Crane cable structure and manufacturing method

Abstract

The invention discloses a crane cable structure and a manufacturing method, solves the problems that a crane cable in the prior art is lack of setting of intelligent perception related functions and cable reciprocating motion and the flexibility of an existing cable is poor, and has the beneficial effect of improving the anti-fatigue performance of the cable. Comprising a plurality of conductive wire cores, an optical unit and an outer sheath, the conductive wire cores are arranged on the two sides of the optical unit, the optical unit and the conductive wire cores are arranged at intervals, the outer sheath wraps the optical unit and the conductive wire cores, each conductive wire core comprises a conductor, and each conductor comprises a compound stranded part. The compound stranded part is made of annealed copper wires in a compound stranded structure mode so as to increase the flexibility of the conductor, the diameter of copper wires in the compound stranded part is 0.10 mm-0. 14 mm, a braid layer is arranged in the circumferential direction of the compound stranded part, the braid layer is formed by braiding copper wires with the diameter of 0.10 mm-0. 12 mm so as to bind the appearance of the conductor and increase radial stress resistance, an insulating layer is arranged in the circumferential direction of the conductor, and a shielding layer is arranged in the circumferential direction of the insulating layer.

Description

TECHNICAL FIELD

[0001] The embodiment of the present application relates to the cable technical field, in particular to a travelling crane cable structure and manufacturing method. BACKGROUND

[0002] Nowadays, the freight port has begun to put into operation the automatic container terminal and the automatic bulk cargo terminal, and during the operation of the automatic container terminal and the automatic bulk cargo terminal, the unmanned travelling crane becomes the "standard configuration" of the smart port and the automatic terminal, and the cable thereon also needs to have the stability and the intelligent characteristics.

[0003] The cable on the current travelling crane mainly has the traditional pure power transmission as the main characteristic. The travelling crane will always reciprocate, and the travelling crane cable will also always reciprocate, which has a higher requirement on the flexibility of the internal conductor of the cable. The diameter of the copper wire of the existing travelling crane cable is relatively large, the flexible copper wire with a large diameter is poor in flexibility, and is easy to cause the service life of the cable to be short. Moreover, some cables with optical fibers directly place the optical fibers in the cable, without considering how to protect the optical fibers and how to improve the fatigue resistance of the optical fibers.

[0004] In addition, the existing travelling crane cable mainly uses ethylene-propylene rubber or polyvinyl chloride as the insulating layer, and polyvinyl chloride or nitrile butyl elastomer as the sheath material, so that the existing travelling crane cable also has the problem of general flame retardant performance. SUMMARY

[0005] In view of the deficiencies of the prior art, the purpose of the embodiment of the present application is to provide a travelling crane cable structure which can improve the flexibility of the conductor and thus improve the overall fatigue resistance of the travelling crane cable.

[0006] In order to achieve the above-mentioned purpose, the present application is realized by the following technical scheme: A travelling crane cable structure, comprising a plurality of conductive cores, an optical unit and an outer sheath, the conductive cores are arranged on both sides of the optical unit, the optical unit and the conductive cores are arranged with a spacing distance, the outer sheath is formed by extrusion to wrap the optical unit and the conductive cores, the optical unit comprises an optical fiber, the optical fiber is a bend-insensitive optical fiber with a polyimide coating, the conductive core comprises a conductor, the conductor comprises a complex twisting piece, the complex twisting piece is made of annealed copper wire in a complex twisting structure to increase the flexibility of the conductor, the diameter of the annealed copper wire in the complex twisting piece is 0.10mm-0.14mm, the complex twisting piece is provided with a circumferential braided layer, the braided layer is woven by copper wire with a diameter of 0.10mm-0.12mm to bind the shape of the conductor and increase the radial stress resistance, the conductor is provided with an insulating layer in the circumferential direction, and the insulating layer is provided with a shielding layer in the circumferential direction.

[0007] Further, the complex twisting member is twisted by several single copper wires as a unit, and the several units are twisted again or twisted again if necessary, the ratio of the longitudinal spiral length of the single copper wire to the diameter of the single copper wire is 18-24, and the ratio of the longitudinal spiral length of the outermost unit to the diameter of the single unit is 12-16 during the secondary twisting or the third twisting. The braiding density of the copper wire in the braiding layer is 50%-60%.

[0008] Further, the insulating layer includes an inner insulating layer and an outer insulating layer, the inner insulating layer is made of extruded soft PVC or PVC-nitrile elastomer or ethylene-propylene rubber insulating material, and the outer insulating layer is made of a heavy overlapping wrapped fireproof paper insulating isolation layer. The outer insulating layer is made of 0.08-0.12mm aromatic polyamide polymer base fireproof paper, and the wrapping overlapping rate is 5%-15%.

[0009] Further, the longitudinal section of the outer sheath is flat.

[0010] Further, the shielding layer includes an inner wrapped shielding layer and an outer braided shielding layer, the inner wrapped shielding layer adopts a heavy overlapping wrapped structure of copper-plastic composite tape or aluminum-plastic composite tape, the total thickness of the inner wrapped shielding layer is 0.04mm-0.05mm, the thickness of the metal layer in the copper-plastic composite tape or aluminum-plastic composite tape is greater than or equal to 0.018mm, and the wrapping overlapping rate is controlled within 15%±5%.

[0011] Further, the outer braided shielding layer adopts a hybrid material braiding structure of aramid and tinned copper wire, the number of spindles of the tinned copper wire and the aramid is the same, and the tinned copper wire and the aramid are braided by crossing. The aramid is selected from materials with a fineness of 1100-1600dtex, the diameter of the single copper wire in the tinned copper wire is 0.10mm-0.15mm, and the braiding density of the outer braided shielding layer is 90%-94%.

[0012] Further, at least one optical fiber is arranged in the optical unit, and the minimum bending radius of the optical fiber is 30mm. The flexible armor layer is circumferentially arranged on the optical fiber, a tension is applied to the flexible armor layer during the manufacturing of the flexible armor layer, so that the length of the flexible armor layer exceeds the length of the optical fiber during the manufacturing of the optical unit, so as to ensure that the optical fiber is not stressed and has a length redundancy, the flexible armor layer is formed by helically winding a steel belt with a thickness of 0.15mm-0.25mm, the helical gap of the flexible armor layer is less than or equal to 10% of the width of the steel belt, and the helical pitch angle of the flexible armor layer is controlled within 5%±0.5%.

[0013] Further, the outer sheath is made of 90℃ black nitrile polyvinyl chloride elastomer sheath material or black polyether polyurethane sheath material. The two side surfaces of the outer sheath are provided with stress grooves at positions corresponding to the light units and the conductive wire cores and between two adjacent conductive wire cores, the stress grooves are realized in the extrusion process of the outer sheath, the stress grooves are square or arc-shaped, the side length of the square stress groove is greater than or equal to 0.6 mm, and the angle of the arc-shaped stress groove is between 160° and 180°.

[0014] Further, the conductive wire cores are provided in multiple places, part of the conductive wire cores are arranged on one side of the light unit, the other conductive wire cores are arranged on the other side of the light unit, and the interval distance is arranged between two adjacent conductive wire cores on the same side of the light unit.

[0015] In the second aspect, the application discloses a manufacturing method of a traveling cable structure, and the manufacturing method comprises the following contents. Manufacturing the conductive wire core: Manufacturing a plurality of conductors, each conductor is selected from an annealed copper wire with a diameter of 0.10 mm to 0.14 mm in the manufacturing process, the annealed copper wire is made into a complex twisting part in a complex twisting structure, and a braided layer is formed by braiding a copper wire with a diameter of 0.10 mm to 0.12 mm in the circumferential direction of the complex twisting part; an insulating layer is arranged in the circumferential direction of the conductor, and a shielding layer is arranged in the circumferential direction of the insulating layer; Manufacturing the light unit; The conductive wire cores are arranged on both sides of the light unit, and the outer sheath is formed in the circumferential direction of the light unit and the conductive wire core by extrusion molding.

[0016] The beneficial effects of the application are as follows: The traveling cable provided by the application comprises a light unit and a conductive wire core, the light unit comprises an optical fiber, the optical fiber can be connected with a sensor and the like as a light conducting tool to facilitate intelligent sensing of the traveling cable, the conductive wire core comprises a conductor, the conductor comprises a complex twisting part, the complex twisting part is made of an annealed copper wire in a complex twisting structure to increase the flexibility of the conductor, the diameter of the annealed copper wire is 0.10 mm to 0.14 mm to facilitate guaranteeing the flexibility of the conductor, a braided layer is arranged in the circumferential direction of the complex twisting part, the braided layer is formed by braiding a copper wire with a diameter of 0.10 mm to 0.12 mm to bind the shape of the conductor and increase the radial stress resistance, and the flexibility of the conductor is guaranteed, which is sufficient to cope with the operation fatigue of the conductor suspended on the traveling crane and reciprocally retracted and released, and the overall fatigue resistance is better than that of a conventional conductor structure. The optical fiber adopts a bending-insensitive optical fiber, so that the optical fiber is relatively less afraid of bending, and the optical fiber is coated with a polyimide coating on the surface, so that the optical fiber is resistant to high temperature and is prevented from being damaged during production of the outer sheath, thereby playing a high-temperature protection role.

[0017] In the forming process of the complex twisting part, the ratio of the longitudinal spiral length of the single copper wire twisting to the diameter of the single copper wire, the ratio of the longitudinal spiral length of the outermost unit twisting to the twisting diameter of the single unit, and the braiding density of the outer braided reinforcing layer of the conductor outermost twisting are limited, so that the structural performance of the conductor is effectively guaranteed, and the flexibility of the conductor is improved.

[0018] The circumferential insulation layer of the conductor in the application includes an inner insulation layer and an outer insulation layer, the material of the inner insulation layer has excellent electrical insulation performance, can effectively isolate the current, and is soft and can closely adhere to the conductor, and plays a mechanical protection role in buffering in the movement of the line body, the outer insulation layer adopts an overlapping wrapping type fireproof paper insulation isolation layer, and adopts an overlapping wrapping process, so that the fireproof paper insulation isolation layer is tightly and uniformly wrapped in the outer insulation layer, the insulation effect is enhanced, and the overall fatigue resistance of the conductor is improved; the fireproof paper is light in quality and does not increase too much burden on the conductor, and has good flexibility and tear resistance.

[0019] The shielding layer in the application is provided with an inner wrapping shielding layer and an outer braided shielding layer, the inner wrapping shielding layer adopts an overlapping wrapping structure, can effectively control low-frequency electromagnetic interference in driving, and the outer aramid-copper wire mixed braided structure can effectively resist high-frequency electromagnetic interference in the running environment, through the cooperation of the inner double-layer shielding, the normal power supply of the line and the normal completion of the system instruction can be ensured; the material of the outer sheath has good elasticity, and through the selection of the flame-retardant property of the material, the overall flame-retardant effect of the cable can be effectively realized, the safety performance of the line is improved, the aramid layer can be directly used as a self-bearing part of the cable, the stress of the insulation layer and the outer sheath is reduced, the service life of the cable is improved, and the setting of the stress groove of the sheath avoids the failure of the sheath caused by stress concentration during the operation of the cable, prolonging the service life of the cable.

[0020] In the application, the flexible armor layer is arranged circumferentially around the optical fiber, which well protects the optical fiber, and the length of the flexible armor layer is set to be longer than the optical fiber during the manufacturing of the flexible armor layer, and the stress of the flexible armor layer is released after the preparation of the optical unit by adopting a rewinding mode, so that the excess length of the optical fiber is formed, so that the optical fiber will not be stressed during use.

[0021] Through the setting of the overall structure, the flexibility of the soft conductor can be effectively improved, long-term repeated bending fatigue can be coped with, the double-insulation structure design ensures that the insulation has fireproof performance in addition to basic electrical and mechanical properties, the reaction time can be increased in case of fire, and the loss under special circumstances can be reduced, through the shielding structure form of wrapping + braiding, the line core flexibility is guaranteed while the high, medium and low frequency electromagnetic interference environment is possessed, the electronic noise generated by the driving itself is avoided to spread, and the normal work of the driving itself is prevented from being affected by external electronic noise of each frequency band, and the adaptability of the electromagnetic environment of the driving application place is widened. BRIEF DESCRIPTION OF DRAWINGS

[0022] The accompanying drawings, which form a part of this specification, are included to provide a further understanding of the application, and are incorporated into and constitute a part of this specification. The embodiments of the application, and their

[0023] Figure 1 is a schematic view of a longitudinal section of a cable structure according to one or more embodiments of the application.

[0024] Figure 2 is a schematic view of a cross section of an optical unit in a cable structure according to one or more embodiments of the application.

[0025] In the drawings: the mutual distances or dimensions are exaggerated for the purpose of showing the positions of the various parts, the schematic views are merely schematic.

[0026] wherein: 1. conductor, 2. inner insulating layer, 3. outer insulating layer, 4. inner layer of a braided shielding, 5. outer layer of a braided shielding, 6. optical unit, 7. outer sheath, 8. stress groove, 9. conductive core, 61. flexible armor layer, 62. optical fiber; 63. filler. DETAILED DESCRIPTION

[0027] It should be noted that the following detailed description is exemplary in nature and is intended to provide further description of the application. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

[0028] It is to be understood that the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. It should be noted that the terms "comprises", "comprising", "includes", "including", "contains", "containing" or variations thereof do not specify an exhaustive inclusion or list, and that the terms are to be construed as specifying at least the stated features, steps, or components, but not excluding others; As introduced in the background section, the prior art lacks the setting of intelligent sensing related functions, and the cable has poor flexibility when reciprocating. In order to solve the above technical problems, the present application provides a cable structure for a travelling crane.

[0029] Embodiment one In a typical embodiment of the application, reference is made to Figure 1As shown, a kind of car cable structure, including optical unit 6 and multiple conductive cores 9, conductive core 9 is arranged in the two sides of optical unit 6, and optical unit 6 is arranged with the distance between conductive core 9, outer sheath 7 is arranged by extrusion molding to surround optical unit 6 and conductive core 9, optical unit 6 includes optical fiber, and conductive core 9 includes conductor 1, conductor 1 includes complex twisting piece, and complex twisting piece is made into complex twisting structure by annealed copper wire to increase the flexibility of conductor, the diameter of annealed copper wire in complex twisting piece is 0.10mm-0.14mm, and the circumferential setting braiding layer of complex twisting piece is woven by copper wire with the diameter of 0.10mm-0.12mm to bind the shape of conductor and increase the radial stress resistance, the circumferential setting insulation layer of conductor 1 is circumferentially set with shielding layer.

[0030] Wherein, annealed copper wire is made of multiple tinned or untinned annealed soft copper wires, and annealed copper wire is a kind of wire material which is heated to soften, improve ductility and reduce resistivity, and copper wire is made into complex twisting structure. The diameter of copper wire in copper wire is 0.10mm-0.14mm, and a plurality of single copper wires are twisted as one unit, and multiple units are twisted twice or twisted again if necessary. The ratio of the longitudinal spiral length of single copper wire twisting to the diameter of single copper wire is 18-24, and the ratio of the longitudinal spiral length of the outermost unit twisting to the diameter of unit twisting is 12-16. The conductor is made of multiple small size annealed soft copper wires, which guarantees the flexibility of the conductor and can cope with the running fatigue of the conductor suspended on the car.

[0031] After all the copper wires are twisted, the copper wires with the diameter of 0.10mm-0.12mm are woven on the outside to form a braiding layer, and the surface coverage of the braiding layer on the whole surface of the complex twisting piece after weaving is 50%-60%, which is used to improve the overall toughness of the conductor.

[0032] It is easy to understand that the insulation layer includes inner insulation layer 2 and outer insulation layer 3, and the inner insulation layer is inner insulation layer 2. The inner insulation layer 2 is made of extruded soft PVC (polyvinyl chloride) or PVC-nitrile elastomer or ethylene-propylene rubber insulation material. The PVC or PVC-nitrile elastomer or ethylene-propylene rubber insulation material has excellent electrical insulation performance, which can effectively isolate electric current and prevent safety hazards such as electric leakage. At the same time, it also has good chemical corrosion resistance and can be used in various complex environmental conditions. It is not easy to be damaged by chemical substances, effectively ensuring the long-term stable operation of the conductor. Moreover, the soft texture closely adheres to the conductor, which will not adversely affect the flexibility of the conductor, and helps to maintain the good performance of the conductor during the reciprocating process of suspension on the car, thereby improving the overall fatigue resistance. The outer layer of the insulation layer is an outer insulation layer 3, the outer insulation layer 3 adopts an overlapping wrapping type fireproof paper insulation isolation layer, the outer insulation layer 3 has excellent fireproof performance, the outer insulation layer 3 adopts an overlapping wrapping process, so that the fireproof paper insulation isolation layer is tightly and uniformly wrapped outside the conductor, which not only enhances the insulation effect, but also further improves the overall fatigue resistance of the conductor; the fireproof paper is light and does not increase the burden of the conductor, and has good flexibility and tear resistance, which can adapt to various deformation requirements of the conductor in complex working environments, ensure the long-term stable operation of the conductor 1, the fireproof paper insulation isolation layer adopts 0.08~0.12mm aromatic polyamide polymer base material fireproof paper, the wrapping overlapping rate is 5%~15%, the double-layer insulation can effectively ensure the electrical insulation performance of the conductive wire core, improve the mechanical properties of the wire core, and through material selection, the wire core has fireproof performance, which increases the safety of the line, and in the event of a fire, the fireproof paper insulation isolation layer can block the spread of the fire for a certain period of time, leaving time for emergency handling of the running and lifting system, and improving the safety margin of the running and lifting system.

[0033] In the embodiment, the shielding layer includes an inner wrapping shielding layer 4 and an outer woven shielding layer 5. The inner wrapping shielding layer 4 adopts an overlapping wrapping structure of copper-plastic composite tape or aluminum-plastic composite tape, and the total thickness of the outer woven shielding layer 5 is selected to be 0.04mm~0.05mm, wherein the thickness of the metal layer in the copper-plastic composite tape or aluminum-plastic composite tape is greater than or equal to 0.018mm, and the wrapping overlapping rate is controlled to be 15%±5%. The inner wrapping shielding layer 4 adopts an overlapping wrapping structure, which can effectively control the low-frequency electromagnetic interference in the travelling crane. The outer woven shielding layer 5 adopts a hybrid material woven structure of aramid fiber (aramid fiber) and tinned copper wire (tinned annealed soft copper wire), wherein the number of spindles of the tinned copper wire and the aramid fiber is the same, and the tinned copper wire and the aramid fiber must be completely crossed for weaving. The aramid fiber is selected to be a material with a fineness of 1100~1600dtex (decitex), and the diameter of a single copper wire of the tinned copper wire is 0.10~0.15mm. The weaving density of the outer woven shielding layer 5 is 90%~94%. The setting of the outer woven shielding layer 5 is conducive to restraining the shape of the conductor, and the outer aramid fiber-copper wire hybrid woven structure can effectively resist high-frequency electromagnetic interference in the operating environment, and through the cooperation of the inner double shielding, the normal power supply of the line and the normal completion of the system command can be ensured.

[0034] In addition, the tinned copper wire in the outer woven shielding layer 5 can be selected as ground wire for grounding or zero connection of the equipment at the terminal end as needed, and part or all of the wire cores can be selected as control wire cores to realize the implementation of electrical control commands, thereby saving one control wire core group or ground wire. The aramid fiber can be stranded at the terminal end for fixing the bearing force, bear the weight of the suspended part of the cable itself, protect the conductive insulated wire core and the outer sheath structure of the cable from stress, thereby prolonging the service life of the cable.

[0035] It needs to be explained that the reference Figure 2 As shown, optical unit 6 includes optical fiber 62. Optical fiber 62 is a bend-insensitive optical fiber with a polyimide coating. The temperature resistance of polyimide-coated optical fiber can reach over 300℃. Since the temperature of the extrusion die head can reach about 180℃, the optical fiber will be subjected to high temperature for a short time. This avoids the coating being damaged due to insufficient temperature resistance of conventional coatings, which would affect the normal communication function of the optical fiber. The bend-insensitive optical fiber is selected to ensure that the optical fiber has a sufficient bending radius. The minimum bending radius of the optical fiber is 30mm, which meets the requirements of the peak and valley physical positions of the optical fiber during the vertical bending and reciprocating motion of the overhead crane cable, ensuring normal communication.

[0036] Multiple optical fibers 62 are arranged in optical unit 6, with a certain spacing between adjacent optical fibers 62. A flexible armor layer 61 is arranged circumferentially on the optical fiber 62, and the flexible armor layer 61 is filled with filler material 63, which is made of cotton thread. The flexible armor layer 61 is formed by spirally winding steel tape with a thickness of 0.15mm to 0.25mm. The steel tape is made of 301 series steel tape or titanium alloy steel tape. The gap between the armor spirals is less than or equal to 10% of the tape width, and the spiral helix angle is controlled at 5% ± 0.5%. The flexible armor layer 61 uses lightweight steel tape. The selection of steel tape material and thickness is combined with process control requirements to ensure that most of the mechanical force on the cable is borne by the flexible armor layer in actual applications, reducing the risk of fiber breakage and communication failure caused by stress on the optical fiber itself. The optical fiber 62 can be connected to remote control terminals such as computers and temperature sensors to realize intelligent remote control, line temperature monitoring and action interlocking for temperature abnormalities, as well as connection to on-site environmental audio and video and collection of information such as on-site environmental temperature and humidity.

[0037] It should be explained that the thermal conductivity of steel is about 16 W / (m·K), which is more than 30 times higher than that of conventional plastic materials. Therefore, in the event of an abnormality such as a fire or short circuit in some structural components at the cable, the flexible armor layer 61 will quickly conduct heat, thereby affecting the attenuation value and waveform of the internal optical fiber at the heat-generating point. This can significantly reduce the time to trigger the alarm and improve the system safety.

[0038] The two ends of the flexible armor layer 61 extend beyond the optical fiber. During installation, the two ends of the flexible armor layer 61 are fixed to the trolley of the crane with fasteners, while leaving more than half a meter of cable fixed position to ensure that the optical fiber is not directly stressed. When manufacturing the optical unit, the flexible armor layer 61 is controlled to maintain a stress value within the stress deformation range. After the flexible armor layer 61 is manufactured, it is rewound to release the tension of the flexible armor layer 61, so that the optical fiber actually has a length of more than 2‰ in the optical unit, and will not be stressed in actual use, thereby improving the fatigue strength of the optical fiber.

[0039] In this embodiment, the outer sheath 7 adopts black nitrile polyvinyl chloride elastomer sheath material or black polyether polyurethane sheath material at 90°C, which has good elasticity and can effectively realize the flame retardant effect of the overall cable through the selection of the flame retardant performance of the material, thereby improving the safety performance of the line. The nitrile polyvinyl chloride sheath requires that the oxygen index be greater than or equal to 34, the tensile strength before aging be greater than or equal to 15 N / mm², and the elongation at break be greater than or equal to 300%. The polyether polyurethane sheath material requires that the oxygen index be greater than or equal to 30, the tensile strength before aging be greater than or equal to 20 N / mm², and the elongation at break be greater than or equal to 300%. The outer sheath 7 ensures that the core does not entangle each other in long-term movement, which may cause insulation breakage and power failure of the line; When the cable is made with the outer sheath 7, the conductive cores 9 are arranged on both sides of the light unit 6, and the light unit 6 can be provided at one or more places. The light unit 6 is placed in the middle position. Spacers are provided between the adjacent two conductive cores 9 on one side of all light units 6 and between the conductive cores 9 and the light unit 6, which can avoid the winding of the adjacent conductive cores 9 in the relaxed state, the deformation of the conductive cores 9 after being tightened, and the abnormal or even failure of the power transmission and communication function. The spacing is according to the product specification, and when the nominal cross-sectional area of the conductor 1 of the conductive core 9 is 6 mm² or less, the core spacing is greater than or equal to 1.4 mm, and when the nominal cross-sectional area of the conductor 1 of the conductive core 9 is 10 mm² or more, the core spacing is greater than or equal to 2.0 mm. Specifically, one light unit can be provided, two conductive cores 9 are provided on one side of the light unit 6, and three conductive cores 9 are provided on the other side, so that the entire cable forms a flat structure, which is also beneficial to the stress dispersion of the cable.

[0040] The middle distance between all conductive cores 9 and between the conductive cores 9 and the light unit 6 corresponds to the surface of the outer sheath 7, which should have a stress groove 8. The stress groove 8 is arranged along the length direction of the cable, and the stress groove 8 is finally realized in the extrusion process of the sheath material through mold design. The stress groove 8 can be square or arc-shaped, the depth of the stress groove 8 is less than the distance between the side of the outer sheath 7 and the conductive core 9, the side length of the square stress groove is greater than or equal to 0.6 mm, and the angle of the arc-shaped stress groove should be controlled between 160° and 180°. The setting of the stress groove 8 ensures that the internal stress of the overall cable in long-term movement can be released through the stress groove, without being accumulated in the cable, thereby prolonging the service life of the cable.

[0041] Embodiment two The embodiment provides a manufacturing method of the cable structure of embodiment one, which includes the following contents. The conductive core 9 is made: The plurality of conductors 1 are made by selecting annealed copper wires with diameters of 0.10mm to 0.14mm during the manufacturing process, and the annealed copper wires are made into a complex twisting member in a complex twisting structure, and the circumferential direction of the complex twisting member is woven with copper wires with diameters of 0.10mm to 0.12mm to form a woven layer; an insulating layer is arranged in the circumferential direction of the conductor, and a shielding layer is arranged in the circumferential direction of the insulating layer; The optical unit 6 is made; The conductive wire core 9 is arranged on both sides of the optical unit 6, and the outer sheath 7 is formed in the circumferential direction of the optical unit 6 and the conductive wire core 9 by extrusion molding, and the stress groove 8 is arranged on both sides of the outer sheath 7, and the stress groove 8 is arranged on both sides of the outer sheath 7 at positions corresponding to the optical unit and the conductive wire core and between adjacent two conductive wire cores.

[0042] The above only describes the preferred embodiments of the present application and is not used to limit the present application. For those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A structure of a power cable for a vehicle, characterized by comprising: The application relates to a flexible optical cable, which comprises a plurality of conductive cores, optical units and an outer sheath, the conductive cores are arranged on both sides of the optical units, the optical units and the conductive cores are arranged at a distance, the outer sheath is formed by extrusion to wrap the optical units and the conductive cores, the optical unit comprises an optical fiber, the optical fiber is a bending-insensitive optical fiber with a polyimide coating, the conductive core comprises a conductor, the conductor comprises a complex twisting part, the complex twisting part is made of annealed copper wire in a complex twisting structure to increase the flexibility of the conductor, the diameter of the annealed copper wire in the complex twisting part is 0.10mm-0.14mm, a circumferential setting braiding layer is arranged in the complex twisting part, the braiding layer is made of copper wire with a diameter of 0.10mm-0.12mm to bind the shape of the conductor and increase the radial stress resistance, an insulating layer is arranged in the circumferential direction of the conductor, and a shielding layer is arranged in the circumferential direction of the insulating layer.

2. A motor vehicle electrical cable construction according to claim 1 wherein, The complex twisting part is twisted by a plurality of single copper wires as one unit, a plurality of units are twisted again or twisted again as required, the ratio of the longitudinal spiral length of the single copper wire to the diameter of the single copper wire is 18-24, and the ratio of the longitudinal spiral length of the outermost unit to the twisting diameter of the single unit is 12-16 during the secondary twisting or the re-twisting. The braiding density of the copper wire in the braiding layer is 50%-60%.

3. A motor vehicle electrical cable construction according to claim 1 wherein, The insulating layer comprises an inner insulating layer and an outer insulating layer, the inner insulating layer is made of extruded soft PVC or PVC-nitrile elastomer or ethylene-propylene rubber insulating material, and the outer insulating layer is made of a fireproof paper insulating isolation layer in an overlapping wrapping type. The outer insulating layer is made of fireproof paper of aromatic polyamide polymer base material with a thickness of 0.08-0.12mm, and the wrapping overlapping rate is 5%-15%.

4. A motor vehicle electrical cable construction according to claim 1 wherein, The longitudinal section of the outer sheath is flat.

5. A motor vehicle electrical cable construction according to claim 1 wherein, The shielding layer comprises an inner wrapping shielding layer and an outer braiding shielding layer, the inner wrapping shielding layer adopts a copper-plastic composite tape or an aluminum-plastic composite tape overlapping wrapping structure, the total thickness of the inner wrapping shielding layer is 0.04mm-0.05mm, the thickness of the metal layer in the copper-plastic composite tape or the aluminum-plastic composite tape is greater than or equal to 0.018mm, and the wrapping overlapping rate is controlled to be 15%+ / -5%.

6. A motor vehicle electrical cable arrangement according to claim 5, wherein, The outer braiding shielding layer adopts a hybrid material braiding structure of aramid and tinned copper wire, the number of spindles of the tinned copper wire and the aramid is the same, and the tinned copper wire and the aramid are braided in an interlaced manner. The aramid is selected from materials with a fineness of 1100-1600dtex, the diameter of the single copper wire in the tinned copper wire is 0.10mm-0.15mm, and the braiding density of the outer braiding shielding layer is 90%-94%.

7. A motor vehicle electrical cable construction according to claim 1 wherein, At least one optical fiber is arranged in the optical unit, and the minimum bending radius of the optical fiber is 30mm. A flexible armor layer is arranged in the circumferential direction of the optical fiber, tension is applied to the flexible armor layer during the manufacturing of the flexible armor layer, the length of the flexible armor layer exceeds the length of the optical fiber during the manufacturing of the optical unit, so that the optical fiber is not stressed and has a length redundancy, the flexible armor layer is made by spirally winding a steel belt with a thickness of 0.15mm-0.25mm, the spiral gap of the flexible armor layer is less than or equal to 10% of the width of the steel belt, and the spiral pitch angle of the flexible armor layer is controlled to be 5%+ / -0.5%.

8. A motor vehicle electrical cable construction according to claim 1 wherein, The outer sheath adopts 90 DEG C black nitrile polyvinyl chloride elastomer sheath material or black polyether polyurethane sheath material. The two side faces of the outer sheath are provided with stress grooves at positions corresponding to the light unit and the conductive wire core and between adjacent two conductive wire cores, the stress grooves are realized in the outer sheath extrusion process, and the stress grooves are square or arc-shaped, the side length of the square stress groove is greater than or equal to 0.6 mm, and the angle of the arc-shaped stress groove is between 160 DEG and 180 DEG.

9. A motor vehicle electrical cable construction according to claim 1 wherein, The conductive wire core is provided with multiple parts, part of the conductive wire core is arranged on one side of the light unit, the other conductive wire core is arranged on the other side of the light unit, and adjacent two conductive wire cores on the same side of the light unit are arranged at an interval.

10. A method of manufacturing a power cable structure according to any one of claims 1-9, characterized in that, The application comprises the following contents: The conductive wire core is manufactured. A plurality of conductors are manufactured, each conductor selects an annealed copper wire with a diameter of 0.10mm-0.14mm in the manufacturing process, the annealed copper wire is made into a complex twisting part in a complex twisting structure, a braided layer is formed by braiding a copper wire with a diameter of 0.10mm-0.12mm in the hoop direction of the complex twisting part; an insulating layer is arranged in the circumferential direction of the conductor, and a shielding layer is arranged in the circumferential direction of the insulating layer; The light unit is manufactured. The conductive wire core is arranged on both sides of the light unit, and the outer sheath is formed in the hoop direction of the light unit and the conductive wire core by extrusion molding.

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