and coat it with a protective jacket to form a cable.

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