A catenary cross-linked cable transition production method

Abstract

The application discloses a kind of catenary crosslinking cable transition production method, by pre-joining the conductor of the aluminum core cable to be produced with the transition conductor of the same material of the cable conductor to be ended production, and the transition conductor is butted with the cable conductor to be ended production, when second joint is pulled out of traction device, close conductor front preheater, when first joint enters the head of extruder, the equipment parameters of extruder are cleared, and the position is defined as the zero point of conductor meter position, when meter position runs to the appropriate, adjust cable suspension parameter, prevent cable from scratching with vulcanization pipe inner wall, finally, the production process parameters of vulcanization pipe parameter are adjusted to the production process parameters of aluminum core cable, realize continuous production without stopping, effectively improve production efficiency, reduce personnel, material and time waste problem, and then reduce cable production cost.

Description

Technical Field

[0001] The present invention relates to the technical field of cable production, in particular to a catenary cross-linked cable transition production method. Background Art

[0002] The catenary cross-linked cable production method is an advanced manufacturing process primarily used to produce high-voltage and ultra-high-voltage power cables. This method ensures excellent electrical performance and mechanical strength. Existing catenary cross-linked cables are mostly copper or aluminum conductors, with copper being the most common. Aluminum-core cables are widely used in power systems, construction sites, transportation facilities, and other fields due to their lightweight, low cost, and excellent electrical conductivity.

[0003] In actual production, both types of cables share a single production line. Due to the high copper content, this type of cable is primarily produced on the line. When aluminum-core cables need to be produced, the copper-core three-layer co-extrusion cross-linking machine must be shut down, and the production process must be readjusted before the aluminum-core three-layer co-extrusion cable can be produced. This shutdown and subsequent production inevitably increases labor and material costs, and consumes considerable time. Therefore, optimization of the existing cable switching production process is necessary. Summary of the Invention

[0004] The purpose of the present invention is to propose a catenary cross-linked cable transition production method to address the shortcomings of the existing technology, effectively solve the problem of waste caused by shutdown and re-production of catenary copper-aluminum cross-linked cables of the same size, effectively improve production efficiency and reduce cable production costs.

[0005] The technical solution for achieving the purpose of the present invention is:

[0006] A catenary cross-linked cable transition production method comprises the following steps:

[0007] Step S1: prepare an aluminum core conductor reel to be replaced on a pay-off device, and connect a section of transition copper conductor to the free end of the aluminum core conductor reel. The connection between the two is defined as the second joint.

[0008] Step S2: connecting the other end of the transition copper conductor to the copper core conductor that is about to be finished, and the connection between the two is defined as the first joint;

[0009] Step S3: After the second joint exits the upper traction device, the conductor preheater is turned off. After the first joint enters the die head of the extruder, the meter counter parameters on the control screen of the extruder are reset to zero, and this position is defined as the zero point of the conductor meter position.

[0010] Step S4: When the meter reaches 10m, the cable draping parameters on the draping controller are set to appropriate values ​​so that the copper core cable does not contact the inner lower wall of the vulcanized tube, and the conductor preheater is turned on according to the set parameters;

[0011] Step S5: When the zero point of the conductor meter position approaches the distance draping controller, the cable draping parameter on the draping controller is set to an appropriate value so that the rear aluminum core cable does not contact the upper wall of the vulcanized tube;

[0012] Step S6: Adjust the temperature of each section of the vulcanized tube to the set parameters of the aluminum core three-layer co-extrusion production process, and remove the transition copper conductor section and a section of the aluminum core conductor at the take-up position to start the machine adjustment process for the necessary test length to complete the transition of the copper-aluminum cross-linked cable of the same size.

[0013] Furthermore, the length of the transition copper conductor is greater than the length from the head of the extruder to the overhang controller.

[0014] Furthermore, in step S2, after the transition copper conductor and the copper core conductor are connected, the wire twister on the wire unwinding device is loosened, and the wire twister is tightened again after the first joint enters the head of the extruder.

[0015] Furthermore, the second joint uses a first connecting tube with a hollow structure to connect the transition copper conductor and the copper core conductor. The transition copper conductor and the copper core conductor are respectively inserted into the two ends of the first connecting tube, and the outer wall of the first connecting tube is pressed by external force to achieve fixed connection.

[0016] Furthermore, the length of the first connecting tube is 3.5 to 4.5 times the diameter of the conductor, and the wall thickness is 2.5 mm.

[0017] Furthermore, the inner wall of the first connecting pipe is provided with anti-slip lines.

[0018] Furthermore, the anti-slip lines are internal threads.

[0019] Furthermore, the first joint uses a second connecting tube and a third connecting tube that are rotatably connected to connect the transition copper conductor and the aluminum core conductor respectively. The outer ends of the second connecting tube and the third connecting tube are provided with blind holes, and the wall thickness of the blind holes is 2.5 mm. The transition copper conductor and the aluminum core conductor are respectively inserted into the corresponding blind holes, and the outer walls of the blind holes are pressed by external force to achieve fixed connection.

[0020] Furthermore, the end of the connecting end of the second connecting tube is arc-shaped and provided with a connecting groove, and both sides of the connecting groove extend to the outer peripheral surface of the second connecting tube. The connecting end of the third connecting tube is provided with a connecting portion with an arc-shaped end, and the connecting portion is inserted into the connecting groove and rotatably connected to the connecting groove through a connecting pin; the rotation direction of the second connecting tube and the third connecting tube is the same as the bending direction of the vulcanized tube.

[0021] Furthermore, the aluminum core conductor and the blind hole section of the third connecting tube are crimped in two sections.

[0022] Furthermore, the pressing force between the second connecting tube and the transition copper conductor is F1, and the pressing forces at the pressing points away from and close to the outer end of the third connecting tube are F2 and F3 respectively, and satisfy F2=85%-95% F1 and F2-F3=10% F1.

[0023] By adopting the above technical solution, the present invention has the following beneficial effects:

[0024] (1) The present invention changes the traditional method of stopping and reproducing copper-aluminum cross-linked cables with the same size specifications but different conductor materials. By pre-connecting a transition conductor made of the same material as the conductor of the cable that is about to be produced to the conductor of the aluminum core cable to be produced, and connecting the transition conductor with the conductor of the cable that is about to be produced, and at the same time adjusting the process parameters during the transition production process, continuous production without stopping is achieved, effectively improving production efficiency, reducing waste of personnel, materials and time, and thus reducing cable production costs.

[0025] (2) The present invention prevents the first joint of the copper-aluminum transition from being twisted off due to rotation after being pulled by adjusting the tightness of the thread twister at an appropriate time.

[0026] (3) The present invention adjusts the cable suspension parameters on the suspension controller at an appropriate time to ensure that the front copper core cable does not contact the lower wall of the vulcanized tube and the rear aluminum core cable does not contact the upper wall of the vulcanized tube, thereby preventing the three-layer co-extrusion from being scratched and damaged by the inner wall of the vulcanized tube, resulting in water ingress after entering the cooling tube.

[0027] (4) The present invention comprehensively considers the different materials of the aluminum core conductor and the copper core conductor. Due to the different tensile strengths of copper and aluminum, two different connection methods are selected at the two joints. A blind hole design is adopted at the second joint to ensure that the joint between the turning part and the aluminum conductor will not be twisted off due to weak tensile strength during the production process. It can not only meet the bending performance, but also ensure the water resistance after entering the cooling pipe (that is, the three-layer co-extruded material of the conductor will enter water after being damaged by hitting the vulcanized pipe wall, and the blind hole design prevents water from entering the other section of the conductor), thereby achieving smooth transition production.

[0028] (5) The second joint of the present invention adopts a two-stage crimping method, which fully considers the weak deformation resistance of the aluminum conductor and its lower strength compared to copper, ensuring that the outer monofilament is not broken by pressure and ensuring that it does not break during the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to make the content of the present invention more clearly understood, the present invention is further described in detail below based on specific embodiments and in conjunction with the accompanying drawings, wherein:

[0030] Figure 1 Flow chart of the method of the present invention;

[0031] Figure 2 This is a simplified structural diagram of the second joint of the present invention;

[0032] Figure 3 This is a simplified structural diagram of the first joint of the present invention. DETAILED DESCRIPTION

[0033] In order to better understand the above technical solution, the above technical solution will be described in detail below with reference to the accompanying drawings and specific implementation methods.

[0034] (Example 1)

[0035] This embodiment takes the switching of copper core conductor cable production to aluminum core conductor cable production as an example, and describes in detail a catenary cross-linked cable transition production method. Figure 1 As shown, the specific steps include:

[0036] Step S1: Prepare an aluminum core conductor reel to be replaced on the pay-off device, and connect a section of transition copper conductor to the free end of the aluminum core conductor reel. The connection between the two is defined as the second joint; the length of the transition copper conductor is greater than the length from the extruder head to the suspension controller. In this embodiment, the length of the transition copper conductor is 40m.

[0037] The second joint uses a hollow first connecting tube to connect the transition copper conductor and the copper core conductor. The length of the first connecting tube is 4 times the diameter of the conductor and the wall thickness is 2.5mm. Figure 2 As shown, after removing the outermost monofilaments of the conductor, the transition copper conductor and the copper core conductor are inserted into the two ends of the first connecting tube. A split hydraulic pliers is then used to crimp the outer wall of the first connecting tube to securely connect the two conductor segments. To enhance the connection strength between the first connecting tube and the conductor, the inner wall of the first connecting tube in this embodiment is provided with anti-slip grooves, preferably internal threads, for ease of processing.

[0038] Step S2: A second connecting tube and a third connecting tube are used to connect the other end of the transition copper conductor and the aluminum core conductor, respectively. The outer ends of the second and third connecting tubes are each provided with a blind hole, 90 mm long and 2.5 mm thick. Specifically, the connecting end of the second connecting tube has an arc-shaped end and a connecting groove, both sides of which extend to the outer circumference of the second connecting tube. The connecting end of the third connecting tube has an arc-shaped connecting portion, which is inserted into the connecting groove and rotatably connected to the connecting groove via a connecting pin.

[0039] After removing the outermost monofilaments from the transition copper conductor and the aluminum core conductor, they are inserted into their corresponding blind holes. A split hydraulic clamp is used to compress the outer walls of the blind holes to securely connect them, forming the first joint. Specifically, the blind hole section between the aluminum core conductor and the third connecting tube utilizes a two-stage crimping method to ensure that the outer monofilaments are not broken and prevent breakage during production. The clamping force between the second connecting tube and the transition copper conductor is defined as F1. The clamping forces at the crimping points away from and near the outer end of the third connecting tube are F2 and F3, respectively. F2 must equal 85% to 95% of F1, and F2 - F3 must equal 10% of F1.

[0040] After the transition copper conductor is connected to the copper core conductor, loosen the wire twister behind the lower seal to prevent the first joint of the copper-aluminum transition from being twisted off due to rotation after being pulled upward; at the same time, it is necessary to ensure that the rotation direction of the second connecting tube and the third connecting tube is the same as the bending direction of the vulcanized tube, so that the first joint can bend normally after entering the vulcanized tube to avoid scratching the inner wall of the vulcanized tube.

[0041] Step S3: After the second joint comes out of the traction device, turn off the conductor preheater. After the first joint enters the head of the extruder, tighten the wire twister again and reset the equipment parameters of the extruder. Define this position as the zero point of the conductor meter position.

[0042] Step S4: When the meter reaches 10m, the cable drape parameters on the drape controller are set to appropriate values ​​to prevent the copper-core cable from contacting the inner lower wall of the vulcanizing tube. The preheater is then activated according to the set parameters. In this embodiment, the preheater is set to 40°C, and the cable drape parameter is set to +15°C to prevent the three-layer co-extrusion cable from being scratched by the lower wall of the vulcanizing tube and causing damage, which could lead to water ingress into the cooling tube.

[0043] Step S5: When the zero point of the conductor meter position moves to 10 m in front of the suspension controller, the cable suspension parameter on the suspension controller is set to an appropriate value so that the rear aluminum core cable does not contact the upper wall of the vulcanized tube. In this embodiment, the cable suspension parameter is set to -15 to prevent the three-layer co-extrusion from being scratched by the upper wall of the vulcanized tube and damaged, resulting in water ingress after entering the cooling tube.

[0044] Step S6: Adjust the temperature of each section of the vulcanized tube to the set parameters of the aluminum core three-layer co-extrusion production process, and remove the transition copper conductor section and a section of the aluminum core conductor at the take-up position to start the machine adjustment process for the necessary test length to complete the transition of the copper-aluminum cross-linked cable of the same size.

[0045] The method of the present invention can effectively solve the problem of waste caused by shutdown and re-production of catenary copper-aluminum cross-linked cables of the same specification, effectively improve production efficiency, and reduce cable production costs. The one-time transition production can shorten the time for specification change due to shutdown by 12 hours, and save about 80m of copper conductor and three-layer co-extruded materials of corresponding specifications. The method is suitable for catenary cross-linking production lines, has low cost, high efficiency and good effect.

[0046] The specific embodiments described above further illustrate the objectives, technical solutions and beneficial effects of the present invention in detail. It should be understood that the above are only specific embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A catenary cross-linked cable transition production method, characterized in that: The following steps are involved: Step S1: prepare an aluminum core conductor reel to be replaced on a pay-off device, and connect a section of transition copper conductor to the free end of the aluminum core conductor reel. The connection between the two is defined as the second joint. Step S2: connecting the other end of the transition copper conductor to the copper core conductor that is about to be finished, and the connection between the two is defined as the first joint; Step S3: After the second joint exits the upper traction device, the conductor preheater is turned off. After the first joint enters the die head of the extruder, the meter counter parameters on the control screen of the extruder are reset to zero, and this position is defined as the zero point of the conductor meter position. Step S4: When the meter reaches 15% to 25% of the vulcanization pipe length, the cable draping parameters on the draping controller are set to appropriate values ​​so that the copper core cable does not contact the inner lower wall of the vulcanization pipe, and the conductor preheater is turned on according to the set parameters; Step S5: When the zero point of the conductor meter position approaches the distance draping controller, the cable draping parameter on the draping controller is set to an appropriate value so that the rear aluminum core cable does not contact the upper wall of the vulcanized tube; Step S6: Adjust the temperature of each section of the vulcanized tube to the set parameters of the aluminum core three-layer co-extrusion production process, and remove the transition copper conductor section and a section of the aluminum core conductor at the take-up position to start the machine adjustment process for the necessary test length to complete the transition of the copper-aluminum cross-linked cable of the same size.

2. A catenary cross-linked cable transition production method according to claim 1, characterized in that: The length of the transition copper conductor is greater than the length from the head of the extruder to the overhang controller.

3. A catenary cross-linked cable transition production method according to claim 1, characterized in that: In the step S2, after the transition copper conductor is connected to the copper core conductor, the wire twister on the wire unwinding device is loosened, and the wire twister is tightened again after the first joint enters the die head of the extruder.

4. The method for producing a catenary cross-linked cable transition according to claim 1, wherein: The second joint uses a first connecting tube with a hollow structure to connect the transition copper conductor and the copper core conductor. The transition copper conductor and the copper core conductor are respectively inserted into the two ends of the first connecting tube and the outer wall of the first connecting tube is pressed by external force to achieve a fixed connection.

5. A catenary cross-linked cable transition production method according to claim 4, characterized in that: The length of the first connecting tube is 3.5 to 4.5 times the diameter of the conductor, and the wall thickness is 2.5 mm.

6. A catenary cross-linked cable transition production method according to claim 4, characterized in that: The inner wall of the first connecting pipe is provided with anti-slip lines.

7. A catenary cross-linked cable transition production method according to claim 1, characterized in that: The first joint uses a second connecting tube and a third connecting tube that are rotatably connected to connect the transition copper conductor and the aluminum core conductor respectively. The outer ends of the second connecting tube and the third connecting tube are provided with blind holes. The wall thickness of the blind holes is 2.5 mm. The transition copper conductor and the aluminum core conductor are respectively inserted into the corresponding blind holes and the outer walls of the blind holes are pressed by external force to achieve fixed connection.

8. A catenary cross-linked cable transition production method according to claim 7, characterized in that: The connecting end of the second connecting tube is arc-shaped and provided with a connecting groove, and both sides of the connecting groove extend to the outer peripheral surface of the second connecting tube. The connecting end of the third connecting tube is provided with a connecting portion with an arc-shaped end, and the connecting portion is inserted into the connecting groove and is rotatably connected to the connecting groove through a connecting pin; the rotation direction of the second connecting tube and the third connecting tube is the same as the bending direction of the vulcanized tube.

9. A catenary cross-linked cable transition production method according to claim 7, characterized in that: The aluminum core conductor and the blind hole section of the third connecting tube are crimped in a two-stage manner.

10. A catenary cross-linked cable transition production method according to claim 9, characterized in that: The pressing force between the second connecting tube and the transition copper conductor is F1, and the pressing forces at the pressing points away from and close to the outer end of the third connecting tube are F2 and F3 respectively, and satisfy F2=85%~95%F1 and F2-F3=10%F1.

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