Preparation process of cable for oil-resistant heavy pump

Abstract

The invention relates to the technical field of wire and cable manufacturing, and discloses a preparation process of a cable for an oil-resistant heavy pump, and the process comprises the following steps: S1, preparing raw materials including a copper wire, an EVA material, a shielding layer material and a special rubber material; s2, after the copper wire conductor is formed, an EVA material is used for insulation treatment; s3, uniformly coating the EVA material on the surface of the copper wire conductor by the extruder; s4, uniformly winding the shielding layer material on the surface of the insulating layer of the cable; s5, heating and forming a special rubber material by using a twin-screw extruder to enable the special rubber material to become soft and plastic, and uniformly coating the special rubber material outside the shielding layer by using the extruder to form a sheath with the thickness of 2.5 mm; and S6, after all production processes are completed, the cable finished product needs to be subjected to strict inspection and performance test. The nano silicon dioxide is added into the insulating layer, so that the durability, the oxidation resistance and the electrical performance of the ethylene-vinyl acetate copolymer are improved, and the production cost can be reduced.

Description

Technical Field

[0001] The invention relates to the technical field of wire and cable manufacturing, and in particular to a preparation process of a cable for an oil-resistant heavy-duty pump. Background Art

[0002] At present, with the continuous development of industrial production, various mechanical equipment have higher and higher requirements for cables. Especially in the field of heavy industry, such as oil drilling platforms, chemical plants and other environments, cables not only need to withstand high mechanical stress, but also need to have good oil resistance and corrosion resistance. However, the performance of existing cable products in this regard still needs to be improved. Most of the mainstream cables on the market currently use PVC materials as insulation layers and sheaths. Although the cost is low, they are prone to aging in extreme environments such as high temperature, high pressure, and oil immersion, resulting in a decrease in electrical performance or even failure. Therefore, it is particularly important to develop a new type of oil-resistant heavy-duty pump cable.

[0003] The heat resistance and oil resistance of PVC materials can be improved by adding additives such as plasticizers and stabilizers. This method can extend the service life of cables to a certain extent, but due to the inherent defects of PVC itself, the effect is limited.

[0004] High-performance elastomer materials such as TPU (thermoplastic polyurethane) and TPEE (thermoplastic polyester elastomer) have good mechanical properties and chemical resistance. However, these materials are expensive and difficult to process, which limits their wide application.

[0005] By setting multiple protective layers inside the cable, such as the inner layer is made of heat-resistant material, the outer layer is made of oil-resistant material, and the middle layer is made of reinforcing material, this structure can improve the overall performance of the cable to a certain extent, but it also increases the production complexity and cost. Summary of the invention

[0006] In view of the deficiencies in the prior art, the present invention provides a process for preparing an oil-resistant heavy-duty pump cable to solve the problems of low durability, high cost and low production efficiency.

[0007] To achieve the above objectives, the present invention is implemented through the following technical solutions: A preparation process for oil-resistant heavy-duty pump cables, comprising the following steps: S1: Prepare raw materials, including copper wire, EVA material, shielding layer material and special rubber material; S2: After the copper wire is prepared in the early stage, it needs to be twisted by a stranding machine. After the copper wire conductor is formed, it is insulated with EVA material; S3: Put the EVA material into the extruder, heat it to 160℃~170℃ to make it flowable plastic state, and the extruder evenly coats the EVA material on the surface of the copper wire conductor to form a uniform insulation layer; S4: After the insulation layer is formed, the surface of the insulation layer is wrapped with the shielding layer material. The shielding layer material is evenly wrapped on the surface of the insulation layer of the cable through a wrapping machine; S5: Use a twin-screw extruder to heat and shape the special rubber material. The special rubber material is heated to 190℃~200℃ in the twin-screw extruder to make it soft and plastic. It is evenly coated on the outside of the shielding layer through the extruder to form a 2.5mm thick sheath; S6: After all production processes are completed, the finished cable products need to undergo strict inspection and performance testing. The test contents include the following aspects: electrical performance test, mechanical performance test, environmental adaptability test and size and appearance inspection.

[0008] Preferably, the copper wire in S1 is a high-purity copper wire with good conductivity and no oxide layer on the surface; the EVA material in S1 is ethylene-vinyl acetate copolymer; the shielding layer material in S1 is a tinned copper braid; and the special rubber material is polyamide or thermoplastic elastomer.

[0009] Preferably, the dimensions of the high-purity copper wire are: 5 mm in diameter and 100 m in length.

[0010] Preferably, the melt index of the ethylene-vinyl acetate copolymer is 1.5 g / 10 min, and nano-silicon dioxide is added.

[0011] Preferably, the main component of the tinned copper braided belt is tinned copper, and the coverage of the tinned copper braided belt is not less than 85%.

[0012] Preferably, the special rubber material is vulcanized by heating and reacting with a vulcanizing agent after being extruded.

[0013] Preferably, the electrical performance test in S5 is a high voltage and withstand voltage test, and the finished cable is tested.

[0014] Preferably, the mechanical property tests in S5 are tensile tests and bending fatigue tests, wherein the tensile test is performed on the finished cable by a tensile testing machine, and the bending fatigue test is performed on the finished cable by bending angle, frequency and duration.

[0015] Preferably, the environmental adaptability test in S5 is a high and low temperature test and an ultraviolet radiation test. The high and low temperature test is performed on the finished cable by simulating extreme weather, and the high and low temperature test temperature is: -40°C ~ 90°C. The ultraviolet radiation test is performed on the finished light blue using an ultraviolet simulator.

[0016] Preferably, in the size inspection in the size and appearance inspection in S5, a laser measuring instrument is used to perform multi-point measurement, and in the appearance inspection, optical image recognition is used to perform multi-point inspection.

[0017] The present invention provides a process for preparing oil-resistant heavy-duty pump cables. It has the following beneficial effects: 1. The present invention adds nano-silicon dioxide to the insulating layer ethylene-vinyl acetate copolymer material, and improves the durability, oxidation resistance and electrical performance of the ethylene-vinyl acetate copolymer through the special chemical properties of the nano-silicon dioxide, and can reduce the production cost.

[0018] 2. The present invention uses polyamide as the sheath material to improve the wear resistance and chemical corrosion resistance of the cable, and can work stably at a higher temperature.

[0019] 3. The present invention uses thermoplastic elastomer in the sheath material to improve the elasticity, cold resistance, heat resistance and UV resistance of the cable, making it suitable for use in different environments.

[0020] 4. In steps S3 and S5 of the present invention, single-screw and twin-screw extruders are used to control temperature and pressure so that EVA material and special rubber material can be quickly and evenly coated on the copper wire conductor and the shielding layer, thereby reducing material waste and increasing production speed. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a preparation flow chart of the present invention. DETAILED DESCRIPTION

[0022] The technical solution of the present invention will be described clearly and completely below in conjunction with the accompanying drawings of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0023] Please refer to the attached Figure 1 The embodiment of the present invention provides a process for preparing an oil-resistant heavy-duty pump cable, comprising the following steps: S1: Prepare raw materials, including copper wire, EVA material, shielding layer material and special rubber material; S2: After the copper wire is prepared in the early stage, it needs to be twisted by a stranding machine. After the copper wire conductor is formed, it is insulated with EVA material; S3: Put the EVA material into the extruder, heat it to 160℃~170℃ to make it flowable plastic state, and the extruder evenly coats the EVA material on the surface of the copper wire conductor to form a uniform insulation layer; S4: After the insulation layer is formed, the surface of the insulation layer is wrapped with the shielding layer material. The shielding layer material is evenly wrapped on the surface of the insulation layer of the cable through a wrapping machine; S5: Use a twin-screw extruder to heat and shape the special rubber material. The special rubber material is heated to 190℃~200℃ in the twin-screw extruder to make it soft and plastic. It is evenly coated on the outside of the shielding layer through the extruder to form a 2.5mm thick sheath; S6: After all production processes are completed, the finished cable products need to undergo strict inspection and performance testing. The test contents include the following aspects: electrical performance test, mechanical performance test, environmental adaptability test and size and appearance inspection.

[0024] The copper wire in S1 is high-purity copper wire with good conductivity and no oxide layer on the surface; the EVA material in S1 is ethylene-vinyl acetate copolymer; the shielding layer material in S1 is tinned copper braid; the special rubber material is polyamide or thermoplastic elastomer.

[0025] The dimensions of high-purity copper wire are: 5mm in diameter and 100M in length.

[0026] The melt index of ethylene-vinyl acetate copolymer is 1.5 g / 10 min, and nano-silica is added.

[0027] The main component of the tinned copper braid is tinned copper, and the coverage of the tinned copper braid is not less than 85%.

[0028] Specifically, the surface of the copper wire has no oxide layer, which can ensure good electrical conductivity. By adding nano-silicon dioxide, the mechanical strength and anti-aging performance of the insulating layer can be improved. The tinned copper braid is used to provide electromagnetic shielding protection. Polyamide or thermoplastic elastomer is used for the sheath of the cable to provide excellent wear resistance and oil resistance. Ethylene-vinyl acetate copolymer containing nano-silicon dioxide is used, and the melt index is 1.5g / 10min to ensure that it has good fluidity during the extrusion process and can form a uniform insulating layer. A wrapping machine is used on the surface of the EVA insulating layer to evenly wrap a layer of tinned copper braid. The braid has good electromagnetic shielding performance and can effectively prevent external electromagnetic interference. The tightness and uniformity of the wrapping are monitored to ensure that the coverage of the shielding layer is not less than 85%. Polyamide or thermoplastic elastomer is used as a sheath material and is placed in a twin-screw extruder. The temperature is set to 190℃~200℃ to make it reach a plastic state. The special rubber material is evenly coated on the outside of the shielding layer through the twin-screw extruder to form a 2.5mm thick sheath layer. The sheath material needs to have high oil resistance, wear resistance and good environmental adaptability.

[0029] The special rubber material is vulcanized by heating and reacting with a vulcanizing agent after extrusion molding.

[0030] Specifically, after the rubber material is extruded, although it has a preliminary shape, its physical properties and structural characteristics are not yet stable. After vulcanization, the rubber molecular chains will undergo a cross-linking reaction, thereby enabling it to obtain the required mechanical strength, elasticity, heat resistance and chemical corrosion resistance.

[0031] The electrical performance tests in S5 are high voltage and withstand voltage tests, which are performed on finished cables.

[0032] Specifically, for the withstand voltage test of finished cables, the test voltage can be appropriately increased according to the rated voltage and application scenario of the cable, and the test time can be reasonably set to ensure that the cable can maintain good performance in a high-voltage environment; pulse high-voltage testing can be used instead of continuous DC high-voltage testing. Pulse testing can better simulate voltage fluctuations in actual use and can detect potential hidden dangers in the cable.

[0033] The mechanical property tests in S5 are tensile test and bending fatigue test. The finished cable is subjected to tensile test by a tensile testing machine, and the finished cable is subjected to bending fatigue test by bending angle, frequency and duration.

[0034] Specifically, force tests are used to detect the strength of the cable when it breaks during stretching. By conducting in-depth analysis of the tensile force data under different environments (temperature, humidity, etc.), the performance of the cable in actual applications can be better predicted. Bending tests are usually used to test the durability of cables in frequent bending environments. Traditional bending tests may ignore more complex application scenarios, such as the impact of bending angles, frequencies, and durations on cable performance. By designing more complex bending fatigue tests to simulate dynamic stresses in actual use environments, such as the movement patterns of cables when used in machines, the authenticity and reliability of the test can be improved.

[0035] The environmental adaptability tests in S5 are high and low temperature tests and ultraviolet radiation tests. The finished cables are tested for high and low temperatures by simulating extreme weather. The test temperatures are -40°C to 90°C. Ultraviolet radiation tests are performed on the finished light blue cables using an ultraviolet simulator.

[0036] Specifically, the temperature range and duration of the test are increased to simulate extreme weather conditions, especially environments with large temperature differences, to ensure that the cable does not experience performance degradation in the alternating high and low temperature changes between -40°C and 90°C, to verify the stability and reliability of the cable when exposed to extreme temperature environments for a long time, and to avoid cable performance problems caused by high temperature aging or low temperature embrittlement; the test standard for ultraviolet radiation is increased, and an ultraviolet simulator is used to simulate the long-term effects of cables exposed to direct sunlight. Strengthen UV aging tests to test the durability of materials under long-term exposure; cables are easily affected by ultraviolet radiation in outdoor environments, causing material aging and embrittlement. By simulating the impact of ultraviolet rays on cables, their stability and safety in long-term use are ensured.

[0037] In the dimensional and appearance inspection of S5, the dimensional inspection uses a laser measuring instrument to perform multi-point measurement, and the appearance inspection uses optical image recognition to perform multi-point inspection.

[0038] Specifically, through the use of high-precision tools such as laser measuring instruments and digital calipers, human errors are reduced, the accuracy of dimensional measurement is ensured, the size range of each cable is clarified, and the standards are unified to avoid inconsistent measurements due to different understandings or experience differences among operators. The outer diameter, inner diameter, conductor diameter and other key dimensions of the cable are measured at multiple points to obtain the average value or deviation range to ensure that the measurement results are representative. Through the use of optical image recognition technology for appearance inspection, small defects (such as surface scratches, bubbles, uneven insulation layer) can be detected in time, which greatly improves inspection efficiency and reduces human omissions.

[0039] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A process for preparing oil-resistant heavy-duty pump cables, characterized in that: The following steps are involved: S1: Prepare raw materials, including copper wire, EVA material, shielding layer material and special rubber material; S2: After the copper wire is prepared in the early stage, it needs to be twisted by a stranding machine. After the copper wire conductor is formed, it is insulated with EVA material; S3: Put the EVA material into the extruder, heat it to 160℃~170℃ to make it flowable plastic state, and the extruder evenly coats the EVA material on the surface of the copper wire conductor to form a uniform insulation layer; S4: After the insulation layer is formed, the surface of the insulation layer is wrapped with the shielding layer material. The shielding layer material is evenly wrapped on the surface of the insulation layer of the cable through a wrapping machine; S5: Use a twin-screw extruder to heat and shape the special rubber material. The special rubber material is heated to 190℃~200℃ in the twin-screw extruder to make it soft and plastic. It is evenly coated on the outside of the shielding layer through the extruder to form a 2.5mm thick sheath; S6: After all production processes are completed, the finished cable products need to undergo strict inspection and performance testing. The test contents include the following aspects: electrical performance test, mechanical performance test, environmental adaptability test and size and appearance inspection.

2. The process for preparing an oil-resistant heavy-duty pump cable according to claim 1, characterized in that: The copper wire in S1 is a high-purity copper wire with good conductivity and no oxide layer on the surface; the EVA material in S1 is ethylene-vinyl acetate copolymer; the shielding layer material in S1 is a tinned copper braid; and the special rubber material is polyamide or thermoplastic elastomer.

3. The process for preparing an oil-resistant heavy-duty pump cable according to claim 2, characterized in that: The dimensions of the high-purity copper wire are: 5 mm in diameter and 100 m in length.

4. The process for preparing an oil-resistant heavy-duty pump cable according to claim 2, characterized in that: The melt index of the ethylene-vinyl acetate copolymer is 1.5 g / 10 min, and nano-silicon dioxide is added.

5. The process for preparing an oil-resistant heavy-duty pump cable according to claim 2, characterized in that: The main component of the tinned copper braided belt is tinned copper, and the coverage rate of the tinned copper braided belt is not less than 85%.

6. The process for preparing an oil-resistant heavy-duty pump cable according to claim 1, characterized in that: The special rubber material is vulcanized by heating and reacting with a vulcanizing agent after being extruded.

7. The process for preparing an oil-resistant heavy-duty pump cable according to claim 1, characterized in that: The electrical performance test in S5 is a high voltage and withstand voltage test, which is performed on the finished cable.

8. The process for preparing an oil-resistant heavy-duty pump cable according to claim 1, characterized in that: The mechanical property tests in S5 are tension test and bending fatigue test. The tension test is performed on the finished cable by a tensile testing machine, and the bending fatigue test is performed on the finished cable by bending angle, frequency and duration.

9. The process for preparing an oil-resistant heavy-duty pump cable according to claim 1, characterized in that: The environmental adaptability test in S5 is a high and low temperature test and an ultraviolet radiation test. The high and low temperature test is performed on the finished cable by simulating extreme weather. The high and low temperature test temperature is: -40℃~90℃. The ultraviolet radiation test is performed on the finished light blue using an ultraviolet simulator.

10. The process for preparing an oil-resistant heavy-duty pump cable according to claim 1, characterized in that: In the dimension inspection and appearance inspection in S5, the dimension inspection uses a laser measuring instrument to perform multi-point measurement, and the appearance inspection uses optical image recognition to perform multi-point inspection.

Images