Carbon fiber composite material distributed reinforced carrier cable and manufacturing method thereof

Abstract

The invention relates to the technical field of carrier cable manufacturing, and particularly discloses a carbon fiber composite material distributed reinforced carrier cable and a manufacturing method thereof, the carrier cable is formed by concentrically stranding a plurality of monofilaments, the center of each monofilament of the carrier cable is a carbon fiber reinforced composite material, and the outer layer of each monofilament is copper or copper alloy. The manufacturing process mainly comprises the steps of fiber material yarn distribution, dipping, copper or copper alloy layer coating, copper or copper alloy coated fiber prepreg monofilament deformation, copper or copper alloy coated prepreg monofilament disc loading, carrier cable stranding and curing forming. According to the invention, the lighter and stronger carbon fiber composite material is used for replacing a part of metal, so that the effects of reducing weight and increasing strength are realized. The brand-new manufacturing method is designed, deformation processing is carried out when the continuous long fiber prepreg coated with the copper and the copper alloy is in an uncured state, and therefore the carbon fiber composite distributed reinforced carrier cable can be continuously produced.

Description

Technical Field

[0001] The invention relates to the technical field of manufacturing catenary cables, and in particular to a carbon fiber composite material distributed reinforced catenary cable and a manufacturing method thereof. Background Art

[0002] At present, the catenary cables used in electrified rail transit, especially high-speed rail contact networks (hereinafter referred to as catenary cables) are mainly copper and copper-magnesium alloy stranded wires, which bear the weight of themselves and the contact network wires and carry a certain amount of current. The catenary cables need to meet the requirements of light weight, large current carrying capacity, high tensile strength, low elongation and strong fatigue resistance. However, the existing copper stranded wires have a relatively large deadweight. Even if copper-magnesium alloy stranded wires are used, their deadweight is still large, and the strength of the copper material itself is limited, resulting in a large part of the tensile load being used to bear the deadweight, and only a part of it is used to bear the weight of the contact network wires. In addition, in the case of ice hanging, the weight increases and exceeds the strength limit, which makes it easy to break the wire. Summary of the invention

[0003] In view of the problems in the background technology, the present invention provides a carbon fiber composite material distributed reinforced bearing cable and a manufacturing method thereof, and utilizes the characteristics of carbon fiber composite materials such as light weight, high strength and strong fatigue resistance to improve the comprehensive performance of the bearing cable through a distributed reinforcement method.

[0004] To achieve the above object, the present invention adopts the following technical solution: A carbon fiber composite material distributed reinforced load-bearing cable, the load-bearing cable is formed by concentrically twisting a plurality of single wires, the center of each single wire of the load-bearing cable is a carbon fiber reinforced composite material, and the outer layer is copper or copper alloy.

[0005] A method for manufacturing a carbon fiber composite material distributed reinforced load-bearing cable comprises the following steps: (1) Preparation of copper or copper alloy coated carbon fiber prepreg The copper or copper alloy coated carbon fiber prepreg preparation system includes: a creel, a glue injection machine, a copper tape unwinding device, a yarn spreading and impregnation device, a tape storage device, a copper tape longitudinal wrapping and welding part, a copper tube drawing and eddy current flaw detection part, a wire take-up controller and a gantry wire take-up device; The yarn frame controls the fiber pay-off tension through a magnetic damping tension controller, and guides the fiber filaments through the yarn cloth and impregnation device. The glue injection machine injects epoxy resin mixed glue of a certain temperature and pressure into the cavity of the yarn cloth and impregnation device through the glue injection tube. The temperature in the device is stabilized at 80°C by a controllable temperature heater, and the fiber filaments are fully impregnated and tightened into bundles of prepreg. The copper tape on the tape storage device is synchronously guided to the copper tape longitudinal wrapping and welding part through the copper tape pay-off device. After the longitudinal wrapping is formed, it is welded into a mother tube. The mother tube passes through the drawing die of the copper tube drawing and eddy current flaw detection part to become a copper tube prepreg wire of specified specifications, and finally the wire is taken up and reeled through the wire take-up controller and the gantry wire take-up device.

[0006] (2) Preparation of carbon fiber composite material distributed reinforced load-bearing cables The catenary preparation system includes: stranding machine, doubling die, curing section, annealing control equipment, cooling section, traction device and gantry take-up device; According to the design requirements, the pitch and the pay-off speed are selected according to the pitch-diameter ratio. The copper tube prepreg wire prepared in step (1) is passed through a wire-drawing die to obtain a stranded wire with a round or polygonal single-wire cross section. The resin of the prepreg is further evenly distributed during the pultrusion process. The prepreg is then cured in a curing section. After the cured and cooled wire is passed through a traction device, it is loaded onto a gantry take-up device.

[0007] Preferably, the glue injection tube is a needle-type glue injection tube.

[0008] Preferably, the prepreg preparation system also includes a track traction device and a tension tracking feedback device and a large wheel traction. The track traction device is the main traction, and the traction tension feedback is tracked by the tension tracking feedback device and the large wheel traction to achieve excess length control of the carbon fiber composite wire prepreg; a stable traction speed difference can obtain a stable excess length.

[0009] Preferably, the stranding machine is a cage-type stranding machine.

[0010] Preferably, the cage stranding machines are two cage stranding machines, one with 1+6 drums and the other with 12 drums, and the wire-releasing speed of the cage stranding machines is synchronized with the double-wheel traction device.

[0011] Preferably, the stranded wire is a plurality of strands twisted concentrically.

[0012] Preferably, each curing tube in the curing section is provided with a set of straightening and collecting devices on both sides, the straightening and collecting devices include a straightening pulley, a conductive slip ring and a drainage bar, and a temperature sensor is provided in the curing tube; the DC current output by the annealing control device is conducted to the pulley.

[0013] Preferably, the curing section comprises two sections of heating tubes, wherein the temperature of the metal tube inside the first heating tube is heated to 100°C to preheat the wire; after the pulley of the straightening collector contacts the metal layer of the wire, the wire can be heated by short-circuit heating because it is connected to the DC power supply of the annealing control device; before entering the second section of the heating tube, the temperature of the wire cannot be higher than 180°C, and when the wire leaves the end of the second section of the curing tube, the temperature reaches 230°C at best.

[0014] Preferably, the cooling section is a hollow metal tube, and the cooling method uses a fan to blow water mist and cold air into the cooling tube for heat exchange, and a meter is provided at the end of the cooling section.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The present invention achieves the effect of reducing weight and increasing strength by replacing a portion of metal with a lighter and stronger carbon fiber composite material. In terms of manufacturing process, a composite material prepreg is placed in the middle of a copper tube to prepare a single wire, and then a plurality of single wire prepregs are twisted and heated at the same time to solidify the composite material prepreg, and finally prepared. The present invention designs a brand-new manufacturing method, in which a deformation process is performed on the continuous long fiber prepreg coated with copper and copper alloy in an uncured state, so that the distributed reinforced load-bearing cables of carbon fiber composite materials can be continuously produced. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Schematic diagram of the preparation process of copper or copper alloy coated carbon fiber prepreg.

[0017] Figure 2 Schematic diagram of the cable stranding and online curing manufacturing process.

[0018] Figure 3 It is a schematic cross-sectional view of a carbon fiber composite material distributed reinforced load-bearing cable of the present invention.

[0019] In the figure: 1. Long-length yarn rack, 2. Glue injection machine, 3. Copper belt unwinding device, 4. Yarn laying and impregnation device, 5. Belt storage device, 6. Copper belt longitudinal wrapping and welding part, 7. Copper tube drawing and eddy current flaw detection part, 8. Crawler traction device, 9. Tension tracking feedback device and large wheel traction, 10. Wire taking-up controller, 11. Gantry wire taking-up device, 12. Cage stranding machine, 13. Wire paralleling die, 14. Curing section, 15. Cooling section, 16. Double-wheel traction device, 17. Gantry wire taking-up device, 18. Annealing control equipment, 19. Copper or copper alloy layer, 20. Carbon fiber reinforced composite material. DETAILED DESCRIPTION

[0020] In order to further explain the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the specific implementation mode, structure, characteristics and effects of the present invention are described in detail below in combination with the accompanying drawings and preferred embodiments.

[0021] like Figure 1 As shown, a manufacturing system for a continuous copper or copper alloy coated composite prepreg single wire comprises: a long length yarn rack 1, a glue injection machine 2, a copper tape unwinding device 3, a yarn spreading and impregnation device 4, a tape storage device 5, a copper tape longitudinal wrapping and welding part 6, a copper tube drawing and eddy current flaw detection part 7, a crawler traction device 8, a tension tracking feedback device and large wheel traction 9, a wire take-up controller 10, and a gantry wire take-up device 11.

[0022] The long-length yarn frame 1 comprises a pay-off frame, and a plurality of single-disc fiber pay-off discs are arranged on both sides of the pay-off frame, and a fiber guide slide bar is arranged. The fiber pay-off disc is mounted on a disc shaft, and the disc shaft is mounted on a double support bearing, and a tension controller is arranged at the end of the disc shaft.

[0023] The copper tape unwinding device 3 is a double-disc unwinding rack, and the copper tape can be connected by laser welding or other welding methods. The longitudinal wrapping of the copper tape is mainly achieved by a longitudinal wrapping mold and a forming roller.

[0024] The yarn cloth and resin impregnation device 4 comprises a temperature-controllable yarn cloth and impregnation device, a glue injection machine, and a needle-type glue injection tube.

[0025] The copper strip longitudinal wrapping and welding part 6 includes a longitudinal wrapping die, a forming roller, and a welding head.

[0026] The copper tube drawing and eddy current flaw detection part 7 mainly includes a drawing die and a weld eddy current flaw detection device, followed by a crawler traction device 8, a tension tracking feedback device and a large wheel traction 9.

[0027] The wire-taking part comprises a wire-taking controller 10 and a gantry wire-taking device 11 .

[0028] When the present invention is working, the long-length yarn rack 1 controls the fiber wire release tension through the magnetic damping tension controller, guides the fiber wire through the yarn and the impregnation device 4, and the glue injection machine 2 injects the epoxy resin mixed glue of a certain temperature and pressure into the conical cavity of the yarn and the impregnation device 4 through the needle-type glue injection tube. The temperature in the device is stabilized at 80°C by the temperature-controllable heater, and the fiber wire is fully impregnated and tightened into a bundled prepreg. The copper belt is guided to the copper belt longitudinal package and welding part 6 by the copper belt release device 3, and the mother tube is welded after the longitudinal package is formed. The welding seam condition can be observed in real time through the welding tracking sensor during the welding process. The mother tube becomes a copper tube of the specified specification after passing through the drawing die of the copper tube drawing and eddy current flaw detection part 7, and the welding quality can be detected online by the eddy current flaw detection device. The strength of the tube body after drawing without defects is stronger than that of the mother tube. When working, the crawler traction device 8 is the main traction, and the traction tension feedback is tracked through the tension tracking feedback device and the large wheel traction 9 to realize the excess length control of the carbon fiber composite wire prepreg. The stable pulling speed difference can obtain a stable surplus length. Finally, the wire is taken up and loaded onto a reel through the wire taking-up controller 10 and the gantry wire taking-up device 11.

[0029] like Figure 2 As shown, a carbon fiber composite material distributed reinforced load-bearing cable production system includes a cage stranding machine 12, a wire drawing die 13, a curing section 14, an annealing control device 18, a cooling section 15, a double-wheel traction device 16 and a gantry take-up device 17.

[0030] The cage stranding machine 12 comprises two cage stranding machines, one with 1+6 drums and the other with 12 drums. The wire-releasing speed of the cage stranding machine is synchronized with the double-wheel traction 16 .

[0031] Before the wire is cured, the prepreg can be deformed, and the wire passes through the wire paralleling die 13 to obtain a stranded wire with a round or polygonal single-wire cross-section. There is a set of straightening and collecting devices on both sides of each curing tube. The straightening and collecting devices have a straightening pulley, a conductive slip ring and a drainage row, and a temperature sensor is installed in the curing tube. The DC current output by the annealing control equipment can be transmitted to the pulley. The cooling section 15 is a section of hollow metal tube. The cooling method uses a fan to blow water mist and cold air into the cooling tube for heat exchange. There is a meter at the end of the cooling section. The cooled wire passes through the double-wheel traction device 16 and then reaches the gantry take-up device 17.

[0032] The specific process is as follows: (1) According to the design requirements, the pitch and the pay-off speed are selected according to the pitch-diameter ratio. After the wire passes through the wire-joining die 13, it becomes a twisted structure of 7 to 19 round wires or 3 to 27 polygonal wires, and the resin of the prepreg is further evenly distributed during the pultrusion process.

[0033] (2) The wire enters the curing section 14 after passing through the straightening pulley of the straightening collector. The curing section includes two sections of heating tubes. The temperature of the metal tube inside the first heating tube is heated to 100°C to preheat the wire. After the pulley of the straightening collector contacts the metal layer of the wire, it is connected to the DC power supply of the annealing control device, so the wire can be heated by short-circuit heating. Before entering the second heating tube, the temperature of the wire cannot be higher than 180°C. When the wire leaves the end of the second curing tube, the temperature is best at 230°C. The horny pulley of the last straightening collector only needs to be in good contact with the surface of the wire, and no excessive pressure can be applied.

[0034] (3) After the wire enters the cooling section 15, a fan is used to blow cold air and water mist into the cooling pipe to cool the wire.

[0035] (4) The wire is cooled to below 40°C to release the thermal stress, and then it is taken up and loaded onto a reel through a double-wheel traction device 16 and a gantry take-up device 17.

[0036] like Figure 3 As shown, the carbon fiber composite material distributed reinforced load-bearing cable prepared by the above process is made of a plurality of concentrically twisted single wires. The center of each single wire of the load-bearing cable is a carbon fiber reinforced composite material 20, and the outer layer is copper or copper alloy 19.

[0037] The above description is only a preferred embodiment of the present invention and does not limit the present invention in any form. Although the present invention has been disclosed as a preferred embodiment as above, it is not used to limit the present invention. Any technical personnel in this field can make some changes or modify the technical contents disclosed above into equivalent embodiments without departing from the scope of the technical solution of the present invention. However, any brief modifications, equivalent changes and modifications made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solution of the present invention are still within the scope of the technical solution of the present invention.

Claims

1. A carbon fiber composite material distributed reinforced load-bearing cable, characterized in that: The load-bearing cable is formed by concentrically twisting a plurality of monofilaments. The center of each monofilament of the load-bearing cable is a carbon fiber reinforced composite material, and the outer layer is copper or copper alloy.

2. A method for manufacturing a carbon fiber composite material distributed reinforced load-bearing cable, characterized in that: The following steps are involved: (1) Preparation of copper or copper alloy coated carbon fiber prepreg The copper or copper alloy coated carbon fiber prepreg preparation system includes: a creel, a glue injection machine, a copper tape unwinding device, a yarn spreading and impregnation device, a tape storage device, a copper tape longitudinal wrapping and welding part, a copper tube drawing and eddy current flaw detection part, a wire take-up controller and a gantry wire take-up device; The yarn rack controls the fiber pay-off tension through a magnetic damping tension controller, guides the fiber to pass through the yarn cloth and impregnation device, and the glue injection machine injects epoxy resin mixed glue of a certain temperature and pressure into the cavity of the yarn cloth and impregnation device through the glue injection tube. The temperature in the device is stabilized at 80°C by a controllable temperature heater, and the fiber is fully impregnated and tightened into a bundle of prepreg. The copper belt on the storage device is synchronously guided to the copper belt longitudinal wrapping and welding part by the copper belt pay-off device. After the longitudinal wrapping is formed, it is welded into a mother tube. The mother tube passes through the drawing die of the copper tube drawing and eddy current flaw detection part to become a copper tube prepreg wire of the specified specification, and finally the wire is taken up and reeled by the wire take-up controller and the gantry wire take-up device. (2) Preparation of carbon fiber composite material distributed reinforced load-bearing cables The catenary preparation system includes: stranding machine, doubling die, curing section, annealing control equipment, cooling section, traction device and gantry take-up device; According to the design requirements, the pitch and the pay-off speed are selected according to the pitch-diameter ratio. The copper tube prepreg wire prepared in step (1) is passed through a wire-drawing die to obtain a stranded wire with a round or polygonal single-wire cross section. The resin of the prepreg is further evenly distributed during the pultrusion process. The prepreg is then cured in a curing section. After the cured and cooled wire is passed through a traction device, it is loaded onto a gantry take-up device.

3. The method for manufacturing a carbon fiber composite material distributed reinforced load-bearing cable according to claim 2, characterized in that: The glue injection tube is a needle-type glue injection tube.

4. The method for manufacturing a carbon fiber composite material distributed reinforced load-bearing cable according to claim 2, characterized in that: The prepreg preparation system also includes a crawler traction device and a tension tracking feedback device and a large wheel traction. The crawler traction device is the main traction. The tension tracking feedback device and the large wheel traction are used to track the traction tension feedback to achieve excess length control of the carbon fiber composite wire prepreg.

5. The method for manufacturing a carbon fiber composite material distributed reinforced load-bearing cable according to claim 2, characterized in that: The wire stranding machine is a cage-type wire stranding machine.

6. The method for manufacturing a carbon fiber composite material distributed reinforced catenary cable according to claim 5, characterized in that: The cage-type stranding machines include two cage-type stranding machines, one with 1+6 drums and the other with 12 drums. The wire-releasing speed of the cage-type stranding machines is synchronized with the double-wheel traction device.

7. The method for manufacturing a carbon fiber composite material distributed reinforced load-bearing cable according to claim 2, characterized in that: The stranded wire is a plurality of strands twisted concentrically.

8. The method for manufacturing a carbon fiber composite material distributed reinforced load-bearing cable according to claim 2, characterized in that: Each curing tube in the curing section is provided with a set of straightening and collecting devices on both sides. The straightening and collecting devices include a straightening pulley, a conductive slip ring and a drainage row. A temperature sensor is provided in the curing tube. The DC current output by the annealing control device is transmitted to the pulley.

9. The method for manufacturing a carbon fiber composite material distributed reinforced catenary cable according to claim 8, characterized in that: The curing section includes two sections of heating tubes, wherein the temperature of the metal tube inside the first heating tube is heated to 100°C to preheat the wire; after the pulley of the straightening collector contacts the metal layer of the wire, it is connected to the DC power supply of the annealing control device, so the wire can be heated by short-circuit heating; before entering the second section of the heating tube, the temperature of the wire cannot be higher than 180°C, and when the wire leaves the end of the second section of the curing tube, the temperature reaches 230°C for the best.

10. The method for manufacturing a carbon fiber composite material distributed reinforced load-bearing cable according to claim 2, characterized in that: The cooling section is a hollow metal tube. The cooling method uses a fan to blow water mist and cold air into the cooling tube for heat exchange. A meter is provided at the end of the cooling section.

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