Insulating layer coating process and device for high-voltage cable

Abstract

The invention discloses a high-voltage cable insulation layer coating technology and device, and the technology comprises the steps: calculating the input-output relation of standard raw materials for the production of cables of different specifications according to historical production data, monitoring the consumption amount of raw materials and the output amount of the cables in real time, and calculating the real-time input-output relation of the raw materials; and judging whether the real-time raw material input-output relationship meets the standard raw material input-output relationship or not based on the calculation result, and analyzing the production process according to the judgment result. According to the invention, whether the production data is normal or not is judged by comparing and analyzing the real-time raw material input-output relationship and the standard raw material input-output relationship; meanwhile, process improvement is carried out according to the real-time raw material input-output relation monitored in real time, on the basis of production according to the standard raw material input-output relation, the cable coating production speed is increased, and the real-time raw material input-output relation is monitored, so that the maximum critical value of the production speed according with the standard raw material input-output relation is found out, and the production efficiency is improved. The cost can be reduced, and the efficiency can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of cable coating, and in particular to a process and device for coating the insulation layer of a high-voltage cable. Background Art

[0002] Coating is a process that involves adding various materials to the conductor using coating and extrusion equipment, tailored to the specific performance requirements of wires and cables. Coating processes vary widely, with different materials requiring different coating techniques. For example, extrusion is often used for materials like rubber, lead, aluminum, and plastic; longitudinal wrapping is often used for strip materials like polyester film and aluminum-plastic composite film; wrapping is often used for fiber materials like mica tape, non-woven fabric, and alkali-free glass; and dipping is often used for materials like asphalt and insulating varnish.

[0003] In the insulation coating process of cables, extrusion coating is usually used to coat the outer insulation layer of the cable inner core. In the specific extrusion coating process, the deviation value of the thickness of the extruded insulation layer is an important indicator of the extrusion process level. Most product structural dimensions and their deviation values ​​are clearly specified in the standards. At the same time, the surface of the extruded insulation layer is required to be smooth, and no poor quality problems such as surface roughness and burnt surface should occur. In addition, the cross-section of the extruded insulation layer should be dense and strong, without pinholes visible to the naked eye, and the presence of bubbles should be eliminated. In the extrusion coating process, common problems include uneven extrusion, a large number of bubbles and cavities in the extruded layer, or rough and scorched outer surface of the extruded layer, etc. These common problems are usually caused by deviations in process parameter settings, such as the melt processing temperature of the coating raw material is too high or too low, and the pressure and speed of the extrusion screw are too high or too low. In the existing technology, it is usually manually judged and adjusted by on-site engineers based on on-site conditions, which has certain limitations. Summary of the Invention

[0004] In response to the problems raised in the above background technology, the purpose of the present invention is to provide an insulation layer coating process and device for high-voltage cables. Specifically, a real-time monitoring method for high-voltage cable production is designed based on past production data experience to facilitate judgment of production conditions and process adjustments.

[0005] In order to achieve the above-mentioned object, the technical solution of the present invention provides, on the one hand, a process for coating an insulation layer of a high-voltage cable, which specifically includes the following steps: S1. Based on historical production data, including the amount of raw materials consumed and the amount of cables produced during the production of cables of different specifications, calculate the standard raw material input-output relationship for the production of cables of different specifications; S2. Real-time monitoring of the raw material consumption and the corresponding cable output during the production process, and calculation of the real-time raw material input-output relationship; S3. Based on the calculation results of S1 and S2, determine whether the real-time raw material input-output relationship conforms to the standard raw material input-output relationship and analyze the production process based on the judgment result; S4. Based on the analysis results of S3, adjust the production process and determine the optimal production plan.

[0006] Furthermore, in the technical solution of the present invention, in step S1, the standard raw material input-output relationship includes: ; Where: Expressed as the production length of the cable, Expressed as the input amount of raw materials, To calculate the constant, Expressed as the corresponding amount of raw materials Standard cable lengths produced At the same time, based on historical production data, the error range is determined by the calculated range of the amount of raw materials consumed in the production process of each specification of cable corresponding to the amount of cables produced: ; ; Where: Expressed as the amount of raw materials input The maximum production length of the produced cables, Expressed as the amount of raw materials input The minimum production length of the produced cables, Indicated as allowable error.

[0007] Furthermore, in the technical solution of the present invention, in step S2, the real-time raw material input-output relationship includes the real-time consumption of raw materials And the corresponding number of cables produced in real time : ; ; ; Where: According to the standard raw material input-output relationship, Expressed as the corresponding amount of raw materials The standard cable lengths produced are Expressed as the amount of raw materials input The maximum production length of the produced cables, Expressed as the amount of raw materials input The minimum production length of the produced cables.

[0008] Furthermore, in the technical solution of the present invention, in step S3, determining whether the real-time raw material input-output relationship conforms to the standard raw material input-output relationship and analyzing the production process according to the determination result includes: : That is, the real-time raw material input-output relationship conforms to the standard raw material input-output relationship, and the analysis shows that the parameters in the production process are normal, including the raw material processing temperature, pressure and cable production speed; :The real-time raw material input-output relationship does not conform to the standard raw material input-output relationship, and the amount of raw materials consumed The length of the corresponding produced cable is too long. The analysis is that the produced cable is unqualified and the parameters in the production process are abnormal, including the processing temperature of the raw materials is too low, the pressure is too low and the cable production speed is too fast. It should be noted that when the processing temperature of the raw materials is too low, it will lead to insufficient melting of the raw materials. There are a lot of bubbles inside the raw materials during the extrusion process. When the extrusion pressure of the extrusion screw is too low and the extrusion speed is too fast, the thickness of the extruded layer will be uneven and the edge will be rough. :The real-time raw material input-output relationship does not conform to the standard raw material input-output relationship, and the amount of raw materials consumed The length of the corresponding produced cable is too short. The analysis shows that the produced cable is unqualified and the parameters in the production process are abnormal, including the raw material processing temperature is too high. It should be noted that when the raw material processing temperature is too high, the raw material in the extrusion screw will be overheated and become blackened, hot, and burnt.

[0009] Furthermore, in the technical solution of the present invention, in step S4, adjusting the production process and determining the optimal production solution includes: When the real-time raw material input-output relationship conforms to the standard raw material input-output relationship, that is, the parameters in the production process are normal, including the processing temperature and pressure of the raw materials and the production speed of the cable, the real-time raw material input-output relationship is monitored and calculated in real time by increasing the production speed of the cable, and the maximum production speed that meets the standard raw material input-output relationship is found. It should be noted that when the real-time raw material input-output relationship conforms to the standard raw material input-output relationship, the cable is in a normal production state. At this time, the production speed of the cable is increased to improve the production efficiency. While increasing the production speed, the consumption of raw materials and the output of the corresponding cables in the production process are monitored in real time, and the real-time raw material input-output relationship is calculated to determine whether the improved process meets the standard raw material input-output relationship. Under the premise of meeting the standard raw material input-output relationship, the critical maximum value of the production speed can be found. When the real-time raw material input-output relationship does not conform to the standard raw material input-output relationship: when When processing raw materials, the temperature and pressure are increased and the production speed of the cable is reduced; when By lowering the processing temperature of the raw materials.

[0010] In the technical solution of the present invention, on the other hand, a coating device is also provided. By adopting the above-mentioned insulation layer coating process of a high-voltage cable, the coating device specifically includes a feeding module, a coating module and a monitoring module.

[0011] Furthermore, in the technical solution of the present invention, the feeding module includes a barrel, a vibrating stirring rod, an extrusion screw and a plurality of conveying wheels, the barrel is used to load the cable coating raw material, and the barrel is provided with an observation surface; the vibrating stirring rod is installed inside the barrel, and the vibrating stirring rod is used to stir and vibrate to level the raw material; the extrusion screw is installed below the barrel and connected to the inside of the barrel, and the extrusion screw is used to heat the raw material and perform extrusion coating; the plurality of conveying wheels are respectively used to convey the cable inner core; the coating module includes a die head and a cooling head, the die head is installed at the output end of the extrusion screw; the cooling head is used to cool the produced cable; the monitoring module includes a plurality of visual sensors, and the plurality of visual sensors are respectively installed on one side of the observation surface of the barrel and one side of the conveying wheel, for monitoring the remaining height of the raw material inside the barrel and the number of rotations of the conveying wheel, and calculating the change in the quantity of the raw material by monitoring the change in the remaining height of the raw material inside the barrel A1, and calculating the production length of the cable by monitoring the number of rotations of the conveying wheel A4.

[0012] In summary, the present invention provides an insulation layer coating process and device for high-voltage cables. The technical solution of the present invention specifically calculates the standard raw material input-output relationship for the production of cables of different specifications based on past production data experience, calculates the real-time raw material input-output relationship by real-time monitoring of the raw material consumption and the output quantity of the corresponding cables during the production process, and compares and analyzes it with the standard raw material input-output relationship to determine whether the production data is normal. At the same time, process improvements are made based on the real-time monitored real-time raw material input-output relationship. On the basis of production in accordance with the standard raw material input-output relationship, the cable coating production speed is improved and the real-time raw material input-output relationship is monitored, so as to find the critical value of the production speed that meets the standard raw material input-output relationship, which is conducive to process improvement. Compared with traditional cable production methods and production method monitoring and improvement processes, it is more efficient and has lower time cost, and can reduce costs and increase efficiency.

[0013] Other features and advantages of the present invention will be set forth in the description that follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 This is a flow chart of an insulation coating process for a high-voltage cable according to the present invention; Figure 2This is a schematic diagram of the standard raw material input-output relationship of the insulation layer coating process of a high-voltage cable of the present invention; Figure 3 This is a structural principle diagram of a coating device of the present invention; In the figure: A1, barrel; A11, observation surface; A2, vibrating stirring rod; A3, extrusion screw; A4, conveying wheel; B1, die head; B2, cooling head; C1, visual sensor. DETAILED DESCRIPTION

[0015] An embodiment of the present invention provides an insulation coating process and apparatus for a high-voltage cable. The embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0016] Figure 1 FIG. 1 is a flow chart of an insulation coating process for a high-voltage cable according to an embodiment of the present invention. Figure 1 As shown, in this embodiment, a high-voltage cable insulation coating process includes the following steps: S1. Based on historical production data, including the amount of raw materials consumed and the amount of cables produced during the production of cables of different specifications, calculate the standard raw material input-output relationship for the production of cables of different specifications; S2. Real-time monitoring of the raw material consumption and the corresponding cable output during the production process, and calculation of the real-time raw material input-output relationship; S3. Based on the calculation results of S1 and S2, determine whether the real-time raw material input-output relationship conforms to the standard raw material input-output relationship and analyze the production process based on the judgment result; S4. Based on the analysis results of S3, adjust the production process and determine the optimal production plan.

[0017] Specifically, in this embodiment, in step S1, the standard raw material input-output relationship includes: ; Where: Expressed as the production length of the cable, Expressed as the input amount of raw materials, To calculate the constant, Expressed as the corresponding amount of raw materials Standard cable lengths produced At the same time, based on historical production data, the error range is determined by the calculated range of the amount of raw materials consumed in the production process of each specification of cable corresponding to the amount of cables produced: ; ; Where: Expressed as the amount of raw materials input The maximum production length of the produced cables, Expressed as the amount of raw materials input The minimum production length of the produced cables, Indicated as allowable error.

[0018] Specifically, in this embodiment, in step S2, the real-time raw material input-output relationship includes the real-time consumption of raw materials And the corresponding number of cables produced in real time : ; ; ; Where: According to the standard raw material input-output relationship, Expressed as the corresponding amount of raw materials The standard cable lengths produced are Expressed as the amount of raw materials input The maximum production length of the produced cables, Expressed as the amount of raw materials input The minimum production length of the produced cables.

[0019] Specifically, in this embodiment, the standard raw material input-output relationship for the production of cables of different specifications is calculated separately based on past production data experience. The real-time raw material input-output relationship is calculated by real-time monitoring of the raw material consumption and the output quantity of the corresponding cables during the production process, and compared with the standard raw material input-output relationship to determine whether the production data is normal.

[0020] Specifically, in this embodiment, Figure 2 This is a schematic diagram of the standard raw material input-output relationship of the insulation layer coating process of a high-voltage cable of the present invention, such as Figure 2 As shown, in step S3, judging whether the real-time raw material input-output relationship conforms to the standard raw material input-output relationship and analyzing the production process according to the judgment result includes: :The real-time raw material input-output relationship conforms to the standard raw material input-output relationship. The analysis shows that the parameters in the production process are normal, including the processing temperature and pressure of the raw materials and the production speed of the cable. Figure 2 middle ; :The real-time raw material input-output relationship does not conform to the standard raw material input-output relationship, and the amount of raw materials consumed The length of the corresponding production cable is too long. The analysis shows that the produced cable is unqualified and the parameters in the production process are abnormal, including the processing temperature of the raw material is too low, the pressure is too low and the production speed of the cable is too fast. Figure 2 middle It should be noted that when the processing temperature of the raw material is too low, the raw material will not be fully melted, and a large number of bubbles will be present inside the raw material during the extrusion process. When the extrusion pressure of the extrusion screw is too low and the extrusion speed is too fast, the thickness of the extruded layer will be uneven and the edge will be rough. :The real-time raw material input-output relationship does not conform to the standard raw material input-output relationship, and the amount of raw materials consumed The length of the corresponding production cable is too short. The analysis shows that the produced cable is unqualified. The parameters in the production process are abnormal, including the processing temperature of the raw materials is too high. Figure 2 middle It should be noted that when the processing temperature of the raw materials is too high, the raw materials in the extrusion screw will be overheated and become black, hot, and burnt.

[0021] Specifically, in this embodiment, process improvements are performed based on the real-time raw material input-output relationship monitored in real time. On the basis of production in accordance with the standard raw material input-output relationship, the cable coating production speed is improved and the real-time raw material input-output relationship is monitored, so as to find the critical value of the maximum production speed that meets the standard raw material input-output relationship. This is conducive to process improvement. Compared with traditional cable production methods and production method monitoring and improvement processes, it is more efficient and has lower time costs, and can reduce costs and increase efficiency.

[0022] Specifically, in this embodiment, in step S4, adjusting the production process and determining the optimal production plan includes: When the real-time raw material input-output relationship conforms to the standard raw material input-output relationship, that is, the parameters in the production process are normal, including the processing temperature and pressure of the raw materials and the production speed of the cable, the real-time raw material input-output relationship is monitored and calculated in real time by increasing the production speed of the cable, and the maximum production speed that meets the standard raw material input-output relationship is found. It should be noted that when the real-time raw material input-output relationship conforms to the standard raw material input-output relationship, the cable is in a normal production state. At this time, the production speed of the cable is increased to improve the production efficiency. While increasing the production speed, the consumption of raw materials and the output of the corresponding cables in the production process are monitored in real time, and the real-time raw material input-output relationship is calculated to determine whether the improved process meets the standard raw material input-output relationship. Under the premise of meeting the standard raw material input-output relationship, the critical maximum value of the production speed can be found. When the real-time raw material input-output relationship does not conform to the standard raw material input-output relationship: when When processing raw materials, the temperature and pressure are increased and the production speed of the cable is reduced; when By lowering the processing temperature of the raw materials.

[0023] On the other hand, this embodiment further provides a coating device, which adopts the above-mentioned insulation coating process of a high-voltage cable. Figure 3 This is a schematic diagram of the structure of a coating device according to an embodiment of the present invention. Figure 3 As shown, it specifically includes a feeding module, a coating module and a monitoring module.

[0024] Specifically, in this embodiment, the feeding module includes a barrel A1, a vibrating stirring rod A2, an extrusion screw A3 and a plurality of conveying wheels A4. The barrel A1 is used to load the cable coating raw material, and the barrel A1 is provided with an observation surface A11, and the observation surface A11 is used to observe the amount of raw material inside the barrel A1; the vibrating stirring rod A2 is installed inside the barrel A1, and the vibrating stirring rod A2 is used to stir and vibrate to make the raw material flat; the extrusion screw A3 is installed below the barrel A1 and is connected to the inside of the barrel A1, and the extrusion screw A3 is used to heat the raw material and perform extrusion coating; the plurality of conveying wheels A4 are used to convey Cable inner core; the coating module includes a die head B1 and a cooling head B2, and the die head B1 is installed at the output end of the extrusion screw A3; the cooling head B2 is used to cool the produced cable; the monitoring module includes multiple visual sensors C1, and the multiple visual sensors C1 are respectively installed on one side of the observation surface A11 of the barrel A1 and one side of the conveying wheel A4, and are used to monitor the remaining height of the raw material inside the barrel A1 and the number of rotations of the conveying wheel A4, and calculate the change in the quantity of the raw material by monitoring the change in the remaining height of the raw material inside the barrel A1, and calculate the production length of the cable by monitoring the number of rotations of the conveying wheel A4.

[0025] This document uses specific examples to illustrate the principles and implementation methods of the present invention. The above examples are only intended to help understand the methods and core concepts of the present invention. It should be noted that those skilled in the art may make various improvements and modifications to the present invention without departing from the principles of the present invention, and such improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A high voltage cable insulation coating process, characterized in that: The following steps are involved: S1. Based on historical production data, including the amount of raw materials consumed and the amount of cables produced during the production of cables of different specifications, calculate the standard raw material input-output relationship for the production of cables of different specifications; S2. Real-time monitoring of the raw material consumption and the corresponding cable output during the production process, and calculation of the real-time raw material input-output relationship; S3. Based on the calculation results of S1 and S2, determine whether the real-time raw material input-output relationship conforms to the standard raw material input-output relationship and analyze the production process based on the judgment result; S4. Based on the analysis results of S3, adjust the production process and determine the optimal production plan.

2. The insulation coating process for a high-voltage cable according to claim 1, characterized in that: In step S1, the standard raw material input-output relationship includes: ； Where: Expressed as the production length of the cable, Expressed as the input amount of raw materials, To calculate the constant, Expressed as the corresponding amount of raw materials Standard cable lengths produced At the same time, based on historical production data, the error range is determined by the calculated range of the amount of raw materials consumed in the production process of each specification of cable corresponding to the amount of cables produced: ； ； Where: Expressed as the amount of raw materials input The maximum production length of the produced cables, Expressed as the amount of raw materials input The minimum production length of the produced cables, Indicated as allowable error.

3. The insulation coating process for a high-voltage cable according to claim 2, characterized in that: In step S2, the real-time raw material input-output relationship includes the real-time consumption of raw materials And the corresponding number of cables produced in real time : ； ； ； Where: According to the standard raw material input-output relationship, Expressed as the corresponding amount of raw materials The standard cable lengths produced are Expressed as the amount of raw materials input The maximum production length of the produced cables, Expressed as the amount of raw materials input The minimum production length of the produced cables.

4. The insulation coating process for a high-voltage cable according to claim 3, characterized in that: In step S3, determining whether the real-time raw material input-output relationship conforms to the standard raw material input-output relationship and analyzing the production process according to the determination result include: : That is, the real-time raw material input-output relationship conforms to the standard raw material input-output relationship, and the analysis shows that the parameters in the production process are normal, including the raw material processing temperature, pressure and cable production speed; :The real-time raw material input-output relationship does not conform to the standard raw material input-output relationship, and the amount of raw materials consumed The length of the corresponding produced cables is too long. The analysis shows that the produced cables are unqualified and the parameters in the production process are abnormal, including the processing temperature of the raw materials being too low, the pressure being too low, and the cable production speed being too fast. :The real-time raw material input-output relationship does not conform to the standard raw material input-output relationship, and the amount of raw materials consumed The length of the corresponding produced cables was too short. Analysis showed that the produced cables were unqualified and the parameters in the production process were abnormal, including the processing temperature of the raw materials being too high.

5. The insulation coating process for a high-voltage cable according to claim 4, characterized in that: In step S4, adjusting the production process and determining the optimal production plan includes: When the real-time raw material input-output relationship meets the standard raw material input-output relationship, that is, the parameters in the production process are normal, including the raw material processing temperature, pressure and cable production speed, by increasing the cable production speed, real-time monitoring and calculation of the real-time raw material input-output relationship, the maximum production speed that meets the standard raw material input-output relationship is found; When the real-time raw material input-output relationship does not conform to the standard raw material input-output relationship: when When processing raw materials, the temperature and pressure are increased and the production speed of the cable is reduced; when By lowering the processing temperature of the raw materials.

6. A coating device, characterized in that: The insulation layer coating process of a high-voltage cable according to any one of claims 1 to 5 is characterized by comprising a feeding module, a coating module and a monitoring module.

7. A coating device according to claim 6, characterized in that: The feeding module comprises: The barrel is used to load the cable sheathing raw materials and is provided with an observation surface; A vibrating stirring rod is installed inside the barrel and is used for vibrating and stirring to level the raw materials; An extrusion screw is installed below the barrel and communicated with the interior of the barrel, and is used to heat the raw material and perform extrusion coating; Multiple conveying wheels are used to convey the cable inner core.

8. A coating device according to claim 6, characterized in that: The cladding module comprises: a die head, mounted on the output end of the extrusion screw; Cooling heads are used to cool the produced cables.

9. A coating device according to claim 7, characterized in that: The monitoring module includes a plurality of visual sensors, which are respectively installed on one side of the observation surface of the barrel and one side of the conveying wheel, and are used to monitor the remaining height of the raw material inside the barrel and the number of rotations of the conveying wheel.

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