5G leaky cable spiral corrugated copper pipe inner conductor welding embossing device and method

Abstract

The invention relates to the technical field of communication wires and cables, in particular to a 5G leaky coaxial cable spiral corrugated copper pipe inner conductor welding embossing device and method.The device comprises a tension unit, a cutter unit, a pressing plate unit, a forming unit, a blow-drying unit, a traction unit and an embossing unit which are sequentially arranged; the tension unit, the cutter unit and the pressing plate unit are used for processing the initial flatness, width and the like of a copper strip, then the copper strip is gradually formed through the forming unit and is matched with the welding unit, the cooling unit and the blow-drying unit to obtain a rough round pipe, then the rough round pipe is guided into the embossing unit through the traction unit, the embossing unit is used for embossing the outer wall of the copper pipe through an embossing cutter, and the copper pipe is formed. And finally, stable, efficient and batch production of the high-precision spiral corrugated copper pipe inner conductor is realized.

Description

Technical Field

[0001] The present invention relates to the technical field of communication wires and cables, and specifically to a device and method for welding and corrugating the inner conductor of a spirally corrugated copper tube of a 5G leaky cable. Background Art

[0002] During signal transmission, if the impedance of the signal source and the feeder do not match or the load and the feeder do not match, the signal will be reflected during the transmission process. At this time, there are incident waves and reflected waves on the leaky cable at the same time, which superimpose on each other to form standing waves. The voltage standing wave ratio is a reflection of the structural uniformity and stability in electrical performance. The leaky coaxial cable consists of an inner conductor, physical foam insulation, an outer conductor and a sheath. The inner conductor is generally a smooth copper tube or a spiral corrugated copper tube. The inner conductor of the spiral corrugated copper tube is formed by longitudinally wrapping a copper strip, welding, and spiral corrugating. The inner conductor of the spiral corrugated copper tube plays a key role in the leaky cable. First, it improves the bendability of the leaky cable; second, the material cost is lower than that of a smooth copper tube; third, the uniformity of its structural dimensions such as crests, troughs, and pitch, as well as the appearance quality, have a greater impact on the attenuation constant and the voltage standing wave ratio.

[0003] The Chinese invention patent application with application number CN202410353596.7 discloses a design method for a metal welded corrugated tube sheath for a mineral insulated cable, comprising the following steps: S1: establishing an equivalent model of the metal welded corrugated tube sheath; S2: calculating various parameters for manufacturing the metal welded corrugated tube sheath based on the equivalent model of the metal welded corrugated tube sheath, the manufacturing parameters including one or more of the diameter of the longitudinally wrapped metal round tube, the width of the longitudinally wrapped metal strip, the corrugation depth and the corrugation pitch; S3: completing the manufacturing of the metal welded corrugated tube sheath according to the manufacturing parameters, thereby achieving consistency and stability in the process structure and quality of the metal threaded tube of the mineral insulated cable.

[0004] However, the above-mentioned design method is mainly a design method for designing welded corrugated tube sheaths to ensure that mineral insulated cables can pass bending pressure resistance tests, flattening pressure resistance tests and combustion fire resistance tests. It mainly involves model and size calculations, and cannot ensure the uniformity of dimensions during its production and processing. It does not describe how to implement the process and equipment. This product belongs to the power field product, and the performance requirements are bending pressure resistance test, flattening pressure resistance test and combustion fire resistance test.

[0005] The Chinese invention patent application with application number CN107819178A discloses a 5G frequency band dedicated ultra-flexible low-loss coaxial cable and its preparation method, wherein the inner conductor and / or the outer conductor are first prepared by passing the copper strip through a U-shaped groove, a horn mold and a forming mold ring into a circle, and then the opening is welded together using argon arc welding, and then an eccentric corrugating device is used to corrugate the welded copper tube, and by adjusting the pulling speed of the copper strip before and after the longitudinal wrapping forming welding corrugation integrated equipment, the thread pitch is shortened as much as possible and the corrugation depth is deepened to improve its softness.

[0006] However, the process described in the aforementioned patent carries the risk of copper tube deformation due to direct corrugation after welding. Corrugation stability depends on the traction speed, which can easily lead to uneven pitch and make it difficult to ensure high-quality processing of the inner conductor. In particular, the use of thin copper strip to produce the inner conductor of spiral copper tubes, with shallow corrugation and large pitch, is prone to deformation during unwinding and rewinding, resulting in high-frequency resonance and a large voltage standing wave ratio. Summary of the Invention

[0007] In view of the problems in the prior art of producing spiral corrugated copper tube inner conductors from thin copper strips, such as shallow corrugation, large pitch, and easy deformation during unrolling and rewinding, which causes high-frequency resonance and large voltage standing wave ratio, the present invention provides a welding corrugation device and method for spiral corrugated copper tube inner conductors of 5G leaky cables.

[0008] The present invention is achieved through the following technical solutions: A 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device comprises a tension unit, a cutter unit, a pressing plate unit, a forming unit, a drying unit, a pulling unit and a corrugating unit which are arranged in sequence; The tension unit is used to adjust the tension of the copper strip; The cutter unit is used to cut the copper strip to the required width; The pressing plate unit is used to flatten the copper strip; The forming unit includes a shoe-shaped seat, a trumpet die, a sizing die and a reducing die which are coaxially arranged in sequence. The shoe-shaped seat, the trumpet die and the sizing die are used to gradually bend the copper strip into a round tube with an open top. The shoe-shaped seat includes a slider with a tapered arc groove, and support frames are provided on both sides of the slider along the copper belt. A movable arc rod is provided on the support frame, and the length axis of the arc rod is parallel to the tapered line of the arc groove, and a gap is left between the slider and the arc rod. The inlet end of the trumpet die is close to the shoe seat, and the outlet end is close to the sizing die; A welding unit is provided between the sizing die and the reducing die. The welding unit is used to weld the top opening to form a copper tube. The welding head of the welding unit faces the top opening of the round tube. A cooling unit for cooling the top weld of the copper tube is provided between the reducing die and the drying unit; The air outlet of the drying unit faces the outer wall of the copper tube; The traction unit is used to pull the copper tube to the corrugating unit; The corrugating unit is used to roll threads onto the outside of copper tubes. Preferably, the corrugating unit includes an XYZ-axis adjustment structure, an inlet guide tube, a corrugating seat, an inlet die and an outlet die arranged in sequence, the XYZ-axis adjustment structure is used to adjust the size of the copper tube; the inlet guide tube is used to guide the copper tube into the corrugating knife; the corrugating knife is installed on the corrugating seat, and the corrugating knife is used to corrugate the copper tube; the inlet die is used to maintain the forward direction of the copper tube, and the outlet die is used to guide the copper tube to leave the corrugating unit.

[0009] Preferably, the corrugating base includes a die base and a rotating base, both of which are annular, and the corrugating knife is rotatably mounted on the inner side of the rotating base. Two mounting shafts are provided on the outer side of the rotating base, and the mounting shafts are threadedly connected to the die base. The end of the mounting shaft away from the rotating base extends out of the die base, and a locking nut is provided at the end of the extending mounting shaft.

[0010] Preferably, the corrugating knife is annular and adopts a stepped design. The inner hole diameter D of the corrugating knife is designed to be 1.35~1.4×D 波峰 , D 波峰 It is the outer diameter of the crest of the inner conductor of the spiral corrugated copper tube.

[0011] Preferably, the drying unit includes a base and a wind tube mounted on the base, and the wind tube is provided with a plurality of inclined holes with a square cross section, and the inclination angle of the inclined holes is 30°.

[0012] A method for welding and corrugating the inner conductor of a 5G leaky cable spiral corrugated copper tube adopts a 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device, and makes the copper strip pass through a tension unit, a cutter unit, a pressing plate unit, a forming unit, a drying unit, a traction unit and a corrugating unit in sequence. Specifically: S1, the copper strip enters the tension unit, which adjusts the tension of the copper strip and provides thrust for the copper strip, so that the copper strip enters the cutter unit; S2, the cutter unit cuts the copper strip to obtain a copper strip that meets the width requirements; S3, the shoe-shaped seat, trumpet die and sizing die of the forming unit bend the copper strip to form a round tube with an open top; S4, the welding unit welds the top opening of the round tube to form a copper tube; S5, the reducing die is used to calibrate the copper tube; S6, the cooling unit and the drying unit cool and dry the weld of the copper tube in turn; S7, the traction unit sends the dried copper tube to the corrugating unit; S8, the corrugating unit corrugates the outer wall of the copper tube to obtain a spirally corrugated copper tube inner conductor.

[0013] Preferably, in S5, the welding unit adopts argon arc welding for welding, and the welding current and production speed meet the following conditions: 实 =I 焊×v×δ+I0, where I 焊 is the welding current; v is the production speed; δ is the copper strip welding coefficient, which is 1.5~2.0; I0 is the welding zero speed current, which is 25%~30% of the welding current.

[0014] Preferably, in S8, during traction, the track tensioning pressure of the traction unit is 3.2 bar±0.5 bar, and the track pressing pressure is 1.4 bar±0.5 bar.

[0015] Preferably, in S9, during embossing, the embossing knife of the embossing unit and the axis of the copper tube have an angle , The range is 13°30′±30′.

[0016] Preferably, in S9, the peak outer diameter D of the inner conductor of the spiral corrugated copper tube is 波峰 for mm, trough outer diameter D 波谷 for mm, wrinkle pitch P is mm; within a pitch P, the peak accounts for 3 / 4, the trough accounts for 1 / 4, and the voltage standing wave ratio of the produced leaky cable in the application frequency band of 700MHz~3700MHz is ≤1.2.

[0017] Compared with the prior art, the present invention has the following beneficial effects: The present invention provides a 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device, which integrates key processes such as tension control, cutting, forming, welding, cooling, drying, pulling, and corrugating into a continuous production line, which can improve the structural uniformity of the inner conductor of the spiral corrugated copper tube. Specifically, the smooth copper strip enters the tension unit after unwinding, and the tension unit eliminates the stress of the copper strip formed by the coiling. At the same time, the tension unit provides a certain thrust for the copper strip to enter the production line, ensuring that the copper strip maintains a constant tension before entering the cutter unit. The cutter unit then cuts the copper strip to the required copper strip width, and the cut copper strip is flattened by the pressing plate unit and enters the forming unit. In the forming unit, the copper strip passes through a boot-shaped seat, a horn die, and a sizing die in sequence, and is gradually bent into a round tube with an open top in a progressive forming path. The length axis of the opening is parallel to the production axis. The top opening of the round tube is then welded by a welding unit to form a copper tube. The copper tube is then rounded through a reducing die, and the weld is cooled and dried using a cooling unit and a blow-drying unit. The tube is then fed into the corrugating unit through a traction unit. In the corrugating unit, the XYZ axis adjustment structure is used to adjust the size of the copper tube, and then the corrugating knife corrugates the outer wall of the copper tube. After corrugation, the copper tube enters the wire feed die. The wire feed conduit and the wire feed die cooperate with each other to prevent the copper tube from swinging up and down during corrugation, causing blockage. The wire outlet die is installed at the rear end to prevent the spirally corrugated copper tube from being bumped or damaged when exiting the corrugator. The device proposed by the present invention can more easily improve the uniformity, stability, and bendability of the inner conductor structure, thereby improving the product performance of 5G leaky cables at high frequencies, reducing the voltage standing wave ratio and improving transmission performance. The voltage standing wave ratio is ≤1.2 in the 700MHz~3700MHz application frequency band.

[0018] Furthermore, the XYZ-axis adjustment structure in the corrugating unit, combined with an adjustable rotating base, enables precise three-dimensional adjustment of the corrugating position and angle. Specifically, the inclination angle of the corrugating cutter axis can be adjusted using a mounting shaft and locking nut, ensuring high consistency in corrugation depth, pitch, and shape (peak / trough ratio). The cutter design also balances rigidity with roll-forming performance, reducing stress concentration.

[0019] Furthermore, the square cross-section of the hair dryer makes the airflow more concentrated, and the 30° bevel angle generates a shearing force that can effectively peel off the water film or water droplets on the surface of the copper tube, improving the drying efficiency and uniformity.

[0020] The initial flatness, width and the like of the copper strip are processed by the tension unit, the cutter unit and the pressing plate unit, then the rough round pipe is obtained by the progressive forming of the forming unit, the cooperation of the welding unit, the cooling unit and the blow-drying unit, then the rough round pipe is introduced into the rolling unit by the traction unit, the rolling action of the outer wall of the round pipe is performed by the XYZ axis adjusting structure and the rolling knife of the rolling unit, the production is completed by the cooperation between the device and the process parameters, and finally the stable, efficient and batch production of the high-precision spiral corrugated copper pipe inner conductor is realized.

[0021] Further, the welding current is limited to improve the welding appearance, reduce defects and improve the stability of the welding process.

[0022] Further, the high-speed operation of the rolling knife can cause the arc elastic deformation in the rolling of the welded copper pipe, and the angle between the rolling knife and the transverse section of the welded copper pipe is limited to eliminate the resonance point generated in the high-speed operation of the rolling knife. BRIEF DESCRIPTION OF DRAWINGS

[0023] Figure 1 is a schematic view of a 5G leak cable spiral corrugated copper pipe inner conductor welding and rolling device of the present application; Figure 2 is a structural schematic view of a boot-shaped seat in the 5G leak cable spiral corrugated copper pipe inner conductor welding and rolling device of the present application; Figure 3 is a structural schematic view of a rolling knife in the 5G leak cable spiral corrugated copper pipe inner conductor welding and rolling device of the present application; Figure 4 is a schematic view of a product obtained by the 5G leak cable spiral corrugated copper pipe inner conductor welding and rolling device of the present application; Figure 5 is a schematic view of a rolling welded copper pipe in the 5G leak cable spiral corrugated copper pipe inner conductor welding and rolling device of the present application.

[0024] In the figure, 1 is a copper strip; 2 is a tension unit; 3 is a cutter unit; 4 is a pressing plate unit; 5 is a forming unit; 5.1 is a boot-shaped seat; 5.11 is a sliding block; 5.12 is a support frame; 5.13 is an arc-shaped rod; 5.2 is a horn die; 5.3 is a sizing die; 5.4 is a reducing die; 6 is a welding unit; 6.1 is a welding gun; 6.2 is a tungsten electrode; 7 is a cooling unit; 8 is a copper pipe; 9 is a blow-drying unit; 10 is a traction unit; 11 is a rolling unit; 11.1 is an X-axis radial adjusting structure; 11.2 is a Y-axis transverse adjusting structure; 11.3 is a Z-axis phase adjusting structure; 11.4 is a rolling knife; 11.5 is an incoming wire guide pipe; 11.6 is an incoming wire die; 11.7 is an outgoing wire die; and 12 is a spiral corrugated copper pipe inner conductor. DETAILED DESCRIPTION​

[0025] The following describes the embodiments of the present invention through specific embodiments. Those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.

[0026] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. However, the present invention may be embodied in many different forms and is not limited to the embodiments described herein. These embodiments are provided so as to provide a thorough and complete disclosure of the present invention and fully convey the scope of the present invention to those skilled in the art. The terminology used in the exemplary embodiments shown in the accompanying drawings is not intended to limit the present invention. In the accompanying drawings, identical elements are denoted by the same reference numerals.

[0027] Unless otherwise specified, the terms used herein (including technical terms) have the meanings commonly understood by those skilled in the art. In addition, it is understood that terms defined in commonly used dictionaries should be understood to have the same meanings as those in the context of the relevant fields, and should not be understood as idealized or overly formal meanings.

[0028] The present invention will be further described in detail below with reference to specific embodiments, which are intended to explain the present invention rather than to limit it.

[0029] The present invention discloses a 5G leaky cable spiral corrugated copper tube inner conductor welding corrugation device, referring to Figure 1 , including a tension unit 2, a cutter unit 3, a pressing plate unit 4, a forming unit 5, a drying unit 9, a traction unit 10 and an embossing unit 11 which are arranged in sequence.

[0030] Tension unit 2 is used to adjust the tension of copper strip 1 and provide forward thrust. It comprises a first, second, and third guide pulleys arranged in parallel and rotating in sequence. The top of the first guide pulley and the bottom of the second guide pulley form a first channel for the raw material to pass through. The third guide pulley is identical to the first guide pulley. Tension unit 2 provides thrust for copper strip 1, ensuring constant tension before it enters cutter unit 3. This prevents the copper strip 1 from becoming too loose or too tight due to speed fluctuations during unwinding, which could affect production stability.

[0031] The cutter unit 3 is used to cut the copper strip 1 to the required width. The cutter unit 3 adopts a horizontal rolling cutting device and is equipped with an upper cutter and two lower cutters. The copper strip 1 is a smooth T2O60 copper strip 1 with a thickness t of 0.18-0.33mm and a width W of 45-59mm. The smooth copper strip 1 enters the cutter unit 3 through the tension unit 2. The copper strip 1 is finely cut on both sides by horizontal rolling cutting to the required width for the welding copper tube 8, that is, the width is × (Dt) + k × t, where: D is the inner diameter of the sizing die 5.3; t is the thickness of the copper strip 1; k is the coefficient.

[0032] The platen unit 4 is used to flatten the copper strip 1 and ensure its smoothness. The platen unit 4 comprises an upper platen and a lower platen positioned opposite each other. The lower platen is fixed to a workbench or the ground, and the upper platen is movably positioned above the lower platen. A second passage for the strip to pass through is defined between the lower and upper surfaces of the upper and lower plates. The distance between the upper and lower platens can be adjusted using a screw mechanism, hydraulic equipment, or a cylinder.

[0033] The forming unit 5 includes a coaxially arranged shoe seat 5.1, a trumpet die 5.2, a sizing die 5.3, and a reducing die 5.4. A welding unit 6 is disposed between the sizing die 5.3 and the reducing die 5.4. The inlet end of the trumpet die 5.2 is adjacent to the shoe seat 5.1, and the outlet end is adjacent to the sizing die 5.3. The trimmed copper strip 1 is sequentially formed into a round tube with an open top after passing through the shoe seat 5.1, the trumpet die, and the sizing die 5.3. After longitudinal welding by the welding unit 6, the copper tube 8 is calibrated using the reducing die 5.4. The trumpet die 5.2 and the sizing die 5.3 are both detachably connected to a workbench or the ground for easy position adjustment. The distance between them is between 50 and 100 mm, determined based on a weld seam width of 1 mm to 3 mm, a residual height of ≤1 mm, as well as the quality of the longitudinal package and uniform tension.

[0034] Reference Figure 2 The shoe-shaped seat 5.1 includes a slider 5.11, which is provided with a tapered arc groove parallel to the direction of the production line. Support frames 5.12 are also provided on both sides of the slider 5.11 along the forward direction of the copper strip 1. A movable arc rod 5.13 is provided on the support frame 5.12. The length axis of the arc rod 5.13 is parallel to the tapered line of the arc groove. A gap is left between the slider 5.11 and the arc rod 5.13. This gap can be adjusted by adjusting the height of the support frame 5.12 to gradually bend the two sides of the copper strip 1. The height of the support frame 5.12 can be adjusted using a pad, or the support frame 5.12 adopts a lifting structure, and the height adjustment of the support frame 5.12 makes the arc rod 5.13 adjusted synchronously, so that the width of the gap can be adjusted to adapt to the processing of round tubes of different specifications. After the copper strip 1 enters the shoe-shaped seat 5.1, the arc groove bends the copper strip 1. The raised ends of the copper strip 1 bend inward under the action of the arc rod 5.13, and move forward under the thrust of the unwinding device and the tension unit 2 to form a round tube with an open top.

[0035] The inlet width of the arc groove is 58mm, and the outlet width is 32mm; the width of the gap is twice the thickness of the copper strip, the diameter curvature radius of the horn die 5.2 gradually decreases, the diameter at the inlet is φ30mm, and the diameter at the outlet is φ16.5mm; the inlet chamfer R5 of the sizing die 5.3, the outlet chamfer R1, and the inner diameter is φ13.2mm; the diameter of the reducing die 5.4 is φ13.1mm.

[0036] Welding unit 6 is used to weld open-top copper tubes 8. The welding head of welding unit 6 is oriented toward the top opening of the circular tube, performing welding. Welding unit 6 comprises a welding gun 6.1 and a tungsten electrode 6.2, which serves as the welding head. The welding gun can be adjusted up, down, left, or right via a removable connection structure, such as a bolted adjustment ring or a combination of a clamp and a telescopic rod. In one embodiment, welding gun 6.1 utilizes a tungsten electrode 6.2 for welding. During welding, the tungsten electrode 6.2 is perpendicular to the weld seam, with a distance of 0.3 mm to 1 mm. The tungsten electrode 6.2 is a 3.2 mm diameter lanthanum tungsten electrode. The tip of the tungsten electrode is ground to a 45° to 60° taper angle using a dedicated sharpening machine, resulting in a 0.5 mm flat tip with a surface finish of 0.8 μm. The grinding direction is parallel to the length of the tungsten electrode 6.2 to prevent arc dispersion caused by transverse graining.

[0037] When welding round pipes, argon gas is used. The purity of argon gas is ≥99.99%, and the flow rate is controlled between 8L / min and 15L / min. The purpose is to stabilize the arc and prevent oxidation and leaks. At the same time, a solid-state video camera and display are also installed at the welding unit to allow personnel to observe the welding status of the weld in real time, adjust the position of the welding gun 6.1, and match the welding current with the production speed, that is, I 实 =I 焊 ×v×δ+I0, where I 实 is the real-time welding current, I 焊 is the welding current, v is the production speed, δ is the welding coefficient for copper strip 1, ranging from 1.5 to 2.0, and I0 is the zero-speed current. A value of 25% to 30% of the welding current is used to improve weld appearance, reduce defects, and further enhance welding process stability. For example, for welding a 0.32mm thick copper tube at a production speed of 10m / min, the welding current is set to 83.2A, δ is set to 0.1, the zero-speed current is 26A, and the real-time welding current is 105.6A.

[0038] A cooling unit 7 is provided between the reducing die 5.4 and the drying unit 9. The cooling unit 7 is used to cool the top weld of the copper tube 8. The cooling unit 7 adopts circulating water cooling, and distilled water is circulated to cool the weld. The flow rate of the distilled water is controlled at 1L / min.

[0039] The drying unit 9 is used to blow away moisture on the outer wall of the copper tube 8, with the air outlet of the drying unit 9 facing the outer wall of the copper tube 8. The drying unit 9 includes a base and a blower mounted on the base. The blower is provided with a plurality of oblique holes with a square cross-section of 2-4 mm x 2-4 mm, and an inclination angle of 30°.

[0040] Traction unit 10 is used to pull the copper tube 8 to the corrugating unit 11. It utilizes a crawler-type traction structure with a U-shaped track design. The track width is d + 0.1 mm and the height is d + 0.2 mm, where d is the diameter of the copper tube. During traction, the track tensioning pressure is 3.2 bar ± 0.5 bar, and the track compression pressure is 1.4 bar ± 0.5 bar, preventing the copper tube 8 from flattening and controlling the tube's ovality to within ± 0.2 mm.

[0041] The corrugating unit 11 comprises an XYZ-axis adjustment structure, an inlet guide tube 11.5, an inlet die 11.6, an embossing seat, and an outlet die 11.7. The XYZ-axis adjustment structure is controlled by a multi-axis coordinated control system and is used to adjust the dimensions of the copper tube 8. The XYZ-axis adjustment structure comprises an X-axis radial adjustment structure 11.1, a Y-axis lateral adjustment structure 11.2, and a Z-axis phase adjustment structure 11.3. The radial pressure of the X-axis radial adjustment structure 11.1 is linked to the thickness of the copper tube 8, preventing it from flattening during corrugation. The Y-axis lateral adjustment structure 11.2 is linked to the diameter of the copper tube 8, i.e., Y = d + 2h + γ, where d is the outer diameter of the copper tube 8, h is the corrugation depth, and γ is the copper springback, ranging from 0.02 mm to 0.05 mm, which improves the roundness of the copper tube 8. The Z-axis phase adjustment structure 11.3 is related to the production stability of the round tube and is used to prevent periodic changes in the structural dimensions of the round tube. Therefore, the X, Y, and Z axis parameters are coordinated with the process parameters, namely, 5.056 for the X axis, 4.389 for the Y axis, and 8.293 for the Z axis. The production speed of the copper tube 8 is 16 m / min, with a rotational speed ratio of 0.97. In one embodiment, the EtherCAT bus is used to synchronously control the three-axis motion, combining precision mechanics, servo control, and process algorithms. Actual adjustments require inputting parameters such as the outer diameter of the copper tube 8, the outer diameter of the corrugated trough, and the spiral corrugation pitch P based on actual production to precisely control the spatial position of the corrugating station.

[0042] The inlet conduit 11.5 guides the copper tube 8 into the corrugating knife 11.4, which is mounted on the corrugating base. The corrugating knife 11.4 corrugates the copper tube 8. Specifically, the corrugating base comprises a die base 5.12 and a rotating base. Both the rotating base and the die base support frame 5.12 are annular. The corrugating knife 11.4 is rotatably mounted on the inner side of the rotating base via an angular contact ball bearing, which ensures high-speed rotation of the corrugating knife 11.4. The corrugating knife 11.4 is embedded in the rotating base and secured with a circular metal plate larger than the corrugating knife 11.4. The circular metal plate has four evenly distributed holes, aligning with the holes on the corrugating knife 11.4. Four M4 bolts are used on each side to secure it.

[0043] Two mounting shafts are located on the outside of the rotating base. These are threaded into the die base, with the ends of the shafts extending 3cm beyond the die base. A locking nut is attached to one end of the shaft to lock the shaft in place. One end of the shaft has a hexagonal port designed to accept an external wrench, which adjusts the angle between the corrugating blade 11.4 and the copper tube 8, thereby varying the corrugation depth. Each clockwise rotation reduces the corrugation depth of the copper tube 8 by 1.2mm.

[0044] The corrugating knife 11.4 with adjustable angle is installed on the corrugating seat, refer to Figure 3 、 4 5. The corrugating blade 11.4 is annular and made of 40Cr. It undergoes quenching and low-temperature tempering, achieving a hardness of HRC50-50. The corrugating blade 11.4 features a stepped structure. Specifically, the inner ring thickness smoothly transitions from 4mm to a 2mm blade edge. The transition zone has an arc chamfer of R2, the blade edge has an arc chamfer of R1.5, and the inner hole diameter D is designed to be 1.35-1.4×d. As the welded copper tube 8 advances, one side of the corrugating blade 11.4 rolls around the welded copper tube 8 without relative friction, providing auxiliary force along the production line. The finished rolling results in arc-shaped troughs, avoiding "tube blockage" or voltage standing wave ratio degradation caused by corrugation instability.

[0045] The rotating base is connected to the die base through the mounting shaft and the locking nut, so that the angle of the corrugating base can be adjusted, and the corrugating knife 11.4 is deflected to form a certain angle with the cross section of the welded copper tube 8. , =arcsin(P / ( π), due to the high speed operation of the corrugating knife 11.4, the arc elastic deformation of the welded copper tube 8 during rolling will be caused. Reduce to , a certain periodic L defect is generated at the edge of the peak, and the corresponding resonant frequency is , if the resonant frequency In the application frequency band, by adjusting the angle Therefore, in order to suppress the arc elastic deformation of the copper tube 8 during the corrugation process, the angle Controlled at 13°30′±30′.

[0046] The inlet die 11.6 is used to maintain the forward direction of the copper tube, and the outlet die 11.7 is used to guide the copper tube 8 to leave the corrugating unit 11. In one embodiment, the distance between the inlet guide tube 11.5 and the corrugating knife 11.4 is 7mm-10mm.

[0047] The present invention discloses a 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device. The copper strip 1 passes through the tension unit 2, the cutter unit 3, the pressure plate unit 4, the forming unit 5, the drying unit 9, the traction unit 10 and the corrugating unit 11 in sequence after the strip is unwound. The tension unit 2 adjusts the tension of the copper strip 1 and pushes the copper strip 1 into the cutter unit 3. The cutter unit 3 cuts the copper strip 1 to the required width of the copper strip 1. The cut copper strip 1 enters the horn die 5.2 and the sizing die 5.3 to form a round tube with an open top. The top opening is welded by the welding unit 6 to form a copper tube 8. The copper tube 8 enters the reducing die 5.4 for roundness correction. The weld is then cooled and dried by the cooling unit 7 and the drying unit 9. The copper tube 8 is then sent to the corrugating unit 11 by the traction device. The size of the copper tube 8 is adjusted by the XYZ axis adjustment structure. The corrugating knife 11.4 corrugates the outside of the round tube. The tube is then sent out of the corrugating unit 11 by the wire inlet and outlet dies 11.7 to obtain the finished spirally corrugated inner conductor of the copper tube 8.

[0048] The present invention also discloses a method for welding and corrugating the inner conductor of a 5G leaky cable spiral corrugated copper tube, which uses a 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device to make a copper strip 1 pass through a tension unit 2, a cutter unit 3, a pressing plate unit 4, a forming unit 5, a drying unit 9, a traction unit 10 and a corrugating unit 11 in sequence. Specifically: S1, the copper strip enters the tension unit 2, which adjusts the tension of the copper strip 1 and provides thrust for the copper strip 1, so that the copper strip enters the cutter unit 3; S2, the cutter unit cuts the copper strip 1 to obtain the copper strip 1 that meets the width requirement; S3, the pressing plate unit 4 flattens the copper strip 1; S4, the shoe-shaped seat 5.1, the horn die 5.2 and the sizing die 5.3 of the forming unit 5 bend the copper strip 1 to form a round tube with an open top; S5, the welding unit 6 welds the top opening of the round tube to form a copper tube 8; wherein the welding unit 6 uses argon arc welding for welding, and the welding current and production speed meet the following requirements: I 实 =I 焊 ×v×δ+I0, where I 焊is the welding current; v is the production speed; δ is the welding coefficient of copper strip 1, which is 1.5~2.0; I0 is the welding zero speed current, which is 25%~30% of the welding current; S6, the reducing die 5.4 calibrates the copper tube 8; S7, the cooling unit 7 and the drying unit 9 cool and dry the weld of the copper tube 8 in sequence; S8, the traction unit 10 sends the dried copper tube 8 to the corrugating unit 11. During traction, the track tensioning pressure of the traction unit 10 is 3.2 bar ± 0.5 bar, and the track pressing pressure is 1.4 bar ± 0.5 bar; S9, the corrugating unit 11 corrugates the outside of the copper tube 8 to obtain a spiral corrugated copper tube inner conductor 12; wherein the corrugating knife 11.4 of the corrugating unit 11 and the axis of the copper tube 8 have an angle , The range is 13°30′±30′. The peak outer diameter D of the inner conductor 12 of the spiral corrugated copper tube is 波峰 for mm, trough outer diameter D 波谷 for mm, wrinkle pitch P is mm; within a pitch P, the peak accounts for 3 / 4, the trough accounts for 1 / 4, and the voltage standing wave ratio of the produced leaky cable in the application frequency band of 700MHz~3700MHz is ≤1.2.

[0049] The present invention discloses a device and method for welding and corrugating an inner conductor of a spirally corrugated copper tube of a 5G leaky cable. The device comprises a tension unit 2, a cutter unit 3, a pressing plate unit 4, a forming unit 5, a welding unit 6, a cooling unit 7, a blow-drying unit 9, a traction unit 10, and a corrugating unit 11. A smooth copper strip 1 enters the tension unit 2 after being unleashed, the tension is adjusted by the tension unit 1 and the strip is pushed into the cutter unit. The cutter unit 3 cuts the copper strip 1 to the required width and sequentially enters the horn die 5.2 and the sizing die 5.3 of the forming unit 5, gradually bending the copper strip 1 into a circular tube with an open top. The top opening is welded by the welding unit 6, and the welded copper tube 8 is rounded by a reducing die 5.4. The weld seam is then cooled and blow-dried by the cooling unit 7 and the blow-drying unit 9, respectively. The copper tube 8 is then sent to the corrugating unit 11 by the traction unit 10, and the corrugating unit 11 produces a spirally corrugated copper tube inner conductor 12 with a uniform structure and clear lines. The inner conductor of the spiral corrugated copper tube 8 requires a coordinated production process between the device and process parameters. This device and method improves the uniformity, stability, and bendability of the inner conductor structure, reducing copper consumption while ensuring the high-frequency performance of 5G leaky cables, lowering the voltage standing wave ratio (VSWR) and improving transmission performance. In the 700MHz to 3700MHz application frequency band, the VSWR is ≤1.2.

[0050] The above description is merely a preferred embodiment of the present invention and is not intended to impose any limitation on the technical solution of the present invention. Those skilled in the art should understand that, without departing from the spirit and principles of the present invention, the technical solution can also be subjected to several simple modifications and replacements, and these modifications and replacements are also within the scope of protection covered by the claims.

Claims

1. A 5G leaky cable spiral corrugated copper tube inner conductor welding corrugation device, characterized in that: It comprises a tension unit (2), a cutter unit (3), a pressing plate unit (4), a forming unit (5), a drying unit (9), a pulling unit (10) and an embossing unit (11) which are arranged in sequence; The tension unit (2) is used to adjust the tension of the copper strip (1) and provide a thrust for the copper strip (1) to move forward; The cutter unit (3) is used to cut the copper strip (1) to a required width; The pressing plate unit (4) is used to flatten the copper strip (1); The forming unit (5) comprises a shoe-shaped seat (5.1), a trumpet die (5.2), a sizing die (5.3) and a reducing die (5.4) which are coaxially arranged in sequence. The shoe-shaped seat (5.1), the trumpet die (5.2) and the sizing die (5.3) are used to gradually bend the copper strip (1) into a round tube with an open top. The shoe-shaped seat (5.1) includes a slider (5.11), a tapered arc groove is provided on the slider (5.11), and support frames (5.12) are provided on both sides of the slider (5.11) along the forward direction of the copper strip (1). An arc rod (5.13) is provided on the support frame (5.12), and the length axis of the arc rod (5.13) is parallel to the tapered line of the arc groove, and a gap is left between the slider (5.11) and the arc rod (5.13); The inlet end of the trumpet die (5.2) is close to the shoe-shaped seat (5.1), and the outlet end is close to the sizing die (5.3); A welding unit (6) is provided between the sizing die (5.3) and the reducing die (5.4), and the welding unit (6) is used to weld the top opening to form a copper tube (8), with the welding head of the welding unit (6) facing the top opening of the round tube; A cooling unit (7) for cooling the top weld of the copper tube (8) is provided between the reducing die (5.4) and the drying unit (9); The air outlet of the drying unit (9) faces the outer wall of the copper tube (8); The pulling unit (10) is used to pull the copper tube (8) to the corrugating unit (11); The corrugating unit (11) is used for rolling threads on the outer wall of the copper tube (8).

2. The 5G leaky cable spiral corrugated copper tube inner conductor welding corrugation device according to claim 1 is characterized in that: The corrugating unit (11) comprises an XYZ axis adjustment structure, an inlet guide tube (11.5), an inlet guide tube (11.6), and an outlet guide tube (11.7) which are arranged in sequence. The XYZ axis adjustment structure is used to adjust the size of the copper tube (8); the inlet guide tube (11.5) is used to guide the copper tube (8) into the corrugating knife (11.4); the corrugating knife (11.4) is installed on the inlet guide tube (11.4), and is used to corrugate the copper tube (8); the inlet guide tube (11.6) is used to maintain the forward direction of the copper tube, and the outlet guide tube (11.7) is used to guide the copper tube (8) out of the corrugating unit (11).

3. The 5G leaky cable spiral corrugated copper tube inner conductor welding corrugation device according to claim 2 is characterized in that: The corrugating base comprises a die base and a rotating base. Both the rotating base and the die base are annular. The corrugating knife (11.4) is rotatably mounted on the inner side of the rotating base. Two mounting shafts are arranged on the outer side of the rotating base. The mounting shafts are threadedly connected to the die base. The ends of the mounting shafts away from the rotating base extend out of the die base, and a locking nut is arranged on one end of the mounting shafts.

4. The 5G leaky cable spiral corrugated copper tube inner conductor welding corrugation device according to claim 2 is characterized in that: The corrugating knife (11.4) is annular and adopts a stepped design. The inner hole diameter D of the corrugating knife (11.4) is designed to be 1.35~1.4×D 波峰 , D 波峰 It is the outer diameter of the crest of the inner conductor (12) of the spiral corrugated copper tube.

5. The 5G leaky cable spiral corrugated copper tube inner conductor welding corrugation device according to claim 1 is characterized in that: The drying unit (9) comprises a base and a wind tube mounted on the base, wherein a plurality of oblique holes with square cross sections are provided on the wind tube, and the inclination angle of the oblique holes is 30 degrees.

6. A method for welding and corrugating the inner conductor of a 5G leaky cable spirally corrugated copper tube, using the 5G leaky cable spirally corrugated copper tube inner conductor welding and corrugating device according to any one of claims 1 to 5, characterized in that: The copper strip (1) is sequentially passed through a tension unit (2), a cutter unit (3), a pressing plate unit (4), a forming unit (5), a drying unit (9), a pulling unit (10) and an embossing unit (11), specifically: S1, the copper strip enters the tension unit (2), the tension unit (2) adjusts the tension of the copper strip (1), and at the same time provides a thrust for the copper strip (1), so that the copper strip enters the cutter unit (3); S2, the cutter unit (3) cuts the copper strip (1) to obtain a copper strip (1) that meets the width requirement; S3, the pressing plate unit (4) flattens the copper strip (1); S4, the shoe-shaped seat (5.1), the trumpet die (5.2) and the sizing die (5.3) of the forming unit (5) bend the copper strip (1) to form a round tube with an open top; S5, the welding unit (6) welds the top opening of the round tube to form a copper tube (8); S6, the reducing die (5.4) is used to calibrate the copper tube (8); S7, the cooling unit (7) and the drying unit (9) cool and dry the weld of the copper tube (8) in sequence; S8, the traction unit (10) sends the dried copper tube (8) to the corrugation unit (11); S9, the corrugating unit (11) corrugates the outer wall of the copper tube (8) to obtain a spiral corrugated copper tube inner conductor (12).

7. The method for welding and corrugating the inner conductor of a spirally corrugated copper tube of a 5G leaky cable according to claim 6, characterized in that: In S5, the welding unit (6) uses argon arc welding for welding, and the welding current and production speed meet the following requirements: I 实 =I 焊 ×v×δ+I0, where I 焊 is the welding current; v is the production speed; δ is the welding coefficient of the copper strip (1), which is 1.5~2.0; I0 is the zero-speed welding current, which is 25%~30% of the welding current.

8. The method for welding and corrugating the inner conductor of a spirally corrugated copper tube of a 5G leaky cable according to claim 6, characterized in that: In S8, during traction, the track tensioning pressure of the traction unit (10) is 3.2 bar ± 0.5 bar, and the track pressing pressure is 1.4 bar ± 0.5 bar.

9. The method for welding and corrugating the inner conductor of a spirally corrugated copper tube of a 5G leaky cable according to claim 6, characterized in that: In S9, during embossing, the embossing knife (11.4) of the embossing unit (11) is at an angle to the axis of the copper tube (8). , The range is 13°30′±30′.

10. The method for welding and corrugating the inner conductor of a spirally corrugated copper tube of a 5G leaky cable according to claim 6, characterized in that: In S9, the peak outer diameter D of the spiral corrugated copper tube inner conductor (12) is 波峰 for mm, trough outer diameter D 波谷 for mm, wrinkle pitch P is mm; within a pitch P, the peak accounts for 3 / 4, the trough accounts for 1 / 4, and the voltage standing wave ratio of the produced leaky cable in the application frequency band of 700MHz~3700MHz is ≤1.2.

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