Extrusion-resistant super-flexible electric reel commutation connection cable for airport and manufacturing method thereof

Abstract

The invention belongs to the technical field of cable manufacturing, and particularly relates to an airport extrusion-resistant super-flexible electric reel phase-change connection cable and a manufacturing method thereof, and the cable comprises a power wire core and a control wire core; a metal conductor of the power wire core is formed by re-stranding divided unit conductors by adopting a 0 + 5 structure, the center of the metal conductor is filled with an aramid rope, the edge gap is filled with aramid yarn, and an insulating material is extruded outside the metal conductor; each segmentation unit conductor is formed by stranding strands in a 1 + 6 structure and wrapping the strands with a polytetrafluoroethylene tape. The control wire core comprises a cable core, the cable core is formed by twisting control wire groups by adopting a 0 + 6 structure, the center of the cable core is filled with an aramid rope, an edge gap is filled with aramid yarn, and a sheath is extruded outside the cable core; the control wire group is formed by twisting insulating wire core pre-cabling, and polyester ropes are filled in side gaps; each insulating wire core comprises a conductor, and an insulating material is extruded outside the conductor. According to the cable, a conductor grouping and twisting mode is adopted, and meanwhile the tensile force and the torsion resistance of the conductors are improved by adopting a torsion-resistant structure and a material assembly.

Description

An airport compression-resistant, ultra-flexible electric reel phase-switching connection cable and its manufacturing method Technical Field

[0001] This invention belongs to the field of cable manufacturing technology, and particularly relates to an airport extrusion-resistant ultra-flexible electric reel phase-switching connection cable and its manufacturing method. Background Technology

[0002] With the rapid development of my country's modern economy, the demand for special cables for specific applications is increasing, and their use is becoming more widespread, primarily in airports, ports, docks, mines, and wind power plants. Among these, aviation power systems require 400Hz cables, mainly for mobile power supply. Due to the extremely high safety requirements of aircraft and their frequent deployment and retraction, the cables require high flexibility, low conductor breakage rate after repeated bending, and high resistance to external tensile forces. Therefore, airport compression-resistant ultra-flexible electric reel phase-changing connection cables are among the most technologically advanced products in the cable industry and must meet the aforementioned requirements.

[0003] The problems and disadvantages of the existing technology are as follows: (1) The reactance of the cable will increase at a high frequency of 400HZ, which will affect the voltage drop of the line during use. The cross-section of the ordinary power core conductor is small and cannot meet the requirements of high frequency cable use.

[0004] (2) The density of copper conductor is 8.89 g / cm³. 3 The resulting cables are heavy, making them unsuitable for long-term, frequent bending and moving, and posing a significant risk of wire breakage.

[0005] (3) The cost of copper is increasing day by day. For the same current carrying capacity, the conductor cross-section produced by existing cable structures is larger, and the overall cost of the cable is higher.

[0006] (4) The airport charging equipment drum was originally commutated by carbon brushes and slip rings, but a slip ring failed and was not easy to replace. The goal is to enable the cable itself to complete the commutation.

[0007] (5) Ordinary flexible cables use copper wires twisted together as a whole conductor. The cables are relatively stiff, inconvenient to install, and have a smaller unit current carrying capacity for the same cross-sectional area. Summary of the Invention

[0008] The purpose of this invention is to overcome the shortcomings of existing technologies and provide an airport compression-resistant, ultra-flexible electric reel phase-switching connection cable and its manufacturing method. To meet the requirements of bending resistance and high current carrying capacity, the cable of this invention employs a grouped stranded conductor method, and simultaneously utilizes anti-torsion structures and material components to increase the tensile strength and torsional resistance of the conductor.

[0009] To achieve the above technical objectives, the technical solution adopted in this embodiment of the invention is as follows: Firstly, this embodiment provides an airport compression-resistant ultra-flexible electric reel phase-switching connection cable. The cable includes a power core and a control core. The power core includes a metal conductor, which is formed by twisting segmented unit conductors in a 0+5 structure. The center of the metal conductor is filled with a first aramid rope, and the edge gaps are filled with first aramid yarn. The conductor is extruded with a first insulating material. The segmented unit conductor is formed by strands of wire in a 1+6 structure and wrapped with a first polytetrafluoroethylene tape. The strands are formed by copper monofilaments through a bundle. The control core includes a cable core, which is formed by twisting control wire groups in a 0+6 structure. The center of the cable core is filled with a second aramid rope, and the edge gaps are filled with second aramid yarn. The cable core is extruded with a sheath. The control wire groups are pre-stitched from insulated cores, with the edge gaps filled with polyester rope. The insulated core includes a conductor, and the conductor is extruded with a second insulating material.

[0010] Furthermore, the five segmented unit conductors in the power core are arranged equilaterally around its axis, and the resistance and cross-sectional area of ​​the strands in each segmented unit conductor are equal.

[0011] Furthermore, the cable includes four power cores and one control core assembled together in a non-twisted structure, the power cores and control cores having the same outer diameter, and the non-twisted structure of the power cores and control cores being laid inside a non-slip ring drum.

[0012] Secondly, embodiments of the present invention provide a method for manufacturing an airport compression-resistant ultra-flexible electric reel phase-switching connection cable, comprising the following steps: I. Stranding of power core conductors 1.1) Bundling: using bare metal monofilament bundles with a pitch multiple of 16-18, the bundles are stranded; 1.2) Stranding: the strands described in step 1.1) are stranded using a 1+6 structure with a pitch multiple of 13-15, and the compression coefficient is controlled at 0.93-0.95. Simultaneously, a first polytetrafluoroethylene (PTFE) tape is wrapped around the strands, with an overlap rate controlled at 10%-15%, forming segmented unit conductors; 1.3) Re-stranding: a first aramid rope is filled in the center, and the five segmented unit conductors are spirally twisted around the first aramid rope to form a metal core conductor. The conductor has a pitch ratio of 11-12 times and a compression factor controlled at 0.96-0.97. The gaps between the metal conductors are filled with first aramid yarn, and the metal conductors are wrapped with non-woven fabric. Secondly, the insulation of the power core is extruded using a 65 extruder to extrude the first insulating material onto the metal conductor. The linear speed is controlled at 12-15 meters per minute. The lead-out cooling uses a combination of segmented water cooling and air cooling, and the take-up uses a metal turntable. Thirdly, the conductor is first bundled and then re-stranded, with a bundle pitch ratio of 12-14 times. Then, a 1+6 regular stranding structure is used for re-stranding, with a pitch ratio of 10-12 times and a compression factor controlled at ≤0.9. Fourthly, the conductor insulation is manufactured using an online preheating method. During extrusion, a preheating device is placed between the wire feeding and the die head, with the temperature set at 50-70℃; 4.2) A PBJ35+50 extruder is used to extrude a second insulating material around the preheated conductor to form an insulated wire core; V. Control wire group pre-cable fabrication: The insulated wire core is stranded in a 0+3 structure, with polyester rope filling the gaps to form a control wire group. The control wire group is wrapped with a second polytetrafluoroethylene tape with an overlap rate of 10-15%. The stranding direction of the insulated wire core is opposite to the wrapping direction of the second polytetrafluoroethylene tape; VI. Control wire core assembly cable fabrication: The control wire group is stranded in a 0+6 structure to the right to form a cable core, with a pitch multiple of 8-10 times the outer diameter. The center of the cable core is filled with a second aramid fiber. Rope, with the edge filled with a second aramid yarn; VII. Control line sheath extrusion: The control line sheath is extruded onto the outside of the cable core using a 65 extruder, with a linear speed controlled at 12-15 m / min. The lead-out cooling uses a combination of segmented water cooling and air cooling, and the take-up uses a metal turntable; VIII. Irradiation: 8.1) The power core is irradiated with a high voltage / beam current of 1.8-2.0 MeV / 10mA at a linear speed of 6-10 m / min, using 25-30 traction passes; 8.2) The control core sheath is irradiated with a high voltage / beam current of 1.8-2.0 MeV / 10mA at a linear speed of 8-12 m / min, using 25-30 traction passes. After irradiation, it is left to stand for 46-50 hours before proceeding to the next process.

[0013] Furthermore, in step one, the stranding direction, the filament direction, the stranding direction of the segmented unit conductor, and the wrapping direction of the first polytetrafluoroethylene tape are the same, and the wrapping direction of the nonwoven fabric is opposite to the stranding direction of the segmented unit conductor to tighten the metal conductor.

[0014] Further, in step two, the temperature zones of the 65 extruder are set as follows: Zone 1 of the machine body: 100±5℃, Zone 2 of the machine body: 120±5℃, Zone 3 of the machine body: 130±5℃, Zone 4 of the machine body: 145±5℃, Flange: 150±5℃, Mold 1: 150±5℃, Mold 2: 150±5℃, Water tank: 45±5℃; The parameters of the die during the extrusion of the first insulating material are as follows: The die sleeve surface is chrome-plated; Die matching calculation: The die core size is d+0.5mm, and the die sleeve size is D-0.2mm, where d is the outer diameter of the conductor (mm); D is the outer diameter of the insulation (mm); Die-to-die distance: The die sleeve-to-die distance is T, where T is the nominal thickness of the insulation.

[0015] Further, in step four, the temperature control of the PBJ35+50 extruder is as follows: Zone 1 of the machine body: 170±5℃, Zone 2 of the machine body: 180±5℃, Zone 3 of the machine body: 200±5℃, Zone 4 of the machine body: 210±5℃, Zone 5 of the machine body: 220±5℃, Flange: 220±5℃, Mold 1: 230±5℃, Mold 2: 235±5℃, Mold 3: 240±5℃, Water tank: 60±5℃; The extrusion die adopts the extrusion type, and the eccentricity is controlled within ≤10%. The die core is d1+0.1mm, and the die sleeve is d1+2×t, where d1 is the outer diameter of the conductor in mm; t is the nominal thickness of the insulation in mm.

[0016] Furthermore, in step six, when forming the cable core, adjacent control wire groups use different stranding pitches, from group 1 to group 6, which are 19-20 times, 17-18 times, 15-16 times, 13-14 times, 11-12 times, and 9-10 times the stranding outer diameter, respectively.

[0017] Further, in step seven, the temperature zones of the 65 extruder are set as follows: Zone 1 of the machine body: 100±5℃, Zone 2 of the machine body: 120±5℃, Zone 3 of the machine body: 130±5℃, Zone 4 of the machine body: 145±5℃, Flange: 150±5℃, Mold 1: 150±5℃, Mold 2: 150±5℃, Water tank: 45±5℃; The parameters of the die during sheath extrusion are as follows: The die surface is chrome-plated; Extrusion is used, and the die matching calculation is as follows: The die core size is the outer diameter of the cable core d + 1.0 mm, and the die sleeve size is D - 0.2 mm, where d is the outer diameter of the cable core (mm); D is the outer diameter of the sheath (mm); Die-to-die distance: The die sleeve-to-die distance is T, where T is the nominal insulation thickness (mm).

[0018] The beneficial effects of the technical solution provided by the embodiments of the present invention are: (1) The conductors of the segmented unit in the power core of the present invention are used in parallel with conductors of the same cross section, which increases the surface area of ​​the power core, reduces the increase of AC resistance caused by the skin effect, effectively reduces the impact of impedance on the current carrying capacity of the cable, and the conductor has the properties of being soft, drag-resistant, and wear-resistant. After bending 10,000 times, the conductor wire breakage rate does not exceed 1%.

[0019] (2) The power core and control core are concentrated in the same cable, the core arrangement is more reasonable, the structure is more compact, the outer diameter is small, and the laying space is small, so that the cable can transmit power and control signals.

[0020] (3) The outer diameters of the power core and the control core are the same. The five cores are laid in a non-slip ring drum with a non-twisted structure. When the cable is stretched and turned, there is no stress between the five cores. The flexible structure ensures that the cable can freely change phases. When subjected to tension and entanglement, it ensures that the transmission of power and signals is unobstructed.

[0021] (4) The strands and conductors of this invention are both made of Class 5 copper conductors as specified in GB / T 3956-2008, which can meet the requirements of frequent reciprocating movement, continuous bending and torsion. The resistivity of the copper conductor is less than or equal to 0.017241 Ω·mm. 2 / m, conductivity greater than or equal to 100% IACS, elongation greater than or equal to 15%. The conductor stranding method uses fine monofilaments, bundles of wire, bundles, and multiple strands. A tensile component is added to the center of the conductor. This structure can withstand 10,000 bending cycles and has a creep rate less than or equal to 1×10⁻⁶. -2 (% / h) increases the overall tensile and compressive strength of the cable.

[0022] (5) By using segmented unit conductors, the outer diameter of the conductor is effectively increased under the same weighing cross section, achieving the required large cross-sectional effect and increasing the total surface area of ​​the conductor. The current carrying capacity of the conventional fifth type copper conductor with the same cross section is 86% of that of the copper conductor with this structure. That is, it takes 1.16 times the cross section of the conventional fifth type copper conductor to meet the same current carrying capacity as this invention, which can effectively improve the effective utilization rate of the cable conductor. The F4 tape wrapped around the strands reaches a high temperature of 240°C, isolating the temperature rise caused by the large current outside the conductor from the influence on the insulation material, increasing the aging time of the cable insulation material, and extending the service life of the cable.

[0023] (6) Replaces carbon brush commutation in reel equipment, achieving commutation through the twisting of the cable itself. Previously, the cable installed inside the reel was fixed to the inner wall of the reel when it started. Carbon brushes were required at both ends of the reel from power input to power output. If the carbon brushes were damaged, the entire reel was difficult to repair. In this invention, the cable is installed inside the reel. Except for the two ends, the cable is not fixed to the reel and is freely placed. The two ends of the cable are fixed to the reel body. When the reel rotates, the cable ends do not rotate, but the entire cable inside the reel twists to achieve commutation. Attached Figure Description

[0024] Figure 1 is a schematic diagram of the structure of the airport compression-resistant ultra-flexible electric reel phase-switching connection cable in an embodiment of the present invention.

[0025] Figure 2 is a schematic diagram of the power core in the airport compression-resistant ultra-flexible electric reel phase-switching connection cable in Figure 1.

[0026] Figure 3 is a schematic diagram of the control conductor in the airport compression-resistant ultra-flexible electric reel phase-switching connection cable in Figure 1.

[0027] Explanation of reference numerals in the attached diagram: 1-Power core; 2-Control core; 11-Divider unit conductor; 12-First aramid rope; 13-First aramid yarn; 14-First insulating material; 111-Strand wire; 112-First PTFE tape; 21-Control wire group; 22-Second aramid rope; 23-Second aramid yarn; 24-Sheath; 25-Second PTFE tape; 211-Insulated core; 212-Polyester rope; 21A-Conductor; 21B-Second insulating material. Detailed Implementation

[0028] In the description of this invention, it should be understood that the orientation or positional relationship indicated by directional terms such as "inner" and "outer", "upper" and "lower", "left" and "right" is usually based on the orientation or positional relationship shown in the accompanying drawings, and is only for the convenience of describing this invention and simplifying the description. Unless otherwise stated, these directional terms do not indicate or imply that the device or element referred to must have a specific orientation or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the scope of protection of this invention.

[0029] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0030] Example 1, as shown in Figure 1, describes an airport compression-resistant, ultra-flexible electric reel phase-changing connection cable. The cable includes a power core 1 and a control core 2. Four power cores 1 and one control core 2 are combined together in a non-twisted structure. The power cores 1 and control cores 2 have the same outer diameter. The non-twisted structure of the power cores 1 and control cores 2 is laid inside a non-slip ring reel. When the cable is stretched and turned, there is no stress generated between the power cores 1 and control cores 2. The flexible structure ensures that the cable can freely change phases. When subjected to tension and winding, it ensures unobstructed transmission of power and signals.

[0031] As shown in Figure 2, the power core 1 includes a copper conductor, which is formed by twisting the segmented unit conductor 11 in a 0+5 structure. The center of the copper conductor is filled with a first aramid rope 12, the edge gaps are filled with a first aramid yarn 13, and the copper conductor is covered with a first insulating material 14.

[0032] The copper conductor is constructed using fine monofilaments, bundles, strands, and multiple strands. All stranded structures are hollow, and the center of the multiple strands is filled with a first aramid rope 12. This conductor structure is suitable for applications with high resistance to external tensile forces and frequent movement.

[0033] The five segmented unit conductors 11 in the power core 1 are arranged equilaterally around its axis at 72°. The resistance and cross-sectional area of ​​the strands are equal. They are combined together and connected in parallel to form a circular structure. This structure increases the surface area of ​​the copper conductor, weakens the skin effect, and can effectively reduce impedance, thereby reducing losses during operation, reducing cable heating, effectively increasing the current carrying capacity of the cable, increasing the cable transmission efficiency, reducing transmission losses, accelerating charging speed, reducing cable operating temperature, and extending cable life.

[0034] The segmented unit conductor 11 is formed by strands 111 bundled together in a 1+6 structure and wrapped with a first polytetrafluoroethylene tape 112. The strands 111 are formed by a bundle of copper monofilaments with a diameter of 0.195 mm.

[0035] As shown in Figure 3, the control core 2 includes a cable core, which is formed by twisting control wire group 21 in a 0+6 structure. The center of the cable core is filled with a second aramid rope 22, and the edge gaps are filled with second aramid yarn 23. The cable core is covered with an extruded sheath 24. The control wire group 21 is formed by pre-twisting insulated wire core 211, and the edge gaps are filled with polyester rope 212. The insulated wire core 211 includes a conductor 21A, and the conductor 21A is covered with a second insulating material 21B.

[0036] The second insulating material 21B has a dielectric loss factor tgδ ≤ 1 × 10⁻⁶. -3 Ultra-high purity medium-density polyethylene insulation material, material grade MDPE, reduces information loss in insulation materials and improves signal transmission efficiency.

[0037] Example 2: A method for manufacturing an airport compression-resistant ultra-flexible electric reel phase-switching connection cable, comprising the following steps: I. Stranding of power core conductors 1.1) Bundling: using bare copper single wires with a diameter of 0.195mm in the left direction, with a pitch multiple of 16, the bundled wires are stranded into strands 111; 1.2) Stranding: the strands 111 of the bundled wires in step 1.1) are stranded leftward in a 1+6 structure, with a pitch multiple of 13, and a compression coefficient controlled at 0.93. While stranding, a first polytetrafluoroethylene tape 112 resistant to high temperature of 240℃ is wrapped in the leftward overlap, with the overlap rate controlled at 10%, forming a segmented unit conductor 11; 1.3) Re-stranding: the center is filled with a tensile-resistant first aramid rope 12. Five segmented unit conductors 11 are spirally twisted around the first aramid rope 12 to the left to form a copper conductor with a pitch multiple of 11 and a compression coefficient controlled at 0.96. The gaps between the copper conductors are filled with the first aramid yarn 13. The copper conductors are wrapped with a thin non-woven fabric with a thickness of 0.07mm to the right and tightly bound. The rewinding equipment adopts a 30-reel (12+18) 500-type cage winding machine. The five reels of copper conductors and the five first aramid yarns 13 at the edge are respectively loaded onto the 500-type nylon turntable. The maximum tension of the wire feeding does not exceed 15% of the calculated tension of the conductor from beginning to end. The cradle tension is set according to the weight, and the wire feeding tension is set inversely to ensure that the tension of the conductor remains uniform from the full reel of conductor to the half reel of conductor during the production process.

[0038] II. Power conductor insulation extrusion: A 65 extruder is used to extrude insulation material 14 around a copper conductor to form power conductor 1. The line speed is controlled at 12 meters / minute. The lead-out cooling adopts a combination of segmented water cooling and air cooling. The take-up uses a metal turntable to prevent abrasion. The insulation material 14 is an irradiated cross-linked elastomer. The temperature zones of the 65 extruder are set as follows: Zone 1: 100℃, Zone 2: 120℃, Zone 3: 130℃, Zone 4: 145℃, Flange: 150℃, Die 1: 150℃, Die 2: 150℃, Water tank: 45℃. The parameters of the die during the extrusion of the first insulation material 14 are as follows: The die sleeve surface is chrome-plated; extrusion is used. Die matching calculation: Die core size: conductor outer diameter d + 0.5mm, die sleeve D - 0.2mm, where d is the conductor outer diameter in mm; D is the insulation outer diameter in mm; Die-to-die distance: the die sleeve-to-die distance is T, where T is the nominal insulation thickness in mm.

[0039] III. Controlling the conductor core: The nominal cross-sectional area of ​​conductor 21A is 1mm². 2 The conductor structure consists of 50 single filaments of 0.155mm each. To ensure minimal insulation eccentricity and improve conductor compactness and surface smoothness, conductor 21A is produced using a process of first bundling the wires and then re-twisting them. During bundling, the center strand uses 8 0.15mm copper wires, and the other 6 strands use 7 0.15mm copper wires each. The bundled wire pitch is 12 times the conductor length and the direction is left-handed. Then, a 1+6 regular twisting structure is used for re-twisting, with the direction being left-handed and the pitch multiple being 10 times the conductor length. The compression coefficient is controlled to be ≤0.9.

[0040] IV. Control Core Insulation Fabrication 4.1) Material Selection: The nominal thickness of the second insulation material 21B is 0.25mm. The second insulation material 21B adopts a dielectric loss factor tgδ≤1×10 -3 Ultra-high purity medium-density polyethylene insulation material, material grade MDPE; 4.2) Conductor 21A adopts online preheating. During extrusion, a preheating device is placed between the wire feeding and the die head, and the temperature is set at 55℃ to alleviate the stress unevenness caused by the temperature difference between the inside and outside of the insulation layer, and also to avoid uneven thickness caused by temperature difference; 4.3) The extrusion die adopts extrusion type. Due to the thin insulation thickness, the eccentricity needs to be controlled within ≤10%. The die core = d1 + 0.1mm, the die sleeve = d1 + 2 × t, where d1 is the outer diameter of the conductor, mm; t is the nominal thickness of the insulation material, mm; 4.4) The insulation material 21B is extruded around conductor 21A using a PBJ35+50 extruder to form insulated wire core 211. The temperature control of the PBJ35+50 extruder is as follows: Zone 1: 170℃, Zone 2: 180℃, Zone 3: 200℃, Zone 4: 210℃, fuselage zone 5: 220℃, flange: 220℃, mold 1: 230℃, mold 2: 235℃, mold 3: 240℃, water tank: 60℃; V. Control line group pre-cable fabrication: Three insulated cores 211 are twisted leftwards in a 0+3 structure, and the gaps are filled with polyester rope 212 to form control line group 21. The control line group 21 is wrapped around the second polytetrafluoroethylene tape 25 in a rightward overlap direction, with an overlap rate of 10%; VI. Control The cable core assembly is made by right-hand twisting the control wire group 21 in a 0+6 structure to form the cable core. The pitch multiple is 8 times the outer diameter. The center of the cable core is filled with five 3-strand twisted second aramid ropes 22, and the edge gaps are filled with second aramid yarns 23. In order to reduce crosstalk, adjacent control wire groups 21 use different twisting pitches. From the 1st group to the 6th group, the pitches are 19 times, 17 times, 15 times, 13 times, 11 times, and 9 times the outer diameter of the twisting, respectively.

[0041] VII. The control line sheath is extruded using a 65 extruder to extrude sheath 24 around the cable core. The linear speed is controlled at 12 meters per minute. The lead-out cooling uses a combination of segmented water cooling and air cooling. The take-up uses a metal turntable to prevent abrasion. The sheath is made of irradiated cross-linked elastomer. The temperature zones of the 65 extruder are set as follows: Zone 1: 100℃, Zone 2: 120℃, Zone 3: 130℃, Zone 4: 145℃, Flange: 150℃, Die 1: 150℃, Die 2: 150℃, Water tank: 45℃. The die parameters used for extruding sheath 24 are as follows: The die surface is chrome-plated; extrusion is used. Die matching calculation: Die core size: cable core outer diameter d + 1.0mm, die sleeve D - 0.2mm, where d is the cable core outer diameter (mm); D is the sheath outer diameter (mm); Die-to-die distance: the die-to-die distance is T, where T is the nominal insulation thickness (mm).

[0042] 8. Irradiation: 8.1) The power wire core 1 is irradiated with a high voltage / beam current of 2.0MeV / 10mA at a linear speed of 10 meters / minute. In order to prevent irradiation of the eccentric side, 30 traction channels are used.

[0043] 8.2) When irradiating the sheath 24 of the control core 2, the irradiation dose needs to be controlled to prevent electrons from passing through the sheath 24 and affecting the second insulation material 21B, thus accelerating the aging of the second insulation material 21B. The irradiation parameters are: high voltage / beam current 2.0MeV / 10mA, line speed 12 meters / minute, and 30-channel traction. 8.3) After the control core is irradiated, it is left to stand for 46 hours to fully release the residual electrons before proceeding to the next process.

[0044] To prevent electrons from remaining inside the cable during irradiation, the conductor must be stripped at the entry point and effectively grounded.

[0045] The first insulation material 14 of the power core 1 and the sheath 24 of the control core 2 are made of ultra-soft thermosetting insulation material, which is cross-linked by irradiation. The material has high strength and improves the cable's resistance to compression.

[0046] The test data for the above cables are as follows: 1. Mechanical properties of power core insulation: original tensile strength is 13.2 MPa (requirement ≥10.0 MPa); original elongation at break is 600% (requirement ≥3000%); after aging at 135℃ for 168 hours (aging temperature 100℃, 168h in GB / T 5013.1-2008 / IEC60245.1-2003): tensile strength change rate is 15% (requirement ≤25%); elongation at break change rate is 15% (requirement ≤25%).

[0047] 2. The maximum DC resistance of the conductor at 20℃ conforms to GB / T 3956-2008.

[0048] 3. Electrical performance: Power conductor withstands AC 3.5kV / 5min without breakdown; Control conductor withstands AC 1500V / 5min without breakdown.

[0049] 4. The maximum elongation under a 15-minute heat extension load at 250℃ is 35% (the requirement is ≤175%); the maximum elongation after cooling is 0 (the requirement is ≤15%).

[0050] Example 3: A method for manufacturing an airport extrusion-resistant ultra-flexible electric reel phase-switching connection cable, comprising the following steps: I. Stranding of power core conductors 1.1) Bundling: using bare copper single wires with a diameter of 0.195mm in the left direction, with a pitch multiple of 18, the bundled wires are stranded into strands 111; 1.2) Stranding: the strands 111 of the bundled wires in step 1.1) are stranded in the left direction using a 1+6 structure, with a pitch multiple of 15, and a compression coefficient controlled at 0.95. While stranding, a first polytetrafluoroethylene tape 112 resistant to high temperatures of 240℃ is wrapped in the left direction with an overlap rate controlled at 15%, forming a segmented unit conductor 11; 1.3) Re-stranding: the center is filled with a tensile-resistant first aramid rope 12. Five segmented unit conductors 11 are spirally twisted around the first aramid rope 12 in a leftward direction to form a copper conductor. The pitch multiple is 12 times, and the compression coefficient is controlled at 0.97. The gaps between the copper conductors are filled with the first aramid yarn 13. The copper conductors are wrapped with a thin non-woven fabric with a thickness of 0.07mm in a rightward direction to secure them. The re-twisting equipment adopts a 30-reel (12+18) 500-type cage winding machine. The five reels of copper conductors and the five first aramid yarns 13 in the gaps are respectively loaded onto 500-type nylon turntables. The maximum tension of the wire feeding does not exceed 15% of the calculated tension of the conductor from beginning to end. The cradle tension is set according to the weight, and the wire feeding tension is set inversely to ensure that the tension of the conductor remains uniform from full reel to half reel during the production process.

[0051] II. The power conductor insulation extrusion uses a 65 extruder to extrude the first insulation material 14 around the copper conductor to form the power conductor 1. The linear speed is controlled at 15 meters / minute. The lead-out cooling adopts a combination of segmented water cooling and air cooling. The take-up uses a metal turntable to prevent abrasion. The first insulation material 14 is an irradiated cross-linked elastomer. The temperature zones of the 65 extruder are set as follows: Zone 1: 100℃, Zone 2: 120℃, Zone 3: 130℃, Zone 4: 145℃, Flange: 150℃, Die 1: 150℃, Die 2: 150℃, Water tank: 45℃. The parameters of the die during the extrusion of the first insulation material 14 are as follows: The die sleeve surface is chrome-plated; extrusion is adopted, and the die matching calculation is as follows: Die core size: conductor outer diameter d + 0.5mm, die sleeve D - 0.2mm, where d is the conductor outer diameter in mm; D is the insulation outer diameter in mm; Die-to-die distance: the die sleeve distance is T, where T is the nominal insulation thickness in mm.

[0052] III. Control conductor fabrication: The nominal cross-sectional area of ​​the 21A control conductor is 1 mm². 2 The conductor structure consists of 50 single wires of 0.155 mm each. To ensure minimal insulation eccentricity and improve conductor compactness and surface smoothness, conductor 21A is produced using a process of first bundling the wires and then re-twisting them. During the bundling process, the center strand uses 8 0.15 mm copper wires, and the other 6 strands use 7 0.15 mm copper wires each. The bundled wire pitch is 14 times the conductor length and the direction is to the left. Then, a 1+6 regular twisting structure is used for re-twisting, with the direction to the left and the pitch multiple being 12 times the conductor length. The compression coefficient is controlled to be ≤0.9.

[0053] IV. Control Core Insulation Fabrication 4.1) Material Selection: The nominal thickness of the control second insulation material 21B is 0.25mm, and the dielectric loss factor tgδ of the second insulation material 21B is ≤1×10 -3 Ultra-high purity medium-density polyethylene insulation material, material grade MDPE; 4.2) Conductor 21A adopts online preheating. During extrusion, a preheating device is placed between the wire feeding and the die head, and the temperature is set at 65℃ to alleviate the stress unevenness caused by the temperature difference between the inside and outside of the insulation layer, and also to avoid uneven thickness caused by temperature difference; 4.3) The extrusion die adopts extrusion type. Due to the thin insulation thickness, the eccentricity needs to be controlled within ≤10%. The die core = d1 + 0.1mm, and the die sleeve = d1 + 2 × t, where d1 is the outer diameter of the conductor, mm; t is the nominal thickness of the insulation material, mm; 4.4) A PBJ35+50 extruder is used to extrude and wrap conductor 21A. Insulating material 21B forms insulated wire core 211. The temperature control of the PBJ35+50 extruder is as follows: Zone 1 of the machine body: 170℃, Zone 2 of the machine body: 180℃, Zone 3 of the machine body: 200℃, Zone 4 of the machine body: 210℃, Zone 5 of the machine body: 220℃, Flange: 220℃, Mold 1: 230℃, Mold 2: 235℃, Mold 3: 240℃, Water tank: 60℃. V. Control line group pre-cable production: Three insulated wire cores 211 are twisted to the left in a 0+3 structure. The gaps are filled with polyester rope 212 to form control line group 21. The control line group 21 is wrapped with a second polytetrafluoroethylene tape 25 to the right in an overlapping manner, with an overlap rate of 15%.

[0054] VI. Control Core Assembly Cable Fabrication: The control wire group 21 is twisted to the right using a 0+6 structure to form the cable core. The pitch multiple is 10 times the outer diameter. The center of the cable core is filled with five 3-strand twisted second aramid ropes 22, and the edge gaps are filled with second aramid yarns 23.

[0055] To reduce crosstalk, adjacent control line groups 21 use different twisting pitches, from group 1 to group 6, which are 20 times, 18 times, 16 times, 14 times, 12 times, and 10 times the outer diameter of the twisting, respectively.

[0056] VII. The control line sheath is extruded using a 65 extruder to encapsulate the sheath 24 around the cable core. The linear speed is controlled at 15 meters per minute. Cooling at the exit point uses a combination of segmented water cooling and air cooling. A metal turntable is used for take-up to prevent abrasion. The sheath is made of irradiated cross-linked elastomer. The temperature zones of the 65 extruder are set as follows: Zone 1: 100℃, Zone 2: 120℃, Zone 3: 130℃, Zone 4: 145℃, Flange: 150℃, Die 1: 150℃, Die 2: 150℃, Water tank: 45℃. The extruded sheath 24 uses... The mold parameters are as follows: The mold sleeve surface is chrome plated; extrusion is adopted, and the mold matching calculation is as follows: Mold core size: cable core outer diameter d + 1.0 mm, mold sleeve D - 0.2 mm, where d is the cable core outer diameter, mm; D is the sheath outer diameter, mm; Mold-to-mold distance: the mold sleeve-to-mold distance is T, where T is the nominal insulation thickness, mm; VIII. Irradiation: 8.1) The power core 1 is irradiated with a high voltage / beam current of 1.8 MeV / 10mA at a linear speed of 6 m / min. In order to prevent irradiation of the opposite side, 25 traction channels are used.

[0057] 8.2) When irradiating the sheath 24 of the control core 2, the irradiation dose needs to be controlled to prevent electrons from passing through the sheath 24 and affecting the second insulation material 21B, thus accelerating the aging of the second insulation material 21B. The irradiation parameters are: high voltage / beam current 1.8MeV / 10mA, line speed 8 meters / minute, and 25-channel traction. 8.3) After the control core is irradiated, it is left to stand for 50 hours to fully release the residual electrons before proceeding to the next process.

[0058] To prevent electrons from remaining inside the cable during irradiation, the conductor must be stripped at the entry point and effectively grounded.

[0059] The first insulation material 14 of the power core 1 and the sheath 24 of the control core 2 are made of ultra-soft thermosetting insulation material, which is cross-linked by irradiation. The material has high strength and improves the cable's resistance to compression.

[0060] The test data for the above cables are as follows: 1. Mechanical properties of power core insulation: original tensile strength is 13.0 MPa (requirement ≥10.0 MPa); original elongation at break is 620% (requirement ≥3000%); after aging at 135℃ for 168 hours (aging temperature 100℃, 168h in GB / T 5013.1-2008 / IEC60245.1-2003): tensile strength change rate is 14% (requirement ≤25%); elongation at break change rate is 14% (requirement ≤25%).

[0061] 2. The maximum DC resistance of the conductor at 20℃ conforms to GB / T 3956-2008.

[0062] 3. Electrical performance: Power core withstands AC 3.5kV / 5min without breakdown.

[0063] Control wire core withstand capability: AC 1500V / 5min, no breakdown.

[0064] 4. At 250℃, under a 15-minute heat extension load, the maximum elongation is 40% (requirement: ≤175%); after cooling, the maximum elongation is 0 (requirement: ≤15%).

[0065] Finally, it should be noted that the above specific embodiments are only used to illustrate the technical solutions of the present invention and not to limit it. Although the present invention has been described in detail with reference to examples, 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, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. An airport compression-resistant, ultra-flexible electric reel phase-switching connection cable, characterized in that, The cable includes a power core (1) and a control core (2); the power core (1) includes a metal conductor, which is formed by twisting segmented unit conductors (11) in a 0+5 structure, with the center of the metal conductor filled with a first aramid rope (12) and the edge gaps filled with a first aramid yarn (13), and the conductor is extruded with a first insulating material (14); the segmented unit conductor (11) is formed by strands (111) in a 1+6 structure and wrapped with a first polytetrafluoroethylene tape (112), and the strands are made of copper monofilaments. The control wire core (2) is formed by stranding the control wire group (21) in a 0+6 structure. The center of the cable core is filled with a second aramid rope (22), and the edge gaps are filled with a second aramid yarn (23). The cable core is extruded with a sheath (24). The control wire group (21) is pre-stranded from insulated wire cores (211) and the edge gaps are filled with polyester rope (212). The insulated wire core (211) includes a conductor (21A), and the conductor (21A) is extruded with a second insulating material (21B).

2. The airport compression-resistant ultra-flexible electric reel phase-switching connection cable according to claim 1, characterized in that, The five segmented unit conductors (11) in the power core (1) are arranged equilaterally around its axis, and the resistance and cross-sectional area of ​​the strands in each segmented unit conductor (11) are equal.

3. The airport compression-resistant ultra-flexible electric reel phase-switching connection cable according to claim 1 or 2, characterized in that, The cable includes four power cores (1) and one control core (2) assembled together in a non-twisted structure. The power cores (1) and the control core (2) have the same outer diameter. The non-twisted structure of the power cores (1) and the control core (2) is laid inside a non-slip ring drum.

4. A method for manufacturing an airport extrusion-resistant, ultra-flexible electric reel phase-commutation connection cable, characterized in that, Includes the following steps:

1. Stranding of the power core conductor 1.1) Bundling: Bare metal monofilament bundles are used, with a pitch multiple of 16-18, and the bundles are stranded into wires (111); 1.2) Stranding: The wires (111) described in step 1.1) are stranded in a 1+6 structure, with a pitch multiple of 13-15, and the compression coefficient is controlled at 0.93-0.

95. At the same time as stranding, the first polytetrafluoroethylene tape (112) is wrapped around it, and the overlap rate is controlled at 10%-15%, forming a segmented unit conductor (11); 1.3) Re-stranding: The center is filled with a first aramid rope (12), and the five segmented unit conductors (11) are spirally twisted around the first aramid rope (12) to form a metal conductor, with a pitch multiple of 11-12. The compression coefficient is controlled at 0.96-0.

97. The gap of the metal conductor is filled with the first aramid yarn (13), and the metal conductor is wrapped with non-woven fabric. Second, the insulation of the power core is extruded by a 65 extruder to extrude the first insulation material (14) on the outside of the metal conductor. The linear speed is controlled at 12-15 meters / minute. The cooling of the lead wire is combined with segmented water cooling and air cooling. The take-up is carried out by a metal turntable. Third, the conductor (21A) is first bundled and then re-twisted. The bundle pitch multiple is 12-14 times. Then, a 1+6 regular stranding structure is used for re-twisting. The pitch multiple is 10-12 times. The compression coefficient is controlled at ≤0.

9. Fourth, the insulation of the control core is manufactured by 4.1) the conductor (21A) is made by online Preheating method: During extrusion, a preheating device is placed between the wire feeding and the die head, and the temperature is set at 50-70℃; 4.2) A PBJ35+50 extruder is used to extrude a second insulating material (21B) around the preheated conductor (21A) to form an insulated wire core (211); V. Control wire group pre-cable production: The insulated wire core (211) is twisted in a 0+3 structure, and the gap is filled with polyester rope (212) to form a control wire group (21). The control wire group (21) is wrapped with a second polytetrafluoroethylene tape (25) with an overlap rate of 10-15%. The twisting direction of the insulated wire core (211) is opposite to the wrapping direction of the second polytetrafluoroethylene tape (25); VI. Control wire core assembly The cable is made by right-hand twisting the control wire group (21) in a 0+6 structure to form the cable core. The pitch multiple is 8-10 times the outer diameter. The center of the cable core is filled with a second aramid rope (22), and the edge gap is filled with a second aramid yarn (23). Seven, the control wire sheath is extruded by using a 65 extruder to extrude a sheath (24) around the cable core. The line speed is controlled at 12-15 meters / minute. The lead-out cooling adopts a combination of segmented water cooling and air cooling. The take-up adopts a metal turntable. Eight, irradiation: 8.1) The power wire core (1) is irradiated with a high voltage / beam current of 1.8-2.0MeV / 10mA. The line speed is 6-10 meters / minute. The number of traction channels is 25-30. 8.2) The high voltage / beam current is 1.8-2.0MeV / 10mA.The sheath (24) of the control wire core (2) is irradiated with 0 MeV / 10mA at a linear speed of 8-12 meters per minute, using 25-30 traction passes. After irradiation, the wire is left to stand for 46-50 hours before proceeding to the next process.

5. The method for manufacturing the airport extrusion-resistant ultra-flexible electric reel phase-switching connection cable according to claim 4, characterized in that, In step one, the twisting direction, the filament direction, the twisting direction of the segmented unit conductor (11) and the wrapping direction of the first polytetrafluoroethylene tape (112) are the same, and the wrapping direction of the nonwoven fabric is opposite to the twisting direction of the segmented unit conductor (11) to tighten the metal conductor.

6. The method for manufacturing the airport extrusion-resistant ultra-flexible electric reel phase-switching connection cable according to claim 4, characterized in that, In step two, the temperature zones of the 65 extruder are set as follows: Zone 1 of the machine body: 100±5℃, Zone 2 of the machine body: 120±5℃, Zone 3 of the machine body: 130±5℃, Zone 4 of the machine body: 145±5℃, Flange: 150±5℃, Mold 1: 150±5℃, Mold 2: 150±5℃, Water tank: 45±5℃; The parameters of the mold when the first insulating material (14) is extruded are as follows: The surface of the mold sleeve is chrome-plated; Mold matching calculation: The mold core size is d+0.5mm, and the mold sleeve size is D-0.2mm, where d is the outer diameter of the conductor, mm; D is the outer diameter of the insulation, mm; Mold distance: The distance between the mold sleeve and the mold is T, where T is the nominal thickness of the insulation.

7. The method for manufacturing the airport compression-resistant ultra-flexible electric reel phase-changing connection cable according to claim 4, characterized in that, In step four, the temperature control of the PBJ35+50 extruder is as follows: Zone 1 of the machine body: 170±5℃, Zone 2 of the machine body: 180±5℃, Zone 3 of the machine body: 200±5℃, Zone 4 of the machine body: 210±5℃, Zone 5 of the machine body: 220±5℃, Flange: 220±5℃, Mold 1: 230±5℃, Mold 2: 235±5℃, Mold 3: 240±5℃, Water tank: 60±5℃; The extrusion die adopts the extrusion type, and the eccentricity is controlled within ≤10%. The die core is set to d1+0.1mm, and the die sleeve is set to d1+2×t, where d1 is the outer diameter of the conductor in mm, and t is the nominal thickness of the insulation in mm.

8. The method for manufacturing the airport compression-resistant ultra-flexible electric reel phase-switching connection cable according to claim 4, characterized in that, In step six, when forming the cable core, the adjacent control line groups (21) adopt different stranding pitches, from group 1 to group 6, which are 19-20 times, 17-18 times, 15-16 times, 13-14 times, 11-12 times, and 9-10 times the stranding outer diameter, respectively.

9. The method for manufacturing the airport compression-resistant ultra-flexible electric reel phase-switching connection cable according to claim 4, characterized in that, In step seven, the temperature zones of the 65 extruder are set as follows: Zone 1 of the machine body: 100±5℃, Zone 2 of the machine body: 120±5℃, Zone 3 of the machine body: 130±5℃, Zone 4 of the machine body: 145±5℃, Flange: 150±5℃, Mold 1: 150±5℃, Mold 2: 150±5℃, Water tank: 45±5℃; The parameters of the die when the sheath (24) is extruded are as follows: The surface of the die is chrome-plated; Extrusion is adopted, and the die matching calculation is as follows: The core size is the outer diameter of the cable core d+1.0mm, and the die size is D-0.2mm, where d is the outer diameter of the cable core, mm; D is the outer diameter of the sheath, mm; Die-to-die distance: The die-to-die distance is T, where T is the nominal insulation thickness, mm.

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