Power cable for frequency converter and method of manufacturing the same

Abstract

The application is suitable for the technical field of cable manufacturing, and particularly relates to a power cable for a frequency converter and a manufacturing method thereof. The manufacturing method of the power cable for the frequency converter comprises the following steps: obtaining large-core insulation layer information and small-core insulation layer information based on matching of working power of the frequency converter; controlling an extrusion device to extrude a large-core insulation layer based on the large-core insulation layer information and to extrude a small-core insulation layer based on the small-core insulation layer information; obtaining large-core information and small-core information; and analyzing the large-core information and the small-core information to obtain cable structure information. The method can accurately consider the size and shape factors of the large core and the small core, and scientifically and reasonably design the cable structure, so that the distribution of the large core and the small core in the cable is more reasonable, thereby meeting the requirements of the frequency converter system on the cable in terms of high performance and high reliability.

Description

Technical Field

[0001] This application belongs to the field of cable manufacturing technology, and in particular relates to a power cable for frequency converters and its manufacturing method. Background Technology

[0002] With the rapid development of industrial automation and power electronics technology, frequency converters have been widely used in various fields. They achieve speed control of motors and other equipment by changing the frequency of the output power supply, effectively improving energy utilization efficiency and equipment operating performance. The power cable used in frequency converters is a key component connecting the frequency converter to the motor and other load equipment; its structure and performance directly affect the stability and reliability of power transmission.

[0003] In cable structure design, for common structures like 3+3 core cables, the distribution of large and small cores significantly impacts the cable's electrical performance, mechanical stability, and electromagnetic compatibility. Currently, cable structure designs are mostly based on experience or simple geometric layouts. Changes to the cable structure or unreasonable design can lead to problems such as localized overheating, mechanical stress concentration, and severe electromagnetic interference during actual use, failing to meet the high-performance and high-reliability requirements of frequency converter systems. Summary of the Invention

[0004] This application provides a power cable for frequency converters and a method for manufacturing the same, which can solve the problems of cable structure changes or unreasonable design, and meet the requirements of frequency converter systems for high performance and high reliability of cables.

[0005] In a first aspect, embodiments of this application provide a method for manufacturing a power cable for a frequency converter, comprising:

[0006] Information on the insulation layer of large and small battery cells is obtained based on the inverter's operating power matching. The inverter's operating power reflects the operating voltage and current of the inverter during operation. The insulation layer information of large battery cells reflects the thickness of the insulation layer covering the surface of large battery cells, and the insulation layer information of small battery cells reflects the thickness of the insulation layer covering the surface of small battery cells.

[0007] The control device controls the extrusion device to extrude the large cell insulation layer based on the large cell insulation layer information, and controls the extrusion device to extrude the small cell insulation layer based on the small cell insulation layer information;

[0008] Obtain information on large cores and small cores; wherein, the information on large cores is used to reflect the cross-sectional shape of the large core formed after the insulation layer of the large core is wrapped around the large core, and the information on small cores is used to reflect the cross-sectional shape of the small core formed after the insulation layer of the small core is wrapped around the small core.

[0009] Based on the analysis of the large core information and the small core information, cable structure information is obtained; wherein, the cable structure information is used to reflect the distribution of the large core and the small core.

[0010] The technical solutions described in this application embodiment have at least the following technical effects:

[0011] The method for manufacturing power cables for frequency converters provided in this application obtains insulation layer information for large and small battery cells based on the operating power of the frequency converter, which reflects the operating voltage and current of the frequency converter during operation. This information is used to determine the insulation layer thickness of the large battery cell and the insulation layer thickness of the small battery cell. This makes the determination of the insulation layer thickness more closely reflect actual operating conditions. Then, the extrusion device is controlled by a control device to extrude the insulation layer of the large battery cell based on the insulation layer information of the large battery cell, and the extrusion device is controlled to extrude the insulation layer of the small battery cell based on the insulation layer information of the small battery cell. Furthermore, by obtaining the cross-sectional information of the large battery cell formed after the insulation layer of the large battery cell covers the large battery cell, and the cross-sectional information of the small battery cell formed after the insulation layer of the small battery cell covers the small battery cell, the cable structure information is obtained by analyzing the large and small battery cell information. Compared with the cable structure design based on experience or simple geometric layout in the prior art, this method can accurately consider the size and shape factors of the large and small battery cells, and make a scientific and reasonable design for the cable structure. This results in a more rational distribution of large and small conductors in the cable, effectively improving the stress conditions of the cable during operation, reducing mechanical stress concentration, optimizing electromagnetic coupling effects, and reducing electromagnetic interference. It also helps to improve the heat dissipation performance of the cable, avoiding local overheating, thereby comprehensively improving the electrical performance, mechanical stability, and electromagnetic compatibility of the cable, meeting the requirements of frequency converter systems for high performance and high reliability of cables.

[0012] In one possible implementation of the first aspect, the step of analyzing the large core information and the small core information to obtain cable structure information includes:

[0013] Based on the analysis of the large core information, the minimum circumcircle information is obtained; wherein, the minimum circumcircle information is used to reflect the circumcircle formed by the pairwise adjacent ones of the three large cores;

[0014] Based on the analysis of the minimum circumscribed circle information and the small core information, the cable structure information is obtained.

[0015] In one possible implementation of the first aspect, the step of analyzing the cable structure information based on the minimum circumcircle information and the small core information to obtain cable structure information includes:

[0016] The maximum straight distance is obtained by analyzing the minimum circumcircle information; wherein, the maximum straight distance is used to indicate the maximum diameter that the minimum circumcircle can accommodate when the three large wire cores are adjacent to each other;

[0017] The maximum straight distance is compared with the small core information. If the maximum straight distance is greater than or equal to the diameter corresponding to the small core information, then the cable structure information is that the three large cores are adjacent to each other, and the three small cores are tangent to the two adjacent large cores respectively.

[0018] In one possible implementation of the first aspect, the step of analyzing the minimum circumcircle information to obtain the maximum straight distance includes:

[0019] Based on the analysis of the minimum circumcircle information, an inscribed triangle is obtained; wherein, the inscribed triangle refers to an equilateral triangle inscribed in a circle corresponding to the minimum circumcircle information;

[0020] The maximum straight distance is obtained by analyzing the information of the inscribed triangle and the minimum circumscribed circle.

[0021] In one possible implementation of the first aspect, the step of analyzing the inscribed triangle and the minimum circumscribed circle information to obtain the maximum straight distance includes:

[0022] Calculate the shortest line segment between the midpoint of any side of the inscribed triangle and the circle corresponding to the smallest circumcircle information;

[0023] Match the corresponding geometric factor based on the minimum circumcircle information;

[0024] The maximum straight distance is determined based on the shortest line segment and the geometric factor.

[0025] In one possible implementation of the first aspect, the step of analyzing the cable structure information based on the minimum circumcircle information and the small core information further includes:

[0026] If the maximum straight distance is less than the diameter corresponding to the small core information, then calculate the difference between the maximum straight distance and the diameter corresponding to the small core information to obtain the design difference.

[0027] The radius of the large circle is obtained based on the information of the large core wire; wherein, the radius of the large circle is used to indicate the radius of the large core wire.

[0028] Based on the design difference and the radius of the large circle, the cable structure information is obtained through analysis.

[0029] In one possible implementation of the first aspect, the step of analyzing the cable structure information based on the design difference and the great circle radius includes:

[0030] The extension length is obtained by analyzing the design difference.

[0031] The center distance is calculated based on the extended length and the radius of the large circle.

[0032] The cable structure information is obtained based on the center-to-center distance.

[0033] In one possible implementation of the first aspect, obtaining the cable structure information based on the center-to-center distance includes:

[0034] An equidistant shape is constructed based on the center-to-center distance; wherein, the equidistant shape is an equilateral triangle constructed with the center-to-center distance as the side length;

[0035] The three corners of the equidistant pattern are used as the centers of the three large wire cores to determine the positional distribution of the three large wire cores.

[0036] The three small core information are respectively set to be tangent to the two large core patterns corresponding to the position distribution of the large core, so as to obtain the cable structure information.

[0037] Secondly, embodiments of this application provide a power cable manufacturing system for frequency converters, comprising:

[0038] The matching module is used to obtain the insulation layer information of the large battery cell and the insulation layer information of the small battery cell based on the operating power of the frequency converter; wherein, the operating power of the frequency converter is used to reflect the operating voltage and operating current of the frequency converter when it is working, the insulation layer information of the large battery cell is used to reflect the thickness of the insulation layer wrapped on the surface of the large battery cell, and the insulation layer information of the small battery cell is used to reflect the thickness of the insulation layer wrapped on the surface of the small battery cell.

[0039] The control module is used to control the extrusion device to extrude the large cell insulation layer based on the large cell insulation layer information, and to control the extrusion device to extrude the small cell insulation layer based on the small cell insulation layer information.

[0040] The acquisition module is used to acquire information about large cores and small cores; wherein, the information about large cores is used to reflect the cross-sectional shape of the large core formed after the insulation layer of the large core is wrapped around the large core, and the information about small cores is used to reflect the cross-sectional shape of the small core formed after the insulation layer of the small core is wrapped around the small core.

[0041] The analysis module is used to analyze the large core information and the small core information to obtain cable structure information; wherein the cable structure information is used to reflect the distribution of the large core and the small core.

[0042] Thirdly, embodiments of this application provide a power cable manufacturing apparatus for frequency converters, including an extrusion device, a filling device, and a control device. The control device is electrically connected to the extrusion device and the filling device. The control device includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the method described in any one of the first aspects above.

[0043] Fourthly, embodiments of this application provide a power cable for a frequency converter, which is manufactured by the power cable manufacturing equipment for a frequency converter described in the third aspect.

[0044] Fifthly, embodiments of this application provide a computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in any one of the first aspects above.

[0045] In a sixth aspect, embodiments of this application provide a computer program product that, when run on a power cable manufacturing equipment for frequency converters, causes the power cable manufacturing equipment for frequency converters to perform the power cable manufacturing method for frequency converters described in any of the first aspects.

[0046] It is understood that the beneficial effects of the second to sixth aspects mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description

[0047] To more clearly illustrate the technical solutions in the embodiments of this application, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0048] Figure 1 This is a schematic flowchart of the method for manufacturing power cables for frequency converters provided in the embodiments of this application;

[0049] Figure 2 This is a schematic diagram illustrating the implementation process of the method for manufacturing power cables for frequency converters provided in the embodiments of this application;

[0050] Figure 3 This is a schematic diagram of the structure of the power cable manufacturing system for frequency converters provided in the embodiments of this application;

[0051] Figure 4 This is a schematic diagram of the control device of the power cable manufacturing equipment for frequency converters provided in the embodiments of this application. Detailed Implementation

[0052] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0053] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0054] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0055] As used in this application specification and the appended claims, the term "if" may be interpreted, depending on the context, as "when," "once," "in response to determination," or "in response to detection." Similarly, the phrase "if determination" or "if the described condition or event is detected" may be interpreted, depending on the context, as "once determination," "in response to determination," "once the described condition or event is detected," or "in response to the detection of the described condition or event."

[0056] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0057] References to "one embodiment" or "some embodiments" as described in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized.

[0058] In cable structure design, for common structures like 3+3 core cables, the distribution of large and small electrical cores significantly impacts the cable's electrical performance, mechanical stability, and electromagnetic compatibility. Current technologies largely rely on experience or simple geometric layouts for cable structure design, lacking precise analysis and optimization of the cross-sectional shapes, dimensions, and relative positions of the large and small electrical cores. For example, when determining the distribution of large and small electrical cores, the stress conditions, electromagnetic coupling effects, and heat dissipation requirements of different cores during cable operation are not fully considered. This leads to problems such as localized overheating, mechanical stress concentration, and severe electromagnetic interference in actual use, failing to meet the high-performance and high-reliability requirements of frequency converter systems.

[0059] To address the aforementioned problems, this application provides a power cable for frequency converters and a method for manufacturing the same. In this method, by matching the operating power of the frequency converter (reflecting its operating voltage and current) to obtain information on the insulation layer thickness of the large and small battery cells (reflecting the thickness of the insulation layer covering the surface of the large battery cell and the insulation layer thickness of the small battery cell), the insulation layer thickness is determined to better reflect actual operating conditions. Then, a control device controls an extrusion device to extrude the large battery cell insulation layer based on the large battery cell insulation layer information, and controls the extrusion device to extrude the small battery cell insulation layer based on the small battery cell insulation layer information. Furthermore, by acquiring information on the large and small battery cells (reflecting the cross-sectional shape of the large battery cell after the large battery cell insulation layer covers it) and the cross-sectional shape of the small battery cell after the small battery cell insulation layer covers it, cable structure information is obtained through analysis based on the large and small battery cell information. Compared to existing cable structure designs based on experience or simple geometric layouts, this method can accurately consider the size and shape factors of the large and small battery cells, enabling a scientifically sound and reasonable cable structure design. This results in a more rational distribution of large and small conductors in the cable, effectively improving the stress conditions of the cable during operation, reducing mechanical stress concentration, optimizing electromagnetic coupling effects, and reducing electromagnetic interference. It also helps to improve the heat dissipation performance of the cable, avoiding local overheating, thereby comprehensively improving the electrical performance, mechanical stability, and electromagnetic compatibility of the cable, meeting the requirements of frequency converter systems for high performance and high reliability of cables.

[0060] The method for manufacturing power cables for frequency converters provided in this application embodiment can be applied to a power cable manufacturing equipment for frequency converters. In this case, the power cable manufacturing equipment for frequency converters is the execution subject of the power cable manufacturing method for frequency converters provided in this application embodiment. This application embodiment does not impose any restrictions on the specific type of power cable manufacturing equipment for frequency converters.

[0061] For example, power cable manufacturing equipment for frequency converters may include an extrusion unit, a filling unit, and a control unit, with the control unit electrically connected to both the extrusion and filling units. The extrusion unit heats the insulating material to a molten state and, according to set process parameters, uniformly extrudes and coats the molten insulating material onto the core to form a wire core. The extrusion unit mainly consists of a barrel, screw, heating system, and die. The barrel contains the insulating material; the screw rotates under motor drive, pushing the insulating material forward while simultaneously stirring and plasticizing it; the heating system surrounds the barrel and precisely controls the temperature of different sections to ensure the insulating material reaches a suitable molten state; the die determines the shape and thickness of the extruded insulation layer, and by changing different die specifications, cable insulation layers meeting different requirements can be produced. The filling unit is used during the cabling process to fill the gaps between the wire cores with suitable materials, such as polypropylene rope, rock wool, rubber, and other soft materials. The filling device consists of a hopper, a conveying pipeline, a metering pump, and a filling head. The hopper stores the filling material; the conveying pipeline transports the filling material from the hopper to the filling head; the metering pump controls the amount of filling material delivered according to the cable structure to ensure uniform filling; and the filling head accurately fills the material into the gaps between the cable cores, making the cable structure more stable and round. The control device comprehensively monitors and precisely controls the entire cable manufacturing process.

[0062] For example, the control device can be a mobile phone, tablet, wearable device, augmented reality (AR) / virtual reality (VR) device, laptop, ultra-mobile personal computer (UMPC), netbook, personal digital assistant (PDA), desktop computer, smart screen, smart TV and other terminal devices, handheld devices with wireless communication capabilities, computing devices or other processing devices connected to a wireless modem, Internet of Things (IoT) terminals, computers, laptops, handheld communication devices, handheld computing devices, satellite wireless devices, wireless modem cards, set-top boxes (STBs), customer premises equipment (CPEs) and / or other devices used for communication over wireless systems, as well as next-generation communication systems, such as mobile terminals in 5G networks or mobile terminals in future evolved Public Land Mobile Networks (PLMNs).

[0063] To better understand the method for manufacturing power cables for frequency converters provided in the embodiments of this application, the specific implementation process of the method for manufacturing power cables for frequency converters provided in the embodiments of this application will be described by way of example below.

[0064] Figure 1 This illustration shows a schematic flowchart of a method for manufacturing power cables for frequency converters according to an embodiment of this application. The method includes:

[0065] S100, based on the inverter's operating power matching, obtains the insulation layer information of the large battery cell and the insulation layer information of the small battery cell; among them, the inverter's operating power is used to reflect the operating voltage and operating current when the inverter is working, the insulation layer information of the large battery cell is used to reflect the thickness of the insulation layer wrapped around the surface of the large battery cell, and the insulation layer information of the small battery cell is used to reflect the thickness of the insulation layer wrapped around the surface of the small battery cell.

[0066] It's understandable that the voltage and current of the inverter during operation affect the cable's power transmission capacity and heat generation, and large and small battery cells in the cable perform different power transmission tasks. Larger cells typically carry the main power, while smaller cells play auxiliary or specific functions. The insulation thickness is determined based on the inverter's operating power, ensuring electrical insulation performance while adapting to the heat generation and mechanical stress requirements of different cells. For example, in high-power inverters, larger cells carry larger currents and generate more heat, requiring a thicker insulation layer to ensure insulation and heat dissipation performance. The insulation thickness for smaller cells is also determined based on their function and power distribution.

[0067] Different inverter operating power corresponds to one large-cell insulation layer and one small-cell insulation layer. For example, the inverter operating power can be matched against an inverter database to obtain the corresponding large-cell and small-cell insulation layer information; alternatively, the inverter operating power can be input into a learning model, which outputs the corresponding large-cell and small-cell insulation layer information, and so on, but not limited to these methods. The inverter database refers to a database containing inverters of different specifications, inverter operating power, and corresponding large-cell and small-cell insulation layer information. This data can be obtained through laboratory experiments, on-site measurements and monitoring, and past experience. After acquisition, the collected data is organized, classified, and archived, useful information and patterns are extracted, and the relevant data is saved to the database to form a raw material database. The learning model is trained using multiple sets of training data, each set of which includes the inverter operating power and corresponding large-cell and small-cell insulation layer information.

[0068] S200, the control device controls the extrusion device to extrude the insulation layer of the large battery cell based on the insulation layer information of the large battery cell, and controls the extrusion device to extrude the insulation layer of the small battery cell based on the insulation layer information of the small battery cell.

[0069] It is understandable that the extrusion device, based on pre-set parameters such as temperature, pressure, and extrusion speed, uniformly extrudes and wraps the insulating material on the surface of the large battery cell according to the thickness requirements of the insulation layer information of the large battery cell, in order to obtain a large wire core; and uniformly extrudes and wraps the insulating material on the surface of the small battery cell according to the thickness requirements of the insulation layer information of the small battery cell, in order to obtain a small wire core.

[0070] S300, acquire large core information and small core information; whereby, the large core information is used to reflect the cross-sectional shape of the large core formed after the insulation layer of the large core is wrapped around the large core, and the small core information is used to reflect the cross-sectional shape of the small core formed after the insulation layer of the small core is wrapped around the small core.

[0071] It can be understood that the large core information refers to the actual cross-sectional dimensions of the insulation material and the large core as a whole, obtained by wrapping the insulation material around the surface of the large core and then cooling and shaping it. The small core information refers to the actual cross-sectional dimensions of the insulation material and the small core as a whole, obtained by wrapping the insulation material around the surface of the small core and then cooling and shaping it.

[0072] S400 analyzes the information of large and small conductors to obtain cable structure information; the cable structure information reflects the distribution of large and small conductors.

[0073] It is understandable that the distribution of large and small conductors directly affects the electrical, mechanical, and heat dissipation performance of cables. Cable structure information can be obtained by analyzing the cross-sectional information of large and small conductors, using geometric analysis and electromagnetic principles to determine their relative positions and arrangements within the cable. Alternatively, the information on large and small conductors can be input into a learning model, which will then output the corresponding cable structure information. These methods are not limited to these approaches.

[0074] This configuration allows for the scientific and rational determination of cable structure information through the information on large and small cores, meeting the performance requirements of cables in different application scenarios and reducing performance problems and failure risks caused by unreasonable cable structures.

[0075] In one possible implementation, in step S400, cable structure information is obtained by analyzing the information of the large core and the small core, including:

[0076] S410, based on the information of the large core, the minimum circumcircle information is obtained; the minimum circumcircle information is used to reflect the circumcircle formed by the two adjacent pairs of the three large cores.

[0077] It is understandable that when three large wire cores are adjacent to each other, there exists a minimum circumcircle that can completely contain them. By analyzing the cross-sectional information of the large wire cores, geometric algorithms can be used to determine the radius, center position, and other information of this minimum circumcircle, which is the minimum circumcircle information.

[0078] S420 analyzes the cable structure information based on the minimum circumscribed circle information and the small core information.

[0079] It is understandable that the minimum circumscribed circle information determines the spatial range occupied by the large conductor, while the small conductors need to be rationally distributed within the remaining space. Combining the cross-sectional information of the small conductors, the optimal distribution position of the small conductors around the large conductors can be further analyzed. For example, the cable structure information can be obtained by analyzing the distribution within the remaining space in the minimum circumscribed circle information, combined with the dimensions of the small conductors; alternatively, the minimum circumscribed circle information and the small conductor information can be input into a learning model, which outputs the corresponding cable structure information, and so on, but not limited to these methods.

[0080] This configuration, by combining the minimum circumcircle information and the small core information to determine the cable structure, fully considers the spatial relationship and performance requirements of large and small cores, improving the scientificity and rationality of the cable structure design, and helping to enhance the overall performance and reliability of the cable.

[0081] In one possible implementation, in step S420, cable structure information is obtained by analyzing the minimum circumcircle information and the small conductor information, including:

[0082] S421, based on the minimum circumscribed circle information, the maximum straight distance is obtained; where the maximum straight distance is used to indicate the maximum diameter that the minimum circumscribed circle can accommodate when the three large wire cores are adjacent to each other.

[0083] It is understandable that after determining the smallest circumcircle, geometric analysis is used to find the maximum diameter, i.e., the maximum distance, that can accommodate a small wire core within this circle. For example, the maximum distance can be determined by analyzing the geometry of the smallest circumcircle, calculating the geometry of the inscribed equilateral triangle, and then determining the maximum distance based on the size of the inscribed triangle; alternatively, the radius of the largest accommodating circle can be obtained by analyzing the area and shape of the remaining space within the smallest circumcircle, and the maximum distance can be determined based on that radius, and so on, but is not limited to these methods.

[0084] In one possible implementation, step S420 involves analyzing the minimum circumcircle information to obtain the maximum straight distance, including:

[0085] S4211, based on the information of the smallest circumcircle, the inscribed triangle is obtained; where the inscribed triangle is the equilateral triangle inscribed in the circle corresponding to the information of the smallest circumcircle.

[0086] It is understandable that inscribed triangles can be drawn or constructed using geometric drawing software based on the information of the smallest circumcircle; or inscribed triangles can be calculated using mathematical calculation software based on the parameters of the smallest circumcircle (radius, diameter, arc length, etc.), but this is not the only method.

[0087] S4212, based on the information of the inscribed triangle and the minimum circumscribed circle, the maximum straight distance is obtained.

[0088] It can be understood that the maximum straight distance is used to reflect the largest circle that can be accommodated in the area outside the region occupied by the large wire core pattern within the minimum circumcircle. For example, the maximum straight distance can be obtained by combining the geometric features of the inscribed triangle and the parameters of the minimum circumcircle through a specific geometric calculation method; or the information of the inscribed triangle and the minimum circumcircle can be input into a learning model, and the learning model outputs the corresponding maximum straight distance, etc., but not limited to these.

[0089] This setup, by constructing an inscribed triangle and combining it with the minimum circumscribed circle information to calculate the maximum straight distance, utilizes a simple yet effective geometric method. This improves the accuracy and efficiency of determining the maximum straight distance, provides a precise data foundation for rationally planning the internal core distribution of the cable, and helps optimize the cable structure design.

[0090] In one possible implementation, step S4212 involves analyzing the inscribed triangle and minimum circumscribed circle information to obtain the maximum straight distance, including:

[0091] S42121, calculate the shortest line segment between the midpoint of any side of an inscribed triangle and the circle corresponding to the smallest circumcircle.

[0092] It is understandable that by using geometric calculation methods, such as the Pythagorean theorem and trigonometric functions, combined with the known parameters of the inscribed triangle and the smallest circumcircle, it is possible to accurately calculate the length of the shortest line segment between the midpoint of any side of the inscribed triangle and the circle corresponding to the information of the smallest circumcircle.

[0093] S42122, Match the corresponding geometric factor based on the minimum circumcircle information.

[0094] The influence coefficient of the geometric characteristics of the minimum circumcircle on the calculation of the maximum straight distance is understandable. It is derived through extensive mathematical derivation and geometric analysis, summarizing the results for minimum circumcircles of different sizes and characteristics. Minimum circumcircles with different radii, center positions, and other parameters have different geometric factors. For example, when the radius of the minimum circumcircle increases, the geometric factor also changes according to specific mathematical rules. This factor is a dimensionless value that comprehensively considers factors such as the shape and size of the minimum circumcircle, playing a corrective and calibrating role in calculating the maximum straight distance, making the calculation result more accurately reflect the maximum diameter that can actually accommodate a small wire core.

[0095] S42123 determines the maximum straight distance based on the shortest line segment and geometric factors.

[0096] It can be understood that the maximum straight distance = the length value reflected by the shortest line segment × geometric factor.

[0097] This setup, combined with calculations using specific geometric factors, determines the maximum straight-line distance, providing precise data for judging whether smaller conductors can be reasonably distributed within the space formed by larger conductors. This calculation method is logically clear and scientifically rigorous, effectively improving the accuracy and reliability of cable structure design. In actual cable manufacturing, based on accurate maximum straight-line distance data, the layout of large and small conductors can be rationally planned, avoiding performance degradation caused by unreasonable conductor distribution. This improves the quality and performance of cable products, meeting the performance requirements of different application scenarios.

[0098] S422a compares the maximum straight distance with the small core information. If the maximum straight distance is greater than or equal to the diameter corresponding to the small core information, then the cable structure information is that the three large cores are adjacent to each other, and the three small cores are tangentially distributed with the two adjacent large cores respectively.

[0099] It is understandable that when the maximum straight-line distance is greater than or equal to the diameter of the smaller conductor, it means that the smaller conductors can be distributed tangentially within the gaps formed by the larger conductors. This distribution method ensures sufficient electrical distance between the conductors while also making the cable structure more compact, which is beneficial for improving the cable's mechanical strength and electrical performance. For example, in terms of electrical performance, a tangential distribution can reduce electromagnetic interference between conductors; in terms of mechanical performance, a compact structure can enhance the overall stability of the cable and facilitate its installation and use. By comparing and determining this distribution method, the cable structure can be quickly and rationally determined, improving the efficiency and quality of cable design.

[0100] In one possible implementation, step S420, which involves analyzing the minimum circumscribed circle information and the small conductor information to obtain cable structure information, further includes:

[0101] S422b, if the maximum straight distance is less than the diameter corresponding to the small core information, then calculate the difference between the maximum straight distance and the diameter corresponding to the small core information to obtain the design difference.

[0102] It can be understood that the design difference = the diameter corresponding to the small core information - the maximum straight distance.

[0103] S423, the radius of the large circle is obtained based on the information of the large core wire; where the radius of the large circle is used to indicate the radius of the large core wire.

[0104] It can be understood that the large circle radius refers to the sum of the radius of the large battery cell and the thickness of the insulation layer of the large battery cell.

[0105] S424, based on the design difference and the radius of the large circle, the cable structure information is obtained through analysis.

[0106] For example, the position between the large wire cores can be adjusted by designing the difference, and the position of the small wire cores can be adjusted by combining the large circle radius to obtain the cable structure information; the design difference and the large circle radius can also be input into the learning model, and the learning model outputs the corresponding cable structure information, etc., but not limited to these.

[0107] This configuration, by comprehensively considering the design difference, the large core radius, and the small core radius to determine the cable structure, allows for flexible adjustment of the core layout when the maximum straight distance is less than the small core diameter. This ensures the rationality of the cable structure and the reliability of its performance, improves the adaptability and flexibility of the cable structure design, and meets the cable design requirements under different core size conditions.

[0108] In one possible implementation, in step S424, cable structure information is obtained by analyzing the design difference and the large circle radius, including:

[0109] S4241, based on the design difference analysis, the extension length is obtained.

[0110] It is understandable that extended length refers to the additional distance that needs to be added between the large conductors. Different design differences correspond to one extended length. The corresponding extended length can be obtained by matching the design differences in the inverter database; alternatively, the design differences can be input into the learning model, and the learning model can output the corresponding extended length, and so on, but it is not limited to these methods.

[0111] S4242, the center distance is calculated based on the extended length and the radius of the large circle.

[0112] It can be understood that the distance between the centers = 2 × the radius of the great circle + the extension length.

[0113] S4243, cable structure information is obtained based on the center-to-center distance.

[0114] It's understandable that once the center-to-center distance is determined, it can be used as a basis to determine the specific distribution positions of the large and small conductors, thereby obtaining cable structure information. The center-to-center distance can be defined as the distance between the centers of the large conductors. By determining the distance, the relative positional relationship of the three large conductors can be obtained, and then the position of the small conductors can be determined to obtain cable structure information. Alternatively, the distance between the large conductors can be determined based on the center-to-center distance analysis, thus determining the layout of the large conductors, and then clarifying the positional relationship between the small and large conductors to obtain cable structure information.

[0115] This setup, through calculating the extension length, determining the center distance, and ultimately obtaining the cable structure information, employs a systematic calculation and analysis method. It can accurately determine the cable structure under complex core size conditions, improve the accuracy and reliability of cable structure design, meet the stringent requirements for cable electrical and mechanical performance, and enhance the overall quality of the cable.

[0116] In one possible implementation, in step S4243, cable structure information is obtained based on the center-to-center distance, including:

[0117] S42431, constructing equidistant figures based on the center-to-center distance; wherein, the equidistant figures are equilateral triangles constructed with the center-to-center distance as the side length.

[0118] It's understandable that constructing an equilateral triangle with the center-to-center distance as the side length is an intuitive and effective method for determining the distribution of large wire cores. The three vertices of this equilateral triangle represent the potential center positions of the three large wire cores. By constructing such an equidistant figure, the abstract center-to-center distance can be transformed into a concrete geometric shape, facilitating an intuitive understanding and planning of the layout of the large wire cores.

[0119] S42432 uses the three corners of the equidistant figure as the centers of the three large wire cores to determine the positional distribution of the three large wire cores.

[0120] It is understandable that when the three corners of the equidistant figure are used as the centers of the three large wire cores, the positional distribution of the large wire cores is precisely determined. At this time, the three large wire cores do not touch each other, and the distance between their edges is the distance value reflected by the extended length.

[0121] S42433 sets the information of the three small wire cores to be tangent to the two large wire core patterns corresponding to the position distribution of the large wire cores, so as to obtain the cable structure information.

[0122] It can be understood that setting the information of the three small cores tangent to the two large core patterns corresponding to the positions of the large cores means that the edge of each small core is in contact with the edges of the two large cores, and each large core is in contact with the edges of the two small cores. At this point, the distribution of the large and small cores constitutes the cable structure information. Furthermore, the smallest circumcircle formed by the outer edges of the three small and three large cores represents the distribution of the power cable's shielding layer. The filling device sets the amount of filler according to the size of this smallest circumcircle to ensure a stable and compact cable structure.

[0123] This setup, by constructing equidistant patterns based on the center-to-center distance to determine the distribution of large conductors, and then tangentially arranging small conductors with large conductors, forms a scientific, rational, and efficient cable structure design method. This design method fully utilizes geometric principles, making the internal structure of the cable more orderly and compact, ensuring stable electrical performance while improving its mechanical properties and overall reliability.

[0124] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0125] Corresponding to the inverter power cable manufacturing method described in the above embodiments, this application also provides an inverter power cable manufacturing system, the various modules of which can implement the various steps of the inverter power cable manufacturing method. Figure 3 A structural block diagram of a power cable manufacturing system for frequency converters provided in an embodiment of this application is shown. For ease of explanation, only the parts related to the embodiments of this application are shown.

[0126] Reference Figure 3 The power cable manufacturing system for this frequency converter includes:

[0127] The matching module is used to obtain the insulation layer information of large battery cells and small battery cells based on the inverter's operating power. The inverter's operating power reflects the operating voltage and current of the inverter when it is working. The insulation layer information of large battery cells reflects the thickness of the insulation layer wrapped around the surface of large battery cells, and the insulation layer information of small battery cells reflects the thickness of the insulation layer wrapped around the surface of small battery cells.

[0128] The control module is used to control the extrusion device to extrude the insulation layer of the large battery cell based on the insulation layer information of the large battery cell, and to control the extrusion device to extrude the insulation layer of the small battery cell based on the insulation layer information of the small battery cell.

[0129] The acquisition module is used to acquire information about large cores and small cores. The information about large cores reflects the cross-sectional shape of the large core after its insulation layer wraps around it, and the information about small cores reflects the cross-sectional shape of the small core after its insulation layer wraps around it.

[0130] The analysis module is used to analyze the information of large and small conductors to obtain cable structure information; the cable structure information reflects the distribution of large and small conductors.

[0131] It should be noted that the information interaction and execution process between the above modules are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, which will not be repeated here.

[0132] Those skilled in the art will understand that, for the sake of convenience and brevity, the above-described module division is merely an example. In practical applications, the above functions can be assigned to different modules as needed, that is, the internal structure of the system can be divided into different modules to complete all or part of the functions described above. The modules in the embodiments can be integrated into one processing unit, or each module can exist physically separately, or two or more modules can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the modules are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the modules in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0133] This application also provides a power cable manufacturing equipment for frequency converters, including an extrusion device, a filling device, and a control device, wherein the control device is electrically connected to the extrusion device and the filling device. Figure 4 This is a schematic diagram of the structure of a control device 6 provided in an embodiment of this application. Figure 4 As shown, the control device 6 in this embodiment includes: at least one processor 60 ( Figure 4 Only one is shown in the image), at least one memory 61 ( Figure 4 (Only one is shown in the diagram) and a computer program 62 stored in the at least one memory 61 and executable on the at least one processor 60, wherein when the processor 60 executes the computer program 62, it causes the control device 6 to perform the steps in any of the above embodiments of the method for manufacturing power cables for frequency converters, or causes the control device 6 to perform the functions of each module in the above embodiments of the device.

[0134] For example, the computer program 62 may be divided into one or more modules / units, which are stored in the memory 61 and executed by the processor 60 to complete this application. The one or more modules / units may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program 62 in the control device 6.

[0135] The control device 6 can be a desktop computer, laptop, handheld computer, or cloud server, etc. The power cable manufacturing equipment for this frequency converter may include, but is not limited to, a processor 60 and a memory 61. Those skilled in the art will understand that... Figure 4 This is merely an example of control device 6 and does not constitute a limitation on control device 6. It may include more or fewer components than shown, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.

[0136] The processor 60 can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0137] In some embodiments, the memory 61 may be an internal storage unit of the control device 6, such as a hard disk or memory of the control device 6. In other embodiments, the memory 61 may be an external storage device of the control device 6, such as a plug-in hard disk, smart media card (SMC), secure digital card (SD), flash card, etc., equipped on the control device 6. Furthermore, the memory 61 may include both internal storage units and external storage devices of the control device 6. The memory 61 is used to store the operating system, applications, bootloader, data, and other programs, such as the program code of the computer program. The memory 61 can also be used to temporarily store data that has been output or will be output.

[0138] This application embodiment also provides a power cable for a frequency converter, which is manufactured by the power cable manufacturing equipment for frequency converters.

[0139] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps in any of the above method embodiments.

[0140] This application provides a computer program product that, when run on a power cable manufacturing equipment for frequency converters, enables the power cable manufacturing equipment for frequency converters to implement the steps in any of the above-described method embodiments.

[0141] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the methods of the above embodiments of this application can be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include at least: any entity or device capable of carrying the computer program code to the inverter power cable manufacturing equipment, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium, such as a USB flash drive, a portable hard drive, a magnetic disk, or an optical disk.

[0142] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0143] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0144] In the embodiments provided in this application, it should be understood that the disclosed inverter power cable manufacturing equipment and system can be implemented in other ways. For example, the inverter power cable manufacturing system embodiments described above are merely illustrative. For instance, the division of modules is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple modules may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be indirect coupling or communication connection through some interfaces, devices, or modules, and may be electrical, mechanical, or other forms.

[0145] The modules described as separate components may or may not be physically separate. The components shown as modules may or may not be physical modules; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs.

[0146] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A method for manufacturing a power cable for a frequency converter, characterized in that, include: Information on the insulation layer of large and small battery cells is obtained based on the inverter's operating power matching. The inverter's operating power reflects the operating voltage and current of the inverter during operation. The insulation layer information of large battery cells reflects the thickness of the insulation layer covering the surface of large battery cells, and the insulation layer information of small battery cells reflects the thickness of the insulation layer covering the surface of small battery cells. The control device controls the extrusion device to extrude the large cell insulation layer based on the large cell insulation layer information, and controls the extrusion device to extrude the small cell insulation layer based on the small cell insulation layer information; Obtain information on large cores and small cores; wherein, the information on large cores is used to reflect the cross-sectional shape of the large core formed after the insulation layer of the large core is wrapped around the large core, and the information on small cores is used to reflect the cross-sectional shape of the small core formed after the insulation layer of the small core is wrapped around the small core. Based on the analysis of the large core information and the small core information, cable structure information is obtained; wherein, the cable structure information is used to reflect the distribution of the large core and the small core; The process of analyzing the large core information and the small core information to obtain cable structure information includes: Based on the analysis of the large core information, the minimum circumcircle information is obtained; wherein, the minimum circumcircle information is used to reflect the circumcircle formed by the pairwise adjacent ones of the three large cores; Based on the analysis of the minimum circumscribed circle information and the small core information, the cable structure information is obtained.

2. The method for manufacturing power cables for frequency converters as described in claim 1, characterized in that, The process of analyzing the minimum circumscribed circle information and the small core information to obtain cable structure information includes: The maximum straight distance is obtained by analyzing the minimum circumcircle information; wherein, the maximum straight distance is used to indicate the maximum diameter that the minimum circumcircle can accommodate when the three large wire cores are adjacent to each other; The maximum straight distance is compared with the small core information. If the maximum straight distance is greater than or equal to the diameter corresponding to the small core information, then the cable structure information is that the three large cores are adjacent to each other, and the three small cores are tangent to the two adjacent large cores respectively.

3. The method for manufacturing power cables for frequency converters as described in claim 2, characterized in that, The step of analyzing the minimum circumcircle information to obtain the maximum straight distance includes: Based on the analysis of the minimum circumcircle information, an inscribed triangle is obtained; wherein, the inscribed triangle refers to an equilateral triangle inscribed in a circle corresponding to the minimum circumcircle information; The maximum straight distance is obtained by analyzing the information of the inscribed triangle and the minimum circumscribed circle.

4. The method for manufacturing power cables for frequency converters as described in claim 3, characterized in that, The step of analyzing the inscribed triangle and the minimum circumscribed circle to obtain the maximum straight distance includes: Calculate the shortest line segment between the midpoint of any side of the inscribed triangle and the circle corresponding to the smallest circumcircle information; Match the corresponding geometric factor based on the minimum circumcircle information; The maximum straight distance is determined based on the shortest line segment and the geometric factor.

5. The method for manufacturing power cables for frequency converters as described in claim 2, characterized in that, The step of analyzing the cable structure information based on the minimum circumscribed circle information and the small core information further includes: If the maximum straight distance is less than the diameter corresponding to the small core information, then calculate the difference between the maximum straight distance and the diameter corresponding to the small core information to obtain the design difference. The radius of the large circle is obtained based on the information of the large wire core; wherein, the radius of the large circle is used to indicate the radius of the large wire core; Based on the design difference and the radius of the large circle, the cable structure information is obtained through analysis.

6. The method for manufacturing power cables for frequency converters as described in claim 5, characterized in that, The analysis based on the design difference and the radius of the large circle yields cable structure information, including: The extension length is obtained by analyzing the design difference. The center distance is calculated based on the extended length and the radius of the large circle. The cable structure information is obtained based on the center-to-center distance.

7. The method for manufacturing power cables for frequency converters as described in claim 6, characterized in that, The process of obtaining cable structure information based on the center-to-center distance includes: An equidistant shape is constructed based on the center-to-center distance; wherein, the equidistant shape is an equilateral triangle constructed with the center-to-center distance as the side length; The three corners of the equidistant pattern are used as the centers of the three large wire cores to determine the positional distribution of the three large wire cores. The three small core information are respectively set to be tangent to the two large core patterns corresponding to the position distribution of the large core, so as to obtain the cable structure information.

8. A power cable manufacturing equipment for frequency converters, characterized in that, The device includes an extrusion apparatus, a filling apparatus, and a control apparatus, wherein the control apparatus is electrically connected to the extrusion apparatus and the filling apparatus, and the control apparatus includes a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the method as described in any one of claims 1 to 7.

9. A power cable for a frequency converter, characterized in that, The power cable for the frequency converter is manufactured by the power cable manufacturing equipment for the frequency converter as described in claim 8.

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