A cold-resistant, low-smoke, airtight explosion-proof control cable and its manufacturing method

Abstract

This invention discloses a cold-resistant, low-smoke, airtight, explosion-proof control cable and its manufacturing method, relating to the field of control cable technology. It includes a central transmission cable with an outer protective rubber layer. The outer protective rubber layer is covered by an inner anti-slip silicone ring, which is further covered by an inner rubber expansion layer. A side-guided inner tube is located outside the inner rubber expansion layer. This invention utilizes a flexible expansion airbag and an adjustable isolation box with a linked internal and external pressure-stabilizing structure to maintain the internal air pressure of the control cable within a suitable range during use. This allows for rapid sealing and protection of the damaged area after external damage, preventing internal damage or electrical sparks caused by external impurities after the outer sheath is damaged. This effectively improves the explosion-proof capability and safety of the control cable.

Description

Technical Field

[0001] This invention relates to the field of control cable technology, specifically to a cold-resistant, low-smoke, airtight explosion-proof control cable and its manufacturing method. Background Technology

[0002] Control cables: Cables with rated AC voltage below 660V, frequency below 100Hz, or DC voltage below 1000V;

[0003] Control cables are widely used electrical connection devices in petrochemical, mining, energy, and transportation industries. As control wiring between electrical equipment, they ensure stable communication and control between devices and power distribution points of power systems, directly transmitting electrical energy to various electrical equipment and appliances. They are used in control, monitoring circuits, and protection circuits with AC rated voltage of 660V and below. For this purpose, a Chinese patent discloses an airtight, cold-resistant, low-smoke, flame-retardant instrument cable for use in explosive environments, application number CN202510038147.8. This patent can make full use of the throttling effect of the heat insulation shell and the conductor ring to improve the flame retardancy of the cable, making the cable more compatible with the external environment. While improving the working stability of the cable, it can effectively expand the application range of the cable.

[0004] However, due to the limitations of its own structure, control cables cannot be detected in time when they are scratched or damaged during use. As a result, broken cables are easily corroded by the external environment during use, and short circuits at the damaged parts of the cables can easily generate electric sparks, thus reducing the safety of control cables. Summary of the Invention

[0005] This invention provides a cold-resistant, low-smoke, airtight, explosion-proof control cable and its manufacturing method. It can effectively solve the problem mentioned in the background art that the control cable is limited by its own structure, making it impossible to detect external scratches and damage during use. This leads to the broken cable being easily corroded by the external environment during use, and the cable breakage is prone to generating electric sparks after short circuit, thus reducing the safety of the control cable.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a cold-resistant, low-smoke, airtight, explosion-proof control cable, comprising a central transmission cable, wherein the central transmission cable is provided with an external protective rubber layer;

[0007] The outer protective rubber layer is provided with an inner cavity flexible dynamic filling detection mechanism. The inner cavity flexible dynamic filling detection mechanism is used to provide flexible protection for the outside of the control cable and to provide continuous power protection for the inside of the control cable through air pressure charging, so as to improve the overall protection performance of the control cable.

[0008] The flexible dynamic filling detection mechanism for the inner cavity includes an inner anti-slip silicone ring.

[0009] The outer protective rubber layer is covered with an inner anti-slip silicone ring, and the outer side of the inner anti-slip silicone ring is covered with an inner rubber expansion layer.

[0010] A side guide tube is provided on the outside of the inner ring rubber expansion layer. Flexible expansion airbags are uniformly and evenly sleeved on the outside of the side guide tube. A flexible filling airbag is wrapped on the outside of the inner ring rubber expansion layer. An isolation connecting rubber block is connected to the end of the side guide tube.

[0011] The top of one end of the side guide inner tube is fixedly connected to a connecting air guide head via an air guide pipe. The middle of the top of the connecting air guide head is fixedly connected to an air guide connecting pipe via a connector. An adjusting isolation round box is fixedly connected to the top of the air guide connecting pipe.

[0012] Preferably, the inner ring rubber expansion layer has a uniformly distributed telescopic cavity along the circumferential direction, the end of the side guide inner tube is isolated by an isolation connecting rubber block, the flexible filling airbag is filled with inert gas, and the flexible filling airbags are connected by a connecting strap.

[0013] Preferably, a one-way flow limiting valve is embedded in the bottom of the inner side of the adjusting isolation round box, and pressure sensors are embedded in both sides of the top surface of the one-way flow limiting valve. A sealing ring is fixedly installed in the bottom of the inner side of the adjusting isolation round box, and a flexible isolation rubber ring is fixedly connected to the top edge of the sealing ring. A lifting drive slide is fixedly connected between the top center of the flexible isolation rubber ring and the inner wall of the adjusting isolation round box.

[0014] A compression energy storage spring is fixedly connected to the top edge of the lifting drive slide plate. Wireless communication modules are embedded in the middle of both sides of the top surface of the adjustment isolation round box. An air guide hose is fixedly connected to the top center of the lifting drive slide plate. An air inlet is connected to the end of the air guide hose at the position corresponding to the top of the adjustment isolation round box.

[0015] The adjustable isolation round box has mounting side plates fixedly connected to the middle of both sides;

[0016] The inner rubber expansion layer and the outer side of the flexible expansion airbag are fixedly connected to a telescopic silicone partition. The telescopic silicone partition is tightly covered with a sealing soft rubber sleeve, and the sealing soft rubber sleeve is tightly covered with a protective rubber outer sleeve.

[0017] Preferably, the bottom air outlet of the one-way flow limiting valve is in close sliding contact with the inner cavity of the air guide connecting pipe, the outer side of the lifting drive slide plate is in close sliding contact with the inner wall of the adjusting isolation round box, and a counterweight is embedded in the middle of the bottom surface of the lifting drive slide plate at the position corresponding to the inside of the flexible isolation rubber ring.

[0018] Preferably, the top of the compression energy storage spring is fixedly connected to the top of the inner cavity of the adjusting isolation round box, and the wireless communication module is powered by an external power source.

[0019] Preferably, the length of the air guide hose is greater than the height of the adjustable isolation box, and the mounting side plate has mounting holes at the four corners of the side. The bottom pipe of the connecting air guide head passes through the telescopic silicone partition, the sealing soft rubber sleeve and the protective rubber jacket.

[0020] Preferably, the outer protective rubber layer is provided with an internal and external synchronous protection mechanism, which is used to provide insulation shielding for the inside of the cable and to strengthen the protection of the outside of the control cable through its external structure.

[0021] The internal and external synchronous protection mechanism includes a polyethylene inner sheath;

[0022] The outer protective rubber layer is tightly wrapped with a polyethylene inner sheath at the position corresponding to the outer side of the center transmission cable. The outer side of the polyethylene inner sheath is tightly wrapped with an insulating protective layer. The outer side of the insulating protective layer is wrapped with galvanized steel tape armor.

[0023] The outer side of the central transmission cable is tightly covered with a PVC insulation layer;

[0024] A top mounting strip is glued to the top of the outer side of the protective rubber jacket. A protective isolation circular groove is opened through the top of the top mounting strip at the position corresponding to the outer side of the air guide head. Guide side sliding grooves are opened in the middle of both sides of the top mounting strip.

[0025] A protective snap-fit ​​slip ring is slidably engaged at the position inside the guide side slide groove on the outer side of the protective rubber jacket. A snap-fit ​​circular hole is opened through the edge of the end face of the protective snap-fit ​​slip ring, and a side reinforcing rod is inserted and installed inside the snap-fit ​​circular hole.

[0026] Preferably, the inner side of the polyethylene inner sheath is tightly fitted to the outer side of the central transmission cable, the outer side of the galvanized steel strip armor is tightly fitted to the inner wall of the outer protective rubber layer, the end of the protective snap-fit ​​slip ring is tightly slidably fitted to the inner side of the guide side slide groove, and the inner ring of the protective snap-fit ​​slip ring is tightly slidably fitted to the outer side of the protective rubber outer jacket.

[0027] Preferably, a method for manufacturing a cold-resistant, low-smoke, airtight explosion-proof control cable includes the following steps:

[0028] S1. Internal component manufacturing and molding: The central transmission cable is wrapped with a PVC insulation layer, then wrapped with a polyethylene inner sheath, an insulation protection layer, and a galvanized steel strip armor in sequence, and finally formed with an outer protective rubber layer by molding.

[0029] S2. External component assembly: The outer protective rubber layer is wrapped with an inner anti-slip silicone ring, and then from the inside out, the inner ring rubber expansion layer, the side guide inner tube, the flexible expansion airbag, the flexible filling airbag and the isolation connecting rubber block are arranged in sequence.

[0030] S3. External accessory connection and forming: Install the one-way flow limiting valve, pressure sensor and other components inside the regulating isolation box in sequence, and connect the regulating isolation box and the internal components of the control cable through the connecting air guide head and the air guide connecting pipe. Then, install the protective clamping slip ring and its components on it to the outside of the cable through the top mounting strip and the guide side slide groove to complete the assembly of the external structure of the cable.

[0031] S4. Testing and Packaging: Inert gas is injected into the flexible insulating rubber ring and flexible expansion airbag through the inflation valve. The internal air pressure is monitored in real time using a pressure sensor to keep the internal air pressure stable within the set range. Then, the overall cable is tested for air tightness, explosion-proof performance and low smoke emission. After passing the test, a cold-proof marking layer is sprayed on the outer surface to complete the production of the cold-resistant, low-smoke, airtight, explosion-proof control cable.

[0032] Preferably, the overall verification and encapsulation of S4 includes a temperature resistance test and an explosion-proof airtightness test. The cable should be able to withstand an ambient temperature of up to 50°C, and the wires and cables should be able to withstand an ambient low temperature of -50°C. The cable can be laid at -15°C without preheating. The cable should be longitudinally sealed. A pressure of not less than 0.3 kPa is supplied in the test equipment connected through the cable. After holding the pressure for 5 minutes, the outlet is opened. After 5 seconds, the residual pressure should not drop below 0.15 kPa.

[0033] Compared with the prior art, the beneficial effects of the present invention are: the present invention has a scientific and reasonable structure and is safe and convenient to use.

[0034] 1. An internal flexible dynamic filling detection mechanism is set up. Through the cooperation between the various components inside the internal flexible dynamic filling detection mechanism, the protection process of the control cable is optimized. Through the flexible expansion airbag and the internal and external linkage of the adjusting isolation box, the internal air pressure of the control cable is kept within a suitable range during use. By utilizing the elastic expansion characteristics of the flexible expansion airbag, flexible filling airbag and sealing soft rubber sleeve, the expansion of the sealing soft rubber sleeve can quickly seal and protect the damaged area after the external of the control cable is damaged. This prevents the control cable from being corroded by external impurities after the outer sheath is damaged, resulting in internal damage or electric sparks. This effectively improves the explosion-proof capability and safety of the control cable.

[0035] Simultaneously, by utilizing the extensible characteristics of flexible expansion airbags and flexible filling airbags, when the cable is subjected to compression during normal use, the expansion and contraction of the components associated with the flexible expansion airbags and flexible filling airbags buffer the radial compressive force on the cable and disperse it circumferentially. This allows the cable to quickly and elastically recover after being subjected to external compression, ensuring the structural stability of the control cable during use and effectively improving the safety of the control cable. Furthermore, energy is stored through the elastic deformation of the flexible insulating rubber ring and the compression energy storage spring, ensuring that the internal pressure of the flexible expansion airbag remains within a suitable range during elastic deformation, thus ensuring the stability of the cable in the event of damage.

[0036] Furthermore, through the cooperation between the various components connected by the pressure sensor and the wireless communication module, the remote detection equipment can quickly respond and repair the control cable after it has been severely damaged, thus effectively improving the convenience of the control cable inspection and maintenance. At the same time, the modular structural design between the flexible expansion airbag and the insulating connecting rubber block makes it faster and more convenient to replace the damaged components during the control cable repair process. In addition, the air valve can quickly replenish the flexible insulating rubber ring, further improving the convenience of cable maintenance and the safety of use.

[0037] 2. An internal and external synchronous protection mechanism is set up. Through the cooperation between the various components inside the internal synchronous protection mechanism, the structural strength and stability of the control cable during use are optimized. The internal area of ​​the cable is isolated and protected by the cooperation between the various components inside the external protective rubber layer, so as to ensure that the control cable has sufficient insulation and electromagnetic shielding effect during use. At the same time, the PVC insulation layer is used to insulate and isolate the individual central transmission cables to prevent interference and confusion in the central transmission cables during operation, thereby effectively improving the internal stability of the control cable.

[0038] Meanwhile, the protective snap-fit ​​slip ring is installed on the outside of the protective rubber jacket by means of the top mounting strip and the guide side sliding groove, and an appropriate number of side reinforcing rods are inserted and installed on the outside of the control cable through the snap-fit ​​circular holes. When the control cable is subjected to lateral impact and compression, the side reinforcing rods can disperse and buffer the impact force, thereby effectively improving the overall compression resistance and overall structural strength of the control cable.

[0039] In summary, through the cooperation between the internal flexible dynamic filling detection mechanism and the internal and external synchronous protection mechanism, and by adjusting the cooperation between the components connected to the isolation box, the flexible expansion airbag and the flexible filling airbag utilize their expandable and contractile structural characteristics to disperse and buffer the external pressure when the cable is subjected to slight external compression. Furthermore, the expansion and contraction characteristics of the flexible expansion airbag and the protective rubber jacket are used to quickly seal and repair damage to the outer side of the control cable, preventing external impurities from rapidly intruding into the control cable and causing secondary damage. In the event of severe damage to the control cable, real-time detection of the internal pressure of the isolation box allows for rapid response and location of leaks, effectively improving the convenience of control cable inspection and maintenance. Simultaneously, the cooperation between the various protective layers within the external protective rubber layer effectively improves the overall structural strength and comprehensive protection performance of the control cable. Moreover, the gas cavities inside the flexible expansion airbag and the flexible filling airbag form a flexible isolation protective layer on the outside of the cable, ensuring good thermal insulation performance in cold environments and improving the overall cold resistance of the cable. Attached Figure Description

[0040] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof.

[0041] In the attached diagram:

[0042] Figure 1 This is a schematic diagram of the structure of the present invention;

[0043] Figure 2 This is a schematic diagram of the end structure of the present invention;

[0044] Figure 3 This is a schematic diagram of the structure for adjusting the installation of the isolation round box according to the present invention;

[0045] Figure 4 This is a schematic diagram of the internal cavity flexible dynamic filling detection mechanism of the present invention;

[0046] Figure 5 This is a schematic diagram of the internal structure of the external protective rubber layer of the present invention;

[0047] Figure 6 This is a schematic diagram of the structure for adjusting the installation of the isolation round box according to the present invention;

[0048] Figure 7 This is a schematic diagram of the installation structure of the one-way flow limiting valve of the present invention;

[0049] Figure 8 This is a schematic diagram of the internal and external synchronous protection mechanism of the present invention;

[0050] Figure 9 This is a schematic diagram of the structure for installing the protective clip slip ring of the present invention;

[0051] Figure 10 This is a schematic diagram of the galvanized steel strip armored installation structure of the present invention;

[0052] Labels in the diagram: 1. Central transmission cable; 2. External protective rubber layer;

[0053] 3. Inner cavity flexible dynamic filling detection mechanism; 301. Inner ring anti-slip silicone ring; 302. Inner ring rubber expansion layer; 303. Side guide inner tube; 304. Flexible expansion airbag; 305. Flexible filling airbag; 306. Isolation connecting rubber block; 307. Connecting air guide head; 308. Air guide connecting pipe; 309. Adjustable isolation round box; 310. One-way flow limiting valve; 311. Pressure sensor; 312. Sealing ring; 313. Flexible isolation rubber ring; 314. Lifting drive slide plate; 315. Compression energy storage spring; 316. Wireless communication module; 317. Air guide hose; 318. Inflation valve port; 319. Mounting side plate; 320. Telescopic silicone partition; 321. Sealing soft rubber sleeve; 322. Protective rubber outer sleeve;

[0054] 4. Internal and external synchronous protection mechanism; 401. Polyethylene inner sheath; 402. Insulating protective layer; 403. Galvanized steel strip armor; 404. PVC insulation layer; 405. Top mounting strip; 406. Protective isolation circular groove; 407. Guide side sliding groove; 408. Protective snap-fit ​​slip ring; 409. Snap-fit ​​circular hole; 410. Side reinforcing thin rod. Detailed Implementation

[0055] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0056] Example: Figure 1-10 As shown, the present invention provides a technical solution, a cold-resistant, low-smoke, airtight explosion-proof control cable, including a central transmission cable 1. Since the conductor of the central transmission cable 1 has a small cross-section, a compacted conductor is sufficient and no additional sealing material is required. An external protective rubber layer 2 is provided on the outside of the central transmission cable 1. The external protective rubber layer 2 is extruded by extrusion. The extrusion pressure is used to tightly wrap the conductor with the insulating material, seal the gaps between the conductor filaments, and block the air gap channel.

[0057] The gaps between the outer insulating cores of the central transmission cable 1 are filled with extruded inner sheaths made of polymer material, PVC or halogen-free polymer material, selected according to product requirements. The material is embedded into the edge gaps between the outer insulating cores of the cable core by extrusion and is cooled and shaped in a water tank to form a permanent sealing structure, blocking the air gaps between the cores.

[0058] The outer protective rubber layer 2 is provided with an inner cavity flexible dynamic filling detection mechanism 3. The inner cavity flexible dynamic filling detection mechanism 3 is used to provide flexible protection to the outside of the control cable and to provide continuous energy protection to the inside of the control cable through air pressure charging, so as to improve the overall protection performance of the control cable.

[0059] The internal cavity flexible dynamic filling detection mechanism 3 includes an inner anti-slip silicone ring 301, an inner rubber expansion layer 302, a side guide inner tube 303, a flexible expansion airbag 304, a flexible filling airbag 305, an isolation connecting rubber block 306, a connecting air guide head 307, an air guide connecting pipe 308, an adjusting isolation round box 309, a one-way flow limiting valve 310, a pressure sensor 311, a sealing ring 312, a flexible isolation rubber ring 313, a lifting drive slide plate 314, a compression energy storage spring 315, a wireless communication module 316, an air guide hose 317, an inflation valve port 318, a mounting side plate 319, a telescopic silicone partition 320, a sealing soft rubber sleeve 321, and a protective rubber outer sleeve 322;

[0060] The outer protective rubber layer 2 is tightly wrapped with an inner anti-slip silicone ring 301, and the outer side of the inner anti-slip silicone ring 301 is tightly wrapped with an inner rubber expansion layer 302.

[0061] The inner rubber expansion layer 302 is provided with side guide tubes 303 at equal intervals on the outer side. Flexible expansion airbags 304 are uniformly sleeved on the outer side of the side guide tubes 303 at equal intervals. Flexible filling airbags 305 are covered on the outer side of the inner rubber expansion layer 302 corresponding to the side position of the flexible expansion airbags 304. Isolation connecting rubber blocks 306 are fixedly connected between the ends of the side guide tubes 303. The inner rubber expansion layer 302 is provided with telescopic cavities evenly opened in the circumferential direction. The ends of the side guide tubes 303 are isolated by the isolation connecting rubber blocks 306. The flexible filling airbags 305 are filled with inert gas and are connected by connecting straps.

[0062] A connecting air guide head 307 is fixedly connected to the top of one end of the side guide inner tube 303 via an air guide tube. An air guide connecting tube 308 is fixedly connected to the middle of the top of the connecting air guide head 307 via a connector. An adjusting isolation round box 309 is fixedly connected to the top of the air guide connecting tube 308.

[0063] A one-way flow limiting valve 310 is embedded in the bottom of the inner side of the adjusting isolation round box 309. Pressure sensors 311 are embedded in both sides of the top surface of the one-way flow limiting valve 310. A sealing ring 312 is fixedly installed in the bottom of the inner side of the adjusting isolation round box 309. A flexible isolation rubber ring 313 is fixedly connected to the top edge of the sealing ring 312. A lifting drive slide plate 314 is fixedly connected between the top center of the flexible isolation rubber ring 313 and the inner wall of the adjusting isolation round box 309. The bottom air outlet of the one-way flow limiting valve 310 is tightly slidably fitted with the inner cavity of the air guide pipe 308. The outer side of the lifting drive slide plate 314 is tightly slidably fitted with the inner wall of the adjusting isolation round box 309. A counterweight is embedded in the middle of the bottom surface of the lifting drive slide plate 314 at the position corresponding to the inside of the flexible isolation rubber ring 313.

[0064] A compression energy storage spring 315 is fixedly connected to the top edge of the lifting drive slide plate 314. Wireless communication modules 316 are embedded in the middle of both sides of the top surface of the adjustment isolation round box 309. The top of the compression energy storage spring 315 is fixedly connected to the top of the inner cavity of the adjustment isolation round box 309. The wireless communication module 316 is powered by an external power source.

[0065] A duct hose 317 is fixedly connected to the middle of the top of the lifting drive slide plate 314, and an inflation valve 318 is connected to the end of the duct hose 317 at the top position of the adjusting isolation round box 309.

[0066] The middle of both sides of the adjustable isolation round box 309 is fixedly connected with mounting side plates 319;

[0067] A telescopic silicone partition 320 is fixedly connected to the outer side of the inner rubber expansion layer 302 and the flexible expansion airbag 304. A sealing soft rubber sleeve 321 is tightly wrapped around the outside of the telescopic silicone partition 320, and a protective rubber outer sleeve 322 is tightly wrapped around the outside of the sealing soft rubber sleeve 321. The length of the air guide hose 317 is greater than the height of the adjusting isolation box 309. Installation holes are provided at the four corners of the side of the mounting plate 319. The bottom pipe connecting the air guide head 307 passes through the telescopic silicone partition 320, the sealing soft rubber sleeve 321, and the protective rubber outer sleeve 322. This is achieved through the mutual cooperation between the various components inside the flexible dynamic filling detection mechanism 3. The protection process of the control cable has been optimized. Through the flexible expansion airbag 304 and the internal and external linkage of the regulating isolation box 309, the internal air pressure of the control cable is kept within a suitable range during use. The elastic expansion characteristics of the flexible expansion airbag 304, the flexible filling airbag 305 and the sealing soft rubber sleeve 321 are utilized to quickly seal and protect the damaged area after the outer sheath of the control cable is damaged. This prevents the control cable from being corroded by external impurities after the outer sheath is damaged, resulting in internal damage or electric sparks. This effectively improves the explosion-proof capability and safety of the control cable.

[0068] Simultaneously, utilizing the expandable and contractile properties of the flexible expansion airbag 304 and the flexible filling airbag 305, when the cable is subjected to compression during normal use, the expansion and contraction of the components associated with the flexible expansion airbag 304 and the flexible filling airbag 305 buffer the radial compressive force on the cable and disperse it circumferentially. This allows the cable to quickly and elastically recover after being subjected to external compression, ensuring the structural stability of the control cable during use and effectively improving its safety. Furthermore, the flexible insulating rubber ring 313 and the compression energy storage spring 315 store energy through elastic deformation, ensuring that the internal pressure of the flexible expansion airbag 304 remains within a suitable range during elastic deformation, thus ensuring the cable's stability in the event of damage.

[0069] Furthermore, through the cooperation between the components connected by the pressure sensor 311 and the wireless communication module 316, the remote detection equipment can quickly respond and repair the control cable after it is severely damaged, thus effectively improving the convenience of the control cable inspection and maintenance. At the same time, the modular structural design between the flexible expansion airbag 304 and the isolation connecting rubber block 306 makes it faster and more convenient to replace the damaged components during the control cable repair process. In addition, the air valve port 318 can quickly replenish air into the flexible isolation rubber ring 313, further improving the convenience of cable maintenance and the safety of use.

[0070] The outer protective rubber layer 2 is equipped with an inner and outer synchronous protection mechanism 4. The inner and outer synchronous protection mechanism 4 is used to provide insulation shielding for the inside of the cable and to strengthen the protection of the outside of the control cable through its external structure.

[0071] The internal and external synchronous protection mechanism 4 includes a polyethylene inner sheath 401, an insulating protective layer 402, a galvanized steel strip armor 403, a PVC insulating layer 404, a top mounting strip 405, a protective isolation circular groove 406, a guide side sliding groove 407, a protective snap-fit ​​slip ring 408, a snap-fit ​​circular hole 409, and a side reinforcing thin rod 410.

[0072] The outer protective rubber layer 2 is tightly wrapped with a polyethylene inner sheath 401 at the position corresponding to the outer side of the center transmission cable 1. The outer side of the polyethylene inner sheath 401 is tightly wrapped with an insulating protective layer 402. The outer side of the insulating protective layer 402 is wrapped with galvanized steel tape armor 403.

[0073] The outer side of the central transmission cable 1 is tightly covered with a PVC insulation layer 404;

[0074] The top of the protective rubber jacket 322 is attached to the top of the outer side of the top mounting strip 405. The top of the top mounting strip 405 is connected to the outer side of the air guide head 307 and a protective isolation circular groove 406 is opened through it. The top mounting strip 405 is provided with guide side sliding grooves 407 on both sides of the middle.

[0075] The protective rubber jacket 322 adopts a semi-extrusion molding process to cover the outer protective material. Through extrusion pressure, the semi-extrusion tube is tightly attached to the wrapping tape and fills the micro gaps on the surface of the wrapping tape to achieve an overall seal of the outer layer.

[0076] A protective locking slip ring 408 is slidably engaged with the outer side of the protective rubber jacket 322 at a position corresponding to the inner position of the guide side slide groove 407. A circular locking hole 409 is provided through the edge of the end face of the protective locking slip ring 408. A side reinforcing rod 410 is inserted and installed inside the circular locking hole 409. The inner side of the polyethylene inner sheath 401 is tightly fitted with the outer side of the central transmission cable 1. The outer side of the galvanized steel strip armor 403 is tightly fitted with the inner wall of the outer protective rubber layer 2. The end of the protective locking slip ring 408 is tightly slidably fitted with the inner side of the guide side slide groove 407. The inner ring of the protective locking slip ring 408 is tightly fitted with the outer side of the protective rubber jacket 322. The sides slide tightly together, and the internal components of the inner and outer synchronous protection mechanism 4 cooperate with each other to optimize the structural strength and stability of the control cable during use. The internal components of the outer protective rubber layer 2 cooperate with each other to isolate and protect the internal area of ​​the cable, so as to ensure that the control cable has sufficient insulation and electromagnetic shielding effect during use. At the same time, the PVC insulation layer 404 insulates and isolates the individual central transmission cables 1 to prevent interference and confusion in the central transmission cables 1 during operation, thereby effectively improving the internal stability of the control cable.

[0077] When the cable structure has both a shielding layer and an armor layer, a double-layer inner sheath structure is required. An inner isolation layer is set between the shielding and armor layers, and polymer material is extruded by extrusion to achieve an airtight effect.

[0078] Meanwhile, the protective snap-fit ​​slip ring 408 is installed on the outside of the protective rubber jacket 322 through the top mounting strip 405 and the guide side slide groove 407, and an appropriate number of side reinforcing rods 410 are inserted and installed on the outside of the control cable through the snap-fit ​​circular hole 409. When the control cable is subjected to lateral impact and compression, the impact force can be dispersed and buffered by the side reinforcing rods 410, thereby effectively improving the overall compression resistance and overall structural strength of the control cable.

[0079] The inner layer of the cable needs to be densely filled with airtight polymer. For multi-layer structures, the appropriate size of the specification needs to be selected for sealing according to the size of the gap between the layers. It also needs to be twisted synchronously with the cable and always embedded in the internal gaps. The dense filling effect is achieved by extrusion molding through a mold.

[0080] According to the above technical solution, a method for manufacturing a cold-resistant, low-smoke, airtight explosion-proof control cable includes the following steps:

[0081] S1. Internal component production and molding: The central transmission cable 1 is wrapped with a PVC insulation layer 404, then wrapped with a polyethylene inner sheath 401, an insulation protection layer 402, and a galvanized steel strip armor 403 in sequence, and finally the outer protective rubber layer 2 is formed by molding.

[0082] S2. External component assembly: The outer protective rubber layer 2 is covered with an inner anti-slip silicone ring 301, and then from the inside out, the inner ring rubber expansion layer 302, the side guide inner tube 303, the flexible expansion airbag 304, the flexible filling airbag 305 and the isolation connecting rubber block 306 are arranged in sequence.

[0083] S3. External accessory connection and forming: Install the one-way flow limiting valve 310, pressure sensor 311 and other components inside the regulating isolation round box 309 in sequence, and connect the regulating isolation round box 309 to the internal components of the control cable through the connecting air guide head 307 and the air guide connecting pipe 308. Then, install the protective clamping slip ring 408 and its components on it to the outside of the cable through the top mounting strip 405 and the guide side slide groove 407 to complete the assembly of the external structure of the cable.

[0084] S4. Testing and Packaging: Inert gas is injected into the flexible insulating ring 313 and the flexible expansion airbag 304 through the inflation valve 318. The internal air pressure is detected in real time by the pressure sensor 311 to keep the internal air pressure stable within the set range. Then, the overall cable is tested for air tightness, explosion-proof performance and low smoke emission. After passing the test, a cold-proof marking layer is sprayed on the outer surface to complete the production of the cold-resistant, low-smoke, airtight, explosion-proof control cable.

[0085] According to the above technical solution, the overall verification and encapsulation of S4 includes temperature resistance test and explosion-proof airtightness test. The cable should be able to withstand the influence of ambient temperature up to 50°C, and the wire and cable should withstand ambient low temperature down to -50°C. The cable can be laid at -15°C without preheating. The cable should be longitudinally sealed. A pressure of not less than 0.3 kPa is supplied in the test equipment connected through the cable. After holding the pressure for 5 minutes, the outlet is opened. After 5 seconds, the residual pressure should not drop below 0.15 kPa.

[0086] The working principle and usage process of this invention: In the actual application of this invention, when the control cable needs to be used, the central transmission cable 1 needs to be connected to a suitable position first. Then, the central transmission cable 1 is protected by the outer protective rubber layer 2, and the outer side of the outer protective rubber layer 2 is protected by the inner anti-slip silicone ring 301. Then, the outer side of the inner anti-slip silicone ring 301 is flexibly isolated by the inner rubber expansion layer 302 to ensure that the control cable has sufficient buffer space during use.

[0087] When the protective rubber jacket 322 used to protect the outside of the control cable is scratched and damaged, the structural constraint strength of the cable at the local damaged point decreases. By adjusting the compression energy storage spring 315 inside the isolation box 309, the lifting drive slide plate 314 is driven to slide down along the inside of the adjustment isolation box 309. During the downward movement of the adjustment isolation box 309, the flexible isolation rubber ring 313 on the top of the sealing ring 312 is squeezed. After the flexible isolation rubber ring 313 is squeezed, the compressed gas is continuously introduced into the side guide inner tube 303 through the one-way flow limiting valve 310, and then introduced into the flexible expansion air bag 304 through the side guide inner tube 303, so that the pressure inside the flexible expansion air bag 304 can be continuously maintained within a suitable range.

[0088] Since the partial damage to the protective rubber jacket 322 can no longer bind and constrain the outer side of the expanded flexible isolation ring 313, the flexible isolation ring 313 expands outward under pressure. After the flexible isolation ring 313 expands, it will simultaneously drive the outer part of the telescopic silicone partition 320 and the sealing soft rubber sleeve 321 to expand outward elastically. As a result, the telescopic silicone partition 320 and the sealing soft rubber sleeve 321 will be squeezed and expand outward along the damage to the protective rubber jacket 322. Then, the expanded telescopic silicone partition 320 and the sealing soft rubber sleeve 321 will seal the worn area, preventing external impurities from entering the control cable through the damage to the outer side of the protective rubber jacket 322. This effectively prevents the metal conductor inside the control cable from being directly exposed to the environment and generating electric sparks, thereby effectively improving the overall protection performance of the control cable.

[0089] When damage to the outside of the protective rubber jacket 322 penetrates into the telescopic silicone partition 320 and the sealing soft rubber sleeve 321, causing the flexible expansion airbag 304 to rupture, the filling gas inside the flexible expansion airbag 304 will be slowly released outward, which will cause the filling gas inside the flexible isolation ring 313 to be slowly consumed. At the same time, the gas continuously leaking from the rupture point can prevent external impurities from entering the control cable for a short time. The pressure sensor 311 is used to monitor the pressure inside the flexible isolation ring 313 in real time. When the pressure sensor 311 detects that the pressure inside the flexible isolation ring 313 reaches the threshold, it notifies the remote control center through the wireless communication module 316 so that maintenance personnel can detect the fault in the control cable in time and repair it in time.

[0090] During normal use of the control cable, air can be injected into the cavity inside the flexible insulating ring 313 through the air inlet 318 and the air guide hose 317, so that the flexible insulating ring 313 and the flexible expansion air bladder 304 are both kept within a suitable air pressure range. Then, the flexible expansion air bladder 304 and the flexible filling air bladder 305 form a flexible common protective layer on the outside of the control cable, so that the control cable can undergo elastic deformation after being subjected to external compression. The elastic deformation of the flexible expansion air bladder 304 and the flexible filling air bladder 305 can buffer and consume the kinetic energy of external compression on the control cable.

[0091] Furthermore, the communication range between the flexible inflatable airbags 304 can be adjusted by the isolation connecting rubber block 306, so that the flexible inflatable airbag 304 can be cut off and replaced from the isolation connecting rubber block 306 after damage, thereby effectively improving the convenience of control cable maintenance. In addition, the mounting side plate 319 can fix the adjusting isolation round box 309 separately to prevent the components inside the adjusting isolation round box 309 from adding extra load to the control cable. And by connecting the air guide head 307 and the air guide connecting pipe 308, the control cable can be given additional auxiliary traction, thereby effectively improving the installation stability of the control cable.

[0092] When it is necessary to strengthen the protection of the control cable as a whole, the outer side of the central transmission cable 1 is protected by the polyethylene inner sheath 401 and the insulation protection layer 402, and the inside of the control cable is isolated and shielded by the galvanized steel tape armor 403. The central transmission cable 1 is isolated and protected by the PVC insulation layer 404 to ensure the stability of signal transmission.

[0093] Steel strip armor: It adopts a tight spiral wrapping, and the steel strip is tightened to the inner protection below by adjusting the wrapping tension, which fills the spiral gap of the lower steel strip;

[0094] Outer sealing: A high flame-retardant strip is wrapped around the outer layer of the steel strip to seal the gap between the steel strip spirals, forming a double seal.

[0095] Steel wire armor: gap sealing: During the steel wire armor stranding process, room temperature curing easy-to-peel electronic silicone is simultaneously injected into the gap between the steel wires;

[0096] Sealing mechanism: The silicone forms a physical bond with the surface of the steel wire, and after curing, a continuous sealing layer is formed;

[0097] Outer protection: The outer layer is wrapped with high flame-retardant tape and polyester tape to tightly seal the cable core and prevent silicone from overflowing.

[0098] The outer side of the connecting air guide head 307 is protected by the top mounting strip 405 and the protective isolation groove 406. The protective snap-fit ​​slip ring 408 is snapped onto the outer side of the protective rubber jacket 322 by the guide side slide groove 407. The side reinforcing rod 410 is installed on the outer side of the control cable by the snap-fit ​​circular hole 409. The overall strength of the control cable is adjusted by adjusting the position of the side reinforcing rod 410, thereby effectively improving the structural strength and stability of the control cable.

[0099] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A cold-resistant, low-smoke, airtight explosion-proof control cable, comprising a central transmission cable (1), characterized in that: The central transmission cable (1) is provided with an external protective rubber layer (2). The outer protective rubber layer (2) is provided with an inner cavity flexible dynamic filling detection mechanism (3). The inner cavity flexible dynamic filling detection mechanism (3) is used to provide flexible protection to the outside of the control cable and to provide continuous energy protection to the inside of the control cable through air pressure charging, so as to improve the overall protection performance of the control cable. The inner cavity flexible dynamic filling detection mechanism (3) includes an inner anti-slip silicone ring (301). The outer protective rubber layer (2) is covered with an inner anti-slip silicone ring (301), and the outer side of the inner anti-slip silicone ring (301) is covered with an inner rubber expansion layer (302). A side guide tube (303) is provided on the outside of the inner ring rubber expansion layer (302). Flexible expansion airbags (304) are uniformly sleeved on the outside of the side guide tube (303) at equal intervals. A flexible filling airbag (305) is wrapped on the outside of the inner ring rubber expansion layer (302). An isolation connecting rubber block (306) is connected to the end of the side guide tube (303). The top of one end of the side guide inner tube (303) is fixedly connected to a connecting air guide head (307) via an air guide tube. The middle of the top of the connecting air guide head (307) is fixedly connected to an air guide connecting tube (308) via a connector. The top of the air guide connecting tube (308) is fixedly connected to an adjusting isolation round box (309). A one-way flow limiting valve (310) is embedded in the bottom of the inner side of the regulating isolation round box (309). Pressure sensors (311) are embedded in both sides of the top surface of the one-way flow limiting valve (310). A sealing ring (312) is fixedly installed in the bottom of the inner side of the regulating isolation round box (309). A flexible isolation rubber ring (313) is fixedly connected to the top edge of the sealing ring (312). A lifting drive slide plate (314) is fixedly connected between the top center of the flexible isolation rubber ring (313) and the inner wall of the regulating isolation round box (309). A compression energy storage spring (315) is fixedly connected to the top edge of the lifting drive slide plate (314). A wireless communication module (316) is embedded in the middle of both sides of the top surface of the adjustment isolation round box (309). An air guide hose (317) is fixedly connected to the middle of the top of the lifting drive slide plate (314). An air inlet (318) is connected to the end of the air guide hose (317) at the top position of the adjustment isolation round box (309). The adjustable isolation round box (309) has mounting side plates (319) fixedly connected to the middle of both sides. The inner rubber expansion layer (302) and the flexible expansion airbag (304) are fixedly connected to a telescopic silicone partition (320). The telescopic silicone partition (320) is tightly covered with a sealing soft rubber sleeve (321), and the sealing soft rubber sleeve (321) is tightly covered with a protective rubber outer sleeve (322).

2. The cold-resistant, low-smoke, airtight explosion-proof control cable according to claim 1, characterized in that, The inner ring rubber expansion layer (302) has a uniformly distributed telescopic cavity along the circumferential direction. The end of the side guide inner tube (303) is isolated by an isolation connecting rubber block (306). The flexible filling airbag (305) is filled with inert gas, and the flexible filling airbags (305) are connected by a connecting strap.

3. The cold-resistant, low-smoke, airtight explosion-proof control cable according to claim 2, characterized in that, The bottom outlet of the one-way flow limiting valve (310) is tightly slidably fitted with the inner cavity of the air guide connecting pipe (308), the outer side of the lifting drive slide plate (314) is tightly slidably fitted with the inner wall of the adjusting isolation round box (309), and a counterweight is embedded in the middle of the bottom surface of the lifting drive slide plate (314) at the position corresponding to the inside of the flexible isolation rubber ring (313).

4. The cold-resistant, low-smoke, airtight explosion-proof control cable according to claim 3, characterized in that, The top of the compression energy storage spring (315) is fixedly connected to the top of the inner cavity of the adjusting isolation round box (309), and the wireless communication module (316) is powered by an external power source.

5. The cold-resistant, low-smoke, airtight explosion-proof control cable according to claim 3, characterized in that, The length of the air guide hose (317) is greater than the height of the adjustable isolation box (309). The four corners of the side of the mounting side plate (319) are provided with mounting holes. The bottom pipe of the connecting air guide head (307) passes through the telescopic silicone partition (320), the sealing soft rubber sleeve (321), and the protective rubber jacket (322).

6. The cold-resistant, low-smoke, airtight explosion-proof control cable according to claim 3, characterized in that, The outer protective rubber layer (2) is provided with an inner and outer synchronous protection mechanism (4). The inner and outer synchronous protection mechanism (4) is used to insulate and shield the inside of the cable and to strengthen the protection of the outside of the control cable through its external structure. The internal and external synchronous protection mechanism (4) includes a polyethylene inner sheath (401). The outer protective rubber layer (2) is tightly wrapped with a polyethylene inner sheath (401) at the position corresponding to the outer side of the central transmission cable (1). The polyethylene inner sheath (401) is tightly wrapped with an insulating protective layer (402) on the outside. The insulating protective layer (402) is wrapped with galvanized steel tape armor (403). The outer side of the central transmission cable (1) is tightly covered with a PVC insulation layer (404). The top of the protective rubber jacket (322) is bonded with a top mounting strip (405). A protective isolation circular groove (406) is provided through the top of the top mounting strip (405) at the position corresponding to the outer side of the air guide head (307). Guide side sliding grooves (407) are provided in the middle of both sides of the top mounting strip (405). The protective rubber jacket (322) is slidably engaged with a protective snap-fit ​​ring (408) at the position inside the guide side slide groove (407) on the outer side. A snap-fit ​​circular hole (409) is opened through the edge of the end face of the protective snap-fit ​​ring (408), and a side reinforcing rod (410) is inserted and installed inside the snap-fit ​​circular hole (409).

7. The cold-resistant, low-smoke, airtight explosion-proof control cable according to claim 6, characterized in that, The inner side of the polyethylene inner sheath (401) is tightly fitted to the outer side of the central transmission cable (1), the outer side of the galvanized steel strip armor (403) is tightly fitted to the inner wall of the outer protective rubber layer (2), the end of the protective snap ring (408) is tightly fitted to the inner side of the guide side groove (407), and the inner ring of the protective snap ring (408) is tightly fitted to the outer side of the protective rubber outer jacket (322).

8. A method for manufacturing a cold-resistant, low-smoke, airtight explosion-proof control cable, used in the manufacture of the cold-resistant, low-smoke, airtight explosion-proof control cable as described in claim 7, characterized in that, Includes the following steps: S1. Production and molding of internal components: A PVC insulation layer (404) is wrapped around the center transmission cable (1), followed by a polyethylene inner sheath (401), an insulation protection layer (402), and a galvanized steel strip armor (403). Finally, an outer protective rubber layer (2) is formed by molding. S2. External component assembly: The outer protective rubber layer (2) is covered with an inner anti-slip silicone ring (301), and then from the inside out, the inner ring rubber expansion layer (302), the side guide inner tube (303), the flexible expansion airbag (304), the flexible filling airbag (305) and the isolation connecting rubber block (306) are arranged in sequence. S3. External accessory connection and forming: Install the one-way flow limiting valve (310), pressure sensor (311) and other components inside the regulating isolation round box (309) in sequence, and connect the regulating isolation round box (309) and the internal components of the control cable through the connecting air guide head (307) and the air guide connecting pipe (308). Then, install the protective clamping slip ring (408) and its components on it to the outside of the cable through the top mounting strip (405) and the guide side slide groove (407) to complete the assembly of the external structure of the cable. S4. Testing and Packaging: Inert gas is injected into the flexible insulating rubber ring (313) and flexible expansion airbag (304) through the inflation valve (318). The internal air pressure is detected in real time by the pressure sensor (311) to stabilize the internal air pressure within the set range. Then, the overall air tightness, explosion-proof performance and low smoke emission of the cable are tested. After passing the test, a cold-proof marking layer is sprayed on the outer surface to complete the production of the cold-resistant, low-smoke, airtight, explosion-proof control cable.

9. A method for manufacturing a cold-resistant, low-smoke, airtight explosion-proof control cable according to claim 8, characterized in that, The overall verification and encapsulation of S4 includes temperature resistance test and explosion-proof airtightness test. The cable should be able to withstand the influence of ambient temperature up to 50°C, and the wire and cable should withstand ambient low temperature down to -50°C. The cable can be laid at -15°C without preheating. The cable should be longitudinally sealed. A pressure of not less than 0.3 kPa is supplied in the test equipment connected through the cable. After holding the pressure for 5 minutes, the outlet is opened. After 5 seconds, the residual pressure should not drop below 0.15 kPa.

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