Preparation process of military cable

Abstract

The invention discloses a preparation process of a military cable, which relates to the field of cables and comprises the steps of material selection and preparation, selection of materials required by the military cable, cable core preparation, conductor material wire drawing forming, insulation injection molding treatment on the outer part of a wire which is independently used, stranding forming of the coated wire, cable core forming and conductivity detection. Assembling and armoring; winding an armoring material outside the qualified wire core; carrying out insulation injection molding; carrying out injection molding of an insulation sleeve outside a wire product to be subjected to injection molding; according to the preparation technology of the military cable, through the steps of material selection and preparation, cable core preparation, conductivity detection, assembly armoring, insulation injection molding and quality detection, the armoring layer and the tensile network cable are arranged between the cable core and the insulating layer, the stability of connection between the cable core and the insulating layer can be improved, and the tensile property of the cable is improved.

Description

Technical Field

[0001] The present invention relates to the field of cables, and particularly to a preparation process for military cables. Background Art

[0002] Military cables refer to cables that are specifically designed and manufactured for military use. They must meet the performance requirements in extreme environments, including high temperature resistance, low temperature resistance, radiation resistance, chemical corrosion resistance, and high reliability. Military cables play a crucial role in modern warfare and military operations. They are the links connecting various military equipment, weapon systems, and communication networks, ensuring the rapid and accurate transmission of information and the effective supply of electricity.

[0003] When manufacturing cables, it includes material selection, conductor preparation, core stranding, and insulation layer preparation. After the core is made, usually, an injection molding machine is directly used to inject the insulation layer outside the core to protect the core. However, in this manufacturing method, when military cables are erected overhead or stretched, the insulation layer may peel off and slip away from the core, and even cause the core to be stretched and broken, so there are certain defects. Summary of the Invention

[0004] The purpose of the present invention is to provide a preparation process for military cables to solve the problems raised in the above background art.

[0005] To achieve the above purpose, the present invention provides the following technical solutions: A preparation process for military cables includes the following specific preparation steps:

[0006] Step 1: Material selection and preparation, select the materials required for military cables. The materials for military cable preparation include but are not limited to one or more of conductor materials, shielding materials, armor materials, insulation materials, and plating materials;

[0007] Step 2: Core preparation, draw the conductor material into a wire, and perform a coating treatment on the drawn wire. Insulation injection treatment is performed on the outside of the wire used alone, and the coated wires are stranded into shape, and a shielding mesh sleeve is stranded outside the stranded wires to form a core;

[0008] Step 3: Conductivity detection, perform conductivity detection on both ends of the core to detect whether the conductivity of the core is qualified;

[0009] Step 4: Armor assembly, wind the armor material around the qualified core, and sleeved an anti-tensile wire mesh outside the armor material to form a wire product to be injected;

[0010] Step 5: Insulation injection, prepare the injection insulation material, and then use an injection molding machine to inject an insulation sleeve outside the wire product to be injected to form a cable product;

[0011] Step 6: Quality inspection. Inspect the quality of the cable product to check whether the quality of the cable product is qualified.

[0012] Preferably, in Step 1, the conductor material includes, but is not limited to, one or more of optical fiber, copper, aluminum, silver, aluminum alloy, and copper alloy; the shielding material includes, but is not limited to, one or more of metal wire shielding mesh and aluminum foil shielding material; the armor material includes, but is not limited to, one or more of steel strip, steel wire, and aluminum strip; the insulating material includes, but is not limited to, one or more of polyvinyl chloride, polyethylene, cross-linked polyethylene, chloroprene rubber, fluororubber, and additives; the plating material includes, but is not limited to, silver and tin materials.

[0013] Preferably, the insulating material consists of 20 - 30 parts of polyvinyl chloride, 90 - 100 parts of polyethylene, 5 - 10 parts of cross-linked polyethylene, 1 - 3 parts of chloroprene rubber, 2 - 4 parts of fluororubber, and 1 - 2 parts of additives, and the additives include, but are not limited to, one or more of compatibilizer, cross-linking agent, plasticizer, antioxidant, curing agent, and stabilizer.

[0014] Preferably, in Step 2, for the wire drawing and forming of the conductor material, the conductor is drawn and formed through a wire drawing machine. The temperature of the conductor during wire drawing on the wire drawing machine is 50 - 60 °C, and the wire drawing speed is 900 - 1000 m / min.

[0015] Preferably, in Step 2, for the stranding and forming of the wire, a stranding machine is used to strand the wire, and the stranding pitch needs to satisfy the following formula:

[0016]

[0017] D = d×n×k

[0018] In the formula, k represents the stranding coefficient, l represents the actual length of the single wire, h represents the length of the stranded wire, D represents the stranding pitch of the stranded wire, d represents the diameter of a single wire, and n represents the diameter of a single wire.

[0019] Preferably, in Step 3, the conductivity detection is to detect the conductivity of the stranded core to check whether the core is broken during stranding.

[0020] Preferably, in Step 4, for the assembly of the armor, the armor material is spirally wound around the outside of the core, and the armor material wound around the outside of the wire is welded and fixed at intervals and fixed points.

[0021] Preferably, in the fifth step, the insulation injection molding is to put 20-30 parts of polyvinyl chloride, 90-100 parts of polyethylene, 5-10 parts of cross-linked polyethylene, 1-3 parts of chloroprene rubber, 2-4 parts of fluororubber and 1-2 parts of additives into a mixer to knead the rubber, process the insulation material in the mixer for 10-20 minutes to obtain the injection molding material, and then transfer the injection molding material to an injection molding machine, so that the injection molding machine injects an insulating layer onto the wire product to be injection molded.

[0022] Preferably, the quality inspection of the cable product in the sixth step includes, but is not limited to, one or more of electrical conductivity, whether there are defects in appearance, appearance dimensions, compressive resistance and corrosion resistance.

[0023] Preferably, the equipment for preparing the military cable further includes, but is not limited to, one or more of a wire drawing machine, an electroplating machine, a stranding machine, a mixer, a wire and cable injection molding machine and a cable detector.

[0024] The technical effects and advantages of the present invention:

[0025] The present invention utilizes a preparation process of a military cable. Through steps of material selection, core preparation, conductivity detection, armor assembly, insulation injection molding and quality inspection, an armor layer and an anti-tensile wire net are arranged between the core and the insulating layer, which can improve the connection stability between the core and the insulating layer and enhance its anti-tensile performance. And in the conductivity detection, whether there is a fault in the core production can be detected in time, reducing the waste of materials. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a flow block diagram of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0028] Embodiment 1

[0029] The present invention provides a preparation process of a military cable as Figure 1 shown, including the following specific preparation steps:

[0030] Step 1: Material selection, select the materials required for the military cable. The materials for preparing the military cable include, but are not limited to, one or more of conductor materials, shielding materials, armor materials, insulation materials and plating materials;

[0031] Step 2: Core preparation. The conductor material is drawn into shape to form a wire, and the drawn wire is coated. The wire used alone is subjected to insulation injection molding on the outside, and the coated wires are stranded into shape. A shielding mesh sleeve is stranded outside the stranded wires to form a core;

[0032] Step 3: Conductivity detection. Conductivity detection is carried out at both ends of the core to detect whether the conductivity performance of the core is qualified. The conductivity detection is to detect the conductivity performance of the stranded core to check whether the core breaks during stranding. Thus, when the core is damaged during stranding, the subsequent processing of the core can be stopped, thereby reducing the waste of resources;

[0033] Step 4: Armoring assembly. An armoring material is wound around the outside of the qualified core, and an anti-tensile wire mesh is sleeved outside the armoring material, and the anti-tensile wire mesh is located between the insulation layer and the armor layer to form a wire product to be injection-molded. The armoring assembly is to helically wind the armoring material around the outside of the core and fixedly weld the armoring material wound around the outside of the wire at intervals and fixed points. Fixed-point welding can improve the stability of the armoring material wound around the outside of the core, and the welding bumps can improve the stability of the connection between the insulation layer and the core and the armor;

[0034] Step 5: Insulation injection molding. The injection-molded insulation material is prepared, and then an insulation sleeve is injection-molded on the outside of the wire product to be injection-molded by an injection molding machine to form a cable product;

[0035] Step 6: Quality inspection. The quality of the cable product is inspected to detect whether the quality of the cable product is qualified. The quality inspection of the cable product includes, but is not limited to, one or more of conductivity performance, whether there are defects in appearance, appearance dimensions, compressive resistance, and corrosion resistance, so as to ensure the production quality of military cables.

[0036] In particular, in Step 1, the conductor material includes but is not limited to one or more of optical fiber, copper, aluminum, silver, aluminum alloy, and copper alloy; the shielding material includes but is not limited to one or more of metal wire shielding mesh and aluminum foil shielding material; the armored material includes but is not limited to one or more of steel strip, steel wire, and aluminum strip; the insulating material includes but is not limited to one or more of polyvinyl chloride, polyethylene, cross-linked polyethylene, chloroprene rubber, fluororubber, and additives. Polyvinyl chloride is a widely used cable sheath material with good corrosion resistance and mechanical strength. It can resist the erosion of various chemical substances and has good weather resistance in outdoor environments. For example, the sheath layer of some low-voltage overhead insulated cables uses polyvinyl chloride material, which can effectively protect the cable from damage by the external environment. Polyethylene is also a commonly used cable sheath material with good insulation performance and heat resistance, and is usually used for cables that require high temperature tolerance. Cross-linked polyethylene is a commonly used cable insulation material with excellent electrical and mechanical properties. Through cross-linking reaction, a three-dimensional network structure is formed, improving the heat resistance, environmental stress resistance, and chemical stability of the material. For example, in some power cables, the cross-linked polyethylene insulation layer can maintain stable insulation performance in high-temperature and humid environments. Chloroprene rubber is a material with good corrosion resistance and elasticity, and is commonly used for the inner or outer sheath of cables. It can resist the erosion of various chemical substances and has good tensile strength and wear resistance. For example, in some corrosion-resistant polypropylene insulated fire-resistant power cables, chloroprene rubber is used as the first inner corrosion-resistant layer to provide additional protection. Fluororubber is a material with excellent chemical corrosion resistance and can resist the erosion of various corrosive substances such as strong acids and strong alkalis. It is usually used in occasions with extremely high corrosion resistance requirements, such as cables in the chemical and pharmaceutical industries. Additives assist in better mixing and solidification of polyvinyl chloride, polyethylene, cross-linked polyethylene, chloroprene rubber, and fluororubber. The plating material includes but is not limited to silver and tin materials. The insulating material consists of 20 parts of polyvinyl chloride, 100 parts of polyethylene, 5 parts of cross-linked polyethylene, 1 part of chloroprene rubber, 2 parts of fluororubber, and 1 part of additives. Additives include but are not limited to one or more of compatibilizers, cross-linking agents, plasticizers, anti-aging agents, curing agents, and stabilizers.

[0037] Further, in Step 2, for the conductor material to be drawn into shape, the conductor is drawn into shape through a wire drawing machine. The temperature of the conductor during wire drawing on the wire drawing machine is 50°C, and the wire drawing speed is 900 meters per minute.

[0038] Even further, in Step 2, for the wire to be stranded into shape, a stranding machine is used to strand the wire, and the stranding pitch needs to satisfy the following formula:

[0039]

[0040] D = d × n × k

[0041] Where k represents the stranding coefficient, l represents the actual length of the single wire, h represents the length of the stranded wire, D represents the pitch of the stranded wire, d represents the diameter of a single wire, and n represents the diameter of a single wire.

[0042] Preferably, in step five, for the insulating injection molding, 20 parts of polyvinyl chloride, 100 parts of polyethylene, 5 parts of cross-linked polyethylene, 1 part of chloroprene rubber, 2 parts of fluororubber, and 1 part of additives are put into a mixer to knead the rubber, and the insulating material is processed in the mixer for 10 minutes to obtain the injection molding material. Then, the injection molding material is transferred to an injection molding machine, and the injection molding machine injects an insulating layer onto the wire product to be injection molded.

[0043] Furthermore, the equipment for preparing the military cable also includes, but is not limited to, one or more of a wire drawing machine, an electroplating machine, a stranding machine, a mixer, a wire and cable injection molding machine, and a cable detector.

[0044] Embodiment 2

[0045] The present invention provides a preparation process for a military cable as Figure 1 shown, including the following specific preparation steps:

[0046] Step 1: Material selection and preparation. Select the materials required for the military cable. The materials for preparing the military cable include, but are not limited to, one or more of conductor materials, shielding materials, armor materials, insulating materials, and plating materials.

[0047] Step 2: Core preparation. The conductor material is drawn into a wire, and the drawn wire is subjected to a coating treatment. The wire used alone is subjected to an insulating injection molding treatment on the outside, and the coated wires are stranded into shape, and a shielding mesh sleeve is stranded outside the stranded wires to form a core.

[0048] Step 3: Conductivity detection. Conductivity detection is carried out on both ends of the core to detect whether the conductivity of the core is qualified. The conductivity detection is to detect the conductivity of the stranded core to check whether there is a break during stranding. Thus, when the core is damaged during stranding, the subsequent processing of the core can be stopped, thereby reducing the waste of resources.

[0049] Step 4: Armor assembly. The armor material is wound around the outside of the qualified core, and an anti-tensile wire mesh is sleeved outside the armor material. The anti-tensile wire mesh is injection molded inside the insulating layer to form a wire product to be injection molded. The armor assembly is to helically wind the armor material around the outside of the core and fixedly weld the armor material wound around the outside of the wire at intervals and fixed points. Fixed-point welding can improve the stability of the armor material wound around the outside of the core, and the welding bumps can improve the stability of the connection between the insulating layer and the core and the armor.

[0050] Step Five: Insulating Injection Molding. Prepare the injection-molded insulating material, and then use an injection molding machine to inject an insulating sleeve onto the outside of the wire product to be injection-molded to form a cable product. The anti-tensile wire mesh is injection-molded inside the insulating layer, that is, the insulating layer is injection-molded in two layers, front and back. Inject an insulator onto the outside of the wire product to be injection-molded, then sleeved with the anti-tensile wire mesh. Before the inner insulator solidifies, inject the outer insulator, so that the anti-tensile wire mesh is located inside the insulating layer, thereby improving the anti-tensile performance of the insulating layer and avoiding the situation where the insulating layer is stretched and separated from the internal wire core;

[0051] Step Six: Quality Inspection. Inspect the quality of the cable product to check whether the quality of the cable product is qualified. The quality inspection of the cable product includes but is not limited to one or more of electrical conductivity, whether there are defects in appearance, appearance dimensions, compressive resistance, and corrosion resistance, so as to ensure the production quality of military cables.

[0052] In particular, in Step 1, the conductor material includes but is not limited to one or more of optical fiber, copper, aluminum, silver, aluminum alloy, and copper alloy; the shielding material includes but is not limited to one or more of metal wire shielding mesh and aluminum foil shielding material; the armored material includes but is not limited to one or more of steel strip, steel wire, and aluminum strip; the insulating material includes but is not limited to one or more of polyvinyl chloride, polyethylene, cross-linked polyethylene, chloroprene rubber, fluororubber, and additives. Polyvinyl chloride is a widely used cable sheath material with good corrosion resistance and mechanical strength. It can resist the erosion of various chemical substances and has good weather resistance in outdoor environments. For example, the sheath layer of some low-voltage overhead insulated cables uses polyvinyl chloride material, which can effectively protect the cable from external environmental damage. Polyethylene is also a commonly used cable sheath material with good insulation performance and heat resistance, and is usually used for cables that require high temperature tolerance. Cross-linked polyethylene is a commonly used cable insulation material with excellent electrical and mechanical properties. Through cross-linking reaction, a three-dimensional network structure is formed, improving the heat resistance, environmental stress resistance, and chemical stability of the material. For example, in some power cables, the cross-linked polyethylene insulation layer can maintain stable insulation performance in high-temperature and humid environments. Chloroprene rubber is a material with good corrosion resistance and elasticity, and is commonly used for the inner or outer sheath of cables. It can resist the erosion of various chemical substances and has good tensile strength and wear resistance. For example, in some corrosion-resistant polypropylene insulated fire-resistant power cables, chloroprene rubber is used as the first inner corrosion-resistant layer to provide additional protection. Fluororubber is a material with excellent chemical corrosion resistance and can resist the erosion of various corrosive substances such as strong acids and strong alkalis. It is usually used in occasions with extremely high corrosion resistance requirements, such as cables in the chemical and pharmaceutical industries. Additives assist in better mixing and solidification of polyvinyl chloride, polyethylene, cross-linked polyethylene, chloroprene rubber, and fluororubber. The plating material includes but is not limited to silver and tin materials. The insulating material consists of 30 parts of polyvinyl chloride, 90 parts of polyethylene, 10 parts of cross-linked polyethylene, 3 parts of chloroprene rubber, 4 parts of fluororubber, and 2 parts of additives. Additives include but are not limited to one or more of compatibilizers, cross-linking agents, plasticizers, anti-aging agents, curing agents, and stabilizers.

[0053] Further, in Step 2, for the conductor material to be drawn into shape, the conductor is drawn into shape through a wire drawing machine. The temperature of the conductor during wire drawing on the wire drawing machine is 60°C, and the wire drawing speed is 1000 meters per minute.

[0054] Even further, in Step 2, for the wire to be stranded into shape, a stranding machine is used to strand the wire, and the stranding pitch needs to satisfy the following formula:

[0055]

[0056] D = d × n × k

[0057] Where k represents the stranding coefficient, l represents the actual length of the single wire, h represents the length of the stranded wire, D represents the stranding pitch of the stranded wire, d represents the diameter of a single wire, and n represents the diameter of a single wire.

[0058] Preferably, in step five, for the insulation injection molding, 30 parts of polyvinyl chloride, 90 parts of polyethylene, 10 parts of cross-linked polyethylene, 3 parts of neoprene, 4 parts of fluororubber, and 2 parts of additives are put into a mixer to knead the rubber, and the insulating material is processed in the mixer for 20 minutes to obtain the injection molding material. Then the injection molding material is transferred to an injection molding machine, and the injection molding machine is used to perform insulation layer injection molding on the wire product to be injection molded.

[0059] Furthermore, the equipment for preparing military cables includes, but is not limited to, more than one of a wire drawing machine, an electroplating machine, a stranding machine, a mixer, a wire and cable injection molding machine, and a cable detector.

[0060] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not used to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some of the technical features. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A preparation process for a military cable, characterized in that: The method comprises the following specific preparation steps: Step 1: Material selection: Select the materials required for military cables. The materials for preparing military cables include but are not limited to one or more conductor materials, shielding materials, armor materials, insulation materials and coating materials; Step 2: preparing the wire core, drawing the conductor material to form a wire, coating the wire formed by drawing, performing insulation injection molding on the outside of the wire used alone, twisting the coated wire into a shape, and twisting a shielding mesh sleeve on the outside of the twisted wire to form a wire core; Step 3: Conductivity test: Conduct conductivity test on both ends of the wire core to check whether the conductivity of the wire core is qualified; Step 4: Assemble the armor, wrap the armor material around the qualified wire core, and sleeve the anti-stretch wire mesh on the outside of the armor material to form the wire product to be injected; Step 5: Insulation injection molding: prepare the injection molding insulation material, and then use the injection molding machine to inject the insulation sleeve on the outside of the injection molded wire product to form a cable product; Step 6: Quality inspection: inspect the cable product quality to see if the cable product quality is qualified.

2. The preparation process of a military cable according to claim 1, characterized in that: In the step 1, the conductor material includes but is not limited to one or more of optical fiber, copper, aluminum, silver, aluminum alloy and copper alloy; the shielding material includes but is not limited to one or more of metal wire shielding mesh and aluminum foil shielding material; the armor material includes but is not limited to one or more of steel strip, steel wire and aluminum strip; the insulating material includes but is not limited to one or more of polyvinyl chloride, polyethylene, cross-linked polyethylene, chloroprene rubber, fluororubber and additives; the coating material includes but is not limited to silver and tin materials.

3. The preparation process of a military cable according to claim 2, characterized in that: The insulating material consists of 20-30 parts of polyvinyl chloride, 90-100 parts of polyethylene, 5-10 parts of cross-linked polyethylene, 1-3 parts of chloroprene rubber, 2-4 parts of fluororubber and 1-2 parts of additives, wherein the additives include but are not limited to one or more of a compatibilizer, a cross-linking agent, a plasticizer, an antioxidant, a curing agent and a stabilizer.

4. The preparation process of a military cable according to claim 1, characterized in that: In the step 2, the conductor material is formed by wire drawing, and the conductor is formed by wire drawing through a wire drawing machine. The temperature of the conductor wire drawing process on the wire drawing machine is 50-60° C., and the speed of the wire drawing process is 900-1000 m / min.

5. The preparation process of a military cable according to claim 4, characterized in that: In the step 2, the wires are twisted into a shape by using a twisting machine to twist the wires, and the twisting pitch needs to satisfy the following formula: D=d×n×k Where k represents the twisting coefficient, l represents the actual length of a single wire, h represents the length of the stranded wire, D represents the lay length of the stranded wire, d represents the diameter of a single conductor, and n represents the diameter of a single conductor.

6. The preparation process of a military cable according to claim 1, characterized in that: The conductive test in step three is to test the conductive performance of the twisted wire core to detect whether the wire core is broken during twisting.

7. The preparation process of a military cable according to claim 1, characterized in that: The armoring in step 4 is to spirally wind the armoring material around the outside of the wire core, and weld and fix the armoring material around the outside of the wire at fixed intervals.

8. The preparation process of a military cable according to claim 1, characterized in that: In the step 5, the insulation injection molding is to put 20-30 parts of polyvinyl chloride, 90-100 parts of polyethylene, 5-10 parts of cross-linked polyethylene, 1-3 parts of chloroprene rubber, 2-4 parts of fluororubber and 1-2 parts of additives into an internal mixer for rubber mixing, and process the insulation material in the internal mixer for 10-20 minutes to obtain the injection molding material, and then transfer the injection molding material to the injection molding machine, so that the injection molding machine performs insulation layer injection molding on the wire product to be injected.

9. The preparation process of a military cable according to claim 1, characterized in that: The cable product quality inspection in step six includes but is not limited to one or more of the electrical conductivity, appearance defects, appearance size, pressure resistance and corrosion resistance.

10. The preparation process of a military cable according to claim 1, characterized in that: The equipment for preparing the military cable also includes but is not limited to one or more of a wire drawing machine, an electroplating machine, a stranding machine, an internal mixer, a cable injection molding machine and a cable detector.

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