Weather-proof multifunctional integrated switch machine cable

Abstract

The invention discloses a weather-proof multifunctional integrated switch machine cable which comprises a cable core composed of a power line unit, an indication line unit, a heating line unit, a telephone line unit, a shielding line unit, a filling rope and an isolation belt, and an isolation layer, a shielding layer, an armor layer and an outer sheath which are sequentially arranged outside the cable core from inside to outside. The power line unit and the indication line unit respectively adopt a design of an active line and a standby line and are isolated through an isolation belt, gaps of the cable core are filled with filling ropes, and each unit of the cable core is independently insulated, so that the problems of complex cable wiring, weak anti-interference capability, low reliability and the like of a traditional point switch are solved, and the cable is suitable for popularization and application. And the high-performance requirement of a railway switch machine system can be met.

Description

Technical Field

[0001] This invention relates to the technical field of cables, and in particular to the technical field of switch machine cables. Background Technology

[0002] As the core actuator of the railway turnout system, the switch machine's operational accuracy and stability directly determine the safety and efficiency of railway transportation. Reliable power supply, precise signal transmission, suitable environmental protection, and emergency communication support are crucial prerequisites for the stable operation of the switch machine. In railway turnout field deployments, traditional switch machines require separate laying of power cables, signal cables, heating cables, and emergency communication cables to meet different functional requirements. However, this distributed wiring scheme has revealed many unavoidable defects in practical applications, severely restricting the operational reliability and maintenance convenience of the switch machine system. These defects include the following: 1) Messy wiring: Multiple independent cables are laid in parallel, which can easily lead to tangling and wear, thus increasing the difficulty of construction and the cost of later maintenance; 2) Weak anti-interference capability: This means that the weak state signal transmitted by the line is easily affected by electromagnetic interference from the power line, which in turn leads to signal distortion and affects the operation accuracy of the switch machine. 3) Insufficient backup lines: Since most power lines and indicator lines lack backup designs, a single line failure necessitates a shutdown for replacement, significantly impacting railway transport efficiency. 4) Poor environmental adaptability: Outdoor railway environments have large temperature differences and high humidity, and ordinary cable sheaths are prone to aging, leading to short circuits or open circuits in the lines.

[0003] In conclusion, developing a special cable for switch machines that can integrate multiple functions, optimize structural design, and improve anti-interference capabilities and environmental adaptability has become a key requirement for solving the defects of traditional wiring and ensuring the stable operation of railway turnout systems. Summary of the Invention

[0004] This invention proposes a weather-resistant, multi-functional integrated switch machine cable through innovative structural design. It integrates the main power cable and backup power cable, main indicator cable and backup indicator cable, heating cable, telephone line, and shielded cable into one unit. Combined with a multi-layer shielding structure and weather-resistant protection design, it achieves integrated functions of power supply, signal transmission, environmental heating, and emergency communication. It also improves electromagnetic interference resistance and adaptability to harsh environments, solving problems such as complex wiring, weak anti-interference ability, and low reliability of traditional switch machine cables. It can meet the high-performance requirements of railway switch machine systems and has significant practical value and broad application prospects (ideally suitable for the long-term stable operation of railway turnout switch machine systems).

[0005] To achieve the above objectives, this invention proposes a weather-resistant, multi-functional integrated switch machine cable, comprising a cable core consisting of a power line unit, an indicator line unit, a heating line unit, a telephone line unit, a shielding line unit, filler rope, and an insulating strip, and an insulating layer, a shielding layer, an armor layer, and an outer sheath arranged sequentially from the inside out outside the cable core. The power line unit and the indicator line unit are designed with a main line plus a spare line and are isolated from each other by the insulating strip. The gaps in the cable core are filled with filler rope, and each unit of the cable core is independently insulated.

[0006] Preferably, the power line unit has 4 to 8 main power wires and 1 to 3 spare power wires. The main power wires and spare power wires have the same structure and include a power conductor and a power insulation layer covering the power conductor. The power conductor is made of several strands of oxygen-free round copper wire, with a nominal conductor diameter of 4.05 to 4.25 mm and a nominal conductor cross-sectional area of ​​13 to 13.5 mm². 2 The power insulation layer is made of high-density polyethylene with a nominal insulation thickness of 1.0 to 1.5 mm and an insulation outer diameter of 6.45 to 6.65 mm.

[0007] Preferably, the indicator wire unit has 2 to 6 main indicator wires and 1 to 3 spare indicator wires. The main indicator wires and spare indicator wires are twisted together with filler rope to form indicator stranded groups. The main indicator wires and spare indicator wires have the same structure and include an indicator conductor and an indicator insulation layer covering the indicator conductor. The indicator conductor is made of oxygen-free copper and has a nominal cross-sectional area of ​​0.75 to 0.8 mm². 2 The insulation layer is made of high-density polyethylene and has a nominal insulation thickness of 0.5 to 0.7 mm.

[0008] Preferably, the heating wire unit has 1 to 3 heating wires, which are twisted together with filler rope to form a heating stranded assembly. Each heating wire includes a heating conductor and a heating insulation layer covering the heating conductor. The heating conductor is made of oxygen-free copper and has a nominal cross-sectional area of ​​0.75 to 0.8 mm². 2 The heating insulation layer is a cross-linked polyethylene insulation layer.

[0009] Preferably, the telephone line unit has 1 to 3 telephone lines, which are twisted together with filler cord to form a telephone stranded assembly. Each telephone line includes a telephone conductor and a telephone insulation layer covering the conductor. The telephone conductor is made of oxygen-free copper and has a nominal cross-sectional area of ​​0.75 to 0.8 mm². 2 The telephone insulation layer is a low-loss polyolefin insulation layer with a nominal insulation thickness of 0.55 to 0.75 mm.

[0010] Preferably, the shielded wire unit has 2 to 6 shielded wires, a sheathing layer longitudinally wrapped around each shielded wire, and a drain wire placed inside the sheathing layer. Each shielded wire includes a shielding conductor and a shielding insulation layer covering the shielding conductor. The shielding conductor is made of oxygen-free copper and has a nominal cross-sectional area of ​​0.75 to 0.8 mm². 2 The shielding insulation layer is a physical foam insulation layer with the thickness of the inner layer controlled at 0.03-0.04 mm, the thickness of the foam layer controlled at 0.68-0.72 mm, and the thickness of the outer layer controlled at 0.2-0.4 mm. The covering layer is a corrugated copper strip, and the drain line is a round copper wire with a diameter of not less than 0.45 mm.

[0011] Preferably, the insulating layer is a polyester film, and the insulating layer further isolates different units in the cable core according to their functions.

[0012] Preferably, the shielding layer has an inner shielding structure formed by longitudinal wrapping of double-sided aluminum-plastic composite tape and an outer shielding structure formed by extruding polyethylene outside the inner shielding structure. The aluminum foil thickness of the inner shielding structure is 0.2-0.25 mm, the plastic coating thickness is 0.08-0.1 mm, and the longitudinal wrapping overlap width is controlled at 10-15 mm. The thickness of the outer shielding structure is 1.5-2.0 mm.

[0013] Preferably, the armor layer is formed by spirally wrapping 1 to 3 layers of galvanized steel strips, the thickness of which is 0.3 to 0.8 mm and the wrapping gap ratio is controlled at 30 to 40%.

[0014] Preferably, the outer sheath is a weather-resistant, cold-resistant, rodent-proof polyethylene sheath.

[0015] The beneficial effects of this invention are: 1) Functional integration simplifies construction and maintenance: This invention, through innovative structural design, integrates the four core functions of power supply, signal transmission, environmental heating, and emergency communication—which traditionally require separate cabling in a switch machine system—into a single cable, completely changing the traditional distributed cabling model. Compared to the parallel laying of multiple independent cables in traditional solutions, this integrated design significantly reduces the amount of cabling on-site, avoiding the problems of multiple cables tangling and crossing. This not only reduces the difficulty and labor intensity of cabling during construction and shortens the construction cycle, but also greatly simplifies the subsequent maintenance process. In addition, maintenance personnel no longer need to troubleshoot among a mess of multiple cables, but can quickly locate the problematic unit through functional partitions (this significantly reduces maintenance costs and reduces the potential risk of failure such as cable wear caused by messy cabling, providing a strong guarantee for the efficient operation and maintenance of the switch machine system). 2) Strong anti-interference capability and improved signal transmission accuracy: Addressing the core defect of traditional switch machine cables where weak status signals transmitted by the indicator lines are easily affected by electromagnetic interference from the power lines, leading to signal distortion, this invention employs a multi-level, all-around shielding protection design. Specifically, the power line unit and the indicator line unit are physically isolated internally by an isolation strip, reducing the transmission path of electromagnetic interference at its source. The corrugated copper tape covering layer and bleeder wire within the shielding line unit actively absorb and shield external electromagnetic interference signals, thus preventing them from affecting the signal transmission of the indicator line unit. The external shielding layer consists of an inner shielding structure formed by longitudinal wrapping of double-sided aluminum-plastic composite tape and an outer shielding structure formed by polyethylene extrusion, effectively blocking electromagnetic radiation generated during power line operation and electromagnetic interference from the external environment through double shielding. Through the synergistic effect of this series of shielding designs, this invention significantly improves the stability and accuracy of indicator line signal transmission, ensuring that the switch machine can accurately receive and respond to control signals, thereby guaranteeing the operational accuracy of the switch machine and providing reliable signal support for railway transportation safety. 3) High reliability design to ensure railway transportation efficiency: This invention adopts a redundant design of active line plus backup line in both the power line unit and the indicator line unit. This redundancy design avoids the shutdown of the switch machine system due to a single line failure, eliminates the need for long-term interruption of railway transportation for line replacement, significantly shortens the fault handling time, and greatly improves the operational reliability of the railway turnout system and the railway transportation efficiency. It can fundamentally solve the problem of insufficient backup lines in traditional cables and the need for shutdown and replacement after a failure, and is especially suitable for high passenger flow and high density railway transportation scenarios. 4) Excellent environmental adaptability, suitable for complex outdoor scenarios: Addressing the characteristics of railway outdoor and tunnel environments such as large temperature differences, high humidity, and susceptibility to mechanical impact, this invention employs a weather-resistant, cold-resistant, rodent-proof polyethylene sheath as the outer sheath, thereby broadening the cable's temperature range and providing excellent aging and UV resistance, effectively slowing down the sheath aging rate in outdoor environments. Furthermore, it uses several layers of galvanized steel strip spirally wrapped to form an armor layer, effectively resisting external mechanical impacts and tensile forces, enabling the cable to adapt to the complex mechanical environment during railway construction and operation. Secondly, the insulation layers of each unit use aging-resistant and moisture-resistant materials such as high-density polyethylene, cross-linked polyethylene, and low-loss polyolefin, which also to some extent avoids short circuits or open circuits caused by high environmental humidity. In addition, the heating line unit can also heat and prevent freezing of the internal mechanical components of the switch machine in winter or low-temperature environments, ensuring the switch machine can still operate stably under harsh weather conditions, fully adapting to the usage requirements of complex railway outdoor environments. 5) Excellent safety performance and reduced usage risks: This invention enhances the safety of the cable through a multi-layered structural design, effectively avoiding mutual interference and safety hazards between lines. Each functional unit of the cable core (power line unit, indicator line unit, heating line unit, etc.) adopts an independent insulation design, and the units are separated by isolation strips and filler ropes. This prevents short-circuit faults caused by insulation damage between different functional lines, especially avoiding the impact of high voltage on low voltage lines such as indicator lines and telephone lines, ensuring the safe and stable transmission of signals and emergency communication. The filler rope is made of flame-retardant polypropylene rope, which not only improves the structural stability of the cable but also has certain flame-retardant properties, reducing fire hazards. At the same time, the multi-layer shielding structure and armor design also indirectly improve safety performance, avoiding safety problems caused by line faults due to external interference or mechanical damage, providing comprehensive protection for the safe operation of the switch machine system.

[0016] The features and advantages of the present invention will be described in detail through embodiments and in conjunction with the accompanying drawings. Attached Figure Description

[0017] Figure 1 This is a cross-sectional view of the weather-resistant, multi-functional integrated switch machine cable of the present invention; Figure 2 This is a cross-sectional view of the cable core of the weather-resistant multifunctional integrated switch machine cable of the present invention. Figure 3 This is a cross-sectional view of the main power wire or backup power wire of the weather-resistant multi-functional integrated switch machine cable of the present invention. Figure 4 This is a cross-sectional view showing the stranded assembly of the weather-resistant multifunctional integrated switch machine cable of the present invention; Figure 5 This is a cross-sectional view of the heated stranding assembly of the weather-resistant multifunctional integrated switch machine cable of the present invention; Figure 6 This is a cross-sectional view of the telephone stranded assembly of the weather-resistant multifunctional integrated switch cable of the present invention; Figure 7 This is a cross-sectional view of the shielding unit of the weather-resistant multifunctional integrated switch machine cable of the present invention.

[0018] In the diagram: 1-Cable core, 11-Power line unit, 111-Power conductor, 112-Power insulation layer, 12-Indicator line unit, 121-Indicator conductor, 122-Indicator insulation layer, 13-Heating line unit, 131-Heating conductor, 132-Heating insulation layer, 14-Telephone line unit, 141-Telephone conductor, 142-Telephone insulation layer, 15-Shielded line unit, 151-Shielded conductor, 152-Shielded insulation layer, 153-Sheathing layer, 154-Draining line, 16-Filling rope, 17-Insulation strip, 2-Insulation layer, 3-Shielding layer, 31-Inner shielding structure, 32-Outer shielding structure, 4-Armor layer, 5-Outer sheath. Detailed Implementation

[0019] This invention provides a special cable for switch machines that integrates power supply, signal transmission, environmental heating and emergency communication functions. It can solve the problems of traditional switch machine cables, such as single function, messy wiring, weak anti-interference ability and high maintenance costs and high failure risk due to insufficient backup lines.

[0020] Specifically, see Figures 1 to 7 The weather-resistant multi-functional integrated switch machine cable of the present invention includes a cable core 1 composed of a power line unit 11, an indicator line unit 12, a heating line unit 13, a telephone line unit 14, a shielding line unit 15, a filler rope 16, and an isolation strip 17, and an isolation layer 2, a shielding layer 3, an armor layer 4, and an outer sheath 5 arranged sequentially from the inside to the outside of the cable core 1. The power line unit 11 and the indicator line unit 12 are designed with active line plus backup line and are isolated from each other by the isolation strip 17. The gaps of the cable core 1 are filled by the filler rope 16. Each unit of the cable core 1 is independently insulated and is evenly distributed in a ring along the central axis of the cable.

[0021] The power line unit 11 has 6 main power wires and 2 backup power wires. The main power wires and backup power wires have the same structure and include a power conductor 111 and a power insulation layer 112 covering the power conductor 111. The power conductor 111 is made of several strands of high-purity oxygen-free round copper wire, with a nominal diameter of 4.15 mm and a nominal cross-sectional area of ​​13.2 mm². 2 The power insulation layer 112 is made of high-density polyethylene with a nominal insulation thickness of 1.2 mm and an insulation outer diameter of 6.55 mm; wherein, the spare power wire with the same conductor specification as the main power wire is used for seamless switching in the event of a failure of the main power wire.

[0022] The indicator line unit 12 has four main indicator wires and two spare indicator wires. The main indicator wires and spare indicator wires are twisted together with filler rope 16 to form indicator stranded groups. The main indicator wires and spare indicator wires have the same structure and include an indicator conductor 121 and an indicator insulation layer 122 covering the indicator conductor 121. The indicator conductor 121 is made of high-purity oxygen-free copper and has a nominal cross-sectional area of ​​0.78 mm². 2 The insulating layer 122 is made of high-density polyethylene and has a nominal insulation thickness of 0.6 mm. The indicator line unit 12 is used to transmit the switch machine's operating position and status signals, while the spare indicator line can maintain signal transmission when the main indicator line fails.

[0023] The heating wire unit 13 has two heating wires, which are twisted together with the filler rope 16 to form a heating stranded assembly. Each heating wire includes a heating conductor 131 and a heating insulation layer 132 covering the heating conductor 131. The heating conductor 131 is made of high-purity oxygen-free copper and has a nominal cross-sectional area of ​​0.78 mm². 2 The heating insulation layer 132 is a cross-linked polyethylene insulation layer with a temperature resistance of 125°C or higher; wherein, the heating wire unit 13 is used to heat and prevent freezing of the internal mechanical parts of the switch machine in winter or low temperature environment.

[0024] The telephone line unit 14 has two telephone lines, which are twisted together with filler cord 16 to form a telephone stranded assembly. Each telephone line includes a telephone conductor 141 and a telephone insulation layer 142 covering the conductor 141. The telephone conductor 141 is made of high-purity oxygen-free copper and has a nominal cross-sectional area of ​​0.78 mm². 2 The telephone insulation layer 142 is a low-loss polyolefin insulation layer with a nominal insulation thickness of 0.65mm; wherein, the telephone line unit 14 is used for on-site emergency communication by switch machine maintenance personnel and remote voice feedback of equipment status.

[0025] The shielded wire unit 15 has four shielded wires, a sheathing layer 153 longitudinally wrapped around each shielded wire, and a drain wire 154 placed inside the sheathing layer 153. The shielded wires include a shielded conductor 151 and a shielded insulation layer 152 covering the shielded conductor 151. The shielded conductor 151 is made of high-purity oxygen-free copper and has a nominal cross-sectional area of ​​0.78 mm². 2The shielding insulation layer 152 is a foamed insulation layer with the inner layer thickness controlled at 0.035mm, the foam layer thickness controlled at 0.7mm, and the outer layer thickness controlled at 0.3mm. The covering layer 153 is a corrugated copper strip, and the drain line 154 is a round copper wire with a diameter of 0.5mm. The drain line 154 is used to absorb and shield external electromagnetic interference signals, which can avoid interference with the signal transmission accuracy of the line unit.

[0026] The filler rope 16 is a flame-retardant polypropylene rope, which is also filled between different units, thereby making the cable cross-section circular and improving structural stability.

[0027] The width of the isolation strip 17 is not less than 5mm.

[0028] The isolation layer 2 is a polyester film, and the isolation layer 2 also isolates different units in the cable core 1 according to their functions.

[0029] The shielding layer 3 has an inner shielding structure 31 formed by longitudinal wrapping of double-sided aluminum-plastic composite tape and an outer shielding structure 32 formed by extruding polyethylene outside the inner shielding structure 31. The aluminum foil thickness of the inner shielding structure 31 is 0.23 mm, the plastic coating thickness is 0.09 mm, and the longitudinal wrapping overlap width is controlled at 12.5 mm to ensure the longitudinal wrapping shielding effect. The thickness of the outer shielding structure 32 is 1.8 mm. Among them, extruding a polyethylene sheath outside the double-sided aluminum-plastic composite tape can greatly improve the cable's anti-interference ability.

[0030] The armor layer 4 is formed by spirally wrapping two layers of galvanized steel strips. The thickness of the galvanized steel strips is 0.5mm and the wrapping gap ratio is controlled at 35%. This armor layer 4 can effectively improve the impact and tensile strength of the cable (to resist external mechanical impact), making the tensile strength of the cable ≥1500N / 100mm.

[0031] The outer sheath 5 is a weather-resistant, cold-resistant, rodent-proof polyethylene sheath (temperature range of -40 to 105℃, and with aging resistance and UV resistance), which enables the cable to adapt to the harsh outdoor environment of railways.

[0032] The above embodiments are illustrative of the present invention and are not intended to limit the present invention. Any simple modifications to the present invention are within the scope of protection of the present invention.

Claims

1. A weather resistant, multi-functional integrated switch machine cable, characterized by: The cable core (1) is composed of a power line unit (11), a indicating line unit (12), a heating line unit (13), a telephone line unit (14), a shielding line unit (15), a filling rope (16) and an isolation belt (17), and the isolation layer (2), the shielding layer (3), the armored layer (4) and the outer sheath (5) are sequentially arranged outside the cable core (1) from inside to outside, the power line unit (11) and the indicating line unit (12) are respectively designed as active line plus standby line and are isolated by the isolation belt (17), the cable core (1) is filled with the filling rope (16) to fill the gaps, and each unit of the cable core (1) is independently insulated.

2. The weatherproof multi-functional integrated switch machine cable of claim 1, wherein: The power line unit (11) has 4-8 main power lines and 1-3 standby power lines, the main power lines and standby power lines are of the same structure and comprise a power conductor (111) and a power insulation layer (112) covering the power conductor (111), the power conductor (111) is twisted by several strands of oxygen-free round copper wire and has a conductor nominal diameter of 4.05-4.25 mm and a conductor nominal sectional area of 13-13.5 mm 2 , the power insulation layer (112) is made of high-density polyethylene and has an insulation nominal thickness of 1.0-1.5 mm and an insulation outer diameter of 6.45-6.65 mm.

3. The weatherproof multi-functional integrated switch machine cable of claim 1, wherein: The display wire unit (12) has 2-6 main display wires and 1-3 standby display wires, the main display wires and standby display wires are twisted with the filling rope (16) to form a display twisted group, the main display wires and standby display wires are the same structure and include a display conductor (121) and a display insulation layer (122) covering the display conductor (121), the display conductor (121) is made of oxygen-free copper and the conductor nominal cross-sectional area is 0.75-0.8 mm 2 , the display insulation layer (122) is made of high-density polyethylene and the insulation nominal thickness is 0.5-0.7 mm.

4. The weatherproof multi-functional integrated switch machine cable of claim 1, wherein: The heating wire unit (13) has 1-3 heating wires, the heating wires and the filling rope (16) are twisted to form a heating twisted group, the heating wire includes a heating conductor (131) and a heating insulation layer (132) covering the heating conductor (131), the heating conductor (131) is made of oxygen-free copper and has a conductor nominal cross-sectional area of 0.75-0.8 mm 2 , and the heating insulation layer (132) is a cross-linked polyethylene insulation layer.

5. The weatherproof multi-functional integrated switch machine cable of claim 1, wherein: The telephone line unit (14) has 1-3 telephone lines, which are twisted with filling ropes (16) to form a telephone twisted group, the telephone line includes a telephone conductor (141) and a telephone insulation layer (142) covering the telephone conductor (141), the telephone conductor (141) is made of oxygen-free copper and has a conductor nominal cross-sectional area of 0.75-0.8 mm 2 , and the telephone insulation layer (142) is a low-loss polyolefin insulation layer and has an insulation nominal thickness of 0.55-0.75 mm.

6. The weatherproof multi-functional integrated switch machine cable of claim 1, wherein: The shielded wire unit (15) has 2-6 shielded wires, a cladding layer (153) longitudinally wrapped outside each shielded wire, and a drain wire (154) placed inside the cladding layer (153), the shielded wire comprises a shielded conductor (151) made of oxygen-free copper and having a conductor nominal cross-sectional area of 0.75-0.8 mm 2 , and a shielded insulation layer (152) wrapped outside the shielded conductor (151), the shielded insulation layer (152) is a skin-bubble-skin physical foaming insulation layer, the thickness of the inner skin layer is controlled to be 0.03-0.04 mm, the thickness of the foaming layer is controlled to be 0.68-0.72 mm, and the thickness of the outer skin layer is controlled to be 0.2-0.4 mm, the cladding layer (153) is a corrugated copper strip, and the drain wire (154) is a round copper wire with a diameter not less than 0.45 mm.

7. The weatherproof multi-functional integrated switch machine cable of claim 1, wherein: The isolation layer (2) is a polyester film, and different units in the cable core (1) are isolated according to functions.

8. The weatherproof multi-functional integrated switch machine cable of claim 1, wherein: The shielding layer (3) has an inner shielding structure (31) formed by longitudinally wrapping a double-sided aluminum-plastic composite belt and an outer shielding structure (32) formed by extruding polyethylene outside the inner shielding structure (31), the aluminum foil thickness of the inner shielding structure (31) is 0.2-0.25 mm, the plastic coating thickness is 0.08-0.1 mm, and the longitudinal wrapping lap width is controlled to be 10-15 mm, and the thickness of the outer shielding structure (32) is 1.5-2.0 mm.

9. The weatherproof multi-functional integrated switch machine cable of claim 1, wherein: The armored layer (4) is formed by spirally wrapping 1-3 layers of galvanized steel belts, the thickness of the galvanized steel belt is 0.3-0.8 mm, and the wrapping gap rate is controlled to be 30-40%.

10. The weatherproof multi-functional integrated switch machine cable of claim 1, wherein: The outer sheath (5) is a weather-resistant, cold-resistant and rat-proof polyethylene sheath.

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