Liquid cooling charging pile super charging cable cabling process and device thereof

Abstract

This invention relates to the field of liquid-cooled charging pile supercharging cable technology, specifically to a cable-laying process and apparatus for liquid-cooled charging pile supercharging cables. The process includes a traction and guide fixture, a shaping fixture, a centralized guide bakelite mold, a horseshoe-shaped tube, and two main power lines. The traction and guide fixture is a T-shaped stainless steel frame with a horseshoe groove. Two symmetrical ceramic eyelets are arranged on either side of the horseshoe groove for positioning the main power lines and the horseshoe-shaped tube. This invention serves as the first step in the semi-finished cable-laying process of liquid-cooled supercharging cables for new energy vehicles, involving the twisting and bonding of the horseshoe-shaped tube and the second step involving the twisting of the main and auxiliary ground wires, control wires, signal wires, and shielding tape. This ensures a high pass rate for all physical and mechanical performance tests and use of the finished cable after extrusion, reducing labor costs and improving process efficiency, thus realizing the economic and social value of liquid-cooled supercharging cables.

Description

Technical Field

[0001] This invention relates to the field of supercharging cable fabrication technology for liquid-cooled charging piles, specifically to a fabrication process and apparatus for supercharging cables for liquid-cooled charging piles. Background Technology

[0002] With high-power DC charging becoming the mainstream direction for new energy vehicle charging, the construction of integrated photovoltaic and energy storage liquid-cooled supercharging systems has become one of the most popular infrastructure projects in the current new energy charging field. Many leading companies in the photovoltaic, wind, energy storage, and charging industries are investing heavily in equipment such as liquid-cooled supercharging cables, smart charging guns, smart charging piles, and smart battery swapping stations. The development of intelligent liquid-cooled modules is progressing rapidly, contributing to the development of a high-quality integrated charging infrastructure system. As liquid-cooled supercharging cables, they exhibit multiple modes, specifications, structures, and functions, including ordinary isolation liquid-cooled structures, copper-clad water liquid-cooled structures, water-clad copper liquid-cooled structures, fully immersed liquid-cooled structures, and crescent-shaped combined liquid-cooled structures. Although the structures of various liquid-cooled supercharging cables differ, their overall functional goals are consistent, and the insulation and sheathing materials used also vary greatly. However, the products suffer from a common and fatal flaw in application: occasional severe leakage occurs during use. This can lead to minor issues such as burning of the charging connector connection points, or even battery fires, causing significant psychological distress for end-users. To this end, new energy charging cable manufacturers have explored a path from liquid cooling channels of cooling water pipes to cooling pipe structure mode, and have made bold innovations in liquid cooling structure and cooling heat dissipation area, constantly pursuing structural optimization and the optimal solution for wire temperature rise.

[0003] Charging stations generate a significant amount of heat during operation. If this heat is not dissipated promptly, it can severely impact the lifespan of the charging station. Currently, the main heat dissipation methods for charging stations are water cooling and air cooling. However, water-cooled high-power charging cables inherently carry significant risks due to their water-coated copper, copper-coated water, and fully submerged structures. These structures are prone to leakage during manufacturing and application, posing a battery fire hazard to users. Furthermore, existing liquid-cooled supercharging cables have limited heat dissipation area, making it difficult to meet the demands of high-power charging. To gain a foothold in the liquid-cooled supercharging field, innovative designs for liquid-cooled pipes and their unique liquid-cooled cable pathways have emerged. Summary of the Invention

[0004] To address the aforementioned deficiencies and problems, this invention provides a cabling process and apparatus for liquid-cooled supercharging cables for charging piles. This invention achieves high pass rates and safety and reliability for all physical and mechanical performance tests and put-in-use of the finished cable after extrusion, while reducing labor costs and improving process efficiency. This realizes the economic and social value of liquid-cooled supercharging cables. Through innovative cabling processes and apparatus design, this invention effectively solves the technical problems existing in current liquid-cooled supercharging cables, significantly improving cable safety, heat dissipation performance, mechanical properties, and production efficiency, while reducing production costs, resulting in significant economic and social benefits.

[0005] The solution adopted by this invention to solve its technical problem is: a cabling device for supercharging cables of liquid-cooled charging piles, including a traction and guiding fixture, a shaping fixture, a centralized guide bakelite mold, a horseshoe-shaped tube, and two main power lines. The traction and guiding fixture is a T-shaped stainless steel frame with a horseshoe groove at its center. Two wire-passing holes are symmetrically arranged on both sides of the horseshoe groove for positioning the main power lines and the horseshoe-shaped tube. The shaping fixture consists of two guide wheels, which are rotatably mounted on bearing guide columns and symmetrically coordinate to form a horseshoe-shaped guide groove at the center, used to clamp the main power lines in the wire grooves at the edge of the horseshoe-shaped tube to form a horseshoe-shielded stranded structure. The centralized guide bakelite mold has a through groove in its center for the horseshoe-shielded stranded structure to pass through, thereby shaping the outer diameter of the horseshoe-shielded stranded structure.

[0006] It also includes a movable tooling base, a horizontal laying load-bearing base, and a middle rectangular structural component. The traction guide tool and the shaping tool are mounted on the movable tooling base to form a first layer of cable-forming device. The horizontal laying load-bearing base, the middle rectangular structural component, and the shaping tool are mounted to form a traction device. The traction guide tool, the shaping tool, the horizontal laying load-bearing base, and the middle rectangular structural component are mounted to form a second layer of cable-forming and diverting device.

[0007] Furthermore, the traction guide fixture is a T-shaped stainless steel frame. At the center of the traction guide fixture, there is a horseshoe-shaped through-channel opening that can be passed through. At two-fifths of the position symmetrically centered on the horseshoe groove, there are two balanced and symmetrical through holes for the main power line to pass through.

[0008] Furthermore, a longitudinal sliding plate is slidably installed on one side of the movable tooling base, and a support seat is vertically fixed above the longitudinal sliding plate. A traction guide tool is installed at the top of the support seat. Longitudinal slide rail grooves are symmetrically arranged on the left and right sides of the longitudinal sliding plate. A positioning bolt passing through the longitudinal slide rail groove is installed on the movable tooling base, and the longitudinal sliding plate is locked and positioned on the movable tooling base by the positioning bolt. Two transverse sliding plates are symmetrically slidably installed on the front side of the movable tooling base. A column is vertically fixed near the end of the two transverse sliding plates. The bearing guide post of the shaping tool is installed on the column, and a locking bolt is installed on the bearing guide post. Transverse slide rail grooves are provided on the transverse sliding plates, and positioning bolts passing through the transverse slide rail grooves are installed on the movable tooling base. The two shaping tools are locked on the transverse sliding plates by the positioning bolt.

[0009] Furthermore, the traction device consists of a horizontal wire laying support base, two upper and lower locking clamps, and a shaping fixture. The horizontal wire laying support base is a circular disc structure with four hollowed-out ring structures on it. The two locking clamps are T-shaped structures that cooperate to form a middle rectangular structure. The front end of the longitudinal rod of the middle rectangular structure is fixed on the horizontal wire laying support base. The bearing guide posts are symmetrically fitted through the horizontal plate bearing seat of the locking clamps, and the two guide wheels are rotatably fitted on the two bearing guide posts.

[0010] Furthermore, locking bolts are installed on both sides of the horizontal plate of the locking clamp and on the shaft seat of the locking clamp to lock and fix the shaped tooling of the traction device.

[0011] Furthermore, the second-layer cable-forming and diverting device includes upper and lower locking clamps, a horizontal cable-laying support base, a shaping fixture, and a traction guide fixture. The upper and lower locking clamps form a middle rectangular structure. The shaping fixture is installed in the rear horizontal plate of the middle rectangular structure. The horizontal cable-laying support base is fixed to the front end of the middle rectangular structure. The traction guide fixture is installed on the middle rectangular structure and located between the shaping fixture and the horizontal cable-laying support base.

[0012] Furthermore, the middle rectangular structural component of the second-layer cable-separating device adopts a slide rail channel design. A slide rail channel is opened on the longitudinal rod of the locking clamp along the extension direction of the rod body. Positioning bolts are set on the upper and lower sides of the traction guide fixture. The positioning bolts pass through the slide rail channel and lock the traction guide fixture.

[0013] Furthermore, locking bolts are installed on the upper and lower locking plates and bearing guide pillars to coordinate the central traction of the cable-forming center horseshoe shield stranded structure.

[0014] Furthermore, the support base is constructed from a telescopic cylindrical alloy steel frame structure, on which two locking bolts are provided for locking.

[0015] A cabling process for a liquid-cooled charging pile supercharging cable, characterized by the following steps:

[0016] First, the two main power lines and the horseshoe-shaped tube are horizontally positioned and pulled forward through the corresponding holes of the traction guide fixture. Through the combined action of centrifugal force and centripetal force generated by the two rotating guide wheels, the left and right symmetrical main power lines are horizontally embedded into the two large semi-circular grooves of the horseshoe-shaped tube, forming a horseshoe shielded stranded structure component consisting of the two main power lines and the central horseshoe-shaped tube, thus completing the first layer of cabling process.

[0017] Next, the horseshoe shielded stranded structure formed by the first layer of cabling process is wrapped with aluminum foil on the cage winding machine and enters the traction device. It passes through the central circular hole of the horizontal laying load-bearing base and the central guide groove of the front shaping tool. It is pulled forward by the rotation of two guide wheels and shaped by the squeezing of the two guide wheels. The horseshoe shielded stranded structure wrapped with aluminum foil is further positioned and shaped.

[0018] Then, the shaped horseshoe-shielded stranded structure enters the second layer of the cable-forming and distribution device. The horseshoe-shielded stranded structure, inner and outer shielding tapes, signal lines, and control lines are respectively pulled into the tooling for positioning by the cable-forming and distribution device and then pulled into the shaping tooling of the cable-forming and distribution device together with the horseshoe-shielded stranded structure to complete the tight stranding of the inner and outer shielding tapes, signal lines, and control lines into a cage-stranded cable.

[0019] The beneficial effects of the present invention are as follows: The cable-forming device of the present invention achieves precise positioning of the main power line and the horseshoe structure tube through the cooperation of the traction guide tool and the shaping tool, ensuring that the main power line can be embedded into the horseshoe structure tube in a uniform, uniform speed and uniform direction, forming a stable horseshoe shielded stranded structure, thereby improving the quality and efficiency of cable formation.

[0020] This invention, through its unique horseshoe-shaped structure design and cabling process, increases the heat dissipation area of ​​the main power lines and liquid-cooled pipes, and utilizes materials with high thermal conductivity, significantly improving the heat dissipation performance of the liquid-cooled supercharging cable. This effectively reduces the temperature rise of the cable during operation, ensuring that the temperature rise of the cable is controlled within a reasonable range during high-power charging, thus extending the cable's service life. Furthermore, by optimizing the cabling process and equipment for the liquid-cooled supercharging cable, this invention effectively solves the problem of leakage risk in the application of liquid-cooled supercharging cables, significantly improving the cable's safety and reliability.

[0021] The cable-forming device of the present invention adopts a modular design, and each component can be adjusted and replaced as needed, which has high flexibility and scalability. By optimizing the process flow and device design, the present invention reduces working hours, lowers production costs, and improves production efficiency, achieving the goal of minimizing working hours and optimizing costs. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the irregular-shaped device for the first layer of cabling structure of the present invention;

[0023] Figure 2 This is a schematic diagram of the movable tooling base and the traction and shaping tooling of the present invention;

[0024] Figure 3 This is a schematic diagram of the traction structure of the present invention;

[0025] Figure 4 This is a schematic diagram of the structure of the two guide wheels of the present invention.

[0026] Figure 5 This is a schematic diagram of the traction device of the present invention;

[0027] Figure 6 This is a schematic diagram of the second-layer cable-forming structure irregular device of the present invention;

[0028] Figure 7 This is a process flow diagram of the present invention.

[0029] In the diagram: 1. Traction guide fixture; 101. Horseshoe groove; 102. Threading hole ceramic eye; 2. Shaping fixture; 201. Bearing guide post; 202. Guide wheel; 203. Horseshoe structural component threading groove; 3. Movable fixture base; 4. Support base; 5. Longitudinal sliding plate; 501. Longitudinal slide rail groove; 6. Transverse sliding plate; 601. Transverse slide rail groove; 7. Column; 8. Centralized guide bakelite mold; 9. Horseshoe shielded twisted structure component; 91. Horseshoe structural tube; 911. Wire groove; 92. Main power line; 10. Locking clamp; 11. Slide rail channel; 12. Horizontal laying load-bearing base; 13. Positioning bolt. Detailed Implementation

[0030] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0031] Please see Figure 1-7 This invention provides a technical solution for the cabling process and apparatus of liquid-cooled charging pile supercharging cables:

[0032] Example 1:

[0033] according to Figure 1 and Figure 2 As shown, a cabling device for a liquid-cooled charging pile supercharging cable includes a traction and guide fixture 1, a shaping fixture 2, and a centralized guide bakelite mold 8. The traction and guide fixture 1 is a T-shaped stainless steel frame, and the positioning groove of the traction and guide fixture 1 consists of two... 102 ceramic eye for threading hole and one pcs The horseshoe groove 101 structure is mainly used to position the horseshoe shielded stranded structure 9 of the liquid-cooled supercharged cable's main power line and the overall liquid-cooled pipeline structure, thus completing the positioning of the cable's central key structure. Specifically, as follows... Figure 3 As shown, a horseshoe-shaped through-passage channel 101 with a horseshoe structure is set at the center of the vertical frame of the T-shaped stainless steel seat traction guide fixture 1. Symmetrically positioned at two-fifths of the distance from the horseshoe groove 101, two symmetrically placed ceramic eye holes 102 are provided for the main power lines 92 of the liquid-cooled charging pile cable to pass through smoothly. With this arrangement, one horseshoe-shaped tube 91 and two main power lines 92 are evenly distributed in the same horizontal direction when passing through the traction guide fixture 1.

[0034] The shaping fixture 2 consists of two The guide wheel is composed of rounded corner electroplated zinc alloy guide wheels. Two guide wheels 202 are installed on the bearing guide post 201 and form a horseshoe structure guide groove 203 in the center in a symmetrical and coordinated manner. The main function is to make the two insulated main power lines 92 of the liquid-cooled supercharging cable accurately, symmetrically and completely stuck in the groove 911 on the edge of the horseshoe structure tube 91. Its function is to take advantage of the self-rotation function of the gyro-shaped rotating structure by the pull force of the wire during the tensionless wire release process. After the two main power lines 92 are introduced into the shaping tool 2 by the traction guide tool 1, they are tightly squeezed by the two guide wheels 202, so that the two balanced and symmetrical horizontally placed main power lines 92 are evenly, at the same speed and in the same direction embedded into the groove 911 of the horizontally advancing horseshoe structure tube 91. This completes the overall shaping and positioning of the wire / groove and realizes the integrated wrapping work for the next high temperature wrapping process.

[0035] Centralized import bakelite mold 8 Made from bakelite molds, the centrally fed bakelite mold 8 has a through slot that allows the horseshoe shielded stranded structure 9 to pass smoothly. Its main function is to allow the two stranded main power lines and the central positioning horseshoe structure tube insulator to pass smoothly and to complete the outer diameter shaping, so as to achieve a compact effect and the purpose of positioning, shaping, rounding and diameter shaping of the stranded cable.

[0036] like Figure 1As shown, the traction guide fixture 1, the shaping fixture 2, and the centralized guide bakelite mold 8 are integrated and installed on the movable fixture base 3, forming the overall structure of the movable guide rail fixture base and the traction guide fixture 1, the shaping fixture 2, and the centralized guide bakelite mold 8. The traction guide fixture 1 and the shaping fixture 2 are movably installed on the movable fixture base 3 through the longitudinal large base, the transverse base, and the locking bolt components. Specifically, the movable tooling base 3 is installed on two sliders of the fixed bracket in the middle of the cage winding machine. The specific structure of the cage winding machine is existing technology and is not shown here. The bottom of the movable tooling base 3 is equipped with locking bolts, which can be adjusted back and forth and left and right on the fixed bracket of the cage winding machine and locked in place. The movable tooling base 3 supports the traction guide tool 1 and the shaping tool 2. A longitudinal sliding plate 5 is slidably installed on one side of the movable tooling base 3. A support seat 4 is vertically fixed above the longitudinal sliding plate 5. The support seat 4 is composed of a telescopic cylindrical alloy steel frame structure, which is equipped with two locking bolts for locking. The top of the alloy steel frame structure support seat 4 is a T-shaped integrated stainless steel seat frame for the traction guide tool 1. The longitudinal sliding plate 5 is symmetrically provided with longitudinal slide rail grooves 501. The movable tooling base 3 is equipped with positioning bolts that pass through the longitudinal slide rail grooves 501. The longitudinal sliding plate 5 can slide back and forth on the movable tooling base 3 through the longitudinal slide rail grooves 501 to adjust the position of the traction guide tool 1 and lock it in place by the positioning bolts.

[0037] Two transverse sliding plates 6 are symmetrically slidably installed on the front side of the longitudinal sliding plate 5 on the movable tooling base 3. The near ends of the two transverse sliding plates 6 are vertically fixed with columns 7. The shaping tooling 2 is installed on the columns 7. Specifically, a bearing guide post 201 is fitted on the column 7. A guide wheel 202 is rotatably fitted on the bearing guide post 201. A locking bolt is installed on the bearing guide post 201. The height of the shaping tooling 2 on the column 7 can be adjusted by the locking bolt, so that the horseshoe structure of the shaping tooling 2 is aligned with the horseshoe groove 101 through the guide groove 203, so that it can play the self-rotation function of the gyro-shaped rotating structure, and the two balanced and symmetrically placed main power lines 92 are evenly, at the same speed and in the same direction embedded into the groove 911 of the horseshoe structure tube 91 that is moving horizontally. A transverse sliding plate 6 is provided with a transverse sliding rail groove 601, and a positioning bolt that passes through the transverse sliding rail groove 601 is installed on the movable tooling base 3. The two fixed toolings 2 can be adjusted to be closer or farther from each other by adjusting their positions through the transverse sliding plate 6, and the position of the fixed tooling 2 can be locked by the positioning bolt, thereby forming a guide groove for matching the horseshoe shielded twisted structure 9.

[0038] The movable main structure tooling base, together with the T-shaped horizontal main power line plus horseshoe structure tube cable guide tooling and the detachable cylindrical support gyroscope-shaped rotatable guide wheel cable feeding tooling, form the main part of the irregular-shaped device for the supercharging cable laying process of liquid-cooled charging piles. Its main function is: through the traction of the horizontal guide wire and the horseshoe structure plastic parts, the two main power lines are horizontally and reliably and stably embedded into the horizontally advancing horseshoe structure tube under the positioning of the fixed horizontal force and the fixed semi-circular structure, plus the rotational force of the two fixed guide wheels.

[0039] In practical use, the cabling device for a liquid-cooled supercharging cable of this invention utilizes the combined centrifugal and centripetal forces generated by the two symmetrical active force lines 92 and two rotating guide wheels in the liquid-cooled supercharging cable to horizontally embed the symmetrical active force lines 92 into the two large semicircular grooves 911 of the horseshoe-shaped tube 91, achieving horizontal and positive fixed positioning. Due to the mechanical horizontal centrifugal force of the cage winding machine causing the core wire to move tangentially around the guide wheel 202, and the centripetal force causing the core wire to move axially towards the rotating guide wheel, when the two active force lines 92 simultaneously generate horizontal movements in the same direction, the two active force lines 92 neither move away from nor close to the rotating guide wheel. The active force lines 92 actively rotate around the axis of the rotating guide wheel, thereby uniformly embedding the two active force lines 92 horizontally into the centrally fixed horseshoe-shaped tube 91. Because the diameter and track size of the rotating zinc alloy guide wheel are in the shape of a frustum, the five components form an inseparable horizontal assembly according to the gyro mechanics structure, realizing a perfect combination of the two main power lines 92, the two rotating guide wheels, and the central horseshoe structure tube 91, thus completing the first layer of cabling process.

[0040] Example 2:

[0041] Based on Embodiment 1, the horseshoe-shaped shielded stranded structure 9, formed by the above-mentioned positioning and pressing, is wrapped with aluminum foil on the outer layer of the cable on the cage winding machine. The process of wrapping the cable with aluminum foil is existing technology and is not the main technical solution of this application, so it is not described in detail here. The shielded horseshoe structure containing the horseshoe-shaped tube 91, two main power lines 92 and shielding aluminum foil is pulled into the cable forming and distribution device by a traction device. The specific structure of the traction device is as follows: Figure 5 As shown, the main structure of the device consists of a horizontal laying load-bearing base 12, upper and lower locking clamps 10, a shaping fixture 2, locking bolts for the upper and lower locking clamps, and locking center bearing studs.

[0042] Specifically, the horizontal laying-out support base 12 adopts a diameter of The disc is circular with four hollowed-out ring structures for easy installation and to coordinate the center of gravity with the central rectangular structure. The upper and lower locking clamps 10 are T-shaped and fit together to form the central rectangular structure. The front end of the longitudinal rod of the T-shaped locking clamp 10 is fixed on the horizontal laying support base 12. The shaping fixture 2 is installed between the upper and lower horizontal plates at the front end of the rectangular locking structure. The shaping fixture 2 here is largely the same as the shaping fixture 2 in Embodiment 1. The difference is that the bearing guide post 201 is symmetrically inserted and fitted into the shaft seat of the horizontal plate of the locking clamp 10. The two guide wheels 202 are respectively rotatably fitted on the two bearing guide posts 201 and located between the upper and lower horizontal plates of the locking clamp. Locking bolts are installed on both sides of the horizontal plate of the locking clamp and on the shaft seat of the locking clamp to lock and fix the shaping fixture 2.

[0043] The horseshoe-shaped tooling 2 has a guide slot 203, the center line of the middle rectangular structure, and the horizontal laying support base 12 set coaxially. The middle rectangular structure is designed as a horseshoe-shaped female seat module, which allows the horseshoe-shaped shielded twisted structure 9 wrapped with aluminum foil to pass through the female seat module smoothly and quickly.

[0044] In practical use, the cabling device for the supercharging cable of the liquid-cooled charging pile of the present invention, after the horseshoe shielded stranded structure 9 formed by the first layer of cabling process is wrapped with aluminum foil on the cage winding machine, it enters the traction device, passes through the central circular hole of the horizontal laying load-bearing base 12 and the central guide groove of the front shaping tool 2, and is pulled forward by the rotational movement of the two guide wheels 202, and is further positioned and shaped by the compression of the two guide wheels 202.

[0045] Example 3:

[0046] Based on Embodiment 2, the horseshoe-shaped shielded stranded structure 9, which has undergone the first layer of processing and is positioned by the traction device, enters the cable-forming and diverting device for the second layer of processing. The cable-forming and diverting device includes a locking clamp 10, a horizontal cable-laying support base 12, a shaping fixture 2, and a traction guide fixture 1. The locking clamp 10, the horizontal cable-laying support base 12, and the shaping fixture 2 of the cable-forming and diverting device have the same structure as the traction device in Embodiment 2. The traction guide fixture 1 of the cable-forming and diverting device has the same structure as the traction guide fixture 1 in Embodiment 1, but the installation method is different. Specifically, the cable-forming and diverting device provided in this embodiment consists of two upper and lower locking clamps 10 forming a middle rectangular structure. The shaping fixture 2 is installed in the rear horizontal plate of the middle rectangular structure, and the horizontal cable-laying support base 12 is fixed to the front end of the middle rectangular structure. The middle rectangular structure adopts a slide rail channel design. A slide rail channel 11 is opened on the longitudinal rod of the locking clamp 10 along the extension direction of the rod body. In this embodiment, the traction guide fixture 1 is provided with positioning bolts 13 on the upper and lower sides, and the positioning bolts 13 penetrate through the slide rail channel 11. The installation range of the traction guide fixture 1 in the cable-forming and diverting device is within the slide rail channel 11. The pitch length of the traction guide fixture 1 for the second layer of cable-forming process can be adjusted and the positioning of the central structure can be fine-tuned. The positioning is locked and positioned by the positioning bolts 13. Furthermore, the upper and lower locking clamps 10, the locking bolts of the upper and lower locking clamps, and the locking bolts of the bearing guide post 201 can fully coordinate the center traction of the horseshoe shield stranded structure 9 in the cable formation center. At the same time, the inner and outer shielding wrapping tapes, signal lines, and control lines are guided into the tooling 1 by the cable formation diversion device and positioned, and together with the horseshoe shield stranded structure 9, they are pulled into the shaping tooling 2 of the cable formation diversion device, completing the tight stranding of the inner and outer shielding wrapping tapes, signal lines, and control lines in the cage stranded cable formation, and achieving the consistency and continuity of the cable's centripetal force.

[0047] Example 4:

[0048] Based on the above embodiments, all structural components of this device that pass through the horseshoe-shaped tube 91 and the main force line 92 guide wheel have undergone rounded corners and smooth electroplating treatment, which can prevent the product from being scratched, abraded, or worn in areas with fine processes.

[0049] All ceramic wire holes 102 can be replaced with wire holes made of nano-steel mold material, but the price is relatively expensive. At the same time, they are particularly wear-resistant and have a long service life. The material of the centralized inlet bakelite mold 8 is bakelite, which belongs to phenolic plastic. It can also be replaced with nylon material. Both have very good wear resistance, but their high temperature resistance is slightly worse than that of bakelite. Considering that it is used indoors, the impact is not obvious.

[0050] Example 5:

[0051] This embodiment provides a cabling process using the apparatus provided in embodiments 1 to 4 above. The horseshoe-shaped tube 91 and the main power line 92 are the central components of the entire liquid-cooled superchargeable cable, serving as the heart of the operation. The rotating guide wheel of the shaping tooling 2 is the running bridge that positions the running trajectory of the main power line 92. The centralized bakelite mold 8 is the clamping ring for shaping, sizing, and speed control in the first and second layers of the process. The traction device and the cabling diversion device are the central operating shielding structure of the horseshoe-shaped tube 91 + main power line 92 + shielding wrapping tape and the left and right locking guide wheel structure in the second layer of the cabling process, and are the key tooling for the second layer of the cabling process.

[0052] The first-layer cable-forming structure shaping device and the second-layer cable-forming structure shaping device provided in Examples 1, 2, and 3 together constitute the cable-forming process device for liquid-cooled charging pile supercharging cables. The two are interdependent and complementary processes, and neither can be omitted. The first-layer cable-forming structure shaping device is the main structural component of the horseshoe-shaped tube at the center of the cable. The second-layer cable-forming structure shaping device is a continuation of the first-layer cable-forming structure shaping device. The semi-finished product completed by the first-layer cable-forming structure shaping device, under the joint action of the second-layer cable-forming structure shaping device, completes the cage-stranding assembly process of the horseshoe-shaped tube main structural component, along with the surrounding 7 control lines, 2 pairs of signal lines, 2 red and black auxiliary ground wires, 1 yellow / green dual-color main power ground wire, high-temperature single-sided aluminum foil, and Class D flame-retardant non-woven fabric. This achieves the unified goal of liquid-cooled supercharging cable in terms of structural dimensions, mechanical and physical properties, electrical performance, and environmental resistance.

[0053] The aforementioned irregular tooling and molds form a complete unit, jointly completing the important process of irregular cable forming for liquid-cooled charging piles. At the same time, they combine to concentrate the mechanical stress and centripetal force of the irregular cable forming process, achieving the necessary process elements for the entire liquid-cooled supercharging cable to pass the swing test, low-temperature winding, and low-temperature tensile test.

[0054] Based on the fact that the thermal conductivity of metals is greater than that of non-metals, and the thermal conductivity of the solid phase of a material is greater than that of the liquid phase; and considering the effects of heat conduction, convection, and radiation at room temperature, the thermal conductivity of copper alloy is greater than that of aluminum foil, which is greater than that of silicone rubber, which is greater than that of silicone oil. Therefore, the main materials used in this irregularly shaped process device are: copper alloy, aluminum foil, silicone rubber, and silicone oil. According to the law of thermal conductivity, the rate of thermal conduction is inversely proportional to the thermal difference and inversely proportional to the thermal conductivity and heat transfer area. The comprehensive design of this structure maximizes the advantages of the heat transfer area and rate of thermal conduction of the materials to achieve the thermal conduction efficiency between the liquid-cooled supercharging cable materials.

[0055] The above description is only a preferred embodiment of the present invention and does not limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A cabling device for a liquid-cooled charging pile supercharging cable, comprising a traction and guide fixture (1), a shaping fixture (2), a centralized guide bakelite mold (8), a horseshoe-shaped tube (91), and two main power lines (92), characterized in that, The traction guide fixture (1) is a T-shaped stainless steel frame with a horseshoe groove (101) at its center. Two wire-passing ceramic eyes (102) are symmetrically arranged on both sides of the horseshoe groove (101) for positioning the main power line (92) and the horseshoe structure tube (91). The shaping fixture (2) consists of two guide wheels (202). The two guide wheels (202) are rotated and mounted on the bearing guide post (201), and symmetrically coordinate left and right to form a horseshoe structure part guide groove (203) at the center, which is used to clamp the main power line (92) in the wire groove (911) at the edge of the horseshoe structure tube (91) to form a horseshoe shielded twisted structure part (9). The central guide bakelite mold (8) has a through groove in the center to allow the horseshoe shielded twisted structure part (9) to pass through, so as to shape the outer diameter of the horseshoe shielded twisted structure part (9). It also includes a movable tooling base (3), a horizontal laying load-bearing base (12) and an intermediate rectangular structural component. The traction guide tool (1) and the shaping tool (2) are mounted on the movable tooling base (3) to form a first layer of cable forming device. The horizontal laying load-bearing base (12), the intermediate rectangular structural component and the shaping tool (2) are mounted to form a traction device. The traction guide tool (1), the shaping tool (2), the horizontal laying load-bearing base (12) and the intermediate rectangular structural component are mounted to form a second layer of cable forming and diverting device.

2. The cabling device for a liquid-cooled charging pile supercharging cable according to claim 1, characterized in that, The traction guide fixture (1) is a T-shaped stainless steel frame. A horseshoe groove (101) with a horseshoe structure is provided at the center of the traction guide fixture (1). At two-fifths of the position symmetrical about the horseshoe groove (101), there are two symmetrical threading holes (102) for the main force line (92).

3. The cabling device for a liquid-cooled charging pile supercharging cable according to claim 1, characterized in that, A longitudinal sliding plate (5) is slidably installed on one side of the movable tooling base (3). A support seat (4) is vertically fixed above the longitudinal sliding plate (5). A traction guide tool (1) is installed at the top of the support seat (4). Longitudinal slide rail grooves (501) are symmetrically arranged on the longitudinal sliding plate (5). A positioning bolt passing through the longitudinal slide rail groove (501) is installed on the movable tooling base (3). The longitudinal sliding plate (5) is locked and positioned on the movable tooling base (3) by the positioning bolt. The front of the movable tooling base (3) Two transverse sliding plates (6) are symmetrically slidably installed on the left and right sides. A column (7) is vertically fixed to the near end of the two transverse sliding plates (6). The bearing guide column (201) of the shaping fixture (2) is installed on the column (7) and a locking bolt is installed on the bearing guide column (201). A transverse slide rail groove (601) is provided on the transverse sliding plate (6), and a positioning bolt that passes through the transverse slide rail groove (601) is installed on the movable fixture base (3). The two shaping fixtures (2) are locked on the transverse sliding plate (6) by the positioning bolt.

4. The cabling device for a liquid-cooled charging pile supercharging cable according to claim 2, characterized in that, The traction device consists of a horizontal wire laying support base (12), two upper and lower locking clamps (10), and a shaping fixture (2). The horizontal wire laying support base (12) is a circular disc structure with four hollow ring structures on it. The two locking clamps (10) are T-shaped structures and are fitted together to form a middle rectangular structure. The front end of the longitudinal rod of the middle rectangular structure is fixed on the horizontal wire laying support base (12). The bearing guide post (201) is symmetrically fitted through the horizontal plate bearing seat of the locking clamp (10). The two guide wheels (202) are rotated and fitted on the two bearing guide posts (201).

5. The cabling device for a liquid-cooled charging pile supercharging cable according to claim 4, characterized in that, Locking bolts are installed on both sides of the horizontal plate of the locking clamp (10) and on the shaft seat of the locking clamp (10) to lock and fix the traction device fixture (2).

6. The cabling device for a liquid-cooled charging pile supercharging cable according to claim 1, characterized in that, The second-layer cable-forming and diverting device includes two upper and lower locking clamps (10), a horizontal cable-laying support base (12), a shaping fixture (2), and a traction guide fixture (1). The upper and lower locking clamps (10) form a middle rectangular structure. The shaping fixture (2) is installed in the rear horizontal plate of the middle rectangular structure. The horizontal cable-laying support base (12) is fixed to the front end of the middle rectangular structure. The traction guide fixture (1) is installed on the middle rectangular structure and located between the shaping fixture (2) and the horizontal cable-laying support base (12).

7. The cabling device for a liquid-cooled charging pile supercharging cable according to claim 6, characterized in that, The middle rectangular structure of the second layer cable distribution device adopts a slide rail channel design. A slide rail channel (11) is opened on the longitudinal rod of the locking clamp (10) along the extension direction of the rod body. Positioning bolts (13) are provided on the upper and lower sides of the traction guide tool (1). The positioning bolts (13) pass through the slide rail channel (11) and lock the traction guide tool (1).

8. A cabling device for a liquid-cooled charging pile supercharging cable according to claim 4 or 6, characterized in that, Locking bolts are installed on the upper and lower locking plates (10) and the bearing guide post (201) to coordinate the center traction of the cable center horseshoe shield stranded structure (9).

9. The cabling device for a liquid-cooled charging pile supercharging cable according to claim 3, characterized in that, The bracket (4) is composed of a telescopic cylindrical alloy steel frame structure with two locking bolts for locking.

10. A cable-forming process method using the cable-forming device for liquid-cooled charging pile supercharging cables according to claims 1-9, characterized in that, The following operational procedures are included: First, the two main power lines (92) and the horseshoe structure tube (91) are horizontally positioned and pulled forward through the corresponding holes of the traction guide tool (1) and the shaping tool (2). Through the combined action of the centrifugal force and centripetal force generated by the two rotating guide wheels (202), the left and right symmetrical main power lines (92) are horizontally embedded into the two large semi-circular grooves (911) of the horseshoe structure tube (91) which resembles a horseshoe structure, forming a horseshoe shielded stranded structure component (9) that is a combination of the two main power lines (92) and the central horseshoe structure tube (91), thus completing the first layer of cabling process. Next, the horseshoe shielded stranded structure (9) formed by the first layer of cabling process is wrapped with aluminum foil on the cage winding machine and then enters the traction device. It passes through the central hole of the horizontal wire laying support base (12) and the central guide groove of the front shaping fixture (2). It is pulled forward by the rotation of the two guide wheels (202) and further positioned and shaped by the compression of the two guide wheels (202). Then, the horseshoe-shaped shielded stranded structure (9) enters the second layer of the cable-forming and distribution device. The horseshoe-shaped shielded stranded structure (9), the inner and outer shielding tapes, and the signal and control lines are respectively guided into the traction tooling (1) of the cable-forming and distribution device and positioned. Together with the horseshoe-shaped shielded stranded structure (9), it is pulled into the shaping tooling (2) of the cable-forming and distribution device to complete the tight stranding of the inner and outer shielding tapes, signal and control lines into the cage-stranded cable.

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