Torsion-resistant aluminum alloy flexible cable for wind power generation

Abstract

This invention relates to the field of cable technology, and more particularly to a torsion-resistant aluminum alloy flexible cable for wind power generation. The cable includes a conductor structure installed inside a protective layer. The conductor structure comprises multiple circumferentially distributed conductive cores, with an insulating layer surrounding each conductive core. This invention, by setting circumferentially distributed torsion-resistant connecting cores between the inner sheath and the outer protective layer, and cooperating with torsion-resistant grooves opened along the length direction, can directionally and uniformly release torsional deformation during torsion, avoiding localized stress concentration and significantly improving the structural fatigue life of the cable under repeated torsion conditions. A return spring is set between adjacent torsion-resistant connecting cores. The return spring can quickly release elastic potential energy, driving the entire cable to return to its original position, avoiding permanent torsional deformation and bending collapse, maintaining internal structural stability, and ensuring effective extension of the cable under torsion conditions.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a torsion-resistant aluminum alloy flexible cable for wind power generation. Background Technology

[0002] Wind power generation torsion-resistant aluminum alloy flexible cable is a special power transmission cable designed for dynamic laying environments inside wind turbine generator sets and between towers. Its conductor is made of aluminum alloy, which improves flexibility and tensile strength while ensuring conductivity.

[0003] During frequent torsion, the internal stress of the cable is significantly concentrated. It is difficult to achieve uniform torsion release by simply relying on the deformation of the sheath material. This can easily lead to local fatigue and cracking, resulting in a low torsion life. After repeated torsion, the cable is prone to permanent deformation, bending and collapse, and cannot automatically recover its original shape, affecting power transmission safety and service life. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a torsion-resistant aluminum alloy flexible cable for wind power generation, which solves the technical problem that cables are prone to permanent deformation and bending collapse after repeated torsion. It achieves the goal of avoiding permanent torsional deformation and bending collapse, maintaining internal structural stability, and ensuring effective extension of the cable under torsion.

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a torsion-resistant aluminum alloy flexible cable for wind power generation, comprising a conductor structure installed inside a protective layer, the conductor structure comprising a plurality of circumferentially evenly distributed conductive cores, the conductive cores being made of aluminum alloy, an insulating layer being sleeved around the outer periphery of the conductive cores, and a strength support member disposed at the center of the plurality of conductive cores, the strength support member separating the plurality of conductive cores from each other, and an inner sheath being disposed around the outer periphery of the plurality of conductive cores, the inner sheath cooperating with the strength support member to achieve radial limiting of the cores; A torsion-resistant structure is provided between the inner sheath and the protective layer. The torsion-resistant structure includes several torsion-resistant connecting cores circumferentially distributed around the outer periphery of the inner sheath. The torsion-resistant connecting cores are made of deformable rubber material, which can undergo controllable elastic deformation with torsion, and have the effects of buffering, vibration reduction, and insulation, thereby improving the safety and reliability of the battery cell under dynamic operating conditions. Torsion-resistant grooves are uniformly opened along the length direction of the torsion-resistant connecting cores. The circumferentially distributed torsion-resistant connecting cores, together with the torsion-resistant grooves opened along the length direction, can release torsional deformation in a directional and uniform manner during torsion, avoiding interference of the return spring with the normal torsion of the torsion-resistant grooves, effectively avoiding local stress concentration, and improving the overall torsion fatigue life.

[0006] Preferably, the strength support is made of a cross-shaped rigid material, the end of the strength support abuts against the inner wall of the inner sheath, and the end of the strength support is a large-area arc surface that closely abuts against the inner side wall of the inner sheath, forming a coordinated inner and outer support.

[0007] Preferably, the gap between the conductor structure and the strength support is filled with a filling layer, which is a flame-retardant material. Filling the gap with flame-retardant material blocks heat conduction and flame spread, reduces the risk of thermal runaway, and improves the safety level of the cable.

[0008] Preferably, a compression-resistant structure extending along the length direction is provided between two adjacent torsion-resistant connecting cores. The compression-resistant structure includes a return spring that extends uniformly along the length direction of the torsion-resistant connecting core. Strong support plates are fixedly installed at both ends of the return spring. The return spring can provide a return force after torsion or bending, while enhancing the radial and axial structural strength. It does not restrict normal torsional deformation, but also prevents excessive deformation failure.

[0009] Preferably, the reset spring and the torsion-resistant groove are staggered in the longitudinal direction, and both the reset spring and the torsion-resistant groove are arranged in a uniform spiral linear path along the longitudinal direction to adapt to the torsion shape of the battery cell. This ensures that the movement paths of the spring and the torsion-resistant groove do not interfere with each other during the torsion process, avoids spring jamming, squeezing or damaging the torsion-resistant groove, and ensures stable and reliable torsion resistance.

[0010] Preferably, a heat dissipation channel is formed between two adjacent torsion-resistant connecting cores.

[0011] Preferably, the protective layer includes a water-resistant layer, a shielding layer, and an outer sheath arranged sequentially from the inside out. The inner circumferential surface of the water-resistant layer and the outer circumferential surface of the inner sheath form a tooth-like outward convex shape. The tooth-like interlocking structure can evenly distribute torsional stress to multiple interlocking tooth surfaces, avoiding local stress concentration that could cause tearing, breakage, or fatigue damage at the connection point, and significantly improving the overall torsional fatigue life and structural stability of the cable.

[0012] Preferably, the two high-strength support plates abut against the water-resistant layer and the inner sheath, respectively.

[0013] By employing the above technical solution, the present invention provides a torsion-resistant aluminum alloy flexible cable for wind power generation, which has at least the following beneficial effects: 1. This invention provides a torsion-resistant connecting core with a circumferential distribution between the inner sheath and the outer protective layer, along with a torsion-resistant groove along the length direction. This allows for the directional and uniform release of torsional deformation during torsion, avoiding localized stress concentration and significantly improving the structural fatigue life of the cable under repeated torsion conditions. A return spring is provided between adjacent torsion-resistant connecting cores. The return spring can quickly release elastic potential energy, causing the cable to return to its original position, preventing permanent torsional deformation and bending collapse, maintaining internal structural stability, and ensuring effective extension of the cable under torsion conditions.

[0014] 2. This invention, by setting a cross-shaped rigid strength support in the center of multiple conductive cells, can evenly divide the cells into independent housing spaces, avoiding contact and compression between the cells; the end of the support uses a large-area arc surface to abut against the inner sheath, effectively dispersing stress and forming a rigid support skeleton, significantly improving the overall compression and impact resistance of the cable, and protecting the cells from deformation and damage.

[0015] 3. The outer periphery of the inner sheath and the inner periphery of the water-resistant layer of this invention are engaged with a toothed structure, which makes the torsion-resistant connecting core and the two ends of the return spring stably fixed. Under long-term torsion, it will not slip, misalign, or fall off, ensuring the continuous reliability of torsion resistance and support functions.

[0016] 4. By forming a heat dissipation channel between adjacent torsion-resistant connecting cores, the present invention can quickly dissipate the heat generated by the battery cell during operation, avoid internal heat accumulation, and reduce the risk of overheating damage; combined with a multi-layer protection structure, the cable simultaneously possesses high torsion resistance, high flame retardancy, high support, high heat dissipation, and long service life, making it more suitable for use in harsh wind power generation conditions. Attached Figure Description

[0017] The accompanying drawings, which are provided to further illustrate this application and form part of this application, illustrate exemplary embodiments of this application and are used to explain this application, but do not constitute an undue limitation of this application.

[0018] In the attached diagram: Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is an internal sectional view of the present invention; Figure 3 For the present invention Figure 2 Enlarged view of section A in the middle; Figure 4 This is a schematic diagram showing the installation positions of the torsion-resistant structure and the extrusion-resistant structure of the present invention; Figure 5 This is a diagram showing the path for setting up the torsion-resistant groove and extrusion-resistant structure of the present invention.

[0019] In the diagram: 1. Protective layer; 11. Water-resistant layer; 12. Shielding layer; 13. Outer sheath; 2. Conductor structure; 21. Conductive cell; 22. Insulation layer; 3. Torsion-resistant structure; 31. Torsion-resistant connecting core; 32. Torsion-resistant groove; 4. Filling layer; 5. Strength support component; 51. Inner sheath; 6. Compression-resistant structure; 61. Return spring; 62. Strong support plate; 7. Heat dissipation channel. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Example 1 Addressing the existing problem that cables are prone to permanent deformation and bending collapse after repeated twisting, this embodiment provides a torsion-resistant aluminum alloy flexible cable for wind power generation. This cable avoids permanent torsional deformation and bending collapse, maintains internal structural stability, and ensures effective cable elongation under torsion. Please refer to... Figures 1-5 The torsion-resistant aluminum alloy flexible cable for wind power generation includes a conductor structure 2 installed inside a protective layer 1. The conductor structure 2 includes multiple circumferentially distributed conductive cores 21. An insulation layer 22 is wrapped around the outer periphery of each conductive core 21. A strength support 5 is set at the center of the multiple conductive cores 21, which separates the multiple conductive cores 21 from each other. An inner sheath 51 is provided around the outer periphery of each conductive core 21. The multiple conductive cores 21 are arranged in a centrally symmetrical manner. The cross-shaped rigid strength support 5 is fixedly set in the central area of ​​the multiple sets of conductive cores 21. Its four support branches extend precisely into the gaps between adjacent conductive cores 21, physically separating each conductive core 21 and forming an independent core housing space, thus avoiding direct contact between the cores from the source.

[0022] To improve the flexibility of cables, such as Figures 2-5As shown, a torsion-resistant structure 3 is provided between the inner sheath 51 and the protective layer 1. The torsion-resistant structure 3 includes several torsion-resistant connecting cores 31 circumferentially distributed around the outer periphery of the inner sheath 51. The torsion-resistant connecting cores 31 are evenly provided with torsion-resistant grooves 32 along their length direction. The circumferentially distributed torsion-resistant connecting cores 31 cooperate with the torsion-resistant grooves 32 along their length direction to release torsional deformation in a directional and uniform manner during torsion. When the cable is in a dynamic laying scenario and is subjected to a combination of external forces such as axial torsion, repeated bending, and radial twisting, the torsion-resistant structure 3 between the inner sheath 51 and the outermost protective layer 1 activates a cooperative deformation working mode to adapt to the torsion shape of the cable, while ensuring that the internal battery core is not affected by torsional deformation, and ensuring that the internal battery core is in a high conductivity mode under harsh environments.

[0023] Example 2 To further protect the multiple internal conductive cells 21, based on Embodiment 1, such as... Figures 1-5 As shown, the strength support 5 is made of a cross-shaped rigid material. The end of the strength support 5 abuts against the inner wall of the inner sheath 51, and the end of the strength support 5 is a large-area arc-shaped surface. After the inner sheath 51 is fitted onto the outer periphery of the battery cell assembly, the large arc-shaped surface of the end of the cross-shaped support abuts tightly against the inner wall of the inner sheath 51. The large-area arc-shaped contact disperses the contact stress, preventing stress concentration from scratching the inner sheath 51 or breaking the strength support 5. At the same time, it forms a rigid support skeleton. When the cable is subjected to external forces such as radial compression or external impact, the rigid support skeleton first bears and disperses the external load, blocking the external force from being directly transmitted to the conductive battery cell 21, and preventing the battery cell from deforming.

[0024] Specifically, such as Figure 2 As shown, a filling layer 4 is provided in the gap between the conductor structure 2 and the strength support 5. The filling layer 4 is a flame-retardant material. At the same time, the gap between the conductive core 21 and the cross-shaped strength support 5 is completely filled with flame-retardant material. The flame-retardant material tightly wraps the outer wall of the core and the side wall of the strength support 5. On the one hand, it fills the internal gap and further fixes the relative position of the core and the strength support 5, preventing the core from shifting due to cable shaking. On the other hand, it blocks the heat conduction path between the cores. If a single core has a local overheating or thermal runaway risk, the flame-retardant material can quickly block the spread of flames and heat, suppress the thermal runaway, and improve the overall fire safety performance of the cable. It also has insulation, buffering and vibration reduction effects, avoiding wear caused by hard contact between the core and the support.

[0025] Example 3 To prevent permanent torsional deformation, bending, and collapse of the cable, and to maintain the stability of the cable's internal structure and the position of the battery cells, based on the above embodiments, such as... Figures 2-5As shown, a compression-resistant structure 6 extending along the length direction is provided between two adjacent torsion-resistant connecting cores 31. The compression-resistant structure 6 includes a return spring 61 that extends uniformly along the length direction of the torsion-resistant connecting core 31. Strong support plates 62 are fixedly installed at both ends of the return spring 61. First, the torsion-resistant connecting cores 31, which are evenly distributed around the outer circumference of the inner sheath 51, are made of deformable elastic rubber material. They can undergo controllable elastic deformation following the cable torsion. With the torsion-resistant grooves 32 that are evenly opened along their own length direction, the torsion deformation is directional and uniformly released, avoiding local stress concentration that could lead to core breakage and structural fatigue. This ensures that the torsion deformation is flexible and controllable throughout the process and will not transmit torsion stress to the inner sheath 51 and the conductive core 21, further improving the safety of the internal conductive core 21.

[0026] Furthermore, in order to improve the overall compressive strength of the cable, such as Figures 2-3 As shown, the reset spring 61 and the torsion-resistant groove 32 are staggered along the length direction, and both the reset spring 61 and the torsion-resistant groove 32 are arranged in a uniform spiral linear path along the length direction to adapt to the torsion shape of the battery core. Furthermore, the reset spring 61 arranged along the length direction between two adjacent torsion-resistant connecting cores 31 is arranged in a staggered, uniform spiral linear path with the torsion-resistant groove 32, and their deformation paths are completely staggered, preventing the support spring and the torsion-resistant groove 32 from squeezing or jamming each other, and not affecting the normal torsion pressure release of the torsion-resistant groove 32. The strength reset spring 61 undergoes elastic expansion and slight bending deformation simultaneously when the cable is twisted and bent, and adapts to the overall torsion shape in conjunction with the torsion-resistant connecting core 31. When the external torsion force is eliminated, the reset spring 61 quickly releases elastic potential energy, driving the torsion-resistant connecting core 31 and the cable to reset as a whole, avoiding permanent torsion deformation, bending and collapse of the cable, and maintaining the stability of the internal structure of the cable and the position of the battery core.

[0027] Example 4 To ensure the secure installation of the torsion-resistant structure 3 and the compression-resistant structure 6, such as Figure 3As shown, a heat dissipation channel 7 is formed between two adjacent torsion-resistant connecting cores 31. This channel disperses the heat generated by the conductive core 21, effectively preventing heat accumulation and potential damage to the internal conductive core 21. The protective layer 1 includes a water-resistant layer 11, a shielding layer 12, and an outer sheath 13 arranged sequentially from the inside out. The inner circumferential surface of the water-resistant layer 11 and the outer circumferential surface of the inner sheath 51 form a toothed, convex shape. Two strong support plates 62 abut against the water-resistant layer 11 and the inner sheath 51, respectively. The inner sheath 5... Both the outer circumferential surface of the cable 1 and the inner circumferential surface of the water-resistant layer 11 are provided with corresponding toothed structures. The two ends of the torsion-resistant connecting core 31 and the return spring 61 are respectively connected to the inner sheath 51 and the water-resistant layer 11 through the toothed structures. When the cable is subjected to external forces such as torsion and bending, the toothed structures can form circumferential limiting and axial fixing of the torsion-resistant connecting core 31 and the return spring 61, effectively preventing the torsion-resistant connecting core 31 and the return spring 61 from misalignment, slippage or separation relative to the inner sheath 51 and the water-resistant layer 11, and ensuring the relative position stability of each component.

[0028] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A torsion-resistant aluminum alloy flexible cable for wind power generation, comprising a conductor structure (2) installed inside a protective layer (1), characterized in that: The conductor structure (2) includes a plurality of circumferentially distributed conductive cores (21), an insulating layer (22) is provided around the outer periphery of the conductive cores (21), and a strength support member (5) is provided at the center of the plurality of conductive cores (21). The strength support member (5) separates the plurality of conductive cores (21) from each other, and an inner sheath (51) is provided around the outer periphery of the plurality of conductive cores (21). A torsion-resistant structure (3) is provided between the inner sheath (51) and the protective layer (1). The torsion-resistant structure (3) includes several torsion-resistant connecting cores (31) circumferentially distributed on the outer periphery of the inner sheath (51). The torsion-resistant connecting cores (31) are uniformly provided with torsion-resistant grooves (32) along their length direction. The circumferentially distributed torsion-resistant connecting cores (31) cooperate with the torsion-resistant grooves (32) provided along their length direction, so that the torsion deformation can be released in a directional and uniform manner when torsion occurs.

2. The torsion-resistant aluminum alloy flexible cable for wind power generation according to claim 1, characterized in that: The strength support member (5) is made of a cross-shaped rigid material. The end of the strength support member (5) abuts against the inner wall of the inner sleeve (51), and the end of the strength support member (5) is a large-area arc surface.

3. The torsion-resistant aluminum alloy flexible cable for wind power generation according to claim 1, characterized in that: The gap between the conductor structure (2) and the strength support (5) is filled with a filling layer (4), which is a flame-retardant material.

4. The torsion-resistant aluminum alloy flexible cable for wind power generation according to claim 1, characterized in that: Between two adjacent torsion-resistant connecting cores (31), there is a compression-resistant structure (6) extending along the length direction. The compression-resistant structure (6) includes a return spring (61) that extends uniformly along the length direction of the torsion-resistant connecting core (31). A strong support plate (62) is fixedly installed at both ends of the return spring (61).

5. The torsion-resistant aluminum alloy flexible cable for wind power generation according to claim 4, characterized in that: The reset spring (61) and the torsion-resistant groove (32) are staggered in the longitudinal direction, and both the reset spring (61) and the torsion-resistant groove (32) are arranged in a uniform spiral linear path along the longitudinal direction to adapt to the torsion shape of the battery cell.

6. The torsion-resistant aluminum alloy flexible cable for wind power generation according to claim 1, characterized in that: A heat dissipation channel (7) is formed between two adjacent torsion-resistant connecting cores (31).

7. The torsion-resistant aluminum alloy flexible cable for wind power generation according to claim 1, characterized in that: The protective layer (1) includes a water-resistant layer (11), a shielding layer (12), and an outer sheath (13) arranged sequentially from the inside to the outside. The inner circumferential surface of the water-resistant layer (11) and the outer circumferential surface of the inner sheath (51) form a toothed outward convex shape.

8. The torsion-resistant aluminum alloy flexible cable for wind power generation according to claim 4, characterized in that: The two high-strength support plates (62) abut against the water-resistant layer (11) and the inner sheath (51), respectively.

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