A handheld laser welding integrated cable

Abstract

This invention belongs to the field of hybrid cable technology and discloses a handheld laser welding integrated cable, including an outer sheath, core wire bundles, a wrapping layer, and a positioning component. The core wire bundles and the positioning component are disposed within the outer sheath, and the positioning component keeps each core wire of the core wire bundle within the outer sheath. The wrapping layer covers the core wire bundles and the positioning component. The core wire bundles include an air tube, an optical fiber cable, a signal wire bundle, and a power wire bundle. This invention achieves effective isolation between the power lines and the signal lines, significantly suppresses electromagnetic interference, improves communication stability, and by placing the signal wire bundles and power wire bundles on both sides of the air tube and the optical fiber cable, further physical isolation in space can be achieved under the positioning and support of the positioning component, better suppressing electromagnetic interference.

Description

Technical Field

[0001] This invention belongs to the field of hybrid cable technology, specifically relating to a handheld laser welding integrated cable. Background Technology

[0002] Handheld laser welding equipment needs to operate in complex industrial environments involving high-frequency bending, weld spatter, and electromagnetic interference, placing extremely high demands on the flexibility, mechanical lifespan, signal integrity, and environmental adaptability of cables. Currently, most handheld laser welding equipment on the market adopts a split cable structure, where the power cable, signal cable, fiber optic armor tube, and air tube are independently arranged and directly installed within a fabric sheath. While this structure solves the signal interference problem to some extent, it increases the complexity of the cable structure, reduces integration, and presents inconveniences in on-site wiring and management. Summary of the Invention

[0003] In view of this, the purpose of the present invention is to provide a handheld laser welding integrated cable to solve the problems of existing handheld laser welding cables being unable to simultaneously solve the problems of internal cable signal interference and structural complexity.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: A handheld laser welding integrated cable includes an outer sheath, a core wire bundle, a wrapping layer, and a positioning component. The core wire bundle and the positioning component are disposed inside the outer sheath. The positioning component keeps each core wire of the core wire bundle inside the outer sheath. The wrapping layer covers the core wire bundle and the positioning component. The core wire harness includes an air tube, an optical fiber cable, a signal wire harness, and a power wire harness. The air tube and the optical fiber cable are arranged in a radial direction within the wrapping layer, and the signal wire harness and the power wire harness are arranged on both sides of the air tube and the optical fiber cable in a first direction perpendicular to the radial direction. Both the signal harness and the power harness are covered with a shielding layer.

[0005] In a possible implementation, the shielding layer of the signal harness includes a braided copper mesh layer and an aluminum foil wrapping layer, with the aluminum foil wrapping layer disposed inside the braided copper mesh layer.

[0006] In one possible implementation, the shielding layer of the power harness is an aluminum foil wrapping layer.

[0007] In a possible implementation, the signal harness includes two twisted pair harnesses, each of which is provided with the shielding layer; And / or, the power harness includes a twisted pair harness two and a single-core harness consisting of multiple core wires, both of which are provided with a shielding layer.

[0008] In one possible implementation, the wrapping layer includes a release film layer and a nonwoven fabric layer, the release film layer being disposed inside the nonwoven fabric layer.

[0009] In one possible implementation, the outer layer is made of TPU material, and the surface of the outer layer has been matte treated.

[0010] In a possible implementation, the twist pitch of the handheld laser welding cable is 110 mm - 130 mm.

[0011] In a possible implementation, the positioning component includes a positioning rope one with a circular cross-section and a positioning rope two with an elliptical cross-section. The positioning rope two is disposed between the air tube and the optical fiber cable, and the positioning rope one is disposed between the air tube and the signal harness and the power harness.

[0012] In one possible implementation, the handheld laser welding cable has a rated voltage of 30V and a rated temperature of 80°C.

[0013] In a possible implementation, the signal harness and power harness have a wire gauge of 26 mm² and a stranded outer diameter of 0.57 mm.

[0014] Compared with the prior art, the present invention has the following beneficial effects: The handheld laser welding integrated cable of the present invention achieves effective isolation between the power line and the signal line by setting shielding layers for the signal line bundle and the power line bundle respectively, which significantly suppresses electromagnetic interference and improves communication stability. Furthermore, by setting the signal line bundle and the power line bundle on both sides of the air tube and the optical fiber cable, further physical isolation in space can be achieved under the positioning and support of the positioning component, which can better suppress electromagnetic interference.

[0015] Furthermore, by shortening the cable twist pitch to the range of 110 mm - 130 mm and combining it with the physical separation design of 5C and 4C wire harnesses, the flexibility and mechanical life of the cable are significantly improved. The shorter twist pitch allows the cable to adapt to a higher frequency of dynamic bending environment, effectively reducing operational fatigue.

[0016] Meanwhile, the modified slag-resistant TPU outer sheath material, combined with matte finish technology, improves both dirt resistance and slag resistance while maintaining good abrasion and oil resistance. The wrapping design of the PET film and non-woven fabric buffer layer not only improves the cable's roundness but also greatly facilitates the stripping operation during terminal installation. The overall solution significantly improves the handling feel and appearance cleanliness while maintaining the original protective performance, and extends the service life in harsh welding environments. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structure of a handheld laser welding integrated cable; In the diagram: 1-Outer sheath; 2-Tape layer; 3-Fiber optic cable; 4-Air tube; 5-Power harness; 6-Signal harness; 7-Shielding layer; 8-Positioning rope one; 9-Positioning rope two. Detailed Implementation

[0018] To enable those skilled in the art to better understand the technical solution of the present invention, the present invention will be further described in detail below with reference to specific embodiments.

[0019] Please refer to Figure 1 As shown, an embodiment of this application provides a handheld laser welding integrated cable, including an outer sheath 1, a core wire bundle, a wrapping layer 2, and a positioning component. The core wire bundle and the positioning component are disposed within the outer sheath 1, and the positioning component keeps each core wire of the core wire bundle within the outer sheath 1. The wrapping layer 2 covers the core wire bundle and the positioning component. The core wire bundle includes an air tube 4, an optical fiber cable 3, and a power wire bundle 5. The air tube 4 and the optical fiber cable 3 are arranged in a radial direction within the wrapping layer 2. The signal wire bundle 6 and the power wire bundle 5 are arranged on both sides of the air tube 4 and the optical fiber cable 3 in a first direction perpendicular to the radial direction. Both the signal wire bundle 6 and the power wire bundle 5 are covered with a shielding layer 7.

[0020] The outer sheath 1 is the outermost layer of the cable, with the core wire bundle and positioning components housed within it. The wrapping layer 2 is located outside the core wire bundle and positioning components, improving the cable's roundness and providing basic fixation between the signal bundle 6, power bundle 5, air tube 4, and fiber optic cable 3. The positioning components, serving as internal fillers, primarily position the core wires and maintain a certain distance between them. These components are rope-like or strip-like, filling the gaps in the cable's inner wall. The signal bundle 6 mainly carries sensitive signals such as RS485 differential communication and millivolt-level analog signals, while the power bundle 5 mainly carries power signals such as power supply and switching signals. Both are equipped with a shielding layer 7. This material-based approach addresses signal interference. Furthermore, by arranging the signal bundle 6 and power bundle 5 along a first direction perpendicular to the radial direction on both sides of the air tube 4 and fiber optic cable 3, the spatial arrangement further mitigates signal interference, significantly suppressing electromagnetic interference and improving communication stability.

[0021] Through the above technical solution, the signal harness 6 and the power harness 5 are respectively equipped with shielding layers 7, which effectively isolates the power line from the signal line, significantly suppresses electromagnetic interference, and improves communication stability. Furthermore, by placing the signal harness 6 and the power harness 5 on both sides of the air tube 4 and the optical fiber cable 3, further physical isolation in space can be achieved under the positioning and support of the positioning component, thus better suppressing electromagnetic interference.

[0022] In one embodiment, the shielding layer 7 of the signal harness 6 includes a braided copper mesh layer and an aluminum foil wrapping layer, wherein the aluminum foil wrapping layer is disposed inside the braided copper mesh layer.

[0023] In this way, signal harness 6 can achieve double shielding through a braided copper mesh layer and an aluminum foil wrapping layer, and can also be grounded at a single point on the device end, providing the highest level of protection for sensitive signals.

[0024] Since the power harness 5 does not have high requirements for shielding, in order to achieve basic shielding, the shielding layer 7 of the power harness 5 is further made of aluminum foil wrapping.

[0025] Preferably, the signal harness 6 includes two twisted-pair bundles, each of which is provided with the shielding layer 7. The signal harness 6 consists of two twisted-pair bundles. In the signal harness 6, two twisted-pair bundles are used, that is, the harness structure is 4C (1P×2).

[0026] Meanwhile, the power harness 5 may include a twisted pair harness 2 and a single-core harness composed of multiple core wires, both of which are provided with a shielding layer 7. The power harness 5 consists of a twisted pair harness 2 and a single-core harness composed of multiple core wires, i.e., the harness structure is 5C (1P+3C).

[0027] The signal harness 6 and power harness 5 of the above-described harness architecture can further optimize space utilization and impedance matching.

[0028] In a preferred embodiment of the wrapping layer 2, the wrapping layer 2 includes a release film layer and a nonwoven fabric layer, wherein the release film layer is disposed on the inner side of the nonwoven fabric layer.

[0029] By peeling off the film layer and the non-woven fabric layer, it is ensured that the outer sheath is only bonded to the non-woven fabric, while being isolated from the internal cable core by the PET film. This allows for easy peeling during final handling and enables rapid, non-destructive peeling of the outer sheath while maintaining the cable's roundness, greatly facilitating on-site installation and maintenance. Specifically, the peeling film layer is a PET film.

[0030] In the embodiments of this application, the twist pitch of the handheld laser welding cable is 110 mm - 130 mm.

[0031] Compared to the traditional 240mm stranded cable structure, the handheld laser welding integrated cable with a strand pitch of 110mm-130mm can adapt to a higher frequency of dynamic bending environment, effectively reducing operator fatigue.

[0032] In specific implementation, the positioning component may include a positioning rope 8 with a circular cross-section and a positioning rope 9 with an elliptical cross-section. The positioning rope 9 is positioned between the air tube 4 and the optical fiber cable 3, and the positioning rope 8 is positioned between the air tube 4 and the signal harness 6 and the power harness 5. The positioning ropes 8 and 9 enable each harness inside the cable to be supported and maintain spacing, and the positioning ropes 8 and 9 may be made of cotton rope.

[0033] In one specific embodiment, the handheld laser welding cable has a rated voltage of 30V and a rated temperature of 80℃. Transmission can be performed more stably within the aforementioned rated voltage and temperature range.

[0034] Preferably, the signal harness 6 and power harness 5 have a wire gauge of 26 mm² and a stranded outer diameter of 0.57 mm. These dimensional parameters ensure a more stable and reliable cable structure after stranding, and a more rational arrangement of the wire cores.

[0035] Preferred embodiment: Combination Figure 1 As shown, a handheld laser welding integrated cable has an outer sheath 1 made of modified TPU with a roofing treatment, with an average thickness of 1.2mm, balancing wear resistance, oil resistance, flexibility, and appearance; the fiber optic cable 3 has a fiber optic tube made of TPEE or TPFE material with an inner diameter of 1.7mm and an outer diameter of 2.7mm, ensuring smooth fiber insertion and improving flexibility; the air tube 4 is made of PU material with an inner diameter of 3.0mm and an outer diameter of 5.0mm, optimizing airflow speed and anti-interference capability; the cable harness adopts a 5C (1P+3C) and 4C (1P×2) separate design, with TPE and PP materials for insulation respectively, and a twisted pair + shielding structure to ensure signal integrity. Overall structure: 5C (1P+3C) and 4C (1P×2C) are separately cabled + PU air tube 4, φ5×3mm (inner diameter 3.0±0.1mm) + φ2.7×1.7mm TPEE fiber optic tube; multiple materials are twisted 180 degrees to form a cable; the rated voltage of the cable is 30V and the rated temperature is 80℃; the wire gauge of the signal harness and power harness is 26mm2, and the twisted outer diameter is 0.57mm.

[0036] In the specific implementation process, the twisting direction is clockwise and the twisting pitch is 180mm; after the cable is formed, PET film and non-woven fabric are wrapped in sequence, and then the outer sheath is squeezed; the shielding layer 7 is wrapped with braided copper mesh and aluminum foil, and the equipment end is grounded at a single point.

[0037] This embodiment significantly improves the cable's flexibility and mechanical lifespan by shortening the twist pitch to 180 mm, optimizing material selection, and employing innovative structural design. The shorter twist pitch allows the cable to adapt to higher-frequency dynamic bending environments, effectively reducing operational fatigue. Through the physical separation design and independent shielding strategy of the 5C and 4C harnesses, effective isolation between power lines and signal lines is achieved, significantly suppressing electromagnetic interference and improving communication stability.

[0038] The modified TPU outer sheath material, combined with a matte finish, maintains excellent abrasion and oil resistance while improving resistance to dirt and weld slag. The PET film and non-woven fabric cushioning layer wrapping design not only improves the cable's roundness but also greatly facilitates stripping during final installation. The overall solution significantly improves handling and appearance cleanliness while maintaining original protective performance, and extends service life in harsh welding environments.

[0039] The above are merely preferred embodiments of the present invention. It should be noted that the above preferred embodiments should not be considered as limitations on the present invention, and the scope of protection of the present invention should be determined by the scope defined in the claims. For those skilled in the art, several improvements and modifications can be made without departing from the spirit and scope of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A handheld laser welding integrated cable, characterized in that, It includes an outer sheath (1), a core wire harness, a wrapping layer (2), and a positioning component. The core wire harness and the positioning component are disposed inside the outer sheath (1). The positioning component keeps each core wire of the core wire harness inside the outer sheath (1). The wrapping layer (2) covers the core wire harness and the positioning component. The core wire harness includes an air tube (4), an optical fiber cable (3), a signal wire harness (6), and a power wire harness (5). The air tube (4) and the optical fiber cable (3) are arranged in a radial direction within the wrapping layer (2). The signal wire harness (6) and the power wire harness (5) are arranged on both sides of the air tube (4) and the optical fiber cable (3) in a first direction perpendicular to the radial direction. Both the signal harness (6) and the power harness (5) are covered with a shielding layer (7).

2. The handheld laser welding integrated cable as described in claim 1, characterized in that, The shielding layer (7) of the signal harness (6) includes a braided copper mesh layer and an aluminum foil wrapping layer, wherein the aluminum foil wrapping layer is disposed inside the braided copper mesh layer.

3. The handheld laser welding integrated cable as described in claim 1, characterized in that, The shielding layer (7) of the power harness (5) is an aluminum foil wrapping layer.

4. The handheld laser welding integrated cable as described in claim 1, characterized in that, The signal harness (6) includes two twisted pair harnesses, each of which is provided with the shielding layer (7). And / or, the power harness (5) includes a twisted pair harness II and a single-core harness consisting of multiple core wires, both of which are provided with a shielding layer (7).

5. The handheld laser welding integrated cable as described in claim 1, characterized in that, The wrapping layer (2) includes a release film layer and a nonwoven fabric layer, wherein the release film layer is disposed on the inner side of the nonwoven fabric layer.

6. The handheld laser welding integrated cable as described in claim 1, characterized in that, The outer layer (1) is made of TPU material, and the surface of the outer layer (1) is treated with a matte finish.

7. The handheld laser welding integrated cable as described in claim 1, characterized in that, The twist pitch of the handheld laser welding cable is 110 mm - 130 mm.

8. The handheld laser welding integrated cable as described in claim 1, characterized in that, The positioning component includes a positioning rope one (8) with a circular cross-section and a positioning rope two (9) with an elliptical cross-section. The positioning rope two (9) is positioned between the air tube (4) and the optical fiber cable (3), and the positioning rope one (8) is positioned between the air tube (4) and the signal harness (6) and the power harness (5).

9. The handheld laser welding integrated cable as described in claim 1, characterized in that, The rated voltage of the handheld laser welding cable is 30V and the rated temperature is 80℃.

10. The handheld laser welding integrated cable as described in claim 1, characterized in that, The signal harness (6) and power harness (5) have a wire gauge of 26 mm² and a stranded outer diameter of 0.57 mm.

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