An optical-electric combined cable integrated laying and protection system for complex working conditions

Abstract

The application relates to the technical field of power engineering cable installation, and discloses an optical and electrical combined cable integrated laying and protection system for complex working conditions, which comprises: a rigid base configured to be anchored at a turning node; and a self-adaptive bearing assembly rotatably installed on the rigid base; the bearing assembly comprises elastic split units arranged in an axial direction; each unit is converted from an open state to a holding state of wrapping the side wall of the cable under radial pressure; and the inner surface of the unit is provided with a partitioned friction structure, which comprises a bottom high-friction rolling driving surface and two side wing low-friction sliding decoupling surfaces; through the cooperation of the tribological anisotropic structure and the self-adaptive geometric deformation, the tangential shear wear in the deep envelope state is eliminated, and the physical damage problem of the cable sheath and the optical unit in high-tension laying is solved.

Description

Technical Field

[0001] This invention relates to an integrated laying and protection system for optoelectronic cables under complex working conditions, belonging to the field of power engineering cable installation technology. Background Technology

[0002] Currently, optoelectronic composite cables integrate power transmission copper conductors and communication optical fiber units, and are widely used in smart grid construction. When laid over long distances with bends in confined spaces such as underground utility tunnels, the cables need to be guided by guide rollers and bear the radial lateral pressure converted from axial traction force. Existing technologies use rigid cylindrical rollers or V-shaped pulleys with fixed curvature radii for guidance. Under the condition of laying cables with multiple bends and high tension, the cable and the surface of the rigid rollers form local line contact or point contact. As the traction tension increases, the normal pressure at the contact interface increases, resulting in a mismatch in the internal structural modulus of the optoelectronic composite cable. Under the action of strong lateral pressure, the high elastic modulus metal conductors squeeze the low elastic modulus optical fiber units inward, producing micro-bending loss or physical breakage. Such internal damage is difficult to detect visually and constitutes a hidden danger for operation.

[0003] To reduce local pressure, a deep-groove pulley with a large envelope angle is used to increase the contact area. However, the rotation radius of the bottom of the deep-groove pulley is smaller than that of the side wing. When the pulley rotates around its axis, the linear velocity of the side wing edge is higher than that of the bottom edge. The cable body maintains a uniform axial velocity, and the pulley side wing and the cable sheath experience tangential differential velocity slippage. This geometric velocity difference, under a tight envelope state, evolves into a grinding effect, damaging the cable sheath and applying torsional shear force to the internal cable core. Some improvement ideas simply focus on static reinforcement of the cable body structure, neglecting the dynamic matching between the laying equipment and the mechanical properties of the cable. For example, the utility model with authorization announcement number CN201788758U... The patent discloses an integrated optoelectronic cable that improves the overall mechanical strength and tensile performance by wrapping the optical fiber and conductor with multiple layers of sheath and copper wire braided tensile layer. However, relying solely on passive protection methods such as increasing the thickness of the protective layer or stacking the strength of materials has limited effectiveness when facing high radial lateral pressure in complex paths. No matter how strong the outer sheath of the cable is, if the external guiding device still adopts a rigid contact mode, the inherent elastic modulus difference between the metal conductor and the optical fiber unit inside the cable cannot be eliminated. Under strong lateral pressure conditions, the high-hardness conductor inside the cable cannot avoid the micromechanical behavior of squeezing the low-hardness optical fiber. The risk of intrinsic damage has not been fundamentally solved by optimizing the cable structure.

[0004] Therefore, how to construct a contact topology that can be adaptively adjusted by traction tension, improve the radial pressure of the contact area, decouple the normal support force and tangential friction force of the contact interface, and avoid internal extrusion damage and external differential wear has become the technical problem to be solved by this invention. Summary of the Invention

[0005] To address the problems mentioned in the background art, the technical solution of the present invention is as follows: An integrated laying and protection system for optoelectronic combined cables for complex working conditions, comprising:

[0006] Rigid base, configured for anchoring at turning points in the laying path;

[0007] An adaptive load-bearing assembly is rotatably mounted on a rigid base. The assembly includes multiple elastic segmented units arranged axially. Each segmented unit has a variable geometry that transitions from an open state to a closed state under radial pressure from the optical fiber combined cable. In the closed state, the side wings of the elastic segmented unit converge inward to wrap around the sidewall of the optical fiber combined cable. The inner surface of each segmented unit has a partitioned friction structure. This structure includes a rolling drive surface located at the center of the bottom of the segmented unit and sliding decoupling surfaces located on both sides of the segmented unit. The rolling drive surface has a first coefficient of friction, which allows the bottom surface of the cable to maintain static frictional contact with the rolling drive surface during cable laying, driving the segmented unit to rotate around its axis. The sliding decoupling surfaces have a second coefficient of friction, which is less than the first coefficient. This allows the sliding decoupling surfaces to slide relative to the sidewall of the optical fiber combined cable when the segmented unit is in the closed state and wraps around the cable sidewall, eliminating the tangential shear force caused by the side wing rotation radius being greater than the bottom rotation radius.

[0008] Preferably, the friction coefficient between the rolling drive surface and the sliding decoupling surface satisfies the following relationship: ,in, The first coefficient of friction, The second coefficient of friction, This represents the maximum half-angle of the elastically segmented unit in its closed state. As a preset safety factor, this relationship is used to ensure that the rotational driving torque provided by the rolling drive surface is greater than the resisting torque generated by the sliding decoupling surface.

[0009] Preferably, the side wing edges of the elastic segmented unit are provided with a stepped overlapping structure; the stepped overlapping structures of adjacent elastic segmented units form a sliding overlapping fit along the circumferential direction in the clamping state, thereby forming a continuous annular support surface around the optoelectronic composite cable to prevent the sheath of the optoelectronic composite cable from being squeezed out from the gap when under pressure.

[0010] Preferably, the inner surface of the elastic segmented unit is provided with a guide groove; the guide groove is distributed in a herringbone or V-shape, and its opening direction is opposite to the travel direction of the photoelectric composite cable; the guide groove is configured to use the squeezing force applied by the photoelectric composite cable to guide the fluid medium or particulate matter between the photoelectric composite cable and the elastic segmented unit to the axial sides of the elastic segmented unit for discharge.

[0011] Preferably, the elastic segmented unit is internally integrated with a bimetallic thermal compensation component; the bimetallic thermal compensation component is composed of metal layers with different coefficients of thermal expansion; the bimetallic thermal compensation component is configured to generate thermal deformation in a first direction when the ambient temperature decreases to reduce the bending stiffness of the elastic segmented unit against radial pressure, and to generate thermal deformation in a second direction opposite to the first direction when the ambient temperature increases to increase the bending stiffness of the elastic segmented unit, thereby compensating for the drift of mechanical properties of the matrix material caused by temperature changes.

[0012] Preferably, the system further includes a follow-up guide mechanism disposed at both ends of the adaptive bearing component; the follow-up guide mechanism is connected to the adjacent elastic segment unit through a linkage mechanism; the linkage mechanism is configured such that when the elastic segment unit generates outward radial displacement, it drives the follow-up guide mechanism to deflect relative to the cable axis, so that the support surface of the follow-up guide mechanism remains aligned with the tangential direction of the optoelectronic composite cable entering or exiting.

[0013] Preferably, the adaptive load-bearing component further includes a friction damping component; the friction damping component includes a wedge-shaped friction pair disposed on the radial movement path of the elastic segment unit; the wedge-shaped friction pair is configured to be in a loose state to provide a smaller frictional resistance when the elastic segment unit generates an outward radial displacement, and in a wedge-tight state to provide a larger frictional resistance when the elastic segment unit generates an inward retraction displacement, thereby suppressing the radial vibration of the elastic segment unit.

[0014] Preferably, a moiré tension indicator is provided between the outer surface of the elastic segmented unit and the rigid base; the moiré tension indicator includes a first grating texture disposed on the elastic segmented unit and a second grating texture disposed on the rigid base; the first grating texture and the second grating texture are configured to use the moiré principle to convert the deformation displacement of the elastic segmented unit into a visual pattern change to indicate the stress state of the optoelectronic composite cable.

[0015] Preferably, the system further includes a locking device; the locking device includes a fastener for applying axial pressure, which restricts the deformation recovery of the elastic segment unit by compressing the side of the elastic segment unit, thereby fixing the adaptive load-bearing assembly in a clamped state.

[0016] Preferably, the elastic segmented unit is an integrally molded elastomer, and the material layer corresponding to the first friction coefficient and the material layer corresponding to the second friction coefficient are bonded to the surface of the elastomer through a two-color injection molding process or a surface coating process; the material layer corresponding to the first friction coefficient is a polyurethane or rubber material with a Shore hardness of A70 to 90, and the material layer corresponding to the second friction coefficient is a polytetrafluoroethylene or diamond-like carbon coating material.

[0017] Compared with the prior art, the beneficial effects of the present invention are:

[0018] 1. In integrated cable laying, a stress homogenization system is established for the internal modulus mismatch characteristics of optoelectronic composite cables by utilizing the geometric topological evolution mechanism of the deformation response unit. The radial lateral pressure generated by the cable bending is used as the driving source to drive the deformation response unit from the bottom linear support state to the side envelope state. This causes the contact area of ​​the support interface to increase nonlinearly with the increase of traction tension. The contact morphology is reconstructed directly by the load, maintaining the pressure per unit contact area below the micro-bending loss threshold of the optical fiber unit. This avoids shearing and squeezing damage to the low-modulus optical fiber unit caused by the high-modulus copper conductor inside the cable under high tension conditions. Without increasing the space occupied by underground pipe corridors, this solves the problem of the core communication unit of optical cables being susceptible to hidden physical damage in long-distance laying under high tension.

[0019] 2. A tribologically orthogonal anisotropic distribution structure is constructed at the contact interface of the deformation response unit to achieve decoupling of normal support and tangential kinematics under deep envelopment state. A rolling drive surface with a first friction coefficient is set at the bottom of the unit to ensure a reliable rolling friction drive relationship between the cable and the roller, preventing slippage failure during startup or speed change. A sliding decoupling surface with a second friction coefficient is set on the side of the unit to allow the side support surface to slide non-destructively relative to the cable sidewall, eliminating the tangential velocity difference that is inevitable due to the larger rotation radius of the roller sidewall than the bottom rotation radius. The tribological characteristics are configured in different regions. When the huge normal reaction force provided by the sidewall is used to balance the lateral pressure, the tangential shear stress acting on the cable sheath surface is limited to an extremely low level, overcoming the problem of traditional variable diameter pulleys tightly wrapping the cable and aggravating sheath wear.

[0020] 3. By utilizing the synergistic effect of asymmetric stepped overlapping surfaces and pressure gradient guide channels, an adaptive protective barrier is constructed for complex silt conditions. The stepped misaligned structure at the edge of the deformation response unit forms an overlapping and sliding fit during the lateral convergence process, eliminating physical gaps between adjacent units and blocking the radial plastic flow extrusion path under strong lateral pressure of the softened cable sheath, thus ensuring the integrity of the sheath structure. The texture of the guide channel on the inner surface uses the positive pressure of the cable on the support surface to construct a fluid dynamic pressure gradient, forcibly guiding silt particles or fluid media between the contact surfaces to both sides of the unit for discharge, transforming the original abrasive medium that causes three-body wear into a fluid lubrication layer that reduces sliding resistance, thereby improving the system's operational stability and maintenance-free cycle in harsh geological environments. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the adaptive response and zoned friction principle of the integrated optical and electrical cable laying system of the present invention.

[0022] Figure 2 This is a graph showing the steady-state adjustment characteristics of the thermal compensation component of the present invention with respect to the envelope switching threshold across the entire temperature range.

[0023] Figure 3This is a multi-level functional module decomposition diagram of the integrated laying and protection system for optoelectronic combined cables of the present invention. Detailed Implementation

[0024] 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. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0025] This invention provides an integrated laying and protection system for optoelectronic composite cables under complex working conditions. It includes a rigid base unit anchored to a turning point in the installation path, and an adaptive load-bearing component rotatably mounted on the rigid base unit via a bearing assembly. This system utilizes the radial lateral pressure generated by the optoelectronic composite cable at the turning point as a driving source, enabling a switch from a low-tension rolling guidance mode to a high-tension envelope protection mode. The adaptive load-bearing component comprises a set of tightly arranged elastic segmented units along the axial direction. These elastic segmented units are made of elastic materials with bistable or gradually varying stiffness characteristics, such as polyurethane elastomers with a Shore hardness of A85 to 95 or high-manganese steel spring sheets. The initial geometry is an outwardly open U-shaped or V-shaped groove structure. The inner contact surface of the elastic segmented unit has a tribologically orthotropic distribution structure, dividing the contact surface into a rolling driving surface at the bottom and sliding decoupling surfaces on both sides. The rolling driving surface is located in the central region of the groove bottom of the elastic segmented unit and uses a high-friction coefficient material, such as micro-textured rubber with a Shore hardness of A70 to 80 or a surface roughness... A polyurethane matrix larger than 6.3 micrometers, with a rolling drive surface having a first coefficient of friction. ,Should The coefficient of friction is set to greater than 0.6 to ensure static friction engagement between the bottom surface of the optoelectronic composite cable and the rolling drive surface during cable laying, driving the elastic segmented unit to rotate synchronously with the linear motion of the optoelectronic composite cable; the sliding decoupling surface covers the two wings of the elastic segmented unit and uses a low-friction coefficient material, such as embedded PTFE strips or diamond-like carbon coating, and the sliding decoupling surface has a second coefficient of friction. ,Should Set to less than 0.1, when the radial pressure exceeds a preset threshold such as 500N, the elastic segmented unit is driven to converge inward and envelop the sidewall of the optoelectronic composite cable. The sliding decoupling surface is in a state of hydrodynamic lubrication or boundary lubrication, limiting the tangential shear stress to below the yield strength of the optoelectronic composite cable sheath material. The friction coefficient between the rolling driving surface and the sliding decoupling surface satisfies the following torque balance relationship: ,in, The first coefficient of friction, The second coefficient of friction, The half-angle of the envelope of the elastic segmented unit to the optoelectronic composite cable in the clamped state. The preset safety factor ranges from 1.2 to 1.5. This relationship ensures that the driving torque at the bottom is always greater than the drag torque on the side wings, maintaining the operation mode of bottom rolling and side sliding.

[0026] The side edges of the elastic segmented unit have an asymmetric stepped overlapping structure. The edges of two adjacent elastic segmented units overlap in the axial projection. When the elastic segmented unit is compressed and contracts inward, the adjacent edges slide circumferentially and form a shingled interlocking fit. This creates a topologically continuous annular rigid support interface around the optoelectronic composite cable, blocking the plastic flow path of the optoelectronic composite cable sheath to the unit gap under strong lateral pressure. The inner surface of the elastic segmented unit has an array of pressure gradient guide grooves. The pressure gradient guide grooves are distributed in a herringbone or V-shape, with their opening direction opposite to the laying direction of the optoelectronic composite cable. The groove depth is 0.5mm to 2.0mm. The positive pressure of the optoelectronic composite cable on the support surface drives the fluid medium or solid particles between the optoelectronic composite cable and the elastic segmented unit into the pressure gradient guide grooves. The fluid medium flows along the channel to the axial edges of the elastic segmented unit and is discharged, utilizing the hydrodynamic pressure effect to reduce the frictional resistance of the sliding decoupling surface. The elastic segmented unit integrates a bimetallic thermal compensation component, which is composed of two metal layers with different coefficients of thermal expansion, such as Invar alloy and brass. When the ambient temperature drops to a preset low temperature threshold, such as -20°C, the bimetallic thermal compensation component generates thermal stress deformation in a first direction to reduce the equivalent bending stiffness of the elastic segmented unit. When the ambient temperature rises to a preset high temperature threshold, such as 40°C, the bimetallic thermal compensation component generates thermal stress deformation in a second direction opposite to the first direction to increase the stiffness of the elastic segmented unit. This mechanism ensures that the fluctuation range of the tension-envelope response curve of the system is controlled within ±5% in the ambient temperature range of -40°C to 60°C.

[0027] The adaptive load-bearing component has follow-up guiding mechanisms at both ends. These mechanisms are connected to adjacent elastic segmented units via a four-bar mechanical coupling assembly. The linkage mechanism converts the radial displacement of the elastic segmented units into angular deflection motion of the follow-up guiding mechanism relative to the axis of the optoelectronic composite cable. By constraining the preset linkage geometric parameters, the support plane of the follow-up guiding mechanism is kept aligned with the tangential direction of the optoelectronic composite cable, achieving a transition from a straight segment to a variable curvature arc segment. An asymmetric friction energy dissipation component is provided on the radial movement path of the adaptive load-bearing component, including a set of wedge-shaped friction pairs with non-self-locking geometric wedge angles. When the elastic segmented units generate outward radial displacement, the wedge-shaped friction pairs are in a loosened slip state and provide the first frictional resistance. When the elastic segmented unit generates an inward retraction displacement, the wedge-shaped friction pair is in a wedge-tight state and provides a second frictional resistance, which is greater than the first frictional resistance. This component dissipates mechanical vibration energy through the force-displacement hysteresis loop determined by the geometric configuration. The end of the rigid base unit is provided with a state locking mechanism, including an axial preload nut. The state locking mechanism is used to apply an axial constraint force to the elastic segmented unit after laying, restricting its deformation or rotational degree of freedom, and converting the adaptive load-bearing component into a static fixed support. A moiré tension indicator is provided between the outer side of the elastic segmented unit and the rigid base unit. It contains two sets of micro-grating textures that generate optical interference, and uses the stripe changes generated by relative displacement to indicate the stress state of the optoelectronic composite cable.

[0028] Example 1: In the scenario of long-distance, large-angle laying of deep underground utility tunnels, the integrated laying and protection system of the photoelectric combined cable of this invention is applied to a complex path with a total length of 200 meters, including two continuous 90-degree turns, and the turning radius is limited by the physical space of the utility tunnel to only 1.5 meters. Due to the long traction distance and the cumulative effect of continuous bending, the axial traction tension borne by the photoelectric combined cable is high. The peak value reached 25kN, according to The calculation shows that P is the lateral pressure and R is the turning radius. The lateral pressure on the rigid contact surface will far exceed the micro-bending resistance threshold of the internal fiber unit of the optoelectronic composite cable, and the cable sheath faces extremely high risk of shear wear. When the system is in the low tension traction stage, i.e., the traction tension... When the resistance is less than 5kN, the elastic segmented unit remains in its initial outward-open first topological state. At this time, the bottom surface of the cable only contacts the rolling drive surface located at the center of the bottom of the elastic segmented unit groove, and uses micro-textured rubber with a Shore hardness of A75, whose first coefficient of friction is... The tension is 0.8, ensuring that during low-speed startup and straight-line propulsion, the elastic segmented unit effectively rotates around its axis using static friction, achieving low-resistance rolling guidance. As the cable advances, when it enters a sharp bend, the traction tension... The pressure rapidly increases to over 20kN, and the surge in radial lateral pressure causes the cable to indent the bottom of the elastic segmented unit, triggering its transition from the first topological state to the second topological state. Driven by a linkage mechanism, the two wings of the elastic segmented unit converge inward, tightly enveloping the cable sidewalls, thus increasing the contact area. The load increases rapidly and nonlinearly, transforming the line contact load that was originally concentrated at the bottom into a surface load distributed along the circumference of the cable, thereby forcibly clamping the pressure per unit area below the safety threshold.

[0029] In this deep envelope state, although the rotation radius of the elastic segmented unit's flanks... Greater than the bottom rotation radius This leads to the linear velocity of the flank. Higher than the cable travel speed However, due to the sliding decoupling surface composed of embedded polytetrafluoroethylene strips covering the side wings, its second coefficient of friction is... With a value of only 0.05, this tribologically orthotropically distributed structure creates a low-resistance differential slip interface between the side wings and the cable sidewall, thus reducing tangential shear stress. Limiting the speed to an extremely low level eliminates the risk of cable sheath abrasion caused by speed differences. Simultaneously, the bottom rolling drive surface maintains static friction anchoring to the cable's bottom surface, ensuring synchronized rotation of the rollers and preventing slippage and traction fluctuations. Furthermore, addressing the issues of cable sheath softening and siltation caused by the high humidity environment within the pipe gallery, the asymmetric stepped overlapping structure on the side edges of the elastic segmented unit forms a shingled interlocking structure in an enveloping state, constructing a topologically continuous rigid ring support that blocks the plastic rheological path of the softened sheath. Simultaneously, the herringbone pressure gradient guide groove on the inner surface utilizes the hydrodynamic effect generated by high-pressure contact to forcefully pump the mud-water mixture between interfaces to both sides of the unit for discharge, preventing abrasive accumulation and further reducing the frictional resistance of the sliding decoupling surface. After the laying operation is completed, axial constraint force is applied to the elastic segmented unit by rotating the axial pre-tightening nut at the end of the rigid base unit, locking it in a clamped state and eliminating rotational and radial deformation degrees of freedom. At this point, the adaptive load-bearing component immediately transforms into a highly stable static fixing clamp, achieving permanent cable fixation and protection.

[0030] Example 2: This example aims to quantitatively verify the effectiveness of the integrated fiber optic cable laying and protection system of the present invention in resolving the core engineering contradiction of pressure concentration and shear wear under high tension by constructing a highly realistic simulation test platform. The core objective of the test is to obtain the micro-bending loss characteristics of the internal fiber unit of the fiber optic cable and the physical wear depth of the outer sheath under different traction tension levels, thereby providing data support for the synergistic effect of the tension-induced envelope mechanism and the tribological orthotropic distribution structure of the present invention. The test platform consists of a hydraulic servo traction machine with a maximum output tension of 50kN and a control accuracy of ±0.1kN, a test path simulating a 90-degree sharp turn in an underground pipe gallery, and a high-precision online monitoring system. The turning points of the test path are designed with quick-replaceable mounting bases to install the present invention sample group using the technical solution of the present invention and the control sample group using a traditional fixed radius of curvature rigid deep groove pulley. The elastic segmented unit of the present invention sample group uses a polyurethane elastomer with a Shore hardness of A90, and the first friction coefficient of the rolling drive surface is... The second friction coefficient of the sliding decoupling surface is set to 0.8. The value was set to 0.05. The bottom radius of the pulley groove of the control sample group was the same as the bottom equivalent radius of the sample group of the present invention when it was in the clamping state, and the material was surface hardened steel. The cross-sectional diameter of the optical fiber combined cable sample used in the test was 50mm. It integrated four optical fiber units and four copper conductor units in a centrally symmetrical distribution. In order to simulate the dynamic interference in the real working condition to the greatest extent, a low-frequency pulsating disturbance signal with an amplitude of 5% of the base tension and a frequency of 0.5Hz was actively superimposed on the output tension of the traction machine.

[0031] The test was conducted using the tension gradient loading method, with axial traction tension... Starting from an initial value of 5 kN, the tension was increased in increments of 2 kN to 35 kN. At each tension step, the system maintained stable operation for 30 minutes. During this period, a distributed Brillouin optical time-domain reflectometer (BOTDA) embedded in the fiber unit was used to collect real-time strain distribution data of the optical fiber to characterize microbending loss. A high-precision laser diameter gauge installed at the path exit was used to monitor the geometric deformation and wear depth of the cable sheath in real time. All collected raw data were processed by notch filters to remove high-frequency noise components introduced by pulsating disturbances. A performance differentiation phenomenon was observed during the experiment, especially at the low tension stage ( Since the sample group of this invention is in an open first topology state, both it and the control sample group exhibit a bottom-supported mode, and the fiber microbending loss of both remains at a low level. When the tension exceeds 15kN, the data of the control sample group deteriorates sharply, and its fiber microbending loss increases rapidly with tension in an approximately linear manner, breaking through the industry-recognized safety threshold of 0.1dB / km at 25kN. When the tension of the sample group of this invention reaches about 15kN, the data curve shows an obvious inflection point, and the growth rate of microbending loss is strongly suppressed, exhibiting a plateau effect. Even if the tension continues to climb to 35kN, the microbending loss is still stably controlled below 0.05dB / km, confirming that the tension-induced envelope mechanism of this invention is triggered, effectively clamping the local contact pressure that originally increased linearly with tension through the nonlinear expansion of the contact area. To intuitively present the above law, Table 1 selects key performance index data at three representative tension levels.

[0032] Table 1: Comparison of Key Performance Indicators

[0033]

[0034] As can be seen from the data in Table 1, under high tension conditions of 25 kN, the average wear depth of the sheath in the sample group of this invention was only 0.03 mm, while that of the control sample group was as high as 0.35 mm, a difference of one order of magnitude. This data difference directly confirms the working mechanism of the tribological orthotropic distribution structure: under deep envelopment state, it has a second friction coefficient. The sliding decoupling surface transforms the high-speed relative motion between the side wing and the cable sidewall into lossless fluid lubrication sliding, thereby eliminating tangential shear force. In addition, the traction resistance coefficient of the present invention sample shows a decreasing trend under high tension (from 0.12 to 0.08), which is completely opposite to the trend of the control sample where friction increases sharply due to increased contact pressure (from 0.15 to 0.28), further confirming the establishment of the hydrodynamic pressure effect. To verify the ability of the asymmetric stepped overlap structure of the present invention to suppress sheath extrusion deformation, a constant tension holding pressure test was conducted for 2 hours under a limit tension of 35kN. After the test, the microstructure of the cable sheath surface was scanned. The results showed that the cable sheath guided by the control sample had a plastic rheological ridge protrusion with a height of about 1.5mm at the corresponding pulley gap position.

[0035] Example 3: This example combines Figures 1 to 3 This document describes an integrated laying and protection system for optoelectronic cables designed for complex operating conditions. Figure 1As shown, a rigid base is configured to anchor at the turning point to provide installation support. The optoelectronic composite cable acts as an input source, applying radial pressure and traction tension to the system. This force drives the axially arranged elastic segmented units in the adaptive bearing assembly, causing the geometry to change from an open state to a closed state that wraps around the cable sidewalls. The elastic segmented unit includes a partitioned friction structure on its inner surface, specifically a rolling driving surface located at the bottom center and sliding decoupling surfaces located on both sides. The rolling driving surface uses a first friction coefficient to establish static friction contact to drive the unit to rotate around the axis. The sliding decoupling surface uses a lower second friction coefficient to allow relative sliding to eliminate tangential shear force, thereby ultimately achieving a non-destructive laying state where the optoelectronic composite cable sidewalls are wrapped and there is no tangential shear wear.

[0036] like Figure 2 As shown, the horizontal axis represents ambient temperature, covering a range of -40℃ to 60℃, and the vertical axis represents the envelope state switching threshold in N. The graph contains three indicator lines: the horizontal dotted line represents the preset design target threshold of 500N; the dashed line represents the switching threshold change trend without thermal compensation, showing that it monotonically decreases from 650N to 250N as the temperature rises; and the solid line represents the switching threshold change trend after incorporating thermal compensation, showing that it remains stable near the design target threshold of 500N throughout the entire temperature range. Figure 3 As shown in the diagram, the system architecture is centered on an integrated fiber optic cable laying and protection system. Its design goals encompass lossless operation, high tension, and adaptive characteristics, and are progressively expanded into five functional modules: the geometric topology adaptive module includes elastic segmented units that enable the transition from open to closed states and a stepped overlapping structure to prevent sheath extrusion; the environmental adaptive module includes a herringbone pressure gradient guide channel for sand and water drainage and a bimetallic thermal compensation component for stiffness and temperature compensation; the partitioned friction structure module is divided into a sliding decoupling surface with a low friction coefficient μ2 and a rolling drive surface with a high friction coefficient μ1; the state locking and monitoring module consists of a moiré tension indicator for visual deformation monitoring and a locking device fastener for fixing the closed state; and the auxiliary control mechanism module includes a friction damping component to suppress radial vibration and a follow-up guide mechanism that achieves tangential alignment through linkage coupling.

[0037] Example 4: This example aims to provide a principled explanation and engineering parameterized calibration of the bistable or gradually varying stiffness characteristics of the elastic segmented unit in the aforementioned specific implementation methods and examples. This aims to eliminate potential technical black boxes regarding the design and manufacturing of this core component, ensuring the reproducibility of its mechanical response characteristics in engineering. The process encompasses a complete technical path from establishing the material constitutive model and parameterizing the geometric topology to simulating and verifying the dynamic response characteristics. In the material constitutive model establishment stage, uniaxial tensile, compression, and plane shear tests were conducted on the selected polyurethane elastomer with a Shore hardness of A90 to obtain its stress-strain curves at different strain rates. Based on the experimental data, the Ogden hyperelastic constitutive model was used to describe the nonlinear mechanical behavior of the material. The strain energy density function of the Ogden model... Expressed as: ,in, Main elongation ratio, To determine the material constants by fitting the experimental data using the nonlinear least squares method, for the polyurethane material used in this embodiment, Select 3, and obtain the key parameters through fitting. This constitutive model provides an accurate materials physics basis for subsequent structural simulations.

[0038] In the geometric topology optimization stage, to achieve the expected tension-induced variable envelope function—that is, the nonlinear stiffness characteristic of remaining open under low pressure and rapidly closing under high pressure—a biomimetic leaf vein skeleton structure with variable cross-section characteristics was designed and modeled in finite element analysis software. Its key geometric parameters include: bottom wall thickness... , radius of the corner at the root of the wing and the wing deployment angle Radial pressure was established through parametric scanning analysis. With flank contraction displacement The response surface model between the two, the analysis results show that, when It is set to 0.6 times the average wall thickness of the flanks, and When the value is 3mm, the structure exhibits significant buckling instability characteristics near the radial pressure threshold of approximately 500N, i.e., tangential stiffness. A sudden drop occurred; during the verification of dynamic response characteristics and calibration of process parameters, the optimized geometric model was imported into a multibody dynamics simulation environment to simulate the dynamic process of the optoelectronic composite cable passing through the elastic segmented unit at different speeds and tensions. The simulation introduced a contact definition based on the Coulomb friction model, with the friction coefficient set according to the calibration values ​​in the aforementioned embodiments. Simulation results showed that under the conditions of a traction speed of 20 m / min and a tension of 25 kN, the response time of the elastic segmented unit, i.e., the time from the start of contact to complete envelopment, was less than 0.1 seconds, and no high-frequency flutter occurred during the envelopment process. To ensure that the manufactured physical component has performance consistent with the simulation, an injection molding process specification was formulated: the mold temperature was controlled at... Injection pressure set to The pressure holding time shall be no less than 20 seconds to eliminate internal residual stress and ensure geometric accuracy.

[0039] Example 5: This example aims to establish a standardized process enhancement and reliability verification procedure for the interfacial bonding strength between the bimetallic thermal compensation component and the polyurethane elastomer matrix in the integrated optical fiber cable laying and protection system of the present invention, as well as the fatigue life of the bimetallic component. This eliminates potential technical black boxes regarding the interfacial bonding process of heterogeneous materials and long-term operational reliability, ensuring the stability of the device throughout its entire lifecycle under complex operating conditions. To guarantee the integrity of the interfacial bonding between the bimetallic thermal compensation component and the polyurethane matrix under repeated thermal cycling and mechanical deformation, an interfacial enhancement treatment process is formulated, and the surface of the bimetallic sheet is roughened by sandblasting to control its surface roughness. achieve To increase mechanical interlocking points, plasma-enhanced chemical vapor deposition (PECVD) technology is used to deposit a thickness of [missing information] on the roughened metal surface. The silicone-containing organic functional primer layer acts as a molecular bridger. One end of the primer layer forms covalent bonds with the oxide layer on the metal surface via silane functional groups, while the other end's active organic groups chemically react with the polyurethane prepolymer during subsequent injection molding, thus establishing a chemically bonded interface between the metal and polyurethane. The peel strength of the treated composite interface is verified through a 90-degree peel test based on ASTM D429 standards. Greater than Furthermore, the failure mode is polyurethane bulk cohesive failure.

[0040] Furthermore, to assess the fatigue resistance of bimetallic thermal compensation components, a low-cycle fatigue life prediction model based on the Coffin-Manson equation was constructed. Cyclic stress-strain curves and fatigue life data of the bimetallic material were obtained through strain-controlled fatigue tests, and the fatigue strength index was determined. and fatigue ductility index Based on the Invar alloy and brass composite material selected in this embodiment, the fitting parameters are as follows: The equivalent plastic strain amplitude under the maximum working deformation extracted by finite element analysis Substituting into the Coffin-Manson equation: ,in, The fatigue ductility coefficient, The theoretical fatigue life is calculated based on the number of reversal cycles required to achieve fatigue failure. Greater than Further accelerated fatigue life testing in subsequent cycles showed that the component withstood mechanical reciprocating loads at a frequency of 1 Hz and an amplitude of maximum working deformation. After one cycle, no microcracks were observed to develop inside or at the interface.

[0041] Example 6: This example aims to address the lack of a basis for setting the friction coefficient threshold in the tribologically orthogonally anisotropic distributed structure of the adaptive load-bearing component, as well as the absence of calibration procedures for response sensitivity under different working conditions—a kind of engineering black box problem. It constructs a standardized offline tribological parameter matching and adaptive response sensitivity calibration procedure, determines the optimal working range of key physical parameters through quantitative experimental methods, and establishes an initial calibration process for different batches of raw materials to ensure the consistency and reproducibility of system performance. In the offline tribological parameter matching stage, to determine the optimal friction coefficient combination that balances bottom anchoring and side decoupling functions, a material screening platform based on a pin-disc friction and wear testing machine is built. For the rolling drive surface, polyurethane and rubber materials with a hardness range of Shore A 60 to 90 are selected to prepare samples. Static friction coefficient tests are performed on a mating disc simulating cable sheath material. The test load is set to the equivalent contact pressure corresponding to a 5kN tension under actual working conditions. The test results show that when the Shore hardness A is 75±5 and the surface has a micro-textured structure, i.e. Between 6.3 and 12.5 At that time, the first coefficient of friction The coefficient of dynamic friction is kept stable between 0.75 and 0.85. This provides sufficient tangential driving torque to prevent slippage while avoiding excessive deformation and energy consumption due to excessive softness. For the sliding decoupling surface, the dynamic friction coefficients of PTFE, UHMWPE, and molybdenum disulfide coatings at different sliding speeds are investigated. Considering the high linear velocity difference of the side wings under the envelope state, the embedded PTFE strip is preferred, as its second coefficient of friction under dry friction conditions is [missing information]. Maintaining at a level between 0.04 and 0.06 satisfies The torque balance constraint ensures the stable establishment of the bottom rolling and side sliding modes.

[0042] In the adaptive response sensitivity calibration stage, to address the issue of envelope response threshold drift caused by modulus fluctuations in different batches of elastomer materials, a factory calibration procedure based on force-displacement hysteresis loops was developed. The assembled adaptive load-bearing component was installed on a servo hydraulic test bench, and radial displacement-controlled reciprocating loading was applied at a loading rate of 5 mm / min. The maximum displacement corresponded to the full envelope state. The reaction force curves during loading and unloading were recorded in real time, and the critical buckling load was extracted. As a key monitoring indicator, if the actual measurement of a certain batch of products... The deviation from the preset standard value exceeds 500N. If the preload is 10%, compensation is achieved by fine-tuning the initial preload strain of the bimetallic thermal compensation component. If the initial tangential stiffness is too high, the thermal compensation component is adjusted to produce a small amount of pre-opening deformation, reducing the initial tangential stiffness of the structure; conversely, pre-closing deformation is applied. After calibration, the consistency error of the force-displacement curve of the component is controlled within 5%, ensuring that all delivered products can accurately trigger topological transformation under the expected tension threshold in field applications.

[0043] Example 7: In this example, an asymmetric damping friction pair is constructed using QSn6.5-0.1 phosphor bronze wedges paired with nitrided 40Cr steel (HRC≥58). The contact surfaces are ground to Ra≤0.4μm and coated with lithium molybdenum disulfide grease; the engineering wedge angle is set to... This parameter, based on the principle of frictional self-locking, satisfies... The unlocking conditions are met, and the return damping force is ensured to be more than three times the expansion stroke resistance, so that while dissipating high-frequency micro-amplitude vibrations, elastic restoring force is used to achieve jam-free reset.

[0044] Based on this, a moiré grating was fabricated on a 0.05 mm thick 301 stainless steel foil using ultraviolet lithography and ferric chloride etching processes. The period of the reference grating on the base side was set to... The period of the vernier grating on the elastic unit side is set to This allows for a 20x optical magnification factor, making the elastic unit appear smaller. Radial deformation is transformed into something visible to the naked eye. Macroscopic displacement; ultimately applied on the assembly and testing stage. Standard cohesion load will generate moiré dark band center Displacement points are marked with red warning lines to establish a visual on-site standard for determining whether protection is effective once the red lines are aligned.

[0045] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the present invention.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. An integrated laying and protection system for optoelectronic composite cables for complex working conditions, characterized in that, include: Rigid base, configured for anchoring at turning points in the laying path; An adaptive load-bearing component is rotatably mounted on a rigid base; The adaptive load-bearing component includes multiple elastic segmented units arranged along the axial direction; each elastic segmented unit has a variable geometry that changes from an open state to a closed state under the radial pressure of the optoelectronic composite cable; in the closed state, the side wings of the elastic segmented unit converge inward to wrap around the sidewall of the optoelectronic composite cable; wherein, the inner surface of the elastic segmented unit is provided with a partitioned friction structure; the partitioned friction structure includes a rolling drive surface located at the bottom center of the elastic segmented unit and a sliding decoupling surface located on both sides of the elastic segmented unit. The rolling drive surface has a first coefficient of friction, which keeps the bottom surface of the cable in static frictional contact with the rolling drive surface during cable laying, so as to drive the elastic segmented unit to rotate around the axis; the sliding decoupling surface has a second coefficient of friction, which is less than the first coefficient of friction, so that when the elastic segmented unit is in a hugging state and wraps around the side wall of the cable, the sliding decoupling surface is allowed to slide relative to the side wall of the optoelectronic composite cable.

2. The integrated laying and protection system for optoelectronic combined cables for complex working conditions according to claim 1, characterized in that, First coefficient of friction of rolling drive surface The second friction coefficient with the sliding decoupling surface The following relationship must be satisfied: ,in, This represents the maximum half-angle of the elastically segmented unit in its closed state. As a preset safety factor, this relationship is used to ensure that the rotational driving torque provided by the rolling drive surface is greater than the resisting torque generated by the sliding decoupling surface.

3. The integrated laying and protection system for optoelectronic combined cables for complex working conditions according to claim 1, characterized in that, The side wing edges of the elastic segmented unit are provided with a stepped overlapping structure; the stepped overlapping structures of adjacent elastic segmented units form a sliding overlap fit along the circumferential direction in the clamping state, thereby forming a continuous annular support surface around the optoelectronic composite cable.

4. The integrated laying and protection system for optoelectronic combined cables for complex working conditions according to claim 1, characterized in that, The inner surface of the flexible segmented unit is provided with a guide groove; the guide groove is distributed in a herringbone or V-shape, and its opening direction is opposite to the travel direction of the photoelectric composite cable; the guide groove is configured to use the squeezing force applied by the photoelectric composite cable to guide the fluid medium or particulate matter between the photoelectric composite cable and the flexible segmented unit to the axial sides of the flexible segmented unit for discharge.

5. The integrated laying and protection system for optoelectronic combined cables for complex working conditions according to claim 1, characterized in that, The elastic segmented unit is internally integrated with a bimetallic thermal compensation component; the bimetallic thermal compensation component is composed of metal layers with different coefficients of thermal expansion; the bimetallic thermal compensation component is configured to generate thermal deformation in a first direction when the ambient temperature decreases to reduce the bending stiffness of the elastic segmented unit against radial pressure, and to generate thermal deformation in a second direction opposite to the first direction when the ambient temperature increases to increase the bending stiffness of the elastic segmented unit, thereby compensating for the drift of mechanical properties of the matrix material caused by temperature changes.

6. The integrated laying and protection system for optoelectronic combined cables for complex working conditions according to claim 1, characterized in that, The system also includes a follow-up guide mechanism, which is located at both ends of the adaptive bearing component. The follow-up guide mechanism is connected to the adjacent elastic segment unit through a linkage mechanism. The linkage mechanism is configured to drive the follow-up guide mechanism to deflect relative to the cable axis when the elastic segment unit generates outward radial displacement, so that the support surface of the follow-up guide mechanism is aligned with the tangential direction of the optoelectronic composite cable entering or exiting.

7. The integrated laying and protection system for optoelectronic combined cables for complex working conditions according to claim 1, characterized in that, The adaptive load-bearing component also includes a friction damping component; the friction damping component includes a wedge-shaped friction pair disposed on the radial movement path of the elastic segment unit; the wedge-shaped friction pair is configured to be in a loose state to provide a smaller frictional resistance when the elastic segment unit produces an outward radial displacement, and in a wedge-tight state to provide a larger frictional resistance when the elastic segment unit produces an inward retraction displacement.

8. The integrated laying and protection system for optoelectronic combined cables under complex working conditions according to claim 1, characterized in that, A moiré tension indicator is provided between the outer surface of the elastic segmented unit and the rigid base; the moiré tension indicator includes a first grating texture disposed on the elastic segmented unit and a second grating texture disposed on the rigid base; the first grating texture and the second grating texture are configured to use the moiré principle to convert the deformation displacement of the elastic segmented unit into a visual pattern change to indicate the stress state of the optoelectronic composite cable.

9. The integrated laying and protection system for optoelectronic combined cables for complex working conditions according to claim 1, characterized in that, The system also includes a locking device; the locking device includes a fastener for applying axial pressure, which restricts the deformation recovery of the elastic segment unit by compressing the side of the elastic segment unit, thereby securing the adaptive load-bearing assembly in a clamped state.

10. The integrated laying and protection system for optoelectronic combined cables for complex working conditions according to claim 1, characterized in that, The elastic segmented unit is an integrally molded elastomer. The material layer corresponding to the first coefficient of friction and the material layer corresponding to the second coefficient of friction are bonded to the surface of the elastomer through a two-color injection molding process or a surface coating process. The material layer corresponding to the first coefficient of friction is a polyurethane or rubber material with a Shore hardness of A70 to 90, and the material layer corresponding to the second coefficient of friction is a polytetrafluoroethylene or diamond-like carbon coating material.

Images