High-strength and high-conductivity overhead conductor

Abstract

The invention relates to the technical field of cables, in particular to a high-strength and high-conductivity overhead conductor which comprises an inner conductor formed by concentrically twisting a plurality of strands of aluminum-clad copper core wires, an outer conductor formed by concentrically twisting a plurality of strands of aluminum core wires is arranged on the outer side of the inner conductor, and an insulating layer is arranged on the outer side of the outer conductor. A plurality of stranded steel ropes are arranged between the insulating layer and the outer conductor and are concentrically stranded on the surface of the outer conductor. Compared with the prior art that a steel core is arranged in the center of a wire, the inner conductor and the outer conductor can be protected from the outer side of the outer conductor by means of the stranded steel rope, and the deformation caused by bending of the outer side is larger than that of the center when the wire naturally falls and swings due to wind, so that the deformation caused by bending is directly coped with through the stranded steel rope, and the service life of the wire is prolonged. Therefore, continuous deformation of the wire can be prevented by means of the mechanical property of the stranded steel rope, so that the inner conductor and the outer conductor are prevented from being broken due to excessive deformation, and the overall mechanical property of the wire is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of cables, in particular to a high-strength and high-conductivity overhead conductor. Background Art

[0002] With the continuous development of power grid construction, overhead cables with voltage levels of 10kV to 30kV play a vital role in the field of power transmission. In urban and rural power grids, these overhead cables are widely used for long-distance power transmission.

[0003] Currently, these overhead conductors typically use a concentrically stranded aluminum core as the conductor, with a polyvinyl chloride (PVC) sheath as insulation and protection. This conventional structure generally meets the requirements for conductivity, external insulation, and basic overhead strength.

[0004] Aluminum has excellent electrical conductivity and relatively low cost. Using a concentrically stranded aluminum core as the conductive core can not only ensure the cable's electrical conductivity but also reduce costs to a certain extent. The concentrically stranded structure can improve the cable's mechanical strength and flexibility, making it more suitable for overhead installation and to withstand certain external forces. For example, in actual overhead lines, the cable needs to withstand external forces such as its own weight and wind, and the concentrically stranded aluminum core structure can better cope with these situations. However, due to the limitations of aluminum itself, its electrical conductivity and strength need to be further improved to better cope with the external forces and weight faced in overhead lines. Summary of the Invention

[0005] The purpose of the present invention is to provide a high-strength and high-conductivity overhead conductor to solve the problem in the prior art that only an aluminum core is used as the conductive core, and its conductive performance and strength need to be further improved, so as to better cope with the influence of external forces and its own weight faced in overhead lines.

[0006] In order to solve the above technical problems, the present invention adopts the following technical solutions: A high-strength and high-conductivity overhead conductor includes an inner conductor formed by concentrically twisting multiple strands of aluminum-clad copper core wires, an outer conductor formed by concentrically twisting multiple strands of aluminum core wires is arranged on the outside of the inner conductor, an insulating layer is arranged on the outside of the outer conductor, and multiple strands of twisted steel ropes are arranged between the insulating layer and the outer conductor. The multiple strands of twisted steel ropes are concentrically twisted on the surface of the outer conductor.

[0007] A further technical solution is that the twisted steel rope includes a central reinforcement layer formed by concentrically twisting at least three galvanized steel wires, and multiple aluminum-clad steel cores and aluminum alloy wires are concentrically twisted on the outer side of the central reinforcement layer.

[0008] A further technical solution is that the processing steps of the aluminum clad copper core wire include: Step S1, pre-treating the copper rod to remove the surface oxide layer; Step S2: pre-coating the copper rod with aluminum strip, hot pressing at a temperature of 480–500°C and a pressure of 120 MPa; Step S3, when the aluminum strip is hot pressed onto the surface of the copper rod, a La / Ce mixed gas is injected between the aluminum strip and the copper rod; Step S4, after the aluminum strip is hot-pressed onto the surface of the copper rod, the joints of the aluminum strip are subjected to argon arc welding under the protection of an inert gas; Step S5, the coated composite wire is gradually reduced in diameter by a wire drawing machine, and the copper and aluminum are deformed synchronously; Step S6: The composite wire is annealed in a pit-type annealing furnace or online continuously, with the temperature controlled below 300° C. to restore ductility and avoid fracture of the copper-aluminum transition layer, thereby obtaining an aluminum-clad copper core wire.

[0009] A further technical solution is that in step S1, the surface oxide layer is removed by acid washing and alkali washing the pure copper rod to remove the oxide layer.

[0010] A further technical solution is that the insulating layer includes polyvinyl chloride doped with silicon carbide particles, the particle size of the silicon carbide particles is 0.3μm-0.5μm, and the mass of the silicon carbide particles accounts for 10%-15% of the total mass of the insulating layer.

[0011] A further technical solution is that the insulating layer includes an inner layer and an outer layer, and multiple strands of iron-chromium-aluminum alloy wires are arranged between the inner layer and the outer layer. The multiple strands of iron-chromium-aluminum alloy wires are concentrically twisted on the outer wall of the inner layer, and conductive rings for connecting the multiple strands of iron-chromium-aluminum alloy wires are provided at intervals on the outer wall of the inner layer. A controller for controlling the power on and off between the conductive rings and the outer conductor is installed on the outer side of the outer layer.

[0012] A further technical solution is that the controller includes a mounting ring and a box body, the mounting ring is fixed to the outside of the outer layer, and the first electric needle and the second electric needle are installed in the box body. The first electric needle passes through the outer layer and is connected to the conductive ring, and the second electric needle passes through the outer layer and the inner layer in turn and is connected to the outer conductor. The first electric needle and the second electric needle are controlled to be on and off by a switch. A single-chip microcomputer and a battery for powering the single-chip microcomputer are provided in the box body, and the single-chip microcomputer is used to control the on and off of the switch; a temperature sensor is provided on the side of the box body, and the temperature sensor is electrically connected to the single-chip microcomputer.

[0013] A further technical solution is that a solar charging panel for charging the battery is installed on the outside of the box body; and a first through hole and a second through hole are provided on the mounting ring to allow the first electric needle and the second electric needle to pass through.

[0014] A further technical solution is that the cross section of the aluminum core wire is one of the following: prototype, square, diamond, trapezoidal, and Z-shaped.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. By arranging an aluminum-clad copper core wire, the conductive core energy of the entire conductor can be increased, and the mechanical properties of the center of the conductor can be increased; 2. By arranging a twisted steel rope on the outside of the outer conductor, compared with the traditional method of arranging a steel core in the center of the conductor, the inner conductor and the outer conductor can be protected from the outside of the outer conductor with the help of the twisted steel rope. When the conductor falls naturally and swings due to wind, the deformation caused by bending on the outside is greater than that in the center. Therefore, the deformation caused by bending is directly dealt with by the twisted steel rope. In this way, the mechanical properties of the twisted steel rope can be used to prevent the conductor from continuing to deform, thereby avoiding the inner conductor and the outer conductor from breaking due to excessive deformation, thereby improving the overall mechanical properties of the conductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 The figure is a schematic cross-sectional view of a high-strength and high-conductivity overhead conductor of the present invention.

[0017] Figure 2 The figure is a schematic cross-sectional view of a twisted steel rope of a high-strength and high-conductivity overhead conductor according to the present invention.

[0018] Figure 3 This is another cross-sectional schematic diagram of a high-strength and high-conductivity overhead wire of the present invention.

[0019] Icon: 1-aluminum-clad copper core wire, 2-aluminum core wire, 3-insulation layer, 4-twisted steel rope, 5-galvanized steel wire, 6-aluminum-clad steel core, 7-aluminum alloy wire, 8-inner layer, 9-outer layer, 10-iron-chromium-aluminum alloy wire, 11-conductive ring, 12-mounting ring, 13-box body, 14-first electric needle, 15-second electric needle, 16-single-chip microcomputer, 17-battery, 18-switch, 19-solar charging panel, 20-first through hole, 21-second through hole. DETAILED DESCRIPTION

[0020] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0021] Figures 1 to 3 Shown is an embodiment of the present invention.

[0022] Example 1: like Figure 1As shown, a high-strength, high-conductivity overhead conductor includes an inner conductor composed of multiple aluminum-clad copper core wires 1 concentrically stranded together. An outer conductor composed of multiple aluminum-clad copper core wires 2 concentrically stranded together is disposed outside the inner conductor. An insulation layer 3 is disposed outside the outer conductor. Multiple strands of twisted steel cords 4 are disposed between the insulation layer 3 and the outer conductor. The strands of twisted steel cords 4 are concentrically stranded on the outer conductor's surface. The aluminum-clad copper core wires 1 increase the conductor's overall conductivity and improve the mechanical properties of the conductor's center. By placing the stranded steel cords 4 outside the outer conductor, compared to conventional methods of placing a steel core in the center of the conductor, the stranded steel cords 4 protect both the inner and outer conductors from the outside of the outer conductor. Because the outer side of the conductor experiences greater deformation due to bending than the center when the conductor falls naturally or sways due to wind, the stranded steel cords 4 directly counteract this deformation. This mechanical properties of the stranded steel cords 4 prevent further deformation of the conductor, thereby preventing breakage of the inner and outer conductors due to excessive deformation and improving the overall mechanical properties of the conductor.

[0023] Example 2: like Figure 2 As shown, the stranded steel cable 4 comprises a central reinforcement layer consisting of at least three concentrically twisted galvanized steel wires 5. Multiple aluminum-clad steel cores 6 and aluminum alloy wires 7 are concentrically twisted around the outer edges of the central reinforcement layer. The concentric twisting of the galvanized steel wires 5 provides the conductor with core tensile strength, making it particularly suitable for demanding applications such as long spans and heavy icing. The galvanized layer, with a thickness of ≥80μm and no detachment during winding tests, significantly improves the steel wire's atmospheric corrosion resistance and extends its service life, passing salt spray tests for ≥1000 hours without corrosion. The aluminum layer, with a thickness of ≥15% of the steel core diameter, forms a metallurgical bond. The outer aluminum layer 9 insulates the steel core from corrosive media, while the inner layer 8 maintains a high strength of ≥1340 MPa, preventing the strength loss associated with pure aluminum cladding. The aluminum alloy wire 7, with magnesium comprising 1.1%–1.15% by mass and silicon comprising 0.88%–0.92% by mass, maintains moderate ductility and an elongation of ≥4%, resisting wind-induced fatigue.

[0024] Example 3: The processing steps of the aluminum clad copper core wire 1 include: Step S1, pre-treating the copper rod to remove the surface oxide layer; Step S2: pre-coating the copper rod with aluminum strip, hot pressing at a temperature of 480–500°C and a pressure of 120 MPa; Step S3, when the aluminum strip is hot pressed onto the surface of the copper rod, a La / Ce mixed gas is injected between the aluminum strip and the copper rod; Step S4, after the aluminum strip is hot-pressed onto the surface of the copper rod, the joints of the aluminum strip are subjected to argon arc welding under the protection of an inert gas; Step S5, the coated composite wire is gradually reduced in diameter by a wire drawing machine, and the copper and aluminum are deformed synchronously; In step S6, the composite wire is annealed in a pit-type annealing furnace or online continuously, with the temperature controlled below 300° C. to restore ductility and avoid fracture of the copper-aluminum transition layer, thereby obtaining the aluminum-clad copper core wire 1.

[0025] In step S1, the surface oxide layer is removed by acid washing and alkali washing the pure copper rod to remove the oxide layer. Removing the oxide layer can make the bonding position more dense.

[0026] Example 4: Insulation layer 3 comprises polyvinyl chloride doped with silicon carbide particles. The particle size of the silicon carbide particles ranges from 0.3 μm to 0.5 μm, and the mass of the silicon carbide particles accounts for 10% to 15% of the total mass of the insulation layer 3. By incorporating silicon carbide particles into insulation layer 3, the resistance drops sharply during a lightning strike, directing the lightning current into the ground.

[0027] Example 5: like Figure 3 As shown, the insulation layer 3 comprises an inner layer 8 and an outer layer 9. Multiple strands of iron-chromium-aluminum alloy wires 10 are interposed between the inner and outer layers 8, 9. These strands are concentrically twisted around the outer wall of the inner layer 8. Conductive rings 11 are spaced apart on the outer wall of the inner layer 8, connecting the multiple strands of iron-chromium-aluminum alloy wires 10. A controller is mounted on the outer side of the outer layer 9 to control the power flow between the conductive rings 11 and the outer conductor. In cold northern regions, where winter temperatures drop below -20°C, ice easily forms on overhead conductors. Ice increases the weight of overhead conductors, placing a greater burden on the conductors and potentially causing cable breakage. Therefore, the present invention incorporates multiple strands of iron-chromium-aluminum alloy wires 10 within the insulation layer 3. When energized, these wires heat up, thereby heating the outer layer 9 of the insulation layer 3, melting any ice adhering to it or preventing ice from forming there. This increased temperature also increases the temperature of both the inner and outer conductors, improving their electrical conductivity.

[0028] The controller includes a mounting ring 12 and a housing 13. The mounting ring 12 is fixed to the outside of the outer layer 9. The housing 13 houses a first electroprobe 14 and a second electroprobe 15. The first electroprobe 14 passes through the outer layer 9 and connects to the conductive ring 11. The second electroprobe 15 passes through the outer layer 9 and the inner layer 8 in sequence and connects to the outer conductor. The first and second electroprobes 14, 15 are controlled on and off by a switch 18. The housing 13 houses a single-chip microcomputer 16 and a battery 17 for powering the single-chip microcomputer 16. The single-chip microcomputer 16 controls the on and off of the switch 18. A temperature sensor is mounted on the side of the housing 13 and is electrically connected to the single-chip microcomputer 16. To avoid wasting resources by energizing the iron-chromium-aluminum alloy wire 10 in non-cold environments, the single-chip microcomputer 16 and the switch 18 work together to connect the iron-chromium-aluminum alloy wire 10 to the circuit in low-temperature environments and disconnect it from the circuit in non-cold environments. Specifically, a controller is provided at the position where the conductive ring 11 is provided in the wire, and the iron-chromium-aluminum alloy wire 10 and the outer conductor are connected through the first electric needle 14 and the second electric needle 15. The switch 18 adopts a high-voltage contactor, and the high-voltage contactor is powered by the single-chip microcomputer 16 and the battery 17 to control the on and off of the high-voltage contactor, thereby controlling the on and off of the first electric needle 14 and the second electric needle 15. The temperature sensor can provide a signal to the single-chip microcomputer, so that the single-chip microcomputer 16 can determine whether the first electric needle 14 and the second electric needle 15 are connected. The connection between the box body 13 and the outer wall of the outer layer 9 is sealed by a sealant. The first electric needle 14 and the second electric needle 15 are arranged front and back, as shown in FIG. Figure 3 The dotted line represents the second electroacupuncture needle 15. The first electroacupuncture needle 14 penetrates the outer layer 9 at the location where the conductive ring 11 is located. The second electroacupuncture needle 15 penetrates the outer layer 9 and the inner layer 8 at a location where the conductive ring 11 is not located. The location of the conductive ring 11 can be confirmed by marking the surface of the outer layer 9 during wire production using inkjet printing, embossing, or other methods.

[0029] A solar charging panel 19 is mounted on the outside of the box body 13 for charging the battery 17. The mounting ring 12 is provided with first and second through-holes 20, 21, which allow the first and second electro-needles 14, 15 to pass through. The solar charging panel 19 effectively utilizes solar energy at high altitudes to charge the battery 17. The first and second through-holes 20, 21 allow the first and second electro-needles 14, 15 to be smoothly inserted into the wires.

[0030] The cross section of the aluminum core wire 2 is one of a prototype, a square, a diamond, a trapezoid, and a Z-shape.

[0031] Although the present invention has been described herein with reference to a number of illustrative embodiments thereof, it will be understood that numerous other modifications and implementations may be devised by those skilled in the art that fall within the scope and spirit of the principles disclosed herein. More specifically, within the scope of the present disclosure, the drawings, and the claims, numerous variations and modifications may be made to the components and / or layout of the subject combination arrangement. In addition to variations and modifications to the components and / or layout, other uses will also be apparent to those skilled in the art.

Claims

1. A high-strength and high-conductivity overhead wire, characterized in that: The invention comprises an inner conductor formed by coaxially twisting a plurality of aluminum-clad copper core wires (1); an outer conductor formed by coaxially twisting a plurality of aluminum core wires (2) is arranged on the outer side of the inner conductor; an insulating layer (3) is arranged on the outer side of the outer conductor; a plurality of twisted steel ropes (4) are arranged between the insulating layer (3) and the outer conductor; and the plurality of twisted steel ropes (4) are coaxially twisted on the surface of the outer conductor.

2. The high-strength and high-conductivity overhead conductor according to claim 1, characterized in that: The twisted steel rope (4) comprises a central reinforcement layer formed by concentrically twisting at least three galvanized steel wires (5), and a plurality of aluminum-clad steel cores (6) and aluminum alloy wires (7) are concentrically twisted on the outer side of the central reinforcement layer.

3. The high-strength and high-conductivity overhead conductor according to claim 1, characterized in that: The processing steps of the aluminum-clad copper core wire (1) include: Step S1, pre-treating the copper rod to remove the surface oxide layer; Step S2: pre-coating the copper rod with aluminum strip, hot pressing at a temperature of 480–500°C and a pressure of 120 MPa; Step S3, when the aluminum strip is hot pressed onto the surface of the copper rod, a La / Ce mixed gas is injected between the aluminum strip and the copper rod; Step S4, after the aluminum strip is hot-pressed onto the surface of the copper rod, the joints of the aluminum strip are subjected to argon arc welding under the protection of an inert gas; Step S5, the coated composite wire is gradually reduced in diameter by a wire drawing machine, and the copper and aluminum are deformed synchronously; Step S6, the composite wire is annealed in a pit-type annealing furnace or online continuously, with the temperature controlled below 300°C to restore ductility and avoid fracture of the copper-aluminum transition layer, thereby obtaining an aluminum-clad copper core wire (1).

4. The high-strength and high-conductivity overhead conductor according to claim 3, characterized in that: In step S1, the surface oxide layer is removed by acid washing and alkali washing the pure copper rod.

5. The high-strength and high-conductivity overhead conductor according to claim 1, characterized in that: The insulating layer (3) comprises polyvinyl chloride doped with silicon carbide particles, the particle size of the silicon carbide particles is 0.3 μm-0.5 μm, and the mass of the silicon carbide particles accounts for 10%-15% of the total mass of the insulating layer (3).

6. The high-strength and high-conductivity overhead conductor according to claim 1, characterized in that: The insulating layer (3) comprises an inner layer (8) and an outer layer (9), a plurality of iron-chromium-aluminum alloy wires (10) are arranged between the inner layer (8) and the outer layer (9), the plurality of iron-chromium-aluminum alloy wires (10) are concentrically twisted on the outer wall of the inner layer (8), and a conductive ring (11) for connecting the plurality of iron-chromium-aluminum alloy wires (10) is provided at intervals on the outer wall of the inner layer (8), and a controller for controlling the power on and off between the conductive ring (11) and the outer conductor is installed on the outer side of the outer layer (9).

7. The high-strength and high-conductivity overhead conductor according to claim 6, characterized in that: The controller comprises a mounting ring (12) and a box body (13), wherein the mounting ring (12) is fixed to the outside of the outer layer (9), and a first electric needle (14) and a second electric needle (15) are installed in the box body (13), wherein the first electric needle (14) passes through the outer layer (9) and is connected to the conductive ring (11), and the second electric needle (15) passes through the outer layer (9) and the inner layer (8) in sequence and is connected to the outer conductor, and the first electric needle (14) and the second electric needle (15) are controlled to be on and off by a switch (18), and a single-chip microcomputer (16) and a battery (17) for powering the single-chip microcomputer (16) are provided in the box body (13), and the single-chip microcomputer (16) is used to control the on and off of the switch (18); a temperature sensor is provided on the side of the box body (13), and the temperature sensor is electrically connected to the single-chip microcomputer (16).

8. The high-strength and high-conductivity overhead conductor according to claim 7, characterized in that: A solar charging panel (19) for charging the battery (17) is installed on the outer side of the box body (13); and a first through hole (20) and a second through hole (21) are provided on the mounting ring (12) for allowing the first electric needle (14) and the second electric needle (15) to pass through.

9. The high-strength and high-conductivity overhead wire according to claim 1, characterized in that The cross section of the aluminum core wire (2) is one of a prototype, a square, a diamond, a trapezoid, and a Z-shape.

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