Flat cable for travelling crane

Abstract

The invention belongs to the technical field of cables. The flat cable comprises a flat sheath, a carbon fiber layer and at least one conductive wire core unit, the plurality of conductive wire core units are arranged in parallel, the flat sheath wraps the plurality of conductive wire core units arranged in parallel, and the carbon fiber layer wraps the flat sheath. The cable is suitable for extreme industrial scenes such as metallurgy, mines, ships and the like, solves the problem that a traditional cable is poor in performance under the conditions of high temperature, abrasion, oil contamination and electromagnetic interference, and has the characteristics of high reliability, intelligence and environmental protection.

Description

TECHNICAL FIELD

[0001] The embodiment of the present application belongs to the technical field of cables, and particularly relates to a flat cable for a travelling crane. BACKGROUND

[0002] In industrial hoisting and travelling crane equipment, the flat cable is a core component for power transmission, and its performance is directly related to the operation stability and safety of the equipment. Traditional flat cables for travelling cranes are mostly made of ethylene-propylene-diene monomer (EPDM) or polyvinyl chloride (PVC) materials, which have certain oil resistance, wear resistance and temperature resistance, but still have obvious deficiencies under complex working conditions.

[0003] For example, the flat cable is easily subjected to problems such as sheath aging, insulation performance degradation and even breakage due to long-term exposure to high temperature, oil pollution and mechanical friction environment, resulting in unstable signal transmission or power interruption and affecting normal operation of the equipment. In addition, under extreme temperature conditions (such as severe cold or continuous high temperature), the mechanical strength and electrical conductivity of the existing cable will further deteriorate, making it difficult to meet the needs of high load and long-time continuous operation.

[0004] At present, most of the travelling crane flat cables on the market have single function and cannot simultaneously meet the multiple requirements of high temperature resistance, wear resistance, oil resistance and environmental protection. SUMMARY

[0005] In order to solve the deficiencies of the prior art, the embodiment of the present application provides a flat cable for a travelling crane, which innovatively introduces a carbon fiber layer as the outermost protective layer, is suitable for extreme industrial scenes such as metallurgy, mining and ships, and has high reliability, intelligence and environmental protection characteristics.

[0006] In order to achieve the above purpose, the embodiment of the present application adopts the following technical solutions: A flat cable for a travelling crane, comprising: a flat sheath, a carbon fiber layer and at least one conductive wire core unit. A plurality of conductive wire core units are arranged side by side, the flat sheath is wrapped outside the plurality of conductive wire core units arranged side by side, and the carbon fiber layer is wrapped outside the flat sheath.

[0007] In the first optional implementation manner of the present application, the conductive wire core unit is an insulated wire core, and the insulated wire core comprises a soft conductor and an insulating layer wrapped outside the soft conductor.

[0008] In the second optional implementation manner of the present application, the conductive wire core unit is an insulated wire core, and the insulated wire core comprises a soft conductor and an insulating layer wrapped outside the soft conductor. Flat cables also include stranded soft steel wires and optical fibers. The stranded soft steel wires and optical fibers are arranged side by side with the conductive core unit, and the stranded soft steel wires and optical fibers are wrapped in a flat sheath.

[0009] In a third optional implementation of the present invention, the conductive core unit is a shielded core, which includes a soft conductor, an insulating layer, and a shielding layer. The insulating layer is wrapped around the outside of the soft conductor, and the shielding layer is wrapped around the outside of the insulating layer.

[0010] In a fourth optional implementation of the present invention, the conductive core unit is a shielded core, which includes a soft conductor, an insulating layer and a shielding layer. The insulating layer is wrapped around the outside of the soft conductor, and the shielding layer is wrapped around the outside of the insulating layer. Flat cables also include stranded soft steel wires and optical fibers. The stranded soft steel wires and optical fibers are arranged side by side with the conductive core unit, and the stranded soft steel wires and optical fibers are wrapped in a flat sheath.

[0011] In a fifth optional implementation of the present invention, the conductive core unit is a stranded core, which includes an insulated core, stranded soft steel wire, a shielding layer, an optical fiber, a first wrapping layer, a second wrapping layer, and a shielding layer. The insulated core includes a soft conductor and an insulating layer wrapped around the outside of the soft conductor. A first wrapping layer is wrapped around the outside of multiple insulated cores stranded at a certain pitch. A shielding layer is wrapped around the outside of the first wrapping layer, and a second wrapping layer is wrapped around the outside of the shielding layer to form a stranded core. Multiple stranded cores are arranged in parallel, with stranded soft steel wires and optical fibers arranged in parallel with the stranded cores, and the stranded soft steel wires and optical fibers are wrapped in a flat sheath.

[0012] As a further limitation of the third, fourth and fifth optional implementations of the present invention, the shielding layer is woven from oxygen-free copper monofilament or tin-plated oxygen-free copper wire; or, the shielding layer is an aluminum foil shielding layer or a composite shielding layer; the composite shielding layer is a shielding layer composed of a shielding woven mesh and aluminum foil, wherein the shielding woven mesh is woven from oxygen-free copper monofilament or tin-plated oxygen-free copper wire.

[0013] As a further limitation of the present invention, the flat sheath is provided with an outer sheath groove, which is disposed on two mutually parallel planes in the width direction of the flat sheath.

[0014] As a further limitation of the first, second, third, fourth and fifth optional implementations of the present invention, the insulating layer is formed by high-temperature compounding of fluoroplastics or flame-retardant polyolefin materials and then by extrusion process. Fluoroplastics include PTFE suspension resin, anti-arc agent, colorant and lubricant. In the preparation of PTFE suspension resin, water-soluble peroxide is used as initiator, a derivative of hexafluoropropylene oxide dimer is used as dispersant, and deionized water is used as reaction medium. The preparation process of PTFE suspension resin includes: Deionized water, dispersant and initiator are added to the reactor and stirred to form a homogeneous system; TFE monomer is introduced while maintaining pressure and temperature to initiate free radical polymerization. The reaction is exothermic and requires cooling and temperature control; the polymerization time is 1–5 hours. After the reaction is complete, the unreacted TFE monomer is recovered; PTFE particles are precipitated from the suspension by mechanical stirring or by adding electrolytes; Repeated washing removes dispersant and residual initiator; Drying at 60℃–150℃ yields a white powdery PTFE suspension resin. After mixing white powdered PTFE suspension resin with an anti-arc agent, a colorant, and a lubricant, the mixture is allowed to stand for a set time. Under inert gas protection, it is sintered by staged heating and then cooled to obtain PTFE suspension resin.

[0015] As a further definition of the second, fourth, and fifth optional implementations of the present invention, the optical fiber includes a stainless steel flexible tube and an optical fiber disposed in the stainless steel flexible tube, and the stainless steel flexible tube is also filled with grease.

[0016] As a further limitation of the embodiments of the present invention, the flat sheath is made of flame-retardant polyolefin, silicone rubber or nitrile elastomer. The nitrile elastomer, by weight, comprises: 100 parts NBR, 40-60 parts carbon black N550, 10-20 parts DOP plasticizer, 6-12 parts stearic acid, 1.5-2.0 parts sulfur, 1.8-2.5 parts dodecyl mercaptan, 5 parts zinc oxide, 1-2 parts antioxidant 4010NA, 6-8 parts sodium phosphate, and 3-5 parts hydroquinone, wherein the NBR is composed of acrylonitrile and butadiene.

[0017] Furthermore, the preparation method of nitrile elastomer includes: Acrylonitrile and butadiene are softened in a thin pass on a two-roll mill in a ratio of 40℃ to 60℃ to form NBR. Add antioxidant, DOP plasticizer, zinc oxide, sodium phosphate, dodecyl mercaptan, sulfur, and carbon black N550 in that order; Disperse each component evenly and control the temperature to ≤100℃; Add hydroquinone.

[0018] Compared with the prior art, the beneficial effects of the present invention are: This invention innovatively proposes a flat cable for overhead cranes. The conductive core units are arranged side-by-side to form a flat structure, which can adapt to the confined installation space of overhead cranes, reducing the cable's volume. Simultaneously, it ensures balanced stress on each core, preventing tensile damage to a single core due to concentrated stress during crane movement, thus guaranteeing circuit continuity stability. The flat sheath encases the parallel cores, fixing their relative positions and preventing misalignment caused by crane vibrations, thus avoiding poor circuit contact. It also isolates the cores from external dust and moisture, preventing corrosion or physical abrasion, maintaining insulation performance, and reducing the risk of short circuits. The outer carbon fiber layer, with its high strength and low deformation characteristics, enhances the cable's overall tensile and bending resistance, adapting to the dynamic stress generated by frequent starts, stops, and reciprocating movements of the crane, reducing sheath cracking and core breakage caused by repeated deformation. The chemical stability of carbon fiber improves the cable's anti-aging performance, extending its service life under complex crane operating conditions without adding extra weight, thus avoiding affecting the crane's operational flexibility.

[0019] This invention innovatively proposes a flat cable for railway vehicles, in which stranded soft steel wires and insulated cores are arranged side by side, significantly enhancing the cable's tensile strength and resistance to mechanical friction. This effectively reduces the risk of sheath aging, insulation damage, and conductor breakage caused by long-term friction, ensuring signal transmission stability and power continuity. The combination of a flat sheath and a carbon fiber layer not only improves the cable's high-temperature and oil resistance through optimized sheath material, preventing insulation failure caused by sheath softening or oil erosion under high-temperature environments, but also enhances the overall mechanical strength of the cable through the high-strength properties of carbon fiber, maintaining structural stability under extreme cold or sustained high temperatures and reducing conductivity degradation. The integration of optical fibers not only improves signal transmission efficiency but also reduces the risk of electromagnetic interference through the separation of optical and electrical signals, further ensuring data transmission reliability. The environmentally friendly characteristics of the carbon fiber layer and the lightweight design of the composite structure enable the cable to meet multiple requirements such as high-temperature resistance, abrasion resistance, and oil resistance, while adapting to the needs of high-load, long-term continuous operation. This solves the problems of traditional cables having single functions and limited performance, and comprehensively improves the stability and service life of equipment operation.

[0020] This invention innovatively proposes a flat cable for cranes. The shielding layer within the shielded core effectively blocks the outward radiation of the internal electric field and suppresses the intrusion of external electromagnetic interference. This avoids interference from electromagnetic noise generated by motor startup, frequency converter operation, etc., ensuring accurate data command transmission and reducing the risk of equipment malfunction. The combined design of the shielding layer and the first wrapping layer strengthens electromagnetic protection through metallic shielding materials (such as copper or aluminum foil) and fixes the shielding layer's position with the wrapping layer, preventing displacement due to cable bending or vibration and ensuring the durability of the shielding effect. Adding a shielding layer not only solves the key problem of electromagnetic interference but also, through the composite optimization of materials and structure, achieves a performance balance under multiple requirements such as high temperature resistance, wear resistance, oil resistance, and environmental friendliness. This adapts to the harsh conditions of high-load, long-term continuous operation, improving the reliability and service life of the equipment.

[0021] This invention innovatively proposes a flat cable for cranes. Through multi-layer composite shielding and structural reinforcement design, it significantly improves the overall performance of the crane flat cable under complex working conditions. The first wrapping layer is wrapped around the outside of the stranded insulated core, effectively fixing the core structure and reducing core displacement caused by mechanical vibration or repeated bending. It also serves as a basic protective layer, initially blocking the intrusion of oil and moisture. The shielding layer is wrapped around the outside of the first wrapping layer, forming double electromagnetic protection through a metallic shielding material (such as copper mesh or aluminum foil). This suppresses the outward radiation of the internal electric field and blocks external electromagnetic interference (such as high-frequency noise generated by motors and frequency converters), ensuring the purity and stability of signal transmission. The second wrapping layer further fixes the position of the shielding layer, preventing displacement during cable bending or stretching, ensuring the durability of the shielding effect. The synergistic effect of the stranded soft steel wire and carbon fiber layer maintains high tensile and friction resistance, combined with the high temperature and oil resistance of the flat sheath, enabling the cable to maintain structural integrity and insulation performance even in high-temperature, oily, and mechanically frictional environments. The structural design of the shielding layer and multi-layer wrapping not only enhances electromagnetic compatibility, but also achieves a performance balance under multiple requirements such as high temperature resistance, wear resistance, oil resistance and electromagnetic interference resistance through the composite optimization of materials and processes. It adapts to the harsh working conditions of high load and long-term continuous operation, and significantly improves the reliability of equipment operation, the stability of signal transmission and service life.

[0022] This invention significantly improves the overall performance of cable sheath materials under high temperature, oil contamination, mechanical friction, and complex electromagnetic environments by optimizing the preparation process of PTFE suspension resin and the compounding of functional additives, specifically addressing the multiple limitations of traditional materials. By using a water-soluble peroxide initiator and a hexafluoropropylene oxide dimer derivative dispersant, combined with a deionized water reaction medium, the molecular weight distribution and particle morphology of PTFE can be precisely controlled, giving the resin a denser crystal structure and thus enhancing its high-temperature resistance. Even under sustained high-temperature environments, the sheath can maintain structural stability, avoiding insulation failure or sheath deformation due to softening. With the addition of an anti-arc agent, the material can rapidly dissipate energy under high voltage or electric spark environments, inhibiting arc burns to the sheath and effectively reducing the risk of localized aging or breakdown caused by arcs, ensuring the reliability of power transmission. The introduction of lubricant improves the processing fluidity of PTFE, making the sheath more uniform during extrusion molding, reducing internal stress, and lowering the coefficient of friction between the cable and the crane rail, thus extending the service life of the sheath under repeated bending or dragging. The colorant, through stable dispersion technology, ensures color durability while avoiding affecting the material's intrinsic properties, facilitating cable identification and management. Through process optimization and the synergistic effect of functional additives, the sheath material simultaneously possesses high temperature resistance, oil resistance, arc resistance, low friction, and environmental protection characteristics, solving the problems of single function and limited performance of traditional materials. It meets the stringent requirements of high load and long-term continuous operation of crane cables, significantly improving the stability of equipment operation and the service life of cables.

[0023] The preferred sheath material of this invention is nitrile butadiene elastomer (NBR). In the NBR formulation, NBR provides oil resistance and flexibility. Carbon black N550 provides reinforcement, enhancing strength and abrasion resistance; DOP plasticizer adjusts hardness and improves low-temperature flexibility; the vulcanization system optimizes crosslinking density, balancing elasticity and strength; antioxidants and stabilizers inhibit aging and processing degradation, extending material life. The preparation process, through component sequence and temperature control (≤100℃), ensures uniform dispersion and avoids performance defects. The overall solution achieves a synergistic effect of multiple properties, including high-temperature resistance, oil resistance, mechanical friction resistance, flame retardancy, and environmental friendliness, adapting to the high-load, long-term operation requirements of crane cables and significantly improving equipment operational stability and cable life.

[0024] Advantages of additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0025] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0026] Figure 1A schematic diagram of a three-core unshielded flat cable for cranes is provided as an exemplary embodiment of the present invention. Figure 2 A schematic diagram of a three-core shielded flat cable structure for railway vehicles is provided as an exemplary embodiment of the present invention; Figure 3 A schematic diagram of a six-core unshielded flat cable for cranes (without outer sheath groove) provided as an exemplary embodiment of the present invention. Figure 4 A schematic diagram of a six-core unshielded flat cable for railway vehicles (with outer sheath groove) is provided as an exemplary embodiment of the present invention. Figure 5 A schematic diagram of a six-core shielded flat cable for cranes (without outer sheath groove) provided as an exemplary embodiment of the present invention. Figure 6 A schematic diagram of a six-core shielded flat cable for cranes (with outer sheath groove) provided as an exemplary embodiment of the present invention. Figure 7 A schematic diagram of a ten-core unshielded flat cable for railway vehicles (without outer sheath groove) provided as an exemplary embodiment of the present invention. Figure 8 A schematic diagram of a ten-core unshielded flat cable for railway vehicles (with outer sheath groove) provided as an exemplary embodiment of the present invention. Figure 9 A schematic cross-sectional view of a flat cable for trains consisting of multi-strand stranded core (power main core) + control signal (control line) + information transmission (optical fiber) provided as an exemplary embodiment of the present invention; Figure 10 A three-dimensional schematic diagram of a flat cable for train operation consisting of multi-strand stranded core (power main core) + control signal (control line) + information transmission (optical fiber) provided as an exemplary embodiment of the present invention; Figure 11 A schematic cross-sectional view of a flat cable for vehicle-specific control signal (control line) + information transmission (optical fiber) provided as an exemplary embodiment of the present invention; Figure 12 A three-dimensional schematic diagram of a control signal (control line) + information transmission (optical fiber) flat cable for vehicles, provided as an exemplary embodiment of the present invention; Figure 13 A schematic diagram of the structure of a multi-strand stranded wire core (control wire) provided for an exemplary embodiment of the present invention; Figure 14 A schematic diagram of the structure of a multi-strand stranded conductor (power main conductor) provided for an exemplary embodiment of the present invention; Figure 15 A schematic diagram of the structure of an optical fiber provided as an exemplary embodiment of the present invention; Among them, 1. Soft conductor; 2. Insulation layer; 3. Flat sheath; 4. Outer sheath groove; 5. Stranded soft steel wire; 6. Optical fiber; 7. Shielding layer one; 8. Wrapping layer one; 9. Carbon fiber layer; 10. Wrapping layer two; 11. Shielding layer two; 12. Wrapping layer three; 13. Optical fiber; 14. Stainless steel flexible hose. Detailed Implementation

[0027] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0028] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of the invention. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0029] In this implementation, a flat cable for vehicle operation is proposed, such as... Figure 1 As shown, it includes: three insulated wire cores, stranded soft steel wire 5, optical fiber 6, flat sheath 3 and carbon fiber layer 9; the insulated wire core includes soft conductor 1 and insulation layer 2 wrapped on soft conductor 1, multiple insulated wire cores are arranged in parallel, and stranded soft steel wire 5 and optical fiber 6 are arranged in parallel with the insulated wire cores respectively. The flat sheath 3 is wrapped around the outside of the insulated core, the stranded soft steel wire 5 and the optical fiber 6, and the carbon fiber layer 9 is wrapped around the outside of the flat sheath 3.

[0030] like Figure 3 As shown, this is the case where six insulated wire cores are used, arranged side by side, as follows: Figure 4 As shown, an outer sheath groove 4 is formed at the middle position of the upper surface and the middle position of the lower surface of the flat sheath 3.

[0031] like Figure 7 The diagram shows the case using ten insulated wire cores, arranged side by side, as shown. Figure 8 As shown, two outer sheath grooves 4 are respectively opened at the middle position of the upper surface and the lower surface of the flat sheath 3.

[0032] like Figure 2 As shown, a flat cable with shielding function for vehicles is also proposed, including: three shielding cores, stranded soft steel wire 5, optical fiber 6, shielding layer 7, flat sheath 3, and carbon fiber layer 9. The shielded core includes a soft conductor 1, an insulation layer 2, a shielding layer, and a wrapping tape layer 8. The insulation layer 2 is wrapped around the outside of the soft conductor 1, the shielding layer 7 is wrapped around the outside of the insulation layer 2, and the wrapping tape is wrapped around the outside of the shielding layer 7. Multiple insulated wire cores are arranged in parallel, and stranded soft steel wire 5 and optical fiber 6 are arranged in parallel with shielded wire cores respectively; The flat sheath 3 is wrapped around the outside of the shielded core, the stranded soft steel wire 5 and the optical fiber 6, and the carbon fiber layer 9 is wrapped around the outside of the flat sheath 3.

[0033] like Figure 5 As shown, this is the case where six shielded wire cores are used, with the six shielded wire cores arranged side by side, as follows: Figure 6 As shown, an outer sheath groove 4 is formed at the middle position of the upper surface and the middle position of the lower surface of the flat sheath 3.

[0034] like Figure 13 The diagram shown is a schematic of the control line, including a soft conductor 1, an insulating layer 2, a second wrapping layer 10 (i.e., the first wrapping layer), a second shielding layer 11, and a third wrapping layer 12 (i.e., the second wrapping layer); as shown... Figure 14 The diagram shown is a schematic of the main power conductor core. It also includes a flexible conductor 1, an insulation layer 2, a second wrapping layer 10, a second shielding layer 11, and a third wrapping layer 12. However, the flexible conductor used in the main power conductor core is thicker (fewer strands), while the flexible conductor used in the control wire is thinner (more strands). The flexible conductor specification for the control wire is 0.5mm. 2 ~240mm 2 The soft conductor specification of the main power line core is 1.5mm. 2 ~240mm 2 .

[0035] like Figure 9 The diagram shown is a cross-sectional view of a flat cable for trains consisting of three stranded cores (power main core, using three stranded cores) + six control signal (control line, 3 to 19 shielded cores twisted together) + information transmission (optical fiber) provided in an exemplary embodiment of the present invention. Figure 10 A three-dimensional schematic diagram of a crane-specific flat cable consisting of three stranded cores (power main core, using three stranded cores) + six control signal strands (control lines, 3-19 shielded cores twisted together) + information transmission (fiber optic cable 6); as shown. Figure 11 The diagram shown is a cross-sectional schematic of a nine-strand control signal (control line, 3 to 19 shielded cores twisted together) + information transmission (optical fiber) flat cable for cranes, provided in an exemplary embodiment of the present invention. Figure 12 A three-dimensional schematic diagram of a flat cable for train operation consisting of nine control signals (control lines, 3 to 19 shielded cores twisted together) and information transmission (optical fiber 6) provided as an exemplary embodiment of the present invention.

[0036] Optionally, when multiple shielded cores are twisted together to form a CAT5e / CAT6 network cable for controlling vehicle communication, the flexible conductor specification is 0.3mm². 2 ~0.75mm 2 .

[0037] In this implementation, the outer sheath groove 4 is set based on the following principles: if the width of the flat sheath 3 exceeds 200mm, one pair of outer sheath grooves 4 are added (i.e., one is symmetrically set on the upper surface and the lower surface respectively); if the width of the flat sheath 3 is ≥400mm and ≤600mm, two pairs of outer sheath grooves 4 are added (i.e., two are symmetrically set on the upper surface and the lower surface respectively); if the width of the flat sheath 3 is ≥600mm, three pairs of outer sheath grooves 4 are added (i.e., three are symmetrically set on the upper surface and the lower surface respectively).

[0038] Based on the flat cable structure provided above, a corresponding fabrication method is proposed, as detailed below: against Figure 1 The basic manufacturing method of the flat cable used for vehicle operation shown includes the following processes: A soft conductor 1 is made by stranding soft conductive materials. Insulating material is uniformly wrapped around the outside of the soft conductor 1 through an extrusion process to form a single insulated wire core. This process is repeated to prepare multiple insulated wire cores. Place multiple prepared insulated wire cores side by side at the designed spacing; The insulated wire cores arranged in parallel are fed into the extrusion equipment, and the sheath material is squeezed through the flat die so that the sheath tightly wraps around the outside of each component to form a flat sheath 3. The carbon fiber material is wrapped around the outside of the flat sheath 3 using a winding or wrapping process to complete the preparation of the flat cable for vehicle use.

[0039] against Figure 2 The basic manufacturing method of the flat cable used for vehicle operation shown includes the following processes: A soft conductor 1 is made by stranding soft conductive materials. An insulating material is uniformly wrapped around the outside of the soft conductor 1 through an extrusion process to form an insulating layer 2. A shielding layer of the shielded wire core itself is made by braiding or wrapping on the outside of the insulating layer 2. This process is repeated to prepare multiple shielded wire cores. Multiple prepared shielded wire cores are placed side by side at the designed spacing, and stranded soft steel wire 5 and optical fiber 6 are placed in the designated side by side positions of the shielded wire cores to form the basic cable core. The cable core is fed into an extrusion machine, and the sheath material is extruded through a flat die, so that the sheath wraps around the outside of the shielding layer to form a flat sheath 3; The flat cable is prepared by wrapping or covering carbon fiber material around the outside of the flat sheath 3 using a winding or wrapping process.

[0040] against Figure 4 The basic manufacturing method of the flat cable used for vehicle operation shown includes the following processes: A soft conductor 1 is made by stranding soft conductive materials. Insulating material is uniformly wrapped around the outside of the soft conductor 1 through an extrusion process to form a single insulated wire core. This process is repeated to prepare multiple insulated wire cores. Multiple prepared insulated wire cores are placed side by side at the designed spacing, and stranded soft steel wire 5 and optical fiber 6 are placed in the designated side by side positions of the insulated wire cores to form the basic structure of the cable core. The insulated wire cores, stranded soft steel wires 5 and optical fibers 6 are fed into the extrusion equipment as a whole. The sheath material is squeezed through the flat mold so that the sheath tightly wraps around the outside of each component to form a flat sheath 3. The carbon fiber material is wrapped around the outside of the flat sheath 3 using a winding or wrapping process to complete the preparation of the flat cable for vehicle use.

[0041] against Figure 6 The basic manufacturing method of the flat cable used for vehicle operation shown includes the following processes: A soft conductor 1 is made by stranding soft conductive materials. An insulating material is uniformly wrapped around the outside of the soft conductor 1 through an extrusion process to form an insulating layer 2. A shielding layer of the shielded wire core itself is made by braiding or wrapping on the outside of the insulating layer 2. This process is repeated to prepare multiple shielded wire cores. Place multiple prepared shielded wire cores side by side at the designed spacing; Multiple shielded wire cores placed side by side are fed into an extrusion device, and sheath material is extruded through a flat die, so that the sheath wraps around the outside of the shielding layer to form a flat sheath 3. The flat cable is prepared by wrapping or covering carbon fiber material around the outside of the flat sheath 3 using a winding or wrapping process.

[0042] against Figure 13 The flat cable shown is manufactured using the following process: A soft conductor 1 is made by stranding soft conductive materials. An insulating material is then extruded using an extrusion device, so that the insulating layer 2 wraps around the outside of the soft conductor 1 to form a single insulated wire core. This process is repeated to prepare multiple desired insulated wire cores. The prepared multiple insulated wire cores are twisted together according to the designed pitch to form an insulated wire core strand; The wrapping tape layer 210 is formed by uniformly winding the tape around the outside of the stranded insulated wire core through a wrapping process. The shielding material is tightly wrapped around the outside of the second layer 10 by using copper wire braiding, copper strip wrapping or aluminum-plastic composite strip wrapping process to form the second layer 11. Continue using the wrapping material, and wrap it around the outside of the second shielding layer 11 through the wrapping process to form the third wrapping layer 12, thus completing the preparation of multiple stranded wire cores; Multiple prepared stranded cores are placed side by side at the designed spacing; at the same time, stranded soft steel wire 5 and optical fiber 6 are placed in the designated side by side positions of the stranded cores to form the cable base core. The cable base core is fed into the extrusion equipment, and the sheath material is extruded through a flat special mold, so that the sheath wraps around the outside of the base core to form a flat sheath 3; A carbon fiber layer 9 is formed by wrapping carbon fiber material around the outside of a flat sheath 3 using a process of spiral winding of carbon fiber tape or overall wrapping of carbon fiber cloth.

[0043] In this implementation, optionally, the soft conductor 1 is made of multiple Category 5 oxygen-free copper monofilaments, tin-plated oxygen-free copper monofilaments, or silver-plated oxygen-free copper monofilaments twisted together. The formula for calculating the cross-sectional area of ​​the soft conductor 1 is as follows: (1); in, Let 1 be the cross-sectional area of ​​the soft conductor 1 (1); This refers to the number of monofilaments. The diameter of a single filament is (mm).

[0044] In this implementation, optionally, the insulation layer 2 is made of fluoroplastic or flame-retardant polyolefin (XHHW) materials through high-temperature compounding and then formed by extrusion. Its mechanical and electrical properties at high temperatures are superior to those of ethylene propylene rubber (EPDM) or polyvinyl chloride (PVC). The fluoroplastic adhesive has a temperature resistance of ≤260℃, and the flame-retardant polyolefin insulation layer 2 has a temperature resistance of ≤150℃, enabling long-term stable operation. Its insulation properties are resistant to acid and alkali corrosion, low smoke and non-toxic, high temperature resistance and chemical stability. By selecting different insulation layer 2 materials, the application requirements in different environments can be met.

[0045] In this implementation, optionally, the shielding layer 7 and shielding layer 11 of the shielding core can be made of oxygen-free copper monofilament or tin-plated oxygen-free copper wire braided shielding layer; aluminum foil shielding or composite shielding (i.e., combining oxygen-free copper monofilament or tin-plated oxygen-free copper wire braided shielding mesh with aluminum foil) can also be used, which has good flexibility and is suitable for high-frequency interference protection.

[0046] The maximum diameter of the single wire in the oxygen-free copper single wire or tin-plated oxygen-free copper braided shielding layer depends on the outer diameter of the shielding core, and is generally φ0.15mm~φ0.51mm. It is braided by a 24-spindle braiding machine, with 3 single wires braided in parallel per spindle; or by a 16-spindle braiding machine, with 5 single wires braided in parallel per spindle; the braiding density is 85%.

[0047] Aluminum foil shielding refers to a shielding layer that uses aluminum foil longitudinally wrapped as the shielding core. It has the advantages of high coverage and low cost, and this method is suitable for low and medium frequency interference.

[0048] In this implementation, the aluminum foil shielding layer can optionally be made of pure aluminum (Al) or aluminum-plastic composite film (such as aluminum + PET polyester). An adhesive (such as acrylic glue) is coated on the inside of the aluminum foil for bonding and fixing to the cable insulation layer 2. The thickness of the pure aluminum (Al) or aluminum-plastic composite film (such as aluminum + PET polyester) is 0.02 to 0.05 mm. The aluminum foil can completely wrap the insulation layer 2 of the shielding core, and the shielding coverage is close to 100% (superior to 90% to 95% of oxygen-free copper monofilament and tin-plated oxygen-free copper braided shielding). The aluminum foil surface is oxidized to improve corrosion resistance. Its manufacturing cost is low and it is suitable for mass production.

[0049] In this implementation, optionally, the composite shielding combines oxygen-free copper monofilament or tin-plated oxygen-free copper wire woven shielding mesh with aluminum foil as the shielding layer, which can provide all-round protection.

[0050] In this implementation, the shielding layer of the shielded core can also serve as a grounding conductor for discharging and diverting induced current, grounding interference current, and providing anti-static and surge protection. It can also conduct static electricity or transient overvoltages (such as lightning strike induction) to the ground through the grounding conductor.

[0051] In this implementation, the shielding layer of the shielded wire core can be used to suppress electromagnetic interference and provide protection. Its specific functions include the following: (1) Electromagnetic interference (EMI) protection.

[0052] Suppressing external interference: Shielding layers (such as copper braided mesh, aluminum foil, etc.) can block external electromagnetic fields (such as high-voltage cables, frequency converters, radio signals, etc.) from interfering with the signals inside the cable, ensuring the stability of signal transmission. Reduce internal radiation: Prevent internal signals in the cable from radiating outwards and interfering with other equipment, especially in sensitive electronic equipment environments (such as PLCs and communication systems).

[0053] (2) Improve signal integrity.

[0054] Noise reduction: In the transmission of weak electrical signals (such as analog signals and communication signals), the shielding layer can reduce signal distortion and noise, ensuring the accuracy of data transmission.

[0055] Suitable for high-frequency signals: High-frequency or differential signals (such as RS485, Ethernet) are sensitive to interference, and the shielding layer can reduce crosstalk and signal attenuation.

[0056] (3) Antistatic and surge protection.

[0057] Drainage: Used for the discharge and drainage of induced current, as well as for grounding interference current; Electrostatic discharge (ESD): The shielding layer can conduct static electricity or transient overvoltage (such as lightning strike induction) to the ground through the grounding conductor, preventing static electricity accumulation from damaging the equipment; Transient overvoltage protection: In the event of lightning strikes or power system failures, the shielding layer can divert some of the surge current, protecting the downstream circuitry.

[0058] (4) Machinery and environmental protection.

[0059] Physical protection: Partial shielding layers (such as metal armor) can enhance the cable's tensile and compressive strength, making it suitable for harsh industrial environments; Chemical corrosion resistance: Some shielding materials (such as tin-plated copper) can resist the erosion of humid or corrosive media.

[0060] (5) Grounding and safety.

[0061] Grounding shielding: By grounding at one or both ends, a low-impedance path is formed to conduct interference current into the ground, while avoiding ground loop problems. Safety protection: In high-voltage environments, the shielding layer can balance the electric field distribution and reduce the risk of insulation breakdown.

[0062] In this implementation, optionally, the wrapping layer 8, wrapping layer 2 10, and wrapping layer 3 12 can be wrapped with materials such as non-woven fabric, polyester tape, and PP tape, with a wrapping coverage rate of 15%.

[0063] In this implementation, optionally, the stranded soft steel wire has a cross-sectional area ≥ 0.10 mm². 2 and ≤0.25 mm 2 It is made of stranded steel wires with circular cross-sections, and the stranded cross-sectional area of ​​the stranded soft steel wires ranges from 1.0 mm. 2 ~6 mm 2 .

[0064] In this implementation, optionally, optical fiber 6 is an optical fiber housed within a stainless steel flexible tube filled with grease; the optical fiber is of type G652D / G657 tensile strength, with a structure of 0.6mm multimode 50 / 125 optical fiber + stainless steel flexible tube; the optical parameters are: attenuation 820nm ≤ 3.00dB; attenuation 1300nm ≤ 1.00dB; bandwidth ≥ 400MHz.km; the optical fiber is tested before use: the optical fiber should meet the following requirements: attenuation coefficient 1300nm ≤ 0.55dB / km; attenuation coefficient 850nm ≤ 2.34dB / km.

[0065] In this implementation, the flat sheath 3 is formed using different processes for flame-retardant polyolefin (resistant to ≤180℃), silicone rubber (resistant to ≤250℃), or nitrile elastomer (resistant to ≤150℃, soft sheath). It has the characteristics of relatively low molecular structure density and high mechanical strength, which makes the flame-retardant polyolefin sheath not only protect the crane-specific flat cable, but also have strong tensile, compressive and impact resistance. At the same time, it has good waterproof and insulation properties, which can effectively prevent moisture and humidity from corroding the crane-specific flat cable, and improve the service life and safety of the crane-specific flat cable.

[0066] In this implementation, the flat sheath 3 is made of flame-retardant polyolefin (resistant to ≤180℃), silicone rubber (resistant to ≤250℃), or nitrile elastomer (resistant to ≤150℃, soft sheath). By selecting different materials for the flat sheath 3, the usage requirements in different environments can be met.

[0067] In this implementation, the carbon fiber layer of the flat sheath 3 is a high-performance composite material layer. When used in lightweight flat cables with electromagnetic interference resistance, the sheath thickness is 0.1 to 0.5 mm; when used in high-strength or high-temperature resistant outer sheath layers, the sheath thickness is 0.5 to 1.5 mm; and when used in extreme environments, the sheath thickness is 1.5 to 3.0 mm.

[0068] In this implementation, the carbon fiber layer 9 is woven into a mesh or sheath and bonded to the outside of the flat sheath 3 using polypropylene adhesive to form the outer protective layer of the flat cable. Its function is as follows: (1) The carbon fiber layer 9 serves as a protective layer for the flat sheath 3. Its tensile strength is more than 5 times that of steel, but its density is only 1 / 4 that of steel. At the same time, it can reduce the overall weight of the flat cable for vehicle use. (2) The carbon fiber layer 9 serves as a protective layer for the flat sheath 3. It is resistant to chemical corrosion (such as acid, alkali, and salt spray) and weathering. It resists external wear, extrusion, and puncture, and is suitable for use in harsh environments. (3) The carbon fiber layer 9 serves as a protective layer for the flat sheath 3. It can withstand temperatures above 300°C and is not self-igniting. It meets fire protection requirements (such as UL94V0 level) and is suitable for high-temperature industrial environments. (4) The carbon fiber layer 9 serves as a protective layer for the flat sheath 3. It can replace metal as an armor layer, while also having a certain degree of flexibility, reducing weight and avoiding metal fatigue. (5) The conductivity of carbon fiber can shield external electromagnetic interference (EMI) and protect internal signal transmission.

[0069] Specifically, the following provides the preparation methods for each component of unshielded flat cables and shielded flat cables for cranes.

[0070] The specification of the soft conductor 1 is 0.5 mm. 2 ~240 mm2 It is made of multiple Category 5 oxygen-free copper monofilaments twisted together. The maximum diameter of the monofilament depends on the nominal cross-sectional area of ​​the conductor, and the specific values ​​are shown in Table 1.

[0071] Table 1: Maximum diameter of a single filament.

[0072]

[0073] The nominal cross-sectional area is 0.5 mm². 2 Soft conductor 1 (1) is made of 16 strands of single wires twisted together, and the diameter of the single wire is: (2); The nominal cross-sectional area is 0.75 mm². 2 Soft conductor 1 (1) is made of 23 strands of single wires twisted together, and the diameter of the single wires is: (3); The nominal cross-sectional area is 1.0 mm². 2 The soft conductor 1 (1) is made of 31 strands of single wires, and the diameter of the single wires is: (4); The nominal cross-sectional area is 1.5 mm². 2 The soft conductor 1 (1) is made of 31 strands of single wires, and the diameter of the single wires is: (5); The nominal cross-sectional area is 2.5 mm². 2 Soft conductor 1 (1) is made of 49 strands of single wires twisted together, and the diameter of the single wires is: (6).

[0074] The insulation layer 2 is made of fluoroplastic or flame-retardant polyolefin (XHHW) material through high-temperature compounding and then formed by extrusion. Its mechanical and electrical properties at high temperatures are superior to those of ethylene propylene rubber (EPDM) or polyvinyl chloride (PVC). Moreover, the temperature resistance of fluoroplastic adhesive is ≤260℃, and the temperature resistance of flame-retardant polyolefin insulation layer 2 is ≤150℃. It can work stably for a long time. Its insulation properties are resistant to acid and alkali corrosion, low smoke and non-toxic, high temperature resistance and chemical stability. Depending on the selection of different insulation layers 2 (2), it can meet the usage requirements in different environments. Fluoroplastics (PTFE) process formulation: (1) Main material: 94.5% PTFE suspension resin. PTFE suspension resin must be strictly deoxygenated and impurities removed (polymerization inhibitors must be added during storage). Materials required for PTFE suspension resin: Initiator is water-soluble peroxide such as ammonium persulfate (APS); dispersant is a derivative of hexafluoropropylene oxide dimer (HFPO-DA); deionized water is used as the reaction medium; Suspension polymerization reaction conditions: The temperature of the reactor is controlled at 50–90℃ (strict control is required to avoid explosive polymerization), and the pressure is 0.5–3MPa. The air in the reactor is replaced with nitrogen. The process is as follows: Deionized water, dispersant, and initiator are added to a reactor and stirred to form a homogeneous system. TFE monomer is then introduced, and pressure and temperature are maintained to initiate free radical polymerization. The reaction is exothermic and requires cooling and temperature control; the polymerization time is typically 1–5 hours. After the reaction is complete, unreacted TFE monomer is recovered.

[0075] Coagulation and washing: PTFE particles are precipitated from the suspension by mechanical stirring or by adding an electrolyte (such as hydrochloric acid or nitric acid); the dispersant and residual initiator are removed by repeated washing; and the mixture is dried at 60–150°C to obtain a white powdery PTFE suspension resin.

[0076] (2) Additives: anti-arc agent (alumina micro powder 1% to 3%), colorant (high temperature resistant inorganic pigment 0.5% to 2%), lubricant (white oil 0.1% to 0.5%). Production method: After mixing PTFE suspension resin and additives, let it stand for 24 hours to avoid fiberization. Then, sinter by staged heating: room temperature → 300℃ → 380℃ → cooling, with inert gas protection throughout the process.

[0077] The shielding layer of the shielded wire core (including shielding layer 7 and shielding layer 11) is made of oxygen-free copper monofilament. The maximum diameter of the tin-plated oxygen-free copper monofilament depends on the outer diameter of the shielded wire core, and is generally φ0.15mm to φ0.51mm. It is braided by a 24-spindle braiding machine, with 3 monofilaments braided in parallel per spindle; or by a 16-spindle braiding machine, with 5 monofilaments braided in parallel per spindle. Its braiding density is 85%.

[0078] The wrapping tape (including wrapping tape layer 8, wrapping tape layer 2, and wrapping tape layer 3) is wrapped with non-woven fabric, polyester tape, PP tape, and other materials, with a wrapping coverage of 15%. The multi-strand stranded mild steel wire 5 has a cross-sectional area ≥0.10 mm². 2 ≤0.25 mm 2 It is made of stranded steel wire with a circular cross-section, consisting of 5 strands of soft steel wire with a cross-sectional area of ​​1.0 mm². 2 ~6 mm 2 ; Optical fiber 6 is formed by optical fiber 13 being housed within a stainless steel flexible tube 14, such as... Figure 15As shown, the stainless steel flexible tube is filled with grease; the optical fiber 13 is of type G652D / G657 tensile type, and its structure is 0.6mm multimode 50 / 125 optical fiber 13 + stainless steel flexible tube 14; its optical parameters are: attenuation 820nm≤3.00db; 1300nm≤1.00db; bandwidth≥400MHz.km; fiber 6 is tested before use: fiber 6 should meet the following requirements: attenuation coefficient 1300nm not greater than 0.55dB / km; attenuation coefficient 850nm not greater than 2.34dB / km.

[0079] The flat sheath 3 is formed using different processes for the sheath structure of flame-retardant polyolefin (resistant to ≤180℃), silicone rubber (resistant to ≤250℃), or nitrile elastomer (resistant to ≤150℃, soft sheath). It has the characteristics of relatively low molecular structure density and high mechanical strength. This allows the flame-retardant polyolefin sheath to not only protect the crane-specific flat cable, but also have strong tensile, compressive and impact resistance. At the same time, it has good waterproof and insulation properties, which can effectively prevent moisture and humidity from corroding the crane-specific flat cable, and improve the service life and safety of the crane-specific flat cable.

[0080] The flat sheath 3 is made of flame-retardant polyolefin (resistant to ≤180℃), silicone rubber (resistant to ≤250℃), or nitrile elastomer (resistant to ≤150℃, soft sheath). Depending on the material of the flat sheath 3, the usage requirements in different environments can be met. The preparation formula of nitrile elastomer is shown in Table 2.

[0081] Table 2: Formulation for the preparation of nitrile elastomer.

[0082]

[0083] In this implementation, the carbon fiber layer 9 of the flat sheath 3 is a high-performance composite material layer. When used in lightweight flat cables with electromagnetic interference resistance, the sheath thickness is 0.1 to 0.5 mm; when used in high-strength or high-temperature resistant outer sheath layers, the sheath thickness is 0.5 to 1.5 mm; and when used in extreme environments, the sheath thickness is 1.5 to 3.0 mm.

[0084] In summary, the high-temperature resistant, wear-resistant, and oil-resistant flat cable for automobiles proposed in this invention has the following beneficial effects: (1) Overall performance has been significantly improved.

[0085] (1-1) High temperature resistance: The insulation layer 2 is made of fluoroplastic (resistant to long-term stable operation at ≤260℃) or flame-retardant polyolefin insulation (XHHW) layer (resistant to long-term stable operation at ≤150℃); the flat sheath 3 (3) is formed by different processes of flame-retardant polyolefin (resistant to ≤180℃), silicone rubber (resistant to ≤250℃) or nitrile elastomer (resistant to ≤150℃ soft sheath). The carbon fiber layer can withstand high temperatures above 300℃, far exceeding the traditional EPDM / PVC materials (usually resistant to ≤105℃), meeting the requirements of extreme high temperature industrial environments.

[0086] (1-2) Wear and oil resistance: The carbon fiber layer (tensile strength is 5 times that of steel) combined with the flame-retardant polyolefin sheath significantly improves the resistance to mechanical wear, extrusion and oil corrosion, and extends the service life of the cable under harsh working conditions.

[0087] (1-3) Environmental adaptability: The carbon fiber layer is resistant to chemical corrosion (acid, alkali, salt spray) and has strong weather resistance, making it suitable for crane-specific flat cables in complex industrial environments (such as metallurgy, chemical industry, ports, etc.).

[0088] (2) Structural design innovation.

[0089] (2-1) Multi-layer shielding protection: Double shielding with braided shielding layer (copper wire braiding density 85%) + carbon fiber layer, effectively suppressing electromagnetic interference (EMI) and ensuring signal transmission stability, especially suitable for high interference environments.

[0090] (2-2) Flexibility Reinforcement and Tensile Design: Soft conductor 1 (diameter ≤ 0.41 mm oxygen-free copper wire) and stranded soft steel wire (cross-sectional area 0.75~5 mm²) 2 The combination of these two properties maintains flexibility while increasing tensile strength, adapting to the needs of frequent vehicle movement.

[0091] (2-3) Groove optimization design: Distribute stress according to the width of the sheath (add groove when ≥200mm) to avoid sheath cracking when the wide cable is bent and improve mechanical reliability.

[0092] (3) Functional integration and intelligence.

[0093] (3-1) Fiber optic integrated monitoring: Built-in G652D / G657 tensile-resistant fiber (stainless steel flexible tube protection), supports real-time temperature monitoring (attenuation coefficient ≤0.55dB / km), realizes cable status early warning, and prevents overheating faults.

[0094] (3-2) Balance between lightweight and high strength: The density of carbon fiber layers is only 1 / 4 that of steel, reducing the weight of the cable by more than 30%, while providing armor-level protection to avoid metal fatigue problems.

[0095] (4) Safety and environmental protection advantages.

[0096] (4-1) Flame retardant and fireproof: Flame retardant polyolefin sheath and silicone rubber or nitrile elastomer + carbon fiber layer (UL94V0 grade) double flame retardant, inhibiting the spread of flame and meeting stringent fire protection standards.

[0097] (4-2) Environmentally friendly materials: halogen-free flame-retardant polyolefin and fluoroplastic insulation layer 2, reducing the release of toxic gases and meeting environmental protection requirements such as RoHS.

[0098] (5) Economic efficiency and long-term effectiveness.

[0099] (5-1) Extended lifespan: The combination of aging-resistant materials (such as silicone rubber + carbon fiber) increases the lifespan by 2 to 3 times compared to traditional cables, reducing the frequency of replacement and maintenance costs.

[0100] Multifunctional replacement: A single cable integrates power transmission, signal shielding, and temperature monitoring functions, reducing wiring complexity and saving installation costs. A comparison is summarized in Table 3.

[0101] Table 3: Comparison of characteristics between conventional cables and the cable of this invention.

[0102]

[0103] This invention addresses the performance limitations of traditional cables under high temperatures, abrasion, oil contamination, and electromagnetic interference through material innovation (silicone rubber, carbon fiber) and structural optimization (multi-layer shielding, fiber optic integration). It combines high reliability, intelligence, and environmental friendliness, making it suitable for flat cables for cranes in extreme industrial scenarios such as metallurgy, mining, and shipbuilding.

[0104] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A flat cable for use in vehicles, characterized in that, include: Flat sheath, carbon fiber layer, and at least one conductive core unit; Multiple conductive core units are arranged in parallel, and a flat sheath is wrapped around the outside of the multiple conductive core units arranged in parallel. The carbon fiber layer is wrapped around the outside of the flat sheath.

2. The flat cable for cranes as described in claim 1, characterized in that, The conductive core unit is an insulated core, which includes a soft conductor and an insulating layer wrapped around the soft conductor.

3. The flat cable for cranes as described in claim 1, characterized in that, The conductive core unit is an insulated core, which includes a soft conductor and an insulating layer wrapped around the soft conductor. The flat cable also includes stranded soft steel wires and optical fibers, which are arranged in parallel with the conductive core unit, and are wrapped by the flat sheath.

4. The flat cable for cranes as described in claim 1, characterized in that, The conductive core unit is a shielded core, which includes a soft conductor, an insulating layer, and a shielding layer. The insulating layer is wrapped around the outside of the soft conductor, and the shielding layer is wrapped around the outside of the insulating layer.

5. The flat cable for cranes as described in claim 1, characterized in that, The conductive core unit is a shielded core, which includes a soft conductor, an insulating layer, and a shielding layer. The insulating layer is wrapped around the outside of the soft conductor, and the shielding layer is wrapped around the outside of the insulating layer. The flat cable also includes stranded soft steel wires and optical fibers, which are arranged in parallel with the conductive core unit, and are wrapped by the flat sheath.

6. The flat cable for cranes as described in claim 1, characterized in that, The conductive core unit is a stranded core, which includes an insulated core, stranded soft steel wire, a shielding layer, an optical fiber, a first wrapping layer, a second wrapping layer, and a shielding layer. The insulated core includes a soft conductor and an insulating layer wrapped around the outside of the soft conductor. The first wrapping layer is arranged around the outside of multiple insulated cores stranded at a certain pitch. The shielding layer is wrapped around the outside of the first wrapping layer, and the second wrapping layer is wrapped around the outside of the shielding layer to form a stranded core. Multiple stranded cores are arranged side by side, and the stranded soft steel wire and the optical fiber are arranged side by side with the stranded cores, and the stranded soft steel wire and the optical fiber are wrapped by the flat sheath.

7. The flat cable for crane operation as described in any one of claims 4-6, characterized in that, The shielding layer is woven from oxygen-free copper monofilament or tin-plated oxygen-free copper wire. or, The shielding layer is an aluminum foil shielding layer or a composite shielding layer; the composite shielding layer is a shielding layer composed of a shielding woven mesh and aluminum foil, wherein the shielding woven mesh is woven from oxygen-free copper monofilament or tin-plated oxygen-free copper wire.

8. The flat cable for crane operation as described in any one of claims 1-6, characterized in that, The flat sheath is provided with an outer sheath groove, which is located on two mutually parallel planes in the width direction of the flat sheath.

9. The flat cable for crane operation as described in any one of claims 2-6, characterized in that, The insulating layer is formed by high-temperature compounding of fluoroplastics or flame-retardant polyolefin materials and then by extrusion process. The fluoroplastics include PTFE suspension resin, anti-arc agent, colorant and lubricant. The PTFE suspension resin is prepared by using water-soluble peroxide as initiator, a derivative of hexafluoropropylene oxide dimer as dispersant, and deionized water as reaction medium. The preparation process of the PTFE suspension resin includes: Deionized water, dispersant and initiator are added to the reactor and stirred to form a homogeneous system; TFE monomer is introduced while maintaining pressure and temperature to initiate free radical polymerization. The reaction is exothermic and requires cooling and temperature control; the polymerization time is 1–5 hours. After the reaction is complete, the unreacted TFE monomer is recovered; PTFE particles are precipitated from the suspension by mechanical stirring or the addition of electrolytes; Repeated washing removes dispersant and residual initiator; Drying at 60℃–150℃ yields a white powdery PTFE suspension resin. White powdered PTFE suspension resin is mixed with an anti-arc agent, a colorant, and a lubricant, and then left to stand for a set time. Under inert gas protection, it is sintered by staged heating, and then cooled to obtain PTFE suspension resin.

10. The flat cable for trolley use as described in claim 3, 5, or 6, characterized in that, The optical fiber includes a stainless steel tube and an optical fiber disposed within the stainless steel tube, the stainless steel tube being filled with grease.

11. The flat cable for crane operation as described in any one of claims 1-6, characterized in that, The flat sheath is made of flame-retardant polyolefin, silicone rubber or nitrile elastomer. The nitrile elastomer comprises, by weight, 100 parts NBR, 40-60 parts carbon black N550, 10-20 parts DOP plasticizer, 6-12 parts stearic acid, 1.5-2.0 parts sulfur, 1.8-2.5 parts dodecyl mercaptan, 5 parts zinc oxide, 1-2 parts antioxidant 4010NA, 6-8 parts sodium phosphate, and 3-5 parts hydroquinone, wherein the NBR is composed of acrylonitrile and butadiene.

12. The flat cable for crane operation as described in claim 11, characterized in that, The method for preparing the nitrile elastomer includes: Acrylonitrile and butadiene are softened in a thin pass on a two-roll mill in a ratio of 40℃ to 60℃ to form NBR. Add antioxidant, DOP plasticizer, zinc oxide, sodium phosphate, dodecyl mercaptan, sulfur, and carbon black N550 in that order; Disperse each component evenly and control the temperature to ≤100℃; Add hydroquinone.

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