A high-power intelligent temperature control cable

Abstract

This invention discloses a high-power intelligent temperature-controlled cable, relating to the field of power transmission technology. It includes a conductor, a first insulation layer, a temperature control system, an early warning system, and a protective sheath. The conductor is made of a high-conductivity material and is covered by a first insulation layer. The temperature control system includes a liquid-cooling pipe and multiple temperature sensors, with coolant flowing inside the liquid-cooling pipe. The early warning system includes temperature-sensing optical fibers distributed along the conductor's axis, connected to a fault early warning module. The protective sheath covers the conductor, temperature control system, and temperature-sensing optical fibers, and includes an electromagnetic shielding layer, a mechanical protection layer, and a safety protection layer. The temperature sensors and the fault early warning module are used to connect to a control unit. This invention effectively suppresses conductor thermal fatigue by regulating the cable's operating temperature in real time through the temperature control system; it provides high-strength electromagnetic shielding, mechanical tensile strength, and bending resistance through the protective sheath; and it improves operational safety by monitoring the cable's temperature and strain status in real time through the early warning system.

Description

Technical Field

[0001] This invention relates to the field of power transmission technology, and in particular to a high-power intelligent temperature-controlled cable. Background Technology

[0002] In high-power cables, temperature control, protection systems, and fault monitoring are crucial for ensuring reliable operation. However, existing cable technologies typically rely on passive heat dissipation methods (such as natural convection or simple air cooling) and basic insulation and shielding structures, which can lead to the following problems:

[0003] Relying on passive heat dissipation or simple air cooling results in large temperature fluctuations, leading to accelerated thermal fatigue of the conductor.

[0004] Existing cables struggle to simultaneously achieve electromagnetic shielding, mechanical strength, and flame retardancy, especially under conditions of high-frequency electromagnetic interference or extreme mechanical stress.

[0005] Conventional cables rely on periodic manual inspections and lack real-time distributed monitoring capabilities, making it impossible to provide early warnings of latent defects.

[0006] To address the aforementioned issues, there is an urgent need for a high-power intelligent temperature control cable that integrates efficient temperature control, composite protection, and real-time fault monitoring to meet the high reliability requirements under extreme environments. Summary of the Invention

[0007] To solve the above-mentioned technical problems, the present invention provides a high-power intelligent temperature control cable, the specific technical solution of which is as follows:

[0008] A high-power intelligent temperature-controlled cable includes a conductor, a first insulation layer, a temperature control system, an early warning system, and a protective sleeve.

[0009] The conductor is made of a highly conductive material and is covered with a first insulating layer.

[0010] The temperature control system includes liquid-cooled pipes distributed along the axial direction of the conductor and multiple temperature sensors, wherein coolant is adapted to flow within the liquid-cooled pipes.

[0011] The early warning system includes a temperature-sensing optical fiber distributed along the axial direction of the conductor, and the temperature-sensing optical fiber is connected to a fault early warning module.

[0012] The protective sleeve covers the conductor, temperature control system, and temperature-sensing optical fiber, and includes an electromagnetic shielding layer, a mechanical protection layer, and a safety protection layer.

[0013] The temperature sensor and fault warning module are used to connect to the control unit.

[0014] Preferably, the liquid cooling pipes are arranged in a spiral pattern; and / or the temperature-sensing optical fiber is laid in an S-shape.

[0015] Preferably, the conductor is copper stranded wire or silver-plated copper stranded wire; and / or the coolant includes an aqueous solution of ethylene glycol; and / or the liquid cooling pipe is made of stainless steel.

[0016] Preferably:

[0017] The electromagnetic shielding layer includes an aluminum foil layer, a copper wire braided mesh layer, and a copper interlocking armor layer.

[0018] The mechanical protective layer includes an aramid composite tape layer, which is formed by spirally winding aramid fiber composite tape at a 40-50° angle.

[0019] The safety protection layer includes a halogen-free, low-smoke, flame-retardant sheath and a polytetrafluoroethylene sheath.

[0020] Preferably:

[0021] The aluminum foil layer, copper wire braided mesh layer, copper interlocking armor layer, aramid composite tape layer, halogen-free low-smoke flame-retardant sheath layer, and polytetrafluoroethylene sheath layer are sequentially nested from the inside out.

[0022] It also includes a polyester film layer bonded to the aluminum foil layer, an inner protective layer disposed between the copper wire braided mesh layer and the copper interlocking armor layer, and a nano-silver thermal paste filled between the polyester film layer and the conductor, temperature control system and temperature-sensing optical fiber.

[0023] Preferably:

[0024] The control unit uses a PID algorithm to dynamically adjust the coolant flow rate or volume based on the temperature sensor data.

[0025] The fault warning module uses a Bayesian algorithm to fuse temperature and strain data and generate fault warning signals by analyzing temperature gradients and impedance spectra.

[0026] Preferably, the temperature control system further includes a segmented temperature control component, and the liquid cooling pipe is covered with a second insulating layer; the segmented temperature control component includes a dielectric layer, a positive electrode strip, a wire, and a negative electrode strip.

[0027] The dielectric layer is disposed on the inner wall of the liquid cooling pipe.

[0028] The positive electrode strip is disposed on the outer wall of the second insulating layer and has multiple segments along the length of the liquid cooling pipe. Each segment of the positive electrode strip is connected to a wire through a thermistor semiconductor material, and the wire is connected to the control unit.

[0029] The negative electrode strip is disposed on the outer wall of the second insulating layer, laid along the length of the liquid cooling pipe, and positioned opposite the positive electrode strip.

[0030] Preferably, the dielectric layer is a parylene coating, which is prepared by chemical vapor deposition; or the dielectric layer is a pre-fabricated polytetrafluoroethylene liner, which is fixed to the inner wall of the liquid cooling pipe by a heat shrinking process.

[0031] Preferably, the thermosensitive semiconductor material is a doped silicon semiconductor; and / or the second insulating layer is a polyimide film, which is coated onto the outer wall of the liquid cooling pipe by a heat shrinking process; and / or the negative electrode strip is a copper foil.

[0032] Preferably, the prefabricated polytetrafluoroethylene liner is prepared using modified polytetrafluoroethylene, and its preparation process includes the following steps:

[0033] Polytetrafluoroethylene powder and nano-alumina particles are mixed at a mass ratio of 100:(5~10), and 1%~2% of the total mass of the two silane coupling agent is added. The mixture is stirred to form a modified polytetrafluoroethylene mixture.

[0034] The modified polytetrafluoroethylene mixture was prepared by extrusion molding.

[0035] The high-power intelligent temperature control cable provided by this invention has the following beneficial effects:

[0036] 1. High-efficiency temperature control: The temperature control system uses liquid cooling pipes distributed along the conductor axis and multiple temperature sensors, along with flowing coolant, to adjust the cable operating temperature in real time, effectively suppress conductor thermal fatigue, and improve the cable's current carrying capacity and service life.

[0037] 2. Comprehensive protection performance: The protective sleeve includes an electromagnetic shielding layer, a mechanical protection layer, and a safety protection layer, which respectively provide high-strength electromagnetic shielding, mechanical tensile and bending resistance, as well as flame retardant and chemical corrosion resistance, significantly enhancing the cable's adaptability to extreme environments (such as high temperature, strong acid and alkali, electromagnetic interference).

[0038] 3. Real-time fault warning: The warning system, through temperature-sensing optical fibers and fault warning modules distributed along the conductor axis, can monitor the temperature and strain status of the cable in real time, promptly detect latent defects and generate warning signals, reduce fault risks and improve operational safety.

[0039] 4. System Integration and Intelligence: Through the communication connection between temperature sensors and fault early warning modules and control units, collaborative management of temperature control and fault monitoring is achieved, optimizing cable operation efficiency. It is suitable for high-reliability scenarios such as nuclear power, deep sea, aerospace, and polar scientific research. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] Figure 1 A cross-sectional view of a high-power intelligent temperature control cable provided for an embodiment of the present invention;

[0042] Figure 2 This is a side view of a liquid cooling pipe provided in another embodiment of the present invention.

[0043] Figure Labels

[0044] conductor;

[0045] First insulating layer;

[0046] Temperature control system; 31-Liquid cooling pipe; 32-Temperature sensor; 33-Positive electrode band; 34-Wire; 35-Negative electrode band;

[0047] Early warning system;

[0048] Protective sleeve; 51-Electromagnetic shielding layer; 511-Aluminum foil layer; 512-Copper wire braided mesh layer; 513-Copper interlocking armor layer; 52-Mechanical protection layer; 521-Aramid composite tape layer; 53-Safety protection layer; 531-Halogen-free low-smoke flame-retardant sheath layer; 532-PTFE sheath layer; 54-Polyester film layer; 55-Inner lining protective layer; 56-Nano silver thermal conductive paste. Detailed Implementation

[0049] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be described in detail below with reference to the accompanying drawings. The description in this part is only exemplary and explanatory, and should not be used to limit the scope of protection of the present invention in any way.

[0050] It should be noted that similar labels in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0051] It should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use. They are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. In addition, the terms "first," "second," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0052] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0053] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0054] Please see Figure 1 and Figure 2 This embodiment provides a high-power intelligent temperature control cable, including a conductor 1, a first insulation layer 2, a temperature control system 3, an early warning system 4, and a protective sleeve 5.

[0055] Conductor 1 is made of a highly conductive material and is covered with a first insulating layer 2.

[0056] The temperature control system 3 includes a liquid cooling pipe 31 distributed along the axial direction of the conductor 1 and a plurality of temperature sensors 32, wherein the liquid cooling pipe 31 is adapted to flow coolant.

[0057] The early warning system 4 includes a temperature-sensing optical fiber distributed along the axial direction of conductor 1, and the temperature-sensing optical fiber is connected to a fault early warning module.

[0058] The protective sleeve 5 covers the conductor 1, the temperature control system 3 and the temperature sensing optical fiber, and includes an electromagnetic shielding layer 51, a mechanical protective layer 52 and a safety protective layer 53.

[0059] Temperature sensor 32 and fault warning module are used to connect to the control unit.

[0060] The conductor 1 is made of a high-conductivity material, such as 99.99% oxygen-free copper or silver-plated copper stranded wire, with a conductivity ≥58 MS / m to ensure efficient current transmission. The silver plating thickness can be selected from 1 to 5 μm to achieve equipotential bonding and reduce contact resistance. The first insulation layer 2 can be made of cross-linked polyethylene or polytetrafluoroethylene, with a thickness of 1 to 2 mm, providing electrical insulation and uniformly covering the conductor. The temperature control system 3 includes a liquid cooling pipe 31 and a temperature sensor 32. The liquid cooling pipe 31 can be made of 316L stainless steel or high thermal conductivity polyimide, with a pipe diameter of 1.5 to 2.5 mm and a wall thickness of 0.1 to 0.3 mm. The coolant can be a 50% ethylene glycol aqueous solution, silicone oil, or a low-conductivity fluorinated liquid, with a flow rate of 8 to 15 L / min. The temperature sensor 32 can be a PT1000 or a thermocouple, with an accuracy of ±0.5℃, and one sensor is arranged every 0.5~1m. The temperature sensing fiber can be a single-mode or multi-mode fiber, based on the Raman scattering principle, with a spatial resolution of 0.1~0.5m. The fault early warning module is based on an embedded processor, runs a Bayesian algorithm, and fuses temperature and strain data. The control unit can be a PLC or an embedded controller, which communicates with the temperature sensor and the fault early warning module via RS485 or CAN bus, and runs PID and Bayesian algorithms.

[0061] The number of liquid cooling tubes 31 and temperature-sensing optical fibers can be multiple. Multiple liquid cooling tubes 31 can be spirally distributed along the conductor axis with a spacing of 10~15mm to ensure uniform heat dissipation. The temperature-sensing optical fibers can be laid in an S-shape or in a straight line, attached to the conductor 1 or the outer wall of the liquid cooling tubes 31. The protective sleeve 5 is layered from the inside to the outside, and the inside can be filled with nano-silver thermal conductive paste (thermal conductivity 5~10W / m·K) to enhance heat conduction.

[0062] The preparation process can specifically include the following steps:

[0063] S1. Conductor processing: Copper stranded wire is ultrasonically cleaned, silver-plated (electroplating or chemical plating), and vacuum annealed (300~400℃, 1~3h).

[0064] S2. Insulation layer coating: XLPE is uniformly coated onto the conductor by extrusion molding, with a curing temperature of 150~200℃.

[0065] S3. Liquid cooling tube integration: Laser welding of liquid cooling tube to the conductor, pressure test (2~4MPa, 20~40min), and filling with coolant.

[0066] S4. Temperature-sensing fiber optic cable installation: S-shaped winding and fixing, with intervals of 0.1~0.5m, connected to the OTDR host.

[0067] S5. Preparation of protective sleeve: The electromagnetic shielding layer, mechanical protection layer and safety protection layer are wound or extruded layer by layer, and filled with thermal conductive paste.

[0068] Specifically, conductor 1 is used to transmit high-voltage current, temperature control system 3 dissipates heat through liquid cooling pipe 31 circulating coolant (driven by pump group), temperature sensor 32 can monitor temperature in real time, and data is transmitted to control unit; early warning system 4 detects temperature and strain through temperature sensing fiber, fault early warning module analyzes abnormalities and generates early warning; protective sleeve 5 provides electromagnetic, mechanical and chemical protection to ensure stable operation of cable in extreme environments (such as -40~120℃).

[0069] The high-power intelligent temperature control cable provided in this embodiment has the following beneficial effects:

[0070] High-efficiency temperature control: The temperature control system uses liquid-cooled pipes distributed along the conductor axis and multiple temperature sensors, along with flowing coolant, to adjust the cable operating temperature in real time, effectively suppress conductor thermal fatigue, and improve the cable's current carrying capacity and service life.

[0071] Comprehensive protection performance: The protective sleeve includes an electromagnetic shielding layer, a mechanical protection layer, and a safety protection layer, which respectively provide high-strength electromagnetic shielding, mechanical tensile and bending resistance, as well as flame retardancy and chemical corrosion resistance, significantly enhancing the cable's adaptability to extreme environments (such as high temperature, strong acid and alkali, and electromagnetic interference).

[0072] Real-time fault warning: The warning system, through temperature-sensing optical fibers and fault warning modules distributed along the conductor axis, can monitor the temperature and strain status of the cable in real time, promptly detect latent defects and generate warning signals, reduce fault risks and improve operational safety.

[0073] System integration and intelligence: Through the communication connection between temperature sensors and fault early warning modules and control units, collaborative management of temperature control and fault monitoring is achieved, optimizing cable operation efficiency. It is suitable for high-reliability scenarios such as nuclear power, deep sea, aerospace, and polar scientific research.

[0074] Furthermore, the liquid cooling pipes 31 are arranged in a spiral pattern; and / or the temperature-sensing optical fibers are laid in an S-shape.

[0075] The temperature-sensing optical fiber can be a high-temperature resistant single-mode optical fiber with a core diameter of 8~10μm and a cladding diameter of 125μm. The liquid cooling tube 31 can be wound in a spiral along the axial direction of the conductor 1 with a pitch of 10~15mm and an angle of 30~60° to ensure that the coolant uniformly covers the conductor 1 and enhances the heat dissipation efficiency. The spiral can be a single spiral or a double spiral, depending on the heat dissipation requirements. The temperature-sensing optical fiber can be laid in an S-shaped curve along the outer wall of the conductor 1 or the liquid cooling tube 31 at intervals of 0.1~0.5m, and fixed by high-temperature resistant cable ties or adhesives to ensure high spatial resolution monitoring.

[0076] During preparation, the liquid cooling tube 31 can be fixed around the conductor 1 with a set pitch using an automated winding device, and the fixing point is laser welded; the temperature sensing optical fiber can be manually or mechanically wound in an S-shape, and fixed with cable ties every 0.1~0.5m, and the terminal is connected to the OTDR host.

[0077] Beneficially, the spiral liquid cooling tube 31 can increase the thermal conductivity area between the coolant and the conductor, optimizing heat transfer; the S-shaped temperature-sensing optical fiber detects temperature and strain through Raman scattering, and combined with OTDR technology, achieves a spatial resolution of 0.1~0.5m, improving fault location accuracy.

[0078] Furthermore, conductor 1 is copper stranded wire or silver-plated copper stranded wire; and / or the coolant includes an aqueous solution of ethylene glycol; and / or the liquid cooling pipe 31 is made of stainless steel.

[0079] Furthermore:

[0080] The electromagnetic shielding layer 51 includes an aluminum foil layer 511, a copper wire braided mesh layer 512, and a copper interlocking armor layer 513.

[0081] The mechanical protective layer 52 includes an aramid composite tape layer 521, which is formed by spirally winding an aramid fiber composite tape at a 40-50° angle.

[0082] The safety protection layer 53 includes a halogen-free, low-smoke, flame-retardant sheath layer 531 and a polytetrafluoroethylene sheath layer 532.

[0083] Among them, the aluminum foil layer 511 has a thickness of 0.1~0.3mm and a shielding effectiveness of 100~120dB@10MHz; the copper wire braided mesh layer 512 has a copper wire diameter of 0.1~0.2mm, a coverage of 90%~95%, and a shielding effectiveness of 120~140dB@10MHz; the copper interlocking armor layer 513 has a thickness of 0.5~1mm and a shielding effectiveness of 140~150dB@10MHz; the aramid fiber composite tape (EPDM substrate) has a thickness of 1~2mm, a tensile strength of 150~200MPa, and a bending radius of 4D; the halogen-free low-smoke flame-retardant sheath 531 conforms to the UL94 V-0 standard, has a smoke density of <100, and a temperature resistance of -40~120℃; and the polytetrafluoroethylene sheath 532 has a thickness of 0.5~1mm and is resistant to strong acids, alkalis, and ultraviolet aging.

[0084] The layers are nested sequentially from the inside out: aluminum foil → copper wire braided mesh → copper armor → aramid composite tape → halogen-free flame-retardant sheath → PTFE protective layer, and the layers are fixed by conductive adhesive or mechanical pressing.

[0085] The preparation process may include:

[0086] Aluminum foil layer: Wrap with 0.2mm aluminum foil, with an overlap rate of 20%~30%.

[0087] Copper wire mesh: woven by automated weaving machines, with a coverage rate of ≥90%.

[0088] Copper armor: Interlocking compression molding ensures contact resistance ≤0.1Ω.

[0089] Aramid composite tape: 45° spiral winding, winding speed 0.5~1m / min.

[0090] Halogen-free flame-retardant sheath and PTFE sheath: extrusion molding, curing temperature 150~200℃.

[0091] Beneficially, aluminum foil and copper wire mesh provide high-frequency electromagnetic shielding, while copper armor enhances low-frequency shielding and mechanical strength; aramid composite tape improves tensile and bending resistance, and halogen-free flame-retardant sheath and PTFE coating ensure fire safety and chemical stability.

[0092] Furthermore:

[0093] The aluminum foil layer 511, the copper wire braided mesh layer 512, the copper interlocking armor layer 513, the aramid composite tape layer 521, the halogen-free low-smoke flame-retardant sheath layer 531, and the polytetrafluoroethylene sheath layer 532 are sequentially nested from the inside out.

[0094] It also includes a polyester film layer 54 bonded to the aluminum foil layer 511, an inner protective layer 55 disposed between the copper wire braided mesh layer 512 and the copper interlocking armor layer 513, and a nano-silver thermal paste 56 filled between the polyester film layer 54 and the conductor 1, the temperature control system 3 and the temperature-sensing optical fiber.

[0095] Specifically, the polyester film layer 54 is polyethylene terephthalate (PET) with a thickness of 0.05~0.1mm, providing inner insulation; the inner protective layer 55 can be made of polyethylene (PE) or polyvinyl chloride (PVC) with a thickness of 0.5~1mm, buffering the mechanical stress between the copper wire braid and the armor; the nano-silver thermal conductive paste 56 has a thermal conductivity of 5~10W / m·K, filling the gaps between conductor 1, liquid cooling pipe 31 and temperature sensing optical fiber, enhancing heat conduction.

[0096] During the arrangement, the polyester film layer 54 is closely attached to the inner side of the aluminum foil layer 511, the inner protective layer 55 is located between the copper wire braid and the copper armor, and the nano silver thermal paste 56 fills the internal gaps to ensure that heat is quickly transferred to the liquid cooling pipe 31.

[0097] During preparation, the polyester film layer 54 is made by wrapping a 0.05mm PET film with an overlap rate of 10%~20%; the inner protective layer 55 is made by extrusion molding of PE or PVC with uniform thickness; the nano silver thermal conductive paste 56 can be filled by injection equipment, and the thermal conductivity is tested after curing.

[0098] Furthermore:

[0099] The control unit uses a PID algorithm to dynamically adjust the coolant flow rate or volume based on data from temperature sensor 32.

[0100] The fault warning module uses a Bayesian algorithm to fuse temperature and strain data and generate fault warning signals by analyzing temperature gradients and impedance spectra.

[0101] The control unit can be a PLC or an embedded controller, running a PID algorithm with a processing capacity of ≥100MHz and a communication interface of RS485 or CAN; the fault early warning module is an embedded processor, running a Bayesian algorithm with a memory of ≥512MB, and fusing temperature (accuracy ±0.5℃) and strain (accuracy ±5) data; the temperature sensor 32 can be a PT1000 with a resistance of 1000Ω@0℃, and one sensor is arranged every 0.5~1m.

[0102] In the arrangement, temperature sensors 32 are evenly distributed along the axial direction of conductor 1 and fixed to the liquid cooling pipe 31 or the outer wall of conductor 1. Data is transmitted via RS485 bus. The fault warning module is integrated into the control unit or a separate module, and the temperature sensing fiber optic terminal is connected to the OTDR host.

[0103] During fabrication, the temperature sensor PT1000 is fixed by welding or bonding and connected to the RS485 bus; the control unit embeds a PID algorithm to set the temperature threshold and flow regulation parameters; the fault warning module is programmed with a Bayesian algorithm to calibrate the temperature and strain data processing logic.

[0104] The PID algorithm calculates the deviation based on temperature sensor data and dynamically adjusts the pump flow rate (8~15L / min) to stabilize the cable temperature. The Bayesian algorithm analyzes the temperature gradient and impedance spectrum of the temperature-sensing optical fiber to identify latent defects (such as buffer layer ablation) and generate early warning signals.

[0105] Furthermore, the temperature control system 3 also includes a segmented temperature control component, with the liquid cooling pipe 31 covered by a second insulating layer; the segmented temperature control component includes a dielectric layer, a positive electrode strip 33, a wire 34, and a negative electrode strip 35.

[0106] The dielectric layer is located on the inner wall of the liquid cooling pipe 31.

[0107] The positive electrode strip 33 is located on the outer wall of the second insulating layer and has multiple segments along the length of the liquid cooling pipe 31. Each segment of the positive electrode strip 33 is connected to the wire 34 through a thermistor semiconductor material, and the wire 34 is connected to the control unit.

[0108] The negative electrode strip 35 is located on the outer wall of the second insulating layer, laid along the length of the liquid cooling pipe 31, and positioned opposite the positive electrode strip 33.

[0109] The dielectric layer can be made of parylene (0.05~0.1mm thick) or polytetrafluoroethylene (0.1~0.2mm thick), with a dielectric strength >10kV / mm; the second insulating layer can be made of polyimide film with a thickness of 0.05~0.1mm; the positive electrode strip 33 can be copper foil, 1~3mm wide and 0.3~0.6mm thick, with each segment 0.5~2m long, and the thermistor material is doped silicon semiconductor; the negative electrode strip 35 can be copper foil, 0.5~1.5mm wide and 0.05~0.2mm thick, and grounded; the conductor 34 can be copper wire with an outer insulating layer, a diameter of 0.1~0.3mm, and a withstand voltage >500V.

[0110] During the arrangement, the second insulating layer covers the outer wall of the liquid cooling pipe, and the positive electrode strip 33 and the negative electrode strip 35 are laid parallel to each other along the axial direction on the insulating layer. The positive electrode strip is segmented (0.5~2m), and the side is connected to the thermal semiconductor material. The semiconductor of each segment is connected to the control unit through the wire 34, and the negative electrode strip 35 is continuously grounded.

[0111] During preparation, heat-shrink PI film is applied to the outer wall of the liquid cooling tube 31 (150~200℃, 20~30min); the positive electrode strip 33 is pasted in segments, the negative electrode strip 35 (copper foil) is pasted continuously, and the wire 34 is welded and then sealed with insulating glue.

[0112] When the temperature in a certain section is greater than 60℃, the thermistor semiconductor material becomes conductive, and the positive electrode 33 and the wire 34 are connected. The control unit applies a voltage of 10~30V, and an electric field (10~50V / cm) is formed between the positive and negative electrodes. The dielectric layer isolates the electric field, triggers the electrowetting effect, changes the contact angle of the coolant, increases the heat exchange area of ​​the pipe wall, and enhances local heat dissipation.

[0113] Furthermore, the dielectric layer is a parylene coating, which is prepared by chemical vapor deposition; or the dielectric layer is a pre-fabricated polytetrafluoroethylene liner, which is fixed to the inner wall of the liquid cooling pipe 31 by heat shrinking process.

[0114] Furthermore, the thermistor material is a doped silicon semiconductor; and / or the second insulating layer is a polyimide film, which is wrapped around the outer wall of the liquid cooling pipe 31 by a heat shrinking process; and / or the negative electrode strip 35 is a copper foil.

[0115] Furthermore, the prefabricated polytetrafluoroethylene liner is prepared using modified polytetrafluoroethylene, and its preparation process includes the following steps:

[0116] Polytetrafluoroethylene powder and nano-alumina particles are mixed at a mass ratio of 100:(5~10), and 1%~2% of the total mass of the two silane coupling agent is added. The mixture is stirred to form a modified polytetrafluoroethylene mixture.

[0117] The modified polytetrafluoroethylene mixture was prepared by extrusion molding.

[0118] Beneficially, nano-alumina can improve the thermal conductivity of PTFE, and silane coupling agents enhance adhesion to the inner wall of stainless steel; plasma treatment activates the surface, further improving the bonding strength and ensuring no peeling during long-term operation.

[0119] Specific embodiments are provided below. These embodiments are intended to enable those skilled in the art to more fully understand the present invention, but do not limit the present invention in any way.

[0120] Example

[0121] Copper wire drawing (10m / s, 6mm diameter), cleaning (ultrasonic, 40kHz, 10min); silver electroplating (50g / L silver sulfate, 3.2A / dm). 2 The coating thickness was 3.1 μm; vacuum annealing (350℃, 2h, heating rate 5℃ / min). XLPE granules (5kg) were added to an extruder (180℃, screw 50rpm), extruded to a thickness of 1.52mm, and cooled in a water bath (20℃, 5min). 316L stainless steel pipes (3 pieces, Φ2.0mm, wall thickness 0.2mm) were laser welded (2kW, speed 1m / min) to the conductor, with a spiral spacing of 12.3mm and a 45° angle; 50% ethylene glycol aqueous solution (10L) was injected, and pressure tested (3.02MPa, 30min, no leakage). PT1000 sensors (10 pieces) were bonded to the outer wall of the liquid-cooled pipe (spacing 1.01m) and connected to an RS485 bus. Single-mode optical fiber (12m) was wound in an S-shape, fixed with high-temperature resistant cable ties, and the terminal was connected to the OTDR host. Wrapped with 0.05mm polyester film and 0.2mm aluminum foil; copper wire braid (0.15mm), copper armor (0.5mm); aramid composite tape (1.5mm, 45° winding, speed 0.82m / min); extruded halogen-free flame-retardant sheath (180℃, 3kg) and PTFE sheath (0.5mm, 2kg); filled with nano-silver thermal conductive paste (0.5kg, injection pressure 0.1MPa).

[0122] The PLC is programmed with a PID algorithm (target temperature 40℃, proportional coefficient Kp=0.8, integral time Ti=10s) and connected to an RS485 bus; a Bayesian algorithm is programmed, and temperature (±0.5℃) and strain (±5με) thresholds are calibrated.

[0123] At an ambient temperature of 25.3℃, an infrared thermal imager and a thermocouple thermometer were used to test the temperature rise. The cable was run for 1 hour under a 1200A load, and the inlet (T1) / outlet (T2) temperature of the liquid cooling pipe and the conductor surface temperature (T3) were recorded. The temperature rise was calculated as: ΔT = max(T3) - 25.3℃. The temperature distribution at 5 points (0m, 2.5m, 5m, 7.5m, 10m) was measured, and the standard deviation σ was calculated.

[0124] Simulate a local temperature rise (60℃, 5cm area), record the positioning accuracy of the OTDR signal, perform 5 tests, and take the average value.

[0125] Simulate local temperature rise (65℃) and strain abrupt change (100με), record the time when the Bayesian algorithm generates the early warning signal, test 5 times, and take the average value.

[0126] The test data is shown in the table below:

[0127]

[0128] Comparative Example

[0129] Copper wire drawing (10m / s, 6mm diameter), ultrasonic cleaning (40kHz, 10min); vacuum annealing (350℃, 2h, heating rate 5℃ / min), no silver plating; XLPE granules (5kg) added to extruder (180℃, 50rpm), extrusion thickness 1.51mm, cooling water tank (20℃, 5min); copper wire braiding (0.15mm); extrusion of halogen-free flame-retardant sheath (180℃, 3kg, screw 60rpm).

[0130] The temperature rise and temperature uniformity test methods are the same as in the embodiment, and the test data are shown in the table below:

[0131]

[0132] It should be noted that, in this document, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0133] This article uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. The above are only preferred embodiments of the present invention. It should be noted that due to the limitations of textual expression, and the objective existence of infinite specific structures, those skilled in the art can make several improvements, modifications, or changes without departing from the principles of the present invention, and can also combine the above technical features in an appropriate manner; these improvements, modifications, changes, or combinations, or the direct application of the inventive concept and technical solution to other occasions without modification, should all be considered within the scope of protection of the present invention.

Claims

1. A high-power intelligent temperature control cable, characterized in that, include: The conductor (1) is made of a highly conductive material and is covered with a first insulating layer (2). The temperature control system (3) includes a liquid cooling pipe (31) distributed along the axial direction of the conductor (1), a plurality of temperature sensors (32) and a segmented temperature control assembly. The liquid cooling pipe (31) is suitable for flowing coolant, and the liquid cooling pipe (31) is covered with a second insulating layer. The early warning system (4) includes a temperature-sensing optical fiber distributed along the axial direction of the conductor (1), and the temperature-sensing optical fiber is connected to a fault early warning module; The protective sleeve (5) covers the conductor (1), the temperature control system (3) and the temperature sensing fiber, including an electromagnetic shielding layer (51), a mechanical protective layer (52) and a safety protective layer (53). The temperature sensor (32) and the fault warning module are used to connect to the control unit; The segmented temperature control component includes: A dielectric layer is disposed on the inner wall of the liquid cooling pipe (31); A positive electrode strip (33) is disposed on the outer wall of the second insulating layer and has multiple segments along the length of the liquid cooling pipe (31). Each segment of the positive electrode strip (33) is connected to a wire (34) through a thermistor semiconductor material. The wire (34) is connected to the control unit. The negative electrode strip (35) is disposed on the outer wall of the second insulating layer, laid along the length of the liquid cooling pipe (31), and positioned opposite the positive electrode strip (33).

2. The high-power intelligent temperature control cable according to claim 1, characterized in that: The liquid cooling pipes (31) are arranged in a spiral pattern; And / or the temperature-sensing optical fiber is laid in an S-shape.

3. The high-power intelligent temperature control cable according to claim 1, characterized in that: The conductor (1) is a copper stranded wire or a silver-plated copper stranded wire; And / or the coolant includes an aqueous solution of ethylene glycol; And / or the liquid cooling pipe (31) is made of stainless steel.

4. The high-power intelligent temperature control cable according to claim 1, characterized in that: The electromagnetic shielding layer (51) includes an aluminum foil layer (511), a copper wire braided mesh layer (512), and a copper interlocking armor layer (513). The mechanical protective layer (52) includes an aramid composite tape layer (521), which is formed by spirally winding an aramid fiber composite tape at 40~50°. The safety protection layer (53) includes a halogen-free low-smoke flame-retardant sheath layer (531) and a polytetrafluoroethylene sheath layer (532).

5. The high-power intelligent temperature control cable according to claim 4, characterized in that: The aluminum foil layer (511), copper wire braided mesh layer (512), copper interlocking armor layer (513), aramid composite tape layer (521), halogen-free low-smoke flame-retardant sheath layer (531) and polytetrafluoroethylene sheath layer (532) are sequentially nested from the inside to the outside; It also includes a polyester film layer (54) bonded to the aluminum foil layer (511), an inner protective layer (55) disposed between the copper wire braided mesh layer (512) and the copper interlocking armor layer (513), and a nano silver thermal paste (56) filled between the polyester film layer (54) and the conductor (1), the temperature control system (3) and the temperature-sensing optical fiber.

6. The high-power intelligent temperature control cable according to any one of claims 1 to 5, characterized in that: The control unit uses a PID algorithm to dynamically adjust the coolant flow rate or flow rate based on the data from the temperature sensor (32); The fault warning module uses a Bayesian algorithm to fuse temperature and strain data and generate fault warning signals by analyzing temperature gradients and impedance spectra.

7. The high-power intelligent temperature control cable according to claim 1, characterized in that: The dielectric layer is a parylene coating, which is prepared by chemical vapor deposition. Alternatively, the dielectric layer may be a prefabricated polytetrafluoroethylene liner, which is fixed to the inner wall of the liquid cooling pipe (31) by a heat shrinking process.

8. The high-power intelligent temperature control cable according to claim 1, characterized in that: The thermosensitive semiconductor material is a doped silicon semiconductor; And / or the second insulating layer is a polyimide film, which is wrapped around the outer wall of the liquid cooling pipe (31) by a heat shrinking process; And / or the negative electrode strip (35) is copper foil.

9. The high-power intelligent temperature control cable according to claim 7, characterized in that, The prefabricated polytetrafluoroethylene liner is prepared using modified polytetrafluoroethylene, and its preparation process includes the following steps: Polytetrafluoroethylene powder and nano-alumina particles are mixed at a mass ratio of 100:(5~10), and 1%~2% of silane coupling agent is added to the total mass of the two. The mixture is stirred to form a modified polytetrafluoroethylene mixture. The modified polytetrafluoroethylene mixture was prepared by extrusion molding.

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