Aluminum alloy conductor cable for tunnel construction equipment and preparation method thereof

Abstract

The present invention relates to the field of cable technology, and in particular to an aluminum alloy conductor cable for tunnel construction equipment and a preparation method thereof. The aluminum alloy conductor cable comprises an aluminum alloy conductor, an insulating layer and a sheath layer arranged in sequence from the inside to the outside; the aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.31% to 0.46%, Fe: 0.1% to 0.28%, Cu: 0.05% to 0.18%, Mn: 0.4% to 0.55%, Mg: 0.3% to 0.5%, Zn: 0.05% to 0.14%, Ti: 0.01% to 0.04%, rare earth elements 0.01% to 0.027%, and the remainder is Al. The cable has good insulation performance and mechanical strength, can effectively prevent the occurrence of safety accidents such as leakage and short circuit, and provides reliable power guarantee for tunnel construction.

Description

Technical Field

[0001] The present invention relates to the technical field of cables, and in particular to an aluminum alloy conductor cable for tunnel construction equipment and a preparation method thereof. Background Art

[0002] In modern tunnel construction, cables are an important medium for power and signal transmission, and their performance directly affects construction efficiency and safety. The complex environment of tunnel construction places higher demands on the flexibility, environmental resistance and electrical performance of cables.

[0003] At present, the cables commonly used in tunnel construction are mostly traditional copper conductor cables or ordinary aluminum alloy conductor cables. These cables are prone to conductor breakage and insulation damage during long-term bending and movement, which affects the service life of the cables and construction safety. In addition, the environment in the tunnel is complex, and there may be adverse factors such as humidity, high temperature, and dust, which also puts higher requirements on the performance of the cable. Although the existing aluminum alloy conductor soft cable has solved the weight and cost problems of the cable to a certain extent, it still needs to be improved in terms of flexibility and adaptability to complex environments.

[0004] Based on the existing technology, the following technical problems can be analyzed:

[0005] 1. During frequent movement and bending of traditional cables, the conductors are prone to breakage and the insulation layer is prone to damage, which shortens the life of the cable.

[0006] 2. The harsh environment in the tunnel, such as humidity, high temperature, and dust, poses a challenge to the environmental resistance of cables, and existing cables are difficult to adapt to.

[0007] 3. The existing cables are not flexible enough to meet the use requirements of tunnel construction equipment in complex construction environments.

[0008] 4. The electrical performance and mechanical strength of the cable need to be further improved to ensure stable power and signal transmission during construction. Summary of the invention

[0009] In view of the deficiencies in the prior art, an object of an embodiment of the present invention is to provide an aluminum alloy conductor cable for tunnel construction equipment to adapt to the working environment of frequent movement and bending in tunnel construction.

[0010] In order to achieve the above objectives, the embodiments of the present invention provide the following technical solutions:

[0011] An aluminum alloy conductor cable for tunnel construction equipment comprises an aluminum alloy conductor, an insulating layer and a sheath layer which are sequentially arranged from the inside to the outside; the aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.31% to 0.46%, Fe: 0.1% to 0.28%, Cu: 0.05% to 0.18%, Mn: 0.4% to 0.55%, Mg: 0.3% to 0.5%, Zn: 0.05% to 0.14%, Ti: 0.01% to 0.04%, rare earth elements 0.01% to 0.027%, and the balance is Al.

[0012] Optionally, the aluminum alloy conductor is formed by twisting a plurality of aluminum alloy wires.

[0013] Optionally, a conductor tape is provided on the outside of the aluminum alloy conductor, the conductor tape wraps a plurality of aluminum alloy conductors therein, and the insulation layer is coated on the outside of the conductor tape.

[0014] Optionally, a cable core tightening layer and a braided reinforcement layer are provided on the outer side of the insulating layer, and the braided reinforcement layer is spun yarn or fiber yarn.

[0015] Optionally, a sheath is provided in the gap between the insulating layers in the cable core tightening layer, and the outer side of the braided reinforcement layer is covered with the sheath layer, and the sheath layer is polyurethane.

[0016] Optionally, the aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.4%, Mg: 0.4%, Zn: 0.05%, Ti: 0.02%, rare earth elements 0.02%, and the balance is Al.

[0017] Optionally, the aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.47%, Mg: 0.4%, Zn: 0.09%, Ti: 0.02%, rare earth elements 0.02%, and the balance is Al.

[0018] Optionally, the aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.55%, Mg: 0.4%, Zn: 0.14%, Ti: 0.02%, rare earth elements 0.02%, and the balance is Al.

[0019] An embodiment of the present invention also provides a method for preparing an aluminum alloy conductor cable for tunnel construction equipment as described above, comprising twisting a plurality of bundles of aluminum alloy wires to form an aluminum alloy conductor; coating the aluminum alloy conductor with rubber insulating material to form an insulating layer; the insulating layer and the conductor constitute an insulating core, the insulating core is twisted into a cable, polyurethane is filled in the gap, and then tied to form a cable core tightening layer; the outer side of the cable core tightening layer is braided and reinforced with spun yarn or fiber yarn to form a braided reinforcement layer; and polyurethane is coated on the outside of the braided reinforcement layer to form a sheath.

[0020] Optionally, during the preparation of the aluminum alloy conductor, rare earth elements, Fe and Cu are added to the aluminum liquid during alloying, and the remaining raw materials are added after the aluminum liquid is melted; during refining, a refining agent composed of sodium chloride, potassium chloride and cryolite is added, and the weight of the refining agent is 0.08-0.12% of the weight of the aluminum liquid.

[0021] One or more technical solutions provided in the embodiments of the present invention have at least the following technical effects or advantages:

[0022] By optimizing the alloy formula of aluminum alloy conductors, adopting layered stranding technology, and selecting highly elastic insulation materials and polyurethane outer sheaths, the cable has extremely high flexibility and can withstand frequent bending and stretching without damage, meeting the use requirements of tunnel construction equipment in complex construction environments. Moreover, the reasonable aluminum alloy conductor formula ensures the good conductivity of the cable, which can stably transmit power and signals and ensure the normal operation of tunnel construction equipment. At the same time, the specially made outer sheath has excellent properties such as wear resistance, oil resistance, and low temperature resistance, which can adapt to the harsh environmental conditions in the tunnel, extend the service life of the cable, and reduce maintenance costs. The overall structure of the cable is reasonably designed, the layers are tightly combined, and it has good insulation performance and mechanical strength. It can effectively prevent the occurrence of safety accidents such as leakage and short circuit, and provide reliable power guarantee for tunnel construction.

[0023] Advantages of additional aspects of the present invention will be given in the following description, and in part will become obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings required for use in the embodiments or the prior art descriptions are briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work. In addition, the spacing or size between each other is exaggerated to show the position of each part, and the schematic diagram is only used for illustration.

[0025] Figure 1 is a schematic diagram of a cable provided by an embodiment of the present invention;

[0026] In the figure: 1. Aluminum alloy conductor; 2. Conductor wrapping tape; 3. Insulation layer; 4. Cable core tightening layer; 5. Braided reinforcement layer; 6. Sheath layer; DETAILED DESCRIPTION

[0027] It should be noted that the following detailed descriptions are illustrative and are intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meanings as those commonly understood by those of ordinary skill in the art to which the present invention belongs. In addition, it should also be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0028] In order to solve the technical problems mentioned in the background technology, this embodiment proposes an aluminum alloy conductor cable for tunnel construction equipment, which is mainly used in cable operation places such as tunnel construction boring machines and shield machines that require towing operation, and has excellent electrical performance, flexibility, light weight, etc. Figure 1 As shown, it includes an aluminum alloy conductor 1, an insulating layer 3 and a sheath layer 6 arranged in sequence from the inside to the outside; the aluminum alloy conductor is composed of the following elements in mass percentage: Si: 0.31% to 0.46%, Fe: 0.1% to 0.28%, Cu: 0.05% to 0.18%, Mn: 0.4% to 0.55%, Mg: 0.3% to 0.5%, Zn: 0.05% to 0.14%, Ti: 0.01% to 0.04%, rare earth elements 0.01% to 0.027%, and the balance is Al.

[0029] The design of this aluminum alloy conductor not only achieves optimal performance through precise alloy ratios, but also ensures that it can adapt to the more demanding working conditions in tunnel construction environments. It not only improves the mechanical properties of the aluminum alloy, but also enhances its high temperature and wear resistance, greatly improving the service life of the cable in harsh environments.

[0030] The aluminum alloy conductor is made of multiple strands of aluminum alloy wires twisted together to improve the flexibility and conductivity of the cable. The twisted structure of the multiple-strand conductor can make the cable have higher tensile strength and effectively avoid the risk of a single conductor breaking due to external force stretching. In addition, the twisting of the aluminum alloy wires also effectively reduces the resistance when the current passes through, reduces the heat generated by the cable, and ensures the stability of the cable when working for a long time. The structural method of twisting multiple strands of aluminum alloy wires can adjust the physical properties of the cable by adopting different twisting angles and numbers of strands. For example, increasing the density of the twisting can improve the ability to resist external interference and reduce the impact of electromagnetic interference on the transmission signal. This structure provides a solid cable foundation for high-load and high-frequency use in tunnel construction equipment.

[0031] A conductor tape 2 is provided on the outside of the aluminum alloy conductor to wrap the aluminum alloy conductor, and an insulating layer is coated on the outside of the conductor tape. The function of the conductor tape is mainly to enhance the overall strength and tensile strength of the conductor, and to ensure that the multi-strand aluminum alloy wire will not be dislocated or broken during the use of the cable. The conductor tape can also effectively isolate the current conductor from external mechanical interference and reduce cable damage caused by external stress. By coating the conductor with a tape, especially using a high-strength, wear-resistant material such as polyester film or similar reinforcing materials, the mechanical strength of the cable can be further improved, especially in a complex environment such as tunnel construction, to ensure the stable operation of the cable. In addition, the coating design of the insulating layer ensures the insulation performance of the cable in high humidity or corrosive gas environments, further improving the safety and reliability of the cable.

[0032] A cable core tightening layer 4 and a braided reinforcement layer 5 are arranged outside the insulation layer of the cable, and the braided reinforcement layer is spun yarn or fiber yarn. The cable core tightening layer mainly serves to fix the inner layer structure of the cable and prevent the internal components from moving relative to each other. By filling the cable with polyurethane material, it not only improves the stability of the cable core, but also plays a role of buffering and pressure resistance, thereby preventing the cable from being deformed or broken due to external pressure during use. The braided reinforcement layer is designed with spun yarn or fiber yarn, which has high tensile strength and good toughness. This reinforcement layer can not only provide additional physical protection, but also effectively improve the wear resistance of the cable. Especially in high-friction and high-load environments such as tunnel construction, the reinforcement layer can provide additional support to prevent the cable from being damaged by friction.

[0033] The gaps in the cable core tightening layer are filled with a sheath, and a sheath layer 6 is provided on the outside of the braided reinforcement layer. The sheath layer is made of polyurethane material, which protects the cable from external physical damage, chemical corrosion and environmental damage. Polyurethane as a sheath material has strong oil resistance, acid and alkali resistance, high temperature resistance and other characteristics, and can effectively cope with common complex environmental factors in tunnel construction, such as moisture, oil pollution, etc., to ensure the long-term and stable operation of the cable. The setting of the sheath not only enhances the durability and service life of the cable, but also further improves the safety of the cable. Through different levels of structural design, including the inner sheath, the tightening layer and the outer braided layer, the overall compressive and tensile strength of the cable has been greatly enhanced, ensuring its high-load operation in tunnel construction.

[0034] The high-flexibility aluminum alloy conductor soft cable for tunnel construction equipment solves the problems of insufficient flexibility, poor environmental resistance, insufficient electrical performance and mechanical strength of existing cables. By optimizing the alloy formula of aluminum alloy conductors, adopting layered twisting technology, and selecting highly elastic insulation materials and polyurethane outer sheaths, the cable has extremely high flexibility and can withstand frequent bending and stretching without damage. At the same time, the specially made outer sheath has excellent properties such as wear resistance, oil resistance, and low temperature resistance. It can adapt to the harsh environmental conditions in the tunnel, extend the service life of the cable, and reduce maintenance costs. In addition, this cable also has good conductivity and safe and reliable electrical performance, providing reliable power guarantee for tunnel construction.

[0035] This embodiment also provides a method for preparing the aluminum alloy conductor cable for tunnel construction equipment, comprising:

[0036] Aluminum alloy conductors are made of multiple fine aluminum alloy wires twisted together. During the preparation of aluminum alloy conductors, rare earth elements, Fe and Cu are added to the aluminum liquid during alloying, and the remaining raw materials are added after it is melted; during refining, a refining agent composed of sodium chloride, potassium chloride and cryolite is added, and the weight of the refining agent is 0.08-0.12% of the weight of the aluminum liquid. This alloy formula can not only ensure the good conductivity of the conductor, but also improve its flexibility and strength.

[0037] The layered stranding technology is used to strand aluminum alloy wires of different diameters in layers according to certain rules. First, the thinner aluminum alloy wires are stranded into bundles, and then the bundles of aluminum alloy wires are stranded as a whole to form a conductor. This stranding method can make the internal structure of the conductor more compact, reduce the stress concentration of the conductor during bending, and improve the flexibility and fatigue resistance of the conductor.

[0038] Insulation extrusion process: Use high-precision extrusion equipment to ensure uniform thickness of the insulation layer. During the extrusion process, strictly control the extrusion temperature and pressure. After extrusion, immediately enter the closed vulcanization pipeline filled with high-temperature and high-pressure water vapor to shape, so as to improve the quality and performance of the insulation layer. The insulation should be cooled before leaving the vulcanization pipeline. The cooling method is water cooling, so that the insulation layer can be fully cooled to avoid bulging or even bursting due to excessive air pressure inside the insulation when leaving the vulcanization pipeline due to insufficient cooling. Highly elastic rubber insulation material is used, and the thickness is evenly coated on the outside of the conductor. This insulation material has excellent insulation performance and aging resistance, and can provide good elastic buffering when the cable is bent to prevent the insulation layer from rupturing.

[0039] Cabling process: When cabling, the consistency of the pay-off strength of each core is controlled, the cable pitch and twisting direction are optimized, the gaps between the cable cores are not filled, and the surface of the cable core is tightened in the reverse direction with a narrow tape or a bundle of high-strength fiber yarn.

[0040] Reinforcement braiding process: Use a special braiding machine to braid aramid or other high-strength fiber yarns. During the braiding process, strictly control the tension and braiding density of the fiber yarn to ensure the stability of the cable core. Keep enough gaps so that the sheath material can fill the gaps when the cable sheath is extruded, so as to achieve a stable cable structure and excellent mechanical strength.

[0041] Outer sheath extrusion process: The polyurethane sheath is extruded by extrusion. Before extrusion, the polyurethane material is fully dried to remove moisture to prevent bubbles from being generated during the extrusion process. During the extrusion process, the extrusion temperature, pressure and speed are strictly controlled. The mold design is optimized, the mold cavity length of the mold sleeve is increased, and the length of the sizing zone is increased to increase the pressure during the sheath extrusion, to ensure that the extruded sheath material fills the gap of the cable core, so that the reinforcement braided layer and the outer sheath are integrated. After extrusion, the cable is cooled and solidified to further improve the mechanical properties and chemical stability of the outer sheath. It is made of special wear-resistant, oil-resistant and low-temperature resistant polyurethane material. The outer sheath has good mechanical properties and chemical stability, and can effectively resist the erosion of the harsh environment in the tunnel, such as friction of equipment, oil pollution and the influence of low temperature environment. At the same time, the high elasticity and flexibility of the polyurethane material further improve the overall flexibility of the cable, so that it can adapt to the frequent movement and bending operations of tunnel construction equipment.

[0042] Example 1

[0043] The aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.4%, Mg: 0.4%, Zn: 0.05%, Ti: 0.02%, rare earth elements 0.02%, and the balance Al.

[0044] Example 2

[0045] The aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.47%, Mg: 0.4%, Zn: 0.09%, Ti: 0.02%, rare earth elements 0.02%, and the balance Al.

[0046] Example 3

[0047] The aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.55%, Mg: 0.4%, Zn: 0.14%, Ti: 0.02%, rare earth elements 0.02%, and the balance is Al.

[0048] Comparative Example 1

[0049] The aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mg: 0.4%, Ti: 0.02%, rare earth elements 0.02%, and the balance Al.

[0050] Comparative Example 2

[0051] The aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mg: 0.4%, Zn: 0.14%, Ti: 0.02%, rare earth elements 0.02%, and the balance Al.

[0052] Comparative Example 3

[0053] The aluminum alloy conductor is composed of the following elements in percentage by mass: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.55%, Mg: 0.4%, Ti: 0.02%, rare earth elements 0.02%, and the balance Al.

[0054] In Example 1, manganese and zinc are minimum values, in Example 2, manganese and zinc are medium values, and in Example 3, manganese and zinc take maximum values; Comparative Example 1 does not contain manganese and zinc, Comparative Example 2 does not contain manganese, and Comparative Example 1 does not contain zinc.

[0055] The following are the performance test results of three groups of embodiments and three groups of comparative examples:

[0056]

[0057] Through comparative analysis, it can be seen that the specific embodiment is superior to the comparative example in terms of tensile strength, elongation, hardness and corrosion resistance. The addition of manganese and zinc improves the strength, hardness and corrosion resistance of the aluminum alloy and maintains good flexibility, making the cable more suitable for high-load and high-pressure application environments, having a longer service life in humid or chemically corrosive environments, and the cable is more durable in repeated bending and friction.

[0058] Although the above describes the specific implementation mode of the present invention in conjunction with the accompanying drawings, it is not intended to limit the scope of protection of the present invention. Those skilled in the art should understand that various modifications or variations that can be made by those skilled in the art on the basis of the technical solution of the present invention without creative work are still within the scope of protection of the present invention.

Claims

1. An aluminum alloy conductor cable for tunnel construction equipment, characterized in that: It includes an aluminum alloy conductor, an insulating layer and a sheath layer arranged in sequence from the inside to the outside; The aluminum alloy conductor is composed of the following elements in percentage by mass: Composition: Si: 0.31% ~ 0.46%, Fe: 0.1% ~ 0.28%, Cu: 0.05% ~ 0.18%, Mn: 0.4% ~ 0.55%, Mg: 0.3% ~ 0.5%, Zn: 0.05% ~ 0.14%, Ti: 0.01% ~ 0.04%, rare earth elements 0.01% ~ 0.027%, and the balance is Al.

2. The aluminum alloy conductor cable for tunnel construction equipment according to claim 1, characterized in that: The aluminum alloy conductor is formed by twisting a plurality of aluminum alloy wires.

3. The aluminum alloy conductor cable for tunnel construction equipment according to claim 1, characterized in that: A conductor tape is arranged on the outside of the aluminum alloy conductor, the conductor tape wraps a plurality of aluminum alloy conductors therein, and the insulation layer is coated on the outside of the conductor tape.

4. The aluminum alloy conductor cable for tunnel construction equipment according to claim 1, characterized in that: A cable core tightening layer and a braiding reinforcement layer are arranged on the outer side of the insulating layer, and the braiding reinforcement layer is spun yarn or fiber yarn.

5. The aluminum alloy conductor cable for tunnel construction equipment according to claim 4, characterized in that: A sheath is provided in the gap between the insulating layers in the cable core tightening layer, and the outer side of the braided reinforcement layer is covered with the sheath layer, which is polyurethane.

6. The aluminum alloy conductor cable for tunnel construction equipment according to claim 1, characterized in that: The aluminum alloy conductor is composed of the following elements in percentage by mass: Composition: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.4%, Mg: 0.4%, Zn: 0.05%, Ti: 0.02%, rare earth elements 0.02%, and the balance is Al.

7. The aluminum alloy conductor cable for tunnel construction equipment according to claim 1, characterized in that: The aluminum alloy conductor is composed of the following elements in percentage by mass: Composition: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.47%, Mg: 0.4%, Zn: 0.09%, Ti: 0.02%, rare earth elements 0.02%, and the balance is Al.

8. The aluminum alloy conductor cable for tunnel construction equipment according to claim 1, characterized in that: The aluminum alloy conductor is composed of the following elements in percentage by mass: Composition: Si: 0.4%, Fe: 0.2%, Cu: 0.1%, Mn: 0.55%, Mg: 0.4%, Zn: 0.14%, Ti: 0.02%, rare earth elements 0.02%, and the balance is Al.

9. A method for preparing an aluminum alloy conductor cable for tunnel construction equipment according to any one of claims 1 to 8, characterized in that: include: Twisting a plurality of bundles of aluminum alloy wires to form an aluminum alloy conductor; The aluminum alloy conductor is coated with rubber insulating material to form an insulating layer; The insulating layer and the conductor form an insulating core, the insulating core is twisted into a synthetic cable, the gap is filled with polyurethane, and then tied to form a cable core tightening layer; The outer side of the cable core tightening layer is braided and reinforced with spun yarn or fiber yarn to form a braided reinforcement layer; The braided reinforcement layer is coated with polyurethane to form a sheath.

10. The preparation method according to claim 9, characterized in that: During the preparation of the aluminum alloy conductor, rare earth elements, Fe and Cu are added to the aluminum liquid during alloying, and the remaining raw materials are added after the aluminum liquid is melted; during refining, a refining agent composed of sodium chloride, potassium chloride and cryolite is added, and the weight of the refining agent is 0.08-0.12% of the weight of the aluminum liquid.

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