Japanese standard circular compression conductor structure and manufacturing method thereof

Abstract

The invention discloses a Japanese standard circular compression conductor structure and a manufacturing method, and belongs to the technical field of cables. Comprising a conductor and an insulating layer conductor, the insulating layer conductor comprises a plurality of wire cores, the wire cores are mutually twisted, when the total number of the wire cores is smaller than or equal to seven, one wire core is arranged on the innermost layer, and the remaining wire cores are arranged on the second layer; when more than seven and less than or equal to ten, the inner layer of the conductor comprises one wire core, the second layer of the conductor comprises six wire cores, and the rest wire cores are arranged in the third layer; when the total number of the wire cores is larger than ten, the remaining wire cores are arranged on the second layer of wire cores, and the twisting directions of the wire cores are the same. According to the cable, a multi-layer twisting mode is adopted, when the number of the cable cores is smaller than 7, one cable core is arranged in the middle, and the remaining cable cores are arranged on the outer side, and when the number of the cable cores is 8-11, one cable core is arranged in the middle, six cable cores are arranged in the second layer, and the remaining cable cores are arranged in the third layer. And when the number of the conductors is more than 11, the number of the conductors in the inner layer is more than three, and the rest conductors are stranded in the second layer.

Description

Technical Field

[0001] The invention relates to a Japanese standard circular compressed conductor structure and a manufacturing method thereof, belonging to the technical field of cables. Background Art

[0002] The automotive industry continues to evolve, and the demand for lightweight, high-performance automotive cables is growing. Japanese-standard automotive cables typically utilize CIVUS ultra-thin-wall conductors, balancing minimized cable outer diameter with high performance. The current demand for electric current in vehicles is increasing. Increasing conductor cross-section can transmit more power, but this increases the cable outer diameter, placing higher demands on materials and wiring space.

[0003] Currently, the conventional stranding process for AVSS thin-walled copper conductors primarily involves twisting round copper wires at a specific pitch to form strands. This process also aims to prevent excessive extrusion of the conductors. While multi-strand conductors produced using this traditional stranding method offer structural stability and ease of control, they still retain significant gaps between the individual conductors, creating a nearly circular cross-section that doesn't fit snugly. This results in a relatively large outer diameter for the finished conductor, and the interstices between the conductors are not fully utilized.

[0004] Conductors manufactured using traditional processes have a relatively large outer diameter and significant gaps between layers. Under the same current-carrying conditions, the gaps between conductors are numerous, resulting in uneven current distribution and high overall resistance. Furthermore, to ensure insulation strength and mechanical durability, the thickness of the cable's outer insulation cannot be further increased, leading to a larger cable diameter and increased use of copper, insulation, and materials placed on the outside of the wire. This also limits the space available for wiring harness layout within the vehicle's interior. Directly compressing the finished conductor can cause the metal wire to deform and harden, increasing its strength and decreasing its conductivity, increasing risks during installation. Therefore, a Japanese-standard circular compressed conductor structure and manufacturing method are needed. This approach can accommodate more conductors within a limited space while ensuring that the compressed conductor's conductivity and flexibility are not significantly affected. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a Japanese standard circular compressed conductor structure and a manufacturing method, which solves the problem.

[0006] The technical problem to be solved by the present invention is achieved by adopting the following technical solutions: a Japanese standard circular compressed conductor structure, comprising Conductor, insulation layer, The insulating layer is provided on the outside of the conductor, The conductor includes a plurality of cores, the cores are twisted together, and the twisted conductor includes at least one core. When the number of the cores is less than or equal to seven, one core is arranged in the center of the conductor, and the remaining cores are arranged outside the central core; When the total number of the cores is greater than seven and less than or equal to ten, one core is provided in the center of the conductor, six cores are provided in the second layer, and the remaining cores are provided in the third layer; When the total number of the cores is greater than ten, the number of cores in the center of the conductor is at least three, and the remaining cores are twisted in the second layer. Preferably, the pitches between the cores are equal, and the pitches are comprised between 20-40 mm.

[0007] Preferably, the manufactured conductor is compressed by a stranding rotation device, which includes a compression die, a rotating motor, and a bracket. The conductor can be compressed and stranded in the stranding rotation device.

[0008] Preferably, the conductor is made of oxygen-free copper, and the diameter of a single wire of the conductor is 0.15 mm to 0.50 mm.

[0009] Preferably, the wire cores are connected through the compression mold, and the gap ratio of the wire cores after manufacture is less than or equal to 8%.

[0010] A method for manufacturing a Japanese standard circular compressed conductor, preferably, The following steps are involved: Step 1: Assemble the stranded wire rotating device, using two brackets, arranging multiple compression molds on the brackets, connecting the rotation motor to the compression molds, and stranding the wire cores through the stranded wire rotating device; Step 2: Apply tension to each of the wire cores through a magnetic powder tensioner, and twist them according to the structure of the conductor and the single-filament twist direction through a front spindle and a stranding machine; Step 3: Press tightly by compressing the rotating mold; Step 4: Annealing the wire; Step 5: After cooling in a water tank, the insulating layer is extruded onto the surface of the conductor; Preferably, in step 2: when the first layer of conductor has only one core, the first layer of core is arranged in the middle of the stranding rotation device, and the second layer of core is twisted on the outside of the first layer of core by a compression die; when the first layer has multiple cores, the first layer is twisted by a compression die, and the second layer is twisted on the outside of the first layer of core by another compression die.

[0011] Preferably, in step 4, the temperature of the annealing process is 450° C.-550° C., and the temperature is maintained for 1-3 hours.

[0012] The beneficial effects of the present invention are: The present invention adopts a multi-layer twisting method. When the number of cores is less than 7, one core is arranged in the middle, and the remaining conductors are arranged on the outside. When the number of cores is 8-11, one core is arranged in the middle, six cores are arranged in the second layer, and the remaining conductors are arranged in the third layer. When the number of cores is greater than 11, the number of inner layer conductors is more than three, and the remaining conductors are twisted in the second layer of cores.

[0013] The present invention provides multiple compression dies that can perform layered closed-loop compression on the conductor, ensuring uniform stress on the conductor. By twisting the layers and rotating the compression dies, a compression ratio of 75%-85% can be achieved, with an interlayer gap ratio of ≤8% and an outer diameter reduction of 5%.

[0014] The present invention utilizes co-directional stranding and consistent pitch across the entire conductor, increasing the overall fill factor to 0.88-0.92 and reducing resistance by 2%. During the manufacturing process, the cable undergoes annealing and cooling to eliminate internal stress, ensuring overall conductor flexibility and preventing a decrease in conductivity. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 This is a schematic cross-sectional view of a conductor made according to the present invention.

[0016] Figure 2 It is a rear schematic diagram of the stranded wire rotating device of the present invention.

[0017] Figure 3 It is a schematic diagram of the internal structure of the stranding machine of the present invention.

[0018] Figure 4 It is a schematic diagram of the installation of the compression mold of the present invention.

[0019] Figure 5 This is another schematic cross-sectional view of a conductor manufactured according to the present invention.

[0020] Figure 6 Schematic diagram of the stranded wire rotating device of the present invention.

[0021] Figure 7 This is another schematic cross-sectional view of a conductor manufactured according to the present invention.

[0022] In the figure: 1-wire core, 2-compression mold 1, 3-compression mold 2, 4-rotation motor, 5-rotation direction, 6-rear spindle, 7-magnetic powder tensioner, 8-take-up reel, 9-front spindle, 10-front spindle introduction, 11-rear spindle introduction. DETAILED DESCRIPTION

[0023] In order to make the technical means, creative features, objectives and effects of the present invention easier to understand, the present invention is further described below in conjunction with specific embodiments. Example 1

[0024] like Figure 1-Figure 7 As shown, a Japanese standard circular compressed conductor structure and manufacturing method.

[0025] The conductors produced meet the requirements of "Automobile Parts - Automotive Wires Part 3: Low Voltage Copper Wires JASO D 625-3: 2020" The Japanese standard round compressed conductor includes a conductor and an insulation layer, wherein the insulation layer is provided on the outside of the conductor. The conductor includes multiple cores, which are twisted together, and the twisted cores have at least one layer.

[0026] In this embodiment, when the number of cores 1 is 1, the outside of the core 1 is covered with an insulating layer, and the core 1 is located at the center of the cross section of the conductor; when the number of cores 1 increases from 1 to 7 or less. A core 1 is set at the center of the core 1 as the first layer, and the remaining cores 1 are set in the second layer. The second layer of cores 1 are arranged on the outside of the first layer of cores 1 by twisting, and the angles between the cores 1 in the second layer are the same. The twisting pitch of the cores 1 in the second layer is 20mm-40mm. The second layer of cores 1 can increase the cross-sectional area of ​​the conductor and can share the current of the first layer of cores 1. The same angle between the cores 1 can ensure the circumferential symmetry of the conductor, which is beneficial to the uniform force on the conductor when compressed.

[0027] When the total number of cores 1 is greater than 7 and less than 10, the original first-layer cores 1 and second-layer cores 1 remain unchanged, and the remaining cores 1 are twisted and arranged in the third layer. The twisting direction of the cores 1 in the third layer is the same as that in the second layer. The third-layer cores 1 can further expand the cross-section and improve the conductivity. The pitch of the cores 1 in the third layer is the same as that in the second layer, ensuring the overall roundness of the conductor between the second and third layers and the consistency of subsequent compression. After the conductors are twisted, they are pressed tightly. There are no obvious gaps between the pressed conductor cores 1. The insulating layer is set on the outside of the pressed conductor by extrusion. After the insulating layer is set on the outside of the conductor, the insulating layer and the conductor are tightly bonded, and there are no bubbles.

[0028] When the total number of cores 1 is greater than 10, the number of cores 1 of the innermost conductor is more than 1, and the remaining cores are arranged in the second layer. The cores 1 of the innermost layer need to be twisted, and the twisting direction of the cores 1 of the second layer is the same as that of the cores 1 of the first layer. Figure 1 , the number of cores 1 is 16, 6 cores 1 are arranged on the first layer, and 10 cores 1 are arranged on the second layer. Figure 7 The number of wire cores 1 is 11, 3 wire cores 1 are arranged on the first layer, and 8 wire cores 1 are arranged on the second layer.

[0029] After twisting, the conductors are compacted, increasing their cross-sectional fill factor to 0.88-0.92, compared to the 0.75-0.80 for conventional wires. With the same cross-sectional area, this reduces electrical resistance by 2% and lowers the temperature rise by 3°C. The compacted conductors occupy a smaller footprint, meeting the lightweighting requirements of automotive wiring harnesses.

[0030] After the conductor is pressed tightly, the insulation layer is set on the outside of the conductor by extrusion, and the conductor is annealed. During the annealing process, it is kept warm at 450℃-550℃ for 1-3 hours to eliminate the metal internal stress of the conductor and restore the flexibility of the wire core.

[0031] Annealing is used to eliminate conductor hardening, ensuring uniform stress between conductor layers and avoiding localized wins. The conductors are twisted in the same direction to ensure uniform distribution of conductor cores and reduce skin effect at the conductor edges.

[0032] Japanese standard circular compression conductor manufacturing method, including Reference Figure 6 , equipped with a branching and tensioning system. During the conductor processing, a first branching tray and a second branching tray are installed at the entrance. The spacing between the first and second branching trays is 15±3cm. The first and second branching trays can be used to lead the wire core 1 in parallel.

[0033] Reference Figure 2 A magnetic powder tensioner 7 is provided between the second distribution disk and the front spindle 9, and the magnetic powder tensioner 7 can be used to guide the wire core into the compression die.

[0034] Compression mold 1 2 and compression mold 2 3 are both located between the front spindle 9 and the rear spindle 6, and the distribution disk is only used to pull out the wire core. Compression mold 1 2 and compression mold 2 3 are coaxially fixed on the bracket, and the rotating motor 4 is connected to the compression mold, and the rotating motor 4 can drive the compression mold to rotate. After the compression mold 1 2 and compression mold 2 3 are assembled, the rear spindle guide wheel 11 and the rear spindle 6 are installed. It is used to receive the wire core that exceeds the second layer and perform the second or third supplementary twisting. An annealing furnace and a constant temperature water tank extruder are set behind the take-up disk 8. After the wire is produced, the annealing, cooling, and insulation layer extrusion production line can be completed. The direction of rotation 5 is as follows Figure 6 After the conductors are manufactured, they can be collected by a wire take-up device, and the collected conductors can be easily sent to an annealing furnace for annealing.

[0035] The production steps include: Step 1: Assemble the stranding rotation device. The stranding rotation device consists of two brackets. Two compression molds, compression mold 1 2 and compression mold 2 3, are mounted on the brackets. The wire cores 1 are twisted by the stranding rotation device. Compression molds 1 2 and 2 3 are mounted on the brackets. The first and second distribution trays are located at the bottoms of compression molds 1 2 and 2 3, respectively. A rotating motor 4 is connected to compression mold 2 1.

[0036] Step 2: Connect multiple wire cores 1 to the first distribution disk and the second distribution disk respectively. After being pulled out through the distribution disk, the wire core 1 is pulled out through the first distribution disk and the second distribution disk and maintained at a tension of 0.5-2.0N through the magnetic powder tensioner 7 until the wire core 1 enters the front spindle 9.

[0037] During the twisting process, the front spindle 9 completes the twisting in the following manner under the control of the inverter: When the number of wire cores 1 is ≤7, one wire core 1 is set in the innermost layer, and the innermost wire core 1 directly passes through the center of the distribution board. The remaining wire cores 1 are set in holes away from the center of the distribution board and are twisted through a compression mold 2. The twisting pitch is 20mm-40mm.

[0038] When the number of cores 1 is between 8 and 11, two layers of "1+6" are twisted in the front spindle first, and the remaining cores are transported to the rear spindle 6 via the front spindle guide wheel 10 to form a third layer of co-directional twisting; When the number of cores 1 is greater than 11: The number of cores 1 in the innermost layer is at least one, and the remaining cores are arranged in the second layer. The innermost cores and the second layer cores are twisted in the same direction. The innermost layer and the second layer cores are twisted in the same direction, and the pitch is 20mm-40mm.

[0039] Step 3: Compress the conductor using a compression and rotational die. The conductor enters compression die 1 (2) and compression die 2 (3) sequentially. Compression die 1 (2) performs initial compression of the conductor, reducing its diameter to approximately 80%-85% of its original diameter. Compression die 2 (3) further compresses the conductor, reducing its diameter to between 75%-85% of its original diameter and ensuring an interlayer gap ratio of ≤8%.

[0040] Step 4: Annealing: The finished wire is coiled and transported by a traction device to an annealing furnace, where it is kept at 450°C-550°C for 1-3 hours. Annealing eliminates internal stress in the wire and restores its flexibility.

[0041] Step 5: After the conductor is annealed, it enters the water tank. The temperature of the water tank is 20℃-30℃. It passes slowly under the control of the tension device and cools and shapes to ensure the linearity and roundness of the conductor.

[0042] The cooled conductor directly enters the three-cavity extruder. The extruded material is XLPE, the extrusion temperature is 170℃-190℃, and the thickness of the insulation layer is set to 0.8mm-1.2mm. The insulation layer is set on the outside of the conductor through the extruder to ensure that the insulation layer and the conductor are tightly fitted and the surface is smooth and free of bubbles.

[0043] In this embodiment, the wire spacing is 15±3cm, which can ensure smooth wire entry and low friction. The tension set by the magnetic powder tensioner 7 is 0.5N-2.0N to prevent loosening or wire breakage. The twisting pitch is 20mm-40mm to ensure consistent roundness and twist direction between layers. The compression ratio of the wire is 75%-85%, and the gap ratio is ≤8%. Compared with traditional cables, the outer diameter is reduced by about 5%. Annealing can eliminate the hardening of the conductor and restore its flexibility.

[0044] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art will appreciate that the present invention is not limited to the foregoing embodiments and that various modifications and improvements may be made to the present invention without departing from the spirit and scope of the present invention. Such modifications and improvements are intended to fall within the scope of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A Japanese standard circular compressed conductor structure, including Conductor, insulation layer, The insulating layer is provided on the outside of the conductor, Its characteristics are: The conductor includes a plurality of cores, the cores are twisted together, and the twisted conductor includes at least one core. When the number of the cores is less than or equal to seven, one core is arranged in the center of the conductor, and the remaining cores are arranged outside the central core; When the total number of the cores is greater than seven and less than or equal to ten, one core is provided in the center of the conductor, six cores are provided in the second layer, and the remaining cores are provided in the third layer; When the total number of the cores is greater than ten, the number of cores in the center of the conductor is at least three, and the remaining cores are twisted in the second layer.

2. The Japanese standard circular compressed conductor structure according to claim 1, characterized in that: The pitches between the cores are equal and range from 20 to 40 mm.

3. The Japanese standard circular compressed conductor structure according to claim 2, characterized in that: The manufactured conductor is compressed by a stranding rotating device, which includes a compression die, a rotating motor, and a bracket. The conductor can be compressed and stranded in the stranding rotating device.

4. The Japanese standard circular compressed conductor structure according to claim 1, characterized in that: The conductor is made of oxygen-free copper, and the diameter of a single wire of the conductor is 0.15 mm to 0.50 mm.

5. The Japanese standard circular compressed conductor structure according to claim 3, characterized in that: The wire cores are connected through the compression mold, and the gap ratio of the wire cores after manufacture is less than or equal to 8%.

6. A method for manufacturing a Japanese standard circular compressed conductor, wherein the method is used to manufacture a Japanese standard circular compressed conductor structure according to any one of claims 1 to 5, characterized in that: The following steps are involved: Step 1: Assemble the stranded wire rotating device, using two brackets, arranging multiple compression molds on the brackets, connecting the rotation motor to the compression molds, and stranding the wire cores through the stranded wire rotating device; Step 2: Apply tension to each of the wire cores through a magnetic powder tensioner, and twist them according to the structure of the conductor and the single-filament twist direction through a front spindle and a stranding machine; Step 3: Press tightly by compressing the rotating mold; Step 4: Annealing the wire; Step 5: After cooling in a water tank, the insulation layer is extruded onto the surface of the conductor.

7. The method for manufacturing a Japanese standard circular compressed conductor according to claim 6, characterized in that: In step 2: when the first layer of conductor has only one core, the first layer core is set in the middle of the stranding rotation device, and the second layer core is twisted on the outside of the first layer core through a compression die; when the first layer has multiple cores, the first layer is twisted through a compression die, and the second layer is twisted on the outside of the first layer core through another compression die.

8. The method for manufacturing a Japanese standard circular compressed conductor according to claim 6, characterized in that: In step 4, the temperature of the annealing process is 450° C.-550° C., and the temperature is kept for 1-3 hours.

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