Manufacturing method of underwater reel pipe cable

Abstract

The invention relates to a manufacturing method of an underwater reel pipe cable. The underwater reel pipe cable specifically comprises a reel mechanism, a hydraulic hose assembly and a watertight cable assembly, wherein the hydraulic hose assembly and the watertight cable assembly are wound around the reel mechanism. Wherein the hydraulic hose sequentially comprises a hollow inner rubber layer, a first steel wire winding layer, a second steel wire winding layer, a steel wire weaving layer and an outer rubber layer from inside to outside, and meanwhile, after the supporting pipe core is preset in the clamping position of the pipe clamp, the hose joints are buckled and pressed at the two ends. According to the composite watertight cable, a protective sleeve is additionally arranged on the outer layer of a standard watertight cable, the protective sleeve sequentially comprises a protective sleeve inner rubber layer, a protective sleeve steel wire braided layer and a protective sleeve outer rubber layer from inside to outside, the two ends of the protective sleeve are plugged through vulcanization joint points, and watertight connectors are assembled at the two ends of the composite watertight cable. The reel pipe cable manufactured by adopting the scheme has the advantages of strong tension resistance, good pressure bearing performance and small bending radius.

Description

Technical Field

[0001] This invention relates to a method for manufacturing underwater cables, specifically a method for manufacturing a hydraulic hose and a watertight cable for an underwater electro-hydraulic composite reel. Background Technology

[0002] As the development and utilization of marine resources gradually extends to underwater areas, the demand for underwater operation equipment is increasing daily. Reels, used for unloading and retracting cables and hoses conveying media such as oil, gas, and water, are a widely used type of underwater operation equipment. Due to the increasing complexity of underwater operations, the diversified needs of underwater tools are driving the development of underwater reels towards multi-functionality. That is, the reel is no longer used to unload or retract a single hose or cable, but can simultaneously integrate both.

[0003] Hydraulic hoses and cables used in underwater electro-hydraulic composite reels must meet the following usage requirements: 1) The cable must have a certain tensile strength to maintain tension; 2) The cable must have a certain degree of flexibility to adapt to the compact installation space of the underwater drum; 3) Hydraulic hoses need to have high rigidity to meet the requirements of underwater use under external pressure; 4) The conduit and cable must have good corrosion resistance; 5) The cables have the same outer diameter to meet the requirements for synchronous deployment and retrieval; Currently, there are no universal technical specifications in China for hydraulic hoses and watertight cables that meet the above working conditions. Tensile tests on standard hydraulic hoses and cables revealed that the elongation of the two-layer steel wire braided hydraulic hose (GB / T 3683-2023) was too large when under tension and could not rebound after the external force was unloaded. Ordinary watertight cables also showed excessive elongation and damage to the internal wire cores when subjected to tensile tests. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention aims to provide a method for manufacturing underwater reel cables, producing hydraulic hoses and watertight cables that meet the requirements of tensile strength, resistance to internal oil pressure and external water pressure, corrosion resistance, and synchronous winding and unwinding, while ensuring that the reel cables have a small bending radius to accommodate the compact installation space of the underwater electro-hydraulic composite reel.

[0005] A method for manufacturing an underwater reel cable according to this solution includes: S1. Fabricate a hydraulic hose by applying a release agent to a rigid core, extruding an inner rubber layer to cover the rigid core, and then attaching a steel wire reinforcement layer to the inner rubber layer. The extruder then covers the steel wire reinforcement layer with an outer rubber layer. After wrapping the outer rubber layer with a water-resistant cloth, the hose is placed in a vulcanizing tank for high-temperature vulcanization. After vulcanization, the water-resistant cloth is removed, and the rigid core is extracted. A support core is then inserted into the hose clamping position, and the hose connector is crimped. S2. To manufacture a composite watertight cable, a sheath is installed on the outer layer of a standard watertight cable. The sheath consists of an inner rubber layer, a steel wire braided layer, and an outer rubber layer, arranged sequentially from the inside out. The inner rubber layer is extruded onto the outer layer of the standard watertight cable using an extruder. Copper-plated steel wire is then braided around the inner rubber layer using a braiding machine to form a steel wire braided layer. The outer rubber layer is then extruded onto the outer rubber layer. The outer rubber layer is wrapped with a water-resistant cloth and vulcanized in a vulcanizing tank. After vulcanization, the water-resistant cloth is removed. Both ends of the sheath are sealed through vulcanization joints, and watertight connectors are assembled at both ends of the composite watertight cable. S3 Several hydraulic hoses and at least one composite watertight cable are wound side-by-side onto a winding mechanism. A pipe clamp is held in place by a support core inside the hose, and the clamp seat is connected to a moving mechanism.

[0006] Furthermore, in step S1, the steel wire reinforcing layer comprises, from the inside out, a first steel wire winding layer and a second steel wire winding layer, with a middle layer of adhesive film sandwiched between the first steel wire winding layer and the second steel wire winding layer.

[0007] Furthermore, the inner adhesive layer with the hard core is wound around the copper-plated steel wire on the winding machine, and the middle adhesive sheet is simultaneously wound between the two layers of copper-plated steel wire. The two layers of copper-plated steel wire respectively form the inner layer of the first steel wire winding layer and the outer layer of the second steel wire winding layer.

[0008] Furthermore, in step S1, the copper-plated steel wires of the first wire winding layer and the second wire winding layer are wound in opposite directions.

[0009] Furthermore, in step S1, a steel wire braided layer is provided outside the second steel wire winding layer. The steel wire braided layer is formed by wrapping copper-plated steel wires around the second steel wire winding layer and the copper-plated steel wires of the steel wire braided layer on a braiding machine. At the same time, a middle layer of adhesive film is wrapped around the copper-plated steel wires of the second steel wire winding layer and the steel wire braided layer on the braiding machine.

[0010] Furthermore, in step S2, the outer rubber layer of the sheath tube is wrapped with water-repellent cloth and placed in a vulcanizing tank for vulcanization, and the vulcanization temperature is 100°C to 110°C.

[0011] Furthermore, a section of the sheath is cut off from each end of the standard watertight cable with the sheath, and the cut ends of the sheath at both ends are sealed by the vulcanized joint.

[0012] Furthermore, 0.3m to 1m of the sheath tube is cut off from both ends of the standard watertight cable with the sheath tube. After cleaning the cut surface, an adhesive is applied for surface activation. Then, the mold and the composite watertight cable are assembled and fixed together on a heating plate and preheated to 70°C. Polyurethane vulcanizing adhesive is poured into the mold cavity and kept at the temperature for about 2 hours. Finally, the mold is removed and the shape is trimmed to form the vulcanized joint.

[0013] Furthermore, the hydraulic hose and the composite watertight cable have the same outer diameter. This collaborative design approach solves the problem of inconsistent cable outer diameters, ensuring synchronized cable winding and unwinding on the same reel.

[0014] Furthermore, the drum mechanism is provided with several independent winding slots, with each hose and cable occupying one winding slot, and the winding slots are separated by partitions. The front end of the hose or cable on the drum is clamped by a pipe clamp, and the pipe clamp seat that fixes the pipe clamp is connected to the moving mechanism.

[0015] The advantages of this invention are: the hydraulic hose uses a non-standard two-layer steel wire spiral layer and one-layer steel wire braided layer as the hose reinforcement layer, which can simultaneously meet the requirements of tensile strength, bearing internal and external pressure, and small bending radius. A sheath is wrapped around a standard watertight cable with a relatively small outer diameter. The sheath wall thickness is designed to make its outer diameter the same as the hydraulic hose's outer diameter, thus achieving synchronous deployment and retraction. The sheath contains a steel wire braided layer to improve the cable's tensile strength. The end of the sheath is sealed with a vulcanized joint to prevent the copper-plated steel wire in the tensile layer from being corroded by seawater. Attached Figure Description

[0016] Figure 1 This is a diagram illustrating the installation effect of an underwater reel cable on a reel mechanism according to the present invention. Figure 2 This is an overall rendering of an underwater reel cable according to the present invention; Figure 3 This is a schematic diagram of the hydraulic hose structure in the underwater reel cable manufacturing method of the present invention; Figure 4 This is a schematic diagram of the internal structure of the hydraulic hose in this invention; Figure 5 This is a schematic diagram of the composite watertight cable structure in the method for manufacturing an underwater reel cable according to the present invention; Figure 6 This is a schematic diagram of the overall structure of the composite watertight cable in the manufacturing method of an underwater reel cable of the present invention. Detailed Implementation

[0017] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: according to Figures 1 to 6As shown, this solution provides a method for manufacturing underwater electro-hydraulic composite reel cables. See details below. Figure 1 and Figure 2 The underwater reel cable provided in this solution occupies an independent winding slot when installed on the reel mechanism 3. The winding slots are separated by partitions 4. The hydraulic hose 1 and the cable 2 have the same outer diameter, enabling synchronous winding and unwinding. The hydraulic hose 1 and the cable 2 are held by pipe clamps. The pipe clamp 5 of the hydraulic hose 1 is held in place by the support core 1-6 inside the hose. The pipe clamp seat 6 that fixes the pipe clamp 5 is connected to the moving mechanism.

[0018] A sheath is wrapped around the outer layer of a standard watertight cable with a relatively small outer diameter. The outer diameter of the watertight cable is made the same as that of the hydraulic hose by designing the wall thickness of the sheath, so as to realize the function of synchronous cable winding and unwinding.

[0019] See details Figure 3 and Figure 4 This hydraulic hose design employs a composite reinforcement layer consisting of two layers of steel wire winding and one layer of steel wire braiding on the inner rubber layer. This balances the hose's tensile and pressure-bearing requirements with its flexibility for winding and frequent bending. An internal support core is incorporated at the hose clamping position to prevent the hose's outer diameter from decreasing under tension and to prevent slippage between the hose and the clamp.

[0020] Specifically, the hydraulic hose 1 comprises, from the inside out, a hollow inner rubber layer 1-1, a first steel wire winding layer 1-2, a second steel wire winding layer 1-3, a steel wire braided layer 1-4, and an outer rubber layer 1-5. In this embodiment, the inner rubber layer 1-1 is made of oil-resistant nitrile rubber, the outer rubber layer 1-5 is made of seawater-resistant neoprene rubber, and the first steel wire winding layer 1-2, the second steel wire winding layer 1-3, and the steel wire braided layer 1-4 are all made of copper-plated steel wire. A middle layer rubber sheet is sandwiched between the first steel wire winding layer 1-2 and the second steel wire winding layer 1-3, and a middle layer rubber sheet is also sandwiched between the second steel wire winding layer 1-3 and the steel wire braided layer 1-4. Furthermore, the copper-plated steel wires of the first steel wire winding layer 1-2 and the second steel wire winding layer 1-3 are wound in opposite directions.

[0021] The specific implementation process of hydraulic hoses is as follows: S1-1: Extrude the inner rubber layer 1-1 using an extruder and wrap it around a 10mm diameter hard core coated with a release agent.

[0022] S1-2: The inner adhesive layer 1-1 with the hard core is wound around copper-plated steel wire on a winding machine, and the middle adhesive sheet is simultaneously wound between the two layers of copper-plated steel wire. The two layers of copper-plated steel wire respectively form the inner layer of the first steel wire winding layer 1-2 and the outer layer of the second steel wire winding layer 1-3. The copper-plated steel wire winding directions of the first steel wire winding layer 1-2 and the second steel wire winding layer 1-3 are opposite.

[0023] S1-3: Copper-plated steel wire is wound around the braided layer 1-4 on the braiding machine to form a steel wire braid layer 1-4. At the same time, a middle layer of rubber sheet is wound around the copper-plated steel wire between the second steel wire winding layer 1-3 and the steel wire braid layer 1-4 on the braiding machine.

[0024] S1-4: After wrapping with water-repellent cloth, place the product in a vulcanizing tank for high-temperature vulcanization. After vulcanization, remove the water-repellent cloth and extract the hard core.

[0025] S1-5: After inserting the support core 1-6 at the clamping position of clamp 5, crimp the hose connector. See details Figure 5 The composite watertight cable has a sheath 200 installed on the outer layer of the standard watertight cable 2-1. The sheath 200 includes, from the inside out, an inner rubber layer 2-2, a steel wire braided layer 2-3, and an outer rubber layer 2-4. In this embodiment, the inner rubber layer 2-2 and the outer rubber layer 2-4 are both made of neoprene rubber, and the steel wire braided layer 2-3 is made of copper-plated steel wire.

[0026] The specific implementation process of composite watertight cables is as follows: S2-1: The inner rubber layer 2-2 of the sheath is extruded onto the outer layer of the standard watertight cable 2-1 using an extruder.

[0027] S2-2: Copper-plated steel wire is wound around a braiding machine to form a sheathing tube steel wire braided layer 2-3.

[0028] S2-3: Extrude the outer rubber layer 2-4 of the sheath tube on the extruder.

[0029] S2-4: After wrapping with water-repellent cloth, place the container in a vulcanizing tank for vulcanization. The vulcanization temperature is 100℃ to 110℃, preferably 110℃.

[0030] S2-5: See details Figure 6 A section of the sheath 200 is cut off from both ends of the standard watertight cable 2-1 with sheath tubes. The length of the cut sheath tube 200 is 0.3m to 1m. In this embodiment, it is preferred to cut off 0.5m of sheath tube 200. The two ends of the standard watertight cable 2-1 exposed at both ends are connected to watertight connectors 2-6.

[0031] S2-6: Clean the surface of the cut where the sheath tube 200 is removed, apply adhesive for surface activation, then assemble the mold and the composite watertight cable at the cut, fix the whole assembly on the heating plate and preheat to 70°C, pour polyurethane vulcanizing adhesive into the mold cavity and keep it warm for about 2 hours, finally remove the mold and trim the shape to form vulcanization joint 2-5.

[0032] S2-7: Watertight connectors are assembled at both ends of the composite watertight cable; The hydraulic hoses and cables involved in this invention not only meet the application requirements in specific scenarios, but also have a certain degree of scalability in their design methods, providing a new technical path for the design of similar products.

[0033] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific structures and characteristics in the solutions is not described in detail here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the structure of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.

Claims

1. A method for manufacturing an underwater reel cable, characterized in that, include: S1. To manufacture a hydraulic hose, a release agent is applied to a rigid core, and an inner rubber layer is extruded from the extruder to cover the rigid core. A steel wire reinforcement layer is set on the inner rubber layer, and an outer rubber layer is wrapped around the steel wire reinforcement layer by the extruder. After wrapping the outer rubber layer with a water-absorbing cloth, the hose is placed in a vulcanizing tank for high-temperature vulcanization. After vulcanization, the water-absorbing cloth is removed, and the rigid core is extracted. A support core is built into the clamping position of the hose and then the hose connector is crimped. S2 manufactures a composite watertight cable. A sheath is installed on the outer layer of a standard watertight cable. The sheath, from the inside out, includes an inner rubber layer, a steel wire braided layer, and an outer rubber layer. The inner rubber layer is extruded onto the outer layer of the standard watertight cable using an extruder. A copper-plated steel wire is then braided around the inner rubber layer using a braiding machine to form the steel wire braided layer. The outer rubber layer is then extruded to cover the outer rubber layer. The outer rubber layer is wrapped with a water-resistant cloth and vulcanized in a vulcanizing tank. After vulcanization, the cloth is removed. Both ends of the sheath are sealed through vulcanization joints, and watertight connectors are assembled at both ends of the composite watertight cable. S3 winds several hydraulic hoses and at least one composite watertight cable in parallel to a reel mechanism, clamps the hoses at the support core inside the hydraulic hoses, and the clamp seat for fixing the clamps is connected to the moving mechanism.

2. The method for manufacturing an underwater reel cable according to claim 1, characterized in that: In step S1, the steel wire reinforcing layer includes a first steel wire winding layer and a second steel wire winding layer from the inside out, with a middle layer of adhesive film sandwiched between the first steel wire winding layer and the second steel wire winding layer.

3. The method for manufacturing an underwater reel cable according to claim 2, characterized in that: The inner rubber layer with the hard core is wound around copper-plated steel wire on a winding machine, and the middle layer rubber sheet is simultaneously wound between the two layers of copper-plated steel wire. The two layers of copper-plated steel wire respectively form the inner layer of the first steel wire winding layer and the outer layer of the second steel wire winding layer.

4. The method for manufacturing an underwater reel cable according to claim 1, characterized in that: In step S1, the copper-plated steel wires of the first wire winding layer and the second wire winding layer are wound in opposite directions.

5. The method for manufacturing an underwater reel cable according to claim 2, characterized in that: In step S1, a steel wire braided layer is also provided outside the second steel wire winding layer. The steel wire braided layer is formed by wrapping copper-plated steel wire around it on a braiding machine. At the same time, a middle layer of adhesive film is wrapped around the copper-plated steel wire of the second steel wire winding layer and the steel wire braided layer on the braiding machine.

6. The method for manufacturing an underwater reel cable according to claim 1, characterized in that: In step S2, the outer rubber layer of the sheath tube is wrapped with water-repellent cloth and placed in a vulcanizing tank for vulcanization. The vulcanization temperature is 100°C to 110°C.

7. The method for manufacturing an underwater reel cable according to claim 1, characterized in that: A section of the sheath is cut off at each end of the standard watertight cable with the sheath, and the cut ends of the sheath at both ends are sealed by the vulcanized joint.

8. The method for manufacturing an underwater reel cable according to claim 7, characterized in that: Cut off 0.3m to 1m of the sheath tube from both ends of the standard watertight cable with the sheath tube. Clean the cut surface and apply adhesive for surface activation. Then, assemble the mold with the composite watertight cable at the cut and fix the whole assembly on the heating plate and preheat to 70°C. Pour polyurethane vulcanizing adhesive into the mold cavity and keep it at the temperature for about 2 hours. Finally, remove the mold and trim the shape to form the vulcanized joint.

9. The method for manufacturing an underwater reel cable according to claim 1, characterized in that: The hydraulic hose and the composite watertight cable have the same outer diameter.

10. A method for manufacturing an underwater reel cable according to claim 1, characterized in that: The drum mechanism is provided with several independent winding slots, with each hose and cable occupying one winding slot. The winding slots are separated by partitions. The front end of the cable on the drum is clamped by a pipe clamp, and the pipe clamp seat that fixes the pipe clamp is connected to the moving mechanism.

Images