ABS composite cable for automobile and preparation method thereof

Abstract

The present invention relates to the technical field of cable preparation, and in particular to an ABS composite cable for automobiles and a preparation method thereof. The method comprises twisting a plurality of copper wires according to a preset twist pitch to obtain a conductor, and performing a torsion test on the conductor; obtaining position information of each copper wire of the conductor before and after the torsion test; determining the tightness of the conductor after the torsion test based on the position deviation of the base copper wire in the conductor before and after the torsion test; determining, based on the tightness of the conductor after the torsion test, whether to adjust the preset twist pitch or to coat the conductor with an insulation layer using different coating trajectories to obtain an insulated conductor; determining, based on the coating uniformity and coating trajectory of the insulated conductor, to further prepare a composite cable or to adjust the insulation coating process based on the uniformity of pore distribution. The present invention improves the insulation performance of the ABS composite cable by improving the accuracy of control over the insulation layer coating process.

Description

Technical Field

[0001] The present invention relates to the technical field of cable preparation, and in particular to an ABS composite cable for automobiles and a preparation method thereof. Background Art

[0002] The accelerating trend toward intelligent and electrified vehicles has led to a surge in the number of in-vehicle electronic devices, posing severe challenges to cable performance. Traditional cables suffer from poor insulation and are prone to leakage and breakdown in complex electrical environments. They are unable to meet the demands of high-voltage and high-current transmission, compromising driving safety. Furthermore, signal transmission stability is insufficient for high-speed data transmission, such as in automated driving assistance systems and in-vehicle infotainment systems, leading to frequent problems such as signal attenuation and interference. Against this backdrop, automotive ABS composite cables have emerged. Their specialized structure and materials promise significant improvements in insulation, conductivity, and signal transmission performance. Their preparation methods also require innovative approaches to precisely control the structure and process parameters of each layer, ensuring cable performance meets the stringent standards of the automotive industry, meeting the industry's evolving needs and providing strong support for the stable operation of automotive electrical systems.

[0003] For example, Chinese patent application publication number: CN219676926U discloses an ABS+EPB+DCC composite cable for electric vehicles, which relates to the field of automotive cable technology. The use of fillers reduces the sliding between the functional cores; by twisting the functional cores + fillers into cable cores, they are bound to each other, and there is only slight friction during frequent vibrations and reciprocating movements, which reduces the possibility of insulation damage and reduces the risk of short circuits; through the presence of the wrapping layer and the extruded sheath layer, the radial positive pressure of the cable core is always present and almost equal in size, greatly reducing the freedom of the functional cores to move with each other. After the cable end is highly integrated, the length of the segment can be completely guaranteed by the machine after the wire harness factory cuts it into sections, eliminating the problem of different lengths of the functional cores. The wire harness factory only needs to complete the terminal crimping and injection molding processes, without consuming a lot of manpower and time for secondary functional integration, which greatly reduces costs and improves production efficiency, and greatly guarantees product consistency.

[0004] It can be seen that the existing technology has the problem that the analysis of the tightness of the conductor twisting is not accurate enough, resulting in inaccurate control of the insulation layer coating process and causing poor insulation performance of the prepared ABS composite cable. Summary of the Invention

[0005] To this end, the present invention provides an ABS composite cable for automobiles and a preparation method thereof, so as to overcome the problem in the prior art that the analysis of the tightness of the conductor twisting is not accurate enough, resulting in inaccurate control of the insulation layer coating process and causing the prepared ABS composite cable to have poor insulation performance.

[0006] To achieve the above object, the present invention provides a method for preparing an ABS composite cable for automobiles, comprising:

[0007] Step S1, twisting a plurality of copper wires according to a preset twisting pitch to obtain a conductor, and performing a torsion test on the conductor;

[0008] Step S2, obtaining the initial position information of each copper wire of the conductor before the torsion test and the position information of each copper wire of the conductor after the torsion test, and determining the tightness of the conductor after the torsion test based on the position deviation of the base point copper wire in the conductor before and after the torsion test;

[0009] Step S3, determining to adjust the preset twist pitch based on the tightness of the conductor after the torsion test, or determining to coat the conductor with an insulation layer using different coating trajectories to obtain an insulated conductor, wherein the coating trajectories include spiral coating trajectories and repeated coating trajectories;

[0010] Step S4, determining whether to further prepare a composite cable or adjust the insulation coating process based on the coating uniformity and coating trajectory of the insulated conductor, wherein the adjustment of the insulation coating process includes adjusting the coating spacing or the coating trajectory based on the uniformity of pore distribution;

[0011] Step S5: Perform a withstand voltage test on several prepared composite cables, and determine whether to adjust the preset coating uniformity or the preset tightness based on the proportion of composite cables that do not exhibit current abnormality in the withstand voltage test and the average breakdown voltage of the composite cables that exhibit current abnormality.

[0012] Furthermore, in step S2, determining the tightness of the conductor after the torsion test based on the position deviation of each copper wire of the conductor before and after the torsion test includes:

[0013] Obtain the initial position information of each copper wire of the conductor before the torsion test, and mark a copper wire as the base copper wire.

[0014] Performing a torsion test on the conductor and obtaining base point copper wire position information of the conductor after the torsion test;

[0015] The degree of tightening is obtained by calculating the displacement deviation of the base point copper wire in the conductor before and after the base point copper wire torsion test.

[0016] Furthermore, in step S3, determining to adjust the preset twist pitch or determining to coat the conductor with an insulation layer using different coating trajectories to obtain an insulated conductor includes:

[0017] If the tightness of the conductor after the torsion test is greater than a first preset tightness, determining to adjust the preset twist pitch;

[0018] If the tightness of the conductor after the torsion test is less than or equal to the first preset tightness and greater than the second preset tightness, determining to coat the conductor with an insulation layer in a repeated trajectory to obtain an insulated conductor;

[0019] If the tightness of the conductor after the torsion test is less than or equal to the second preset tightness, it is determined that the conductor is covered with an insulation layer in a spiral track to obtain an insulated conductor.

[0020] Furthermore, in step S4, determining whether to further prepare a composite cable or adjust the insulation layer coating process based on the coating uniformity and coating trajectory of the insulated conductor includes:

[0021] If the coating uniformity of the insulated conductor is less than the preset coating uniformity, determining to further prepare the composite cable;

[0022] If the coating uniformity of the insulated conductor is greater than or equal to a preset coating uniformity, it is determined that the insulation layer coating process is adjusted.

[0023] Furthermore, it is determined that adjustments to the insulation coating process include:

[0024] If the pore distribution uniformity is less than the preset uniformity, it is determined to adjust the coating spacing;

[0025] If the pore distribution uniformity is greater than or equal to the preset uniformity, it is determined to adjust the coating trajectory.

[0026] Furthermore, the adjustment amount of the coating spacing is positively correlated with the uniformity of pore distribution, and determining to adjust the coating trajectory includes replacing the secondary coating trajectory in the repeated trajectory.

[0027] Furthermore, in step S5, determining whether to adjust the preset coating uniformity or the preset tightening degree includes:

[0028] If the proportion of composite cables with abnormal current in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current is greater than the preset breakdown voltage, it is determined to adjust the preset coating uniformity;

[0029] If the proportion of composite cables with abnormal current in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current is less than or equal to the preset breakdown voltage, it is determined to adjust the preset tightness.

[0030] Furthermore, the abnormal current phenomenon occurring during the withstand voltage test includes the current value of the cable exceeding 1.5 times its rated working current during the withstand voltage test.

[0031] Furthermore, the adjustment amount of the preset coating uniformity is negatively correlated with the average breakdown voltage of the composite cable with abnormal current phenomenon, and the adjustment amount of the preset tightness is negatively correlated with the proportion of composite cables with abnormal current phenomenon.

[0032] An ABS composite cable for automobiles prepared by the method for preparing an ABS composite cable for automobiles, wherein the ABS composite cable for automobiles is composed of an inner conductor, an insulating layer, a shielding layer, and a protective layer from inside to outside;

[0033] The inner conductor is composed of a plurality of twisted copper wires and is used to transmit signals;

[0034] The insulating layer is wrapped around the outer periphery of the inner conductor to isolate current and reduce heat conduction, and the insulating layer is made of a flexible material;

[0035] The shielding layer is wrapped around the outer periphery of the insulating layer in parallel with the axial direction of the cable to shield internal and external signal interference;

[0036] The protective layer is coated on the outer periphery of the shielding layer to protect the shielding layer. The protective layer is made of ABS composite material.

[0037] Compared with the prior art, the beneficial effect of the present invention lies in that the present invention obtains the initial position information of each copper wire of the conductor before the torsion test, marks a copper wire as the base copper wire, performs a torsion test on the conductor, and obtains the position information of the base copper wire of the conductor after the torsion test; calculates the displacement deviation of the base copper wire in the conductor before and after the torsion test of the base copper wire to obtain the tightness; when the tightness of the conductor after the torsion test is greater than the first preset tightness, it indicates that the conductor twisting process is unqualified, at this time, the preset twisting pitch is reduced to enhance the conductor's anti-bending ability, when the tightness of the conductor after the torsion test is less than or equal to the first preset tightness And when it is greater than the second preset tightness, it means that the conductor twisting process is qualified but the conductor may still be loose. At this time, it is determined to wrap the conductor with an insulation layer in a repeated trajectory to increase the insulation coating thickness and then tighten the conductor for a second time. When the conductor tightness after the torsion test is less than or equal to the second preset tightness, it means that the conductor twisting is tight. At this time, a spiral trajectory is used to wrap the conductor with an insulation layer to improve the uniformity of the insulation layer coating. The above method improves the accuracy of the analysis of the conductor twisting tightness to improve the accuracy of the insulation layer coating process control and thus prepares an ABS composite cable with excellent insulation performance.

[0038] Furthermore, the present invention determines whether to further manufacture a composite cable or adjust the insulation layer coating process by dynamically monitoring the coating uniformity of the insulated conductor, and determines whether to further manufacture a composite cable or adjust the insulation layer coating process based on the coating uniformity of the insulated conductor. When adjusting the insulation layer coating process, if the distribution uniformity of the pores is less than a preset uniformity, it means that the coating spacing of the coating track is set unreasonably, resulting in pores in uniform positions, and it is determined to reduce the coating spacing. If the distribution uniformity of the pores is greater than or equal to the preset uniformity, it means that the positions of the pores are irregular, and it is determined to adjust the coating track. The above method improves the accuracy of the analysis of the tightness of the conductor twisting, thereby improving the accuracy of the control of the insulation layer coating process, and thus preparing an ABS composite cable with excellent insulation performance.

[0039] Furthermore, the present invention determines whether to adjust the preset coating uniformity or the preset tightness by the proportion of the number of composite cables with abnormal current phenomena in the withstand voltage test and the average breakdown voltage of the abnormal current phenomena. If the proportion of the number of composite cables with abnormal current phenomena in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current phenomena is greater than the preset breakdown voltage, it means that the preset coating uniformity is unreasonable and the insulation layer is locally too thick or too thin, and it is determined to adjust the preset coating uniformity. If the proportion of the number of composite cables with abnormal current phenomena in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current phenomena is less than or equal to the preset breakdown voltage, it means that the preset tightness is unreasonable and the conductor structure is loose, and it is determined to adjust the preset tightness. The above method improves the accuracy of the analysis of the tightness of the conductor twisting, thereby improving the accuracy of the control of the insulation layer coating process, and thus preparing an ABS composite cable with excellent insulation performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 This is a flowchart of a method for preparing an ABS composite cable for automobiles according to an embodiment of the present invention;

[0041] Figure 2 This is a flowchart of a process for determining the tightness of a conductor after a torsion test in a method for preparing an ABS composite cable for an automobile according to an embodiment of the present invention;

[0042] Figure 3 This is a flowchart for determining whether to adjust a preset twist pitch or a coating trajectory in a method for preparing an ABS composite cable for automobiles according to an embodiment of the present invention;

[0043] Figure 4 This is a schematic structural diagram of an ABS composite cable for automobiles according to an embodiment of the present invention;

[0044] In the figure, 1, conductor; 2, insulation layer; 3, shielding layer; 4, protective layer. DETAILED DESCRIPTION

[0045] In order to make the objects and advantages of the present invention more clearly understood, the present invention is further described below in conjunction with embodiments; it should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0046] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood by those skilled in the art that these embodiments are only used to explain the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0047] See also Figure 1-Figure 3 As shown, Figure 1 This is a flowchart of a method for preparing an ABS composite cable for automobiles according to an embodiment of the present invention; Figure 2 This is a flowchart of a process for determining the tightness of a conductor after a torsion test in a method for preparing an ABS composite cable for an automobile according to an embodiment of the present invention; Figure 3 This is a workflow diagram for determining whether to adjust the preset twist pitch or the coating trajectory in the method for preparing the automotive ABS composite cable according to an embodiment of the present invention.

[0048] The method for preparing an ABS composite cable for automobiles according to an embodiment of the present invention comprises:

[0049] Step S1, twisting a plurality of copper wires according to a preset twisting pitch to obtain a conductor, and performing a torsion test on the conductor;

[0050] Step S2, obtaining the initial position information of each copper wire of the conductor before the torsion test and the position information of each copper wire of the conductor after the torsion test, and determining the tightness of the conductor after the torsion test based on the position deviation of the base point copper wire in the conductor before and after the torsion test;

[0051] Step S3, determining to adjust the preset twist pitch based on the tightness of the conductor after the torsion test, or determining to coat the conductor with an insulation layer using different coating trajectories to obtain an insulated conductor, wherein the coating trajectories include spiral coating trajectories and repeated coating trajectories;

[0052] Step S4, determining whether to further prepare a composite cable or adjust the insulation coating process based on the coating uniformity and coating trajectory of the insulated conductor, wherein the adjustment of the insulation coating process includes adjusting the coating spacing or the coating trajectory based on the uniformity of pore distribution;

[0053] Step S5: Perform a withstand voltage test on several prepared composite cables, and determine whether to adjust the preset coating uniformity or the preset tightness based on the proportion of composite cables that do not exhibit current abnormality in the withstand voltage test and the average breakdown voltage of the composite cables that exhibit current abnormality.

[0054] The preset twisting pitch in the embodiment of the present invention is 10 times the conductor diameter. If this value is too small, it may easily lead to excessive rigidity of the conductor and stress concentration when the insulation layer is covered; if it is too large, the twisting will be loose and the torsional resistance will decrease. However, the above value is not limited to this, and technical personnel in this field can also adjust the value according to actual needs.

[0055] Specifically, in step S2, the step of determining the tightness of the conductor after the torsion test includes:

[0056] Step S2201, obtaining the initial position information of each copper wire of the conductor before the torsion test, and marking a copper wire as the base copper wire;

[0057] Step S2202, performing a torsion test on the conductor, and obtaining base point copper wire position information of the conductor after the torsion test;

[0058] Step S2203 , calculating the displacement deviation of the base point copper wire in the conductor before and after the base point copper wire torsion test to obtain the tightening degree.

[0059] The torsion test described in the embodiments of the present invention involves preparing several conductor samples, twisted to a predetermined twist pitch, with a length of 500 mm. Using a dedicated cable torsion tester, one end of the conductor sample is securely clamped to the tester's fixed clamp and the other end is connected to a movable clamp that provides torsional force. The torsion tester parameters are set to a test speed of 10 revolutions per minute, a torsion angle of 180° clockwise and 180° counterclockwise, and 50 cycles of testing. After the torsion test, the conductor's tightness is calculated based on the displacement deviation of the base copper wire before and after torsion. A small displacement deviation indicates a high degree of conductor tightness, with the copper wires remaining relatively stable during the torsion process. Conversely, a large displacement deviation indicates a low degree of tightness.

[0060] In this embodiment of the present invention, seven copper wires with a diameter of 1.78 mm were twisted at an initial twist pitch of 17.8 mm (10 times the conductor diameter). Base point copper wires were marked at 10 cm intervals on the conductor surface, and their initial three-dimensional coordinates were recorded. A 90° torsion test was then performed by applying a torque of 5 N·m. After releasing the torque, the base point positions were recaptured. By calculating the displacement deviation Δd (in this example, Δd = 0.6 mm, which is less than the threshold of 0.64 mm), a spiral wrapping trajectory (helix angle 35°) was triggered to complete the insulation wrapping and determine the degree of tightening.

[0061] Specifically, in step S3, when it is determined that the preset twist pitch is to be adjusted or that the conductor is to be coated with an insulation layer using a different coating trajectory to obtain an insulated conductor, it is determined that the preset twist pitch is to be adjusted or that the conductor is to be coated with an insulation layer using a different coating trajectory to obtain an insulated conductor based on a comparison result of the tightness of the conductor after the torsion test and the preset tightness;

[0062] When the tightness of the conductor after the torsion test is greater than a first preset tightness, determining to adjust the preset twist pitch by a first adjustment coefficient;

[0063] When the tightness of the conductor after the torsion test is less than or equal to the first preset tightness and greater than the second preset tightness, it is determined that the conductor is covered with an insulation layer in a repeated trajectory to obtain an insulated conductor;

[0064] When the tightness of the conductor after the torsion test is less than or equal to the second preset tightness, it is determined that the conductor is covered with an insulation layer in a spiral track to obtain an insulated conductor.

[0065] In the embodiment of the present invention, the method of repeatedly wrapping the conductor with an insulation layer in a parallel trajectory or a spiral trajectory to obtain an insulated conductor includes repeatedly wrapping the conductor in a parallel trajectory. When the conductor is wrapped with an insulation layer in a parallel trajectory, the insulating material wraps the conductor along the axial direction of the conductor in a path parallel to the axis of the conductor. When the conductor is wrapped with an insulation layer in a spiral trajectory, the insulating material wraps the conductor with a wrapping spacing equal to the spiral path. The value range of the first adjustment coefficient is set to 0.83-0.96, and the optimal value of the first adjustment coefficient is 0.88. After several experiments and data analysis, it was found that when the adjustment coefficient is 0.88, the tightness of the conductor can be effectively reduced while ensuring the basic performance of the cable. The adjustment amount of the preset twist pitch is negatively correlated with the tightness of the conductor after the torsion test, but the above value is not limited to this. Those skilled in the art can also adjust the value according to actual needs.

[0066] The preset tightness in the embodiment of the present invention includes a first preset tightness and a second preset tightness; the first preset tightness is determined based on the average tightness of several groups of cable samples after the torsion test, and the second preset tightness is four-fifths of the first tightness. For example, if the first preset tightness is 0.8 mm, then the second tightness is 0.8 mm multiplied by four-fifths, which equals 0.64 mm. Then the second preset tightness is 0.64 mm. However, the above values ​​are not limited to this, and those skilled in the art can also adjust the values ​​according to actual needs.

[0067] The present invention obtains the initial position information of each copper wire of the conductor before the torsion test, marks a copper wire as the base copper wire, performs a torsion test on the conductor, and obtains the position information of the base copper wire of the conductor after the torsion test; calculates the displacement deviation of the base copper wire in the conductor before and after the torsion test to obtain the tightness; when the tightness of the conductor after the torsion test is greater than the first preset tightness, it indicates that the conductor twisting process is unqualified, at this time, the preset twisting pitch is reduced to enhance the bending resistance of the conductor; when the tightness of the conductor after the torsion test is less than or equal to the first preset tightness and greater than the second preset tightness, the conductor is twisted. When the degree of tightness of the conductor after the torsion test is less than or equal to the second preset tightness, it means that the conductor twisting process is qualified but the conductor may still be loose. At this time, it is determined to wrap the conductor with an insulation layer in a repeated trajectory to increase the thickness of the insulation layer coating and then tighten the conductor for a second time. When the tightness of the conductor after the torsion test is less than or equal to the second preset tightness, it means that the conductor twisting is tight. At this time, a spiral trajectory is used to wrap the conductor with an insulation layer to improve the uniformity of the insulation layer coating. The above method improves the accuracy of the analysis of the tightness of the conductor twisting, thereby improving the accuracy of the control of the insulation layer coating process and thus preparing an ABS composite cable with excellent insulation performance.

[0068] Specifically, in step S4, when it is determined to further prepare the composite cable or adjust the insulation coating process, it is determined to further prepare the composite cable or adjust the insulation coating process according to the coating uniformity and coating trajectory of the insulated conductor;

[0069] When the coating uniformity of the insulated conductor is less than the preset coating uniformity, it is determined to further prepare the composite cable;

[0070] When the coating uniformity of the insulated conductor is greater than or equal to a preset coating uniformity, it is determined that the insulation layer coating process is to be adjusted.

[0071] In the embodiment of the present invention, the thickness of the insulating layer is measured at different positions of the insulated conductor, and the multiple thickness values ​​obtained by measurement are statistically analyzed to calculate their standard deviation. The smaller the standard deviation, the more uniform the thickness of the insulating layer and the higher the coating uniformity; conversely, the larger the standard deviation, the lower the coating uniformity.

[0072] In the embodiment of the present invention, the insulating layer of the insulated conductor is evenly divided into several small blocks along the axial and circumferential directions. The porosity is obtained by the ratio of the total volume of the pores in the area to the total volume of the area. The standard deviation of the porosity of all small blocks is calculated. The smaller the standard deviation, the more uniform the distribution of the pores.

[0073] In the embodiment of the present invention, the preset coating uniformity is the average value of the coating uniformity of the insulating conductors obtained under several identical coating conditions (including but not limited to "the same coating trajectory, the same coating spacing and the same conductor"). The preset uniformity is the average value of the distribution uniformity of the pores of the several insulating conductors. The average value is the ratio of the sum of the distribution uniformity of the pores of the several insulating conductors to the number of the several insulating conductors.

[0074] Specifically, in step S4, when it is determined that the insulation layer coating process is to be adjusted, it is determined that the insulation layer coating spacing is to be adjusted or the insulation layer coating process is to be adjusted according to the comparison result of the pore distribution uniformity with the preset uniformity;

[0075] When the distribution uniformity of the pores is less than the preset uniformity, it is determined to adjust the coating spacing by a second adjustment coefficient;

[0076] When the distribution uniformity of the pores is greater than or equal to the preset uniformity, it is determined that the coating trajectory is to be adjusted.

[0077] The determination of adjusting the coating trajectory in the embodiment of the present invention includes replacing the second coating trajectory in the repeated trajectory. For example, when determining to replace the second coating trajectory in the repeated trajectory, if the initial coating trajectory is a spiral trajectory, the trajectory during the second coating is adjusted to a parallel trajectory. The value range of the second adjustment coefficient is 0.74-0.86, and the optimal value of the second adjustment coefficient is 0.8. The adjustment amount of the coating spacing is positively correlated with the uniformity of the pore distribution, but the above value is not limited to this. Those skilled in the art can also adjust the value according to actual needs.

[0078] The present invention dynamically monitors the coating uniformity of the insulated conductor to determine whether to further manufacture a composite cable or adjust the insulation layer coating process, and judges whether to further manufacture a composite cable or adjust the insulation layer coating process based on the coating uniformity of the insulated conductor. When adjusting the insulation layer coating process, if the distribution uniformity of the pores is less than a preset uniformity, it means that the coating spacing of the coating track is set unreasonably, resulting in pores in uniform positions, and it is determined to reduce the coating spacing. If the distribution uniformity of the pores is greater than or equal to the preset uniformity, it means that the positions of the pores are irregular, and it is determined to adjust the coating track. The above method improves the accuracy of the analysis of the tightness of the conductor twisting, thereby improving the accuracy of the control of the insulation layer coating process, and thus preparing an ABS composite cable with excellent insulation performance.

[0079] Specifically, in step S5, when it is determined to adjust the preset coating uniformity or the preset tightness, it is determined to adjust the preset coating uniformity or the preset tightness based on the proportion of composite cables with abnormal current in the withstand voltage test and the average breakdown voltage of the abnormal current;

[0080] When the proportion of composite cables with abnormal current in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current is greater than the preset breakdown voltage, it is determined to adjust the preset coating uniformity by a third adjustment coefficient;

[0081] When the proportion of composite cables with abnormal current in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current is less than or equal to the preset breakdown voltage, it is determined to adjust the preset tightness using the fourth adjustment coefficient.

[0082] The preset proportion in the embodiment of the present invention is set to 8%, which can be determined through several voltage withstand tests. The number of composite cables with abnormal current phenomena in several voltage withstand tests accounts for up to 8% of the total test quantity, which is used to judge whether the overall performance of the current production batch of cables meets expectations. It is set to the average breakdown voltage of the abnormal phenomena in several voltage withstand tests.

[0083] In the embodiment of the present invention, the abnormal current phenomenon occurring in the voltage withstand test includes that the current value of the cable exceeds 1.5 times its rated working current during the voltage withstand test. The value range of the third adjustment coefficient is 1.09-1.21, and the optimal value of the third adjustment coefficient is 1.15. After a large number of experiments and data analysis, it is found that when the adjustment coefficient is 1.15, it can ensure the improvement of cable performance while taking into account the feasibility of the production process and cost control. The value range of the fourth adjustment coefficient is 1.11-1.32, and the optimal value of the fourth adjustment coefficient is 1.21. After a large number of experiments and data analysis, it is found that when the adjustment coefficient is 1.21, it can effectively improve the tightness of the conductor, enhance the insulation performance of the cable, and significantly improve the performance of the cable in the voltage withstand test.

[0084] In the embodiment of the present invention, the adjustment amount of the preset coating uniformity is negatively correlated with the average breakdown voltage of the composite cable with abnormal current phenomenon, and the adjustment amount of the preset tightness is negatively correlated with the proportion of composite cables with abnormal current phenomenon.

[0085] The present invention determines whether to adjust the preset coating uniformity or the preset tightness by the proportion of the number of composite cables with abnormal current phenomena in the withstand voltage test and the average breakdown voltage of the abnormal current phenomena. If the proportion of the number of composite cables with abnormal current phenomena in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current phenomena is greater than the preset breakdown voltage, it means that the preset coating uniformity is unreasonable and the insulation layer is locally too thick or too thin, and it is determined to adjust the preset coating uniformity. If the proportion of the number of composite cables with abnormal current phenomena in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current phenomena is less than or equal to the preset breakdown voltage, it means that the preset tightness is unreasonable and the conductor structure is loose, and it is determined to adjust the preset tightness. The above method improves the accuracy of the analysis of the tightness of the conductor twisting, thereby improving the accuracy of the control of the insulation layer coating process, and thus preparing an ABS composite cable with excellent insulation performance.

[0086] See also Figure 4 As shown, Figure 4 This is a schematic structural diagram of an ABS composite cable for automobiles according to an embodiment of the present invention.

[0087] Specifically, an ABS composite cable for automobiles prepared by the method for preparing an ABS composite cable for automobiles is provided, wherein the ABS composite cable for automobiles is composed of an inner conductor, an insulating layer, a shielding layer, and a protective layer from inside to outside;

[0088] The inner conductor is composed of a plurality of twisted copper wires and is used to transmit signals;

[0089] The insulating layer is wrapped around the outer periphery of the inner conductor to isolate current and reduce heat conduction, and the insulating layer is made of a flexible material;

[0090] The shielding layer is wrapped around the outer periphery of the insulating layer in parallel with the axial direction of the cable to shield internal and external signal interference;

[0091] The protective layer is coated on the outer periphery of the shielding layer to protect the shielding layer. The protective layer is made of ABS composite material.

[0092] Thus far, the technical solutions of the present invention have been described in conjunction with the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art may make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will fall within the scope of protection of the present invention.

[0093] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that the present invention is susceptible to various modifications and variations. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A method for preparing an ABS composite cable for automobiles, characterized in that: include: Step S1, twisting a plurality of copper wires according to a preset twisting pitch to obtain a conductor, and performing a torsion test on the conductor; Step S2, obtaining the initial position information of each copper wire of the conductor before the torsion test and the position information of each copper wire of the conductor after the torsion test, and determining the tightness of the conductor after the torsion test based on the position deviation of the base point copper wire in the conductor before and after the torsion test; Step S3, determining to adjust the preset twist pitch based on the tightness of the conductor after the torsion test, or determining to coat the conductor with an insulation layer using different coating trajectories to obtain an insulated conductor, wherein the coating trajectories include spiral coating trajectories and repeated coating trajectories; Step S4, determining whether to further prepare a composite cable or adjust the insulation coating process based on the coating uniformity of the insulated conductor, wherein the adjustment of the insulation coating process includes adjusting the coating spacing or the coating trajectory based on the distribution uniformity of the pores; Step S5: Perform a withstand voltage test on several prepared composite cables, and determine whether to adjust the preset coating uniformity or the preset tightness based on the proportion of composite cables that do not exhibit current abnormality in the withstand voltage test and the average breakdown voltage of the composite cables that exhibit current abnormality.

2. The method for preparing an ABS composite cable for automobiles according to claim 1, wherein: In step S2, determining the tightness of the conductor after the torsion test based on the position deviations of the copper wires of the conductor before and after the torsion test includes: Obtain the initial position information of each copper wire of the conductor before the torsion test, and mark a copper wire as the base copper wire. Performing a torsion test on the conductor and obtaining base point copper wire position information of the conductor after the torsion test; The degree of tightening is obtained by calculating the displacement deviation of the base point copper wire in the conductor before and after the base point copper wire torsion test.

3. The method for preparing an ABS composite cable for automobiles according to claim 2, wherein: In step S3, determining to adjust the preset twist pitch or determining to coat the conductor with an insulation layer using different coating trajectories to obtain an insulated conductor includes: If the tightness of the conductor after the torsion test is greater than a first preset tightness, determining to adjust the preset twist pitch; If the tightness of the conductor after the torsion test is less than or equal to the first preset tightness and greater than the second preset tightness, determining to coat the conductor with an insulation layer in a repeated trajectory to obtain an insulated conductor; If the tightness of the conductor after the torsion test is less than or equal to the second preset tightness, it is determined that the conductor is covered with an insulation layer in a spiral track to obtain an insulated conductor.

4. The method for preparing an ABS composite cable for automobiles according to claim 3, wherein: In step S4, determining whether to further prepare a composite cable or adjust the insulation coating process based on the coating uniformity of the insulated conductor includes: If the coating uniformity of the insulated conductor is less than the preset coating uniformity, determining to further prepare the composite cable; If the coating uniformity of the insulated conductor is greater than or equal to a preset coating uniformity, it is determined that the insulation layer coating process is adjusted.

5. The method for preparing an ABS composite cable for automobiles according to claim 4, wherein: Adjustments to the insulation wrapping process identified include: If the pore distribution uniformity is less than the preset uniformity, it is determined to adjust the coating spacing; If the distribution uniformity of the pores is greater than or equal to the preset uniformity, it is determined that the coating trajectory is adjusted.

6. The method for preparing an ABS composite cable for automobiles according to claim 5, wherein: The adjustment amount of the coating spacing is positively correlated with the uniformity of pore distribution, and determining to adjust the coating trajectory includes replacing the secondary coating trajectory in the repeated trajectory.

7. The method for preparing an ABS composite cable for automobiles according to claim 6, wherein: In step S5, determining whether to adjust the preset coating uniformity or the preset tightening degree includes: If the proportion of composite cables with abnormal current in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current is greater than the preset breakdown voltage, it is determined to adjust the preset coating uniformity; If the proportion of composite cables with abnormal current in the withstand voltage test is greater than the preset proportion and the average breakdown voltage of the composite cables with abnormal current is less than or equal to the preset breakdown voltage, it is determined to adjust the preset tightness.

8. The method for preparing an ABS composite cable for automobiles according to claim 7, wherein: Abnormal current phenomena during the withstand voltage test include the current value of the cable exceeding 1.5 times its rated working current during the withstand voltage test.

9. The method for preparing an ABS composite cable for automobiles according to claim 7, wherein: The adjustment amount of the preset coating uniformity is negatively correlated with the average breakdown voltage of the composite cable with abnormal current phenomenon, and the adjustment amount of the preset tightness is negatively correlated with the proportion of the composite cables with abnormal current phenomenon.

10. An ABS composite cable for automobiles prepared by the method for preparing an ABS composite cable for automobiles according to any one of claims 1 to 9, characterized in that: The automotive ABS composite cable consists of an inner conductor, an insulating layer, a shielding layer, and a protective layer from the inside to the outside; The inner conductor is composed of a plurality of twisted copper wires and is used to transmit signals; The insulating layer is wrapped around the outer periphery of the inner conductor to isolate current and reduce heat conduction, and the insulating layer is made of a flexible material; The shielding layer is wrapped around the outer periphery of the insulating layer in parallel with the axial direction of the cable to shield internal and external signal interference; The protective layer is coated on the outer periphery of the shielding layer to protect the shielding layer. The protective layer is made of ABS composite material.

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