A composite cable extrusion test device and test method

Abstract

The application provides a composite cable extrusion test device and a test method, wherein a loading device is used to apply tension to the sample cable, the sample cable between the extrusion wheel and the fixing device and the sample cable between the extrusion wheel and the loading device form an included angle to simulate the bending working condition in actual application, the extrusion wheel is used to apply extrusion force to the sample cable to simulate the extrusion working condition in actual application, the three-dimensional adjustable design of the tension, the extrusion working condition and the bending angle makes the test working condition highly consistent with the actual service working condition of the composite cable, the precise simulation of the actual engineering stress field of the composite cable is realized, the idealization problem of the test working condition of the existing device is solved, more real and more valuable composite cable extrusion performance parameters can be obtained, scientific basis is provided for the research and development, quality control and engineering application of the composite cable, and the gap of the special extrusion test device for the composite cable for the ICCP system in the industry is filled.

Description

Technical Field

[0001] This invention relates to the field of composite cable testing technology, and in particular to a composite cable extrusion test apparatus and test method. Background Technology

[0002] Impressed current cathodic protection (ICCP), a key technology, applies cathodic current to metal structures such as offshore platforms via an external power source to prevent corrosion. The composite cable is the core component connecting the potentiostat and the electrodes. With the development of deep-water tensioned ICCP technology, the composite cable must simultaneously undertake the tasks of power transmission and mechanical tension, and serve in complex marine environments for extended periods. During this process, it must not only withstand constant tension but also resist the dynamic compression and impact risks caused by wave impacts and current-induced vibrations.

[0003] If the composite cable suffers sheath damage or core wire breakage due to compression, it will lead to an interruption of anode power supply, severely affecting the reliability of the cathodic protection system. Therefore, it is necessary to conduct compression tests on the composite cable under simulated actual working conditions during the research and development and quality control phases.

[0004] Currently, there are core technical problems in the industry regarding the extrusion performance testing of composite cables used in ICCP systems. These problems mainly manifest as a lack of unified testing standards and a disconnect between testing conditions and actual engineering practices. Specifically: The lack of specific extrusion test standards for composite cables means that key performance parameters such as extrusion strength and resistance to bending and extrusion are entirely dependent on the manufacturers. Users lack effective means to verify the authenticity and reliability of these parameters, creating a technical blind spot and posing safety hazards to engineering applications.

[0005] Existing testing equipment is general-purpose cable testing equipment, which can only perform a single static compression test. It cannot simulate the complex stress state of composite cables in actual engineering, such as high-frequency dynamic compression caused by wind and waves during typhoons, the combined stress of compression and bending when bypassing seabed obstacles, and static compression under long-term tension.

[0006] The performance parameters provided by manufacturers are based on idealized test conditions, which deviate significantly from the actual service environment of composite cables in marine engineering. Composite cables selected based on these parameters are difficult to guarantee in actual service and are prone to failure in the field.

[0007] In summary, existing technologies lack a dedicated extrusion testing device capable of simulating the complex stress conditions of composite cables in actual engineering projects, making it impossible to objectively and accurately assess the structural strength and functional integrity of composite cables. Therefore, there is an urgent need to develop an extrusion testing device suitable for composite cables used in ICCP systems, filling a technological gap in the industry, providing scientific testing basis for the research and development, quality control, and engineering applications of composite cables, and ensuring the long-term stable operation of ICCP systems. Summary of the Invention

[0008] This invention provides a composite cable extrusion testing device and method to overcome the above-mentioned technical problems.

[0009] To achieve the above objectives, the technical solution of the present invention is as follows: A composite cable extrusion testing device includes: a base; A loading device mounted on the base is used to connect one end of the sample cable and is capable of applying tension to the sample cable. The loading device includes a force sensor for detecting the tension. A fixing device installed on the base is used to connect the end of the sample cable away from the loading device; The extrusion device mounted on the base includes an extrusion wheel. The extrusion device applies extrusion force to the sample cable through the reciprocating linear motion of the extrusion wheel. The extrusion device is detachably connected to the base and is located between the loading device and the fixing device. When the two ends of the sample cable are connected to the fixing device and the loading device respectively, the portion of the sample cable between the extrusion wheel and the fixing device and the portion between the extrusion wheel and the loading device form a certain angle.

[0010] Furthermore, the extrusion device also includes a support, a first linear drive mechanism, and a rotating shaft; the support is provided with a guide groove, the rotating shaft is located in the guide groove, and the extrusion wheel is mounted on the rotating shaft through a bearing; Two first linear drive mechanisms are symmetrically arranged on the support. The first linear drive mechanism can drive the rotating shaft to reciprocate linearly along the guide groove. The support and the base are detachably connected by bolts. The first linear drive mechanism is selected from any one of a pneumatic cylinder, a hydraulic cylinder, or an electric cylinder.

[0011] Furthermore, the loading device also includes a loading frame, a lead screw, a tightening nut, and a connecting buckle; The loading frame is fixed on the base, and the lead screw passes through the through hole provided on the loading frame. The two ends of the lead screw are respectively threaded to a tightening nut and a force sensor. The force sensor is fixedly connected to a connecting buckle, and the connecting buckle is provided with a hole for connecting to the sample cable.

[0012] Furthermore, the loading device also includes a second linear drive mechanism and a connecting buckle; The second linear drive mechanism is fixed on the base and is fixedly connected to the force sensor. The force sensor is fixedly connected to the connecting buckle, and the connecting buckle is provided with a hole for connecting to the sample cable. The second linear drive mechanism is selected from any one of a pneumatic cylinder, hydraulic cylinder, electric cylinder, or linear module.

[0013] Furthermore, it also includes a controller, which is signal-connected to the force sensor and the second linear drive mechanism; the controller can control the second linear drive mechanism to operate based on the data fed back by the force sensor in order to maintain a constant tension on the sample cable.

[0014] Furthermore, the fixing device includes a lug disposed on the base.

[0015] Furthermore, the fixing device includes an adjusting seat welded to the base, the adjusting seat having two opposing ear plates, the ear plates having vertically extending elongated holes, and the elongated holes having connecting bolts for connecting the sample cable.

[0016] Furthermore, the side of the elongated hole near the extrusion device is evenly provided with a plurality of semi-circular positioning grooves arranged along the length of the elongated hole.

[0017] Furthermore, the base includes a first pier, a second pier, and a reaction frame. The first pier and the second pier are fixed on the reaction frame. The loading device is fixed on the first pier, the compression device is fixed on the second pier, and the fixing device is disposed on the reaction frame.

[0018] This invention also relates to a composite cable extrusion test method, using the aforementioned composite cable extrusion test apparatus, comprising the following steps: S1: Select extrusion devices with extrusion rollers of different specifications according to the test requirements, determine the fixed position of the sample cable on the base according to the bending angle of the sample cable, and set the reciprocating stroke and speed of the extrusion rollers. S2: Connect both ends of the sample cable to the loading device and the fixing device respectively; S3: Apply tension to the sample cable through the loading device, and observe the magnitude of the tension through the force sensor until the preset tension value of the test is reached; S4: Start the extrusion device to extrude the sample cable that is in a tensioned and bent state; S5: Real-time monitoring of the tension change of the sample cable through force sensors, observation of the appearance and structural changes of the sample cable, recording the number of extrusions, extrusion stroke, extrusion pressure, and the critical value at which the sample cable is damaged or the core wire breaks.

[0019] Furthermore, according to the test plan, steps S1 to S5 were repeated to complete multiple sets of extrusion tests under different tension forces, different bending angles, and different extrusion conditions.

[0020] Beneficial effects: This invention provides a composite cable compression testing device and method. A tension force is applied to the sample cable via a loading device. An angle is formed between the sample cable positioned between the compression wheel and the fixing device, and between the sample cable positioned between the compression wheel and the loading device, to simulate bending conditions in actual applications. A compressive force is applied to the sample cable via the compression wheel to simulate compression conditions in actual applications. Through a three-dimensional adjustable design of tension force, compression conditions, and bending angle, the test conditions closely match the actual service conditions of the composite cable, achieving accurate simulation of the actual engineering stress scenarios of the composite cable. This solves the problem of idealized test conditions in existing devices and can obtain more realistic and valuable composite cable compression performance parameters. It provides a scientific basis for the research, development, quality control, and engineering applications of composite cables. This device fills a gap in the industry for a dedicated extrusion testing device for composite cables used in ICCP systems. It breaks away from the single-reference model of manufacturers providing parameters, allowing users to independently verify the performance parameters of composite cables and effectively avoid safety hazards in engineering applications. The device allows for flexible adjustment of test parameters according to the actual needs of different marine engineering projects, enabling extrusion testing of composite cables under multiple working conditions and specifications. It eliminates the need to design separate testing devices for different working conditions, reducing testing costs and improving testing efficiency. It achieves extrusion testing of composite cables under tension, dynamic extrusion, and bending stress coupling conditions, enabling the testing of composite stress in composite cables. This allows for accurate evaluation of the structural strength and functional integrity of composite cables under extreme working conditions, providing testing support for the development of high-reliability composite cables. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 This is a schematic diagram of the structure of a composite cable extrusion testing device disclosed in Embodiment 1 of the present invention; Figure 2 This is a front view schematic diagram of a composite cable extrusion testing device disclosed in Embodiment 1 of the present invention; Figure 3 This is a schematic diagram of the extrusion device of a composite cable extrusion testing apparatus disclosed in Embodiment 1 of the present invention. Figure 1 ; Figure 4This is a schematic diagram of the extrusion device of a composite cable extrusion testing apparatus disclosed in Embodiment 1 of the present invention. Figure 2 ; Figure 5 for Figure 2 Enlarged view of point A; Figure 6 for Figure 2 Enlarged view of point B; Figure 7 This is a schematic diagram of the structure of a composite cable extrusion testing device disclosed in Embodiment 2 of the present invention; Figure 8 This is a front view schematic diagram of a composite cable extrusion testing device disclosed in Embodiment 2 of the present invention; Figure 9 for Figure 8 Enlarged view of point C; Figure 10 for Figure 8 Enlarged diagram of point D.

[0023] In the diagram: 1. Base; 11. First pier; 12. Second pier; 13. Reaction frame; 2. Loading device; 21. Force sensor; 22. Loading frame; 23. Lead screw; 24. Tightening nut; 25. Connecting buckle; 26. Second linear drive mechanism; 3. Sample cable; 31. Wire rope clamp; 4. Fixing device; 41. Lifting lug; 42. Adjusting seat; 421. Ear plate; 422. Oblong hole; 423. Semicircular positioning groove; 5. Extrusion device; 51. Extrusion wheel; 52. Support; 521. Guide groove; 53. First linear drive mechanism; 54. Rotating shaft. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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.

[0025] Example 1 This embodiment provides a composite cable extrusion testing device, such as... Figure 1 As shown, it includes: base 1; The loading device 2, mounted on the base 1, is used to connect one end of the sample cable 3 and can apply tension to the sample cable 3, such as... Figure 5 As shown, the loading device 2 includes a force sensor 21 for detecting tension force. The force sensor 21 collects the tension force value of the sample cable 3 in real time and displays it synchronously, providing the test personnel with accurate force value reference and realizing the visual adjustment of tension force. The fixing device 4, which is installed on the base 1, is used to connect the end of the sample cable 3 away from the loading device 2; The extrusion device 5 installed on the base 1, such as Figure 3 and Figure 4 As shown, it includes a compression wheel 51. The compression device 5 applies compression force to the sample cable 3 through the reciprocating linear motion of the compression wheel 51. The compression device 5 is detachably connected to the base 1 by bolts. The compression device 5 is located between the loading device 2 and the fixing device 4. like Figure 2 As shown, when the two ends of the sample cable 3 are connected to the fixing device 4 and the loading device 2 respectively, the portion of the sample cable 3 between the extrusion wheel 51 and the fixing device 4 and the portion between the extrusion wheel 51 and the loading device 2 form a certain angle.

[0026] The sample cable 3 is a composite cable (containing a steel wire rope core) for the ICCP system to be tested. A specified length is cut according to the test requirements, and the outer sheath is stripped from both ends to expose the inner steel wire rope core. Figure 6 As shown, the wire rope core is symmetrically fixed by multiple sets of wire rope clamps 31 after bending to prevent the wire rope core from slipping during the test. The actual extrusion performance parameters are obtained by performing an extrusion test on it.

[0027] The present invention provides a composite cable compression testing device, which applies tension to the sample cable through the loading device 2, and forms an angle between the sample cable 3 between the compression wheel 51 and the fixing device 4 and the sample cable between the compression wheel 51 and the loading device 2 to simulate the bending condition in actual application; and applies extrusion force to the sample cable 3 through the compression wheel 51 to simulate the extrusion condition in actual application.

[0028] Specifically, such as Figure 3 and Figure 4 As shown, the extrusion device 5 also includes a support 52, a first linear drive mechanism 53, and a rotating shaft 54; the support 52 is provided with a guide groove 521, the rotating shaft 54 ​​is located in the guide groove 521, and the extrusion wheel 51 is mounted on the rotating shaft 54 ​​through a bearing; Two first linear drive mechanisms 53 are symmetrically arranged on the support 52. The first linear drive mechanism 53 can drive the rotating shaft 54 ​​to reciprocate linearly along the guide groove 521. The support 52 and the base 1 are detachably connected by bolts. The first linear drive mechanism 53 is selected from any one of a pneumatic cylinder, a hydraulic cylinder, or an electric cylinder.

[0029] The support 52 consists of two symmetrically arranged side plates and a top plate. The two side plates and the top plate are fixedly connected by high-strength internal hexagon screws to form a closed frame. In this embodiment, the first linear drive mechanism 53 uses an electric cylinder (or a hydraulic cylinder; the large thrust of the hydraulic cylinder is suitable for extrusion testing of large-specification composite cables). The screw used for fixing passes through the pre-set through holes on the two side plates and is connected to the tail ends of the two electric cylinders by nuts to fix the electric cylinders. The rotating shaft 54 ​​has threads at both ends. After tightening the nut, it is connected to the output end of the electric cylinder, realizing the transmission of electric cylinder power to the extrusion wheel 51. The extension and retraction movement of the electric cylinder drives the extrusion wheel 51 to perform reciprocating linear motion, realizing static / dynamic extrusion of the sample cable 3 (the extrusion wheel 51 still extrudes the sample cable 3 when it is stationary). Different extrusion conditions can be simulated by changing the specifications of the extrusion wheel 51 (replacing the entire extrusion device 5) and adjusting the extension and retraction speed of the electric cylinder.

[0030] Specifically, such as Figure 5 As shown, the loading device 2 also includes a loading frame 22, a lead screw 23, a tightening nut 24, and a connecting buckle 25; The loading frame 22 is fixed on the base 1, bearing and distributing the tensile load of the sample cable 3 to the base 1. The lead screw 23 passes through the through hole provided on the loading frame 22. The lead screw 23 is threadedly connected to the force sensor 21. The tightening nut 24 installed on the lead screw 23 can abut against the loading frame 22 after tightening, ensuring the stability of force transmission. The force sensor 21 is fixedly connected to the connecting buckle 25. The connecting buckle 25 is provided with a hole for connecting to the sample cable 3. The tightened nut 24 is fitted into the loading frame 22. The axial displacement of the lead screw 23 is adjusted by tightening. The lead screw 23 transmits the tightening force of the tightened nut 24 to the axial tension of the force sensor 21, providing a power transmission path for adjusting the tension of the sample cable 3, changing the force state of the force sensor, and realizing the precise adjustment and locking of the tension of the sample cable 3.

[0031] The loading frame 22 is an integral rigid frame structure with a through hole in the center that matches the lead screw 23. It bears the tensile load at one end of the sample cable 3 as a whole, providing a support base for tension adjustment. One end of the connecting buckle 25 is machined with an external thread, which matches and connects with the internal thread of the force sensor 21. The hole at the other end is movably connected to one end of the sample cable 3 through a shackle and a pin, so as to realize the transfer between the force sensor 21 and the sample cable 3 and the stable and lossless force transmission.

[0032] In this embodiment, the force sensor 21 is a high-precision pressure / tension dual-measurement sensor with a range of 10t. Both sides are machined with internal threads. One end is threaded to the lead screw 23, and the other end is threaded to the connecting buckle 25. During the test, the tensile force value of the sample cable 3 is collected and displayed in real time.

[0033] Specifically, such as Figure 6As shown, the fixing device 4 includes a lifting lug 41 welded to the base 1. In this embodiment, the lifting lug 41 is fully welded to the reaction frame 13 and is movably connected to the sample cable 3 through a shackle and a pin. The welding height of the lifting lug 41 is determined according to the bending angle required for the sample cable 3. Multiple lifting lugs 41 can be welded vertically, or the lifting lugs can be cut off and re-welded when the angle needs to be adjusted, so as to realize the adjustment of the bending angle of the sample cable 3 and simulate the bending force state of the composite cable when it bypasses the obstacle. In practical applications, longitudinal slide rails can also be welded to the base 1, and lifting lugs 41 can be welded to the slider. The slider and slide rail are connected, and the slider and slide rail are locked by locking bolts, so as to realize the rapid adjustment and locking of the lifting lug height without secondary welding, thereby improving the efficiency of bending angle adjustment.

[0034] Specifically, such as Figure 2 As shown, the base 1 includes a first pier 11, a second pier 12 and a reaction frame 13. The first pier 11 and the second pier 12 are fixed on the reaction frame 13. The loading device 2 is fixed on the first pier 11. The compression device 5 is fixed on the second pier 12. The fixing device 4 is fixed on the reaction frame 13.

[0035] The first pier 1 is a rigid support structure. Its bottom end is fully welded to the upper surface of the reaction frame, and its top end is fixedly connected to the bottom end of the loading frame 22 with high-strength bolts. Anti-slip pads are added to the connection surface to prevent loosening during the test. The second pier 12 is a rigid support structure. Its bottom end is fully welded to the upper surface of the reaction frame, and its top end is fixedly connected to the bottom end of the support 52 with high-strength bolts. Anti-slip pads are added to the connection surface to prevent loosening during the test. The first pier 1 and the second pier 12 provide stable vertical support for the loading frame 22 and the compression device 5, respectively, to distribute the test load and prevent excessive local stress in the reaction frame 13.

[0036] The reaction frame 13 serves as the overall load-bearing foundation of the device. It is constructed from welded steel profiles into a frame structure and is symmetrically fixed to the concrete ground of the test site using multiple sets of anchor bolts to ensure the overall stability of the device during the test. The upper surface of the reaction frame is precisely welded with the first pier 11, the second pier 12, and the lifting lug 41 according to the test layout, providing a fixed foundation for each component. This distributes the tension of the sample cable 3 and the extrusion force of the extrusion device 5 to the test site, ensuring that the device remains stable and does not shift or shake during the test. It can withstand high loads and high-frequency extrusion tests, improving the service life of the device and the safety of the test. It can effectively resist the impact and vibration during the test and prevent the device from shifting and affecting the test accuracy.

[0037] Compared with existing general-purpose cable extrusion testing devices, the core improvement of this application lies in achieving accurate simulation of the actual engineering stress scenarios of composite cables. Through three adjustable designs, it solves the problem of the disconnect between the testing conditions of existing devices and actual engineering. The specific improvements are as follows: The tension can be precisely adjusted: Through the combination design of tightening nut + screw + force sensor, the tension of the sample cable can be precisely adjusted and locked within the range of 0-10t. The force value can be visualized through the force sensor, which can simulate the different constant tension states of the composite cable in actual engineering, such as the tension difference at different depths in deep water. The extrusion conditions can be flexibly adjusted: The extrusion device adopts a replaceable extrusion device + adjustable speed electric cylinder design. By replacing the extrusion rollers with different outer diameters, the extrusion scenario of the composite cable bypassing seabed obstacles of different sizes can be simulated. By adjusting the extension and retraction rate and extrusion stroke of the electric cylinder, various extrusion conditions such as static extrusion, low-frequency dynamic extrusion, and high-frequency dynamic extrusion can be realized, accurately restoring the dynamic extrusion effect brought about by the impact of wind, waves and currents. The bending angle can be freely adjusted: by changing the welding height of the lifting lug, the bending angle at the contact point between the sample cable and the extrusion wheel can be flexibly adjusted to simulate different bending stress states when the composite cable bypasses obstacles during actual laying, thus realizing the simulation test of extrusion + bending composite stress.

[0038] The three major improvements mentioned above work together to enable this testing device to flexibly adjust the test parameters according to the specific working conditions of the actual project, so that the test stress state of the composite cable closely matches the actual service state, thus solving the technical defect of the existing device that can only complete a single static extrusion test.

[0039] The testing apparatus provided in this application is a dedicated testing device for composite cables used in ICCP systems. It is primarily applied to composite cables in impressed current cathodic protection systems containing steel wire rope cores, specifically including: composite cables for deep-water tensioned ICCP systems; composite cables for offshore platform ICCP systems; composite cables for submarine pipeline ICCP systems; and composite cables for offshore wind power platform ICCP systems, among other composite cable products used in various marine engineering ICCP systems. Furthermore, this apparatus can be adjusted according to testing requirements to be suitable for testing composite cables in other industries that require tensile and compressive stress, such as composite cables in mining, bridge, and rail transportation fields.

[0040] Example 2 This embodiment provides a composite cable extrusion testing device, such as... Figure 7 and Figure 8 As shown, the main structure of this embodiment is similar to that of Embodiment 1. The differences between this embodiment and Embodiment 1 are as follows: In Example 1, as Figure 5As shown, the loading device 2 includes a loading frame 22, a lead screw 23, a tightening nut 24, and a connecting buckle 25; The loading frame 22 is fixed on the base 1. The lead screw 23 passes through the through hole provided on the loading frame 22. The two ends of the lead screw 23 are threadedly connected to the tightening nut 24 and the force sensor 21, respectively. The force sensor 21 is fixedly connected to the connecting buckle 25. The connecting buckle 25 is provided with a hole for connecting to the sample cable 3.

[0041] In this embodiment, as Figure 9 As shown, the loading device 2 includes a second linear drive mechanism 26 and a connecting buckle 25; The second linear drive mechanism 26 is fixed on the base 1 (the second linear drive mechanism 26 can be fixed on the base 1 by a bracket). The second linear drive mechanism 26 is fixedly connected to the force sensor 21. The force sensor 21 is fixedly connected to the connecting buckle 25. The connecting buckle 25 is provided with a hole for connecting to the sample cable 3. The second linear drive mechanism 26 is selected from any one of a pneumatic cylinder, hydraulic cylinder, electric cylinder, or linear module. In this embodiment, the second linear drive mechanism 26 adopts a servo electric cylinder, and the output end of the electric cylinder is threadedly connected to the force sensor 21 to achieve high-precision displacement control. The second linear drive mechanism 26 can also be a linear module. Through the precise control of the servo motor, the tension of the sample cable 3 can be automatically adjusted and locked, improving the adjustment accuracy and efficiency, and achieving high-precision displacement control. In this embodiment, the force sensor 21 is a high-precision pressure / tension dual-measurement sensor with a range of 10t.

[0042] In this embodiment, a controller is also included. The controller is signal-connected to the force sensor 21 and the second linear drive mechanism 26. During the process of the extrusion roller 51 reciprocating to extrude the sample cable 3, the controller can control the second linear drive mechanism 26 to perform extension and contraction compensation based on the data fed back by the force sensor 21, so as to maintain the constant tension on the sample cable 3.

[0043] Based on Example 1, this embodiment further optimizes the loading device 2 to solve the technical problem of tension fluctuation in composite cable during dynamic extrusion.

[0044] The specific principle is as follows: Because the sample cable 3 is arranged in a bent shape between the loading device 2 and the fixing device 4, its geometry will dynamically change during the reciprocating linear extrusion of the extrusion roller 51, such as slight changes in length and friction, causing fluctuations in its internal tension and deviating from the preset static tension value. This deviates from the actual working condition of composite cables in engineering, which is "constant tension + external interference".

[0045] To address the aforementioned issues, the tension data (real-time tension value) of the sample cable 3 is collected by force sensor 21 and fed back to the controller. The controller then compares the real-time tension value with the preset tension target value. When the real-time tension value is greater than the target value, the controller controls the second linear drive mechanism 26 to extend and release part of the tension. When the real-time tension value is less than the target value, the controller controls the second linear drive mechanism 26 to retract and replenish the tension.

[0046] Through the aforementioned closed-loop control mechanism of "perception-feedback-execution", this device can ensure that the tension force acting on the sample cable 3 is always kept at the set target value under the dynamic interference of repeated extrusion by the extrusion wheel 51.

[0047] This allows the test process to highly replicate the real stress scenario of composite cables "bearing constant tension while encountering dynamic compression" in actual engineering applications, significantly improving the accuracy of test data and its engineering reference value.

[0048] In Example 1, as Figure 6 As shown, the fixing device 4 includes a lug 41 disposed on the base 1.

[0049] In this embodiment, as Figure 10 As shown, the fixing device 4 includes an adjusting seat 42 welded to the base 1. The adjusting seat 42 is provided with two opposing ear plates 421. The ear plates 421 are provided with vertically extending elongated holes 422. The elongated holes 422 are provided with connecting bolts 43 for connecting the sample cable 3. The connecting bolts 43 are movably connected to the sample cable 3 through shackles and pins. The position can be adjusted by sliding the connecting bolts 43 in the elongated holes 422 (corresponding to different bending angles of the sample cable 3). After adjustment, tightening the connecting bolts 43 can achieve locking.

[0050] Specifically, such as Figure 10 As shown, the elongated hole 422 has a plurality of semicircular positioning grooves 423 evenly distributed on the side near the extrusion device 5, which are arranged along the length of the elongated hole 422. The connecting bolts 43 located in the semicircular positioning grooves 423 are less likely to slip after locking.

[0051] Example 3 This embodiment provides a composite cable extrusion test method, using a composite cable extrusion test apparatus described in Embodiment 1 or Embodiment 2, including the following steps: S1: Select an extrusion device 5 with extrusion rollers 51 of different specifications according to the test requirements (to simulate seabed obstacles of different sizes). Determine the fixed position of the sample cable 3 on the base 1 according to the bending angle of the sample cable 3 (adjust the welding height of the lifting lug 41 or change the fixed position of the connecting bolt 43) to determine the bending angle of the sample cable 3, and set the reciprocating stroke and extension rate of the extrusion rollers 51 (to simulate static / dynamic extrusion conditions). S2: Cut a sample cable to the specified length according to the test requirements, process both ends of the sample cable 3 (strip the sheath and fix the steel wire rope core), and connect both ends of the sample cable 3 to the loading device 2 and the fixing device 4 respectively through shackles; S3: Apply tension to the sample cable 3 through the loading device 2 (tighten the nut 24 or drive the second linear drive mechanism 26), observe the tension of the sample cable 3 through the force sensor 21 until the preset tension value of the test is reached (stop tightening the nut 24 or stop the second linear drive mechanism 26). S4: Start the extrusion device 5, and the extrusion wheel 51 performs reciprocating linear motion to extrude the sample cable 3, which is in a state of tension and bending. S5: During the test, the tension change of the sample cable 3 is monitored in real time by the force sensor 21, the appearance and structural changes of the sample cable 3 are observed, and key test data such as the number of extrusions, extrusion stroke, extrusion force, and critical values ​​for the sample cable 3 to break or the core wire breaks are recorded.

[0052] Specifically, according to the test plan, steps S1 to S5 are repeated to complete multiple sets of extrusion tests under different tension forces, different bending angles, and different extrusion conditions. After the test, the extrusion wheel 51 is reset to the initial position, the loading device 2 releases the tension of the sample cable 3, the shackles at both ends of the sample cable 3 are removed, the sample cable 3 after the test is taken off, the test device is cleaned, the test data is recorded and organized, and the test is completed.

[0053] It is highly convenient to operate, the mechanical adjustment method is simple and easy to understand, and the extrusion device 5 and sample cable 3 are easy to disassemble and assemble. Test personnel can quickly complete the pre-test debugging and post-test reset, which reduces the operation threshold. It can evaluate the structural strength and functional integrity of the composite cable and ensure the long-term stable operation of the ICCP system.

[0054] This application utilizes a three-dimensional adjustable design for tension, compression conditions, and bending angles to ensure that the test conditions closely match the actual service conditions of composite cables. This achieves accurate simulation of the stress scenarios in actual engineering projects, solving the problem of idealized test conditions in existing devices. It provides more realistic and valuable compressive performance parameters for composite cables, offering a scientific basis for their research, quality control, and engineering applications. It fills the gap in the industry for dedicated compression testing equipment for composite cables used in ICCP systems, breaking away from the single-reference model of manufacturer-provided parameters. Users can independently verify the performance parameters of composite cables using this device, effectively avoiding safety hazards in engineering applications. Test parameters can be flexibly adjusted according to the actual needs of different marine engineering projects, enabling compression testing of composite cables under multiple conditions and specifications without the need for separate test equipment design for different conditions, reducing testing costs and improving testing efficiency. It achieves compression testing of composite cables under tension, dynamic compression, and bending stress coupling states, enabling the testing of composite stress in composite cables. This allows for accurate evaluation of the structural strength and functional integrity of composite cables under extreme conditions, providing testing support for the research and development of high-reliability composite cables.

[0055] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A composite cable extrusion testing device, characterized in that, include: Base (1); A loading device (2) is installed on the base (1) to simulate the tension force on the composite cable. It is used to connect one end of the sample cable (3) and can apply tension force to the sample cable (3). The loading device (2) includes a force sensor (21) for detecting the tension force. The fixing device (4) provided on the base (1) is used to connect the end of the sample cable (3) away from the loading device (2); The extrusion device (5) installed on the base (1) includes an extrusion wheel (51). The extrusion device (5) applies extrusion force to the sample cable (3) through the extrusion wheel (51) which moves in a reciprocating linear motion. The extrusion device (5) is detachably connected to the base (1). The extrusion device (5) is located between the loading device (2) and the fixing device (4). When the two ends of the sample cable (3) are connected to the fixing device (4) and the loading device (2) respectively, the part of the sample cable (3) between the extrusion wheel (51) and the fixing device (4) and the part between the extrusion wheel (51) and the loading device (2) form a certain angle. The angle is used to simulate the bending stress state of the composite cable when it bypasses the obstacle. The extrusion wheel (51) applies extrusion force to the sample cable (3), which is connected to the fixing device (4) and the loading device (2) at both ends and is subjected to the tension force of the loading device (2), in order to simulate the actual working conditions of the composite cable.

2. The composite cable extrusion testing device according to claim 1, characterized in that, The extrusion device (5) further includes a support (52), a first linear drive mechanism (53), and a rotating shaft (54); the support (52) is provided with a guide groove (521), the rotating shaft (54) is located in the guide groove (521), and the extrusion wheel (51) is mounted on the rotating shaft (54) through a bearing; Two first linear drive mechanisms (53) are symmetrically arranged on the support (52). The first linear drive mechanism (53) can drive the rotating shaft (54) to reciprocate linearly along the guide groove (521). The support (52) and the base (1) are detachably connected by bolts. The first linear drive mechanism (53) is selected from any one of a cylinder, a hydraulic cylinder or an electric cylinder.

3. The composite cable extrusion testing device according to claim 1, characterized in that, The loading device (2) also includes a loading frame (22), a lead screw (23), a tightening nut (24), and a connecting buckle (25); The loading frame (22) is fixed on the base (1). The lead screw (23) passes through the through hole provided on the loading frame (22). The two ends of the lead screw (23) are threadedly connected to the tightening nut (24) and the force sensor (21) respectively. The force sensor (21) is fixedly connected to the connecting buckle (25). The connecting buckle (25) is provided with a hole for connecting to the sample cable (3).

4. The composite cable extrusion testing device according to claim 1, characterized in that, The loading device (2) also includes a second linear drive mechanism (26) and a connecting buckle (25); The second linear drive mechanism (26) is fixed on the base (1). The second linear drive mechanism (26) is fixedly connected to the force sensor (21). The force sensor (21) is fixedly connected to the connecting buckle (25). The connecting buckle (25) is provided with a hole for connecting to the sample cable (3). The second linear drive mechanism (26) is selected from any one of a cylinder, hydraulic cylinder, electric cylinder or linear module.

5. The composite cable extrusion testing device according to claim 4, characterized in that, It also includes a controller, which is signal-connected to the force sensor (21) and the second linear drive mechanism (26); the controller can control the second linear drive mechanism (26) to operate according to the data fed back by the force sensor (21) so as to maintain the tension on the sample cable (3) constant.

6. The composite cable extrusion testing device according to claim 1, characterized in that, The fixing device (4) includes a lug (41) disposed on the base (1).

7. The composite cable extrusion testing device according to claim 1, characterized in that, The fixing device (4) includes an adjusting seat (42) welded to the base (1). The adjusting seat (42) has two opposing ear plates (421). The ear plates (421) have vertically extending elongated holes (422). The elongated holes (422) have connecting bolts (43) for connecting the sample cable (3).

8. The composite cable extrusion testing device according to claim 1, characterized in that, The base (1) includes a first pier (11), a second pier (12) and a reaction frame (13). The first pier (11) and the second pier (12) are fixed on the reaction frame (13). The loading device (2) is fixed on the first pier (11). The squeezing device (5) is fixed on the second pier (12). The fixing device (4) is set on the reaction frame (13).

9. A method for testing the compression of a composite cable, using the composite cable compression testing apparatus according to any one of claims 1 to 8, characterized in that, Includes the following steps: S1: Select an extrusion device (5) with extrusion rollers (51) of different specifications according to the test requirements, determine the fixed position of the sample cable (3) on the base (1) according to the bending angle of the sample cable (3), and set the reciprocating stroke and speed of the extrusion roller (51). S2: Connect the two ends of the sample cable (3) to the loading device (2) and the fixing device (4) respectively; S3: Apply tension force to the sample cable (3) through the loading device (2), and observe the tension force of the sample cable (3) through the force sensor (21) until the preset tension force value of the test is reached; S4: Start the extrusion device (5) to extrude the sample cable (3) which is in a state of tension and bending; S5: Monitor the tension change of the sample cable (3) in real time through the force sensor (21), observe the appearance and structural changes of the sample cable (3), and record the number of extrusions, extrusion stroke, extrusion force, and critical values ​​of the sample cable (3) when it is damaged or the core wire breaks.

10. A composite cable compression test method according to claim 9, characterized in that, According to the test plan, repeat steps S1 to S5 to complete multiple sets of extrusion tests under different tension forces, different bending angles, and different extrusion conditions.

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