A device and method for welding and corrugating the inner conductor of a spiral corrugated copper tube for 5G leaky cable

Abstract

This invention relates to the field of communication wire and cable technology, specifically to a welding and corrugating device and method for the inner conductor of a 5G leaky cable spiral corrugated copper tube. The device includes a tension unit, a cutting unit, a pressure plate unit, a forming unit, a drying unit, a traction unit, and a corrugating unit arranged sequentially. The tension unit, cutting unit, and pressure plate unit process the initial flatness and width of the copper strip. After progressive forming by the forming unit, a rough round tube is obtained in conjunction with the welding unit, cooling unit, and drying unit. Then, the tube is guided by the traction unit to the corrugating unit, where a corrugating knife corrugates the outer wall of the copper tube. This ultimately achieves stable, efficient, and mass production of the inner conductor of a high-precision spiral corrugated copper tube.

Description

Technical Field

[0001] This invention relates to the field of communication wire and cable technology, specifically to a device and method for welding and corrugating the inner conductor of a spiral corrugated copper tube for 5G leaky cables. Background Technology

[0002] During signal transmission, if the signal source impedance is mismatched with the feeder impedance or the load impedance is mismatched with the feeder impedance, the signal will be reflected during transmission. At this time, both incident and reflected waves exist simultaneously on the leaky coaxial cable, and their superposition forms a standing wave. The voltage standing wave ratio (VSWR) reflects the electrical performance of the structural uniformity and stability. A leaky coaxial cable consists of an inner conductor, physically foamed insulation, an outer conductor, and a sheath. The inner conductor is generally made of smooth copper tubing or spiral corrugated copper tubing. The spiral corrugated copper tubing inner conductor is made by longitudinally wrapping, welding, and spirally corrugating copper strip. The spiral corrugated copper tubing inner conductor plays a crucial role in the leaky cable: firstly, it improves the cable's flexibility; secondly, its material cost is lower than that of smooth copper tubing; and thirdly, the uniformity of its structural dimensions (crests, troughs, pitch, etc.) and its appearance quality have a significant impact on the attenuation constant and VSWR.

[0003] Chinese invention patent application CN202410353596.7 discloses a design method for a metal welded corrugated tube sheath of 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, including one or more of the following parameters: diameter of the longitudinally wrapped metal tube, width of the longitudinally wrapped metal strip, corrugation depth, and corrugation pitch; S3: completing the manufacturing of the metal welded corrugated tube sheath according to the manufacturing parameters, which can achieve consistency and stability in the process structure and quality of the metal threaded tube of the mineral-insulated cable.

[0004] However, the above design method is mainly a design method for welding corrugated tube sheaths to ensure that mineral-insulated cables can pass bending withstand voltage test, flattening withstand voltage test and combustion fire resistance test. It mainly involves models and size calculations, but cannot determine the uniformity of dimensions during production and processing. It does not describe how to achieve the process and equipment. However, this product belongs to the power industry and its performance requirements are bending withstand voltage test, flattening withstand voltage test and combustion fire resistance test.

[0005] Chinese invention patent application CN107819178A discloses a 5G band dedicated ultra-flexible low-loss coaxial cable and its preparation method. In the preparation process, the inner conductor and / or the outer conductor are first made by passing copper strip through a U-shaped groove, a horn mold and a forming mold to form a circle, and then the opening is welded together by argon arc welding. After that, the welded copper tube is corrugated by an eccentric corrugating equipment. The thread pitch is shortened and the corrugation depth is increased by adjusting the traction speed of the copper strip in the longitudinal forming, welding and corrugating integrated equipment to improve its flexibility.

[0006] However, the process described in the aforementioned patent carries the risk of copper tube deformation due to direct rolling after welding. The stability of the rolling depends on the adjustment of the traction speed, which can easily lead to uneven pitch and make it difficult to guarantee high-quality processing of the inner conductor. In particular, when using thin copper strip to produce spiral copper tube inner conductors, the shallow rolling and large pitch make it easy for deformation to occur during unfolding and rewinding, resulting in high-frequency resonance and a large voltage standing wave ratio. Summary of the Invention

[0007] To address the problems in existing technologies where shallow corrugations and large pitches cause deformation during the production of spiral corrugated copper tube inner conductors from thin copper strips, resulting in high-frequency resonance and high voltage standing wave ratio, this invention provides a welding and corrugating device and method for spiral corrugated copper tube inner conductors in 5G leaky cable production.

[0008] This invention is achieved through the following technical solution:

[0009] A 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device includes a tension unit, a cutting unit, a pressure plate unit, a forming unit, a drying unit, a traction unit and a corrugating unit arranged in sequence.

[0010] The tension unit is used to adjust the tension of the copper strip;

[0011] The cutting unit is used to cut the copper strip to the required width;

[0012] The pressure plate unit is used to flatten the copper strip;

[0013] The forming unit includes a boot-shaped seat, a horn mold, a sizing mold and a reducing mold arranged coaxially in sequence. The boot-shaped seat, the horn mold and the sizing mold are used to gradually bend the copper strip into a round tube with an open top.

[0014] The boot-shaped seat includes a slider with a tapered arc groove. Support frames are provided on both sides of the slider as it advances along the copper strip. Movable arc rods are provided on the support frames. The longitudinal axis of the arc rods is parallel to the tapering line of the arc groove. A gap is left between the slider and the arc rods.

[0015] The inlet end of the horn mold is close to the boot-shaped seat, and the outlet end is close to the sizing mold;

[0016] A welding unit is set 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.

[0017] A cooling unit for cooling the top weld of the copper tube is provided between the reducing die and the drying unit;

[0018] The air vents of the drying unit face the outer wall of the copper tube;

[0019] The traction unit is used to pull the copper tube to the corrugating unit;

[0020] The threading unit is used to roll threads on the outside of a copper tube.

[0021] Preferably, the texturing unit includes an XYZ axis adjustment structure, an inlet guide tube, a texturing seat, an inlet die, and an outlet die arranged sequentially. 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 texturing blade; the texturing blade is mounted on the texturing seat and is used to texture 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 out of the texturing unit.

[0022] Preferably, the embossing seat includes a die holder and a rotating base. Both the rotating base and the die holder are annular. The embossing cutter is rotatably mounted on the inner side of the rotating base. Two mounting shafts are provided on the outer side of the rotating base. The mounting shafts are threadedly connected to the die holder. The end of the mounting shaft away from the rotating base extends out of the die holder, and a locking nut is provided at the end of the extended mounting shaft.

[0023] Preferably, the texturing cutter is annular, with a stepped design, and the inner diameter D of the cutter 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-shaped corrugated copper tube.

[0024] Preferably, the drying unit includes a base and a blower mounted on the base, the blower having multiple oblique holes with a square cross-section and an inclination angle of 30°.

[0025] A method for welding and corrugating the inner conductor of a spiral corrugated copper tube for 5G leaky cable, employing a welding and corrugating device for the inner conductor of a spiral corrugated copper tube for 5G leaky cable, wherein the copper strip sequentially passes through a tension unit, a cutting unit, a pressure plate unit, a forming unit, a drying unit, a traction unit, and a corrugating unit, specifically:

[0026] S1, the copper strip enters the tension unit, the tension of the copper strip is adjusted by the tension unit, and at the same time, the copper strip is pushed so that the copper strip enters the cutting unit;

[0027] S2, the cutting unit cuts the copper strip to obtain a copper strip that meets the width requirements;

[0028] S3, the boot-shaped seat, horn mold and sizing mold of the forming unit bend the copper strip to form a round tube with an open top;

[0029] S4, the welding unit welds the top opening of the round tube to form a copper tube;

[0030] S5, the reducing die is used to round the copper tube;

[0031] S6, the cooling unit and the drying unit sequentially cool and dry the weld seam of the copper tube;

[0032] S7, the traction unit sends the dried copper tube into the corrugating unit;

[0033] S8, the corrugating unit corrugates the outer wall of the copper tube to obtain a spiral-shaped corrugated copper tube inner conductor.

[0034] Preferably, in S5, the welding unit uses argon arc welding, and the welding current and production speed satisfy: I 实 =I 焊 ×v×δ+I0, where I 焊 δ is the welding current; v is the production speed; δ is the copper strip welding coefficient, taken as 1.5~2.0; I0 is the zero-speed welding current, taken as 25%~30% of the welding current.

[0035] Preferably, in S8, during traction, the track tension pressure of the traction unit is 3.2 bar ± 0.5 bar, and the track clamping pressure is 1.4 bar ± 0.5 bar.

[0036] Preferably, in S9, during the corrugating process, the corrugating blade of the corrugating unit forms an angle with the axis of the copper tube. , The range is 13°30′±30′.

[0037] Preferably, in S9, the outer diameter D of the crest of the inner conductor of the spiral corrugated copper tube is... 波峰 for mm, outer diameter of the trough D 波谷 for mm, wrinkle pitch P is mm; within a pitch P, the peak ratio is 3 / 4 and the trough ratio is 1 / 4, and the voltage standing wave ratio of the produced leaky cable is ≤1.2 in the application frequency band of 700MHz~3700MHz.

[0038] Compared with the prior art, the present invention has the following beneficial effects:

[0039] This invention discloses a welding and corrugating device for the inner conductor of a 5G leaky cable spiral corrugated copper tube. It integrates key processes such as tension control, cutting, forming, welding, cooling, drying, traction, and corrugating into a continuous production line, improving the uniformity of the inner conductor structure of the spiral corrugated copper tube. Specifically, a smooth copper strip enters the tension unit after being unloaded. The tension unit eliminates the stress caused by the coiling of the copper strip and provides a certain thrust for the copper strip to enter the production line, ensuring a constant tension before the copper strip enters the cutting unit. The cutting unit then cuts the copper strip to the required width. The cut copper strip is flattened by the pressure plate unit and enters the forming unit. In the forming unit, the copper strip passes sequentially through a shoe-shaped seat, a trumpet mold, and a sizing mold, gradually bending the copper strip 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. Finally, the welding unit welds the top opening of the round tube to form the copper tube. The copper tube is then rounded using a reducing die, followed by cooling and drying of the weld seam using a cooling and drying unit. Afterward, the copper tube is fed into the corrugating unit via a traction unit. In the corrugating unit, the dimensions of the copper tube are adjusted using an XYZ axis adjustment structure. Then, a corrugating cutter corrugates the outer wall of the copper tube. After corrugation, the copper tube enters the infeed die. The infeed guide tube and the infeed die work together to prevent the copper tube from swaying up and down during corrugation, which could cause blockage. The exit die is installed at the rear end to prevent the spirally corrugated copper tube from being bumped or damaged when exiting the corrugating machine. The device proposed in this invention can more easily improve the uniformity, stability, and flexibility of the inner conductor structure, thereby improving the product performance of 5G leaky cables at high frequencies, reducing the voltage standing wave ratio (VSWR), and improving transmission performance, achieving a VSWR ≤1.2 in the 700MHz~3700MHz application frequency band.

[0040] Furthermore, the XYZ axis adjustment structure in the riveting unit, combined with an adjustable rotating base, enables three-dimensional precision adjustment of the riveting position and angle. Specifically, the tilt angle of the riveting cutter axis can be adjusted by mounting the shaft and locking nut, ensuring high consistency in riveting depth, pitch, and shape (peak / trough ratio). The cutter design also balances rigidity and rolling forming effect, reducing stress concentration.

[0041] Furthermore, the square cross-section of the air duct makes the airflow more concentrated, and the 30° angle generates a shearing force, which can effectively peel off the water film or water droplets on the surface of the copper tube, improving the drying efficiency and uniformity.

[0042] This invention discloses a method for welding and corrugating the inner conductor of a spiral corrugated copper tube for 5G leaky cables. The tension unit, cutting unit, and pressure plate unit process the initial flatness and width of the copper strip. After progressive forming by the forming unit, a rough round tube is obtained in conjunction with the welding unit, cooling unit, and drying unit. Then, the tube is guided by the traction unit to the corrugating unit. The corrugating unit uses an XYZ axis adjustment structure and a corrugating blade to perform corrugation on the outer wall of the round tube. Through the coordination of the device and process parameters, production is completed, ultimately achieving stable, efficient, and mass production of high-precision spiral corrugated copper tube inner conductors.

[0043] Furthermore, limiting the welding current is to improve the weld appearance, reduce defects, and enhance the stability of the welding process.

[0044] Furthermore, the high-speed rotation of the texturing cutter causes arc-shaped elastic deformation during the rolling of the welded copper tube, affecting the angle between the texturing cutter and the cross-section of the welded copper tube. The limitation is to eliminate the resonance point generated during the high-speed operation of the texturing knife. Attached Figure Description

[0045] Figure 1 This is a schematic diagram of a 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device according to the present invention.

[0046] Figure 2 This is a schematic diagram of the boot-shaped seat in the welding and corrugating device for the inner conductor of a spiral corrugated copper tube for 5G leaky cable according to the present invention.

[0047] Figure 3 This is a schematic diagram of the corrugating knife in the corrugating device for welding the inner conductor of a spiral corrugated copper tube for 5G leaky cable according to the present invention.

[0048] Figure 4 This is a schematic diagram of the product obtained by the 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device of the present invention.

[0049] Figure 5 This is a schematic diagram of the corrugated copper tube in the spiral corrugated copper tube welding device for 5G leaky cable according to the present invention.

[0050] In the diagram, 1. Copper strip; 2. Tension unit; 3. Cutting unit; 4. Pressure plate unit; 5. Forming unit; 5.1. Boot-shaped seat; 5.11. Slider; 5.12. Support frame; 5.13. Arc rod; 5.2. Horn mold; 5.3. Sizing mold; 5.4. Reducing mold; 6. Welding unit; 6.1. Welding torch; 6.2. Tungsten electrode; 7. Cooling unit; 8. Copper tube; 9. Drying unit; 10. Traction unit; 11. Corrugated unit; 11.1. X-axis radial adjustment structure; 11.2. Y-axis lateral adjustment structure; 11.3. Z-axis phase adjustment structure; 11.4. Corrugated knife; 11.5. Inlet conduit; 11.6. Inlet mold; 11.7. Outlet mold; 12. Spiral corrugated copper tube inner conductor. Detailed Implementation

[0051] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.

[0052] 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 to fully and completely disclose the invention and to fully convey its scope to those skilled in the art. The terminology used in the exemplary embodiments illustrated in the drawings is not intended to limit the invention. In the drawings, the same units / elements are referred to by the same reference numerals.

[0053] Unless otherwise stated, the terms used herein (including technical terms) have their common meaning as understood by one of ordinary skill in the art. Furthermore, it is understood that terms defined in commonly used dictionaries should be understood to have a meaning consistent with the context of their relevant field, and not to be interpreted as having an idealized or overly formal meaning.

[0054] The present invention will be further described in detail below with reference to specific embodiments. These descriptions are for explanation purposes only and are not intended to limit the scope of the invention.

[0055] This invention discloses a device for welding and corrugating the inner conductor of a spiral corrugated copper tube for 5G leaky cable, with reference to... Figure 1 It includes a tension unit 2, a cutter unit 3, a pressure plate unit 4, a forming unit 5, a drying unit 9, a traction unit 10, and a texturing unit 11 arranged in sequence.

[0056] The tension unit 2 is used to adjust the tension of the copper strip 1 and provide thrust for its forward movement. The tension unit 2 includes a first guide wheel, a second guide wheel, and a third guide wheel arranged in parallel and rotating in sequence. A first channel for the raw material strip is formed between the top of the first guide wheel and the bottom of the second guide wheel. The third guide wheel is identical to the first guide wheel. The tension unit 2 provides thrust to the copper strip 1, ensuring that the copper strip 1 maintains a constant tension before entering the cutting unit 3. This prevents the copper strip 1 from becoming too loose or too tight due to speed changes during unwinding, thus avoiding impacts on production stability.

[0057] Cutting unit 3 is used to cut copper strip 1 to the required width. Cutting unit 3 is a horizontal rolling cutter with one upper cutter and two lower cutters. Copper strip 1 is a smooth T2O60 copper strip with a thickness t of 0.18~0.33mm and a width W of 45~59mm. The smooth copper strip 1 enters the cutting unit 3 via tension unit 2, and both sides of the copper strip 1 are horizontally rolled to precisely cut to the required width for welding copper pipe 8, i.e., the width is... ×(Dt)+k×t, where: D is the inner diameter of the sizing die 5.3; t is the thickness of copper strip 1; k is a coefficient.

[0058] The pressure plate unit 4 is used to flatten the copper strip 1, ensuring its flatness. The pressure plate unit 4 includes an upper pressure plate and a lower pressure plate arranged opposite each other. The lower pressure plate is fixed to the workbench or the ground, and the upper pressure plate is movably positioned above the lower pressure plate. A second channel for the strip is provided between the lower surface of the upper pressure plate and the upper surface of the lower pressure plate. The distance between the upper and lower pressure plates can be adjusted using a screw structure, hydraulic equipment, or pneumatic cylinder equipment.

[0059] The forming unit 5 includes a boot-shaped seat 5.1, a horn mold 5.2, a sizing mold 5.3, and a reducing mold 5.4 arranged coaxially in sequence. A welding unit 6 is set between the sizing mold 5.3 and the reducing mold 5.4. The inlet end of the horn mold 5.2 is close to the boot-shaped seat 5.1, and the outlet end is close to the sizing mold 5.3. The cut copper strip 1 passes through the boot-shaped seat 5.1, the horn mold, and the sizing mold 5.3 in sequence to form a round tube with an open top. After longitudinal welding by the welding unit 6, the copper tube 8 is rounded by the reducing mold 5.4. The horn mold 5.2 and the sizing mold 5.3 are detachably connected to the worktable or the ground to facilitate position adjustment. The distance between them is between 50 and 100 mm, which is determined based on the weld width of 1 mm to 3 mm, the excess height of ≤ 1 mm, and the longitudinal wrapping quality and tension uniformity.

[0060] Reference Figure 2The boot-shaped seat 5.1 includes a slider 5.11, on which a tapered arc groove parallel to the production line direction is formed. Support frames 5.12 are also provided on both sides of the slider 5.11 along the forward direction of the copper strip 1. Movable arc rods 5.13 are mounted on the support frames 5.12. The longitudinal axis of the arc rods 5.13 is parallel to the tapering line of the arc groove. A gap is left between the slider 5.11 and the arc rods 5.13. This gap can be adjusted by adjusting the height of the support frames 5.12, causing the copper strip 1 to gradually bend on both sides. The height of the support frames 5.12 can be adjusted using shims, or the support frames 5.12 can adopt a lifting structure, allowing the arc rods 5.13 to be adjusted synchronously with the height adjustment of the support frames 5.12, thereby adjusting the width of the gap and adapting to the processing of round tubes of different specifications. After the copper strip 1 enters the boot-shaped seat 5.1, the arc groove bends the copper strip 1. The two ends of the copper strip 1 that are raised are bent inward under the action of the arc rod 5.13. Under the pushing action of the tape feeding device and the tension unit 2, it moves forward to form a round tube with an open top.

[0061] The inlet width of the arc groove is 58mm and the outlet width is 32mm; the gap width is twice the thickness of the copper strip; the diameter radius of curvature of the horn mold 5.2 gradually decreases, with an inlet diameter of φ30mm and an outlet diameter of φ16.5mm; the inlet chamfer of the sizing mold 5.3 is R5, the outlet chamfer is R1, and the inner diameter is φ13.2mm; the diameter of the reducing mold 5.4 is φ13.1mm.

[0062] Welding unit 6 is used to weld the copper tube 8 with a top opening. The welding head of welding unit 6 faces the top opening of the round tube and welds the top opening of the round tube. Welding unit 6 includes a welding torch 6.1 and a tungsten electrode 6.2 as the welding head. The position of the welding torch can be adjusted up, down, left, and right through a detachable connection structure, such as an adjusting ring fixed with bolts or a combination of a clamp and a telescopic rod. In one embodiment, the welding torch 6.1 uses the tungsten electrode 6.2 for welding. During welding, the tungsten electrode 6.2 is perpendicular to the weld seam, with a distance of 0.3mm to 1mm. The tungsten electrode 6.2 is a 3.2mm lanthanum tungsten electrode. A special grinding machine is used to grind the tip of the tungsten electrode to a cone angle of 45° to 60°, and the tip is ground flat to a 0.5mm flat head, with a surface finish of 0.8μm. The grinding direction is parallel to the length direction of the tungsten electrode 6.2 to avoid transverse lines causing arc dispersion.

[0063] When welding round tubes, argon gas with a purity ≥99.99% is used, and the flow rate is controlled between 8L / min and 15L / min to stabilize the arc and prevent oxidation and incomplete welding. Simultaneously, a solid-state video camera and monitor are installed at the welding unit to allow personnel to observe the welding process in real time, adjust the position of the welding torch (6.1), and match the welding current with the production speed (I). 实 =I焊 ×v×δ+I0, where I 实 For real-time welding current, I 焊 Where is the welding current, v is the production speed, δ is the welding coefficient for copper strip 1 (1.5~2.0), and I0 is the zero-speed welding current, taken as 25%~30% of the welding current, to improve the weld appearance, reduce defects, and further enhance the stability of the welding process. For example, when welding a 0.32mm thick copper tube at a production speed of 10m / min, the welding current is set to 83.2A, δ is taken as 0.1, the zero-speed current is 26A, and the real-time welding current is 105.6A.

[0064] 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 uses circulating water cooling, with distilled water circulating directly onto the weld for cooling. The flow rate of the distilled water is controlled at 1L / min.

[0065] The drying unit 9 is used to blow away the moisture on the outer wall of the copper tube 8, and the air outlet of the drying unit 9 faces the outer wall of the copper tube 8. The drying unit 9 includes a base and an air duct mounted on the base. The air duct is provided with multiple oblique holes with a cross-section of 2~4mm×2~4mm square, and the oblique angle of the oblique holes is 30°.

[0066] The traction unit 10 is used to pull the copper tube 8 to the corrugated unit 11. The traction unit 10 adopts a tracked traction structure. The track is designed with a U-shaped groove structure, with a width of d+0.1mm and a height of d+0.2mm, where d is the diameter of the copper tube. During traction, the track tension pressure is 3.2bar±0.5bar, and the track clamping pressure is 1.4bar±0.5bar, which can prevent the copper tube 8 from being flattened, and the ellipticity of the copper tube 8 is controlled within ±0.2mm.

[0067] The crimping unit 11 includes, in sequence, an XYZ axis adjustment structure, an inlet guide tube 11.5, an inlet die 11.6, a crimping seat, and an outlet die 11.7. The XYZ axis adjustment structure is controlled by a multi-axis collaborative control system to adjust the dimensions of the copper tube 8. The XYZ axis adjustment structure includes 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 pressing of the X-axis radial adjustment structure 11.1 is related to the thickness of the copper tube 8 and is used to prevent the copper tube 8 from being flattened during crimping. The Y-axis lateral adjustment structure 11.2 is related to the diameter of the copper tube 8, i.e., Y = d + 2h + γ, where the outer diameter of the copper tube 8 is d, the crimping depth is h, and γ is the springback of the copper, which is taken as 0.02mm~0.05mm, which can improve 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 the structural dimensions of the round tube from changing periodically. Therefore, the parameters of the XYZ axes are coordinated with the process parameters, namely, X-axis is 5.056, Y-axis is 4.389, and Z-axis is 8.293, the production speed of copper tube 8 is 16 m / min, and the speed ratio is 0.97. In one embodiment, the three-axis motion is synchronously controlled using an EtherCAT bus, combining precision mechanics, servo control, and process algorithms. In actual adjustments, the spatial position of the corrugated board needs to be precisely controlled by combining parameters such as the outer diameter of copper tube 8, the outer diameter of the trough, and the pitch P of the spiral wrinkles, which are input from actual production data.

[0068] The inlet conduit 11.5 guides the copper tube 8 into the texturing blade 11.4. The texturing blade 11.4 is mounted on the texturing base and is used to texture the copper tube 8. Specifically, the texturing base includes a die base 5.12 and a rotating base. Both the rotating base and the die base support frame 5.12 are annular. The texturing blade 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 texturing blade 11.4. The texturing blade 11.4 is embedded in the rotating base and fixed with a circular metal plate larger than the texturing blade 11.4. The circular metal plate has four evenly distributed holes, which are evenly distributed with the holes on the texturing blade 11.4. It is fixed on each side with four M4 bolts.

[0069] Two mounting shafts are provided on the outer side of the rotating base. The mounting shafts are threaded to the mold base, and the ends of the mounting shafts extend 3cm beyond the mold base. A locking nut is provided at one end of the mounting shaft to lock its position. One end of the mounting shaft is machined into a hexagonal shape to cooperate with an external wrench, which can adjust the angle between the embossing cutter 11.4 and the copper tube 8 to change the embossing depth. One clockwise rotation reduces the embossing depth of the copper tube 8 by 1.2mm.

[0070] An adjustable-angle crimping cutter 11.4 is mounted on the crimping seat, refer to... Figure 3 , 45. The texturing cutter 11.4 is ring-shaped and made of 40Cr. It undergoes quenching and low-temperature tempering to achieve a hardness of HRC50-50. The texturing cutter 11.4 has a stepped structure; specifically, the inner ring thickness smoothly transitions from 4mm to 2mm at the cutting edge. The transition area has a chamfer of R2, and the cutting edge has a chamfer of R1.5. The inner diameter D is designed to be 1.35~1.4×d. As the welded copper tube 8 advances, one side of the texturing cutter 11.4 rolls around the tube without relative friction, providing auxiliary force along the production line direction. The finishing roll forms an arc-shaped trough, avoiding "tube blockage" or voltage standing wave ratio degradation caused by unstable texturing.

[0071] The rotating base and the mold base are connected by a mounting shaft and a locking nut, making the angle of the texturing base adjustable. The texturing cutter 11.4 deflects at a certain angle to the cross-section of the welded copper tube 8. , =arcsin(P / ( π), because the high-speed rotation of the rolling cutter 11.4 will cause the arc-shaped elastic deformation of the welded copper tube 8 during rolling, making the angle Reduce to A periodic L-shaped defect is generated at the edge of the wave crest, and the corresponding resonant frequency is... If the resonant frequency Within the applied frequency band, the angle is adjusted. To eliminate the resonance point. Therefore, in order to suppress the arc-shaped elastic deformation of the copper tube 8 during the rolling process, the angle... Controlled within 13°30′±30′.

[0072] The infeed die 11.6 is used to maintain the forward direction of the copper tube, and the outfeed die 11.7 is used to guide the copper tube 8 away from the corrugating unit 11. In one embodiment, the distance between the infeed guide tube 11.5 and the corrugating blade 11.4 is 7mm to 10mm.

[0073] This invention discloses a 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device. The copper strip 1 is fed sequentially through a tension unit 2, a cutting unit 3, a pressure plate unit 4, a forming unit 5, a drying unit 9, a traction unit 10, and a corrugating unit 11. The tension unit 2 adjusts the tension of the copper strip 1 and pushes it into the cutting unit 3. The cutting unit 3 cuts the copper strip 1 to the required width. The cut copper strip 1 then enters a horn mold 5.2 and a sizing mold 5.3 to form a round tube with an open top. The top opening is welded by welding unit 6 to form copper tube 8. Copper tube 8 enters the reducing die 5.4 for rounding. Then, the weld is cooled and dried by cooling unit 7 and drying unit 9. After that, copper tube 8 is sent to the corrugating unit 11 by traction device. The size of copper tube 8 is adjusted by XYZ axis adjustment structure. Corrugation is performed on the outside of the round tube by corrugating knife 11.4. Then, it is sent out of corrugating unit 11 by infeed die and outfeed die 11.7 to obtain the inner conductor of finished spiral corrugated copper tube 8.

[0074] This invention also discloses a method for welding and corrugating the inner conductor of a spiral corrugated copper tube for 5G leaky cable. The method employs a welding and corrugating device for the inner conductor of a spiral corrugated copper tube for 5G leaky cable, in which the copper strip 1 sequentially passes through a tension unit 2, a cutting unit 3, a pressure plate unit 4, a forming unit 5, a drying unit 9, a traction unit 10, and a corrugating unit 11. Specifically:

[0075] S1, the copper strip enters the tension unit 2, the tension of the copper strip 1 is adjusted by the tension unit 2, and at the same time, the copper strip 1 is provided with a thrust so that the copper strip enters the cutting unit 3.

[0076] S2, the cutting unit cuts the copper strip 1 to obtain a copper strip 1 that meets the width requirements;

[0077] S3, pressure plate unit 4 flattens copper strip 1;

[0078] S4, the boot-shaped seat 5.1, the horn mold 5.2 and the sizing mold 5.3 of the forming unit 5 bend the copper strip 1 to form a round tube with an open top;

[0079] S5, welding unit 6 welds the top opening of the circular tube to form copper tube 8; wherein, welding unit 6 uses argon arc welding, and the welding current and production speed satisfy: I 实 =I 焊 ×v×δ+I0, where I 焊 δ is the welding current; v is the production speed; δ is the welding coefficient of copper strip 1, which is taken as 1.5~2.0; I0 is the zero-speed welding current, which is taken as 25%~30% of the welding current;

[0080] S6, reducing die 5.4 is used to round the copper tube 8;

[0081] S7, cooling unit 7 and drying unit 9 sequentially cool and dry the weld of copper tube 8;

[0082] S8, the traction unit 10 sends the dried copper tube 8 into the corrugated unit 11. During traction, the track tension pressure of the traction unit 10 is 3.2 bar ± 0.5 bar, and the track clamping pressure is 1.4 bar ± 0.5 bar.

[0083] S9, the corrugating unit 11 corrugates the outside of the copper tube 8 to obtain a spiral corrugated inner conductor 12; wherein, the corrugating blade 11.4 of the corrugating unit 11 forms an angle with the axis of the copper tube 8. , The range is 13°30′±30′. The outer diameter D of the crest of the inner conductor 12 of the spiral-shaped corrugated copper tube. 波峰 for mm, outer diameter of the trough D 波谷 for mm, wrinkle pitch P is mm; within a pitch P, the peak ratio is 3 / 4 and the trough ratio is 1 / 4, and the voltage standing wave ratio of the produced leaky cable is ≤1.2 in the application frequency band of 700MHz~3700MHz.

[0084] This invention discloses a welding and corrugating device and method for the inner conductor of a spiral corrugated copper tube used in 5G leaky cable. The device includes a tension unit 2, a cutting unit 3, a pressure plate unit 4, a forming unit 5, a welding unit 6, a cooling unit 7, a drying unit 9, a traction unit 10, and a corrugating unit 11. A smooth copper strip 1 is fed into the tension unit 2, where the tension is adjusted and the strip is pushed into the cutting unit. The cutting unit 3 cuts the copper strip 1 to the required width. The strip then enters the forming unit 5 through the horn mold 5.2 and the sizing mold 5.3, gradually bending the copper strip 1 into a round tube with an open top. The welding unit 6 welds the open top. The welded copper tube 8 is then rounded by the reducing mold 5.4. The cooling unit 7 and the drying unit 9 cool and dry the weld, respectively. Finally, the traction unit 10 feeds the copper tube 8 into the corrugating unit 11, where the corrugating unit 11 produces a spiral corrugated copper tube inner conductor 12 with a uniform structure and clear corrugations. The production of the spiral corrugated copper tube with eight inner conductors requires coordination between the equipment and process parameters. This equipment and method more easily improves the uniformity, stability, and flexibility of the inner conductor structure, which not only reduces copper material consumption but also ensures the high-frequency performance of 5G leaky cables, reduces voltage standing wave ratio (VSWR), and improves transmission performance, achieving a VSWR ≤1.2 in the 700MHz~3700MHz application frequency band.

[0085] The above description is merely a preferred embodiment of the present invention and is not intended to limit the technical solution of the present invention in any way. Those skilled in the art should understand that, without departing from the spirit and principles of the present invention, the technical solution can be modified and replaced in several simple ways, and these modifications and replacements are all within the scope of protection covered by the claims.

Claims

1. A device for welding and corrugating the inner conductor of a spiral corrugated copper tube for 5G leaky cable, characterized in that, It includes a tension unit (2), a cutter unit (3), a pressure plate unit (4), a forming unit (5), a drying unit (9), a traction unit (10), and a texturing unit (11) arranged in sequence; The tension unit (2) is used to adjust the tension of the copper strip (1) and provide thrust for the copper strip (1) to move forward; The cutting unit (3) is used to cut the copper strip (1) to the required width; The pressure plate unit (4) is used to flatten the copper strip (1); The forming unit (5) includes a boot-shaped seat (5.1), a horn mold (5.2), a sizing mold (5.3) and a reducing mold (5.4) arranged coaxially in sequence. The boot-shaped seat (5.1), the horn mold (5.2), and the sizing mold (5.3) are used to gradually bend the copper strip (1) into a round tube with an open top. The boot-shaped seat (5.1) includes a slider (5.11), on which a tapered arc groove is provided. Support frames (5.12) are also 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). 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). The inlet end of the horn mold (5.2) is close to the boot-shaped seat (5.1), and the outlet end is close to the sizing mold (5.3); A welding unit (6) is provided between the sizing die (5.3) and the reducing die (5.4). The welding unit (6) is used to weld the top opening to form a copper tube (8). The welding head of the welding unit (6) faces 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 traction unit (10) is used to pull the copper tube (8) to the corrugating unit (11); The threading unit (11) is used to roll threads on the outer wall of the copper tube (8).

2. The 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device according to claim 1, characterized in that, The texturing unit (11) includes an XYZ axis adjustment structure, an inlet guide tube (11.5), a texturing seat, an inlet die (11.6), and an outlet die (11.7) 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 texturing knife (11.4). The texturing knife (11.4) is mounted on the texturing seat and is used to texture the copper tube (8). 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) out of the texturing unit (11).

3. The 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device according to claim 2, characterized in that, The embossing base includes a die base and a rotating base. Both the rotating base and the die base are annular. The embossing cutter (11.4) is rotatably mounted on the inner side of the rotating base. Two mounting shafts are provided on the outer side of the rotating base. 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 mounting shaft that extends out.

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

5. The 5G leaky cable spiral corrugated copper tube inner conductor welding and corrugating device according to claim 1, characterized in that, The drying unit (9) includes a base and a blower mounted on the base. The blower has multiple oblique holes with a square cross-section and an inclination angle of 30°.

6. A method for welding and corrugating the inner conductor of a spiral corrugated copper tube for 5G leaky cable, comprising the welding and corrugating apparatus for the inner conductor of a spiral corrugated copper tube for 5G leaky cable as described in any one of claims 1 to 5, characterized in that, The copper strip (1) is passed sequentially through the tension unit (2), the cutting unit (3), the pressure plate unit (4), the forming unit (5), the drying unit (9), the traction unit (10), and the corrugating unit (11). Specifically: S1, the copper strip enters the tension unit (2), the tension of the copper strip (1) is adjusted by the tension unit (2), and at the same time, the copper strip (1) is provided with a thrust so that the copper strip enters the cutter unit (3); S2, the cutting unit (3) cuts the copper strip (1) to obtain a copper strip (1) that meets the width requirements; S3, the pressure plate unit (4) flattens the copper strip (1); S4, the boot-shaped seat (5.1), the horn mold (5.2) and the sizing mold (5.3) of the forming unit (5) bend the copper strip (1) to form a round tube with an open top; S5, 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 round the copper tube (8); S7, the cooling unit (7) and the drying unit (9) sequentially cool and dry the weld of the copper tube (8); S8, the traction unit (10) sends the dried copper tube (8) into the corrugating 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 spiral corrugated copper tube in a 5G leaky cable according to claim 6, characterized in that, In S5, welding unit (6) uses argon arc welding, and the welding current and production speed satisfy: I 实 =I 焊 ×v×δ+I0, where I 焊 δ is the welding current; v is the production speed; δ is the copper strip (1) welding coefficient, taken as 1.5~2.0; I0 is the welding zero speed current, taken as 25%~30% of the welding current.

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

9. The method for welding and corrugating the inner conductor of a spiral corrugated copper tube in a 5G leaky cable according to claim 6, characterized in that, In S9, during the texturing process, the texturing blade (11.4) of the texturing unit (11) forms an angle with 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 spiral corrugated copper tube in a 5G leaky cable according to claim 6, characterized in that, In S9, the outer diameter D of the crest of the inner conductor (12) of the spiral corrugated copper tube 波峰 for mm, outer diameter of the trough D 波谷 for mm, wrinkle pitch P is mm; within a pitch P, the peak ratio is 3 / 4 and the trough ratio is 1 / 4, and the voltage standing wave ratio of the produced leaky cable is ≤1.2 in the application frequency band of 700MHz~3700MHz.

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