Manufacturing method of segmented molded line copper conductor, copper conductor and cable

Abstract

The invention discloses a method for manufacturing a split molded line copper conductor, which comprises the following steps of: 1, wire drawing processing: carrying out stretching plasticity on copper metal through a wire drawing die to form a copper wire with a circular cross section; 2, shaping treatment is conducted, specifically, the copper wires in the step 1 are subjected to drawing treatment through a molded wire mold to form molded wire units with special-shaped cross sections; and step 3, stranding and forming: stranding the plurality of molded wire units in the step 2 into a circular copper conductor through a circular bunch stranding die. According to the invention, the copper metal is firstly subjected to wire drawing and drawing treatment to form the molded wire units with special-shaped cross sections, and finally, the special-shaped molded wire units are stranded to form the copper conductor, so that inevitable gaps during stranding of circular monofilaments are eliminated to the greatest extent, the effective utilization rate of the cross sections is improved, and magnetic field interference among the conductors is reduced.

Description

Technical Field

[0001] This invention belongs to the field of wire and cable manufacturing technology, specifically relating to a method for manufacturing a segmented copper conductor, the copper conductor, and the cable. Background Technology

[0002] With the growth in electricity demand and technological advancements, higher demands are being placed on the conductor performance and economic cost of electric wires and cables. As the core component of a cable, the conductor's performance is crucial. Currently, copper conductors in power cables generally employ a circular monofilament stranded structure. This structure has inherent defects; significant gaps exist when multiple circular monofilaments are stranded, resulting in a low conductor fill rate, typically only around 78%. This not only increases the amount of insulation and sheathing materials used but also leads to a larger cable outer diameter, occupying more space, increasing installation difficulty, and affecting the conductor's conductivity and mechanical properties.

[0003] To effectively reduce cable dimensions, conductor cross-sectional area, and overall cable cost, most manufacturers use compacted circular, fan-shaped, or tile-shaped compression methods to optimize the copper conductor dimensions. However, excessive compression can lead to hardening and severe deformation of the copper filaments, resulting in a stiffer copper conductor and a larger actual conductor cross-sectional area. Summary of the Invention

[0004] To address at least one technical problem of the prior art, the present invention provides a method for manufacturing a segmented copper conductor, a copper conductor, and a cable.

[0005] To achieve the above-mentioned objectives, the technical solution adopted by this invention is: a method for manufacturing a segmented copper conductor, comprising the following steps: Step 1, wire drawing process: The copper metal is stretched and plasticized using a wire drawing die to form a copper wire with a circular cross-section; Step 2, shaping process: The copper wire from Step 1 is drawn through a wire drawing die to form a wire unit with an irregular cross-section; Step 3, stranding and shaping: The multiple wire units from Step 2 are stranded into a circular copper conductor using a circular stranding die.

[0006] In some embodiments, the wire drawing die includes a die sleeve and a stranded die core mounted within the die sleeve, the stranded die core having a die hole extending through the stranded die core along an axial direction.

[0007] In some embodiments, the die hole has, in sequence along the axial extension direction, an inlet lubrication zone, a working zone, a sizing zone, and an outlet zone.

[0008] In some embodiments, the inlet end of the inlet lubrication zone is arc-shaped.

[0009] In some embodiments, the diameter of the working area gradually decreases from the inlet lubrication area toward the sizing area.

[0010] In some implementations, the height of the working area is not less than the minimum diameter of the working area.

[0011] In some embodiments, the stranded mold core is fixed inside the mold sleeve by locating pins, and the mold sleeve has multiple heat dissipation holes.

[0012] In some embodiments, the cross-section of the profile unit is tile-shaped, fan-shaped, trapezoidal, or flat.

[0013] A copper conductor, said copper conductor being manufactured by the above-described method for manufacturing segmented wire copper conductors.

[0014] A cable comprising the aforementioned copper conductor.

[0015] Due to the application of the above technical solution, the present invention has the following advantages compared with the prior art: This invention first forms irregularly shaped wire units by drawing and stretching copper metal, and then twists these irregularly shaped wire units together to form a copper conductor. This process eliminates the gaps that inevitably exist when twisting circular single wires to the maximum extent, improves the effective utilization rate of the cross-section, and reduces magnetic field interference between conductors. Attached Figure Description

[0016] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the cross-section of various copper conductors of the present invention; Figure 2 This is a front view of the wire drawing die of the present invention; Figure 3 This is a cross-sectional view of the stranded die core of the present invention. Detailed Implementation

[0018] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0019] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate for the embodiments of the invention described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0020] In this invention, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing the invention and its embodiments, and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to be constructed and operated in a specific orientation.

[0021] Furthermore, in addition to indicating direction or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in certain situations to indicate a dependency or connection. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0022] Furthermore, the terms "installation," "setup," "equipped with," "connection," "linking," and "socketing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0023] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other. The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0024] This invention provides a method for manufacturing a segmented copper conductor, comprising the following steps: Step 1, wire drawing process: The copper metal is stretched and plasticized using a wire drawing die to form a copper wire with a circular cross-section; Step 2, shaping process: The copper wire from Step 1 is drawn through a wire drawing die to form a wire unit 1 with an irregular cross-section; Step 3, stranding and shaping: The multiple wire units 1 from step 2 are stranded into a circular copper conductor using a circular stranding die.

[0025] In some implementations, the wire drawing process is a critical step in cable production. Whether the drawn copper wires meet the design specifications determines the cable's qualification, and the smoothness of the wire drawing largely depends on the selection of the drawing die. (Refer to...) Figure 2 and Figure 3 The wire drawing die includes a die sleeve 21 and a stranded die core 22 installed in the die sleeve 21. The stranded die core 22 has a die hole 220 that passes through the stranded die core 22 along the axial direction. The stranded die core 22 is made of tungsten steel.

[0026] In some embodiments, the die 220 is used for drawing copper metal. The die 220 has an inlet lubrication area, a working area, a sizing area and an outlet area in sequence along the axial extension direction.

[0027] In some embodiments, the inlet end of the inlet lubrication zone is arc-shaped so that the copper metal can enter the working area without being scratched by the edge of the die hole 220. The surface of the inlet lubrication zone is covered with lubricant so that the copper metal can be lubricated.

[0028] In some implementations, the working area is a tensile and plastic region of copper metal, and the diameter of the working area gradually decreases from the inlet lubrication area toward the sizing area. As the copper metal passes through the working area, its diameter decreases.

[0029] In some implementations, the height of the working area is not less than the minimum diameter of the working area. If the height of the working area is too small, the stretched copper metal will exert excessive stress on the working area of ​​the wire drawing die 22. Increased tensile stress will lead to faster wear of the wire drawing die.

[0030] The height of the working area varies depending on the material being stretched, the diameter of the material being stretched, and the lubrication condition of the material being stretched. Generally, the height of the stranding die 22 for stretching soft metals is shorter than that for stretching hard metals, the height of the stranding die 22 for stretching small-diameter wires is shorter than that for stretching large-diameter wires, and the height of the stranding die 22 for wet-lubricated stretching is shorter than that for dry-lubricated stretching.

[0031] In some implementations, the selection of the working cone angle in the working area also affects the stretching quality. Generally, a larger working cone angle increases the normal force perpendicular to the die hole 220 surface, while a smaller working cone angle increases the frictional force along the die hole 220 surface. The ideal working cone angle is when the resultant force line of the normal force and frictional force is minimized. The selection of the working cone angle follows these principles: the smaller the compression ratio, the smaller the working cone angle; the harder the material being stretched, the smaller the working cone angle; the working cone angle for stretching small-diameter wire is smaller than that for stretching large-diameter wire.

[0032] In some implementations, the drawn material is shaped and sized as required by the sizing zone. The length of the sizing zone varies depending on the hardness, cross-sectional area, and lubrication of the drawn material. The selection principle for the height of the sizing zone is as follows: the height of the sizing zone for drawing soft metal materials is shorter than that for drawing hard metal materials; the height of the sizing zone for drawing large-diameter materials is shorter than that for drawing small-diameter materials; and the height of the sizing zone for wet-lubricated drawing is shorter than that for dry-lubricated drawing.

[0033] In some implementations, the exit zone is the last part through which the stretched material leaves the die 220. It protects the sizing zone from cracking and prevents the wire from being scratched by reversing when the machine stops.

[0034] In some embodiments, the stranded mold core 22 is fixed inside the mold sleeve 21 by a positioning pin 23, and the mold sleeve 21 has a plurality of heat dissipation holes 210.

[0035] In some implementations, the profiled unit 1 is a component of the profiled copper conductor. Its manufacturing process can be customized according to different copper conductor specifications. The cross-section of the profiled unit 1 can be sheet-like, tile-shaped, fan-shaped, trapezoidal, or flat. Compared to the circular profiled unit 1, the surface area of ​​the irregularly shaped profiled unit 1 is typically larger than that of the circular profiled unit 1 under the same cross-sectional area. This increases the heat dissipation area, and the better heat dissipation capacity allows the conductor to carry higher currents at the same temperature rise, increasing the current carrying capacity by approximately 10% to 20%. Furthermore, it operates at a lower temperature under the same current, extending cable life. When the irregularly shaped profiled unit 1 is stranded into a copper conductor, it can tightly fill the space, achieving a fill rate of over 90%, reducing gaps and improving the effective utilization of the cross-section. Multiple irregularly shaped profiled units 1 can be tightly fitted together, reducing magnetic field interference between conductors, lowering AC losses, reducing loop inductance, facilitating high-frequency signal transmission, and reducing transient voltage stress in the power system. The copper conductor formed by twisting irregularly shaped wire units 1 exhibits excellent mechanical and connection stability and resistance to bending fatigue when the cable is laid and installed in the equipment room. For example, the stress distribution of the flat wire unit 1 is more uniform when it is bent in a specific direction, which greatly enhances the connection reliability of the crimped copper lugs for equipment installation. The rectangular or sheet-shaped wire unit 1 has a larger contact area when connected to the terminal, which reduces the contact resistance and the risk of local overheating.

[0036] Reference Figure 1 The present invention also provides a copper conductor, which is manufactured by the above-described method for manufacturing segmented wire copper conductors.

[0037] Furthermore, the copper conductor has a hollow structure.

[0038] The present invention also provides a cable comprising the aforementioned copper conductor.

[0039] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for manufacturing a segmented copper conductor, characterized in that, Includes the following steps: Step 1, wire drawing process: The copper metal is stretched and plasticized using a wire drawing die to form a copper wire with a circular cross-section; Step 2, shaping process: The copper wire from Step 1 is drawn through a wire drawing die to form a wire unit with an irregular cross-section; Step 3, stranding and shaping: The multiple wire units from Step 2 are stranded into a circular copper conductor using a circular stranding die.

2. The method for manufacturing segmented copper conductors as described in claim 1, characterized in that, The wire drawing die includes a die sleeve and a stranded die core installed within the die sleeve, the stranded die core having a die hole extending through the stranded die core along the axial direction.

3. The method for manufacturing segmented copper conductors as described in claim 2, characterized in that, The die hole has, in sequence, an inlet lubrication zone, a working zone, a sizing zone, and an outlet zone along the axial extension direction.

4. The method for manufacturing a segmented copper conductor as described in claim 3, characterized in that, The inlet end of the inlet lubrication zone is arc-shaped.

5. The method for manufacturing a segmented copper conductor as described in claim 3, characterized in that, The diameter of the working area gradually decreases from the inlet lubrication area toward the sizing area.

6. The method for manufacturing a segmented copper conductor as described in claim 3, characterized in that, The height of the work area is not less than the minimum diameter of the work area.

7. The method for manufacturing a segmented copper conductor as described in claim 2, characterized in that, The stranded mold core is fixed inside the mold sleeve by positioning pins, and the mold sleeve has multiple heat dissipation holes.

8. The method for manufacturing a segmented copper conductor as described in claim 1, characterized in that, The cross-section of the profile unit is tile-shaped, fan-shaped, trapezoidal, or flat.

9. A copper conductor, characterized in that, The copper conductor is manufactured by the method of manufacturing a segmented copper conductor as described in any one of claims 1 to 8.

10. A cable, characterized in that, Includes the copper conductor as described in claim 9.

Images