Production process of fatigue-resistant composite copper alloy dropper wire
By independently processing and twisting copper-chromium-zirconium alloy filaments and copper-magnesium alloy wires to form inner and outer layer structures, the problem of performance degradation of suspension strings caused by factors such as current, vibration and wind force at high-speed rail speeds is solved, and the fatigue resistance of the suspension strings and the production efficiency are improved.
Patent Information
- Application Number
- CN202511091618.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-08-05
- Publication Date
- 2025-09-26
AI Technical Summary
The performance of suspension strings degrades rapidly at high-speed rail speeds due to factors such as current, vibration, and wind. Existing technology makes it difficult to produce them efficiently while improving fatigue resistance.
Copper-chromium-zirconium alloy filaments and copper-magnesium alloy wires are processed independently, and the inner and outer stranded wire structures are formed by bundle twisting, forming a fatigue-resistant composite copper alloy suspension string with a 1×7×(7+6) structure. The use of copper-magnesium alloy wires is increased to improve fatigue resistance.
It significantly improves the fatigue resistance of the suspension wire, reduces the frequency of wire breakage, improves the safety of the contact network power supply, ensures the stable operation of the train, and improves the production efficiency of the suspension wire.
Smart Images
Figure CN120700720A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of dropper string production, and in particular to a production process of fatigue-resistant composite copper alloy dropper string. Background Art
[0002] As train speeds increase, performance requirements for contact network components are also gradually increasing. Dropper strings connect the load-bearing cables and the contact wire, playing the important role of ensuring the straightness of the contact wire and forming a current loop when the train passes. Dropper strings are constantly affected by current, vibration, wind, light, and other factors, and their performance degrades rapidly. To extend the service life of dropper strings and improve their fatigue resistance to meet the needs of increasing high-speed rail speeds, it is necessary to develop a fatigue-resistant composite dropper string. While theoretical parameters can meet fatigue resistance requirements, how to rationally and efficiently produce the corresponding dropper strings is also a technical challenge that urgently needs to be solved. Summary of the Invention
[0003] In response to the above problems, the present invention provides a process for producing fatigue-resistant composite copper alloy dropper strings, which is produced by independently processing copper-chromium-zirconium alloy wire and copper-magnesium alloy wire, and then twisting them together to produce fatigue-resistant composite copper alloy dropper strings. This increases the production speed of the dropper strings and improves the fatigue resistance of the dropper strings.
[0004] A fatigue-resistant composite copper alloy dropper string production process is characterized in that: copper-chromium-zirconium alloy filaments and copper-magnesium alloy wires are separately produced in advance, wherein the copper-chromium-zirconium alloy filaments have a size of Φ0.10 mm to Φ0.30 mm, and the copper-magnesium alloy wires have a size of Φ0.40 mm to Φ0.70 mm; then, a first strand is formed by twisting seven copper-chromium-zirconium alloy filaments, wherein the outer diameter of the first strand is Φ0.40 mm to Φ0.70 mm; then, the seven first strands are twisted together to obtain an inner copper-chromium-zirconium alloy wire bundle of the dropper string, wherein the bundle has a diameter of Φ1.20 mm to Φ2.5 mm; then, the seven copper-magnesium alloy wires are twisted together to obtain a copper-magnesium alloy wire bundle with a diameter of Φ1.20 mm to Φ2.5 mm; and then, the inner copper-chromium-zirconium alloy wire bundle and the six outer copper-magnesium alloy wire bundles are twisted together as a whole to obtain the fatigue-resistant composite copper alloy dropper string.
[0005] It is further characterized by: The fatigue-resistant composite copper alloy suspension string obtained has a structure of 1×7×(7+6), and the product outer diameter is Φ3.50 to Φ8.00 mm. After the product is twisted, it is placed on a wooden tray and sampled for testing. Qualified products are completely wrapped with a waterproof protective film and then covered with a partition board, and the outer layer is wrapped with bamboo strips for protection; The fatigue resistance test of the fatigue-resistant composite copper alloy suspension string shows that there is no damage after vibrating for more than 2 million times. The conductivity of the fatigue-resistant composite copper alloy suspension string is greater than 75% IACS and the tensile strength is greater than 560 MPa. The whole fatigue-resistant composite copper alloy suspension string can be bent to breakage ≥ 120 times and to fracture ≥ 300 times. When producing copper-chromium-zirconium alloy fine wires, first, smelting is performed to obtain copper-chromium-zirconium alloy rod blanks of Φ18mm to Φ25mm, and then extrusion is performed to obtain copper-chromium-zirconium alloy extruded rod blanks of Φ16 to Φ25mm, and then rolling is performed to obtain copper-chromium-zirconium alloy rolled rods of Φ6 to Φ10mm. The copper-chromium-zirconium alloy rolled rods of Φ6 to Φ10mm are then continuously drawn using a wire drawing machine, and after multiple die drawing, copper-chromium-zirconium alloy single wires of Φ1.0 to Φ3mm are obtained. After multiple die drawing, copper-chromium-zirconium alloy single wires of Φ0.4 to Φ0.70mm are obtained. Finally, the copper-chromium-zirconium alloy material of Φ0.4 to Φ0.70mm single wires are further refined and annealed during the drawing process to obtain copper-chromium-zirconium alloy fine wires of Φ0.10mm to Φ0.30mm. The copper-chromium-zirconium alloy fine wires are placed on small iron plates for standby use. When making copper-magnesium alloy wire, first, smelting is performed to obtain copper-magnesium alloy rod blanks of Φ18mm to Φ25mm, and then extrusion is performed to obtain copper-magnesium alloy extruded rod blanks of Φ16 to Φ25mm, and then rolling is performed to obtain copper-magnesium alloy rolled rods of Φ6 to Φ10mm, and then the copper-magnesium alloy of Φ6 to Φ10mm is continuously drawn by a wire drawing machine, and after multiple die drawing, a copper-magnesium alloy single wire of Φ1.0 to Φ3.0mm is obtained, and then after multiple die drawing, a copper-magnesium alloy wire of Φ0.4 to Φ0.70mm is obtained, and the copper-magnesium alloy wire is placed on a small iron plate for standby use; Preferably, the copper-chromium-zirconium alloy filaments and copper-magnesium alloy wires are cleaned and surface-treated, then passed through a tinning bath and electroplated to obtain tinned copper alloy filaments to improve environmental tolerance, and then placed on small iron plates for standby use.
[0006] After adopting the present invention, the copper-chromium-zirconium alloy filaments of the first strand of the inner layer of the suspension string and the copper-magnesium alloy wires of the outer layer of the copper-magnesium alloy wire bundle are independently manufactured. During the manufacturing process, the performance of the Φ1.0-Φ3.0 mm single wire corresponding to the copper-chromium-zirconium alloy wire and the copper-magnesium alloy wire is ensured, wherein the tensile strength is greater than 620 MPa and the resistivity (20°C) is ≤ 0.01982 Ω•mm. 2 / m, and then the first strand is twisted again to obtain an inner copper-chromium-zirconium alloy wire bundle, and the outer copper-magnesium alloy wire bundle is twisted at the same time, and then the inner copper-chromium-zirconium alloy wire bundle and the outer 6 copper-magnesium alloy wire bundles are twisted as a whole to obtain a fatigue-resistant composite copper alloy dropper string, wherein the copper-chromium-zirconium alloy filaments constitute the inner layer structure of the dropper string, and 7 groups of 1×7 structures replace the inner layer 1 group of 1×7 structure of the ordinary dropper string. The copper-magnesium alloy wire constitutes the outer layer structure of the dropper string, which is composed of 6 groups of 1×7 twisted bundles, thereby improving the fatigue resistance of the overall dropper string. According to testing, the fatigue resistance can be improved by more than 30%, which greatly reduces the disconnection frequency, improves the power supply safety of the contact network, and ensures the stable operation of the train. The copper-chromium-zirconium alloy filaments and the copper-magnesium alloy wires are independently manufactured and then twisted into corresponding bundles to obtain the dropper string. The production efficiency of the dropper string produced by this process is high, which improves the production speed of the dropper string and improves the fatigue resistance of the dropper string. BRIEF DESCRIPTION OF THE DRAWINGS
[0007] Figure 1 This is a schematic diagram of the three-dimensional structure of the suspension string manufactured corresponding to the present invention; The names corresponding to the serial numbers in the figure are as follows: Copper-chromium-zirconium alloy filaments 1, first twisted wires 2, copper-chromium-zirconium alloy wire bundles 3, copper-magnesium alloy wires 4, copper-magnesium alloy wire bundles 5, and fatigue-resistant composite copper alloy suspension strings 10. DETAILED DESCRIPTION
[0008] A fatigue-resistant composite copper alloy dropper string production process: the process comprises pre-producing copper-chromium-zirconium alloy filaments and copper-magnesium alloy wires, wherein the size of the produced copper-chromium-zirconium alloy filaments is Φ0.10mm-Φ0.30mm, and the size of the copper-magnesium alloy wires is Φ0.4-Φ0.70mm. Then, a first strand is formed by bundling 7 copper-chromium-zirconium alloy filaments, and the outer diameter of the first strand is 0.40-Φ0.70mm. Then, the 7 first strands are twisted together to obtain an inner copper-chromium-zirconium alloy wire bundle of the dropper string, and the bundle diameter after twisting is Φ1.20-Φ2.5mm. Then, the 7 copper-magnesium alloy wires are twisted together to obtain a copper-magnesium alloy wire bundle with a diameter of Φ1.20-Φ2.5mm. Then, the inner copper-chromium-zirconium alloy wire bundle and the 6 outer copper-magnesium alloy wire bundles are twisted together as a whole to obtain a fatigue-resistant composite copper alloy dropper string (see Figure 1 ).
[0009] The fatigue-resistant composite copper alloy suspension string structure obtained is 1×7×(7+6), with an outer diameter of Φ3.50 to Φ8.00 mm. After the products are twisted, they are placed on wooden trays and sampled for testing. Qualified products are completely wrapped with waterproof protective film and then covered with air-insulating boards. The outer layer is wrapped with bamboo strips for protection. The fatigue resistance test of the fatigue-resistant composite copper alloy suspension string shows that there is no damage after vibrating for more than 2 million times. The conductivity of the fatigue-resistant composite copper alloy suspension string is greater than 75% IACS and the tensile strength is greater than 560 MPa. The entire fatigue-resistant composite copper alloy suspension string can be bent to wire breakage for ≥120 times and to fracture for ≥300 times.
[0010] The specific production process steps are as follows: Copper-chromium-zirconium alloy filaments are made as follows: S1 smelting Using electrolytic copper, copper-chromium alloy, and copper-zirconium alloy as raw materials, the mixed raw materials are melted in a vacuum melting furnace and then drawn out horizontally to obtain Φ18mm-Φ25mm copper-chromium-zirconium alloy rod blanks (Cr: 0.20-0.50%, Zr: 0.05-0.20%). During the melting process, the composition is tested every 1 hour to ensure the stability of the alloy composition content in the rod blank. S2 Squeeze The copper-chromium-zirconium alloy rod blank is extruded by a continuous extruder to obtain a copper-chromium-zirconium alloy extruded rod blank with a size of Φ16 to Φ25 mm. During the extrusion process, the water temperature is controlled at 20 to 50° C. and the rotation speed is 2.0 to 4.0 r / min. The extruded rod is placed on an iron plate for subsequent rolling processing. S3 rolling: The copper-chromium-zirconium alloy extruded rod blanks with a diameter of 16 to 25 mm are rolled and deformed by a rolling mill to obtain copper-chromium-zirconium alloy rolled rods with a diameter of 6 to 10 mm. S4 brushed S401, continuously drawing a Φ6-Φ10 mm copper-chromium-zirconium alloy rolled rod using a wire drawing machine, obtaining a Φ1.0-Φ3.0 mm single wire after multiple die drawing, and placing the single wire on a small iron plate to facilitate subsequent precision wire drawing; S402. Perform performance testing on the monofilament to ensure that the tensile strength is greater than 620 MPa and the resistivity (20°C) is less than or equal to 0.01982 Ω•mm. 2 / m to Φ2.0 mm monofilament meets the requirements and enters the next process; S403, continuing to draw a copper-chromium-zirconium alloy monofilament of Φ1.0-Φ3.0 mm using a precision wire drawing machine, accompanied by annealing during the drawing process, and obtaining a copper-chromium-zirconium alloy monofilament of Φ0.40-Φ0.70 mm after multiple die drawing, and placing the monofilament on a small iron plate; S404, further finely drawing the copper-chromium-zirconium alloy monofilament of Φ0.40-Φ0.70 mm, accompanied by annealing during the drawing process, to obtain copper-chromium-zirconium alloy filaments of Φ0.10-Φ0.30 mm, and placing the copper-chromium-zirconium alloy filaments on a small iron plate for standby use; S5 coating The copper-chromium-zirconium alloy filaments obtained by drawing are cleaned and surface-treated, and then passed through a tinning bath and electroplated to obtain tinned copper alloy filaments to improve environmental tolerance.
[0011] Copper-magnesium alloy wire is made as follows: S1 smelting Electrolytic copper and pure magnesium ingots are used as raw materials. The raw materials are melted in a non-vacuum melting furnace and then continuously cast upward to obtain Φ18mm~Φ25mm copper-magnesium alloy rod billets (Mg: 0.15~0.40%). The composition is tested every 2 hours during the melting process to ensure the stability of the alloy composition content in the rod billets. S2 Squeeze The copper-magnesium alloy rod billet is extruded by a continuous extruder to obtain a copper-magnesium alloy extruded rod billet with a size of Φ16 to Φ25 mm. During the extrusion process, the water temperature is controlled at 20 to 50°C and the rotation speed is 2.0 to 4.0 r / min. The extruded rod is placed on an iron plate for subsequent rolling processing. S3 rolling: The copper-magnesium alloy extruded rod blanks with a diameter of 16 to 25 mm are rolled and deformed by a rolling mill to obtain copper-magnesium alloy rolled rods with a diameter of 6 to 10 mm. S4 brushed S401, continuously drawing a Φ6-Φ10 mm copper-magnesium alloy rolled rod using a wire drawing machine, obtaining a Φ1.0-Φ3.0 mm single wire after multiple die drawing, and placing the single wire on a small iron plate to facilitate subsequent precision wire drawing; S402. Perform performance testing on the monofilament to ensure that the tensile strength is greater than 620 MPa and the resistivity (20°C) is less than or equal to 0.01982 Ω•mm. 2 / m to Φ1.0~Φ3.0 mm monofilament meets the requirements and enters the next process; S403, continuing to draw the copper-magnesium alloy single wire of Φ1.0-Φ3.0 mm using a precision wire drawing machine, accompanied by annealing during the drawing process, and obtaining the copper-magnesium alloy wire of Φ0.40-Φ0.70 mm after multiple die drawing. The single wire is placed on a small iron plate for standby use; S5 coating The copper-magnesium alloy wire obtained by drawing is cleaned and surface treated, then passed through a tinning bath and electroplated to obtain tinned copper alloy filaments to improve environmental tolerance.
[0012] The stranding of the suspension strings includes the following steps: Inner layer stranding: 7 reels of Φ0.10mm-Φ0.30mm copper-chromium-zirconium alloy filaments 1 are taken and stranded using a stranding machine to obtain a first stranded wire 2 having a length of 1×7 / (0.10mm-Φ0.30m). The outer diameter of the first stranded wire 2 is Φ0.40-Φ0.70mm. The seven stranded first stranded wires 2 having an outer diameter of Φ0.40-Φ0.70mm are then further stranded using a stranding machine to obtain an inner layer copper-chromium-zirconium alloy wire bundle 3 of the suspension string. The bundle diameter after stranding is Φ1.20-Φ2.50mm. Outer layer stranding: 7 reels of drawn copper-magnesium alloy wires 4 with a diameter of 0.40 to 0.70 mm are taken and stranded using a stranding machine to obtain a copper-magnesium alloy wire bundle 5 with a diameter of 1.20 to 2.50 mm. Overall twisting: A bundle of twisted alloy wires with a diameter of Φ1.20 to Φ2.50 mm is taken, including one reel of copper-chromium-zirconium alloy wire bundle 3 (inner layer) and six reels of copper-magnesium alloy wire bundle 5 (outer layer), and is overall twisted in a twisting machine to obtain a fatigue-resistant composite copper alloy hanger string 10. The fatigue-resistant composite copper alloy hanger string structure 10 is 1×7×(7+6), and the outer diameter of the fatigue-resistant composite copper alloy hanger string 10 is Φ3.50 to Φ8.00 mm.
[0013] After the fatigue-resistant composite copper alloy suspension strings 10 are twisted, they are placed on a wooden plate and sampled for testing. Qualified products are completely wrapped with a waterproof protective film and then covered with a partition board, and the outer layer is wrapped with bamboo strips for protection.
[0014] Fatigue-resistant suspension string products undergo fatigue resistance testing and can withstand more than 2 million vibrations without damage, with a conductivity >75%IACS, a tensile strength >560MPa, and the entire suspension string can be bent to breakage ≥120 times and to rupture ≥300 times.
[0015] The copper-chromium-zirconium alloy filaments of the first strand of the inner layer of the suspension string and the copper-magnesium alloy wires of the outer layer of the copper-magnesium alloy wire bundle are independently manufactured. During the manufacturing process, the performance of the Φ1.0-Φ3.0 mm single wires corresponding to the copper-chromium-zirconium alloy wires and the copper-magnesium alloy wires is ensured, wherein the tensile strength is greater than 620 MPa and the resistivity (20°C) is ≤ 0.01982Ω•mm. 2 / m, and then the first strand is twisted again to obtain an inner copper-chromium-zirconium alloy wire bundle, and the outer copper-magnesium alloy wire bundle is twisted at the same time, and then the inner copper-chromium-zirconium alloy wire bundle and the outer 6 copper-magnesium alloy wire bundles are twisted as a whole to obtain a fatigue-resistant composite copper alloy dropper string, wherein the copper-chromium-zirconium alloy filaments constitute the inner layer structure of the dropper string, and 7 groups of 1×7 structures replace the inner layer 1 group of 1×7 structure of the ordinary dropper string. The copper-magnesium alloy wire constitutes the outer layer structure of the dropper string, which is composed of 6 groups of 1×7 twisted bundles, thereby improving the fatigue resistance of the overall dropper string. According to testing, the fatigue resistance can be improved by more than 30%, which greatly reduces the disconnection frequency, improves the power supply safety of the contact network, and ensures the stable operation of the train. The copper-chromium-zirconium alloy filaments and the copper-magnesium alloy wires are independently manufactured and then twisted into corresponding bundles to obtain the dropper string. The production efficiency of the dropper string produced by this process is high, which improves the production speed of the dropper string and improves the fatigue resistance of the dropper string.
[0016] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.
[0017] In addition, it should be understood that although this specification is described in terms of implementation methods, not every implementation method contains only one independent technical solution. This narrative method of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment can also be appropriately combined to form other implementation methods that can be understood by those skilled in the art.
Claims
1. A process for producing fatigue-resistant composite copper alloy suspension strings, characterized by: Copper-chromium-zirconium alloy filaments and copper-magnesium alloy wires are prepared in advance, wherein the size of the copper-chromium-zirconium alloy filaments prepared is Φ0.10mm-Φ0.30mm, and the size of the copper-magnesium alloy wires is Φ0.40-Φ0.70mm. Then, a first stranded wire is formed by twisting 7 copper-chromium-zirconium alloy filaments, and the outer diameter of the first stranded wire is Φ0.40-Φ0.70mm. Then, the 7 first stranded wires are twisted together to obtain an inner copper-chromium-zirconium alloy wire bundle of a suspension string, and the bundle diameter after twisting is Φ1.20-Φ2.50mm. Then, the 7 copper-magnesium alloy wires are twisted together to obtain a copper-magnesium alloy wire bundle with a diameter of Φ1.20-Φ2.50mm. Then, the inner copper-chromium-zirconium alloy wire bundle and the 6 outer copper-magnesium alloy wire bundles are twisted together as a whole to obtain a fatigue-resistant composite copper alloy suspension string.
2. The fatigue-resistant composite copper alloy dropper wire production process according to claim 1, characterized in that: The fatigue-resistant composite copper alloy suspension string structure obtained is 1×7×(7+6), and the product outer diameter size is Φ3.50~Φ8.00mm. After the product is twisted, it is placed on a wooden plate and sampled for inspection. Qualified products are completely wrapped with a waterproof protective film and then covered with a partition board, and the outer layer is wrapped with bamboo strips for protection.
3. The fatigue-resistant composite copper alloy dropper wire production process according to claim 1, characterized in that: When making copper-chromium-zirconium alloy filaments, first, smelting is performed to obtain copper-chromium-zirconium alloy rod blanks of Φ18 to Φ25 mm, and then copper-chromium-zirconium alloy extruded rod blanks of Φ16 to Φ25 mm are obtained by extrusion. Then, copper-chromium-zirconium alloy rolled rods of Φ6 to Φ10 mm are obtained by rolling. Then, the copper-chromium-zirconium alloy rolled rods of Φ6 to Φ10 mm are continuously drawn by a wire drawing machine. After multiple die drawing, copper-chromium-zirconium alloy single wires of Φ1.0 to Φ3.0 mm are obtained. Then, copper-chromium-zirconium alloy single wires of Φ0.40 to Φ0.70 mm are obtained after multiple die drawing. Finally, the copper-chromium-zirconium alloy material of Φ0.40 to Φ0.70 mm single wires are further refined by wire drawing. The drawing process is accompanied by annealing treatment to obtain copper-chromium-zirconium alloy filaments of Φ0.10 mm to Φ0.30 mm. The copper-chromium-zirconium alloy filaments are placed on small iron plates for standby use.
4. The fatigue-resistant composite copper alloy dropper wire production process according to claim 3, characterized in that: When making copper-magnesium alloy wire, first smelting is performed to obtain copper-magnesium alloy rod blanks of Φ18 to Φ25 mm, and then copper-magnesium alloy extruded rod blanks of Φ16 to Φ25 mm are obtained by extrusion, and then copper-magnesium alloy rolled rods of Φ6 to Φ10 mm are obtained by rolling. Then, the Φ6 to Φ10 mm copper-magnesium alloy is continuously drawn by a wire drawing machine, and after multiple die drawing, Φ1.0 to Φ3.0 mm copper-magnesium alloy single wires are obtained, and then after multiple die drawing, Φ0.40 to Φ0.70 mm copper-magnesium alloy wires are obtained. A small iron plate is placed on the copper-magnesium alloy wire for standby use.
5. The fatigue-resistant composite copper alloy dropper wire production process according to claim 4, characterized in that: After cleaning and surface treatment, the copper-chromium-zirconium alloy wire and the copper-magnesium alloy wire are passed through a tinning bath and electroplated to obtain tinned copper alloy wires to improve environmental tolerance. They are then placed on small iron plates for standby use.