Wear-resistant wind energy cable

Abstract

The invention discloses a wear-resistant wind energy cable, relates to the technical field of cables, and solves the problem that a wind energy cable in the prior art is difficult to meet the reliability requirement of long-term operation in a wind power generation scene due to the poor protection effect of a sheath layer. Comprising a cable core structure, and the cable core structure comprises a plurality of conductors distributed in a longitudinal array, insulation shielding layers wrapping the conductors and wrapping tape layers wrapping the insulation shielding layers; the cable also comprises an outer sheath which wraps the cable core structure, and the outer sheath comprises an outer protection layer and a lining layer which are arranged outside the belting layer. The functional layer comprises an armor layer and a pressure-resistant buffer layer, and the armor layer is arranged between the inner side of the lining layer and the outer side of the belting layer; according to the design scheme of the cable outer sheath, by optimizing the structural design, the structural bearing capacity of the cable is remarkably improved, and meanwhile the protection effect of the cable is enhanced. The design can meet the reliability requirement of long-term operation of the cable in a wind power generation scene.

Description

Technical Field

[0001] The invention belongs to the technical field of cables, and in particular relates to a wear-resistant wind power cable. Background Art

[0002] Wind power cables are specially designed and manufactured for wind power generation systems. They are used to transmit electrical energy within wind turbines and between wind turbines and the power grid. Because wind power generation often occurs in harsh environments such as offshore, mountainous areas, and grasslands, wind power cables must possess a range of special properties to ensure reliability and safety during long-term operation.

[0003] Currently, cables used in wind power generation scenarios often need to withstand significant weight and complex environmental stresses. The sheath layer typically serves as a crucial protective structure for the cable, providing additional mechanical support and protection for the internal layers, buffering external mechanical pressure and friction, and preventing deformation and damage to the cable due to its own weight or external factors. However, existing cable sheaths suffer from poor overall strength. When installed and used on wind turbines, the cable's own weight subjects it to continuous tension and pressure. Prolonged exposure to this condition can lead to stress concentration and fatigue damage in the sheath layer, increasing the likelihood of cracking.

[0004] This defect makes it difficult for the cable to meet the requirements of the standard load test. The standard load test is designed to simulate the gravity load that the cable will withstand during actual use, in order to verify the cable's performance stability and reliability under long-term load conditions. Due to the lack of a protective sheath layer, the sheath of this cable may not be able to withstand the specified load during the load test, and may suffer damage such as cracking. This will not only affect the cable's electrical performance, but may also pose a safety hazard, limiting the cable's widespread application and reliability in the wind power industry.

[0005] In summary, the wind power cables in the prior art have the problem of poor protection effect of the sheath layer, which makes it difficult for them to meet the reliability requirements of long-term operation in wind power generation scenarios. Summary of the Invention

[0006] The present invention provides a wear-resistant wind power cable, which can solve the problem of poor sheath protection effect of wind power cables in the prior art, resulting in its difficulty in meeting the reliability requirements of long-term operation in wind power generation scenarios.

[0007] To achieve the above object, according to an embodiment of the first aspect of the present invention, a wear-resistant wind power cable is provided, comprising a cable core structure, wherein the cable core structure comprises a plurality of conductors distributed in a longitudinal array, an insulating shielding layer wrapped around each conductor, and a tape layer wrapped around the outside of the insulating shielding layer; Also includes: An outer sheath wrapped around the outside of the cable core structure, the outer sheath comprising an outer protective layer and an inner lining layer arranged outside the tape layer; The functional layer includes an armor layer and a pressure-resistant buffer layer. The armor layer is arranged between the inner side of the inner lining layer and the outer side of the tape layer. The pressure-resistant buffer layer is arranged between the inner lining layer and the outer protective layer.

[0008] A further improvement is that the gap between the tape layer and the outside of each insulating shielding layer is filled with glass fiber rope.

[0009] A further improvement is that the outer sheath is made of one of polyvinyl chloride, low-smoke halogen-free material or thermoplastic elastomer.

[0010] A further improvement is that the pressure-resistant buffer layer is composed of a plurality of copper plates, which are distributed in a longitudinal array outside the inner lining layer and are tightly attached to the inner wall of the outer protective layer. Multiple buffer zones are formed between adjacent copper plates, the inner lining layer and the outer protective layer, and the buffer zones are filled with chloroprene rubber material.

[0011] A further improvement is that the armor layer is wrapped around the outside of the inner lining layer and is made of glass fiber tape.

[0012] A further improvement is that the functional layer further includes a flame retardant layer arranged between the inner side of the outer protective layer and the outer side of the pressure-resistant layer, and the flame retardant layer is made of ceramic silicone rubber material.

[0013] A further improvement is that it also includes a functional coating, which includes an anti-oxidation coating layer, a flame retardant coating layer and a chemical coating layer. The anti-oxidation coating layer, the flame retardant coating layer and the chemical coating layer are sequentially coated on the outside of the outer protective layer.

[0014] A further improvement is that it also includes a waterproof structural layer, which includes a waterproof inner layer and a waterproof outer layer. The waterproof inner layer is arranged between the outer layer of the armor layer and the inner side of the lining layer, and the waterproof outer layer is arranged between the outer side of the pressure-resistant buffer layer and the inner side of the outer protective layer.

[0015] A further improvement is that the waterproof inner layer is a water-blocking tape, and the waterproof outer layer is made of a high-efficiency water-blocking yarn material.

[0016] Compared with the prior art, the present invention has the following beneficial effects: The present invention incorporates a functional layer within the outer sheath, comprising an armor layer, a pressure-resistant buffer layer, and a flame-retardant layer. The pressure-resistant buffer layer is composed of a plurality of copper plates arranged in a longitudinal array outside the inner lining layer and in close contact with the inner wall of the outer sheath. Multiple buffer zones are formed between adjacent copper plates, the inner lining layer, and the outer sheath, and these buffer zones are filled with chloroprene rubber. This design, due to the excellent weather resistance of chloroprene rubber, is resistant to erosion by environmental factors such as ultraviolet rays and ozone, and possesses outstanding wear resistance, effectively withstanding the friction and wear generated during cable operation. During operation, the copper plates provide rigid support for the cable core structure, while the chloroprene rubber buffer layer absorbs and disperses excess pressure and vibration. This design not only ensures the cable's pressure resistance but also reduces damage to the internal conductor. Furthermore, the copper plate design dissipates heat generated by the cable core structure, achieving a cooling effect and effectively preventing the effects of high temperature on the cable's performance. The flame-retardant layer is made of ceramic silicone rubber. Designed to have the flexibility of rubber at room temperature, it facilitates cable installation and routing. Under high temperatures or flames, it rapidly ceramicizes, forming a hard, ceramic-like shell that provides thermal insulation, fire resistance, and flame retardancy. The armor layer, wrapped around the inner liner, is made of fiberglass tape. Due to the high strength-to-weight ratio of fiberglass, this layer provides excellent mechanical protection without significantly increasing the cable's weight. It also exhibits excellent chemical resistance, resisting corrosion from acids, alkalis, salts, and other chemicals, thereby extending the cable's service life.

[0017] The present invention further designs a functional coating and a waterproof structural layer on the cable. The antioxidant coating layer, the flame retardant coating layer and the chemical coating layer are sequentially coated on the outside of the outer sheath; the functional coating and the antioxidant coating layer can effectively delay the aging process of the cable, the flame retardant coating layer significantly improves the flame retardant performance of the cable, and the chemical coating layer has a rat and ant-proof function, which can prevent rats and ants from gnawing on the cable. Through this design, the functional coating not only improves the corrosion resistance of the cable, but also further extends the service life of the cable. The waterproof structural layer includes a waterproof inner layer and a waterproof outer layer. The waterproof inner layer is arranged between the outer layer of the armor layer and the inner side of the lining layer, and the waterproof outer layer is arranged between the outer side of the pressure-resistant buffer layer and the inner side of the outer sheath; the waterproof inner layer is a water-blocking tape, and the waterproof outer layer is made of a high-efficiency water-blocking yarn material. The design of the waterproof structural layer is that the waterproof outer layer adopts a high-efficiency water-blocking yarn material, and the waterproof inner layer adopts a water-blocking tape. When the cable is used, the water-blocking tape and the high-efficiency water-blocking yarn are used to form a longitudinal water-blocking barrier due to their swellable properties when exposed to water. At the same time, with the cooperation of the outer sheath, a sealing barrier is formed to further enhance the waterproof performance of the composite cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2It is a schematic diagram of the overall cross-sectional structure of the present invention; Figure 3 It is a schematic diagram of the cross-sectional structure of the functional coating on the outer sheath of the present invention.

[0019] Markings in the figure: 1. Cable core structure; 11. Tape layer; 12. Insulation shielding layer; 13. Glass fiber rope; 14. Conductor; 2. Outer sheath; 21. Outer sheath; 22. Inner lining layer; 3. Functional layer; 31. Armor layer; 32. Compressive buffer layer; 4. Functional coating; 41. Anti-oxidation coating layer; 42. Flame retardant coating layer; 43. Chemical coating layer; 5. Waterproof structural layer; 51. Waterproof inner layer; 52. Waterproof outer layer. DETAILED DESCRIPTION

[0020] The technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments. Obviously, the embodiments described are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0021] like Figures 1 to 3 As shown, a wear-resistant wind power cable includes a cable core structure 1, wherein the cable core structure 1 includes a plurality of conductors 14 distributed in a longitudinal array, an insulating shielding layer 12 wrapped around each conductor 14, and a tape layer 11 wrapped around the outside of the insulating shielding layer 1; Specifically, the gap between the tape layer 11 and the outside of each insulating shielding layer 12 is filled with a glass fiber rope 13 to fix and support the conductor 14 and prevent the conductor 14 from moving inside the cable, thereby maintaining the circular structure of the cable and facilitating laying and installation; It should be noted that each conductor 14 of the cable core structure 1 of this embodiment is made of high-purity cathode copper, which can reduce impedance and improve conduction efficiency; The outer sheath 2 is wrapped around the outside of the cable core structure 1. The outer sheath 2 includes an outer sheath 21 and an inner lining layer 22. The inner lining layer 22 is wrapped around the outside of the tape layer 11. Specifically, the outer sheath 2 is made of polyvinyl chloride, low-smoke halogen-free material, or thermoplastic elastomer. In this embodiment, polyvinyl chloride is selected as the material, which has the advantages of low price, environmental protection, easy processing and good electrical performance. Functional layer 3, which includes an armor layer 31 and a pressure-resistant buffer layer 32. The armor layer 31 is arranged between the inner side of the inner lining layer 22 and the outer side of the tape layer 11, and the pressure-resistant buffer layer 32 is arranged between the inner lining layer 22 and the outer sheath 21; Specifically, the compressive buffer layer 32 is composed of a number of copper plates, which are distributed in a longitudinal array on the outside of the inner lining layer 22 and closely attached to the inner wall of the outer sheath 21. A number of buffer zones are formed between adjacent copper plates and the inner lining layer 22 and the outer sheath 21, and the buffer zones are filled with chloroprene rubber. This design, because chloroprene rubber has excellent weather resistance and can resist the erosion of environmental factors such as ultraviolet rays and ozone, and at the same time has outstanding wear resistance, can effectively withstand the friction and wear generated by the cable during operation. When the cable is running, the copper plate provides rigid support for the cable core structure, while the chloroprene rubber buffer layer can absorb and disperse the remaining pressure and vibration. This design not only ensures the compressive performance of the cable, but also reduces damage to the internal conductor. In addition, the design of the copper plate can also dissipate the heat generated by the cable core structure to achieve a cooling effect, thereby effectively avoiding the impact of high temperature on the performance of the cable. Specifically, the armor layer 31 is wrapped around the outside of the inner lining layer 22 and is made of glass fiber tape. This layer is designed because glass fiber has a high strength-to-weight ratio. It can provide good mechanical protection while not significantly increasing the weight of the cable. It also has good chemical corrosion resistance and can resist corrosion by chemicals such as acids, alkalis, and salts, thereby extending the service life. As a preferred embodiment, the functional layer 3 further includes a flame retardant layer 34 disposed between the inner side of the outer sheath 21 and the outer side of the pressure-resistant layer 32. The flame retardant layer 34 is made of ceramic silicone rubber. This layer is designed to have the flexibility of rubber at room temperature, which facilitates the installation and laying of the cable. Under the action of high temperature or flame, it can be quickly ceramicized to form a hard ceramic shell, which plays the role of heat insulation, fire isolation and flame retardancy. like Figure 3 As shown, this embodiment also provides an implementation scheme, which is as follows: Based on the above embodiment, to improve the performance of the cable, a functional coating 4 is also designed. The functional coating 4 includes an antioxidant coating layer 41, a flame-retardant coating layer 42, and a chemical coating layer 43. The antioxidant coating layer 41, the flame-retardant coating layer 42, and the chemical coating layer 43 are sequentially coated on the exterior of the outer sheath 21. The antioxidant coating layer 41 can effectively delay the aging process of the cable, the flame-retardant coating layer 42 significantly improves the flame retardancy of the cable, and the chemical coating layer 43 has a rodent-ant repellent function, preventing rodents and ants from gnawing on the cable. Through this design, the functional coating 4 not only improves the corrosion resistance of the cable, but also further extends the service life of the cable. like Figure 2 As shown, this embodiment also provides an implementation scheme, which is as follows: On the basis of the above embodiment, in order to improve the performance of the cable, a waterproof structural layer 5 is further designed. The waterproof structural layer 5 includes a waterproof inner layer 51 and a waterproof outer layer 52. The waterproof inner layer 51 is arranged between the outer layer of the armor layer 31 and the inner side of the inner lining layer 22. The waterproof outer layer 52 is arranged between the outer side of the compressive buffer layer 32 and the inner side of the outer sheath 21. Specifically, the inner waterproof layer 51 is a water-blocking tape, and the outer waterproof layer 52 is made of a high-efficiency water-blocking yarn. This design of the waterproof structural layer 5 utilizes the high-efficiency water-blocking yarn for the outer waterproof layer 52 and the water-blocking tape for the inner waterproof layer 51. When the cable is in use, the water-blocking tape and the high-efficiency water-blocking yarn swell in water to form a longitudinal water-blocking barrier. Furthermore, in conjunction with the outer sheath 21, they form a sealing barrier, further enhancing the waterproof performance of the composite cable.

[0022] like Figures 1 to 3 As shown in this embodiment, it should be noted that the wind power cable in the application document is manufactured by twisting using existing equipment. The manufacturing process is existing technology, and the working principle is public, so it has been omitted in this embodiment. In addition, it should be noted that this application document only improves the shortcomings of wind power cables in the existing technology, such as the poor protection effect of the sheath layer, which makes it difficult for them to meet the reliability requirements of long-term operation in wind power generation scenarios, and does not involve other aspects. The working principle of this wear-resistant wind power cable is introduced as follows: The present invention incorporates a functional layer 3 within the outer sheath. This layer comprises an armor layer 31, a compressive buffer layer 32, and a flame-retardant layer 34. The compressive buffer layer 32 is composed of several copper plates arranged in a longitudinal array outside the inner lining layer 22 and in close contact with the inner wall of the outer sheath 21. These plates form multiple buffer zones between adjacent copper plates and the inner lining layer 22 and outer sheath 21, each filled with chloroprene rubber. This design, due to chloroprene rubber's excellent weather resistance, is resistant to environmental factors such as ultraviolet rays and ozone. It also possesses outstanding wear resistance, effectively withstanding the friction and wear generated during cable operation. During operation, the copper plates provide rigid support for the cable core structure, while the chloroprene rubber buffer layer absorbs and dissipates excess pressure and vibration. This design not only ensures the cable's compressive strength but also reduces damage to the internal conductors. Furthermore, the copper plates dissipate heat generated by the cable core structure, achieving a cooling effect and effectively preventing the impact of high temperatures on the cable's performance. The flame-retardant layer 34 is made of ceramic silicone rubber. Designed to have the flexibility of rubber at room temperature, it facilitates cable installation and routing. Under high temperatures or flames, it rapidly ceramicizes, forming a hard, ceramic-like shell that provides thermal insulation, fire resistance, and flame retardancy. The armor layer 31, wrapped around the inner liner 22, is made of fiberglass tape. Due to the high strength-to-weight ratio of fiberglass, this layer provides excellent mechanical protection without significantly increasing the cable's weight. It also exhibits excellent chemical resistance, resisting corrosion from acids, alkalis, salts, and other chemicals, thereby extending the cable's service life.

[0023] The cable also features a functional coating 4 and a waterproof structural layer 5. An antioxidant coating layer 41, a flame-retardant coating layer 42, and a chemical coating layer 43 are sequentially applied to the exterior of the outer sheath 21. The functional coating 4 includes the antioxidant coating 41, which effectively slows down cable aging, the flame-retardant coating 42, which significantly enhances the cable's flame retardancy, and the chemical coating 43, which provides rat and ant protection. This design not only enhances the cable's corrosion resistance but also extends its service life. The waterproof structural layer 5 comprises a waterproof inner layer 51 and a waterproof outer layer 52. The inner layer 51 is positioned between the outer layer of the armor layer 31 and the inner side of the inner lining layer 22, while the outer layer 52 is positioned between the outer side of the compressive buffer layer 32 and the inner side of the outer sheath 21. The inner layer 51 is a water-blocking tape, while the outer layer 52 is made of a high-efficiency water-blocking yarn. This design of the waterproof structural layer 5 utilizes high-efficiency water-blocking yarn for the outer layer 52 and water-blocking tape for the inner layer 51. When the cable is in use, the water-blocking tape and the high-efficiency water-blocking yarn expand in water to form a longitudinal water-blocking barrier. Furthermore, in conjunction with the outer sheath 21, they form a sealing barrier, further enhancing the waterproof performance of the composite cable.

[0024] The above embodiments are only used to illustrate the technical method of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical method of the present invention may be modified or replaced by equivalents without departing from the spirit and scope of the technical method of the present invention.

Claims

1. A wear-resistant wind power cable, comprising a cable core structure (1), wherein the cable core structure (1) comprises a plurality of conductors (14) distributed in a longitudinal array, an insulating shielding layer (12) wrapped around each conductor (14), and a tape layer (11) wrapped around the outside of the insulating shielding layer (1); It is characterized by: Also includes: An outer sheath (2) wrapped around the outside of the cable core structure (1), the outer sheath (2) comprising an outer sheath (21) and an inner lining layer (22) arranged outside the tape layer (11); A functional layer (3), the functional layer (3) comprising an armor layer (31) and a pressure-resistant buffer layer (32), the armor layer (31) being arranged between the inner side of the inner lining layer (22) and the outer side of the tape layer (11), and the pressure-resistant buffer layer (32) being arranged between the inner lining layer (22) and the outer protective layer (21).

2. A wear-resistant wind power cable according to claim 1, characterized in that: The gap between the tape layer (11) and the outside of each insulating shielding layer (12) is filled with glass fiber rope (13).

3. The wear-resistant wind power cable according to claim 1, characterized in that: The outer sheath (2) is made of one of polyvinyl chloride, low-smoke halogen-free material or thermoplastic elastomer.

4. The wear-resistant wind power cable according to claim 1, characterized in that: The compressive buffer layer (32) is composed of a plurality of copper plates (321), which are longitudinally arranged in an array outside the inner lining layer (22) and closely attached to the inner wall of the outer protective layer (21). A plurality of buffer zones are formed between the adjacent copper plates (321), the inner lining layer (22), and the outer protective layer (21), and the buffer zones are filled with a chloroprene rubber material (322).

5. The wear-resistant wind power cable according to claim 1, characterized in that: The armor layer (31) is wrapped around the outside of the inner lining layer (22) and is made of glass fiber tape.

6. The wear-resistant wind power cable according to claim 1, characterized in that: The functional layer (3) further comprises a flame retardant layer (34) arranged between the inner side of the outer protective layer (21) and the outer side of the pressure-resistant layer (32), and the flame retardant layer (34) is made of ceramic silicone rubber.

7. The wear-resistant wind power cable according to claim 1, characterized in that: The invention also includes a functional coating (4), wherein the functional coating (4) includes an anti-oxidation coating layer (41), a flame retardant coating layer (42), and a chemical coating layer (43), and the anti-oxidation coating layer (41), the flame retardant coating layer (42), and the chemical coating layer (43) are sequentially coated on the outside of the outer protective layer (21).

8. The wear-resistant wind power cable according to claim 1, characterized in that: The invention also includes a waterproof structural layer (5), wherein the waterproof structural layer (5) includes a waterproof inner layer (51) and a waterproof outer layer (52), wherein the waterproof inner layer (51) is arranged between the outer layer of the armor layer (31) and the inner side of the inner lining layer (22), and the waterproof outer layer (52) is arranged between the outer side of the pressure-resistant buffer layer (32) and the inner side of the outer protective layer (21).

9. The wear-resistant wind power cable according to claim 8, characterized in that: The waterproof inner layer (51) is a water-blocking tape, and the waterproof outer layer (52) is made of a high-efficiency water-blocking yarn material.

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