Extra-high voltage smooth type wedge cable strain clamp

Abstract

The present application relates to the technical field of extra-high voltage transmission fittings, and discloses a special high-voltage smooth type wedge cable strain clamp, which comprises a wedge, a sliding cover and a shell, the inner side of the wedge is provided with a cable placing groove, and the outer side of the sliding cover is provided with a positioning structure. The special high-voltage smooth type wedge cable strain clamp is designed with different formulas according to the functional requirements of the shell, the wedge and the sliding cover, so that the performance of light weight, high bearing capacity, low friction and corrosion resistance is achieved, and the problem that a single formula cannot take into account multiple performances is solved. The wedge formula is matched with a ceramic coating, and the sliding cover formula introduces a composite solid lubricant, so that the sliding fit performance is greatly optimized and the smooth type wedge structure design is adapted. The preparation process is accurately matched with the formula, material defects are eliminated through processes such as low-pressure casting, hot forging and targeted heat treatment, and the consistency and stability of the product are improved.

Description

Technical Field

[0001] This invention relates to the field of ultra-high voltage power transmission fittings technology, specifically to an ultra-high voltage smooth-type inclined wedge cable tension clamp. Background Technology

[0002] As a core hardware component of transmission lines, the UHV smooth-fit wedge cable tension clamp must simultaneously withstand the axial tension of large-section cables and the corrosion of complex outdoor environments. Furthermore, the sliding fit performance between the wedge, the sliding cover, and the housing directly affects assembly efficiency and operational stability. Existing tension clamp materials have significant shortcomings: the housing is mostly made of ordinary cast steel or aluminum alloy. The former has high density and poor corrosion resistance, making it prone to rust during long-term outdoor operation, leading to increased clearance. The latter lacks sufficient strength to meet the ultra-high tension load requirements of UHV lines. The wedge component relies on a single alloy steel material, making it difficult to balance surface smoothness and wear resistance. This can easily cause jamming during assembly, and long-term friction leads to severe surface wear, increasing the risk of stress concentration. The sliding cover material lacks targeted lubrication compatibility, easily causing adhesion and wear at the contact surface with the wedge, shortening the clamp's service life.

[0003] In existing technologies, such as the smooth-type wedge cable tension clamp disclosed in CN118336623B, only the structural design is optimized without any innovation in material formulation. The use of conventional fitting materials cannot meet the comprehensive requirements of "high tension, strong corrosion, and low friction" in ultra-high voltage scenarios. Furthermore, existing formulations often focus on improving the performance of individual components, lacking overall synergistic design. For example, mismatched hardness between the shell material and the wedge material can easily lead to excessive wear on one side. Simultaneously, poor compatibility between the manufacturing process and the formulation, with some high-performance alloy formulations exhibiting defects such as internal shrinkage cavities and cracks due to improper casting and heat treatment processes, further reducing the clamp's load-bearing capacity. Therefore, developing a material formulation and manufacturing method that adapts to the smooth-type wedge structure and considers the synergistic performance of all components is crucial to overcoming the bottlenecks of existing technologies. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an ultra-high voltage (UHV) smooth-type inclined wedge cable tension clamp. It features a specially designed material formula for the shell, inclined wedge, and sliding cover, combined with appropriate manufacturing processes, achieving comprehensive performance of "high load-bearing capacity, low friction, corrosion resistance, and long service life." This design is suitable for the complex operating conditions of UHV lines and solves the problems of insufficient material strength, poor wear resistance, weak corrosion resistance, and poor material synergy among components in existing UHV tension clamps, which lead to short service life and high failure risk.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a high-voltage smooth-type inclined wedge cable tension clamp, comprising an inclined wedge, a sliding cover, and a housing, wherein a cable placement groove is provided on the inner side of the inclined wedge, and a positioning structure is provided on the outer side of the sliding cover.

[0006] Preferably, the positioning structure includes a sliding protrusion, a positioning block, and a return spring. The return spring has an elastic rod inside. The top of the positioning structure is threaded with a bolt. The lower end of the bolt is fixedly connected to the sliding protrusion and the bolt is threadedly connected to the inner wall of the positioning structure. The wedge has a limiting groove inside that matches the positioning block.

[0007] A preferred method for manufacturing ultra-high voltage smooth-type inclined wedge cable tension clamps comprises materials in the following proportions by weight: The shell is made of a high-strength, corrosion-resistant aluminum alloy with the following composition: aluminum 88.5–91.2%, magnesium 4.5–5.8%, silicon 1.8–2.5%, copper 0.8–1.2%, manganese 0.3–0.6%, chromium 0.15–0.3%, titanium 0.05–0.1%, and impurities ≤0.25%. Magnesium and silicon form the Mg2Si reinforcing phase, enhancing material strength; copper and aluminum form the Al2Cu phase, optimizing corrosion resistance; chromium and titanium work together to refine the grain, preventing coarse grain defects during casting and ensuring the shell possesses both high load-bearing capacity and strong resistance to outdoor corrosion. The density is controlled at 2.75–2.85 g / cm³, meeting the lightweight requirements for high-altitude operations. The wedge is made of wear-resistant alloy steel with the following composition: iron 92.5-94.8%, carbon 0.45-0.6%, chromium 1.8-2.6%, molybdenum 0.8-1.3%, nickel 0.5-0.9%, vanadium 0.15-0.3%, sulfur ≤0.02%, and phosphorus ≤0.02%. Carbon, chromium, and molybdenum form carbide reinforcing phases to improve surface hardness and wear resistance. Nickel optimizes the material's toughness to prevent brittle fracture under stress. Vanadium refines the grain structure, improving the overall strength and wear resistance of the material. This ensures that the surface wear of the wedge is kept extremely low during sliding contact at an inclination angle of 2.3-2.8°, while also withstanding high tensile loads. The sliding cover uses a low-friction, wear-resistant aluminum alloy formula with the following components: aluminum 90.2-92.5%, magnesium 3.2-4.5%, silicon 1.5-2.2%, zinc 0.8-1.2%, graphite 0.3-0.6%, molybdenum disulfide 0.2-0.4%, and impurities ≤0.25%. Among them, graphite and molybdenum disulfide act as solid lubricants, uniformly dispersed in the aluminum alloy matrix to form a self-lubricating surface layer, reducing the coefficient of friction with the wedge contact surface. Magnesium and silicon enhance the strength of the matrix, while zinc optimizes the material's processing performance, ensuring smooth and unobstructed assembly of the sliding cover and wedge, and maintaining a stable fit clearance even after long-term friction.

[0008] Preferably, the shell manufacturing process is as follows: Step 1: Batching and Melting: Accurately weigh each raw material according to the formula, put them into a medium-frequency induction furnace, heat to 720-750℃, stir at a speed of 30-50 r / min for 15-20 min to ensure uniform mixing of raw materials; add refining agent (0.1-0.2% of the total mass of raw materials), keep warm for 30 min to remove gas and impurities from the melt, and let stand for 20 min after refining; Step 2: Casting and Molding: Low-pressure casting is adopted, with the mold temperature controlled at 200-250℃, the pouring temperature at 700-720℃, the pouring pressure at 0.06-0.08MPa, and the holding time at 25-35min. After cooling to room temperature, the shell blank is demolded to obtain the shell blank. Low-pressure casting avoids defects such as shrinkage cavities and porosity inside the blank and improves the density of the shell. Step 3: Heat treatment strengthening: Place the shell blank in a heat treatment furnace, heat to 530-550℃, hold for 2-3 hours for solution treatment; then rapidly water cool to room temperature at a cooling rate ≥20℃ / min; then heat to 170-190℃ and hold for 4-6 hours to complete the artificial aging treatment, so that the strengthening phases such as Mg2Si and Al2Cu are fully precipitated, improving the shell strength and hardness. The final shell tensile strength is ≥420MPa and yield strength is ≥380MPa. Step 4: Finishing: Turn and mill the heat-treated shell blank to ensure the dimensional accuracy and surface roughness (Ra≤1.6μm) of the shell. Leave a 0.02~0.05mm fit gap on the splicing surface to ensure that the left and right shells are spliced ​​tightly.

[0009] Preferably, the wedge manufacturing process is as follows: Step 1: Batching and Melting: Weigh each alloy raw material according to the formula, put them into the electric arc furnace, heat to 1550-1600℃, and after the raw materials are completely melted, add the deoxidizer (silicon-calcium alloy, accounting for 0.3-0.5% of the total mass of raw materials), deoxidize for 10-15 minutes to remove oxygen impurities in the melt; stir evenly and let stand for 15 minutes to ensure uniform composition; Step 2: Forging and forming: The molten steel is poured into steel ingots, cooled to room temperature, heated to 1100-1150℃, held for 1.5-2 hours, and hot forged. The forging pressure is 80-100MPa. After forging, the steel is cooled to room temperature by air cooling to refine the grain structure and improve the toughness and wear resistance of the wedge material. Step 3: Heat Treatment and Surface Treatment: The forged wedge blank is heated to 860-880℃ and held for 1.5-2 hours, followed by oil quenching. Then, it is heated to 550-580℃ and held for 3-4 hours for tempering, so that the wedge hardness reaches HRC40-45, which combines hardness and toughness. The surface is coated with an Al2O3-TiO2 ceramic coating using plasma spraying technology. The coating thickness is 0.15-0.25mm, which improves the surface smoothness (Ra≤0.8μm) and wear resistance, and meets the requirements of smooth assembly. Step 4: Finishing: Grind the surface-treated wedge to ensure the accuracy of the outer side tilt angle (2.3~2.8°) and control the height of the raised pattern in the arc groove to 0.2~0.5mm, which meets the assembly design requirements.

[0010] Preferably, the sliding cover manufacturing process Step 1: Batching and Melting: Weigh aluminum, magnesium, silicon, zinc and other metal raw materials according to the formula, put them into a medium-frequency induction furnace, heat to 710-730℃, melt and stir evenly; mix graphite and molybdenum disulfide powder (particle size ≤5μm) evenly, add it to the melt using mechanical stirring, stirring speed 60-80r / min, stirring time 20-25min, to ensure that the solid lubricant is evenly dispersed in the matrix; add refining agent to remove gas and impurities, let stand for 20min; Step 2: Extrusion molding: The melt is extruded into a sliding cover blank using a hot extrusion process. The extrusion temperature is 680-700℃, the extrusion speed is 5-8mm / s, the die temperature is 220-250℃, and the material is air-cooled to room temperature after extrusion to improve the density and structural stability of the sliding cover material. Step 3: Heat treatment and surface treatment: Heat the sliding cover blank to 520-540℃, hold for 2 hours, perform solution treatment, and then water cool; then heat to 160-180℃, hold for 5 hours, and perform artificial aging treatment to make the tensile strength of the sliding cover ≥380MPa; the surface is anodized to form an oxide film with a thickness of 0.08-0.12mm, which improves corrosion resistance and further reduces the coefficient of friction. Step 4: Finishing: Mill and grind the sliding cover to ensure the dimensional accuracy of the slide groove and the integrity of the chamfers at both ends (R4mm). The surface roughness of the contact surface is Ra≤1.2μm to ensure smooth fit with the housing slider and wedge.

[0011] Compared with the prior art, the present invention provides an ultra-high voltage smooth-type inclined wedge cable tension clamp, which has the following beneficial effects: 1. This ultra-high voltage smooth-type wedge cable tension clamp features a differentiated formula designed to meet the functional requirements of the shell, wedge, and sliding cover. This achieves synergistic performance in terms of lightweight, high load-bearing capacity, low friction, and corrosion resistance, solving the problem that a single formula cannot simultaneously address multiple performance aspects. The wedge formula is combined with a ceramic coating, while the sliding cover formula incorporates a composite solid lubricant, significantly optimizing sliding fit performance and adapting to the smooth-type wedge structure design. The manufacturing process is precisely matched with the formula, eliminating material defects through low-pressure casting, hot forging, and targeted heat treatment, thereby improving product consistency and stability. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the cable tension clamp structure of the present invention.

[0013] Figure 2 For the present invention Figure 1 Enlarged view of region A in the middle.

[0014] The components are: 1. wedge; 2. sliding cover; 3. housing; 4. limiting groove; 5. cable placement groove; 6. positioning structure; 7. sliding protrusion; 8. positioning block; 9. return spring; 10. elastic rod; 11. bolt. Detailed Implementation

[0015] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0016] Please see Figure 1-2 A high-voltage smooth-type inclined wedge cable tension clamp includes an inclined wedge 1, a sliding cover 2, and a housing 3. The inner side of the inclined wedge 1 is provided with a cable placement groove 5, and the outer side of the sliding cover 2 is provided with a positioning structure 6.

[0017] Furthermore, the positioning structure 6 includes a sliding protrusion 7, a positioning block 8, and a return spring 9. The return spring 9 has an elastic rod 10 inside. The top of the positioning structure 6 is threaded with a bolt 11. The lower end of the bolt 11 is fixedly connected to the sliding protrusion 7 and the bolt 11 is threadedly connected to the inner wall of the positioning structure 6. The wedge 1 has a limiting groove 4 inside that matches the positioning block 8.

[0018] Furthermore, the manufacturing method of the ultra-high voltage smooth-type inclined wedge cable tension clamp consists of the following materials in parts by weight: The shell is made of a high-strength, corrosion-resistant aluminum alloy with the following composition: aluminum 88.5–91.2%, magnesium 4.5–5.8%, silicon 1.8–2.5%, copper 0.8–1.2%, manganese 0.3–0.6%, chromium 0.15–0.3%, titanium 0.05–0.1%, and impurities ≤0.25%. Magnesium and silicon form the Mg2Si reinforcing phase, enhancing material strength; copper and aluminum form the Al2Cu phase, optimizing corrosion resistance; chromium and titanium work together to refine the grain, preventing coarse grain defects during casting and ensuring the shell possesses both high load-bearing capacity and strong resistance to outdoor corrosion. The density is controlled at 2.75–2.85 g / cm³, meeting the lightweight requirements for high-altitude operations. The wedge is made of wear-resistant alloy steel with the following composition: iron 92.5-94.8%, carbon 0.45-0.6%, chromium 1.8-2.6%, molybdenum 0.8-1.3%, nickel 0.5-0.9%, vanadium 0.15-0.3%, sulfur ≤0.02%, and phosphorus ≤0.02%. Carbon, chromium, and molybdenum form carbide reinforcing phases to improve surface hardness and wear resistance. Nickel optimizes the material's toughness to prevent brittle fracture under stress. Vanadium refines the grain structure, improving the overall strength and wear resistance of the material. This ensures that the surface wear of the wedge is kept extremely low during sliding contact at an inclination angle of 2.3-2.8°, while also withstanding high tensile loads. The sliding cover uses a low-friction, wear-resistant aluminum alloy formula with the following components: aluminum 90.2-92.5%, magnesium 3.2-4.5%, silicon 1.5-2.2%, zinc 0.8-1.2%, graphite 0.3-0.6%, molybdenum disulfide 0.2-0.4%, and impurities ≤0.25%. Among them, graphite and molybdenum disulfide act as solid lubricants, uniformly dispersed in the aluminum alloy matrix to form a self-lubricating surface layer, reducing the coefficient of friction with the wedge contact surface. Magnesium and silicon enhance the strength of the matrix, while zinc optimizes the material's processing performance, ensuring smooth and unobstructed assembly of the sliding cover and wedge, and maintaining a stable fit clearance even after long-term friction.

[0019] Furthermore, the shell manufacturing process is as follows: Step 1: Batching and Melting: Accurately weigh each raw material according to the formula, put them into a medium-frequency induction furnace, heat to 720-750℃, stir at a speed of 30-50 r / min for 15-20 min to ensure uniform mixing of raw materials; add refining agent (0.1-0.2% of the total mass of raw materials), keep warm for 30 min to remove gas and impurities from the melt, and let stand for 20 min after refining; Step 2: Casting and Molding: Low-pressure casting is adopted, with the mold temperature controlled at 200-250℃, the pouring temperature at 700-720℃, the pouring pressure at 0.06-0.08MPa, and the holding time at 25-35min. After cooling to room temperature, the shell blank is demolded to obtain the shell blank. Low-pressure casting avoids defects such as shrinkage cavities and porosity inside the blank and improves the density of the shell. Step 3: Heat treatment strengthening: Place the shell blank in a heat treatment furnace, heat to 530-550℃, hold for 2-3 hours for solution treatment; then rapidly water cool to room temperature at a cooling rate ≥20℃ / min; then heat to 170-190℃ and hold for 4-6 hours to complete the artificial aging treatment, so that the strengthening phases such as Mg2Si and Al2Cu are fully precipitated, improving the shell strength and hardness. The final shell tensile strength is ≥420MPa and yield strength is ≥380MPa. Step 4: Finishing: Turn and mill the heat-treated shell blank to ensure the dimensional accuracy and surface roughness (Ra≤1.6μm) of the shell. Leave a 0.02~0.05mm fit gap on the splicing surface to ensure that the left and right shells are spliced ​​tightly.

[0020] Furthermore, the wedge manufacturing process is as follows: Step 1: Batching and Melting: Weigh each alloy raw material according to the formula, put them into the electric arc furnace, heat to 1550-1600℃, and after the raw materials are completely melted, add the deoxidizer (silicon-calcium alloy, accounting for 0.3-0.5% of the total mass of raw materials), deoxidize for 10-15 minutes to remove oxygen impurities in the melt; stir evenly and let stand for 15 minutes to ensure uniform composition; Step 2: Forging and forming: The molten steel is poured into steel ingots, cooled to room temperature, heated to 1100-1150℃, held for 1.5-2 hours, and hot forged. The forging pressure is 80-100MPa. After forging, the steel is cooled to room temperature by air cooling to refine the grain structure and improve the toughness and wear resistance of the wedge material. Step 3: Heat Treatment and Surface Treatment: The forged wedge blank is heated to 860-880℃ and held for 1.5-2 hours, followed by oil quenching. Then, it is heated to 550-580℃ and held for 3-4 hours for tempering, so that the wedge hardness reaches HRC40-45, which combines hardness and toughness. The surface is coated with an Al2O3-TiO2 ceramic coating using plasma spraying technology. The coating thickness is 0.15-0.25mm, which improves the surface smoothness (Ra≤0.8μm) and wear resistance, and meets the requirements of smooth assembly. Step 4: Finishing: Grind the surface-treated wedge to ensure the accuracy of the outer side tilt angle (2.3~2.8°) and control the height of the raised pattern in the arc groove to 0.2~0.5mm, which meets the assembly design requirements.

[0021] Furthermore, the sliding cover manufacturing process Step 1: Batching and Melting: Weigh aluminum, magnesium, silicon, zinc and other metal raw materials according to the formula, put them into a medium-frequency induction furnace, heat to 710-730℃, melt and stir evenly; mix graphite and molybdenum disulfide powder (particle size ≤5μm) evenly, add it to the melt using mechanical stirring, stirring speed 60-80r / min, stirring time 20-25min, to ensure that the solid lubricant is evenly dispersed in the matrix; add refining agent to remove gas and impurities, let stand for 20min; Step 2: Extrusion molding: The melt is extruded into a sliding cover blank using a hot extrusion process. The extrusion temperature is 680-700℃, the extrusion speed is 5-8mm / s, the die temperature is 220-250℃, and the material is air-cooled to room temperature after extrusion to improve the density and structural stability of the sliding cover material. Step 3: Heat treatment and surface treatment: Heat the sliding cover blank to 520-540℃, hold for 2 hours, perform solution treatment, and then water cool; then heat to 160-180℃, hold for 5 hours, and perform artificial aging treatment to make the tensile strength of the sliding cover ≥380MPa; the surface is anodized to form an oxide film with a thickness of 0.08-0.12mm, which improves corrosion resistance and further reduces the coefficient of friction. Step 4: Finishing: Mill and grind the sliding cover to ensure the dimensional accuracy of the slide groove and the integrity of the chamfers at both ends (R4mm). The surface roughness of the contact surface is Ra≤1.2μm to ensure smooth fit with the housing slider and wedge. Example

[0022] This embodiment describes the fabrication of a UHV smooth-type inclined wedge cable tension clamp. The formulations and manufacturing processes for each component are as follows: formula: Shell composition: Al 88.5%, Mg 4.5%, Si 1.8%, Cu 0.8%, Mn 0.3%, Cr 0.15%, Ti 0.05%, impurities 0.2%; Inclined wedge: Fe 90.5%, C 0.45%, Cr 1.8%, Mo 0.8%, Ni 0.5%, V 0.15%, S 0.02%, P0.02%; Sliding cover: Al 90.2%, Mg 3.2%, Si 1.5%, Zn 0.8%, graphite 0.3%, MoS2 0.2%, impurities 0.23%.

[0023] Preparation process: Shell: Melted in a medium-frequency furnace at 735℃, cast under low pressure (mold temperature 220℃, pouring temperature 710℃, pressure 0.07MPa), solution treated at 540℃ for 2.5h, aged at 180℃ for 5h, surface roughness Ra 1.4μm after finishing; Wedge: Smelted in an electric arc furnace at 1580℃, hot forged at 1120℃ (pressure 90MPa), quenched at 870℃, tempered at 560℃, plasma sprayed with a 0.2mm Al2O3-TiO2 coating, and finished with an inclination angle of 2.5° and a surface roughness Ra of 0.7μm; Sliding cover: Melted in a medium-frequency furnace at 720℃, hot extruded at 690℃ (speed 6.5mm / s), solution-treated at 530℃ for 2 hours, aged at 170℃ for 5 hours, anodized to form a 0.1mm oxide film, and finished with a chamfer R4mm and a surface roughness Ra 1.0μm.

[0024] Performance testing: The shell tensile strength is 435MPa, the wedge hardness is HRC 42, the sliding cover friction coefficient is 0.13, all components fit smoothly without jamming, and there is no rust after salt spray test (500h), meeting the requirements of UHV operation. Example

[0025] This embodiment describes the fabrication of a UHV smooth-type inclined wedge cable tension clamp. The formulations and manufacturing processes for each component are as follows: formula: Shell composition: Al 90.1%, Mg 5.2%, Si 2.1%, Cu 1.0%, Mn 0.45%, Cr 0.2%, Ti 0.08%, impurities 0.22%; Inclined wedge: Fe 93.6%, C 0.52%, Cr 2.2%, Mo 1.0%, Ni 0.7%, V 0.22%, S 0.015%, P0.018%; Sliding cover: Al 91.3%, Mg 3.8%, Si 1.8%, Zn 1.0%, graphite 0.45%, MoS2 0.3%, impurities 0.23%.

[0026] Preparation process: Shell: Melted in a medium-frequency furnace at 735℃, cast under low pressure (mold temperature 220℃, pouring temperature 710℃, pressure 0.07MPa), solution treated at 540℃ for 2.5h, aged at 180℃ for 5h, surface roughness Ra 1.4μm after finishing; Wedge: Smelted in an electric arc furnace at 1580℃, hot forged at 1120℃ (pressure 90MPa), quenched at 870℃, tempered at 560℃, plasma sprayed with a 0.2mm Al2O3-TiO2 coating, and finished with an inclination angle of 2.5° and a surface roughness Ra of 0.7μm; Sliding cover: Melted in a medium-frequency furnace at 720℃, hot extruded at 690℃ (speed 6.5mm / s), solution-treated at 530℃ for 2 hours, aged at 170℃ for 5 hours, anodized to form a 0.1mm oxide film, and finished with a chamfer R4mm and a surface roughness Ra 1.0μm.

[0027] Performance testing: The shell tensile strength is 435MPa, the wedge hardness is HRC 42, the sliding cover friction coefficient is 0.13, all components fit smoothly without jamming, and there is no rust after salt spray test (500h), meeting the requirements of UHV operation. Example

[0028] This embodiment describes the fabrication of a UHV smooth-type inclined wedge cable tension clamp. The formulations and manufacturing processes for each component are as follows: Formula (percentage by weight): Shell composition: Al 91.2%, Mg 5.8%, Si 2.5%, Cu 1.2%, Mn 0.6%, Cr 0.3%, Ti 0.1%, impurities 0.15%; Wedge: Fe 94.8%, C 0.6%, Cr 2.6%, Mo 1.3%, Ni 0.9%, V 0.3%, S 0.02%, P 0.02%; Sliding cover: Al 92.5%, Mg 4.5%, Si 2.2%, Zn 1.2%, graphite 0.6%, MoS2 0.4%, impurities 0.15%.

[0029] Preparation process: Shell: Melted in a medium-frequency furnace at 740℃, cast under low pressure (mold temperature 240℃, pouring temperature 715℃, pressure 0.075MPa), solution treated at 545℃ for 2.8h, aged at 185℃ for 5.5h, surface roughness Ra 1.5μm after finishing; Wedge: Smelted in an electric arc furnace at 1590℃, hot forged at 1140℃ (pressure 95MPa), quenched at 875℃, tempered at 570℃, plasma sprayed with a 0.23mm Al2O3-TiO2 coating, and finished with an inclination angle of 2.8° and a surface roughness Ra of 0.75μm; Sliding cover: Melted in a medium-frequency furnace at 725℃, hot extruded at 695℃ (speed 7mm / s), solution-treated at 535℃ for 2 hours, aged at 175℃ for 5.5 hours, anodized to form a 0.11mm oxide film, and finished with a chamfer of R4mm and a surface roughness of Ra 1.1μm.

[0030] Performance testing: Shell tensile strength 442MPa, wedge hardness HRC 44, sliding cover friction coefficient 0.12, all components fit smoothly, salt spray test (500h) corrosion rate ≤0.02mm / a, suitable for ultra-high pressure and high tension working conditions. Example

[0031] This embodiment describes the fabrication of a UHV smooth-type inclined wedge cable tension clamp. The formulations and manufacturing processes for each component are as follows: Formula (percentage by weight): Shell composition: Al 89.2%, Mg 5.6%, Si 2.4%, Cu 1.1%, Mn 0.5%, Cr 0.25%, Ti 0.09%, impurities 0.24%; Inclined wedge: Fe 92.8%, C 0.58%, Cr 2.5%, Mo 1.2%, Ni 0.8%, V 0.28%, S 0.016%, P0.017%; Sliding cover: Al 90.5%, Mg 4.3%, Si 2.1%, Zn 1.1%, graphite 0.55%, MoS2 0.38%, impurities 0.24%.

[0032] Preparation process: Shell: Melted in a medium-frequency furnace at 740℃, cast under low pressure (mold temperature 240℃, pouring temperature 715℃, pressure 0.075MPa), solution treated at 545℃ for 2.8h, aged at 185℃ for 5.5h, surface roughness Ra 1.5μm after finishing; Wedge: Smelted in an electric arc furnace at 1590℃, hot forged at 1140℃ (pressure 95MPa), quenched at 875℃, tempered at 570℃, plasma sprayed with a 0.23mm Al2O3-TiO2 coating, and finished with an inclination angle of 2.8° and a surface roughness Ra of 0.75μm; Sliding cover: Melted in a medium-frequency furnace at 725℃, hot extruded at 695℃ (speed 7mm / s), solution-treated at 535℃ for 2 hours, aged at 175℃ for 5.5 hours, anodized to form a 0.11mm oxide film, and finished with a chamfer of R4mm and a surface roughness of Ra 1.1μm.

[0033] Performance testing: shell tensile strength 442MPa, wedge hardness HRC 44, sliding cover friction coefficient 0.12, all components fit smoothly, salt spray test (500h) corrosion rate ≤0.02mm / a, suitable for ultra-high pressure and high tension working conditions.

[0034] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-voltage smooth-type inclined wedge cable tension clamp, comprising an inclined wedge (1), a sliding cover (2), and a housing (3), characterized in that: The inner side of the wedge (1) is provided with a cable placement groove (5), and the outer side of the sliding cover (2) is provided with a positioning structure (6).

2. The UHV smooth-type inclined wedge cable tension clamp according to claim 1, characterized in that: The positioning structure (6) includes a sliding protrusion (7), a positioning block (8), and a return spring (9). The return spring (9) has an elastic rod (10) inside. The top of the positioning structure (6) is threaded with a bolt (11). The lower end of the bolt (11) is fixedly connected to the sliding protrusion (7), and the bolt (11) is threadedly connected to the inner wall of the positioning structure (6). The wedge (1) has a limiting groove (4) inside that matches the positioning block (8).

3. A method for manufacturing an ultra-high voltage smooth-type inclined wedge cable tension clamp applicable to the ultra-high voltage smooth-type inclined wedge cable tension clamp described in claims 1-2, characterized in that: Composed of the following parts by mass: The shell is made of high-strength corrosion-resistant aluminum alloy with the following components: aluminum 88.5-91.2%, magnesium 4.5-5.8%, silicon 1.8-2.5%, copper 0.8-1.2%, manganese 0.3-0.6%, chromium 0.15-0.3%, titanium 0.05-0.1%, and impurities ≤0.25%. The wedge is made of wear-resistant alloy steel with the following components: iron 92.5-94.8%, carbon 0.45-0.6%, and chromium 1%. 8-2.6%, molybdenum 0.8-1.3%, nickel 0.5-0.9%, vanadium 0.15-0.3%, sulfur ≤0.02%, phosphorus ≤0.02%; the sliding cover uses a low-friction, wear-resistant aluminum alloy formula with the following component contents: aluminum 90.2-92.5%, magnesium 3.2-4.5%, silicon 1.5-2.2%, zinc 0.8-1.2%, graphite 0.3-0.6%, molybdenum disulfide 0.2-0.4%, impurities ≤0.25%.

4. The method for manufacturing a UHV smooth-type inclined wedge cable tension clamp according to claim 3, characterized in that: The shell manufacturing process is as follows: Step 1: Batching and Melting: Accurately weigh each raw material according to the formula, put them into the medium frequency induction furnace, heat to 720-750℃, stir at a speed of 30-50 r / min for 15-20 min; add refining agent, keep warm for 30 min to remove gas and impurities from the melt, and let stand for 20 min after refining. Step Two: Casting: Low-pressure casting process is adopted, with the mold temperature controlled at 200-250℃, the pouring temperature at 700-720℃, the pouring pressure at 0.06-0.08MPa, the holding time at pressure at 25-35min, and the shell blank obtained after cooling to room temperature. Step 3: Heat treatment strengthening: Place the shell blank in a heat treatment furnace, heat to 530-550℃, hold for 2-3 hours for solution treatment; then rapidly water cool to room temperature at a cooling rate ≥20℃ / min; then heat to 170-190℃ and hold for 4-6 hours to complete the artificial aging treatment, so that the strengthening phases such as Mg2Si and Al2Cu are fully precipitated, improving the shell strength and hardness. The final shell tensile strength is ≥420MPa and yield strength is ≥380MPa. Step 4: Finishing: Turn and mill the heat-treated shell blank, leaving a 0.02-0.05mm fit gap on the splicing surface to ensure that the left and right shells are tightly spliced.

5. The method for manufacturing a UHV smooth-type inclined wedge cable tension clamp according to claim 3, characterized in that: The wedge manufacturing process is as follows: Step 1: Batching and Melting: Weigh each alloy raw material according to the formula, put them into the electric arc furnace, heat to 1550-1600℃, and after the raw materials are completely melted, add the deoxidizer and deoxidize for 10-15 minutes to remove oxygen impurities in the melt; stir evenly and let stand for 15 minutes to ensure uniform composition. Step 2: Forging and shaping: The molten steel is poured into steel ingots, cooled to room temperature, heated to 1100-1150℃, held for 1.5-2 hours, and hot forged. The forging pressure is 80-100MPa. Step 3: Heat treatment and surface treatment: The forged wedge blank is heated to 860-880℃ and held for 1.5-2 hours, followed by oil quenching; then heated to 550-580℃ and held for 3-4 hours; the surface is coated with an Al2O3-TiO2 ceramic coating using plasma spraying process, with a coating thickness of 0.15-0.25 mm. Step 4: Finishing: Grind the surface-treated wedge to ensure the accuracy of the outer side tilt angle, and control the height of the raised pattern in the arc groove to 0.2-0.5mm, which meets the assembly design requirements.

6. The method for manufacturing a UHV smooth-type inclined wedge cable tension clamp according to claim 3, characterized in that: The sliding cover manufacturing process Step 1: Batching and Melting: Weigh aluminum, magnesium, silicon, zinc and other metal raw materials according to the formula, put them into a medium frequency induction furnace, heat to 710-730℃, melt and stir evenly; mix graphite and molybdenum disulfide powder evenly, add them to the melt using mechanical stirring, stirring speed 60-80 r / min, stirring time 20-25 min, add refining agent to remove gas and impurities, let stand for 20 min; Step 2: Extrusion molding: The melt is extruded into a sliding cover blank using a hot extrusion process. The extrusion temperature is 680-700℃, the extrusion speed is 5-8mm / s, the die temperature is 220-250℃, and the extrusion is air-cooled to room temperature. Step 3: Heat treatment and surface treatment: Heat the sliding cover blank to 520-540℃, hold for 2 hours, and then water cool after solution treatment; The temperature is then raised to 160-180℃ and held for 5 hours for artificial aging treatment, so that the tensile strength of the sliding cover is ≥380MPa; the surface is anodized to form an oxide film with a thickness of 0.08-0.12mm. Step 4: Finishing: Mill and grind the sliding cover to ensure the dimensional accuracy of the slide groove and the integrity of the chamfered corners at both ends (R4mm). The surface roughness of the contact surface is Ra≤1.2μm.

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