Floating type water photovoltaic dynamic cable and manufacturing method thereof

Abstract

The invention relates to a floating type water photovoltaic dynamic cable and a manufacturing method thereof, and relates to the technical field of cables. The floating type overwater photovoltaic dynamic cable comprises a core body, an isolation sleeve layer, a first armor layer and a first sheath layer, the core body comprises a cable core assembly and optical fiber sensing units, the cable core assembly comprises a plurality of power line cores and elastic filling pieces which are twisted, the optical fiber sensing units are continuously arranged among the power line cores, and the first armor layer is arranged between the power line cores. The optical fiber sensing unit is at least used for detecting the propagation characteristic change of an optical signal in the optical fiber so as to monitor temperature and vibration parameters in real time, and the first sheath layer comprises salt-fog-resistant high-density polyethylene, an anti-ultraviolet auxiliary agent and an anti-biological adhesion auxiliary agent. According to the application, the power wire cores and the elastic filling member are twisted, and the salt-fog-resistant high-density polyethylene, the anti-ultraviolet auxiliary agent and the anti-biological adhesion auxiliary agent are arranged in the first sheath layer, so that the flexibility, the fatigue resistance, the corrosion resistance and the aging resistance are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cables, in particular to a floating type dynamic cable for waterborne photovoltaics and a manufacturing method thereof. BACKGROUND

[0002] Floating offshore photovoltaics is a new power generation method combining photovoltaic power generation technology with marine engineering. The floating offshore photovoltaics provides buoyancy through a floating structure to support photovoltaic components, supports, cables and other equipment on the sea surface. The floating offshore photovoltaics can generate electricity using a large amount of idle sea space without occupying land resources, thereby improving the utilization efficiency of land resources. The cooling effect of seawater can effectively reduce the temperature of the photovoltaic components, inhibit the rise in surface temperature of the components, and reduce the problem of reduced power generation efficiency caused by excessively high temperature. Compared with land photovoltaic projects, the floating offshore photovoltaics has relatively small impact on the ecological environment. With the continuous maturity of technology and the reduction of cost, the scale of the floating offshore photovoltaics will continue to expand from the current megawatt level to tens of megawatts or even higher levels, so as to improve the power generation efficiency and economic benefits.

[0003] However, compared with calm inland waters, the nearshore sea environment is extremely complex, and there are strong winds and rough seas. This not only poses a great threat to the overall safety and reliability of the floating photovoltaic system, but also brings severe challenges to each component of the floating photovoltaic system, especially higher requirements for the performance and quality of the cable.

[0004] In the prior art, traditional submarine cables are mainly designed for fixed offshore facilities, such as fixed wind power, submarine oil and gas platforms, etc. Such cables usually adopt a rigid structure and can better adapt to the stable working environment of fixed facilities. However, due to the repeated bending and stretching of the dynamic load under the action of waves, tides and other external forces, the traditional rigid cable cannot withstand the dynamic stress, and long-term action can easily lead to conductor fatigue fracture, insulation layer damage and other problems, seriously affecting the reliability and service life of the cable. In addition, the corrosion-resistant coating and armored design of the traditional cable are mainly to meet the relatively static marine environment exposure requirements of fixed facilities, and are difficult to meet the special requirements of long-term exposure in a dynamic environment for floating platforms. Moreover, the existing cable lacks anti-twist design for floating scenarios. When the floating platform rotates, the cable structure is prone to failure, which cannot guarantee the stable operation of the floating offshore photovoltaic system. SUMMARY

[0005] The purpose of the present application is to provide a floating type dynamic cable for waterborne photovoltaics and a manufacturing method thereof to solve the problems existing in the prior art.

[0006] To achieve the above purpose, the technical solution adopted by the present application is: The application provides a floating type dynamic cable for water photovoltaics, which comprises, from inside to outside, a core body, an isolation sleeve layer, a first armored layer and a first sheath layer, the core body comprises a cable core assembly and an optical fiber sensing unit, the cable core assembly comprises a plurality of power line cores and an elastic filler which are twisted together, and the optical fiber sensing unit is continuously arranged between the plurality of power line cores, the optical fiber sensing unit is used at least for detecting changes in propagation characteristics of optical signals in the optical fiber, so as to monitor temperature and vibration parameters in real time, and the first sheath layer comprises salt mist resistant high-density polyethylene, ultraviolet resistant additives and anti-bioadhesion additives.

[0007] Further, the formula of the first sheath layer is as follows in terms of mass fraction: high-density polyethylene 100 parts, hydrophobic nano-silicon dioxide 2-3 parts, carbon black master batch 5-6 parts, antioxidant 0.4-0.6 parts, silane 1-1.5 parts and zinc stearate 0.8-1.2 parts.

[0008] Further, the nominal thickness of the first sheath layer is 3.0-6.0 mm, and the thickness of the thinnest point of the first sheath layer is not less than 85% of the nominal thickness.

[0009] Further, the power line core comprises, from inside to outside, an electric conductor, a conductor shielding layer, an insulation layer, an insulation shielding layer and a metal shielding layer.

[0010] Further, the electric conductor is composed of a plurality of tinned copper wires which are bundled and twisted.

[0011] Further, the diameter of the tinned copper wire is 0.5-0.6 mm, and the diameter of the electric conductor is 17.0-30.0 mm.

[0012] Further, the conductor shielding layer comprises a peroxide cross-linked semi-conductive shielding material, the nominal thickness of the conductor shielding layer is 0.8 mm, and the thinnest thickness is not less than 0.5 mm.

[0013] Further, the insulation layer comprises high-purity water tree resistant cross-linked polyethylene insulation material, the nominal thickness of the insulation layer is 10.5 mm, and the thinnest thickness of the insulation layer is not less than 90% of the nominal thickness.

[0014] Further, the insulation shielding layer comprises a peroxide cross-linked semi-conductive shielding material, the thickness of the insulation shielding layer is 1.0 mm, and the thinnest thickness is not less than 0.6 mm.

[0015] Further, the metal shielding layer comprises soft copper wires and fastening copper belts, the soft copper wires are arranged outside the insulation shielding layer through loose winding, the total cross-sectional area of each phase of the soft copper wires is not less than 35 mm 2The gap between adjacent soft copper wires is no more than 4mm. The fastening copper strip is wrapped around the surface of the soft copper wire through the gap to fasten the soft copper wire. The winding direction of the fastening copper strip is opposite to the winding direction of the soft copper wire. The nominal thickness of the fastening copper strip is 0.1mm, and the thinnest thickness is not less than 90% of the nominal thickness.

[0016] Furthermore, a protective layer is provided between the insulating shielding layer and the metal shielding layer. The protective layer is composed of semi-conductive nylon tape wrapped in overlapping layers. The nominal thickness of the semi-conductive nylon tape is 0.12mm, the thinnest thickness is not less than 90% of the nominal thickness, and the minimum overlap of the semi-conductive nylon tape is not less than 5mm.

[0017] Furthermore, the elastic filler has a fan-shaped elongated structure and is made of foamed polypropylene material through extrusion.

[0018] Furthermore, the elastic filler is provided with a central through hole extending along its own length.

[0019] Furthermore, the density of the elastic filler is 0.045-0.06 g / cm³. 3 .

[0020] Furthermore, the cable section diameter ratio of the twisted elastic filler and the power conductor core is 15-25.

[0021] Furthermore, the cable core assembly includes a first water-blocking layer, which is disposed outside the power wire core and the elastic filler. The nominal thickness of the first water-blocking layer is 0.3 mm, and the thinnest thickness is not less than 90% of the nominal thickness. The first water-blocking layer is formed by overlapping and wrapping water-blocking tape, and the overlapping and wrapping is at least two layers, with an overlap rate of 15-25%.

[0022] Furthermore, the fiber optic sensing unit comprises, from the inside out, the fiber optic body, the tight-buffered layer, the second armor layer, the aramid reinforcement layer, and the second sheath layer.

[0023] Furthermore, the first armor layer comprises, from the inside out, a carbon fiber layer and a second water-blocking layer. The carbon fiber layer is formed by multiple carbon fiber reinforced polymer fiber bundles wrapped together, and the second water-blocking layer is formed by overlapping water-blocking tape wrapped together, with at least two overlapping wrapping layers.

[0024] Furthermore, the nominal diameter of the carbon fiber reinforced polymer fiber bundle is 4.0 mm, the minimum diameter is not less than 90% of the nominal diameter, and the sum of the gaps between multiple carbon fiber reinforced polymer fiber bundles is not greater than the diameter of one carbon fiber reinforced polymer fiber bundle.

[0025] Furthermore, the nominal thickness of the second water-blocking layer is 0.3 mm, the thinnest thickness is not less than 90% of the nominal thickness, and the overlap rate of the water-blocking strip is 15-25%.

[0026] Furthermore, the isolation sleeve is made of high-density polyethylene material through extrusion, and the nominal thickness of the isolation sleeve is 2.0-4.0 mm, and the thickness of the thinnest point of the isolation sleeve is not less than 85% of its nominal thickness.

[0027] This application also provides a method for manufacturing a floating dynamic cable for underwater photovoltaic systems as described in any of the above claims, comprising the following steps: S1. Preparation of power conductor core; S2. Prepare the elastic filler; S3. The plurality of power conductors in S1 are twisted together with the elastic filler in S2 to form a cable core assembly. The twisting method is untwisting cabling, the cabling pitch ratio is 15-25, and the tension is not greater than 20KN. The elastic filler is placed on the side of the plurality of power conductors. During the twisting process, the optical fiber sensing unit is placed longitudinally in the middle of the plurality of power conductors to form the core. The roundness of the core is greater than 95%. S4. The core in S3 is wrapped in the isolation sleeve, the first armor layer and the first sheath layer in sequence. The first sheath layer is made of salt spray resistant high-density polyethylene material by extrusion, and its formula is recorded in parts by weight as follows: 100 parts of high-density polyethylene, 2-3 parts of hydrophobic nano silica, 5-6 parts of carbon black masterbatch, 0.4-0.6 parts of antioxidant, 1-1.5 parts of silane and 0.8-1.2 parts of zinc stearate.

[0028] Furthermore, in S1, A power conductor core, from the inside out, consists of an electrical conductor, a conductor shielding layer, an insulation layer, an insulation shielding layer, and a metallic shielding layer, wherein: S1.1 Multiple tinned copper wires are stranded in layers using a stranding machine to form an electrical conductor. The diameter of the tinned copper wires is 0.5-0.6 mm, the elongation is 20-35%, and the resistivity does not exceed 0.0172 Ω·mm. 2 / m, the nominal cross-sectional area of ​​the electrical conductor is 120mm². 2 150 mm 2 185 mm 2 240mm 2 240mm 2 400mm 2 or 500 mm 2 And the DC resistance of the conductor at 20℃ satisfies: When the nominal cross-sectional area is 120mm 2 At that time, it is not greater than 0.1463Ω / km; When the nominal cross-sectional area is 150mm 2 At that time, it is not greater than 0.1197 Ω / km; When the nominal cross-sectional area is 185mm 2 At that time, it is not greater than 0.095Ω / km; When the nominal cross-sectional area is 240mm 2 At that time, it is not greater than 0.0724Ω / km; When the nominal cross-sectional area is 400mm² 2 At that time, it is not greater than 0.0451Ω / km; When the nominal cross-sectional area is 500mm² 2 At that time, it is not greater than 0.0351Ω / km; S1.2 Preparation of insulated wire core: The conductor shielding layer, insulation layer and insulation shielding layer are extruded by a three-layer co-extrusion, dry cross-linking and continuous vulcanization production method. The conductor shielding layer, insulation layer and insulation shielding layer are wrapped around the electric conductor in sequence to obtain the insulated wire core. The obtained insulated wire core is placed in a drying room at 60±2℃ for degassing treatment for 120h. The starting time is calculated from the time when the surface temperature of the insulated wire core reaches 58℃. S1.3, Wrapping with a metallic shielding layer: Soft copper wire is loosely wound and placed on the outside of the insulated core, with the total cross-sectional area of ​​the soft copper wire in each phase not less than 35 mm². 2 The gap between adjacent soft copper wires is no more than 4mm. The fastening copper strip is wrapped around the surface of the soft copper wire through the gap to fasten the soft copper wire. The winding direction of the fastening copper strip is opposite to the winding direction of the soft copper wire. The nominal thickness of the fastening copper strip is 0.1mm, and the thinnest thickness is no less than 90% of the nominal thickness.

[0029] Furthermore, the conductor shielding layer is extruded from peroxide cross-linked semiconductive shielding material, with a nominal thickness of 0.8 mm and a minimum thickness of not less than 0.5 mm. The insulation layer is extruded from high-purity water-tree resistant cross-linked polyethylene insulation material, with a nominal thickness of 10.5 mm and a minimum thickness of not less than 90% of the nominal thickness. The insulating shielding layer is extruded from peroxide cross-linked semiconductive shielding material, with a nominal thickness of 1.0 mm and a minimum thickness of not less than 0.6 mm.

[0030] Furthermore, in S4, The isolation sleeve is made of high-density polyethylene material through extrusion. The nominal thickness of the isolation sleeve is 2.0-4.0 mm, and the thickness of the thinnest point of the isolation sleeve is not less than 85% of its nominal thickness.

[0031] Furthermore, the first armor layer is made of multiple carbon fiber reinforced polymer fiber bundles wrapped around it. The nominal diameter of the carbon fiber reinforced polymer fiber bundles is 4.0 mm, the minimum diameter is not less than 90% of the nominal diameter, and the sum of the gaps between the multiple carbon fiber reinforced polymer fiber bundles is not greater than the diameter of one carbon fiber reinforced polymer fiber bundle.

[0032] The beneficial effects of the technical solution provided in this application include at least the following: (1) This application improves the flexibility and fatigue resistance of the cable by twisting the power conductor core with the elastic filler, enabling it to work stably for a long time under dynamic loads caused by waves, tides, etc., effectively reducing the occurrence of conductor fatigue fracture, insulation layer damage and other problems, and significantly extending the service life of the cable.

[0033] (2) By setting up an optical fiber sensing unit, this application can monitor its own operating status in real time, realize the real-time perception of key parameters such as cable temperature and vibration, and staff can predict cable faults in advance based on the monitoring data, make reasonable maintenance plans, and reduce system operation and maintenance costs.

[0034] (3) The synergistic effect of salt spray resistant high-density polyethylene, anti-ultraviolet additives and anti-biofouling additives in the first sheath layer of this application enables the cable to effectively adapt to the harsh environment of high salt spray, strong ultraviolet radiation and active marine organisms in the ocean, improves the corrosion resistance and anti-aging performance of the cable, reduces the frequency of cable damage caused by environmental factors, and enhances the overall reliability and stability of the floating water photovoltaic system. Attached Figure Description

[0035] The accompanying drawings are provided to further illustrate the present application and form part of the specification. They are used together with the embodiments of the present application to explain the application and do not constitute a limitation thereof. In the drawings: Figure 1 This is a cross-sectional schematic diagram of the cable structure in one embodiment of the present invention; Figure 2 This is a cross-sectional schematic diagram of the optical fiber sensing unit structure in one embodiment of the present invention.

[0036] Explanation of key figure labels: 100. Core; 110. Cable core assembly; 111. Power conductor core; 1111. Electrical conductor; 1112. Conductor shielding layer; 1113. Insulation layer; 1114. Insulation shielding layer; 1115. Metal shielding layer; 1116. Protective layer; 112. Elastic filler; 1121. Central through hole; 113. First water-blocking layer; 120. Fiber optic sensing unit; 121. Fiber optic body; 122. Tight-buffered layer; 123. Second armor layer; 124. Aramid reinforcement layer; 125. Second sheath layer; 200. Isolation sleeve layer; 300. First armor layer; 310. Carbon fiber layer; 320. Second water-blocking layer; 400. First sheath layer. Detailed Implementation

[0037] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0038] In this specification, identical components are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "upper," and "lower" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions towards or away from a specific component, respectively. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this specification, "multiple" means two or more.

[0039] Example 1 Please see Figures 1-2 A floating dynamic cable for waterborne photovoltaic applications includes a core 100, an isolation sheath 200, a first armor layer 300, and a first sheath layer 400 arranged sequentially from the inside out. The core 100 includes a cable core assembly and an optical fiber sensing unit 120. The cable core assembly includes multiple twisted power conductors 110 cable core assemblies 111 and an elastic filler 112. The optical fiber sensing unit 120 is continuously arranged between the multiple power conductors 110 cable core assemblies 111. The optical fiber sensing unit 120 is used at least to detect changes in the propagation characteristics of light signals in optical fibers to monitor temperature and vibration parameters in real time. The first sheath layer 400 includes salt spray resistant high-density polyethylene, anti-ultraviolet additives, and anti-bioadhesion additives.

[0040] In this embodiment, as Figure 1As shown, the cable comprises, from the inside out, a core 100, an isolation sheath 200, a first armor layer 300, and a first sheath layer 400. The innermost core 100 serves as the core, and the cable core assembly therein is formed by twisting together multiple power wire cores 110 and elastic filler 112. The elastic filler 112 has a certain degree of elasticity, which not only fills the gaps after the power wire cores 110 are twisted together, ensuring the compactness of the cable core assembly structure, but also acts as a buffer when the cable is subjected to external force stretching or compression. The fiber optic sensing unit 120 is arranged longitudinally in a continuous manner between multiple power line core 110 cable core assemblies 111. For example, the cable in this embodiment has three power line core 110 cable core assemblies 111. The three power line core 110 cable core assemblies 111 are twisted together with an elastic filler 112. In cross-section, the three power line core 110 cable core assemblies 111 are abutting each other and distributed circumferentially, with a space in the middle. The fiber optic sensing unit 120 is disposed in this space. The fiber optic sensing unit 120 can detect changes in the propagation characteristics of light signals in the optical fiber, such as changes in intensity, wavelength, phase, scattering, etc., thereby enabling real-time monitoring of parameters such as temperature and vibration.

[0041] The insulating sheath 200 wraps around the outside of the core 100, effectively isolating the core 100 from the external structure and preventing current leakage and signal interference. The first armor layer 300 wraps around the outside of the insulating sheath 200, forming a robust protective net that enhances the cable's tensile and compressive strength and resists external impacts in the marine environment. The first sheath layer 400 wraps around the first armor layer 300 and is located as the outermost layer of the cable. It uses salt spray-resistant high-density polyethylene as the base material, which has excellent seawater corrosion resistance and can effectively prevent ocean current erosion. It also contains UV-resistant additives to effectively resist UV radiation and prevent sheath aging, and anti-biofouling additives to create a special microstructure on the sheath surface, reducing the adhesion of marine organisms such as barnacles and shellfish to the cable surface and lowering the risk of cable damage caused by biofouling.

[0042] During power transmission, the elastic filler 112 adaptively adjusts its shape according to the dynamic deformation of the cable, ensuring that the power conductor core 110 cable core assembly 111 always maintains good contact and stable electrical performance, preventing the power conductor core 110 cable core assembly 111 from loosening or breaking due to external forces, thus ensuring the continuity of power transmission. When the cable temperature changes, the refractive index of the optical fiber changes accordingly, affecting the propagation characteristics of the optical signal. When the cable is subjected to vibrations caused by waves, tides, etc., the optical fiber will experience slight strain, which will also lead to changes in the optical signal. The fiber optic sensing unit 120 converts these detected changes in optical signal into electrical signals and transmits them to the monitoring center through a specific communication protocol. The computer system at the monitoring center analyzes and processes the electrical signals to achieve real-time monitoring of cable temperature and vibration. Once an anomaly is detected, it can issue an early warning in a timely manner, reminding staff to carry out inspection and maintenance. The fiber optic sensing unit 120 includes a distributed optical fiber temperature measurement system (DTS) and a distributed optical fiber vibration system (DAS). The distributed optical fiber temperature measurement system is used to measure temperature changes, and the distributed optical fiber vibration system is used to monitor vibration and sound waves.

[0043] In the aforementioned structure, the cable core assembly 110 (power conductor core 110) is twisted with the elastic filler 112, improving the cable's flexibility and fatigue resistance. This allows the cable to operate stably for extended periods under dynamic loads caused by waves and tides, effectively reducing conductor fatigue fracture and insulation layer 1113 damage, significantly extending the cable's service life. The fiber optic sensing unit 120 allows for real-time monitoring of its operating status, enabling real-time sensing of key parameters such as cable temperature and vibration. Based on the monitoring data, staff can predict cable faults in advance, rationally plan maintenance, and reduce system operation and maintenance costs. Furthermore, the synergistic effect of salt spray-resistant high-density polyethylene, UV-resistant additives, and anti-biofouling additives in the first sheath layer 400 effectively adapts the cable to the harsh marine environment of high salt spray, strong ultraviolet radiation, and active marine life, improving its corrosion resistance and aging resistance, reducing the frequency of cable damage caused by environmental factors, and enhancing the overall reliability and stability of the floating photovoltaic system.

[0044] In the specific structure of the first sheath layer 400, the formulation of the first sheath layer 400 by mass parts is as follows: 100 parts high-density polyethylene, 2-3 parts hydrophobic nano-silica, 5-6 parts carbon black masterbatch, 0.4-0.6 parts antioxidant, 1-1.5 parts silane, and 0.8-1.2 parts zinc stearate. The nominal thickness of the first sheath layer 400 is 3.0-6.0 mm, and the thickness of the thinnest point of the first sheath layer 400 is not less than 85% of the nominal thickness.

[0045] In this embodiment, as Figure 1As shown, the first sheath layer 400 includes high-density polyethylene, hydrophobic nano-silica, carbon black masterbatch, antioxidant, silane, and zinc stearate. The high-density polyethylene uses a high molecular weight, highly crystalline base material to improve weather resistance, water resistance, and resistance to smoke corrosion. The addition of hydrophobic nano-silica to the resin enhances mechanical strength, and the surface hydrophobic modification reduces biofouling. The selected hydrophobic silane reduces water damage to the material, lowers the surface energy, and prevents marine organism attachment. The hydrophobic nano-silica and silane act as anti-biofouling agents. The carbon black masterbatch is photosensitive. (Especially ultraviolet light) has a strong absorption and shielding effect, which can effectively prevent the first sheath layer 400 from deteriorating due to light exposure, while reducing the aging effect of light on the material itself. Antioxidants can delay or inhibit the oxidative degradation of materials. By blocking the oxidation reaction chain, they protect materials or products from damage caused by factors such as oxygen, heat, and light. Carbon black masterbatch and antioxidants act as anti-ultraviolet additives. Zinc stearate can play a role in demolding and improving processing performance during processing. In subsequent sheath materials, it gradually migrates to the surface and neutralizes chloride ions in salt spray to form a passivation film, thus delaying the salt spray corrosion.

[0046] The nominal thickness of the first sheath layer 400 is 3.0-6.0mm, which can effectively protect the cable from mechanical forces in the marine environment, such as the impact of floating objects and the scouring of ocean currents. At the same time, the thicker first sheath layer 400 can better isolate the corrosion of the internal structure of the cable by seawater, salt spray and ultraviolet rays. The limitation on the thickness of the thinnest point avoids the problem of protection failure caused by local excessive thinness, and ensures the balance of the protection capability of the entire sheath layer.

[0047] In the specific structure of the power conductor core 110 cable core assembly 111, the power conductor core 110 cable core assembly 111 includes, from the inside out, an electrical conductor 1111, a conductor shielding layer 1112, an insulation layer 1113, an insulation shielding layer 1114, and a metal shielding layer 1115. The electrical conductor 1111 is composed of multiple tinned copper wires bundled and twisted together. The diameter of the tinned copper wires is 0.5-0.6 mm, and the diameter of the electrical conductor 1111 is 17.0-30.0 mm.

[0048] In this embodiment, as Figure 1As shown, the conductor 1111 is made of multiple tin-plated copper wires through a bundling and stranding process. The tin plating treatment effectively prevents the copper wires from oxidizing, ensuring long-term stable conductivity. The stranding of multiple tin-plated copper wires increases the conductive cross-sectional area, reduces resistance, and reduces losses during power transmission, enabling efficient power transmission. The diameter of the tin-plated copper wires is 0.5-0.6 mm, and the diameter of the conductor 1111 is 17.0-30.0 mm. This diameter range ensures that each tin-plated copper wire has good flexibility, a suitable conductive cross-sectional area, and also guarantees the flexibility and tensile strength of the conductor 1111.

[0049] Specifically, the conductor shielding layer 1112 comprises a peroxide cross-linked semiconductive shielding material, and the nominal thickness of the conductor shielding layer 1112 is 0.8 mm, with a minimum thickness of not less than 0.5 mm. In this embodiment, as... Figure 1 As shown, the conductor shielding layer 1112 wraps around the outside of the electrical conductor 1111. The conductivity of the peroxide cross-linked semi-conductive shielding material allows it to adhere tightly to the surface of the electrical conductor 1111, effectively eliminating electric field distortion caused by protrusions and burrs on the surface of the electrical conductor 1111 due to the stranding process. The nominal thickness of the conductor shielding layer 1112 is 0.8 mm, ensuring that the shielding layer has sufficient conductivity and uniformity. It can homogenize the uneven electric field distribution on the surface of the electrical conductor 1111, allowing the electric field to transition to the insulation layer 1113 in a relatively stable and balanced state. This avoids excessively high local electric field strength, reduces the risk of corona discharge and partial discharge, and ensures stable operation of the cable in high-voltage environments.

[0050] Specifically, the insulation layer 1113 comprises high-purity water-tree resistant cross-linked polyethylene insulation material, the nominal thickness of the insulation layer 1113 is 10.5 mm, and the thickness of the thinnest point of the insulation layer 1113 is not less than 90% of its nominal thickness. In this embodiment, as... Figure 1 As shown, the insulation layer 1113 wraps around the outside of the conductor shielding layer 1112. The water-tree-resistant additives in the high-purity water-tree-resistant cross-linked polyethylene insulation material effectively prevent moisture penetration, inhibit the formation and development of water trees, and avoid partial discharge and insulation breakdown problems caused by water trees. The nominal thickness of the insulation layer 1113 at 10.5mm and the minimum thickness limit provide a sufficient and uniform insulation barrier for the cable, improving the electrical insulation performance of the cable, effectively withstanding the electric field effect under high voltage environment, and preventing current leakage.

[0051] Specifically, the insulating shielding layer 1114 comprises a peroxide cross-linked semiconductive shielding material, and the nominal thickness of the insulating shielding layer 1114 is 1.0 mm, with a minimum thickness of not less than 0.6 mm. In this embodiment, as... Figure 1As shown, the insulating shielding layer 1114 is wrapped around the outside of the insulating layer 1113. The insulating shielding layer 1114 is made of a similar material to the conductor shielding layer 1112, including peroxide cross-linked semi-conductive shielding material. Utilizing its conductivity, it can effectively eliminate the uneven electric field phenomenon on the surface of the insulating layer 1113 caused by the manufacturing process or material characteristics. The nominal thickness of the insulating shielding layer 1114 of 1.0 mm can effectively ensure that it has sufficient conductivity and shielding effectiveness, and can uniformly disperse the electric field on the surface of the insulating layer 1113, avoiding corona discharge and partial discharge problems caused by local electric field concentration.

[0052] The metal shielding layer 1115 includes soft copper wires and fastening copper strips. The soft copper wires are loosely wound on the outside of the insulating shielding layer 1114, and the total cross-sectional area of ​​each phase of the soft copper wires is not less than 35 mm². 2 The gap between adjacent soft copper wires is no more than 4mm. The fastening copper strip is wrapped around the surface of the soft copper wire through the gap to fasten the soft copper wire. The winding direction of the fastening copper strip is opposite to the winding direction of the soft copper wire. The nominal thickness of the fastening copper strip is 0.1mm, and the thinnest thickness is not less than 90% of the nominal thickness.

[0053] In this embodiment, as Figure 1 As shown, a metal shielding layer 1115 wraps around the outside of an insulating shielding layer 1114. The metal shielding layer 1115 includes soft copper wire and a fastening copper strip. During manufacturing, the soft copper wire is first wound around the outside of the insulating shielding layer 1114 using a loose winding process. Then, the fastening copper strip is wound in the opposite direction with a gap around the surface of the soft copper wire to fix it in place. The total cross-sectional area of ​​each phase of the soft copper wire is not less than 35 mm². 2 The larger conductive cross-sectional area effectively reduces resistance, ensuring the cable can carry large currents and quickly conduct fault currents during short-circuit faults. Simultaneously, the gap between adjacent soft copper wires is no more than 4mm. This ensures effective shielding of electromagnetic signals while avoiding a decrease in shielding effectiveness due to excessively large gaps, and also prevents excessively small gaps from increasing cable rigidity and affecting its bending performance. The fastening copper strip is processed into a thin strip with a nominal thickness of only 0.1mm through rolling. The fastening copper strip is applied to the surface of the soft copper wires through a gap-wrapping method. When the fastening copper strip is tightened, it interacts with the soft copper wires, generating significant frictional force, thus firmly securing the soft copper wires and preventing displacement or loosening during dynamic cable operation, ensuring the stability of the 1115 metal shielding layer structure.

[0054] In addition, a protective layer 1116 is provided between the insulating shielding layer 1114 and the metal shielding layer 1115. The protective layer 1116 is formed by overlapping and wrapping semi-conductive nylon tape. The nominal thickness of the semi-conductive nylon tape is 0.12mm, the thinnest thickness is not less than 90% of the nominal thickness, and the minimum overlap of the semi-conductive nylon tape is not less than 5mm.

[0055] In this embodiment, as Figure 1 As shown, since the metal shielding layer 1115 is made of copper, it is easily scratched by seawater. Therefore, a protective layer 1116 is provided between the metal shielding layer 1115 and the insulating shielding layer 1114. Semi-conductive nylon tape is wrapped around the outside of the insulating shielding layer 1114. The semi-conductive nylon tape and conductive nylon tape are overlapped and wrapped together. The nominal thickness of the semi-conductive nylon tape is 0.12mm, and the thinnest thickness is not less than 90% of the nominal thickness. The minimum overlap during wrapping is not less than 5mm. This ensures that the adjacent two turns of semi-conductive nylon tape are tightly fitted and overlap each other to form a continuous and uniform protective layer 1116, thereby avoiding gaps and effectively protecting the insulating shielding layer 1114.

[0056] In the specific structure of the elastic filler 112, the elastic filler 112 has a fan-shaped elongated structure, and the elastic filler 112 is formed by extrusion of foamed polypropylene material. The elastic filler 112 has a central through hole 1121 extending along its own length direction. The density of the elastic filler 112 is 0.045-0.06 g / cm³. 3 The cable core assembly of the elastic filler 112 and the power conductor core 110; the cable section diameter ratio of the twisted phases of 111 is 15-25.

[0057] In this embodiment, as Figure 1 As shown, the elastic filler 112 is a fan-shaped strip structure made of foamed polypropylene material through an extrusion process. This fan-shaped strip structure can accommodate multiple power conductor cores 110 cable core assemblies. The gaps in 111 allow for better space filling. After the elastic filler 112 and the power conductor core 110 cable core assembly 111 are twisted together, the overall structural stability of the cable core assembly is improved. The foamed polypropylene material is lightweight and has good elastic buffering performance, which can evenly distribute external forces. The density of the elastic filler 112 is 0.045 - 0.06 g / cm³. 3Within this density range, foamed polypropylene material can maintain sufficient mechanical strength while ensuring good elasticity and cushioning performance. Furthermore, when the elastic filler 112 and the power conductor core 110 cable core assembly 111 are twisted into a cable, the pitch ratio is set to 15-25. This pitch ratio ensures a tight fit between the elastic filler 112 and the power conductor core 110 cable core assembly 111, achieving stable twisting of the structure while maintaining cable flexibility. In addition, the elastic filler 112 has a central through-hole 1121, which, while ensuring support strength, further reduces weight and provides space for possible internal wiring, sensor installation, and other operations, increasing the flexibility of the cable structure design.

[0058] In addition, the cable core assembly includes a first water-blocking layer 113, which is disposed on the outside of the power wire core 110 cable core assembly 111 and the elastic filler 112. The nominal thickness of the first water-blocking layer 113 is 0.3 mm, and the thinnest thickness is not less than 90% of the nominal thickness. The first water-blocking layer 113 is formed by overlapping and wrapping water-blocking tape, and the overlapping and wrapping is at least two layers, with an overlap rate of 15-25%.

[0059] like Figure 1 As shown, after the power line core 110 cable core assembly 111 and the elastic filler 112 are twisted together, a first water-blocking layer 113 is formed by wrapping it with water-blocking tape on the outside. During the wrapping process, at least two layers of water-blocking tape are wrapped, and the overlap rate of the water-blocking tape is controlled at 15-25%, which further improves the penetration of seawater and reduces the risk of failure caused by moisture inside the cable. After the wrapping is completed, the nominal thickness of the first water-blocking layer 113 is 0.3mm, and the thinnest thickness is not less than 90% of the nominal thickness, ensuring the uniformity of waterproofing.

[0060] In the structure of the optical fiber sensing unit 120, the optical fiber sensing unit 120 includes, from the inside out, an optical fiber body 121, a tight-buffered layer 122, a second armor layer 123, an aramid reinforcement layer 124, and a second sheath layer 125.

[0061] In this embodiment, as Figure 2As shown, the innermost fiber body 121 uses single-mode fiber, such as G.652 or G.654 fiber, which has extremely low signal attenuation and excellent transmission bandwidth. This ensures the stability of the optical signal during long-distance transmission, reduces signal loss, and provides a reliable data transmission foundation for accurate monitoring. A tight-fitting layer 122 tightly covers the outer side of the fiber. This tight-fitting layer 122 is a thermoplastic structure made of polyurethane material, formed by high-temperature extrusion. Polyurethane material has good flexibility and abrasion resistance, which not only tightly fits the fiber, providing buffer protection and preventing breakage or damage under external forces, but also effectively isolates the fiber from external environmental interference, ensuring the stability of optical signal transmission. The second armor layer 123 is woven from fine steel wires, forming a robust mesh structure with resistance to seawater corrosion. It provides strong mechanical protection for the fiber optic sensing unit 120, resisting external impacts such as impacts from floating objects and ocean currents in the marine environment. The aramid reinforcement layer 124 is made of high-performance aramid fiber winding. Aramid fiber has the characteristics of high strength and low density; its strength is several times that of steel wire, while its weight is very light. The aramid reinforcement layer is tightly wound around the outside of the second armor layer 123, which can significantly improve the tensile strength of the fiber optic sensing unit 120. When the cable is subjected to tensile force, it effectively disperses stress and prevents the optical fiber from being damaged due to tensile stress. It also enhances the flexibility of the entire sensing unit, enabling it to adapt to the dynamic bending deformation of the cable. The outermost second sheath layer 125 is made of weather-resistant polyolefin material, with added anti-ultraviolet, anti-salt spray, and anti-biofouling agents. It is coated on the outside of the aramid reinforcement layer through an extrusion process, forming a comprehensive protective barrier. This sheath layer can not only resist ultraviolet radiation, salt spray corrosion, and marine organism adhesion in the marine environment, but also has good wear resistance and aging resistance, effectively protecting the internal structure and extending the service life of the fiber optic sensing unit 120.

[0062] In the specific structure of the isolation sleeve 200, the isolation sleeve 200 is made of high-density polyethylene material through extrusion. The nominal thickness of the isolation sleeve 200 is 2.0-4.0mm, and the thickness of the thinnest point of the isolation sleeve 200 is not less than 85% of its nominal thickness.

[0063] In this embodiment, as Figure 1As shown, the insulating sleeve 200 wraps around the outside of the core 100. The insulating sleeve 200 is made of high-density polyethylene (HDPE) through an extrusion process. HDPE possesses excellent chemical stability, electrical insulation, and wear resistance. Its dense molecular structure and high crystallinity effectively resist corrosion from seawater, salt spray, and other corrosive substances. The nominal thickness of the insulating sleeve 200 is controlled within the range of 2.0-4.0 mm, ensuring sufficient insulation and protection performance without excessively increasing the weight and cost of the cable. To further ensure the uniformity and reliability of the insulating sleeve 200, its thinnest point is no less than 85% of its nominal thickness.

[0064] In the specific structure of the first armor layer 300, the first armor layer 300 includes, from the inside out, a carbon fiber layer 310 and a second water-blocking layer 320. The carbon fiber layer 310 is formed by multiple carbon fiber reinforced polymer fiber bundles wrapped together. The second water-blocking layer 320 is formed by overlapping and wrapping water-blocking tape, with at least two overlapping wrapping layers. The nominal diameter of the carbon fiber reinforced polymer fiber bundles is 4.0 mm, the minimum diameter is not less than 90% of the nominal diameter, and the total gap between multiple carbon fiber reinforced polymer fiber bundles is not greater than the diameter of one carbon fiber reinforced polymer fiber bundle. The nominal thickness of the second water-blocking layer 320 is 0.3 mm, the thinnest thickness is not less than 90% of the nominal thickness, and the overlap rate of the water-blocking tape is 15-25%.

[0065] In this embodiment, as Figure 1 As shown, the carbon fiber layer 310 wraps around the outside of the isolation sleeve layer 200. The carbon fiber layer 310 is made of multiple carbon fiber reinforced polymer fiber bundles through a wrapping process. The carbon fiber reinforced polymer fiber bundles have high strength and toughness. Each carbon fiber reinforced polymer fiber bundle preferably has a nominal diameter of 4.0 mm, and the thinnest thickness is not less than 90% of the nominal diameter. During the wrapping process, the gap between the multiple carbon fiber reinforced polymer fiber bundles does not exceed the diameter of a single carbon fiber reinforced polymer fiber bundle, i.e., 4.0 mm, thereby forming a tight and continuous carbon fiber layer 310. This allows the carbon fiber layer 310 to uniformly distribute external stress and improve the tensile and compressive strength of the cable.

[0066] A second water-blocking layer 320, made of water-blocking tape through an overlapping wrapping process, is wrapped around the outside of the carbon fiber layer 310. This effectively prevents seawater penetration. During the wrapping process, at least two layers of water-blocking tape are wrapped, and the overlap rate of the water-blocking tape is maintained between 15% and 25%, ensuring a tight overlap between each layer of water-blocking tape. The multi-layer structure works together to form a tight waterproof barrier, effectively preventing water penetration. The second water-blocking layer 320 of the first armor layer 300 and the first water-blocking layer 113 of the cable core assembly work together to form a double-layer water-blocking structure, further improving the cable's waterproof performance.

[0067] Example 2 A method for manufacturing a floating dynamic cable for underwater photovoltaic applications, comprising the following steps: S1. Prepare the 110 power conductor core assembly; 111; S2. Prepare elastic filler 112; S3. The plurality of power line cores 110 cable core assemblies 111 in S1 are twisted together with the elastic filler 112 in S2 to form a cable core assembly. The twisting method is untwisting cable forming, the cable pitch ratio is 15-25, and the tension is not greater than 20KN. The elastic filler 112 is placed on the side of the plurality of power line cores 110 cable core assemblies 111. During the twisting process, the optical fiber sensing unit 120 is placed vertically in the middle of the plurality of power line cores 110 cable core assemblies 111 to form the core body 100. The roundness of the core body 100 is greater than 95%. S4. The core 100 in S3 is wrapped with the isolation sleeve 200, the first armor layer 300 and the first sheath layer 400 in sequence. The first sheath layer 400 is made of salt spray resistant high-density polyethylene material by extrusion, and its formula is recorded in parts by weight as follows: 100 parts of high-density polyethylene, 2-3 parts of hydrophobic nano silica, 5-6 parts of carbon black masterbatch, 0.4-0.6 parts of antioxidant, 1-1.5 parts of silane and 0.8-1.2 parts of zinc stearate.

[0068] In S1, the power conductor core 110 is a cable core assembly; 111 includes, from the inside out, an electrical conductor 1111, a conductor shielding layer 1112, an insulation layer 1113, an insulation shielding layer 1114, and a metallic shielding layer 1115, wherein: S1.1 Multiple tinned copper wires are stranded in layers using a stranding machine to form an electrical conductor 1111. The diameter of the tinned copper wires is 0.5-0.6 mm, the elongation is 20-35%, and the resistivity does not exceed 0.0172 Ω·mm. 2 / m, the nominal cross-sectional area of ​​conductor 1111 is 120 mm². 2 150 mm 2 185 mm 2 240mm 2 240mm 2 400mm 2 or 500 mm 2 And the DC resistance of conductor 1111 at 20℃ satisfies: When the nominal cross-sectional area is 120mm 2 At that time, it is not greater than 0.1463Ω / km; When the nominal cross-sectional area is 150mm 2 At that time, it is not greater than 0.1197 Ω / km; When the nominal cross-sectional area is 185mm 2 At that time, it is not greater than 0.095Ω / km; When the nominal cross-sectional area is 240mm 2 At that time, it is not greater than 0.0724Ω / km; When the nominal cross-sectional area is 400mm² 2 At that time, it is not greater than 0.0451Ω / km; When the nominal cross-sectional area is 500mm² 2 At that time, it is not greater than 0.0351Ω / km; S1.2 Preparation of insulated wire core: The conductor shielding layer 1112, insulation layer 1113 and insulation shielding layer 1114 are extruded using a three-layer co-extrusion, dry cross-linking and continuous vulcanization production method. The conductor shielding layer 1112, insulation layer 1113 and insulation shielding layer 1114 are wrapped around the conductor 1111 in sequence to obtain the insulated wire core. The obtained insulated wire core is placed in a drying oven at 60±2℃ for degassing treatment for 120h. The starting time is calculated from when the surface temperature of the insulated wire core reaches 58℃. S1.3, Wrapping the metal shielding layer 1115: Soft copper wire is loosely wound and placed on the outside of the insulated core, with the total cross-sectional area of ​​the soft copper wire in each phase not less than 35mm². 2 The gap between adjacent soft copper wires is no more than 4mm. The fastening copper strip is wrapped around the surface of the soft copper wire through the gap to fasten the soft copper wire. The winding direction of the fastening copper strip is opposite to the winding direction of the soft copper wire. The nominal thickness of the fastening copper strip is 0.1mm, and the thinnest thickness is no less than 90% of the nominal thickness.

[0069] More specifically, the conductor shielding layer 1112 is extruded from peroxide cross-linked semiconductive shielding material, with a nominal thickness of 0.8 mm and a minimum thickness of not less than 0.5 mm. The insulation layer 1113 is extruded from high-purity water-tree resistant cross-linked polyethylene insulation material, with a nominal thickness of 10.5 mm and a minimum thickness of not less than 90% of the nominal thickness. The insulating shielding layer 1114 is extruded from peroxide cross-linked semiconductive shielding material, with a nominal thickness of 1.0 mm and a minimum thickness of not less than 0.6 mm.

[0070] Furthermore, in S4, the isolation sleeve 200 is extruded from high-density polyethylene material, and the nominal thickness of the isolation sleeve 200 is 2.0-4.0 mm, with the thinnest point of the isolation sleeve 200 having a thickness of not less than 85% of its nominal thickness. The first armor layer 300 is made by wrapping multiple carbon fiber reinforced polymer fiber bundles, with a nominal diameter of 4.0 mm, a minimum diameter of not less than 90% of the nominal diameter, and the sum of the gaps between the multiple carbon fiber reinforced polymer fiber bundles not greater than the diameter of one carbon fiber reinforced polymer fiber bundle.

[0071] In this embodiment, during the fabrication of the core 100: Preparation of power conductor core 110 cable core assembly; 111: First, prepare the electrical conductor 1111: Take a copper rod with a diameter of 8mm and draw it into a copper wire with a diameter of 0.51mm. The tolerance requirement for the copper wire is 0.51±0.01mm, the elongation is 20%-35%, and the resistivity of the copper wire does not exceed 0.0172Ω·mm. 2 / m.

[0072] For copper single wires with a diameter of 0.51 mm, surface tin plating is performed. The concentration of acid in the electroplating solution (sulfuric acid can be used) is controlled within the range of (170-220) mL / L, the temperature is (40-50)℃, the pH value of the washing water is controlled within the range of 8.5-10.0, and the plating thickness of the round copper wire after tin plating is (6.00±0.50) μm.

[0073] The conductor monofilaments are bundled using a wire bundling machine: the strand bundling direction is set to right (Z), and each layer of re-twisting is set to left (S). The conductor pitch ratio is 15-17 times for strands, 13-16 times for inner layers, and 12-14 times for outer layers.

[0074] In this embodiment, the conductor 1111 made of tin-plated copper wire is required to have the following characteristics: at a temperature of 20°C, the DC resistance of the conductor 1111 is less than 0.07163 Ω / km, and the weighing cross-sectional area of ​​the conductor 1111 is 235.2 mm². 2 The outer diameter of conductor 1111 is 17.8 ± 0.2 mm.

[0075] Multiple tinned copper wires are stranded in layers using a stranding machine to form an electrical conductor 1111. The tinned copper wires have a diameter of 0.5-0.6 mm, an elongation of 20%-35%, and a resistivity not exceeding 0.0172 Ω·mm². 2 / m, and the nominal cross-sectional area of ​​the manufactured electrical conductor 1111 is typically 120 mm². 2 150 mm 2 185 mm 2 240mm 2 240mm 2 400mm2 500 mm 2 These types can also be designed individually according to the operating conditions, and the DC resistance at 20℃ is better than 5% of the value specified in GB / T 3956-2008.

[0076] Further preparation of insulated wire cores: Conductor shielding layer 1112, insulation layer 1113, and insulation shielding layer 1114 are extruded using a three-layer co-extrusion, dry cross-linking, and continuous vulcanization process to obtain the insulated wire core. The insulated wire core is processed using a CCV (cab cross-linking) production line. The conductor shielding layer 1112 can be extruded from Borealis' environmentally friendly peroxide cross-linked semi-conductive shielding material LE0592. The nominal thickness of the conductor shielding layer 1112 is 0.8 mm, and the minimum thickness is not less than 0.5 mm. Extrusion is performed using a Φ100 extruder. The die head filter has four layers: 20 mesh, 120 mesh, 80 mesh, and 20 mesh. The temperatures of the extruder's first to eighth temperature zones are 80℃, 100℃, 110℃, 112℃, 112℃, 115℃, 116℃, and 118℃, respectively. The screw speed of the extruder is 10.2 rpm, and the extrusion pressure is 338 bar.

[0077] Insulation layer 1113 can be extruded from high-purity, water-tree resistant, cross-linked polyethylene insulation material LE4212 from Borealis. The nominal thickness of insulation layer 1113 is 10.5 mm, and the thinnest thickness is not less than 90% of the nominal thickness. Extrusion is performed using a Φ200 extruder. The die head filter has seven layers: 20 mesh, 80 mesh, 150 mesh, 300 mesh, 150 mesh, 80 mesh, and 20 mesh. The temperatures of the extruder's first to eighth temperature zones are 116℃, 118℃, 118℃, 118℃, 118℃, 118℃, and 120℃, respectively. The screw speed of the extruder is 21.0 rpm, and the extrusion pressure is 135 bar.

[0078] The insulating shielding layer 1114 can be extruded from Borealis' environmentally friendly peroxide cross-linked semi-conductive shielding material LE0520. The nominal thickness of the insulating shielding layer 1114 is 1.0 mm, and the minimum thickness is not less than 0.6 mm. Extrusion is performed using an 80mm extruder. The die head filter has four layers: 20 mesh, 120 mesh, 80 mesh, and 20 mesh. The temperatures of the extruder's first to eighth temperature zones are 60℃, 90℃, 100℃, 105℃, 105℃, 115℃, 116℃, and 116℃, respectively. The screw speed of the extruder is 6.0 rpm, and the extrusion pressure is 266 bar.

[0079] In addition, the die dimensions for the three-layer co-extrusion are as follows: core Φ19.3mm, Φ20.8mm, Φ50.0mm, die sleeve Φ42.7mm, and the average speed of the production line is 5.6±0.3m / min.

[0080] The prepared insulated wire cores were then placed in a drying oven at 60±2℃ for 120 hours to degas, starting from when the surface temperature of the insulated wire cores reached 58℃. This is because during the manufacturing process of the insulated wire cores, polymerization byproducts, moisture, and other volatile impurities may remain inside the insulation material. The 60±2℃ temperature environment creates suitable conditions for the volatilization of these impurities, and the continuous treatment time of 120 hours ensures that the gases are fully discharged. Removing these impurities can prevent partial discharge caused by the electric field during cable operation, reduce the risk of electrical tree growth, and effectively improve the long-term reliability of the insulated wire cores.

[0081] Then, a metal shielding layer 1115 is included outside the insulated conductor: soft copper wires are loosely wound and arranged on the outside of the insulated shielding layer, and the total cross-sectional area of ​​each phase of soft copper wires is not less than 35mm². 2 The gap between adjacent soft copper wires is no more than 4mm. The fastening copper strip is wrapped around the surface of the soft copper wire through the gap to fasten the soft copper wire. The winding direction of the fastening copper strip is opposite to the winding direction of the soft copper wire. The nominal thickness of the fastening copper strip is 0.1mm, and the thinnest thickness is no less than 90% of the nominal thickness. Next, the elastic filler 112 is prepared: the elastic filler 112 is a fan-shaped strip structure made of foamed polypropylene material through an extrusion process, and its density is 0.045-0.06 g / cm³. 3 between.

[0082] Finally, the power conductor core 110 cable core assembly 111 is twisted together with the elastic filler 112. The elastic filler 112 is placed on the sides of the three power conductor core 110 cable core assemblies 111, with the cabling direction being right-handed and the cabling method being untwisting cabling. The cabling pitch ratio range is 15-25, and the tension is set not to exceed 20kN. During the cable core twisting process, a fiber optic sensing unit 120 is placed longitudinally in the middle. The fiber optic sensing unit 120 consists of a distributed fiber optic temperature measurement system (DTS) and a distributed fiber optic vibration system (DAS). The distributed fiber optic temperature measurement system (DTS) is used to measure temperature changes, and the distributed fiber optic vibration system (DAS) is used for vibration and acoustic wave monitoring. Using pulsed lasers and fast photodetectors, combined with real-time signal processing algorithms, tens of thousands of data acquisitions per second can be achieved. After filling, the roundness of the cable core reaches over 95%. Finally, a first water-blocking layer 113 is wrapped around the outside of the cable core. The material of the first water-blocking layer 113 is water-blocking tape with a nominal thickness of 0.3 mm and a minimum thickness of not less than 90% of the nominal thickness. The overlap rate of the wrapping is in the range of 15-25% to form the core 100. The outer diameter of the core 100 after wrapping is 91.8±2 mm.

[0083] During the cable manufacturing process: An isolation sleeve layer 200, a first armor layer 300, and a first protective sleeve layer 400 are sequentially extruded on the outside of the core 100.

[0084] First, prepare the isolation sleeve 200: The isolation sleeve 200 can be made by extrusion of Linhai Yadong high-density polyethylene sheath material GPH-90. The nominal thickness of the isolation sleeve 200 is 2.5mm. The extrusion is carried out using a Φ150 extruder. The temperatures of the first to ninth temperature zones of the extruder are 148℃, 175℃, 178℃, 177℃, 176℃, 175℃, 176℃, 181℃, and 180℃, respectively. The temperatures of the four temperature zones of the die head are 179℃, 178℃, 178℃, and 179℃, respectively. The screw speed of the extruder is 12.0 rpm, and the extrusion current is 280A.

[0085] In the preparation of the first armor layer 300: The first armor layer 300 is composed of multiple carbon fiber reinforced polymer fiber bundles wrapped around each other. The nominal diameter of the carbon fiber reinforced polymer fiber bundles is 4.0 mm, and the minimum diameter is not less than 90% of the nominal diameter. The total gap between the carbon fiber reinforced polymer fiber bundles does not exceed the diameter of one carbon fiber reinforced polymer fiber bundle. During the manufacturing process, the downward pressure of the traction machine is controlled to keep the cables at the same horizontal height during production. The upward pressure of the traction machine is 0.30-0.50 MPa, the tensioning pressure is 1.0-1.2 MPa, and the take-up tension is 2500-4000 N. The outermost part of the first armor layer 300 is the second water-blocking layer 320, which is composed of two layers of water-blocking tape wrapped around each other. The water-blocking tape has a nominal thickness of 0.3 mm, and the thinnest thickness is not less than 90% of the nominal thickness. The overlap rate ranges from 15% to 25%.

[0086] Finally, the first sheath layer 400 is prepared: The first sheath layer 400 is extruded from salt spray resistant high-density polyethylene material. Its formula, by weight, consists of the following raw materials: 100 parts high-density polyethylene, 2-3 parts hydrophobic nano-silica, 5-6 parts carbon black masterbatch, 0.4-0.6 parts antioxidant, 1-1.5 parts silane, and 0.8-1.2 parts zinc stearate. Specifically, the high-density polyethylene can be YGH041 from Sinopec Shanghai Petrochemical Co., Ltd., the hydrophobic nano-silica can be R8200 from Evonik Industries, Inc., the carbon black masterbatch can be Cabot Corporation's 6269, the antioxidant can be Zibo Vanke Chemical Co., Ltd.'s 300, the silane can be Dow Chemical's Z-6011, and the zinc stearate can be Dongguan Hanwei Technology Co., Ltd.'s AV300.

[0087] The nominal thickness of the first sheath layer (400) is 4.6 mm, and the thinnest thickness is not less than 85% of the nominal thickness, resulting in an overall cable outer diameter of 116.9 ± 2 mm. The extruded sheath material is produced using a Φ180 extruder. The temperatures of the extruder's first to ninth temperature zones are 148℃, 150℃, 170℃, 175℃, 178℃, 178℃, 181℃, and 180℃, respectively. The temperatures of the four temperature zones at the die head are 179℃, 178℃, 178℃, and 179℃, respectively. The screw speed of the extruder is 13.5 rpm, and the extrusion current is 270 A.

[0088] In the embodiments disclosed in this application, the terms "installation," "connection," "linking," and "fixing" should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in the embodiments disclosed in this application according to the specific circumstances.

[0089] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

Claims

1. A floating dynamic cable for waterborne photovoltaic applications, characterized in that, The device comprises, from the inside out, a core, an isolation sleeve, a first armor layer, and a first sheath layer. The core includes a cable core assembly and an optical fiber sensing unit. The cable core assembly includes multiple stranded power conductors and an elastic filler. The optical fiber sensing unit is continuously disposed between the multiple power conductors. The optical fiber sensing unit is used at least to detect changes in the propagation characteristics of optical signals in the optical fiber to monitor temperature and vibration parameters in real time. The first sheath layer includes salt spray resistant high-density polyethylene, UV resistant additives, and anti-bioadhesion additives.

2. The floating dynamic cable for waterborne photovoltaic applications according to claim 1, characterized in that, The formulation of the first sheath layer is as follows by mass parts: 100 parts high-density polyethylene, 2-3 parts hydrophobic nano silica, 5-6 parts carbon black masterbatch, 0.4-0.6 parts antioxidant, 1-1.5 parts silane, and 0.8-1.2 parts zinc stearate; And / or, the nominal thickness of the first sheath layer is 3.0-6.0 mm, and the thickness of the thinnest point of the first sheath layer is not less than 85% of the nominal thickness.

3. The floating dynamic cable for waterborne photovoltaic applications according to claim 1, characterized in that, The power conductor core comprises, from the inside out, an electrical conductor, a conductor shielding layer, an insulation layer, an insulation shielding layer, and a metal shielding layer; And / or, the electrical conductor is composed of multiple tin-plated copper wires bundled or twisted together; And / or, the diameter of the tin-plated copper wire is 0.5-0.6 mm, and the diameter of the electrical conductor is 17.0-30.0 mm; And / or, the conductor shielding layer comprises a peroxide cross-linked semiconductive shielding material, and the nominal thickness of the conductor shielding layer is 0.8 mm, and the thinnest thickness is not less than 0.5 mm; And / or, the insulation layer comprises high-purity water-tree resistant cross-linked polyethylene insulation material, the nominal thickness of the insulation layer is 10.5 mm, and the thickness of the thinnest point of the insulation layer is not less than 90% of its nominal thickness; And / or, the insulating shielding layer comprises a peroxide cross-linked semiconductive shielding material, and the nominal thickness of the insulating shielding layer is 1.0 mm, and the thinnest thickness is not less than 0.6 mm; And / or, the metal shielding layer comprises soft copper wire and fastening copper strip, wherein the soft copper wire is loosely wound on the outside of the insulating shielding layer, and the total cross-sectional area of ​​the soft copper wire in each phase is not less than 35 mm². 2 The gap between adjacent soft copper wires is no greater than 4mm. The fastening copper strip is wrapped around the surface of the soft copper wire through the gap to fasten the soft copper wire. The winding direction of the fastening copper strip is opposite to the winding direction of the soft copper wire. The nominal thickness of the fastening copper strip is 0.1mm, and the thinnest thickness is not less than 90% of the nominal thickness. And / or, a protective layer is provided between the insulating shielding layer and the metal shielding layer. The protective layer is formed by overlapping and wrapping semi-conductive nylon tape. The nominal thickness of the semi-conductive nylon tape is 0.12 mm, the thinnest thickness is not less than 90% of the nominal thickness, and the minimum overlap of the semi-conductive nylon tape is not less than 5 mm.

4. The floating dynamic cable for waterborne photovoltaic applications according to claim 3, characterized in that, The elastic filler has a fan-shaped elongated structure and is made of foamed polypropylene material through extrusion. And / or, the elastic filler is provided with a central through hole extending along its own length direction; And / or, the density of the elastic filler is 0.045-0.06 g / cm³. 3 ; And / or, the cable section diameter ratio of the twisted elastic filler to the power conductor is 15-25; And / or, the cable core assembly includes a first water-blocking layer, which is disposed outside the power wire core and the elastic filler. The nominal thickness of the first water-blocking layer is 0.3 mm, and the thinnest thickness is not less than 90% of the nominal thickness. The first water-blocking layer is formed by overlapping and wrapping water-blocking tape, and the overlapping and wrapping is at least two layers. The overlap rate of the water-blocking tape is 15-25%.

5. The floating dynamic cable for waterborne photovoltaic applications according to claim 1, characterized in that, The optical fiber sensing unit comprises, from the inside out, an optical fiber body, a tight-buffered layer, a second armor layer, an aramid reinforcement layer, and a second sheath layer.

6. The floating dynamic cable for waterborne photovoltaic applications according to claim 1, characterized in that, The first armor layer comprises, from the inside out, a carbon fiber layer and a second water-blocking layer. The carbon fiber layer is formed by multiple carbon fiber reinforced polymer fiber bundles wrapped together. The second water-blocking layer is formed by water-blocking tape wrapped together in overlapping layers. And / or, the nominal diameter of the carbon fiber reinforced polymer fiber bundle is 4.0 mm, the minimum diameter is not less than 90% of the nominal diameter, and the sum of the gaps between multiple carbon fiber reinforced polymer fiber bundles is not greater than the diameter of one carbon fiber reinforced polymer fiber bundle. And / or, the nominal thickness of the second water-blocking layer is 0.3 mm, the thinnest thickness is not less than 90% of the nominal thickness, and the overlap rate of the water-blocking strip is 15-25%.

7. The floating photovoltaic dynamic cable according to claim 1, characterized in that, The isolation sleeve is made of high-density polyethylene material through extrusion. The nominal thickness of the isolation sleeve is 2.0-4.0 mm, and the thickness of the thinnest point of the isolation sleeve is not less than 85% of its nominal thickness.

8. A method for manufacturing a floating dynamic cable for underwater photovoltaic applications as described in any one of claims 1-7, characterized in that, The steps are as follows: S1. Preparation of power conductor core; S2. Prepare the elastic filler; S3. Twisting the plurality of power conductors in S1 with the elastic filler in S2 to form a cable core assembly, wherein the twisting method adopts untwisting cabling, the cabling pitch ratio is 15-25, the tension is not greater than 20KN, the elastic filler is placed on the side of the power conductor, and during the twisting process, the optical fiber sensing unit is placed in the middle of the power conductor and longitudinally to form the core body, the roundness of the core body is greater than 95%; S4. The core in S3 is wrapped in the isolation sleeve, the first armor layer and the first sheath layer in sequence. The first sheath layer is made of salt spray resistant high-density polyethylene material by extrusion, and its formula is recorded in parts by weight as follows: 100 parts of high-density polyethylene, 2-3 parts of hydrophobic nano silica, 5-6 parts of carbon black masterbatch, 0.4-0.6 parts of antioxidant, 1-1.5 parts of silane and 0.8-1.2 parts of zinc stearate.

9. The method for manufacturing a floating dynamic cable for waterborne photovoltaic systems according to claim 8, characterized in that, In S1, The power conductor core comprises, from the inside out, an electrical conductor, a conductor shielding layer, an insulation layer, an insulation shielding layer, and a metallic shielding layer, wherein: S1.1 The conductor is formed by stranding multiple tin-plated copper wires in layers using a stranding machine. The diameter of the tin-plated copper wires is 0.5-0.6 mm, the elongation is 20-35%, and the resistivity does not exceed 0.0172 Ω·mm. 2 / m, the nominal cross-sectional area of ​​the electrical conductor is 120 mm. 2 150 mm 2 185 mm 2 240mm 2 240mm 2 400mm 2 or 500 mm 2 And the DC resistance value of the electrical conductor at 20°C satisfies: When the nominal cross-sectional area is 120mm 2 At that time, it is not greater than 0.1463Ω / km; When the nominal cross-sectional area is 150mm 2 At that time, it is not greater than 0.1197 Ω / km; When the nominal cross-sectional area is 185mm 2 At that time, it is not greater than 0.095Ω / km; When the nominal cross-sectional area is 240mm 2 At that time, it is not greater than 0.0724Ω / km; When the nominal cross-sectional area is 400mm² 2 At that time, it is not greater than 0.0451Ω / km; When the nominal cross-sectional area is 500mm² 2 At that time, it is not greater than 0.0351Ω / km; S1.

2. Prepare the insulated wire core by extruding the conductor shielding layer, the insulation layer and the insulation shielding layer using a three-layer co-extrusion, dry cross-linking and continuous vulcanization production method. Sequentially wrap the conductor shielding layer, the insulation layer and the insulation shielding layer around the electrical conductor to obtain the insulated wire core. Place the obtained insulated wire core in a drying oven at 60±2℃ for degassing treatment for 120 hours, starting from when the surface temperature of the insulated wire core reaches 58℃. S1.3 Wrapping the metal shielding layer: Soft copper wire is loosely wound around the outside of the insulated core, with the total cross-sectional area of ​​the soft copper wire in each phase not less than 35 mm². 2 The gap between adjacent soft copper wires is no greater than 4mm. A fastening copper strip is wrapped around the surface of the soft copper wire through the gap to fasten the soft copper wire. The winding direction of the fastening copper strip is opposite to the winding direction of the soft copper wire. The nominal thickness of the fastening copper strip is 0.1mm, and the thinnest thickness is not less than 90% of the nominal thickness. And / or, the conductor shielding layer is extruded from a peroxide cross-linked semiconductive shielding material, the nominal thickness of the conductor shielding layer is 0.8 mm, and the minimum thickness is not less than 0.5 mm; the insulation layer is extruded from a high-purity water-tree resistant cross-linked polyethylene insulation material, the nominal thickness of the insulation layer is 10.5 mm, and the minimum thickness is not less than 90% of the nominal thickness; the insulating shielding layer is extruded from a peroxide cross-linked semiconductive shielding material, the nominal thickness of the insulating shielding layer is 1.0 mm, and the minimum thickness is not less than 0.6 mm.

10. The method for manufacturing a floating dynamic cable for waterborne photovoltaic systems according to claim 8, characterized in that, In S4, The isolation sleeve is made of high-density polyethylene material through extrusion. The nominal thickness of the isolation sleeve is 2.0-4.0 mm, and the thickness of the thinnest point of the isolation sleeve is not less than 85% of its nominal thickness. And / or, the first armor layer is made of multiple carbon fiber reinforced polymer fiber bundles wrapped around each other, wherein the nominal diameter of the carbon fiber reinforced polymer fiber bundles is 4.0 mm, the minimum diameter is not less than 90% of the nominal diameter, and the sum of the gaps between the multiple carbon fiber reinforced polymer fiber bundles is not greater than the diameter of one carbon fiber reinforced polymer fiber bundle.

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