Leakage cable processing method and system

Abstract

The invention provides a leaky coaxial cable processing method and system, and the method comprises the following steps: carrying out the first embossing of a copper strip to form a pre-embossed pattern, and obtaining a copper strip with the pre-embossed pattern; the laser cutting device is used for cutting the copper strip with the pre-embossed lines to form a plurality of slotted holes, and the slotted copper strip is obtained; the grooved copper strip is embossed for the second time to form finish rolling grains, and the copper strip with the finish rolling grains is obtained; longitudinally wrapping the insulating cable core with a copper strip with finish rolling grains to form an outer conductor; each insulating cable core comprises an inner conductor and an insulating layer wrapping the inner conductor. And extruding a sheath on the outer conductor to obtain the leaky coaxial cable. Based on the leaky coaxial cable processing method provided by the invention, the problem of poor consistency of slotted holes in the leaky coaxial cable processing process is solved.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing technology, and more specifically, to a method and system for processing leaky cables. Background Technology

[0002] Leaky coaxial cable (LCX), also known as a leaky cable or leaky wire, has regularly spaced slots or holes in its outer conductor. These slots or holes allow electromagnetic waves to partially leak into the surrounding space during transmission, while also receiving electromagnetic waves from the surrounding space, thus achieving effective signal coverage and transmission within a specific area. Compared to ordinary radio frequency coaxial cable, the core technology of leaky coaxial cable is the production of the slotted outer conductor; the precision of the slotting has a decisive impact on the performance of the leaky cable.

[0003] In traditional leaky coaxial cable (LCX) manufacturing technology, the outer conductor is typically prepared using a process of first slotting and then corrugating. This usually involves punching holes or laser cutting to create the slots, followed by longitudinally wrapping and overlapping the copper strip. However, when the copper strip is punched or slotted before corrugating, the mechanical pressure during the corrugating process can easily cause irregular deformations in the formed slots, such as warping, stretching, collapse, and twisting. Furthermore, the slots are subjected to stretching during the longitudinal drawing process, which can easily lead to breakage or further deformation at the slots. This can also cause inconsistencies in the pitch of the slots and / or the spacing between adjacent slots on the resulting outer conductor.

[0004] Irregular deformation of leaky cable slots, slot pitch deviations, and spacing deviations between adjacent slots alter the electromagnetic energy leakage path, causing electromagnetic energy to diffuse in non-target directions. This results in insufficient signal strength in the target area, shortened communication distance, and a significant reduction in communication coverage quality. Furthermore, the slot spacing design of the leaky cable must match the wavelength (or half-wavelength) of the applied frequency to ensure in-phase signal superposition at the slot. Inconsistent slot spacing or pitch disrupts phase matching, causing chaotic radiated signals that cannot be concentrated in the designated direction, leading to a sharp drop in radiation efficiency. Additionally, irregular slot deformation weakens the leaky cable's resistance to bending, preventing the bending radius from meeting design requirements. This can lead to installation failure or secondary damage to the slots after installation due to bending, exacerbating losses. Therefore, providing a processing method that improves the consistency of leaky cable slots, thereby enhancing the cable's radiation and bending performance, is of great significance. Summary of the Invention

[0005] The main objective of this invention is to provide a leaky cable processing method to solve the problem of poor consistency of slot holes in the prior art during leaky cable processing.

[0006] To achieve the above objectives, according to one aspect of the present invention, a method for processing a leaky cable is provided, comprising the following steps:

[0007] The copper strip is first rolled to form pre-rolled patterns, resulting in a copper strip with pre-rolled patterns.

[0008] A laser cutting device cuts a copper strip with pre-rolled patterns to form several slots, resulting in a slotted copper strip.

[0009] The slotted copper strip is then subjected to a second rolling process to form fine rolling patterns, resulting in a copper strip with fine rolling patterns.

[0010] A finely rolled copper strip is longitudinally wrapped around an insulated cable core to form an outer conductor; the insulated cable core includes an inner conductor and an insulating layer covering the inner conductor;

[0011] A sheath is extruded onto the outer conductor to obtain a leaky cable.

[0012] Furthermore, the thickness of the copper strip is greater than or equal to 0.05 mm and less than 0.15 mm, the depth of the pre-rolled groove is 0.3 mm to 0.9 mm, and the depth of the finishing groove is 0.5 mm to 1.5 mm; preferably, the temperature of the grooved area of ​​the first rolling is 25°C to 35°C, and the rolling pressure is 3 MPa to 5 MPa; preferably, the temperature of the grooved area of ​​the second rolling is 25°C to 35°C, and the rolling pressure is 6 MPa to 9 MPa.

[0013] Furthermore, the thickness of the copper strip is 0.15mm to 0.3mm, the depth of the pre-rolled groove is 0.8mm to 1.8mm, and the depth of the finishing groove is 1.6mm to 3mm; preferably, the temperature of the first rolling zone is 25℃ to 35℃, and the rolling pressure is 5MPa to 7MPa; preferably, the temperature of the second rolling zone is 25℃ to 35℃, and the rolling pressure is 10MPa to 15MPa.

[0014] Furthermore, during the process of cutting to form each slot, the temperature of the cutting area is 15℃~20℃.

[0015] Furthermore, the pre-rolled groove pitch is 3mm to 8mm.

[0016] The first rolling, cutting, second rolling, and copper strip movement are carried out simultaneously, with the copper strip moving at a speed of 12m / min to 15m / min. Preferably, at the same time, the straight-line distance between the position where the copper strip is first rolled and the position where the pre-rolled copper strip is cut is greater than 1m along the centerline direction of the copper strip movement; the straight-line distance between the position where the pre-rolled copper strip is cut and the position where the slotted copper strip is second rolled is greater than 1m along the centerline direction of the copper strip movement.

[0017] Furthermore, the leaky cable processing method also includes the preparation of an insulated cable core, comprising the following steps: performing a straightening pretreatment on the inner conductor to obtain a straightened pretreated inner conductor, and extruding an insulation layer onto the straightened pretreated inner conductor to form an insulated cable core.

[0018] Furthermore, the leaky cable processing method also includes pre-stretching the copper strip before the first rolling process to form pre-rolled grooves.

[0019] Furthermore, the leaky cable processing method also includes covering at least one surface of the slotted copper strip with a film layer before performing a second rolling process to form fine rolling patterns on the slotted copper strip. The film layer includes one or both of high-temperature resistant tape and high-temperature resistant coating.

[0020] Furthermore, the leaky cable processing method also includes adding a wrapping layer to the outer conductor before extruding the sheath onto the outer conductor. The wrapping layer material includes one or more of non-woven fabric, polyester, and binding yarn.

[0021] Furthermore, the pattern type of the pre-rolled pattern is either an arc pattern or a diagonal pattern.

[0022] Furthermore, the pre-rolled lines are arranged sequentially at intervals, and a finishing line is arranged between any two adjacent pre-rolled lines, with any adjacent pre-rolled lines and finishing lines connected end to end.

[0023] Furthermore, the inner conductor is selected from one of the following: smooth copper-clad aluminum tube, smooth copper tube, corrugated copper-clad aluminum tube, and corrugated copper tube.

[0024] Furthermore, before the laser cutting device cuts the copper strip with pre-rolled texture to form each slot, the leaky cable processing method also includes obtaining the position of the texture node of the pre-rolled texture, establishing a three-dimensional reference coordinate system based on the position of the texture node, and determining the cutting path of each slot and its preset cutting starting point based on the three-dimensional reference coordinate system and the slot parameters.

[0025] The laser cutting device cuts a copper strip with pre-rolled grooves to form slots. This includes: the laser cutting device cuts the copper strip with pre-rolled grooves according to the cutting path of each slot and its preset cutting start point; after completing the cutting of a specific number of slots and before cutting the next slot, the position of the groove node corresponding to the actual cutting start point of the next slot is obtained; when the deviation between the position of the groove node corresponding to the actual cutting start point of the next slot and the position of the groove node corresponding to its preset cutting start point is greater than a first preset value, the cutting path and preset cutting start point of the remaining slots to be cut are re-determined; and the laser cutting device cuts the copper strip with pre-rolled grooves according to the preset cutting start point and cutting path of the remaining slots to form the remaining slots to be cut.

[0026] According to a second aspect of the present invention, a leaky cable processing system is provided, comprising: an insulated cable core unwinding device, a cable core traction device, a tape unwinding device, a pre-texturing device, a laser cutting device, a fine texturing device, a longitudinal wrapping die, and a first extruder.

[0027] The insulated cable core release device is used to release the insulated cable core;

[0028] A cable core pulling device is used to pull the released insulated cable core so that the insulated cable core passes sequentially through the longitudinal wrapping mold and the first extruder; the insulated cable core includes an inner conductor and an insulating layer covering the inner conductor;

[0029] The tape-releasing device is used to release the copper tape;

[0030] The pre-rolling device is used to perform the first rolling of the released copper strip to form pre-rolled patterns, so as to obtain copper strip with pre-rolled patterns;

[0031] Laser cutting equipment is used to cut pre-rolled copper strips to form several slots, so as to obtain slotted copper strips;

[0032] The fine rolling device is used to perform a second rolling process on the slotted copper strip to form fine rolling patterns, so as to obtain a copper strip with fine rolling patterns.

[0033] Longitudinal wrapping dies are used to longitudinally wrap copper strips with finely rolled patterns onto the insulated cable core to form the outer conductor;

[0034] The first extruder is used to extrude a sheath onto the outer conductor to obtain a leaky cable.

[0035] Furthermore, the leaky cable processing system also includes a temperature control system, which is used to control the temperature of the first-round rolling area, the temperature of the cutting area, and the temperature of the second-round rolling area.

[0036] Preferably, the temperature control system includes a first constant temperature enclosure, a second constant temperature enclosure, and a third constant temperature enclosure. The pre-rolling device is located inside the first constant temperature enclosure, the laser cutting device is located inside the second constant temperature enclosure, and the fine rolling device is located inside the third constant temperature enclosure.

[0037] Furthermore, the leaky cable processing system also includes:

[0038] The speed feedback unit includes a first speed sensor, a second speed sensor, a third speed sensor, a fourth speed sensor, a fifth speed sensor, and a control module. The first speed sensor detects the moving speed of the pre-grooved copper strip at the inlet end of the laser cutting device and sends it to the control module. The second speed sensor detects the moving speed of the copper strip at the inlet end of the pre-grooving device and sends it to the control module. The third speed sensor detects the moving speed of the grooved copper strip at the inlet end of the finishing grooved device and sends it to the control module. The fourth speed sensor detects the speed of the insulated cable core released by the wire feeding device and sends it to the control module. The fifth speed sensor detects the speed of the copper strip released by the wire feeding device and sends it to the control module.

[0039] When the error between the moving speed of the copper strip at the inlet of the pre-rolling device and the moving speed of the pre-rolled copper strip at the inlet of the laser cutting device is greater than the second preset value, the control module controls the pre-rolling device to adjust the moving speed of the copper strip at the inlet of the pre-rolling device to be the same as the moving speed of the pre-rolled copper strip at the inlet of the laser cutting device.

[0040] When the error between the moving speed of the copper strip after slotting at the inlet end of the fine rolling device and the moving speed of the copper strip with pre-rolled patterns at the inlet end of the laser cutting device is greater than the third preset value, the control module controls the fine rolling device to adjust the moving speed of the copper strip after slotting at the inlet end of the fine rolling device to be the same as the moving speed of the copper strip with pre-rolled patterns at the inlet end of the laser cutting device.

[0041] When the error between the speed of the insulated cable core released by the insulated cable core release device and the moving speed of the copper strip with pre-rolled texture at the inlet end of the laser cutting device is greater than the fourth preset value, the control module controls the insulated cable core release device to adjust the speed of the insulated cable core released by the insulated cable core release device to be the same as the moving speed of the copper strip with pre-rolled texture at the inlet end of the laser cutting device.

[0042] When the error between the speed of the copper strip released by the feeding device and the moving speed of the pre-rolled copper strip at the inlet end of the laser cutting device is greater than the fifth preset value, the control module controls the feeding device to adjust the speed of the released copper strip to be the same as the moving speed of the pre-rolled copper strip at the inlet end of the laser cutting device.

[0043] Furthermore, the leaky cable processing system also includes:

[0044] The positioning and calibration unit includes a camera device, an image analysis and processing module, and a control module. Before the laser cutting device cuts the copper strip with pre-rolled patterns to form slots, the camera device acquires an image of the pre-rolled patterns on the copper strip and sends it to the image analysis and processing module. The image analysis and processing module obtains the position of the pattern nodes based on the image of the pre-rolled patterns, establishes a three-dimensional reference coordinate system based on the position of the pattern nodes, determines the cutting path of each slot and its preset cutting start point based on the three-dimensional reference coordinate system and the slot parameters, and sends it to the control module. The control module controls the laser cutting device to cut the copper strip with pre-rolled patterns to form slots according to the cutting path of each slot and its preset cutting start point.

[0045] After a specific number of slots are cut and before the next slot is cut, the camera device acquires the pre-rolled groove corresponding to the actual cutting start point of the next slot and sends it to the image analysis and processing module. The image analysis and processing module, based on the pre-rolled groove corresponding to the actual cutting start point of the next slot, acquires the position of the texture node corresponding to the actual cutting start point of the next slot and sends it to the control module. When the deviation between the position of the texture node corresponding to the actual cutting start point of the next slot and the position of the texture node corresponding to its preset cutting start point exceeds a first preset value, the control module controls the camera device... The system acquires an image of the remaining pre-rolled textures of the copper strip and sends it to the image analysis and processing module. Based on the image, the image analysis and processing module obtains the positions of the remaining pre-rolled texture nodes, establishes a three-dimensional calibration coordinate system, and redetermines the cutting paths and preset cutting start points for each remaining slot based on the three-dimensional calibration coordinate system and slot parameters, sending these to the control module. The control module, based on the cutting paths and preset cutting start points for each remaining slot, controls the laser cutting device to cut the copper strip with pre-rolled textures to form the remaining slots.

[0046] Furthermore, the leaky cable processing system also includes an insulated cable core preparation device, which includes an inner conductor laying device, a straightening pretreatment device, and an insulation layer extrusion device: the inner conductor laying device is used to lay out the inner conductor; the straightening pretreatment device is used to straighten and pretreat the laid-out inner conductor to obtain a straightened and pretreated inner conductor; the insulation layer extrusion device is used to extrude an insulation layer onto the straightened and pretreated inner conductor to form an insulated cable core.

[0047] Furthermore, the leaky cable processing system also includes a pre-stretching device for pre-stretching the copper strip before the first corrugation to form pre-corrugations.

[0048] Furthermore, the leaky cable processing system also includes a cable winding device for winding and storing the leaky cable.

[0049] The technical solution of this invention involves a first rolling process, i.e., pre-rolling to form pre-rolled patterns. This releases the internal stress of the copper strip, improving the stability of subsequent laser cutting. The pre-rolled patterns stabilize the copper strip structure, reducing deformation during subsequent grooving and improving the regularity of the slot shape, as well as the consistency of spacing and pitch. Laser cutting is a non-contact process, highly flexible, and suitable for processing complex slots. It eliminates mechanical extrusion and wear, and the slot shape and size are easy to control. However, if laser cutting is used directly to form slots, stress relaxation can easily lead to slot stretching and pitch deviation, affecting the consistency of the slots in the processing. The pre-rolled patterns stabilize the copper strip structure, and laser cutting after pre-rolling helps reduce slot deformation, pitch deviation, and spacing deviation caused by stress relaxation. After laser cutting, a second rolling process is performed to form a fine rolling pattern. The pre-rolled pattern stabilizes the copper strip structure, minimizing interference with the slots during the subsequent fine rolling. This significantly improves slot consistency and helps reduce coupling loss fluctuations caused by slot deformation, pitch deviation, and spacing deviation. This ensures uniform signal radiation and frequency adaptation in the leaky cable, improving communication coverage quality and radiation efficiency. Furthermore, the two-stage rolling process releases internal stress accumulated during copper strip rolling and unrolling, while the second rolling applies further pressure, avoiding stress concentration caused by a single deep rolling. This step-by-step rolling process releases internal stress in the copper strip while ensuring the final rolling depth, resulting in reliable rolling quality and improved bending performance of the leaky cable. Moreover, in traditional processes, complex slots such as closed figure-eight patterns and dense micropores are prone to mutual destruction with complex rolling patterns such as orthogonal mesh patterns, making them difficult to combine. Laser cutting offers flexibility to support arbitrary slot designs. After pre-rolling to strengthen the copper strip structure, there is no risk of breakage when processing complex slots. Using laser cutting to form slots, combined with pre-rolling and secondary precision rolling, can achieve a combination of complex slots and complex rolling patterns.

[0050] Based on the leaky cable processing method of the present invention, the outer conductor is prepared by first pre-rolling to prepare pre-rolled patterns, then laser cutting to form slots, and then secondary rolling to prepare fine patterns. This process significantly improves the consistency of slots during leaky cable processing, enhances the processing quality of leaky cable slots, ensures uniform radiation and frequency adaptation of leaky cable signals, effectively improves the communication coverage quality, radiation efficiency and bending performance of leaky cable, and is suitable for processing complex slots. Attached Figure Description

[0051] The accompanying drawings, which form part of this application, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings:

[0052] Figure 1A schematic diagram of a leaky cable processing system according to an embodiment of the present invention is shown.

[0053] The above figures include the following reference numerals:

[0054] 1. Tape feeding device;

[0055] 2. Pre-stretching device;

[0056] 3. Pre-texturing device; 31. First belt feed traction device; 32. First belt output traction device; 33. First texturing roll;

[0057] 4. Laser cutting device; 41. Second infeed traction device; 42. Second outfeed traction device; 43. Laser;

[0058] 5. Finishing embossing device; 51. Third belt feed traction device; 52. Third belt output traction device; 53. Second embossing roll;

[0059] 6. Inner conductor wire feeding device;

[0060] 7. Straightening pretreatment device;

[0061] 8. Insulation layer extrusion device;

[0062] 9. Longitudinal packaging mold;

[0063] 10. First extruder;

[0064] 11. Cable winding device;

[0065] 12. First thermostatic cover;

[0066] 13. Second thermostatic cover;

[0067] 14. Third thermostatic cover;

[0068] 15. Camera device;

[0069] 16. Purge nozzle. Detailed Implementation

[0070] It should be noted that, unless otherwise specified, the embodiments and features described in this application can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0071] As described in the background section, existing technologies suffer from poor slot consistency during cable processing, which affects the radiation and bending performance of leaky cables. To address this problem, the present invention provides a leaky cable processing method, comprising the following steps:

[0072] The copper strip is first rolled to form pre-rolled patterns, resulting in a copper strip with pre-rolled patterns.

[0073] A laser cutting device cuts a copper strip with pre-rolled patterns to form several slots, resulting in a slotted copper strip.

[0074] The slotted copper strip is then subjected to a second rolling process to form fine rolling patterns, resulting in a copper strip with fine rolling patterns.

[0075] A finely rolled copper strip is longitudinally wrapped around an insulated cable core to form an outer conductor; the insulated cable core includes an inner conductor and an insulating layer covering the inner conductor;

[0076] A sheath is extruded onto the outer conductor to obtain a leaky cable.

[0077] Based on the technical solution of this invention, the copper strip first undergoes a first rolling process, i.e., pre-rolling to form pre-rolled patterns. This releases the internal stress of the copper strip and improves the stability of subsequent laser cutting. The pre-rolled patterns stabilize the copper strip structure, reducing deformation during subsequent grooving and improving the regularity of the slot shape, as well as the consistency of spacing and pitch. Laser cutting is a non-contact process, highly flexible, and suitable for processing complex slots. It eliminates mechanical extrusion and wear, and the slot shape and size are easy to control. However, if laser cutting is used directly to form slots, stress relaxation can easily lead to slot stretching and pitch deviation, affecting the consistency of the slots in the processing. The pre-rolled patterns stabilize the copper strip structure, and laser cutting after pre-rolling helps reduce slot deformation, pitch deviation, and spacing deviation caused by stress relaxation. After laser cutting, a second rolling process is performed to form a fine rolling pattern. The pre-rolled pattern stabilizes the copper strip structure, minimizing interference with the slots during the subsequent fine rolling. This significantly improves slot consistency and helps reduce coupling loss fluctuations caused by slot deformation, pitch deviation, and spacing deviation. This ensures uniform signal radiation and frequency adaptation in the leaky cable, improving communication coverage quality and radiation efficiency. Furthermore, the two-stage rolling process releases internal stress accumulated during copper strip rolling and unrolling, while the second rolling applies further pressure, avoiding stress concentration caused by a single deep rolling. This step-by-step rolling process releases internal stress in the copper strip while ensuring the final rolling depth, resulting in reliable rolling quality and improved bending performance of the leaky cable. Moreover, in traditional processes, complex slots such as closed figure-eight patterns and dense micropores are prone to mutual destruction with complex rolling patterns such as orthogonal mesh patterns, making them difficult to combine. Laser cutting offers flexibility to support arbitrary slot designs. After pre-rolling to strengthen the copper strip structure, there is no risk of breakage when processing complex slots. Combining laser cutting to form slots with pre-rolling and secondary finishing rolling allows for the creation of complex slots and patterns. Based on this invention's leaky cable processing method, the outer conductor is prepared using a process of first pre-rolling to create pre-rolled patterns, then laser cutting to form slots, and finally secondary finishing rolling to create finishing patterns. This significantly improves the consistency of slots during leaky cable processing, enhances the processing quality of the leaky cable slots, ensures uniform signal radiation and frequency adaptation, effectively improves the communication coverage quality, radiation efficiency, and bending performance of the leaky cable, and is suitable for processing complex slots.

[0078] In some embodiments, the thickness of the copper strip is greater than or equal to 0.05 mm and less than 0.15 mm, the depth of the pre-rolled groove is 0.3 mm to 0.9 mm, and the depth of the finish-rolled groove is 0.5 mm to 1.5 mm. For thin copper strips with a thickness greater than or equal to 0.05 mm and less than 0.15 mm, the depths of the pre-rolled groove and the finish-rolled groove are within the above ranges, and the prepared leaky cable has better bending performance. Preferably, the temperature of the first-rolled groove area is 25°C to 35°C, and the rolling pressure is 3 MPa. The first embossing of the thin copper strip at the above temperature and pressure (~5MPa) helps to improve the plasticity of the copper strip, reduce embossing stress, reduce copper strip deformation during subsequent grooving, and improve the regularity of the groove shape as well as the consistency of pitch and spacing. Preferably, the temperature of the embossing area for the second embossing is 25℃~35℃, and the embossing pressure is 6MPa~9MPa. Performing the second embossing of the thin copper strip at the above temperature and pressure helps to improve the plasticity of the copper strip, reduce embossing stress, and improve the bending performance of the leaky cable.

[0079] In some embodiments, the thickness of the copper strip is 0.15 mm to 0.3 mm, the depth of the pre-rolled groove is 0.8 mm to 1.8 mm, and the depth of the finishing groove is 1.6 mm to 3 mm. For a thick copper strip with a thickness of 0.15 mm to 0.3 mm, the depths of the pre-rolled groove and the finishing groove are within the above ranges, and the prepared leaky cable has better bending performance. Preferably, the temperature of the first rolling zone is 25°C to 35°C, and the rolling pressure is 5 MPa to 7 MPa. Performing the first rolling on the thick copper strip at the above temperature and pressure is beneficial to improving the plasticity of the copper strip, reducing rolling stress, reducing copper strip deformation during subsequent grooving, and improving the regularity of the groove shape and the consistency of pitch and spacing. Preferably, the temperature of the second rolling zone is 25°C to 35°C, and the rolling pressure is 10 MPa to 15 MPa. Performing the second rolling on the thick copper strip at the above temperature and pressure helps to improve the plasticity of the copper strip, reduce rolling stress, and improve the bending performance of the leaky cable.

[0080] In some embodiments, during the process of cutting to form each slot, the temperature of the cutting area is 15°C to 20°C. Maintaining the temperature of the cutting area within this range helps reduce thermal stretching of the slots and interference from copper strip deformation during laser cutting, thus reducing slot deformation, pitch deviation, and spacing deviation. Especially when the temperature of the first rolled area is 25°C to 35°C, and the temperature of the second rolled area is also 25°C to 35°C, controlling the temperature of the cutting area within these ranges helps reduce thermal expansion and contraction of the copper strip caused by ambient temperature changes, reducing the impact of temperature changes on slot shape, pitch, and spacing, and improving the communication coverage quality, radiation efficiency, and bending performance of the leaky cable.

[0081] In cable manufacturing technology, especially in the production of leaky cables, the corrugation pitch refers to the straight-line distance along the centerline of the copper strip's movement direction when the outer conductor copper strip passes through a corrugating device to form a pattern. This distance is measured along the cable length and is the standard interval between repeating pattern features. In some embodiments, the pre-corrugation pitch is 3mm to 8mm. This corrugation pitch is beneficial as a positioning reference for subsequent laser-cut slots and for slot distribution design, thereby achieving higher radiation efficiency. Furthermore, at this pitch, it helps release internal stress in the copper strip, resulting in higher structural stability. This reduces copper strip deformation during subsequent slotting, improves the regularity of the slot shape and the consistency of pitch and spacing, and enhances the communication coverage quality and radiation efficiency of the leaky cable. It also strengthens the mechanical strength and bending performance of the leaky cable.

[0082] In some embodiments, the first corrugation, cutting, second corrugation, and movement of the copper strip are performed simultaneously, with the copper strip moving at a speed of 12 m / min to 15 m / min. This simultaneous operation of the first corrugation, laser cutting to form grooves, the second precision corrugation, and the entire movement process helps ensure coordination and continuity between the various process steps, improving the efficiency and quality of the leaky cable processing. Maintaining the copper strip's movement speed within the range of 12 m / min to 15 m / min helps maintain the stability of the processing.

[0083] In some preferred embodiments, at the same time, the straight-line distance between the position where the copper strip undergoes its first grooving and the position where the pre-grooved copper strip is cut, along the centerline direction of the copper strip's movement, is greater than 1 meter; the straight-line distance between the position where the pre-grooved copper strip is cut and the position where the slotted copper strip undergoes its second grooving, along the centerline direction of the copper strip's movement, is also greater than 1 meter. By setting the distance between the position where the copper strip undergoes its first grooving and the laser cutting position to be greater than 1 meter, and the distance between the position where the copper strip undergoes its second grooving and the laser cutting position to be greater than 1 meter, two effective temperature buffer sections are constructed. Because laser cutting generates localized high temperatures, adjacent grooving areas will be at different temperature states. This temperature difference may lead to uneven stress distribution within the copper strip, thus affecting the consistency of the slots. By reserving temperature buffer sections, the influence of temperature differences on the copper strip can be effectively mitigated, ensuring a smooth transition of the copper strip's physical properties from the first grooving to laser cutting and then to the second precision grooving. This reduces the changes in slot size or shape distortion caused by temperature differences, improves the processing quality of the leaky cable, especially the consistency and stability of the slots, thereby improving the radiation performance and mechanical properties of the leaky cable.

[0084] In some embodiments, the leaky cable processing method further includes: preparing an insulated cable core, comprising the following steps: performing a straightening pretreatment on the inner conductor to obtain a straightened pretreated inner conductor; and extruding an insulating layer onto the straightened pretreated inner conductor to form an insulated cable core. The straightening pretreatment helps reduce bending defects and surface impurities within the inner conductor, improving stability and the mechanical properties of the leaky cable during subsequent processing. Subsequently, extruding an insulating layer onto the inner conductor forms an insulated cable core, providing a good signal transmission environment for the leaky cable.

[0085] In some embodiments, the insulation layer is a polyethylene foam insulation layer, which helps to improve signal transmission speed and reduce signal attenuation during transmission; preferably, the polyethylene foam insulation layer includes an inner adhesive layer and an intermediate foam layer and an outer skin layer sequentially covering the inner adhesive layer; more preferably, the inner adhesive layer material is a mixture of low-density polyethylene and an adhesive, for example, the weight percentage content of low-density polyethylene in the inner adhesive layer material is 70% to 85%, and the weight percentage content of the adhesive is 15% to 30%; more preferably, the intermediate foam layer material is a mixture of low-density polyethylene, high-density polyethylene and a nucleating agent, for example, in the intermediate foam layer, the weight percentage content of low-density polyethylene, high-density polyethylene and nucleating agent are 15% to 30%, 68% to 84% and 1% to 2%, respectively, and the nucleating agent is a polyethylene nucleating agent; more preferably, the outer skin layer material is high-density polyethylene or low-density polyethylene. Specifically, high-density polyethylene (HDPE) has a linear molecular structure with few and short branches, and its molecular chains are arranged regularly and tightly. Low-density polyethylene (LDPE) has many and long branches, and its molecular chains are randomly intertwined and loosely arranged. The density of the HDPE used above is 0.941–0.965 g / cm³. 3 The density of low-density polyethylene is 0.910 g / cm³. 3 ~0.925g / cm 3 The adhesive includes one or both of epoxy resin and polyurethane.

[0086] In some specific embodiments, the preparation steps of the polyethylene foam insulation layer include: adding the raw material of the inner adhesive layer material to a second extruder and heating it to 120°C to 195°C to melt and mix it to obtain a first molten material; preheating the straightened and pretreated inner conductor to a temperature of 40°C to 60°C; and extruding the first molten material onto the inner conductor through the second extruder to form an inner adhesive layer; adding the raw material of the foaming layer material to the foaming extruder, heating it to a molten state at 40°C to 195°C, and injecting nitrogen or carbon dioxide gas under high pressure to fill the molten material and gas. The foamed mixture is obtained by mixing the components separately. This mixture is then extruded onto the inner adhesive layer using a foaming extruder to form the foamed layer. The raw material for the outer skin layer is added to the outer skin extruder and heated to 120℃~230℃ to melt and mix with the second molten material. This second molten material is then extruded onto the foamed layer using the outer skin extruder to form the outer skin layer. Pressure release treatment is then performed to allow the foamed layer cells to grow. Subsequently, the mixture is cooled and solidified in a hot water bath at 35℃~38℃, a warm water bath at 28℃~30℃, and a cold water bath at 18℃~20℃ to obtain the polyethylene foamed insulation layer. This three-stage cooling process helps improve the stability of the cells and the insulation performance of the polyethylene foamed insulation layer.

[0087] In some embodiments, the leaky cable processing method further includes pre-stretching the copper strip before the first corrugation to form pre-corrugations. Pre-stretching the copper strip helps eliminate natural curling during subsequent processing, making the copper strip more structurally stable after the first corrugation, reducing deformation during slot cutting, improving the processing accuracy and stability of the slots, and enhancing the consistency and reliability of slot processing.

[0088] In some embodiments, the leaky cable processing method further includes covering at least one surface of the slotted copper strip with a film layer before performing a second corrugation to form fine corrugations. The film layer includes one or both of high-temperature resistant tape and high-temperature resistant coating. By covering the surface of the laser-cut slotted copper strip with a film layer, the film layer can adhere tightly to the copper strip and provide additional support for the edge of the slot, which helps to reduce the elongation of the slot during the subsequent longitudinal drawing process of the copper strip. At the same time, it reduces the shape distortion caused by the slot directly contacting the corrugating device, such as the corrugating rollers, during the second corrugation. The introduction of the film layer not only protects the integrity of the slot edge but also improves the structural stability of the leaky cable, especially when dealing with complex slots such as arc-shaped and closed slots, significantly improving the processing quality and performance of the leaky cable.

[0089] In some embodiments, a wrapping layer is added to the outer conductor before the sheath is extruded onto the outer conductor. The wrapping layer material includes one or more of nonwoven fabric, polyester, and binding yarn. By adding a wrapping layer to the outer conductor before extruding the sheath onto the extruder, the outer conductor can obtain better tensile strength and bending resistance, reduce the risk of slot torsion after longitudinal wrapping, reduce the risk of slot spacing and pitch instability caused by pull-out, and reduce the risk of sharp slot edges piercing the sheath.

[0090] In some embodiments, the pre-rolled texture type is an arc pattern or a diagonal pattern. Pre-rolling with an arc or diagonal pattern effectively releases the internal stress of the copper strip, reducing the risk of material deformation during subsequent laser cutting, such as warping, stretching, or collapse, thereby ensuring the consistency and accuracy of the slots. An arc pattern is preferred, as the smooth texture helps reduce the risk of stress concentration during cutting caused by sharp patterns.

[0091] In some embodiments, pre-rolled lines are arranged sequentially at intervals, and a finishing line is arranged between two adjacent pre-rolled lines. Any adjacent pre-rolled lines and finishing lines are connected end to end to form a continuous pattern and improve bending performance.

[0092] In some embodiments, the inner conductor is selected from one of a smooth copper-clad aluminum tube, a smooth copper tube, a corrugated copper-clad aluminum tube, or a corrugated copper tube. Using the aforementioned smooth or pre-corrugated copper-clad aluminum tube or copper tube as the inner conductor not only provides good electrical conductivity but also enhances the mechanical strength and durability of the finished leaky cable. Preferably, the inner conductor is selected from one of a corrugated copper-clad aluminum tube or a corrugated copper tube. For scenarios requiring frequent bending or bearing large external forces, the use of a corrugated inner conductor can improve the bending radius and fatigue resistance of the leaky cable.

[0093] In some embodiments, before the laser cutting device cuts the copper strip with pre-rolled texture to form slots, the leaky cable processing method further includes: obtaining the position of the texture nodes of the pre-rolled texture; establishing a three-dimensional reference coordinate system based on the position of the texture nodes; and determining the cutting path and preset cutting start point of each slot based on the three-dimensional reference coordinate system and slot parameters. The laser cutting device cutting the copper strip with pre-rolled texture to form slots includes: the laser cutting device cutting the copper strip with pre-rolled texture to form slots according to the cutting path and preset cutting start point of each slot; after completing the cutting of a specific number of slots and before cutting the next slot, obtaining the position of the texture node corresponding to the actual cutting start point of the next slot; when the deviation between the position of the texture node corresponding to the actual cutting start point of the next slot and the position of the texture node corresponding to its preset cutting start point is greater than a first preset value, re-determining the cutting path and preset cutting start point of the remaining slots to be cut; and the laser cutting device cutting the copper strip with pre-rolled texture to form the remaining slots according to the preset cutting start point and cutting path of the remaining slots.

[0094] Based on the technical solution of this embodiment, the pre-rolled groove nodes are used as positioning references, effectively reducing cutting deviations and improving the consistency of slots. Furthermore, by using the pre-rolled grooves as a positioning reference to establish a three-dimensional reference coordinate system, and through position deviation feedback, the cutting starting point is adjusted in a timely manner, ensuring that the laser cutting device can accurately cut at the predetermined position. This improves cutting accuracy, reduces slot size and position errors caused by copper strip offset, and improves the consistency of slot pitch and spacing, thereby enhancing the radiation and bending performance of the leaky cable.

[0095] The definition of a texture node is as follows: The arc or diagonal patterns on the copper strip are not continuous straight lines, but rather composed of "protruding vertices," "recessed low points," or "pattern transitions." These distinctive, fixed-position points are called "texture nodes." Before laser cutting, the relative positions of the texture nodes are very stable; for example, the distance between two adjacent arc vertices is fixed. This is equivalent to creating a natural scale on the copper strip, allowing the establishment of a three-dimensional reference coordinate system based on the positions of each texture node.

[0096] The slot parameters are determined according to product requirements, including pitch, spacing, length, width, and tilt angle. Based on a three-dimensional reference coordinate system and these parameters, the cutting path and preset cutting start point for each slot can be determined. For example, the preset cutting start point and cutting path are calculated based on the three-dimensional reference coordinate system and slot parameters to align the slot center with the vertex of the arc pattern. Alternatively, the preset cutting start point and cutting path are calculated based on the three-dimensional reference coordinate system and slot parameters to ensure that the distance between the slot edge and the protruding vertex is greater than a specific distance, thus pre-setting the cutting position of the slot (including the cutting start point and cutting path) to avoid the protruding areas of the rolled pattern and prevent uneven slot depth due to uneven texture during cutting. Therefore, the preset cutting start point and cutting path for each slot can be determined based on the position of the pre-rolled pattern nodes, the slot center position, the slot edge position, and other slot parameters in the three-dimensional reference coordinate system.

[0097] In some embodiments, during the process of the laser cutting device cutting a copper strip with pre-rolled grooves to form various slots, copper waste generated during cutting is collected in order to remove metal shavings, fumes and other by-products generated during the laser cutting process, improve the cleanliness of the production environment and the quality of the cable, reduce the impact of copper waste on subsequent processing processes, and improve the consistency of leaky cable processing.

[0098] In some embodiments, the step of extruding a sheath onto the outer conductor includes adding sheath material into a first extruder and heating it to 120°C to 230°C to obtain a molten sheath material, extruding the molten sheath material onto the outer conductor through the first extruder, and then cooling and molding it in a cold water bath to obtain the sheath.

[0099] like Figure 1 As shown, according to a second aspect of the present invention, a leaky cable processing system is provided, comprising: an insulated cable core feeding device, a cable core pulling device, a tape feeding device 1, a pre-texturing device 3, a laser cutting device 4, a fine texturing device 5, a longitudinal wrapping die 9, and a first extruder 10.

[0100] The insulated cable core release device is used to release the insulated cable core;

[0101] The cable core pulling device is used to pull the released insulated cable core so that the insulated cable core passes sequentially through the longitudinal wrapping mold 9 and the first extruder 10; the insulated cable core includes an inner conductor and an insulation layer covering the inner conductor;

[0102] The tape-releasing device 1 is used to release the copper tape;

[0103] The pre-rolling device 3 is used to perform the first rolling on the released copper strip to form pre-rolled patterns, so as to obtain a copper strip with pre-rolled patterns;

[0104] The laser cutting device 4 is used to cut a copper strip with pre-rolled patterns to form several slots, so as to obtain a slotted copper strip.

[0105] The fine rolling device 5 is used to perform a second rolling process on the slotted copper strip to form fine rolling patterns, so as to obtain a copper strip with fine rolling patterns.

[0106] The longitudinal wrapping die 9 is used to longitudinally wrap copper strip with fine rolled texture onto the insulated cable core to form the outer conductor;

[0107] The first extruder 10 is used to extrude a sheath onto the outer conductor to obtain a leaky cable.

[0108] Based on the leaky cable processing system of this invention, a process flow of "pre-rolling grooves - laser cutting slots - fine rolling grooves" can be realized, thereby improving the consistency and precision of the slots in the outer conductor of the leaky cable, and thus enhancing the radiation and bending performance of the leaky cable. The pre-rolling groove device 3 in the system first pre-rolls the copper strip to form pre-rolled grooves. This step helps release the internal stress of the copper strip, providing a stable material basis for subsequent processes. The laser cutting device 4 then performs non-contact cutting on the copper strip with pre-rolled grooves to form precise slots. The high precision and flexibility of laser cutting ensure the consistency of the slot shape and size, avoiding the deformation problems caused by mechanical impact in traditional punching processes. The fine rolling groove device 5 performs deep rolling grooves on the slotted copper strip after laser cutting to form fine rolling grooves. During this process, since the copper strip has formed a stable structure in the pre-rolling groove stage, the fine rolling grooves will not damage the slots, while ensuring the required depth of grooves for the leaky cable, thus improving the bending performance of the leaky cable. The longitudinal wrapping die 9 tightly wraps the copper strip with fine rolled texture onto the insulated cable core to form the outer conductor, while the extruder extrudes a sheath onto the outer conductor, ultimately forming a leaky cable.

[0109] In some embodiments, the tape feeding device 1 employs a servo tape feeding machine with an integrated tension controller, specifically, its tension range is 0.3N to 0.8N, in order to stably release the copper tape and reduce the deviation of subsequent rolling and cutting caused by tension fluctuations.

[0110] In some embodiments, the leaky cable processing system further includes a temperature control system for controlling the temperature of the embossed area in the first embossing, the temperature of the cutting area, and the temperature of the embossed area in the second embossing. The temperature control system helps improve the accuracy of slot and texture processing, and precise temperature control reduces copper strip deformation caused by temperature changes, further improving the processing quality of the leaky cable and enhancing slot consistency.

[0111] In some preferred embodiments, the temperature control system includes a first thermostatic enclosure 12, a second thermostatic enclosure 13, and a third thermostatic enclosure 14. The pre-rolling device 3 is located inside the first thermostatic enclosure 12, the laser cutting device 4 is located inside the second thermostatic enclosure 13, and the finishing rolling device 5 is located inside the third thermostatic enclosure 14. The pre-rolling device 3, located inside the first thermostatic enclosure 12, ensures that the pre-rolling process is carried out in a medium-temperature environment, optimizing the plasticity of the copper strip and effectively releasing stress, thereby guaranteeing the quality of the pre-rolling and avoiding slot deformation caused by internal stress in the copper strip during subsequent processing. The laser cutting device 4, placed inside the second thermostatic enclosure 13, helps to avoid localized heating of the copper strip during laser cutting by maintaining a lower temperature, reducing deformation of the slot due to thermal expansion and contraction, and thus improving the dimensional accuracy and consistency of the slot. The fine rolling device 5 is placed inside the third constant temperature chamber 14, which helps to improve the structural stability of the copper strip during the secondary rolling process, reduce the problem of changes in copper strip properties caused by temperature fluctuations, so that the depth of the fine rolling is more controllable, and ultimately achieves the precise formation of deep grooves, thereby improving the consistency of the grooves and improving the bending performance of the leaky cable.

[0112] The first thermostatic enclosure 12, the second thermostatic enclosure 3, and the third thermostatic enclosure 14 can each utilize existing thermostatic enclosure products to achieve precise temperature control. In some embodiments, the first thermostatic enclosure 12 includes an insulating shell, a heater, a cooler, and a temperature controller. The insulating shell is made of a high-insulation-performance material. The heater and cooler are disposed within the insulating shell. The temperature controller includes a temperature sensor and a processor. The temperature sensor monitors the temperature data of the internal area of ​​the insulating shell in real time and sends it to the processor. The processor adjusts the operating state of the heater and cooler based on the temperature data sent by the temperature sensor to control the temperature of the first rolling zone. The insulating shell is made of a high-insulation-performance material to reduce the influence of the external ambient temperature on the internal temperature. The heater is embedded in the inner wall of the insulating shell. By adjusting the power of the heater, the temperature of the copper strip is raised to a set medium-temperature range before entering the pre-rolling, laser cutting, and finishing rolling zones, thereby enhancing the plasticity of the metal strip and reducing stress accumulation during processing. The heater can be a resistance wire or an infrared heating lamp, including but not limited to the above-described structure. The cooler is also integrated into the insulation shell and works in conjunction with the heater. It can respond quickly to temperature changes. Through the rapid cooling effect of the cooler, it ensures that the temperature of the metal strip can be quickly reduced to the target medium temperature range after laser cutting. The cooling methods of the cooler include water cooling, air cooling or liquid nitrogen cooling, including but not limited to the above methods.

[0113] In some specific embodiments, the second thermostatic cover 13 may adopt the same structure as the first thermostatic cover 12 described above, in order to control the temperature of the cutting area. The third thermostatic cover 14 may adopt the same structure as the first thermostatic cover 12 described above, in order to control the temperature of the embossed area of ​​the second embossing.

[0114] In some embodiments, the leaky cable processing system further includes a speed feedback unit, which includes a first speed sensor, a second speed sensor, a third speed sensor, a fourth speed sensor, a fifth speed sensor, and a control module. The first speed sensor is used to detect the moving speed of the pre-grooved copper strip at the inlet end of the laser cutting device 4 and send it to the control module. The second speed sensor is used to detect the moving speed of the copper strip at the inlet end of the pre-grooved device 3 and send it to the control module. The third speed sensor is used to detect the moving speed of the grooved copper strip at the inlet end of the fine-grooved device 5 and send it to the control module. The fourth speed sensor is used to detect the speed of the insulated cable core released by the wire feeding device and send it to the control module. The fifth speed sensor is used to detect the speed of the copper strip released by the wire feeding device 1 and send it to the control module.

[0115] When the error between the moving speed of the copper strip at the inlet end of the pre-rolled strip device 3 and the moving speed of the copper strip with pre-rolled strip at the inlet end of the laser cutting device 4 is greater than the second preset value, the control module controls the pre-rolled strip device 3 to adjust the moving speed of the copper strip at the inlet end of the pre-rolled strip device 3 to be the same as the moving speed of the copper strip with pre-rolled strip at the inlet end of the laser cutting device 4.

[0116] When the error between the moving speed of the copper strip after slotting at the inlet end of the fine-rolling device 5 and the moving speed of the copper strip with pre-rolled patterns at the inlet end of the laser cutting device 4 is greater than the third preset value, the control module controls the fine-rolling device 5 to adjust the moving speed of the copper strip after slotting at the inlet end of the fine-rolling device 5 to be the same as the moving speed of the copper strip with pre-rolled patterns at the inlet end of the laser cutting device 4.

[0117] When the error between the speed of the insulated cable core released by the insulated cable core release device and the moving speed of the copper strip with pre-rolled texture at the inlet end of the laser cutting device 4 is greater than the fourth preset value, the control module controls the insulated cable core release device to adjust the speed of the insulated cable core released by the insulated cable core release device to make it the same as the moving speed of the copper strip with pre-rolled texture at the inlet end of the laser cutting device 4.

[0118] When the error between the speed of the copper strip released by the feeding device 1 and the moving speed of the pre-rolled copper strip at the inlet end of the laser cutting device 4 is greater than the fifth preset value, the control module controls the feeding device 1 to adjust the speed of the released copper strip to be the same as the moving speed of the pre-rolled copper strip at the inlet end of the laser cutting device 4.

[0119] Through the aforementioned speed feedback unit, a "master-slave linkage" control mode is adopted, with the traction speed of the laser cutting device 4 as the master speed and the speeds of the pre-rolling device 3, the fine rolling device 5, the tape feeding device 1, and the insulated cable core feeding device as slave speeds. This effectively reduces pitch offset caused by speed mismatch, ensures precise alignment of the slots and patterns, and thus improves the overall processing accuracy and performance stability of the leaky cable. Specifically, the first, second, third, fourth, and fifth speed sensors can each be laser velocimeters to accurately detect the moving speed of the copper strip.

[0120] In some preferred embodiments, the pre-texturing device includes a first infeed traction device 31, a first outfeed traction device 32, two first texturing rollers 33, and a first controller; the laser cutting device 4 includes a second infeed traction device 41, a second outfeed traction device 42, a laser 43, and a second controller; the finishing texturing device 5 includes a third infeed traction device 51, a third outfeed traction device 52, two second texturing rollers 53, and a third controller; the two first texturing rollers 33 are arranged opposite to each other and located between the first infeed traction device 31 and the first outfeed traction device 32, and the laser 43 is located at... Between the second infeed traction device 41 and the second outfeed traction device 42; two second corrugated rollers 53 are arranged opposite each other and located between the third infeed traction device 51 and the third outfeed traction device 52; the infeed end of the first infeed traction device 31 is located close to the outfeed end of the unloading device 1, and the outfeed end of the first outfeed traction device 32 is located close to the infeed end of the second infeed traction device 41; the outfeed end of the second outfeed traction device 42 is located close to the infeed end of the third infeed traction device 51, and the outfeed end of the third outfeed traction device 52 is located close to the infeed end of the longitudinal wrapping mold 9.

[0121] The first controller is used to adjust the rubbing pressure of the two first rubbing rollers 33, and to receive a first control signal from the control module and adjust the traction speed of the first infeed traction device 31 and the traction speed of the first outfeed traction device 32 based on the first control signal when the error between the moving speed of the copper strip at the infeed end of the pre-rubbing device 3 and the moving speed of the pre-rubbing copper strip at the infeed end of the laser cutting device 4 is greater than a second preset value, so that the moving speed of the copper strip at the infeed end of the pre-rubbing device 3 is the same as the moving speed of the pre-rubbing copper strip at the infeed end of the laser cutting device 4.

[0122] The second controller is used to control the laser 43 to cut the copper strip with pre-rolled patterns to form various slots;

[0123] The third controller is used to adjust the rolling pressure of the two second rolling rollers 53, and to receive a third control signal from the control module and adjust the traction speed of the third inlet traction device 51 and the third outlet traction device 52 based on the third control signal when the error between the moving speed of the copper strip after slotting at the inlet end of the fine rolling device 5 and the moving speed of the copper strip with pre-rolled texture at the inlet end of the laser cutting device 4 is greater than a third preset value, so that the moving speed of the copper strip after slotting at the inlet end of the fine rolling device 5 is the same as the moving speed of the copper strip with pre-rolled texture at the inlet end of the laser cutting device 4.

[0124] The pre-rolling device 3, laser cutting device 4, and fine rolling device 5 all include a strip feeding traction device and a strip exit traction device to provide power for the movement of the copper strip. At the same time, in coordination with the speed feedback unit mentioned above, the copper strip speed feedback and automatic speed adjustment are realized, which improves the automation level of the leaky cable processing process, helps to simplify the operation process, reduce human intervention, and improve production efficiency and economic benefits. Moreover, by precisely controlling the movement speed of the copper strip at each stage and making it consistent, the material deformation caused by speed differences is effectively reduced, and the processing quality of the leaky cable is improved.

[0125] In some embodiments, the pre-texturing device 3 and the finishing texturing device 5 can each be existing precision texturing machines. Precision texturing machines are used to form fine textures on the surface of metal strips (such as copper strips) and are widely used in cable manufacturing, metal packaging, decorative materials, and other fields. In precision texturing machines, the surface of the texturing rollers can be designed with various textures, such as straight lines, arcs, and diagonal lines, to meet different processing requirements.

[0126] In some specific embodiments, the laser cutting device 4 remains stationary in the direction of movement of the copper strip and moves perpendicular to the direction of movement of the copper strip to cut the copper strip with pre-rolled grooves to form various slots. Specifically, existing lasers can be used to cut the slots in the moving copper strip, and conventional lasers on the market can already meet the requirements of this invention for cutting slots in moving copper strips. For example, the laser can be a solid-state laser such as a 365nm solid-state laser, a 1064nm solid-state laser, a fiber laser, a gas laser such as a carbon dioxide laser, a copper vapor laser, or a semiconductor laser. The preferred laser power is 800W to 1200W, and the cutting speed is 300cm / min to 600cm / min. When the copper strip thickness is greater than or equal to 0.05mm and less than 0.15mm, the laser power is 800W to 900W. When the copper strip thickness is 0.15mm to 0.3mm, the laser power is 1100W to 1200W. This is beneficial for stable cutting, reducing thermal stretching of the slot and copper strip deformation interference during laser cutting, and reducing slot deformation, pitch deviation, and spacing deviation.

[0127] In some specific embodiments, the insulated cable core laying device, the cable core pulling device, the tape laying device 1, and the longitudinal wrapping mold 9 can each adopt existing devices, which will not be described in detail here.

[0128] In some embodiments, the leaky cable processing system further includes a positioning calibration unit, which includes a camera device 15, an image analysis and processing module, and a control module. Before the laser cutting device 4 cuts the copper strip with pre-rolled patterns to form slots, the camera device 15 acquires an image of the pre-rolled patterns on the copper strip and sends it to the image analysis and processing module. The image analysis and processing module acquires the position of the pattern nodes based on the image of the pre-rolled patterns, establishes a three-dimensional reference coordinate system based on the position of the pattern nodes, determines the cutting path of each slot and its preset cutting start point based on the three-dimensional reference coordinate system and the slot parameters, and sends it to the control module. The control module controls the laser cutting device 4 to cut the copper strip with pre-rolled patterns to form slots according to the cutting path of each slot and its preset cutting start point. After each specific number of slots is cut and before the next slot is cut, the camera device 15 acquires the pre-rolled pattern corresponding to the actual cutting start point of the next slot and sends it to the image analysis and processing module. The image analysis and processing module... The processing module obtains the position of the texture node corresponding to the actual cutting start point of the next slot based on the pre-rolled texture and sends it to the control module. When the position of the texture node corresponding to the actual cutting start point of the next slot deviates from the position of the texture node corresponding to its preset cutting start point by more than a first preset value, the control module controls the camera device 15 to acquire the image of the remaining pre-rolled texture of the copper strip with pre-rolled texture and sends it to the image analysis and processing module. The image analysis and processing module obtains the position of the texture node of the remaining pre-rolled texture based on the image of the remaining pre-rolled texture, establishes a three-dimensional calibration coordinate system based on the position of the texture node of the remaining pre-rolled texture, and redetermines the cutting path and its preset cutting start point of each remaining slot to be cut based on the three-dimensional calibration coordinate system and the slot parameters, and sends it to the control module. The control module controls the laser cutting device 4 to cut the copper strip with pre-rolled texture to form the remaining slots to be cut according to the cutting path and its preset cutting start point of each remaining slot. Using the pre-rolled groove as a positioning reference, a three-dimensional reference coordinate system is established. Through real-time monitoring and position deviation feedback, the cutting starting point and cutting path of the slot are adjusted in a timely manner to ensure that the laser cutting device 4 can accurately cut at the predetermined position, thereby improving the consistency of the slot pitch and spacing, and thus improving the radiation performance and bending performance of the leaky cable.

[0129] In some embodiments, the leaky cable processing system further includes an insulated cable core preparation device, which comprises an inner conductor laying device 6, a straightening pretreatment device 7, and an insulation layer extrusion device 8. The inner conductor laying device 6 is used to lay out the inner conductor; the straightening pretreatment device 7 is used to perform straightening pretreatment on the laid-out inner conductor to obtain a straightened pretreated inner conductor; and the insulation layer extrusion device 8 is used to extrude an insulation layer onto the straightened pretreated inner conductor to form an insulated cable core. The straightening pretreatment device 7 helps reduce bending defects and surface impurities inside the inner conductor, improving stability and mechanical properties of the leaky cable in subsequent processing. The insulation layer extrusion device 8 extrudes an insulation layer onto the inner conductor to form an insulated cable core, providing a good signal transmission environment for the leaky cable.

[0130] In some specific embodiments, the straightening pretreatment device 7 includes a plurality of straightening wheels arranged sequentially along a straight line parallel to the inner conductor. Specifically, the straightening pretreatment device 7 can be an existing metal wire straightening device, which will not be described in detail here.

[0131] In some embodiments, the leaky cable processing system further includes a pre-stretching device 2 for pre-stretching the copper strip before the first corrugation to form pre-corrugations. Pre-stretching the copper strip using the pre-stretching device 2 helps eliminate natural curling of the copper strip during subsequent processing, making the copper strip structurally more stable after the first corrugation, reducing deformation during slot cutting, improving the processing accuracy and stability of the slots, and enhancing the consistency and reliability of slot processing. Specifically, the pre-stretching device 2 can employ servo rollers and set a constant tension force; preferably, the tension force ranges from 0.5N to 1N to improve the straightness and structural stability of the copper strip.

[0132] In some embodiments, the leaky cable processing system further includes a cable winding device 11 for winding and storing the leaky cable. In some specific embodiments, the cable winding device 11 can use existing cable winding device products to wind and store the leaky cable, while improving the dimensional accuracy and structural integrity of the leaky cable during the winding process through precise speed control and tension adjustment.

[0133] In some embodiments, the leaky cable processing system further includes a waste collection device for collecting copper waste generated during cutting. In some specific embodiments, the waste collection device includes a blowing nozzle 16, an air compressor, and a dust collection device. The blowing nozzle 16 is located close to the laser cutting device 4 and is used to generate a blowing airflow to blow away the copper waste generated during cutting. The air compressor is connected to the blowing nozzle through a pipe. The dust collection device is located below the laser cutting device 4 and is used to capture the copper waste carried by the blowing airflow after blowing.

[0134] The present application will be further described in detail below with reference to specific embodiments, which should not be construed as limiting the scope of protection claimed in the present application.

[0135] Example 1

[0136] A method for processing leaky cable includes the following steps:

[0137] Step 1: Perform straightening pretreatment on the inner conductor to obtain the straightened inner conductor. Then, extrude an insulation layer onto the straightened inner conductor to form an insulated cable core.

[0138] Step 2: After pre-stretching the copper strip, the copper strip is first rolled to form pre-rolled grooves, resulting in a copper strip with pre-rolled grooves.

[0139] Step 3: The laser cutting device cuts the copper strip with pre-rolled patterns to form several slots, resulting in the slotted copper strip.

[0140] Step four: The slotted copper strip is then subjected to a second rolling process to form fine rolling patterns, resulting in a copper strip with fine rolling patterns.

[0141] Step 5: Longitudinally wrap the finely rolled copper strip onto the insulated cable core to form the outer conductor; the insulated cable core includes an inner conductor and an insulating layer covering the inner conductor;

[0142] Step six: Extrude a sheath onto the outer conductor to obtain the leaky cable.

[0143] The temperature of the first rolling zone is 30℃ and the rolling pressure is 4MPa; the temperature of the cutting zone is 18℃ during the process of cutting to form each slot; the temperature of the second rolling zone is 30℃ and the rolling pressure is 7MPa.

[0144] The copper strip has a thickness of 0.1 mm, a pre-rolled groove depth of 0.8 mm, and a finishing groove depth of 1.2 mm; the pre-rolled groove pitch is 6 mm.

[0145] The first rolling, cutting, second rolling, and copper strip movement are carried out simultaneously, with the copper strip moving at a speed of 14 m / min.

[0146] The laser cutting device uses a 365nm solid-state laser with a power of 850W and a cutting speed of 500cm / min;

[0147] At the same time, the straight-line distance between the position where the copper strip is first rolled and the position where the copper strip with pre-rolled patterns is cut along the center line of the copper strip's movement direction is 2m; the straight-line distance between the position where the copper strip with pre-rolled patterns is cut and the position where the grooved copper strip is second rolled is 2m along the center line of the copper strip's movement direction.

[0148] The pattern type of the pre-rolled pattern and the pattern of the finishing pattern are both arc patterns. The pre-rolled patterns are arranged sequentially at intervals, and a finishing pattern is set between any two adjacent pre-rolled patterns. Any adjacent pre-rolled patterns and finishing patterns are connected end to end.

[0149] The inner conductor is selected from a smooth copper tube; the insulation layer is a polyethylene foam insulation layer, which includes an inner adhesive layer and an intermediate foam layer and an outer skin layer sequentially covering the inner adhesive layer; the inner adhesive layer material is a mixture of low-density polyethylene and an adhesive, with the low-density polyethylene accounting for 75% by weight and the adhesive accounting for 25% by weight; the intermediate foam layer material is a mixture of low-density polyethylene, high-density polyethylene, and a nucleating agent, with the low-density polyethylene, high-density polyethylene, and nucleating agent accounting for 20%, 78%, and 2% by weight, respectively, and a polyethylene nucleating agent is used; the outer skin layer material is high-density polyethylene. The density of the high-density polyethylene used above is 0.945 g / cm³. 3 The density of low-density polyethylene is 0.915 g / cm³. 3 The adhesive includes epoxy resin;

[0150] The design requirements are as follows: the length of the slot (perpendicular to the direction of copper strip movement) is 5.5 mm, the width (parallel to the direction of copper strip movement) is 3.2 mm, the slot pitch is 240 mm, and the slot spacing is 14.4 mm.

[0151] Example 2

[0152] A method for processing leaky cable includes the following steps:

[0153] Step 1: Perform straightening pretreatment on the inner conductor to obtain the straightened inner conductor. Then, extrude an insulation layer onto the straightened inner conductor to form an insulated cable core.

[0154] Step 2: After pre-stretching the copper strip, the copper strip is first rolled to form pre-rolled grooves, resulting in a copper strip with pre-rolled grooves.

[0155] Step 3: The laser cutting device cuts the copper strip with pre-rolled patterns to form several slots, resulting in the slotted copper strip.

[0156] Step four: The slotted copper strip is then subjected to a second rolling process to form fine rolling patterns, resulting in a copper strip with fine rolling patterns.

[0157] Step 5: Longitudinally wrap the finely rolled copper strip onto the insulated cable core to form the outer conductor; the insulated cable core includes an inner conductor and an insulating layer covering the inner conductor;

[0158] Step six: Extrude a sheath onto the outer conductor to obtain the leaky cable.

[0159] The temperature of the first rolling zone is 25℃ and the rolling pressure is 3MPa; the temperature of the cutting zone is 15℃ during the process of cutting to form each slot; the temperature of the second rolling zone is 25℃ and the rolling pressure is 6MPa.

[0160] The copper strip has a thickness of 0.05 mm, a pre-rolled groove depth of 0.3 mm, and a finishing groove depth of 0.15 mm; the pre-rolled groove pitch is 0.5 mm.

[0161] The first rolling, cutting, second rolling, and copper strip movement are carried out simultaneously, with the copper strip moving at a speed of 12 m / min.

[0162] The laser cutting device uses a 365nm solid-state laser with a power of 900W and a cutting speed of 300cm / min.

[0163] At the same time, the straight-line distance between the position where the copper strip is first rolled and the position where the copper strip with pre-rolled patterns is cut along the center line of the copper strip's movement direction is 3m; the straight-line distance between the position where the copper strip with pre-rolled patterns is cut and the position where the grooved copper strip is second rolled is 3m along the center line of the copper strip's movement direction.

[0164] The pattern type of the pre-rolled pattern and the pattern of the finishing pattern are both arc patterns. The pre-rolled patterns are arranged sequentially at intervals, and a finishing pattern is set between any two adjacent pre-rolled patterns. Any adjacent pre-rolled patterns and finishing patterns are connected end to end.

[0165] The inner conductor is selected from a smooth copper tube; the insulation layer is a polyethylene foam insulation layer, which includes an inner adhesive layer and an intermediate foam layer and an outer skin layer sequentially covering the inner adhesive layer; the inner adhesive layer material is a mixture of low-density polyethylene and an adhesive, with the low-density polyethylene accounting for 75% by weight and the adhesive accounting for 25% by weight; the intermediate foam layer material is a mixture of low-density polyethylene, high-density polyethylene, and a nucleating agent, with the low-density polyethylene, high-density polyethylene, and nucleating agent accounting for 20%, 78%, and 2% by weight, respectively, and a polyethylene nucleating agent is used; the outer skin layer material is high-density polyethylene. The density of the high-density polyethylene used above is 0.945 g / cm³. 3 The density of low-density polyethylene is 0.915 g / cm³. 3 The adhesive includes epoxy resin;

[0166] The design requirements are as follows: the length of the slot (perpendicular to the direction of copper strip movement) is 5.5 mm, the width (parallel to the direction of copper strip movement) is 3.2 mm, the slot pitch is 240 mm, and the slot spacing is 14.4 mm.

[0167] Example 3

[0168] A method for processing leaky cable includes the following steps:

[0169] Step 1: Perform straightening pretreatment on the inner conductor to obtain the straightened inner conductor. Then, extrude an insulation layer onto the straightened inner conductor to form an insulated cable core.

[0170] Step 2: After pre-stretching the copper strip, the copper strip is first rolled to form pre-rolled grooves, resulting in a copper strip with pre-rolled grooves.

[0171] Step 3: The laser cutting device cuts the copper strip with pre-rolled patterns to form several slots, resulting in the slotted copper strip.

[0172] Step four: The slotted copper strip is then subjected to a second rolling process to form fine rolling patterns, resulting in a copper strip with fine rolling patterns.

[0173] Step 5: Longitudinally wrap the finely rolled copper strip onto the insulated cable core to form the outer conductor; the insulated cable core includes an inner conductor and an insulating layer covering the inner conductor;

[0174] Step six: Extrude a sheath onto the outer conductor to obtain the leaky cable.

[0175] The temperature of the first rolling zone is 35℃ and the rolling pressure is 6MPa; the temperature of the cutting zone is 20℃ during the process of cutting to form each slot; the temperature of the second rolling zone is 35℃ and the rolling pressure is 12MPa.

[0176] The copper strip has a thickness of 0.3 mm, a pre-rolled groove depth of 1.8 mm, and a finishing groove depth of 3 mm; the pre-rolled groove pitch is 8 mm.

[0177] The first rolling, cutting, second rolling, and copper strip movement are carried out simultaneously, with the copper strip moving at a speed of 15 m / min.

[0178] The laser cutting device uses a 365nm solid-state laser with a power of 1150W and a cutting speed of 600cm / min.

[0179] At the same time, the straight-line distance between the position where the copper strip is first rolled and the position where the copper strip with pre-rolled patterns is cut along the center line of the copper strip's movement direction is 5m; the straight-line distance between the position where the copper strip with pre-rolled patterns is cut and the position where the grooved copper strip is second rolled is 5m along the center line of the copper strip's movement direction.

[0180] The pattern type of the pre-rolled pattern and the pattern of the finishing pattern are both arc patterns. The pre-rolled patterns are arranged sequentially at intervals, and a finishing pattern is set between any two adjacent pre-rolled patterns. Any adjacent pre-rolled patterns and finishing patterns are connected end to end.

[0181] The inner conductor is selected from a smooth copper tube; the insulation layer is a polyethylene foam insulation layer, which includes an inner adhesive layer and an intermediate foam layer and an outer skin layer sequentially covering the inner adhesive layer; the inner adhesive layer material is a mixture of low-density polyethylene and an adhesive, with the low-density polyethylene accounting for 75% by weight and the adhesive accounting for 25% by weight; the intermediate foam layer material is a mixture of low-density polyethylene, high-density polyethylene, and a nucleating agent, with the low-density polyethylene, high-density polyethylene, and nucleating agent accounting for 20%, 78%, and 2% by weight, respectively, and a polyethylene nucleating agent is used; the outer skin layer material is high-density polyethylene. The density of the high-density polyethylene used above is 0.945 g / cm³. 3 The density of low-density polyethylene is 0.915 g / cm³. 3 The adhesive includes epoxy resin;

[0182] The inner conductor is selected from a smooth copper tube;

[0183] The design requirements are as follows: the length of the slot (perpendicular to the direction of copper strip movement) is 5.5 mm, the width (parallel to the direction of copper strip movement) is 3.2 mm, the slot pitch is 240 mm, and the slot spacing is 14.4 mm.

[0184] Example 4

[0185] The only difference between it and Example 1 is that the temperature of the first embossing area is 25°C and the embossing pressure of the first embossing is 3MPa.

[0186] Example 5

[0187] The only difference between it and Example 1 is that the temperature of the first embossing area is 35°C and the embossing pressure of the first embossing is 5MPa.

[0188] Example 6

[0189] The only difference between it and Example 1 is that the temperature of the first embossing zone is 15°C and the embossing pressure of the first embossing is 2MPa.

[0190] Example 7

[0191] The only difference between it and Example 1 is that the temperature of the cut area is 15°C during the process of cutting to form each slot.

[0192] Example 8

[0193] The only difference between it and Example 1 is that the temperature of the cut area is 20°C during the process of cutting to form each slot.

[0194] Example 9

[0195] The only difference between it and Example 1 is that the temperature of the cut area is 25°C during the process of cutting to form each slot.

[0196] Example 10

[0197] The only difference between it and Example 1 is that the depth of the pre-rolled groove is 0.3 mm and the depth of the finish rolled groove is 0.5 mm.

[0198] Example 11

[0199] The only difference between it and Example 1 is that the depth of the pre-rolled groove is 0.9 mm and the depth of the finishing groove is 1.5 mm.

[0200] Example 12

[0201] The only difference between it and Example 1 is that the depth of the pre-rolled groove is 0.1 mm and the depth of the finish rolled groove is 0.3 mm.

[0202] Comparative Example 1

[0203] The only difference between this and Example 1 is that in step two, the copper strip is not pre-stretched and then subjected to the first embossing, while in step three, the laser cutting device directly cuts the pre-stretched copper strip to form several slots, thus obtaining the slotted copper strip.

[0204] Performance testing

[0205] The leaky cables prepared in the examples and comparative examples were subjected to the following tests:

[0206] Slot tolerance testing: The width of the slot is measured using a laser scanning microscope, and the data is recorded. The deviation between the measured width and the design requirement is calculated. The deviations in the slot dimensions are statistically analyzed to obtain the range of slot tolerance.

[0207] Pitch deviation test: The pitch between continuous slots is measured using a 3D vision camera and the data is recorded. The average deviation of the slot pitch is calculated based on each measured pitch and the pitch required by the design, and this deviation is taken as the pitch deviation.

[0208] Spacing deviation test: The spacing between slots is measured using a 3D vision camera and the data is recorded. Based on the measured spacing and the pitch required by the design, the average deviation of the slot spacing is statistically calculated as the spacing deviation.

[0209] The minimum bending radius was tested according to the YD / T 2491-2023 standard.

[0210] A repeated bending test was conducted according to the YD / T 2491-2023 standard, and the voltage standing wave ratio after repeated bending was tested.

[0211] The slot tolerance, pitch deviation, spacing deviation, minimum bending radius test, and voltage standing wave ratio after repeated bending are shown in Table 1.

[0212] Table 1

[0213]

[0214] As shown in Table 1, compared with Comparative Example 1, the leaky cables prepared in Examples 1 to 12 have smaller slot tolerances, pitch deviations, and spacing deviations, which improves the consistency of slots during the processing of leaky cables and can improve communication coverage quality and radiation efficiency.

[0215] Compared to Comparative Example 1, the leaky cables prepared in Examples 1 to 12 have a smaller bending radius and can maintain structural integrity after repeated bending deformation, thereby maintaining a low voltage standing wave ratio and having better bending performance.

[0216] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for processing leaky cable, characterized in that, Includes the following steps: The copper strip is first rolled to form pre-rolled patterns, resulting in a copper strip with pre-rolled patterns. A laser cutting device cuts the copper strip with pre-rolled patterns to form several slots, resulting in a slotted copper strip. The slotted copper strip is then subjected to a second rolling process to form fine rolling patterns, resulting in a copper strip with fine rolling patterns. The copper strip with finely rolled grooves is longitudinally wrapped around the insulated cable core to form an outer conductor; the insulated cable core includes an inner conductor and an insulating layer covering the inner conductor; A sheath is extruded onto the outer conductor to obtain a leaky cable.

2. The leaky cable processing method according to claim 1, characterized in that, The thickness of the copper strip is greater than or equal to 0.05 mm and less than 0.15 mm, the depth of the pre-rolled groove is 0.3 mm to 0.9 mm, and the depth of the finish-rolled groove is 0.5 mm to 1.5 mm. Preferably, the temperature of the embossed area in the first embossing is 25°C to 35°C, and the embossing pressure is 3MPa to 5MPa. Preferably, the temperature of the second rolling zone is 25℃~35℃, and the rolling pressure is 6MPa~9MPa.

3. The leaky cable processing method according to claim 1, characterized in that, The thickness of the copper strip is 0.15mm to 0.3mm, the depth of the pre-rolled grooves is 0.8mm to 1.8mm, and the depth of the finish-rolled grooves is 1.6mm to 3mm. Preferably, the temperature of the embossed area in the first embossing is 25°C to 35°C, and the embossing pressure is 5MPa to 7MPa. Preferably, the temperature of the second rolling zone is 25℃~35℃, and the rolling pressure is 10MPa~15MPa.

4. The leaky cable processing method according to claim 1, characterized in that, During the process of cutting to form each of the slots, the temperature of the cutting area is 15℃~20℃; and / or, The pre-rolled groove pitch is 3mm to 8mm; and / or, The first rolling, the cutting, the second rolling, and the movement of the copper strip are performed synchronously, with the copper strip moving at a speed of 12m / min to 15m / min. Preferably, at the same time, the straight-line distance between the position where the copper strip is subjected to the first rolling and the position where the pre-rolled copper strip is cut is greater than 1m along the centerline direction of the copper strip's movement; the straight-line distance between the position where the pre-rolled copper strip is cut and the position where the slotted copper strip is subjected to the second rolling is greater than 1m along the centerline direction of the copper strip's movement.

5. The leaky cable processing method according to claim 1, characterized in that, The leaky cable processing method further includes: The preparation of the insulated cable core includes the following steps: performing a straightening pretreatment on the inner conductor to obtain a straightened pretreated inner conductor; extruding an insulation layer onto the straightened pretreated inner conductor to form an insulated cable core; and / or, Before the copper strip is subjected to the first rolling to form the pre-rolled grooves, the copper strip is pre-stretched; and / or, Before performing the second rolling process on the slotted copper strip to form the finishing grooves, a film layer is applied to at least one surface of the slotted copper strip. The film layer comprises one or both of high-temperature resistant tape and high-temperature resistant coating; and / or, Before extruding the sheath onto the outer conductor, a wrapping layer is added to the outer conductor, the wrapping layer material including one or more of nonwoven fabric, polyester, and yarn.

6. The leaky cable processing method according to claim 1, characterized in that, The pre-rolled pattern is either an arc pattern or a diagonal pattern; and / or, The pre-rolled grooves are arranged sequentially at intervals, and a finishing groove is arranged between any two adjacent pre-rolled grooves; any adjacent pre-rolled grooves and finishing grooves are connected end-to-end; and / or, The inner conductor is selected from one of the following: smooth copper-clad aluminum tube, smooth copper tube, corrugated copper-clad aluminum tube, and corrugated copper tube.

7. The leaky cable processing method according to any one of claims 1 to 6, characterized in that, Before the laser cutting device cuts the copper strip with pre-rolled texture to form each of the slots, the leaky cable processing method further includes obtaining the position of the texture node of the pre-rolled texture, establishing a three-dimensional reference coordinate system based on the position of the texture node, and determining the cutting path and preset cutting starting point of each slot based on the three-dimensional reference coordinate system and the slot parameters. The laser cutting device cuts the copper strip with pre-rolled texture to form each slot by means of: the laser cutting device cutting the copper strip with pre-rolled texture to form each slot according to the cutting path of each slot and its preset cutting start point; after completing the cutting of a certain number of slots and before cutting the next slot, obtaining the position of the texture node corresponding to the actual cutting start point of the next slot; when the deviation between the position of the texture node corresponding to the actual cutting start point of the next slot and the position of the texture node corresponding to the preset cutting start point is greater than a first preset value, re-determining the cutting path and the preset cutting start point of the remaining slots to be cut; and the laser cutting device cutting the copper strip with pre-rolled texture to form the remaining slots according to the preset cutting start point and the cutting path of the remaining slots.

8. A leaky cable processing system, characterized in that, include: Insulated cable core laying device, cable core pulling device, tape laying device (1), pre-rolling device (3), laser cutting device (4), fine rolling device (5), longitudinal wrapping mold (9), and first extruder (10): The insulated cable core release device is used to release the insulated cable core; The cable core traction device is used to pull the released insulated cable core so that the insulated cable core passes sequentially through the longitudinal wrapping mold (9) and the first extruder (10); the insulated cable core includes an inner conductor and an insulating layer covering the inner conductor; The tape-releasing device (1) is used to release the copper tape; The pre-rolling device (3) is used to perform the first rolling on the released copper strip to form pre-rolled patterns, so as to obtain a copper strip with pre-rolled patterns; The laser cutting device (4) is used to cut the copper strip with pre-rolled patterns to form several slots, so as to obtain the slotted copper strip. The fine rolling device (5) is used to perform a second rolling process on the slotted copper strip to form fine rolling patterns, so as to obtain a copper strip with fine rolling patterns. The longitudinal wrapping mold (9) is used to longitudinally wrap the copper strip with fine rolled patterns onto the insulated cable core to form an outer conductor; The first extruder (10) is used to extrude a sheath onto the outer conductor to obtain a leaky cable.

9. The leaky cable processing system according to claim 8, characterized in that, The leaky cable processing system also includes a temperature control system, which is used to control the temperature of the first rolled area, the temperature of the cutting area, and the temperature of the second rolled area, respectively. Preferably, the temperature control system includes a first constant temperature cover (12), a second constant temperature cover (13) and a third constant temperature cover (14), the pre-rolling device (3) is located inside the first constant temperature cover, the laser cutting device (4) is located inside the second constant temperature cover, and the fine rolling device (5) is located inside the third constant temperature cover.

10. The leaky cable processing system according to claim 9 or 9, characterized in that, The leaky cable processing system also includes: A speed feedback unit, comprising a first speed sensor, a second speed sensor, a third speed sensor, a fourth speed sensor, a fifth speed sensor, and a control module; The first speed sensor is used to detect the moving speed of the pre-rolled copper strip at the inlet end of the laser cutting device (4) and send it to the control module respectively; the second speed sensor is used to detect the moving speed of the copper strip at the inlet end of the pre-rolled device (3) and send it to the control module; the third speed sensor is used to detect the moving speed of the slotted copper strip at the inlet end of the fine rolling device (5) and send it to the control module; the fourth speed sensor is used to detect the speed of the insulated cable core released by the wire feeding device and send it to the control module; the fifth speed sensor is used to detect the speed of the copper strip released by the wire feeding device (1) and send it to the control module respectively. When the error between the moving speed of the copper strip at the inlet end of the pre-rolled strip device (3) and the moving speed of the copper strip with pre-rolled strip at the inlet end of the laser cutting device (4) is greater than a second preset value, the control module controls the pre-rolled strip device (3) to adjust the moving speed of the copper strip at the inlet end of the pre-rolled strip device (3) to be the same as the moving speed of the copper strip with pre-rolled strip at the inlet end of the laser cutting device (4). When the error between the moving speed of the grooved copper strip at the inlet end of the fine rolling device (5) and the moving speed of the pre-rolled copper strip at the inlet end of the laser cutting device (4) is greater than a third preset value, the control module controls the fine rolling device (5) to adjust the moving speed of the grooved copper strip at the inlet end of the fine rolling device (5) to be the same as the moving speed of the pre-rolled copper strip at the inlet end of the laser cutting device (4). When the error between the speed of the insulated cable core released by the insulated cable core release device and the moving speed of the copper strip with pre-rolled texture at the inlet end of the laser cutting device (4) is greater than a fourth preset value, the control module controls the insulated cable core release device to adjust the speed of the insulated cable core released by the insulated cable core release device to be the same as the moving speed of the copper strip with pre-rolled texture at the inlet end of the laser cutting device (4). When the error between the speed of the copper strip released by the tape feeding device (1) and the moving speed of the copper strip with pre-rolled texture at the tape inlet end of the laser cutting device (4) is greater than a fifth preset value, the control module controls the tape feeding device (1) to adjust the speed of the released copper strip to be the same as the moving speed of the copper strip with pre-rolled texture at the tape inlet end of the laser cutting device (4). And / or, The positioning calibration unit includes a camera device (15), an image analysis and processing module, and a control module. Before the laser cutting device (4) cuts the copper strip with pre-rolled patterns to form each slot, the camera device (15) acquires an image of the pre-rolled patterns of the copper strip and sends it to the image analysis and processing module. The image analysis and processing module acquires the position of the pattern nodes based on the image of the pre-rolled patterns, establishes a three-dimensional reference coordinate system based on the position of the pattern nodes, determines the cutting path and preset cutting start point of each slot based on the three-dimensional reference coordinate system and the slot parameters, and sends it to the control module. The control module controls the laser cutting device (4) to cut the copper strip with pre-rolled patterns to form each slot according to the cutting path and preset cutting start point of each slot. After a certain number of slots are cut and before the next slot is cut, the camera device (15) acquires the pre-rolled pattern corresponding to the actual cutting start point of the next slot and sends it to the image analysis and processing module; the image analysis and processing module acquires the position of the texture node corresponding to the actual cutting start point of the next slot based on the pre-rolled pattern and sends it to the control module; when the position of the texture node corresponding to the actual cutting start point of the next slot deviates from the position of the texture node corresponding to the preset cutting start point by a first preset value, the control module controls the camera device. (15) Obtain an image of the remaining pre-rolled texture of the copper strip with pre-rolled texture and send it to the image analysis and processing module; the image analysis and processing module obtains the position of the texture node of the remaining pre-rolled texture based on the image of the remaining pre-rolled texture, establishes a three-dimensional calibration coordinate system based on the position of the texture node of the remaining pre-rolled texture, and redetermines the cutting path and preset cutting start point of each remaining slot based on the three-dimensional calibration coordinate system and the slot parameters and sends it to the control module; the control module controls the laser cutting device (4) to cut the copper strip with pre-rolled texture to form the remaining slots according to the cutting path and preset cutting start point of each remaining slot; And / or, An insulated cable core preparation apparatus, comprising an inner conductor laying device (6), a straightening pretreatment device (7), and an insulation layer extrusion device (8): the inner conductor laying device (6) is used to lay out the inner conductor; the straightening pretreatment device (7) is used to perform straightening pretreatment on the laid-out inner conductor to obtain a straightened pretreated inner conductor; the insulation layer extrusion device (8) is used to extrude an insulation layer onto the straightened pretreated inner conductor to form the insulated cable core; And / or, The pre-stretching device (2) is used to pre-stretch the copper strip before the first rolling process to form pre-rolled grooves. And / or, Cable winding device (11) for winding and storing the leaky cable.

Images