Manufacturing method of photoelectric composite cable

Abstract

The invention discloses a manufacturing method of a photoelectric composite cable, and relates to the technical field of cables. The method sequentially comprises the steps of raw material selection pretreatment, conductor back-twist stranding, insulation extrusion, optical fiber unit prefabrication, synchronous back-twist cabling, shielding layer application, double-layer sheath extrusion molding and the like. An on-line optical state monitoring mechanism is introduced in the synchronous back-twist cabling process, a'monitoring-judging-adjusting 'closed-loop control system is constructed by collecting optical fiber light attenuation change data in real time, and automatic linkage adjustment is carried out on key parameters such as optical fiber pay-off tension, back-twist ratio and twisting pitch. In addition, the cable core structure adopts a compression-resistant gasket to realize unit physical isolation, and is matched with a reverse double-layer twisting and partition temperature control extrusion process. According to the method, the problems of signal loss fluctuation and structure instability of the humanoid robot cable under a severe dynamic working condition are effectively solved, and the bending resistance life, the torsion resistance and the manufacturing consistency of a finished product are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and more particularly to a method for manufacturing optoelectronic composite cables. Background Technology

[0002] As the application scenarios of industrial robots and service robots (especially humanoid robots) expand from factories to commercial buildings, municipal roads and home environments, the robot joints place higher demands on the follow-up cables during walking, turning and lifting movements: the cables need to provide a stable power supply while achieving high-speed, low-loss optical signal transmission, and withstand long-term high-frequency bending, repeated twisting, dragging and wear, and complex electromagnetic interference.

[0003] While existing optoelectronic composite cables have been applied in fields such as drones and industrial cable chains, there are still shortcomings in the specialized manufacturing methods for humanoid robots and other applications that require high-frequency bending, torsion resistance, and interference resistance.

[0004] On the one hand, the industry often uses modified traditional cable manufacturing processes for composite manufacturing, lacking manufacturing standards and key process control for the coordinated transmission of "power unit - fiber optic unit", resulting in poor product consistency and insufficient adaptability to operating conditions.

[0005] On the other hand, relevant testing standards are gradually clarifying the requirements for high flexibility and lifespan of robot cables, which is further forcing the manufacturing process to achieve more refined process control and quality closed-loop.

[0006] Furthermore, from the perspective of the manufacturing process, the existing solutions mainly have the following problems:

[0007] (1) Insufficient optoelectronic synergy: Electromagnetic radiation and structural compression factors of the power core during the cabling process can have an adverse effect on the optical fiber unit; at the same time, when the gap matching between the loose tube and the optical fiber and the water blocking paste are insufficient, the micro-bending loss of the optical fiber can be easily induced, which will increase the attenuation of the optical signal.

[0008] (2) Insufficient stability and consistency of cable making: When the tension control accuracy of each unit is insufficient or the tension difference is large during cable making, it is easy to cause poor roundness of the cable core, loose structure and uneven stress distribution, which in turn affects the torsional reliability and batch stability.

[0009] (3) Lack of closed-loop process control: In the critical step of "synchronous untwisting and cabling", relying solely on offline detection or experience-based parameter adjustment makes it difficult to detect changes in the optical fiber status in a timely manner and adjust key process parameters accordingly. This makes it difficult to balance high flexibility, low loss, and stable mass production. Therefore, it is necessary to provide an industrially feasible manufacturing method that introduces online optical status monitoring during the cabling stage and establishes a linkage adjustment mechanism with parameters such as tension, untwisting ratio, strand pitch, and traction speed to improve the transmission stability and manufacturing consistency of optoelectronic composite cables under harsh operating conditions. Summary of the Invention

[0010] Based on the technical problems existing in the background technology, the present invention proposes a method for manufacturing optoelectronic composite cables.

[0011] The manufacturing method of the optoelectronic composite cable proposed in this invention includes the following steps:

[0012] S1: Select oxygen-free copper wire as the conductor material, and select insulation material, sheath material and optical fiber for pretreatment;

[0013] S2: Untwist and twist oxygen-free copper wire to form at least one conductor, said conductor including at least one of power conductor and signal conductor;

[0014] S3: The conductor is insulated and extruded to form at least one wire core, the wire core including at least one of power wire core and signal wire core;

[0015] S4: Insert the optical fiber into the loose tube and fill the loose tube with water-blocking paste to form an optical fiber unit, and seal both ends of the loose tube.

[0016] S5: Perform synchronous untwisting cabling: a central reinforcing member is placed in the center, and at least one wire core and optical fiber unit are distributed around the central reinforcing member to form a cable core. Anti-compression pads are set between adjacent units, and filling components are set in the gaps between adjacent units. Then, wrapping tape is formed around the outer periphery of the cable core to tighten and fix it.

[0017] S6: During the synchronous untwisting cabling process, the optical fiber unit is monitored online for optical status; when the optical status is detected to meet the preset judgment conditions, at least one cabling process parameter is adjusted in linkage, and the cabling process parameter includes at least: optical fiber laying tension, tension difference between each unit, untwisting ratio, stranding pitch or traction speed; and after the linkage adjustment is completed, online optical status monitoring is continued to determine whether linkage adjustment is needed again.

[0018] S7: A shielding layer is formed on the outer periphery of the cable core, an inner sheath is formed on the outer periphery of the shielding layer, and an outer sheath is formed on the outer periphery of the inner sheath.

[0019] S8: Cooling and aging treatment of finished cables;

[0020] S9: Conduct factory testing on finished cables.

[0021] Preferably, the online optical condition monitoring in step S6 includes: real-time acquisition of the optical power, optical attenuation, or changes thereof of the optical fiber, and using the deviation of the acquired data from a preset threshold as the preset judgment condition.

[0022] Preferably, the linkage adjustment in step S6 includes:

[0023] Simultaneously, the tension of the fiber optic cable and the tension difference between each unit are adjusted; the unwinding ratio is also adjusted; and the stranding pitch is selectively adjusted according to preset judgment conditions.

[0024] Preferably, the tensioner is calibrated during the synchronous untwisting cabling stage, and the tension error of each unit is controlled to be ≤5% and the fiber tension is ≤10N during cabling.

[0025] Preferably, in the synchronous untwisting cabling step, the stranding pitch ratio is 20–25 times, and the outer diameter tolerance of the cable core is controlled to be ±0.15mm.

[0026] Preferably, in step S2, the stranded pitch ratio is 12–16 times, and the double stranded pitch ratio is 16–20 times; the conductor is preheated to 60±1°C before step S3; in step S3, at least one core includes a power core, which is extruded using a three-layer co-extrusion process at an extrusion temperature of 180–220°C and a screw speed of 20–50 rpm.

[0027] Preferably, in step S4, the loose tube is formed by extrusion of TPE or PP material at an extrusion temperature of 160–190℃, and the inner diameter of the loose tube is 0.2–0.3 mm larger than the outer diameter of the optical fiber; the optical fiber laying area is kept at a constant temperature of 23℃ and the tension is controlled at 5–10N.

[0028] Preferably, the synchronous untwisting cable is produced using a reverse double-layer stranding process, and the outer layer pitch is 5–8 times larger than that of the inner layer.

[0029] A photoelectric composite cable includes a cable core, a shielding layer covering the outer periphery of the cable core, an inner sheath covering the outer periphery of the shielding layer, and an outer sheath covering the outer periphery of the inner sheath.

[0030] The cable core includes a central reinforcing member and multiple units arranged circumferentially around the central reinforcing member. Each of the multiple units includes at least one of an optical fiber unit, a power line core, and a signal line core. A circumferential gap is formed between any two circumferentially adjacent units. A pressure-resistant pad is sandwiched within the circumferential gap, extending along the cable length and abutting against the outer circumferential surfaces of the two circumferentially adjacent units. A filling component is provided in the remaining gap within the circumferential gap. A wrapping tape is provided around the outer periphery of the multiple units to achieve tightening and fixation.

[0031] Preferably, the optical fiber unit includes a loose tube, an optical fiber, and a water-blocking paste filled in the loose tube. The inner diameter of the loose tube is 0.2–0.3 mm larger than the outer diameter of the optical fiber. The two ends of the loose tube are sealed. The outer periphery of the loose tube is also covered with an aramid yarn reinforcement layer, and the aramid yarn reinforcement layer is extruded with a secondary sheath.

[0032] Beneficial effects:

[0033] 1. This invention monitors the optical fiber unit's optical status online during the synchronous untwisting cabling process, and adjusts process parameters such as fiber tension, tension difference between units, untwisting ratio, stranding pitch, or traction speed in conjunction with preset judgment conditions, forming a closed-loop process of "monitoring-judgment-adjustment-remonitoring". This reduces the risk of optical signal performance fluctuations from the manufacturing process side and improves the consistency and controllability of the finished product.

[0034] 2. This invention forms an optical fiber unit by inserting optical fiber into a loose tube and filling it with water-blocking paste, and then sealing the end of the loose tube to place the optical fiber in a buffered protective cavity. Combined with the tension control and online monitoring mechanism during the cabling stage, this invention can reduce the probability of micro-bending loss and optical attenuation abnormalities caused by structural compression and sudden tension changes.

[0035] 3. In this invention, the cable core is arranged with a central reinforcing member as the skeleton, and the wire core and optical fiber unit are arranged around it. Anti-compression pads are set between adjacent units in the circumferential direction, and filling components are set in the circumferential gaps. Then, the cable core is tightened and fixed by wrapping tape, which makes it easier for the cable core to maintain roundness and stability during manufacturing and service, thereby improving the structure's resistance to impact, compression and deformation.

[0036] 4. This invention introduces a de-twisting stranding process in the conductor formation stage, and further adopts reverse double-layer stranding and the setting of the pitch difference between the outer and inner layers in the synchronous de-twisting cabling stage, so that the torque in the cable core can be more easily balanced, which helps to reduce the stress concentration and structural loosening risk of the cable under repeated torsion conditions.

[0037] 5. The present invention forms a shielding layer on the outer periphery of the cable core, and together with the inner sheath and the outer sheath, achieves multi-layer encapsulation protection, which can provide a structural basis for electromagnetic shielding and external protection. In conjunction with the internal unit isolation / fixing structure, it improves the stability and environmental adaptability of composite transmission.

[0038] 6. This invention forms a continuous process from conductor untwisting and stranding, insulation extrusion, optical fiber unit prefabrication, synchronous untwisting cabling, shielding sheath forming to cooling aging and factory testing. It also introduces online monitoring and parameter linkage adjustment mechanisms for key processes, making process windows easier to solidify and quality control easier to trace, thereby improving the stability of large-scale production. Attached Figure Description

[0039] Figure 1 This is a flowchart of the manufacturing method of the optoelectronic composite cable proposed in this invention.

[0040] Figure 2 This is a schematic diagram of the structure of the optoelectronic composite cable proposed in this invention.

[0041] Figure 3 This is a schematic diagram of the shielding layer of the optoelectronic composite cable proposed in this invention.

[0042] Figure 4 This is a schematic diagram of the cable core structure of the optoelectronic composite cable proposed in this invention.

[0043] Figure 5 This is a schematic diagram of the optical fiber unit structure in the optoelectronic composite cable proposed in this invention.

[0044] In the picture:

[0045] 200. Cable core;

[0046] 212. Compression gasket;

[0047] 213. Fill component;

[0048] 214. Wrapping with straps;

[0049] 215. Center reinforcement component;

[0050] 220. Power conductor core;

[0051] 230. Signal wire core;

[0052] 240. Fiber optic unit;

[0053] 241. Loose sleeve;

[0054] 242. Optical fiber;

[0055] 243. Water-resistant paste;

[0056] 300. Shielding layer;

[0057] 400, Inner Sheath;

[0058] 500, outer sheath. Detailed Implementation

[0059] Example 1

[0060] like Figure 1 As shown, the present invention also provides a method for preparing the above-mentioned optoelectronic composite cable. This method solves the problems of poor stability and low yield of optoelectronic synergistic transmission by means of online optical state monitoring and closed-loop process control. The specific process includes the following steps:

[0061] S1: Raw material selection and pretreatment

[0062] S1.1 Conductor prefabrication: Oxygen-free copper wire (single wire diameter 0.08mm) is selected and stranded using an untwisting stranding process. The bundle stranding pitch ratio is controlled at 14 times and the re-stranding pitch ratio is controlled at 18 times to reduce the residual stress inside the conductor.

[0063] S1.2 Insulation Extrusion:

[0064] The power conductor is insulated by XLPE extrusion using a three-layer co-extrusion process. The extrusion temperature is controlled at 200℃ and the screw speed is 35rpm to form a 220mm power core.

[0065] The signal conductor is subjected to irradiation cross-linked polyolefin insulation extrusion at an extrusion temperature of 180°C to form signal core 230.

[0066] Key point: Before insulation extrusion, preheat the conductor to 60±1℃ to eliminate stranding stress and ensure uniform adhesion of the insulation layer.

[0067] S1.3 Fiber Optic Unit Prefabrication: G.657.A2 fiber 242 is inserted into a PP loose tube 241, and water-blocking paste 243 is simultaneously filled. The extrusion temperature of the loose tube is controlled at 160-190℃, and the inner diameter of the loose tube (1.2mm) is controlled to be 0.3mm larger than the outer diameter of the fiber. During this process, the fiber laying area is kept at a constant temperature of 23℃, and the laying tension is strictly controlled at 5-10N to prevent micro-bending loss. Furthermore, for different pressure resistance levels, there are two preferred forms of fiber optic unit fabrication in this step: for conventional pressure resistance requirements (lateral pressure ≤1000N / 10cm), the above-mentioned single-layer loose tube structure is directly used; for high pressure resistance requirements (lateral pressure >1000N / 10cm), a TPE secondary sheath (not shown in the figure) is extruded over the loose tube with an extrusion thickness of 0.4-0.6mm, and an aramid yarn reinforcement layer is evenly distributed between the loose tube and the secondary sheath to further improve the fiber optic unit's resistance to compression and tension.

[0068] S2: Synchronous untwisting and cable forming with closed-loop control (core steps)

[0069] S2.1 Cable Core Assembly: Before assembling the S2.1 cable cores, all tensioners of the cabling equipment (including active tensioners and passive damping tensioners) are first zero-point calibrated and dynamically calibrated to ensure that the output error at the set tension value is ≤ ±0.1N. Tension warning thresholds are also set for each unit to meet the process consistency requirement of "tension error of each unit ≤ 5% and fiber tension ≤ 10N". An aramid yarn central reinforcement 215 (tension 8N) is placed in the center, and two power cores, two signal cores, and two fiber units are distributed around the central reinforcement. Compression pads 212 are placed between adjacent units, and flame-retardant rope 213 is used for filling.

[0070] S2.2 Process parameter control: The synchronous untwisting cable forming machine is used for processing, the stranding pitch ratio is set to 22 times, the tension difference of each unit is controlled to be ≤3%, and the cable core outer diameter tolerance is controlled within ±0.15mm.

[0071] S2.3 Online Optical Condition Monitoring and Closed-Loop Control (S6): This step relies on the intelligent monitoring system integrated on the cable-laying machine, and specifically includes the following hardware links and control logic:

[0072] (1) Hardware Implementation: Since the cable-forming cage is in a high-speed rotating state during the cabling process, traditional static testing cannot be implemented. In this invention, a fiber optic rotary joint (FORJ) is set between the pay-off frame and the take-up end of the cable-forming machine. The inner end of the fiber unit is connected to an external high-precision OTDR (Optical Time Domain Reflectometer) in real time through the rotary joint. The OTDR scans the attenuation curve of the entire fiber length at a set frequency (e.g., once per second) and transmits the data to the PLC main control unit. The fiber pay-off reel is placed inside the cable-forming cage, and the inner end of the fiber is led out through the hollow channel in the center of the cable-forming cage spindle and connected to the FORJ stator / rotor interface installed at the tail end of the spindle.

[0073] (2) Judgment and linkage adjustment strategy: The preset judgment condition is set as follows: the real-time additional loss increment Δα of the optical fiber unit in the cabling section is ≤0.05dB. The main control unit executes the following PID linkage adjustment based on the monitoring results:

[0074] Scenario 1 (Abnormal Tension): If a sudden change in optical attenuation is detected, accompanied by fluctuations in the tension sensor reading, it is determined that excessive tension during fiber feeding has caused micro-bending of the optical fiber. The system automatically issues a command to reduce the damping torque of the fiber feeding motor, reducing the fiber feeding tension by 0.5-1.0N until the optical attenuation returns to normal.

[0075] Scenario 2 (Structural Compression): If the optical decay shows a slow upward trend, it is determined that the stranding structure is too tight, causing lateral compression. The system automatically adjusts the ratio of the traction motor speed to the winch speed, that is, fine-tunes the stranding pitch (for example, increasing the pitch ratio from 22 times to 23 times), or increases the unwinding ratio (from 30% to 35%), to release the torsional compression stress inside the cable core.

[0076] Scenario 3 (Synchronization Deviation): If the tension difference between units exceeds 5%, the system independently adjusts the tension controller of the abnormal unit to achieve rebalancing of the tension difference between units through dynamic compensation.

[0077] Through the closed-loop process of "collection-analysis-execution" described above, the optical performance of every meter of cable is ensured to be controlled in real time during the manufacturing process, avoiding the risk of batch scrapping caused by traditional post-inspection.

[0078] S3: Shielding and Sheath Forming

[0079] S3.1 Shielding application: Aluminum-plastic composite tape is wrapped around the outside of the cable core (inner shielding), followed by Kevlar copper foil braiding (outer shielding), with a coverage of 90%.

[0080] S3.2 Sheath Extrusion:

[0081] A 400mm TPE inner sheath is extruded outside the shielding layer at an extrusion temperature of 190℃.

[0082] The inner sheath is extruded with a PUR outer sheath of 500, using an extrusion die. The extrusion section adopts a zoned temperature control process: feeding section 160℃ → melting section 190℃ → die head 210℃, screw speed 25rpm, extrusion pressure 8MPa.

[0083] S4: Post-processing and Inspection

[0084] S4.1 Cooling and Aging: Use 20-30℃ warm water for cooling to prevent the sheath from cracking due to excessive temperature difference; then allow natural aging for 24-48 hours to eliminate internal stress.

[0085] S4.2 Factory Inspection: Perform full performance testing on the finished product, including electrical performance, optical performance and mechanical bending performance.

[0086] It should be noted that for humanoid robot joint applications requiring higher torsional resistance (such as withstanding ±360° / m torsion), the cabling process in step S2 can employ a reverse double-layer stranding process. Specifically, the cable core is designed with an inner and outer concentric stranded structure: the inner layer consists of three power conductors stranded around a central reinforcing member in a leftward direction; the outer layer consists of the remaining power conductors, signal conductors, and fiber optic units stranded around the inner layer in a rightward direction. In this case, the outer layer stranding pitch ratio (e.g., 22 times) is controlled to be 5-8 times larger than the inner layer stranding pitch ratio (e.g., 16 times). This design, with its "opposite stranding directions and differentiated pitches," utilizes the torque cancellation principle in mechanics, ensuring that when the cable is subjected to external torsional force, the torsional stresses of the inner and outer layers cancel each other out, thereby significantly improving the overall torsional fatigue life of the cable.

[0087] Example 2

[0088] like Figures 2 to 5 As shown, the present invention provides an optoelectronic composite cable adapted to the harsh working conditions of humanoid robots. The composite cable includes, from the inside out, a cable core 200, a shielding layer 300, an inner sheath 400, and an outer sheath 500.

[0089] A central reinforcing member 215 is provided at the center of the cable core 200. This central reinforcing member 215 is preferably made of aramid yarn (Kevlar) with a diameter of approximately 2.0 mm. It is used to bear the axial tensile force and torsional stress of the cable during robot joint movement. Several functional units are arranged around the central reinforcing member 215, specifically including:

[0090] Power conductor core 220: Used for powering robot drive motors, it adopts the sixth type of soft conductor, and is made of 1728 strands of oxygen-free copper wire with a single wire diameter of 0.08mm twisted together, with an outer extruded cross-linked polyethylene (XLPE) insulation layer, and the insulation thickness is 1.2±0.05mm;

[0091] Signal core 230: Used for transmitting control signals, conductor cross-sectional area is 0.75mm², externally extruded with irradiated cross-linked polyolefin insulation layer, insulation thickness is 0.8±0.05mm;

[0092] Fiber unit 240: Used to transmit 10Gbps high-definition image signals, including G.657.A2 bend-insensitive single-mode fiber 242 (2 cores). The fiber is externally inserted into a loose tube 241 made of PP material. The inner diameter of the loose tube 241 is 1.2mm (0.3mm larger than the outer diameter of the fiber). The tube is filled with water-blocking paste 243. The loose tube is longitudinally wrapped with aramid yarn for reinforcement and extruded with a TPE secondary sheath. The outer diameter of the unit is 2.8mm.

[0093] In each of the above functional units, a circumferential gap is formed between any two circumferentially adjacent units. A pressure-resistant pad 212 (or a pressure-resistant isolation component) is sandwiched in the circumferential gap. The pressure-resistant pad 212 extends along the length of the cable and abuts against the outer circumferential surface of the adjacent unit, playing a role in physical isolation and pressure resistance support. The remaining gap of the circumferential gap is filled with a filling component 213 (flame-retardant filling rope + water-blocking paste) to ensure the roundness of the cable core. A wrapping tape 214 (polyester tape) with a thickness of 0.1mm is provided on the outer circumference of the cable core for tightening and fixing.

[0094] The shielding layer 300 adopts a double-layer structure. The inner layer is an aluminum-plastic composite tape with an overlap rate of 30%, and the outer layer is a Kevlar copper foil wire mesh with a weaving angle of 45° and a coverage rate of ≥90%, which effectively suppresses electromagnetic interference (EMI).

[0095] The inner sheath 400 is made of TPE material extrusion with a thickness of 1.0mm, protecting the shielding layer and the cable core.

[0096] The outer sheath 500 is made of wear-resistant PUR / TPU material with a Shore hardness of 85A and a thickness of 0.65mm. It has oil resistance, flame retardancy (IEC60332-3A) and tear resistance.

[0097] Example 3: Performance Testing and Comparative Analysis

[0098] To further verify the technical advantages of the photoelectric composite cable of the present invention under the harsh working conditions of humanoid robots, this embodiment selects three groups of experimental objects for comparative testing.

[0099] 1. Preparation of experimental subjects

[0100] Example Group (Invention): RCP-OP-2.5 / 4G2 type cable manufactured using the method of Example 1 above. Key features: 0.08mm micro-conductor, S6 online closed-loop monitoring, and zoned temperature-controlled extrusion.

[0101] Comparative Example 1 (Conventional Drag Chain Cable): Manufactured using traditional drag chain cable technology, with a conductor single filament diameter of 0.15mm. There is no online optical monitoring during the cabling process, and open-loop tension control is used.

[0102] Comparative Example 2 (Ordinary Optical Cable): Commercially available general-purpose optical composite cable, without special structural design for robot torsion resistance (no pressure-resistant pads, no untwisting process).

[0103] 2. Experimental Testing Items and Methods This experiment was conducted in a standard laboratory environment. The main testing items are as follows:

[0104] (1) Bending resistance test: According to the standard T / SZRCA002-2024, the cable is fixed on the bending test machine with a weight of 1.5kg, a bending radius of 8 times the outer diameter (100mm), and a frequency of 45 times / minute, and is subjected to 180° reciprocating bending.

[0105] Judgment criteria: After 1 million bends, the additional loss of the optical fiber is ≤0.1dB, and the conductor core is not broken, which is considered qualified.

[0106] (2) Torsion test: A torsion test of ±180° / m was conducted.

[0107] Judgment criteria: After 5000 cycles of torsion, the sheath shows no cracks and the electrical performance is normal.

[0108] (3) Fiber attenuation test: The attenuation value at wavelengths of 1310nm and 1550nm was measured using an OTDR.

[0109] 3. Experimental Results Analysis The experimental data obtained based on the above testing methods are shown in the table below:

[0110] Testing items Example Group (Invention) Comparative Example 1 (Conventional Drag Chain Cable) Comparative Example 2 (Ordinary Optical Fiber Cable) Data Analysis and Conclusions Conductor resistance (2.5mm²) 7.0 Ω / km 7.3 Ω / km 7.4 Ω / km This invention employs a sixth type of soft conductor and a de-twisting process, resulting in a more compact conductor structure and superior conductivity. Fiber attenuation (1310nm) 0.32 dB / km 0.45 dB / km 0.60 dB / km S6 online monitoring and closed-loop regulation effectively avoid micro-bending loss during cabling, ensuring the quality of optical signal transmission. Bending resistance (1 million cycles) Qualified (Additional loss 0.08dB) Unqualified (core breaks after 300,000 cycles) Unacceptable (100,000 fiber optic cable breaks) The 0.08mm ultra-fine copper wire and the pressure-resistant pad structure significantly improve dynamic tolerance. Torsional resistance (±180° / m) 5000 cycles without cracking 2000 times the sheath wrinkles 500 times the sheath cracked The reverse double-layer twisting process and the high-strength PUR sheath effectively offset torsional stress. Finished product yield 98.5% 88% 80% Closed-loop process control significantly improves manufacturing consistency and is suitable for industrial mass production.

Claims

1. A method for manufacturing an optoelectronic composite cable, characterized in that, Includes the following steps: S1: Select oxygen-free copper wire as conductor material, and select insulation material, sheath material and optical fiber (242) for pretreatment; S2: Untwist and twist oxygen-free copper wire to form at least one conductor, said conductor including at least one of power conductor and signal conductor; S3: The conductor is insulated and extruded to form at least one wire core, the wire core including at least one of power wire core (220) and signal wire core (230); S4: Insert the optical fiber (242) into the loose tube (241) and fill the loose tube (241) with water-blocking paste (243) to form an optical fiber unit (240), and seal both ends of the loose tube (241). S5: Perform synchronous untwisting cabling: Place a central reinforcing member (215) in the center, and arrange the at least one wire core and optical fiber unit (240) around the central reinforcing member (215) to form a cable core (200), and set an anti-compression pad (212) between adjacent units, and set a filling component (213) at the gap between adjacent units, and then form a wrapping tape (214) around the cable core (200) to tighten and fix it; S6: During the synchronous untwisting cabling process, the optical fiber unit (240) is monitored online; when the optical state is found to meet the preset judgment conditions, at least one cabling process parameter is adjusted in linkage, and the cabling process parameter includes at least: optical fiber laying tension, tension difference between each unit, untwisting ratio, stranding pitch or traction speed; and after the linkage adjustment is completed, online optical state monitoring is continued to determine whether linkage adjustment is needed again. S7: A shielding layer (300) is formed on the outer periphery of the cable core (200), and an inner sheath (400) is formed on the outer periphery of the shielding layer (300), and an outer sheath (500) is formed on the outer periphery of the inner sheath (400). S8: Cooling and aging treatment of finished cables; S9: Conduct factory testing on finished cables.

2. The method for manufacturing the optoelectronic composite cable according to claim 1, characterized in that, The online optical status monitoring in step S6 includes: real-time acquisition of the optical power, optical attenuation or their changes in the optical fiber (242), and using the deviation of the acquired data from a preset threshold as the preset judgment condition.

3. The method for manufacturing the optoelectronic composite cable according to claim 1, characterized in that, The linkage adjustment in step S6 includes: Simultaneously, the tension of the fiber optic cable and the tension difference between each unit are adjusted; the unwinding ratio is also adjusted; and the stranding pitch is selectively adjusted according to preset judgment conditions.

4. The method for manufacturing the optoelectronic composite cable according to claim 1, characterized in that, During the synchronous untwisting cabling stage, the tensioner is calibrated, and the tension error of each unit during cabling is controlled to be ≤5%, and the fiber tension is ≤10N.

5. The method for manufacturing the optoelectronic composite cable according to claim 1, characterized in that, In the synchronous untwisting cabling step, the stranding pitch ratio is 20–25 times, and the outer diameter tolerance of the cable core is controlled to be ±0.15mm.

6. The method for manufacturing the optoelectronic composite cable according to claim 1, characterized in that, In step S2, the stranded pitch ratio is 12–16 times, and the double stranded pitch ratio is 16–20 times; before step S3, the conductor is preheated to 60±1℃; in step S3, at least one core includes a power core (220), which is extruded using a three-layer co-extrusion process at an extrusion temperature of 180–220℃ and a screw speed of 20–50 rpm.

7. The method for manufacturing the optoelectronic composite cable according to claim 1, characterized in that, In step S4, the loose tube (241) is formed by extrusion of TPE or PP material at an extrusion temperature of 160–190℃, and the inner diameter of the loose tube is 0.2–0.3 mm larger than the outer diameter of the optical fiber; the optical fiber laying area is kept at a constant temperature of 23℃ and the tension is controlled at 5–10N.

8. The method for manufacturing the optoelectronic composite cable according to claim 1, characterized in that, Synchronous untwisting cabling adopts a reverse double-layer stranding process, and the outer layer pitch is 5–8 times larger than that of the inner layer.

9. A photoelectric composite cable, characterized in that, It includes a cable core (200), a shielding layer (300) covering the outer periphery of the cable core (200), an inner sheath (400) covering the outer periphery of the shielding layer (300), and an outer sheath (500) covering the outer periphery of the inner sheath (400). The cable core (200) includes a central reinforcing member (215) and a plurality of units arranged circumferentially around the central reinforcing member (215). The plurality of units include at least one of an optical fiber unit (240), a power line core (220), and a signal line core (230). A circumferential gap is formed between any two circumferentially adjacent units in the plurality of units. A pressure-resistant pad (212) is sandwiched in the circumferential gap. The pressure-resistant pad (212) extends along the length of the cable and abuts against the outer circumferential surface of the two circumferentially adjacent units respectively. A filling component (213) is provided in the remaining gap in the circumferential gap. A wrapping tape (214) is provided on the outer periphery of the plurality of units to achieve tightening and fixation.

10. The optoelectronic composite cable according to claim 9, characterized in that, The optical fiber unit (240) includes a loose tube (241), an optical fiber (242), and a water-blocking paste (243) filled in the loose tube (241). The inner diameter of the loose tube (241) is 0.2–0.3 mm larger than the outer diameter of the optical fiber (242). The two ends of the loose tube (241) are sealed. The outer periphery of the loose tube (241) is also covered with an aramid yarn reinforcement layer, and the aramid yarn reinforcement layer is extruded with a secondary sheath.

Images