Dynamic hoisting power cable and preparation method thereof

Abstract

The invention relates to a dynamic hoisting power cable and a preparation method thereof, the dynamic hoisting power cable comprises a cable core and an armor layer, the armor layer is arranged on the periphery of the cable core, and the armor layer comprises a plurality of armor pieces arranged along the circumferential direction of the cable core; wherein the cross section of the armoring piece is provided with a first arc-shaped edge, a first side edge, a second arc-shaped edge and a second side edge which are connected in sequence, and the first arc-shaped edge and the second arc-shaped edge are arranged in the circumferential direction of the cable core. By adopting the dynamic hoisting power cable, the first arc-shaped edge and the second arc-shaped edge of the armoring piece are arranged along the circumferential direction of the cable core, so that invalid gaps in the structure can be reduced when the plurality of armoring pieces are arranged along the periphery of the cable core, the cable core is wrapped and protected with less radial space, the filling coefficient in the armoring layer is obviously improved, and the cable core is protected. The overall outer diameter of the cable is effectively reduced, light weight, compactness and excellent lateral pressure resistance are realized, and the mechanical reliability and stability of the cable under a vertical hoisting working condition are effectively enhanced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power transmission, in particular to a dynamic hoisting power cable and a preparation method thereof. BACKGROUND

[0002] With the energy structure accelerating to clean energy such as wind power and photovoltaic, the large-scale installation of new energy facilities puts unprecedented technical requirements on special cables. Taking offshore wind power as an example, the height of the wind turbine tower and the single machine capacity continue to rise, resulting in the internal power transmission cable needing to withstand long-term self-weight stretching and dynamic composite stress caused by tower swing. This dynamic vertical laying scene not only requires the cable to have composite properties such as high voltage level, tensile strength, corrosion resistance, etc., but also puts forward strict requirements on the weight, mechanical reliability and operation stability of the cable, far exceeding those of traditional cables.

[0003] However, the current underground direct-buried or static-laid medium-voltage power cable is difficult to adapt to such a harsh vertical dynamic laying condition in terms of structure design and material system, and there are significant technical bottlenecks. SUMMARY

[0004] Therefore, it is necessary to provide a dynamic hoisting power cable and a preparation method thereof to solve the problem that the current power cable is difficult to adapt to the vertical dynamic laying condition.

[0005] In a first aspect, the present application provides a dynamic hoisting power cable, comprising:

[0006] a cable core;

[0007] an armor layer arranged outside the cable core, the armor layer comprising a plurality of armor pieces arranged circumferentially around the cable core;

[0008] wherein the cross section of the armor piece has a first arc-shaped side, a first side, a second arc-shaped side and a second side connected in sequence, and the first arc-shaped side and the second arc-shaped side are arranged circumferentially around the cable core.

[0009] In one of the embodiments, the length of the first arc-shaped side is less than the length of the second arc-shaped side, and the first side and the second side are symmetrically arranged about the first arc-shaped side or the second arc-shaped side.

[0010] In one of the embodiments, the ratio of the width to the height of the cross section of the armor piece is greater than 3.5 and less than 4, wherein the height of the cross section of the armor piece is the length of the projection of the first side or the second side on the axis in the cross section of the armor piece, and the width of the cross section of the armor piece is the length of the projection of the second arc-shaped side in the tangent direction of itself.

[0011] In one of the embodiments, the armor piece adopts a copper single-wire structure, and the armor layer adopts a twisted structure of copper single wires.

[0012] In one of the embodiments, the dynamic hoisting power cable further comprises a first fixing layer, which is arranged between the cable core and the armored layer.

[0013] The cable core comprises at least one cable core and a filler, each cable core is arranged around the central axis of the cable core, a gap is formed between the first fixing layer and the cable core, and the filler is located in the gap.

[0014] In one of the embodiments, the cable core comprises, from inside to outside, a conductor, a first shielding layer, an insulation layer and a second shielding layer; the first shielding layer comprises a semi-conductive shielding layer and a conductor shielding layer; and the second shielding layer comprises an insulation shielding layer and a metal shielding layer.

[0015] The semi-conductive shielding layer is wrapped around the outside of the conductor by using a semi-conductive shielding material, the conductor shielding layer is extruded around the outside of the semi-conductive shielding layer by using a conductor shielding material, the insulation layer is extruded around the outside of the conductor shielding layer by using an insulation material, the insulation shielding layer is extruded around the outside of the insulation layer by using an insulation shielding material, and the metal shielding layer is wrapped around the outside of the insulation shielding layer by using a metal shielding material.

[0016] In one of the embodiments, the conductor is stranded by a plurality of conductive single wires, the conductor comprises a plurality of layers of conductive single wires from inside to outside, and the conductive single wires in adjacent layers are twisted in opposite directions.

[0017] In one of the embodiments, the cable core further comprises an optical cable, and the filler is provided with an assembly space, and the optical cable is arranged in the assembly space.

[0018] In one of the embodiments, the dynamic hoisting power cable further comprises a second fixing layer and an outer sheath.

[0019] The second fixing layer is wrapped around the outside of the armored layer, and the outer sheath is arranged outside the second fixing layer by using a polyethylene material.

[0020] In a second aspect, the application provides a preparation method of a dynamic hoisting power cable, comprising:

[0021] providing a cable core;

[0022] forming an armored layer around the cable core, the armored layer comprising a plurality of armored members arranged along the circumference of the cable core;

[0023] The cross section of the armored member has, in sequence, a first arc-shaped side, a first side, a second arc-shaped side and a second side, and the first arc-shaped side and the second arc-shaped side are arranged along the circumference of the cable core.

[0024] The dynamic hoisting power cable and the preparation method thereof, by arranging the first arc-shaped edge and the second arc-shaped edge of the armored member circumferentially around the cable core, the arc-shaped edges can be surface-shapedly attached to the cable core and the adjacent outer layer component, the contact area between the layers is increased, the dynamic lateral pressure acting on the cable can be more uniformly dispersed, and stress concentration is avoided. Meanwhile, by the special-shaped armored member, when the plurality of armored members are arranged along the outer periphery of the cable core, the invalid space in the structure can be reduced, the cable core can be wrapped and protected with less radial space, the filling coefficient inside the armored layer is significantly improved, the overall outer diameter of the cable is effectively reduced, the structural compactness is improved, and the material cost is reduced. The dynamic hoisting power cable realizes lightweight, compactness, and excellent lateral pressure resistance, effectively enhances the mechanical reliability and stability of the cable under the vertical hoisting working condition. BRIEF DESCRIPTION OF DRAWINGS

[0025] In order to more clearly illustrate the technical solutions in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiments or the prior art description will be briefly introduced. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0026] Figure 1 The structure schematic diagram of the hoisting power cable in some embodiments of the present application.

[0027] Figure 2 The structure schematic diagram of the armored member in some embodiments of the present application.

[0028] Figure 3 The structure schematic diagram for embodying the size relationship of the armored member in some embodiments of the present application.

[0029] Figure 4 The structure schematic diagram of the dynamic hoisting power cable in some other embodiments of the present application.

[0030] Figure 5 The flowchart of the preparation method of the dynamic hoisting power cable in some embodiments of the present application.

[0031] Figure 6 The flowchart of obtaining the cable core in some embodiments of the present application.

[0032] Figure 7 The flowchart of forming the armored layer in some embodiments of the present application.

[0033] Figure 8 The flowchart of obtaining the dynamic hoisting power cable in some embodiments of the present application.

[0034] BRIEF DESCRIPTION OF DRAWINGS:

[0035] 10. Cable core; 110. Cabling core; 111. Conductor; 112. First shielding layer; 1121. Semi-conductive shielding layer; 1122. Conductor shielding layer; 113. Insulation layer; 114. Second shielding layer; 1141. Insulation shielding layer; 1142. Metal shielding layer; 120. Filler; 130. Optical cable; 20. First fixing layer; 210. Bundling layer; 220. Isolating layer; 30. Armoring layer; 310. Armoring member; 301. First arc-shaped side; 302. First side; 303. Second arc-shaped side; 304. Second side; 40. Second fixing layer; 50. Outer jacket. DETAILED DESCRIPTION

[0036] In the description of the present application, it is to be understood that the orientations or positional relationships indicated by the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", "perpendicular", "horizontal" and the like are based on the orientations or positional relationships shown in the drawings, and are merely intended to facilitate the description of the present application and simplify the description, and therefore cannot be understood as indicating or implying that the devices or elements indicated must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0037] In addition, the terms "first", "second", "third", etc. are used only for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined with "first", "second", etc. can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "a plurality of" is at least two, such as two, three, etc., unless otherwise explicitly specified and limited.

[0038] In the present application, unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connecting", "fixing" and the like should be understood in a broad sense, for example, can be fixedly connected, or can be detachably connected, or can be integrated; can be mechanically connected, or can be electrically connected; can be directly connected, or can be indirectly connected through an intermediate medium; can be the internal communication of two elements or the interaction relationship between two elements, unless otherwise explicitly limited. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances. It should be noted that when an element is referred to as "fixed to" or "disposed on" another element, it can be directly on the other element or there can be a middle element. When an element is considered to be "connected" to another element, it can be directly connected to the other element or a middle element can exist at the same time.

[0039] With the energy structure accelerating to clean energy such as wind power and photovoltaic, the large-scale installation of new energy facilities puts forward unprecedented technical requirements for special cables. Taking offshore wind power as an example, the height of the wind turbine tower and the single machine capacity continue to rise, resulting in the internal power transmission cable needing to withstand long-term self-weight stretching and dynamic composite stress caused by tower swing. This dynamic vertical laying scene not only requires the cable to have composite properties such as high voltage level, tensile strength, corrosion resistance, etc., but also puts forward strict requirements on the weight, mechanical reliability and operation stability of the cable, far exceeding those of traditional cables.

[0040] The current design and material system of medium-voltage power cables are mainly aimed at static laying scenes such as direct burial, and their technical architecture is difficult to adapt to vertical hoisting conditions, and there are significant technical bottlenecks. For example, hoisting cables are generally mainly copper cores, and the cable weight is large, and its bearing structure mainly includes round steel wires, and ductility and technical reliability are the core advantages of such cables. However, the diameter of the round steel wire is large, the cable outer diameter increases, the material cost and self-weight increase significantly, at the same time, the contact area between the round steel wire and the adjacent layer is small, and the steel wire has a large extrusion stress on the sheath when subjected to dynamic lateral pressure, the cable structure is not compact, and the outer peripheral round wire is difficult to fix. With the increasing amount of new energy installation, there are still no effective solutions to the technical problems of hoisting power cables, and breakthroughs are needed.

[0041] In order to solve the problem that the power cable in the related art is difficult to adapt to the vertical dynamic laying condition, in a first aspect, with reference to Figure 1 An embodiment of the present application provides a dynamic hoisting power cable, which comprises a cable core 10 and an armored layer 30 arranged on the outer periphery of the cable core 10, wherein the armored layer 30 comprises a plurality of armored pieces 310 arranged circumferentially along the cable core 10. The transverse section of each armored piece 310 has a first arc-shaped side 301, a first side 302, a second arc-shaped side 303 and a second side 304 connected in sequence, and the first arc-shaped side 301 and the second arc-shaped side 303 are arranged along the circumference of the cable core 10.

[0042] In the embodiments of the present application, please refer to Figure 2 Each armored piece 310 is provided in a special-shaped structure, and the boundary of the transverse section thereof comprises the oppositely arranged first arc-shaped side 301 and the second arc-shaped side 303. In the radial cross-section of the cable, the first arc-shaped side 301 and the second arc-shaped side 303 are arranged circumferentially around the cable core 10, so that the first arc-shaped side 301 and the second arc-shaped side 303 can be adapted or fitted with the circumferential surface of the radially adjacent part of the armored layer 30. For example, the second arc-shaped side 303 of the armored piece 310 can be adapted to the outer peripheral surface of the cable core 10, and the first arc-shaped side 301 can be adapted to the inner peripheral surface of the outer part of the armored layer 30.

[0043] It can be understood that the armor piece 310 can be a strip structure, which can include a first arc-shaped surface, a second arc-shaped surface, a first side surface, a second side surface, a first end surface, and a second end surface, wherein the first arc-shaped surface, the first side surface, the second arc-shaped surface, and the second side surface are sequentially arranged along the outer periphery of the armor piece 310. Specifically, the first arc-shaped surface is a curved surface formed by the extension of the first arc-shaped edge 301 in the axial direction of the armor piece 310, and the second arc-shaped surface is a curved surface formed by the extension of the second arc-shaped edge 303 in the axial direction of the armor piece 310. The first arc-shaped surface and the second arc-shaped surface respectively realize the surface contact with the circumferential surface of the radially adjacent component.

[0044] In one possible implementation, please refer to Figure 2 The first side edge 302 and the second side edge 304 of each armor piece 310 are arranged along the radial direction of the cable core 10, so that the armor piece 310 has better support in the radial direction, effectively limiting the relative displacement of the internal structure of the cable. At the same time, when a plurality of armor pieces 310 are arranged closely along the outer periphery of the cable core 10, such as a plurality of armor pieces 310 being arranged in a twisted manner along the outer peripheral wall of the cable core 10 to form an armor layer 30 with an annular structure, the radial side surfaces of adjacent armor pieces 310 can be in close contact with each other to form a surface-to-surface contact, thereby uniformly transmitting and dispersing the radial pressure and compression stress acting on the cable.

[0045] In other implementations, the first side edge 302 and the second side edge 304 can also be wavy, zigzag, or concave-convex, so that the side edges of adjacent armor pieces 310 can form physical interlocking when arranged along the circumferential direction of the cable core 10. Alternatively, the first side edge 302 and the second side edge 304 can also be composed of multiple straight lines or curves, which are not limited in the embodiments of the present application.

[0046] In the embodiments, the first arc-shaped edge 301 and the second arc-shaped edge 303 of the armor piece 310 are arranged along the circumferential direction of the cable core 10, so that the arc-shaped edges can be in surface contact with the cable core 10 and the adjacent outer component, increasing the contact area between the layers and enabling the dynamic lateral pressure acting on the cable to be more uniformly dispersed to avoid stress concentration. At the same time, the armor piece 310 with the above-mentioned special-shaped structure enables the plurality of armor pieces 310 to reduce the invalid space in the structure when arranged along the outer periphery of the cable core 10, to realize the wrapping and protection of the cable core 10 with less radial space, significantly improve the filling coefficient inside the armor layer 30, effectively reduce the overall outer diameter of the cable, improve the structural compactness, and reduce the material cost. The above-mentioned dynamic hoisting power cable realizes lightweight, compactness, and excellent lateral pressure resistance, effectively enhancing the mechanical reliability and stability of the cable in the vertical hoisting working condition.

[0047] Please refer to Figure 2In some embodiments, the length of the first arc-shaped side 301 of the armor piece 310 is less than the length of the second arc-shaped side 303 of the armor piece 310, and the first side edge 302 of the armor piece 310 and the second side edge 304 of the armor piece 310 are symmetrically arranged about the first arc-shaped side 301 or the second arc-shaped side 303 thereof.

[0048] The first arc-shaped side 301 can be an inner arc of the armor piece 310, and the radius of curvature thereof matches the radius of curvature of the outer peripheral surface of the cable core 10. The second arc-shaped side 303 can be an outer arc of the armor piece 310, and the radius of curvature thereof can match the radius of curvature of the inner surface of the component radially outside the armor layer 30. The first arc-shaped side 301 is arranged close to the cable core 10, and the second arc-shaped side 303 is arranged away from the cable core 10. In this way, the first arc-shaped sides 301 of the plurality of armor pieces 310 can form the inner surface of the armor layer 30, and the second arc-shaped sides 303 of the plurality of armor pieces 310 can form the outer surface of the armor layer 30.

[0049] Exemplarily, the transverse section of the armor piece 310 can have a fan-shaped structure with a narrow inner part and a wide outer part. The first arc-shaped side 301 is the upper base of the fan-shaped structure, the second arc-shaped side 303 is the lower base of the fan-shaped structure, and the first side edge 302 and the second side edge 304 can be symmetrically arranged about the central axis of the armor piece 310.

[0050] In the present embodiment, by arranging the length of the first arc-shaped side 301 to be less than the length of the second arc-shaped side 303, the armor piece 310 can not only be in close contact with the cable core 10 of the inner layer, but also be in close contact with other components of the outer layer, thereby ensuring the high filling coefficient and structural stability of the entire armor layer 30. At the same time, the symmetric arrangement of the first side edge 302 and the second side edge 304 helps to simplify the production process of the armor piece 310 and ensures that each armor piece 310 can remain stable during the stranding process, preventing problems such as turning over caused by asymmetry.

[0051] Referring to Figure 3 In some embodiments, the ratio of the width to the height of the transverse section of the armor piece 310 can be 3.5-4.0. The height of the transverse section of the armor piece 310 is the length of the projection of the first side edge 302 or the second side edge 304 on the central axis of the transverse section of the armor piece 310, and the width of the transverse section of the armor piece 310 is the length of the projection of the second arc-shaped side 303 in the tangent direction thereof.

[0052] The armor piece 310 of the present embodiment can be made of a material such as Figure 3The irregular line structure shown has the following characteristics: line height h represents the height of the cross-section of armor 310, line width w represents the width of the cross-section of armor 310, and both ends of the first side 302 and the second side 304 are rounded, with r1 being the rounded corner radius and r2 and r3 being the arc radii. Considering that the asymmetry of the structure may cause problems such as flipping during the production of armor 310, its width and height should be reasonably controlled.

[0053] As an example, the ratio of the width to the height of the cross-section of the armor piece 310 can be, but is not limited to, 3.5, 3.6, 3.7, 3.8, 3.9, or 4.0. Preferably, the armor piece 310 has a radius of r1 of 0.4 mm, a width of w of 7.5 mm, and a height of 2.0 mm.

[0054] In this embodiment, by controlling the aspect ratio of the armor 310 within the range of 3.5 to 4.0, both the actual laying conditions and the technical difficulty of equipment production are fully taken into account, while providing excellent tensile strength and effectively reducing its operating losses in the AC system.

[0055] In some embodiments, the material of the armor 310 includes copper, wherein the armor 310 can be a copper single-wire structure, the armor layer 30 can be a copper single-wire stranded structure, the copper single-wire structure of the armor 310 has the irregular cross-sectional shape in the above embodiments, and multiple copper single wires are stranded and arranged around the outer periphery of the cable core 10 to form the armor layer 30.

[0056] As an example, multiple copper single wires are twisted together without untwisting to form an armor layer 30. The twisting factor can be determined according to the actual application and production process. For example, the twisting factor can be 1.015~1.050, preferably 1.048, to ensure that the twisted cable structure is tight and the stress is moderate.

[0057] In this embodiment, the armor 310 is made of copper. Copper, due to its excellent electrical conductivity, thermal conductivity, and ductility, can significantly improve the electrical performance and current-carrying capacity of the cable. Copper single wires with the aforementioned irregular cross-sectional shape are used as the armor 310 and are stranded along the outer periphery of the cable core 10 to form the armor layer 30. This not only provides the necessary mechanical support for the cable but also, due to the low AC loss characteristics of copper itself, further ensures the high efficiency and stability of the cable during power transmission. In this way, this embodiment significantly enhances the electrical performance of the cable while maintaining a lightweight and compact structure, making it perform better under dynamic hoisting conditions in new energy applications.

[0058] Reference Figure 4 In some embodiments, the dynamically hoisted power cable further includes a first fixing layer 20, which is disposed between the cable core 10 and the armor layer 30.

[0059] The first fixing layer 20 can include a bundling layer 210 and an isolation layer 220, and the isolation layer 220 is externally provided with the armor layer 30. The bundling layer 210 can be wrapped around the outer periphery of the cable core 10 by using a polyolefin material, and the isolation layer 220 can be extruded around the outside of the bundling layer 210 by using a polyethylene material.

[0060] For example, the bundling layer 210 can be bundled around the outer periphery of the cable core 10 by using two layers of high-strength polyolefin tape with a thickness of 0.2 mm, and the isolation layer 220 can be extruded around the outside of the high-strength polyolefin tape by using black high-strength corrosion-resistant polyethylene (PE) material.

[0061] In this embodiment, the bundling layer 210 provides effective radial fixation and constraint for the cable core 110 and the filler strip inside the cable core 10, and the isolation layer 220 made of high-strength and corrosion-resistant polyethylene material not only provides additional mechanical and chemical protection, but also provides a flat and solid base for the armor layer 30.

[0062] Please continue to refer to Figure 4 In some embodiments, the cable core 10 includes at least one cable core 110 and a filler 120, and each cable core 110 is arranged around the central axis of the cable core 10.

[0063] The cable core 10 can include at least one cable core 110, and when the cable core 10 includes a plurality of cable cores 110, the plurality of cable cores 110 can be twisted to form a core twisted structure.

[0064] For example, the cable core 10 includes a core twisted structure formed by three cable cores 110, and the three cable cores 110 are twisted into the core twisted structure at a twist-in coefficient of 1.004.

[0065] In this embodiment, the twisting of the plurality of cable cores 110 can effectively improve the structural stability and stress dispersion capability of the cable core 10, while achieving compactness.

[0066] Please continue to refer to Figure 4 In some embodiments, the cable core 10 further includes a filler 120, and a gap is formed between the first fixing layer 20 and the cable core 110, and the filler 120 is located in the gap.

[0067] The cable core 10 further includes a filler 120, and a gap is formed between the bundling layer 210 and the cable core 110, and the filler 120 is located in the gap.

[0068] For example, the filler 120 includes at least one filler strip, and the filler strip can be made of rubber-modified polyethylene material, and the filler strip has a circular arc surface which is attached to the high-strength polyolefin bundling tape of the bundling layer 210.

[0069] In this embodiment, the filler 120 can ensure the roundness and compactness of the cable core 10 structure, and provide uniform radial support for the inside of the cable. In addition, the traditional solid filling form is abandoned, and a light arc edge rubber modified polyethylene (PE) filling strip is used, which effectively limits the relative displacement of the internal elements on the basis of realizing the lightweight of the cable.

[0070] Please continue to refer to Figure 4 In some embodiments, the cable core 10 further comprises an optical cable 130, and the filler 120 of the cable core 10 is reserved with an assembly space, and the optical cable 130 is arranged in the assembly space.

[0071] In the embodiment of the application, the optical cable 130 is used to monitor the operation state of the cable, for example, to monitor the temperature, strain, partial discharge and other parameters of the cable in real time to meet the needs of new power systems driven by data.

[0072] As an example, the optical cable 130 can be arranged in the assembly space reserved in the inside of the filling strip, and the inner diameter of the assembly space and the outer diameter of the optical cable 130 are in interference fit. In this way, the filler 120 can generate a radial pre-pressure on the optical cable 130 after assembly, so that the optical cable 130 is tightly fastened in the inside of the filler 120 without gap, so as to realize accurate and rigid positioning of the optical cable 130.

[0073] As an example, the optical cable 130 is arranged in the inside of the filler 120, and the optical cable 130 and the filler 120 can be twisted into a cable together with the cabling core 110, and the twist coefficient can match the twist pitch of the cabling core 110 to keep the stability of the geometric shape. In this way, the optical cable 130 is twisted synchronously with the light filling strip, and the strain transmission efficiency is high, so that the online monitoring result based on the sensing signal can more truly and timely reflect the structural state change of the cable, and provide a high-reliability data basis for the safe operation, fault warning and preventive maintenance of the cable.

[0074] As an example, the optical cable 130 can adopt an embedded round soft optical cable, and the attenuation coefficient is shown in Table 1.

[0075] Table 1 Attenuation coefficient table of optical cable

[0076]

[0077] In this way, the attenuation coefficient of the embedded round soft optical cable is low, which can ensure the accuracy of data transmission.

[0078] In this embodiment, by arranging the optical cable 130 in the cable core 10, the real-time structural health monitoring capability of the dynamic hoisting power cable and the online monitoring function of the key physical parameters can be realized.

[0079] Please continue to refer to Figure 4 In some embodiments, the cable core is provided with the conductor 111, the first shielding layer 112, the insulation layer 113 and the second shielding layer 114 from inside to outside.

[0080] The first shielding layer 112 is located between the conductor 111 and the insulation layer 113, and is used to homogenize the electric field on the surface of the conductor 111. The second shielding layer 114 is located on the outer periphery of the insulation layer 113, and is used to homogenize the electric field on the surface of the insulation layer 113.

[0081] In one of the embodiments, the conductor 111 is formed by twisting a plurality of conductive single wires. The conductor includes a plurality of layers of conductive single wires from inside to outside, and the conductive single wires in adjacent layers are twisted in opposite directions.

[0082] As an example, the mechanical form of the conductor can be a multi-layer concentric structure, the center of which is one or more conductive single wires, and the periphery of which is wrapped with more conductive single wires in the form of concentric circles layer by layer, and the twist directions of adjacent layers are in opposite arrangement.

[0083] In one of the embodiments, the number X of conductive single wires in each layer of the conductor 111 N satisfies: X N ≤ 6N, where N is the number of layers. In this way, by limiting the number of conductive single wires in each layer, the wire stacking or excessive gap in the twisting process can be effectively avoided, thereby significantly improving the filling factor of the conductor 111, and finally realizing the minimization of the outer diameter of the conductor 111.

[0084] In one of the embodiments, the material of the conductive single wire includes at least one of aluminum or aluminum alloy.

[0085] As an example, the conductive single wire can be an aluminum single wire, the conductor 111 can be an aluminum conductor, and the aluminum conductor can be manufactured by a round tight pressing forming process.

[0086] As an example, the aluminum conductor 111 includes a 4-layer concentric structure, which includes a central aluminum single wire, and on the outside of which are sequentially wrapped concentric layers composed of 6, 12 and 17 aluminum single wires, with a total of 36 single wires. The diameter Φ of each aluminum single wire is 2.58±0.02mm, and the tight pressing process is used to control the outer diameter of the aluminum conductor within the tolerance range of 16.1±0.1mm, and to form a conductive structure with a cross-sectional area of 3×185mm².

[0087] In this way, by using high-performance aluminum and / or aluminum alloy as the conductor material, the cost is reduced, and the basis for lightening the cable is also provided.

[0088] In one of the embodiments, the first shielding layer 112 includes a semi-conductive shielding layer 1121 and a conductor shielding layer 1122, and the second shielding layer 114 includes an insulating shielding layer 1141 and a metal shielding layer 1142. The semi-conductive shielding layer 1121 is wrapped around the outside of the conductor 111 with a semi-conductive shielding material, the conductor shielding layer 1122 is extruded around the outside of the semi-conductive shielding layer 1121 with a conductor shielding material, the insulating layer 113 is extruded around the outside of the conductor shielding layer 1122 with an insulating material, the insulating shielding layer 1141 is extruded around the outside of the insulating layer 113 with an insulating shielding material, and the metal shielding layer 1142 is wrapped around the outside of the insulating shielding layer 1141 with a metal shielding material.

[0089] For example, the semi-conductive shielding layer 1121 is made of a semi-conductive shielding tape with a volume resistivity less than 10 5 Ω⋅cm, and the conductor 111 is wrapped and tied by the semi-conductive shielding tape with an overlapping rate controlled at 20%.

[0090] For example, the conductor shielding layer 1122 is extruded around the outside of the semi-conductive shielding layer 1121 with a conductor shielding material, the material of the conductor shielding layer 1122 includes low-resistance conductive carbon black, and the low-resistance conductive carbon black is in a nano-chain structure with thermal stability.

[0091] For example, the insulating material of the insulating layer 113 includes super-clean cross-linked polyethylene.

[0092] For example, the insulating layer 113 is extruded outside with the insulating shielding layer 1141, the material of the insulating shielding layer 1141 includes low-resistance conductive carbon black, and the low-resistance conductive carbon black is in a nano-chain structure with thermal stability.

[0093] For example, the conductor shielding layer 1122, the insulating layer 113 and the insulating shielding layer 1141 can be integrally formed by a three-layer co-extrusion technology to ensure smooth interface and no impurities between the layers.

[0094] For example, the metal shielding material of the metal shielding layer 1142 includes copper, and a copper shielding tape can be wrapped around the outside of the insulating shielding layer 1141.

[0095] In this embodiment, the conductor shielding layer 1122, the insulating layer 113 and the insulating shielding layer 1141 are extruded by a three-layer co-extrusion process, the shielding material is smooth and contains a unique nano-chain conductive carbon black structure with thermal stability, a dense three-dimensional conductive network can be formed, the uniformity of the electric field distribution is significantly improved, the partial discharge is effectively suppressed, the risk of insulation weakness puncture is eliminated, and fundamental safety protection is provided for dynamic power transmission.

[0096] Please continue to refer to Figure 4In some embodiments, the dynamic hoisting power cable further comprises a second fixing layer 40 and an outer sheath 50, the second fixing layer 40 is wrapped outside the armored layer 30, and the outer sheath 50 is arranged outside the second fixing layer 40 by using a polyethylene material.

[0097] In the embodiments of the present application, the armored layer 30 is twisted by profiled wires, and due to the limitation of the twist coefficient and the production process, irregular gaps may exist on the outer surface of the armored layer 30. The second fixing layer 40 is wrapped outside the armored layer 30, which can fill these irregular surface gaps and provide a flat and rounded base for the outer sheath 50.

[0098] For example, the second fixing layer 40 is a reinforced non-woven fabric with a thickness of 0.25 mm, which is tightly wrapped outside the armored layer 30 in a reverse winding manner, so as to fill and flatten the surface of the armored layer 30. The outer sheath 50 is made of black high-density polyethylene material and is extruded outside the second fixing layer 40 to provide mechanical protection.

[0099] In the embodiments, the second fixing layer 40 is reversely wrapped outside the armored layer 30 to fill the irregular gaps and save the amount of outer sheath material and reduce the production cost. The outer sheath 50 made of polyethylene material provides the cable with wear resistance, ultraviolet resistance and corrosion resistance, and ensures the long-term safe operation of the cable under harsh dynamic vertical laying conditions.

[0100] In a second aspect, as shown in Figure 5 One embodiment of the present application provides a preparation method of a dynamic hoisting power cable, which comprises steps 502 and 504, wherein:

[0101] Step 502, providing a cable core 10.

[0102] Step 504, forming an armored layer 30 on the peripheral wall of the cable core 10, the armored layer 30 comprising a plurality of armored pieces 310 arranged in the circumferential direction of the cable core 10.

[0103] The cross section of the armored piece 310 has a first arc-shaped side 301, a first side 302, a second arc-shaped side 303 and a second side 304 connected in sequence, and the first arc-shaped side 301 and the second arc-shaped side 303 are arranged in the circumferential direction of the cable core 10.

[0104] In one embodiment, as shown in Figure 6 Step 502 comprises steps 602 to 614, wherein:

[0105] Step 602, providing aluminum liquid, and sequentially casting and rolling the aluminum liquid to obtain an aluminum rod.

[0106] For example, the molten aluminum liquid is continuously cast into billets, and directly subjected to multi-pass continuous rolling to continuously produce aluminum rods with a diameter of 8.0 mm.

[0107] At step 604, the aluminum rod is subjected to wire drawing to obtain aluminum wires.

[0108] The wire drawing refers to a cold working process of reducing the diameter and increasing the length of a rod or a bar through one or a series of dies (drawing dies).

[0109] For example, the aluminum rod with a diameter of 8.0 mm is subjected to cold drawing through a double-end wire drawing machine equipped with 6 drawing dies, and the deformation process is controlled to obtain aluminum single wires with a diameter of 2.58 mm.

[0110] At step 606, the aluminum single wires are subjected to stranding to obtain aluminum conductors.

[0111] The stranding refers to a process of stranding a plurality of aluminum single wires into one body according to a predetermined structure and parameters.

[0112] For example, a plurality of aluminum single wires are subjected to stranding according to a 4-layer concentric structure using a frame stranding machine, the 4-layer concentric structure including a center aluminum single wire, and concentric layers of 6, 12 and 17 aluminum single wires successively wound outside the center aluminum single wire, with a total number of 36 single wires. The diameter of each aluminum single wire is Φ 2.58±0.02 mm, the outer diameter of the aluminum conductor 111 is 16.1±0.1 mm, and the processing parameters are shown in Table 2.

[0113] Table 2 Processing parameters

[0114]

[0115] At step 608, a semi-conductive shielding tape is wrapped around the aluminum conductor.

[0116] For example, to optimize the electric field distribution and suppress partial discharge, a semi-conductive shielding tape with a thickness of 0.14 mm is wrapped around the outer periphery of the aluminum conductor in a spiral manner, and the overlap rate of adjacent shielding tapes is controlled to be 20% to ensure the continuity of the shielding layer and the reliability of the electrical performance.

[0117] At step 610, the aluminum conductor wrapped with the semi-conductive shielding tape is subjected to three-layer co-extrusion molding to obtain an insulated core.

[0118] The three-layer co-extrusion molding refers to a process of extruding the conductor shielding layer 1122, the insulation layer 113 and the insulation shielding layer 1141 onto the conductor at one time.

[0119] For example, by adopting the catenary cross-linking technology, the conductor shielding material, the insulating material and the insulating shielding material are extruded into a mold after the conductor passes through the preheating device, with thicknesses of 0.8 mm, 10.5 mm and 0.6 mm respectively, and the outer diameter of the insulated wire core being 40.3 mm.

[0120] In step 612, a metal shielding layer 1142 is formed outside the insulated wire core to obtain the cable core 110.

[0121] For example, a copper tape with a wrapping thickness of 0.1 mm and a lap rate of 15% is used as the metal shielding layer 1142 to achieve anti-interference and uniform electric field, and the outer diameter of the obtained cable core 110 is 40.6 mm.

[0122] In step 614, the plurality of cable cores 110 are subjected to a cabling process to obtain the cable core 10.

[0123] The cabling process refers to a process of twisting the plurality of wire cores, optical cables 130 and filling pieces 120 into the cable core 10 according to specific parameters.

[0124] For example, a disc twister is used to twist three cable cores 110 into a cable, and an inner type (circular) soft optical cable 130 and a rubber modified PE type filling strip are twisted in according to a cabling twist-in coefficient of 1.004.

[0125] In one embodiment, as shown in Figure 7 Step 504 includes steps 702 to 706, in which:

[0126] In step 702, a first fixing layer 20 is formed outside the cable core 10.

[0127] For example, two layers of high-strength polyolefin tape are used to tie with an overlap rate of 15%, and the outer diameter of the cabling tape is 88.9 mm.

[0128] In step 704, an isolation sleeve is formed outside the first fixing layer 20.

[0129] For example, an extruder is used to extrude 90℃ black high-strength corrosion-resistant polyethylene (PE) to form an isolation sleeve with an extrusion thickness of 2.0 mm, and the outer diameter of the isolation sleeve is 92.9 mm.

[0130] In step 706, an armor layer 30 is formed around the isolation sleeve.

[0131] For example, a profiled copper single wire is twisted around the isolation sleeve by a non-retracting process to form the armor layer 30, which has both shielding and excellent comprehensive performance and is suitable for dynamic vertical laying. As shown in Figure 3 r1 is 0.4 mm, w is 7.5 mm, h is 2.0 mm, 36 profiled copper single wires are twisted according to a twist-in coefficient of 1.048 to form the armor layer 30.

[0132] In one embodiment, as shown in step 504, it further comprises steps 802 and 804, wherein: Figure 8

[0133] Step 802, forming a second fixed layer 40 on the outer periphery of the armored layer 30.

[0134] For example, using a reinforced non-woven fabric with a thickness of 0.25mm, reverse bundling is performed on the outer periphery of the armored layer 30, and the outer diameter after bundling is 97.3mm.

[0135] Step 804, forming an outer sheath 50 on the outer periphery of the second fixed layer 40.

[0136] For example, using a 200 type extruder to extrude a high-strength wear-resistant high-density polyethylene (HDPE) sheath material, the thickness is:

[0137] ;

[0138] In the formula: t is the thickness of the outer sheath, D is the outer diameter of the cable before extrusion. Thus, the outer sheath thickness is 4.4mm, and the dynamic hoisting power cable outer diameter is 106.1mm.

[0139] The above embodiment has the following beneficial effects:

[0140] (1) Through the optimization of the special-shaped copper single wire armored structure, the comprehensive performance of the cable is improved. By selecting a special-shaped copper single wire with a width-height ratio of 3.5-4.0, and combining with the non-back-twist process to form an armored layer, compared with the round steel wire armored technology, the filling coefficient and the adjacent layer contact area are significantly improved, effectively reducing the cable outer diameter, optimizing the structure compactness, and reducing the cost of sheath materials and process difficulty.

[0141] (2) The low AC loss and high thermal conductivity of copper material can simultaneously improve the current-carrying capacity. Compared with carbon fiber load-bearing cables, the armored layer formed by the special-shaped copper single wire significantly enhances the electrical conductivity, dynamic side pressure dispersion, and anti-electromagnetic interference performance, providing long-term stable protection for power transmission.

[0142] (3) Due to the particularity of dynamic vertical working conditions, the application realizes lightweight and cost control through aluminum alloy conductors.

[0143] (4) Due to the particularity of dynamic vertical working conditions, the application discards the solid form of the filling structure and uses light filling strips of rubber modified PE, which effectively suppresses the displacement of internal elements through elastic constraint.

[0144] (5) In terms of materials, the shielding material of the application is smooth and contains a unique thermally stable nanochain conductive carbon black structure, which can form a dense three-dimensional conductive network, significantly improving the uniformity of electric field distribution. ​

[0145] (6) Through the composite structure design of the application, a multi-physical field coupling mechanism of "electricity, heat and force" is constructed. Among them, the special-shaped armor disperses mechanical stress, the electric field is uniformly distributed, and the thermal field gradient is reduced, so that the performance under the dynamic vertical laying condition is realized Triple protection. Through the synchronous twisting design of the optical cable and the light filling strip, the cable is given the real-time structural health monitoring capability. The optical cable senses key physical parameters such as deformation and temperature, and provides core data support for safe operation and fault warning. The application can provide a fundamental solution for dynamic high-drop and vertical power transmission environment.

[0146] In the description of the present specification, the description referring to the terms "some embodiments", "other embodiments", and the like means that the specific features, structures, materials or characteristics described in connection with the embodiments or examples are contained in at least one embodiment or example of the present application. In the present specification, the illustrative description of the above terms does not necessarily refer to the same embodiment or example.

[0147] The technical features of the above-described embodiments can be combined arbitrarily. In order to make the description simple, all possible combinations of the technical features in the above-described embodiments are not described, however, as long as the combinations of the technical features do not exist contradictory, it should be considered that they are within the scope of the present application.

[0148] The above-described embodiments only express several implementation manners of the present application, and the description is more specific and detailed, but it should not be understood as a limitation on the patent scope of the application. It should be noted that for ordinary skilled in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which are within the scope of the present application. Therefore, the patent protection scope of the present application should be subject to the appended claims.

Claims

1. A dynamic overhead power cable, characterized in that, The dynamic hoisting power cable comprises: a cable core; an armor layer arranged outside the cable core, the armor layer comprising a plurality of armor pieces arranged circumferentially along the cable core; wherein the cross section of the armor piece has a first arc-shaped side, a first side, a second arc-shaped side and a second side connected in sequence, and the first arc-shaped side and the second arc-shaped side are arranged circumferentially along the cable core.

2. The dynamic pendant power cable according to claim 1, characterized in that, The length of the first arc-shaped side is smaller than the length of the second arc-shaped side, and the first side and the second side are symmetrically arranged about the first arc-shaped side or the second arc-shaped side.

3. The dynamic pendant power cable of claim 2, wherein, The ratio of the width to the height of the cross section of the armor piece is greater than 3.5 and less than 4, wherein the height of the cross section of the armor piece is the length of the projection of the first side or the second side on the axis in the cross section of the armor piece, and the width of the cross section of the armor piece is the length of the projection of the second arc-shaped side in the tangential direction of the second arc-shaped side.

4. The dynamic pendant power cable of claim 1, wherein, The armor piece adopts a copper single wire structure, and the armor layer adopts a twisted structure of copper single wires.

5. The dynamic pendant power cable of claim 1, wherein, The dynamic hoisting power cable further comprises a first fixing layer arranged between the cable core and the armor layer. The cable core comprises at least one cable-forming core and a filler, each cable-forming core is arranged around the central axis of the cable core, a gap is formed between the first fixing layer and the cable-forming core, and the filler is located in the gap.

6. The dynamic pendant power cable of claim 5, wherein, The cable-forming core sequentially comprises a conductor, a first shielding layer, an insulation layer and a second shielding layer from inside to outside; the first shielding layer comprises a semi-conductive shielding layer and a conductor shielding layer; and the second shielding layer comprises an insulation shielding layer and a metal shielding layer. The semi-conductive shielding layer is wrapped around the outside of the conductor by a semi-conductive shielding material, the conductor shielding layer is extruded on the outside of the semi-conductive shielding layer by a conductor shielding material, the insulation layer is extruded on the outside of the conductor shielding layer by an insulation material, the insulation shielding layer is extruded on the outside of the insulation layer by an insulation shielding material, and the metal shielding layer is wrapped around the outside of the insulation shielding layer by a metal shielding material.

7. A dynamic pendant power cable according to claim 6, characterized in that, The conductor is twisted by a plurality of conductive single wires, the conductor comprises a plurality of layers of conductive single wires from inside to outside, and the conductive single wires in adjacent layers are twisted in opposite directions.

8. The dynamic pendant power cable of claim 5, wherein, The cable core further comprises an optical cable, and the filler has an assembly space reserved therein, and the optical cable is arranged in the assembly space.

9. The dynamic pendant power cable according to any one of claims 1 to 8, characterized in that, The dynamic hoisting power cable further comprises a second fixing layer and an outer sheath. The second fixing layer is wrapped around the outside of the armor layer, and the outer sheath is arranged outside the second fixing layer by a polyethylene material.

10. A method of preparing a dynamic hoisting power cable, characterized by comprises: providing a cable core; forming an armor layer outside the cable core, the armor layer comprising a plurality of armor pieces arranged circumferentially along the cable core; wherein the cross section of the armor piece has a first arc-shaped side, a first side, a second arc-shaped side and a second side connected in sequence, and the first arc-shaped side and the second arc-shaped side are arranged circumferentially along the cable core.

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