A high-temperature environment wind power torsion resistant flexible cable

Abstract

This invention discloses a high-temperature environment wind power torsion-resistant flexible cable, belonging to the field of cable technology. It includes: an outer sheath; a protective mechanism disposed within the outer sheath; and a buffer mechanism disposed within the protective mechanism. The buffer mechanism includes a mounting component, buffer springs, and buffer filling material. The mounting component is disposed within the outer sheath, and multiple buffer springs are installed within the mounting component, with the multiple buffer springs evenly distributed. The buffer filling material is installed within the mounting component. This high-temperature environment wind power torsion-resistant flexible cable, through the use of the buffer mechanism, significantly improves torsional fatigue life, avoids stress concentration, and, through the synergistic effect of the buffer springs and filling material, transforms externally applied concentrated torsional force into uniform and orderly deformation and energy dissipation of internal components, avoiding local overload. This allows the cable to withstand long-term alternating torsional cycles far exceeding those of traditional structures, significantly extending its service life.

Description

Technical Field

[0001] This invention belongs to the field of cable technology, specifically a high-temperature environment wind power torsion-resistant flexible cable. Background Technology

[0002] A cable is an electrical energy or signal transmission device, usually composed of several or several groups of conductors. Cables include power cables, control cables, compensating cables, shielded cables, high-temperature cables, computer cables, signal cables, coaxial cables, fire-resistant cables, marine cables, mining cables, aluminum alloy cables, etc.

[0003] As a crucial component of clean energy, wind power generation relies heavily on the reliability and durability of its equipment to directly impact power generation efficiency and operating costs. Wind turbine generators, especially large units, require extensive use of cables connecting power, control, and signal systems in the dynamic areas between the nacelle and rotor blades, as well as within the tower. These cables must continuously withstand complex alternating torsion, bending, and vibration caused by turbine yaw, pitch, and natural wind loads. Therefore, cables used in this scenario, particularly torsion-resistant flexible cables, must possess extremely high mechanical fatigue life and high-temperature environmental stability. Currently, traditional wind power torsion-resistant cables generally face the following structural bottlenecks when dealing with these extreme conditions:

[0004] 1. Existing cable designs often focus on conductor stranding and outer sheath reinforcement, lacking systematic planning for the stress transmission path and release mechanism of the internal cores during dynamic processes. When the cable is twisted as a whole, the internal cores are often in a rigid constraint state or rely solely on the passive compression of the filling material, resulting in the inability to effectively disperse torsional stress. This easily leads to stress concentration at fixed points or weak links, which directly causes the accumulation of micro-fatigue in the core metal. Under long-term operation, this may lead to core breakage and electrical faults. In addition, the disordered relative movement between cores will also exacerbate insulation wear.

[0005] 2. In traditional structures, the gap between wire cores may change due to material softening under hot conditions, weakening the original supporting effect of the filler. This makes the wire cores more prone to displacement, collapse, or entanglement, which not only increases the risk of short circuits but also creates local hot spots due to frictional heat generation and poor heat dissipation, accelerating insulation degradation and creating a vicious cycle of mutual weakening of thermo-mechanical properties.

[0006] Therefore, a high-temperature environment wind power torsion-resistant flexible cable is provided to solve the above problems. Summary of the Invention

[0007] The purpose of this invention is to significantly improve torsional fatigue life and avoid stress concentration through the use of a buffer mechanism. By leveraging the synergistic effect of the buffer block and filling material, the concentrated torsional force applied externally is transformed into uniform and orderly deformation and energy dissipation of the internal components, preventing localized overload. This allows the cable to withstand long-term alternating torsional cycles far exceeding those of traditional structures, significantly extending its service life. Through the use of the inner wire mechanism, each wire core is precisely placed within a spiral groove. When the cable is subjected to overall torsion, the wire cores undergo guided micro-sliding and slight extension or contraction along the spiral groove trajectory, transforming torsional deformation into low-resistance, orderly micro-movement of the wire cores along a fixed path. This converts destructive concentrated shear stress into distributed stress, achieving smooth release and dissipation of torsional energy and preventing fatigue fracture of the wire cores due to stress concentration. The spiral-shaped inner support bar continuously provides radial support, effectively preventing multiple cores from collapsing towards the cable center or squeezing and tangling with each other under dynamic conditions. At the same time, each core is equipped with an independent track to ensure that each core can maintain a preset relative position under complex bending and twisting conditions. The use of the separation mechanism ensures the dynamic stability of the internal multi-core structure, eliminating mutual interference and wear. The precise locking components between the limiting block, the separation block and the insulation layer construct an independent, mechanically interlocked running track for each group of cores. When the cable is twisted and deformed, it can strictly limit the radial and axial displacement range of each core group, preventing them from colliding, rubbing or entangled with each other. This ensures that the multi-core cable maintains the integrity of physical and electrical isolation under severe dynamic conditions, reducing the risk of short circuits, local overheating or signal interference caused by internal friction.

[0008] The technical solution adopted in this invention is as follows: A high-temperature environment wind power torsion-resistant flexible cable, comprising:

[0009] Outer sheath;

[0010] The protective mechanism is located inside the outer sheath;

[0011] A buffer mechanism is provided within a protective mechanism. The buffer mechanism includes a mounting component, buffer blocks, and buffer filling material. The mounting component is located within an outer sheath. Multiple buffer blocks are provided, and all multiple buffer blocks are installed within the mounting component and are evenly distributed. The buffer filling material is installed within the mounting component and wraps around the multiple buffer blocks.

[0012] The insulation mechanism is located inside the outer sheath;

[0013] The inner wire mechanism is provided in multiple sets, and each set of the inner wire mechanism is located within an insulating mechanism. Each set of the inner wire mechanism includes an inner support component, a spiral groove, and a wire core. There are multiple spiral grooves, and each spiral groove is located within an insulating mechanism. There are multiple wire cores, and each wire core is located within a spiral groove. The inner support component is located within the insulating mechanism and is connected to multiple wire cores.

[0014] A separating mechanism is provided within an insulating mechanism. The separating mechanism includes a locking component, a limiting block, and a separating block. Multiple limiting blocks are provided, and all of the multiple limiting blocks are provided within the insulating mechanism. Multiple separating blocks are provided, and all of the multiple separating blocks are provided within the insulating mechanism. The locking component is provided on the insulating mechanism and is connected to the limiting blocks and the separating blocks.

[0015] The protective mechanism includes a metal mesh and a metal shielding layer. The metal mesh is installed inside the outer sheath, and the metal shielding layer is installed inside the metal mesh.

[0016] The mounting component includes an outer buffer layer and an inner buffer layer. The outer buffer layer is installed inside the metal shielding layer, the inner buffer layer is installed inside the outer buffer layer, and the buffer filling material is filled between the outer buffer layer and the inner buffer layer.

[0017] The insulation mechanism includes a wrapping layer and an insulation layer. The wrapping layer is installed inside the inner buffer layer. Multiple insulation layers are provided, and all multiple insulation layers are installed inside the wrapping layer and are evenly distributed.

[0018] The inner support component includes an air cavity assembly and an inner support strip. The inner support strip is installed at the center of the insulation layer, and the air cavity assembly is located inside the inner support strip.

[0019] The air chamber assembly includes a support block and a pressure-resistant chamber. The pressure-resistant chamber is opened inside the inner support bar. There are multiple support blocks, and the multiple support blocks are fixedly connected to the pressure-resistant chamber at equal intervals.

[0020] The engaging components are provided in multiple sets. Each set of engaging components includes a mating block, a mating groove, a snap-fit ​​block, and a snap-fit ​​groove. The mating block is fixedly connected to the insulating layer. The mating groove is opened on the limiting block and the mating block is installed inside the limiting block. The snap-fit ​​groove is opened on the separating block and the snap-fit ​​block is installed inside the snap-fit ​​groove and fixedly connected to the insulating layer.

[0021] Each of the limiting blocks and separating blocks is provided with a movable groove, and each of the limiting blocks is provided with a reinforcing rib.

[0022] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0023] (1) In this invention, the use of a buffer mechanism significantly improves the torsional fatigue life and avoids stress concentration. Through the synergistic effect of the buffer block and the filling material, the concentrated torsional force applied externally is transformed into uniform and orderly deformation and energy dissipation of the internal components, avoiding local overload, enabling the cable to withstand long-term alternating torsional cycles far exceeding those of traditional structures, and greatly extending its service life.

[0024] (2) In this invention, by using the inner wire mechanism, each wire core is precisely placed in the spiral groove. When the cable is twisted as a whole, the wire core slides and extends or contracts slightly along the spiral groove trajectory in a guided manner, transforming the torsional deformation into an ordered micro-movement of the wire core along a fixed path with low resistance, transforming the destructive concentrated shear stress into distributed stress, realizing the smooth release and dissipation of torsional energy, avoiding fatigue fracture of the wire core due to stress concentration, and the spiral inner support bar continuously provides radial support, effectively preventing multiple wire cores from collapsing towards the center of the cable or squeezing and tangling with each other under dynamic working conditions. At the same time, each wire core is set with an independent track to ensure that each wire core can maintain a preset relative position under complex bending and twisting conditions.

[0025] (3) In this invention, the use of the separation mechanism ensures the dynamic stability of the internal multi-core structure and eliminates mutual interference and wear. The precise locking components between the limiting block, the separation block and the insulation layer construct an independent, mechanically interlocked running track for each group of core units. When the cable is twisted and deformed, it can strictly limit the radial and axial displacement range of each core group, prevent them from colliding, rubbing or entangled with each other, and realize that the multi-core cable still maintains the integrity of physical and electrical isolation under severe dynamic conditions, reducing the risk of short circuit, local overheating or signal interference caused by internal friction. Attached Figure Description

[0026] Figure 1 This is an exploded cross-sectional view of the present invention;

[0027] Figure 2 This is an exploded view of the present invention;

[0028] Figure 3 This is a partial cross-sectional view of the present invention;

[0029] Figure 4 This is a perspective view of the present invention;

[0030] Figure 5 This is an exploded view of the inner line mechanism of the present invention;

[0031] Figure 6 This is a perspective view of the inner wire mechanism of the present invention;

[0032] Figure 7 This is an exploded view of the partition mechanism of the present invention;

[0033] Figure 8 This is a perspective view of the separating mechanism of the present invention.

[0034] The markings in the diagram are: 1. Outer sheath; 2. Metal mesh; 3. Metal shielding layer; 4. Outer buffer layer; 5. Buffer spring block; 6. Buffer filling material; 7. Reinforcing rib; 8. Inner support bar; 9. Support block; 10. Pressure-resistant cavity; 11. Inner buffer layer; 12. Wrapping layer; 13. Limiting block; 14. Insulation layer; 15. Butt joint block; 16. Wire core; 17. Snap-fit ​​block; 18. Spiral groove; 19. Separator block; 20. Butt joint groove; 21. Snap-fit ​​groove; 22. Movable groove. Detailed Implementation

[0035] 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.

[0036] Example 1, refer to Figure 1-8 A high-temperature environment wind power torsion-resistant flexible cable, comprising:

[0037] Outer sheath 1;

[0038] The protective mechanism is located inside the outer sheath 1;

[0039] The buffer mechanism is located within the protective mechanism. The buffer mechanism includes an installation component, buffer springs 5, and buffer filling material 6. The installation component is located within the outer sheath 1. There are multiple buffer springs 5, and all multiple buffer springs 5 ​​are installed within the installation component and are evenly distributed. The buffer filling material 6 is installed within the installation component and wraps around the multiple buffer springs 5.

[0040] The insulation mechanism is located inside the outer sheath 1;

[0041] The inner wire mechanism is provided in multiple sets, and all sets of inner wire mechanisms are located within the insulation mechanism. Each set of inner wire mechanisms includes an inner support component, a spiral groove 18, and a wire core 16. There are multiple spiral grooves 18, and all the spiral grooves 18 are located within the insulation mechanism. There are multiple wire cores 16, and each wire core 16 is located within each spiral groove 18. The inner support component is located within the insulation mechanism and is connected to multiple wire cores 16.

[0042] The separating mechanism is located within the insulating mechanism. The separating mechanism includes a locking component, a limiting block 13, and a separating block 19. There are multiple limiting blocks 13, all of which are located within the insulating mechanism. There are multiple separating blocks 19, all of which are located within the insulating mechanism. The locking component is located on the insulating mechanism and is connected to the limiting blocks 13 and the separating blocks 19.

[0043] In this implementation scheme: the outer sheath 1 resists oil, dust, ultraviolet rays, and physical scratches in the environment, providing the first layer of protection. Combined with the internal protective mechanism, it ensures the safety of the internal conductor 16. The buffer spring block 5 is hollow inside and, together with the buffer filling material 6, buffers the entire cable. The buffer spring block 5 is partially compressed and partially stretched, absorbing and dissipating the torsional and impact energy entering from the outer sheath 1, thus dispersing concentrated stress. The buffer filling material 6 flows in the deformation gaps of the buffer spring block 5, further homogenizing the internal pressure and providing a damping effect to suppress vibration and prevent... To prevent pressure during use and ensure the internal core 16 from being affected, multiple cores 16 are spirally wound to form a whole conductor, ensuring structural strength during twisting. Furthermore, each core 16 is installed in a corresponding spiral groove 18, ensuring overall positional stability during twisting. The core 16 slides or extends / contracts in an orderly manner along the spiral groove 18, avoiding excessive stretching or stress concentration caused by the core 16 being fixed. The limiting block 13 and the separating block 19 cooperate to separate the multiple sets of internal wire mechanisms, preventing mutual interference between the internal wires.

[0044] Specifically: The protective mechanism includes a metal mesh 2 and a metal shielding layer 3. The metal mesh 2 is installed inside the outer sheath 1, and the metal shielding layer 3 is installed inside the metal mesh 2.

[0045] In this embodiment, the metal mesh 2 and the metal shielding layer 3 work together to strengthen the overall structural strength of the cable and provide electromagnetic shielding. The metal mesh 2 provides additional tensile strength and anti-flattening ability, while the metal shielding layer 3 effectively suppresses the influence of internal electromagnetic interference on the outside world and prevents external electromagnetic interference from intruding.

[0046] Specifically: The mounting components include an outer buffer layer 4 and an inner buffer layer 11. The outer buffer layer 4 is installed inside the metal shielding layer 3, the inner buffer layer 11 is installed inside the outer buffer layer 4, and the buffer filling material 6 is filled between the outer buffer layer 4 and the inner buffer layer 11.

[0047] In this embodiment: the outward end of the multiple buffer blocks 5 is fixedly connected to the outer buffer layer 4, and the inward end of the multiple buffer blocks 5 is fixedly connected to the inner buffer layer 11, so that the multiple buffer blocks 5, the outer buffer layer 4 and the inner buffer layer 11 form a whole, ensuring the overall structural strength.

[0048] Specifically: The insulation mechanism includes a wrapping layer 12 and an insulation layer 14. The wrapping layer 12 is installed inside the buffer inner layer 11. Multiple insulation layers 14 are provided, and all multiple insulation layers 14 are installed inside the wrapping layer 12 and are evenly distributed.

[0049] In this embodiment: the insulation layer 14 is used to wrap and insulate the wire core 16, and works with the wrapping layer 12 to wrap the whole, so that multiple insulation layers 14 are positioned. There are seven insulation layers 14, one in the center and six surrounding the center.

[0050] Specifically: the inner support component includes an air cavity assembly and an inner support strip 8. The inner support strip 8 is installed at the center inside the insulation layer 14, and the air cavity assembly is located inside the inner support strip 8.

[0051] In this embodiment, the inner support bar 8 is in a spiral state and is connected to multiple wire cores 16, so that the centers of the multiple wire cores 16 are separated, preventing them from collapsing towards the center or entangled with each other. In addition, the inner support bar 8 is made of soft material, which ensures the position of the multiple wire cores 16 during the twisting process.

[0052] Specifically: the air chamber assembly includes a support block 9 and a pressure-resistant chamber 10. The pressure-resistant chamber 10 is opened inside the inner support bar 8. There are multiple support blocks 9, and the multiple support blocks 9 are fixedly connected to the pressure-resistant chamber 10 at equal intervals.

[0053] In this embodiment, the support block 9 and the pressure-resistant cavity 10 cooperate with each other to enable the multiple wire cores 16 to resist pressure during the twisting process. When the cable is subjected to radial compression or bending, it absorbs part of the pressure through deformation to protect the internal wire cores 16 from mechanical compression.

[0054] Specifically: The engaging components are provided in multiple sets. Each set of engaging components includes a mating block 15, a mating groove 20, a snap-fit ​​block 17, and a snap-fit ​​groove 21. The mating block 15 is fixedly connected to the insulating layer 14. The mating groove 20 is opened on the limiting block 13 and the mating block 15 is installed in the limiting block 13. The snap-fit ​​groove 21 is opened on the separating block 19 and the snap-fit ​​block 17 is installed in the snap-fit ​​groove 21 and is fixedly connected to the insulating layer 14.

[0055] In this embodiment: each of the six outer insulating layers 14 is provided with two sets of snap-fit ​​components. Through the cooperation of the docking block 15 and the docking groove 20, the six outer insulating layers 14 are connected with the six limiting blocks 13, so that the positions of the six outer insulating layers 14 correspond to each other, preventing structural instability. Each of the six outer insulating layers 14 is provided with two sets of snap-fit ​​components, and one inner insulating layer 14 is provided with six sets of snap-fit ​​components. Through the cooperation of the snap-fit ​​block 17 and the snap-fit ​​groove 21, multiple insulating layers 14 are separated from multiple partition blocks 19, forming physical isolation, ensuring that even under high intensity dynamic conditions, each group of cores 16 is completely separated, eliminating the risk of mutual friction, interference or short circuit.

[0056] Specifically: each limiting block 13 and partition block 19 is provided with a movable groove 22, and each limiting block 13 is provided with a reinforcing rib 7.

[0057] In this embodiment: the movable groove 22 provides a buffer space between the limiting block 13 and the separating block 19 during the twisting and completion process of the cable. The movable groove 22 provides a precise buffer space for the relative movement between the limiting block 13 and the separating block 19, allowing the structure to generate the necessary elastic deformation to absorb stress. At the same time, it prevents disorderly displacement through mechanical locking, thus completing the use of the whole. The reinforcing rib 7 improves the overall structural strength of the cable.

[0058] In use, the buffer block 5 does not deform significantly, and the wire cores 16 are stably placed in their respective spiral grooves 18. The limit block 13 and the separator block 19 maintain the initial distance through the movable groove 22. Multiple sets of wire cores 16 begin to carry current or transmit signals. When the cable is twisted as a whole, there is a tendency for relative movement between the buffer outer layer 4 and the buffer inner layer 11. The buffer block 5, together with the buffer filling material 6, disperses the concentrated stress. The torsional force is transmitted to the wrapping layer 12 and the insulation mechanism through the buffer inner layer 11. The spiral grooves 18 of the wire cores 16 act in an orderly manner, and the inner support bar 8 deforms synchronously with the torsion, continuously supporting the center of multiple wire cores 16. During the torsion and bending process, the limit block 13 engages with the docking block 15 on the insulation layer 14 through the docking groove 20 on it, limiting the excessive displacement of each insulation layer 14 in the radial plane. The separator block 19 engages with the snap-fit ​​block 17 on the insulation layer 14 through the snap-fit ​​groove 21, firmly holding each set of wire cores 16 between the limit block 13 and the separator block 19 in the movable groove 22 to absorb stress.

[0059] The control method of this invention is to control the device by manually starting and stopping the switch. The wiring diagram of the power element and the supply of power are common knowledge in the field. Since this invention is mainly used to protect mechanical devices, the control method and wiring layout will not be explained in detail.

[0060] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-temperature environment wind power torsion-resistant flexible cable, characterized in that, include: Outer sheath (1); The protective mechanism is located inside the outer sheath (1); A buffer mechanism is provided inside the protective mechanism. The buffer mechanism includes an installation component, a buffer spring (5), and a buffer filling material (6). The installation component is provided inside the outer sheath (1). There are multiple buffer springs (5). The multiple buffer springs (5) are all installed in the installation component and are evenly distributed. The buffer filling material (6) is installed in the installation component and is wrapped around the multiple buffer springs (5). An insulating mechanism is provided inside the outer sheath (1). The insulating mechanism includes a wrapping layer (12) and an insulating layer (14). The wrapping layer (12) is installed inside the inner buffer layer (11). There are multiple insulating layers (14). All multiple insulating layers (14) are installed inside the wrapping layer (12), and the multiple insulating layers (14) are evenly distributed. The inner wire mechanism is provided in multiple sets, and all sets of the inner wire mechanism are located within the insulation mechanism. Each set of the inner wire mechanism includes an inner support component, a spiral groove (18), and a wire core (16). There are multiple spiral grooves (18), and all the spiral grooves (18) are located within the insulation mechanism. There are multiple wire cores (16), and each wire core (16) is located within each spiral groove (18). The inner support component is located within the insulation mechanism and is connected to multiple wire cores (16). A separating mechanism is provided within an insulating mechanism. The separating mechanism includes a locking component, a limiting block (13), and a separating block (19). Multiple limiting blocks (13) are provided, and all of the multiple limiting blocks (13) are provided within the insulating mechanism. Multiple separating blocks (19) are provided, and all of the multiple separating blocks (19) are provided within the insulating mechanism. The locking component is provided within the insulating mechanism and is connected to the limiting block (13) and the separating block (19). The engaging components are provided in multiple sets. Each set of engaging components includes a docking block (15), a docking groove (20), a snap-fit ​​block (17), and a snap-fit ​​groove (21). The docking block (15) is fixedly connected to the insulating layer (14). The docking groove (20) is opened on the limiting block (13). The docking block (15) is installed in the limiting block (13). The snap-fit ​​groove (21) is opened on the separating block (19). The snap-fit ​​block (17) is installed in the snap-fit ​​groove (21) and is fixedly connected to the insulating layer (14).

2. The high-temperature environment wind power torsion-resistant flexible cable as described in claim 1, characterized in that: The protective mechanism includes a metal mesh (2) and a metal shielding layer (3). The metal mesh (2) is installed inside the outer sheath (1), and the metal shielding layer (3) is installed inside the metal mesh (2).

3. The high-temperature environment wind power torsion-resistant flexible cable as described in claim 2, characterized in that: The mounting component includes an outer buffer layer (4) and an inner buffer layer (11). The outer buffer layer (4) is installed inside the metal shielding layer (3), and the inner buffer layer (11) is installed inside the outer buffer layer (4). The buffer filling material (6) is filled between the outer buffer layer (4) and the inner buffer layer (11).

4. The high-temperature environment wind power torsion-resistant flexible cable as described in claim 1, characterized in that: The inner support component includes an air cavity assembly and an inner support strip (8). The inner support strip (8) is installed at the center of the insulation layer (14), and the air cavity assembly is located inside the inner support strip (8).

5. A high-temperature environment wind power torsion-resistant flexible cable as described in claim 4, characterized in that: The air chamber assembly includes a support block (9) and a pressure-resistant chamber (10). The pressure-resistant chamber (10) is opened inside the inner support bar (8). There are multiple support blocks (9), and the multiple support blocks (9) are fixedly connected to the pressure-resistant chamber (10) at equal intervals.

6. The high-temperature environment wind power torsion-resistant flexible cable as described in claim 1, characterized in that: A movable groove (22) is installed between each of the limiting blocks (13) and the partition blocks (19), and a reinforcing rib (7) is provided in each of the limiting blocks (13).

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