High strength crosslinked polyethylene insulated aerial cable

Abstract

The application discloses a high-strength cross-linked polyethylene insulated overhead cable applied to the cable field, and realizes the integration of mechanical strength improvement and intelligent monitoring of an operating state through the multilayer structure design of an inner buffer framework, a composite shielding layer, an outer protective framework and an outer insulation layer, the reinforced strips are integrated with pressure strain strips and temperature change strips, overvoltage and overheating areas can be directly identified through color change, the temperature detection lines are arranged in the composite reinforced lines, the sensor interfaces of the sectional sleeves are used to build a real-time monitoring network, the collection and abnormal early warning of the core temperature, the surface temperature and the moisture state are realized, the cable operation safety and operation and maintenance response efficiency are improved, and through the reinforced strip design of the outer protective framework, the radial compression strength of the cable is improved, overvoltage and overheating areas can be directly identified through color change, and operation and maintenance visualization is realized through the observation holes of the outer insulation layer.

Description

Technical Field

[0001] This invention relates to the field of cables, and particularly to a high-strength cross-linked polyethylene insulated overhead cable. Background Technology

[0002] Overhead cables are power transmission lines erected above ground and fixed by poles, towers, or supports. They consist of a conductive core, insulation layer, and protective layer, and are characterized by large transmission capacity, convenient installation, and low maintenance costs. The conductive core is often made of aluminum or copper, and the insulation layer commonly uses cross-linked polyethylene or polyvinyl chloride, which effectively isolates current and resists environmental corrosion. Compared to underground cables, overhead cables have shorter construction periods and lower investment costs, making them suitable for long-distance power transmission and complex terrain areas such as rural and mountainous regions.

[0003] Chinese invention CN119049786B discloses a wear-resistant and flame-retardant insulated overhead cable. When installing outdoor overhead cables in residential areas, the outer sheath of the cable is placed on the outer surface of the cable to protect it, which solves the problem of low wear resistance of existing overhead cables used in residential areas due to the influence of the external environment.

[0004] Chinese invention CN120473239B discloses a heat-dissipating and moisture-controlling overhead cable. This invention introduces external airflow into the cooling chamber through rectangular grooves on the outer surface of the armor layer. With the help of inclined baffles, it not only blocks rainwater but also uses the low temperature of the outside environment to assist the coolant in the cooling chamber. The coolant in the cooling chamber is connected to the coolant inside the spiral tube through an L-tube. The coolant inside the spiral tube can also always maintain a low temperature, which improves the heat dissipation effect of the cable core.

[0005] In existing technologies, overhead cables have limited tensile, compressive, and bending resistance, making them prone to deformation or breakage under external forces, thus affecting the stability and safety of power transmission. Furthermore, insufficient condition monitoring during cable operation hinders the timely detection of cable anomalies and makes it difficult to pinpoint fault areas during maintenance. This makes timely fault warnings and maintenance difficult to implement, increasing the risks and costs of system operation. Summary of the Invention

[0006] The core of this invention lies in addressing the problems of insufficient mechanical strength and inadequate operational status monitoring in existing cables through a multi-layered structural design comprising an inner buffer skeleton and an outer protective skeleton. Simultaneously, it achieves synergistic optimization of mechanical strength and intelligent monitoring, easily improving cable operational safety and maintenance response efficiency.

[0007] To solve the above problems, the present invention adopts the following technical solution.

[0008] A high-strength cross-linked polyethylene insulated overhead cable includes a core bundle, an inner buffer skeleton surrounding the outer end of the core bundle, the inner buffer skeleton including multiple evenly distributed buffer lines, a composite shielding layer covering the outer end of the inner buffer skeleton, an outer protective skeleton fitted on the outer end of the composite shielding layer, multiple strip grooves opening on the outer end of the outer protective skeleton, reinforcing strips embedded in the strip grooves, a strip cavity between two adjacent strip grooves, a buffer pad layer filling the space between the strip cavity and the composite shielding layer, and an outer insulation layer covering the outer end of the outer protective skeleton.

[0009] The buffer line includes a C-shaped sleeve that is fixedly connected to the wire core harness, and a composite reinforcing wire is threaded inside the C-shaped sleeve;

[0010] The reinforcing strip includes a hollow strip, the surface of which is provided with multiple strain indicator strips, which change color when subjected to pressure or high temperature;

[0011] Multiple evenly distributed segmented sleeves are installed on the outer insulation layer, and inner connecting rings matching multiple buffer pipelines are installed on the inner ends of the segmented sleeves.

[0012] Furthermore, a thermally conductive pad with a closed strip cavity opening is laid between the strain gauge strip and the hollow strip. An optical fiber temperature sensor and a moisture sensor are installed inside the strain gauge strip. The sensing end of the optical fiber temperature sensor is connected to the thermally conductive pad. Both ends of the segmented sleeve are provided with external wiring rings for wiring with the optical fiber temperature sensor. Multiple interfaces matching the reinforcing strip are provided on the external wiring rings.

[0013] Furthermore, the C-shaped sleeve has a C-shaped cross-section and is made of elastic thermally conductive material. Multiple evenly distributed temperature detection units are set on the temperature detection line, and the sensing end of the temperature detection unit is attached to the wire core bundle.

[0014] Furthermore, a flame-retardant pad is filled between the composite shielding layer and multiple buffer pipelines. The flame-retardant pad is composed of a blend of aluminum hydroxide and polyethylene.

[0015] Furthermore, the strain gauge strips include pressure strain gauges and temperature-sensitive strain gauges. The pressure strain gauges are made of pressure-sensitive color-changing material, and their color change threshold pressure is 0.5-3.0 MPa. The temperature-sensitive strain gauges are made of thermochromic material, and their color change initiation temperature is 80℃, and their complete color change temperature is 120℃.

[0016] Furthermore, multiple pairs of through holes are formed on the strip groove, which are used to connect the strip groove and the strip cavity.

[0017] Furthermore, the surface of the outer insulation layer is coated with an identification strip that matches the position of the reinforcing strip. Multiple evenly distributed observation holes are provided at the identification strip, and the observation holes are sealed with transparent resin.

[0018] Furthermore, the cushioning layer is made of porous polyethylene foam material, and silicon carbide microparticles are incorporated into the cushioning layer to enhance thermal conductivity.

[0019] Furthermore, it also includes a monitoring and early warning system, which includes a data acquisition module, a data processing module, and an early warning output module. The data acquisition module is used to collect various monitoring data during the cable operation process in real time; the data processing module is used to receive the monitoring data transmitted by the data acquisition module, analyze and process it, and comprehensively determine whether there is any abnormality in the cable; the early warning output module is used to issue an early warning signal in a timely manner when the data processing module determines that there is an abnormality in the cable.

[0020] Compared with the prior art, the advantages of this invention are:

[0021] (1) This solution improves the radial compressive strength of the cable by designing the reinforcing strip of the outer protective skeleton, and can intuitively identify the overvoltage and overheat areas by color change. Combined with the observation hole of the outer insulation layer, it realizes the visualization of operation and maintenance. At the same time, the C-shaped sleeve and composite reinforcing wire of the inner buffer skeleton further enhance the mechanical protection of the wire core and the real-time temperature monitoring capability.

[0022] (2) Fireproof, buffer and heat conduction triple protection is constructed by flame retardant pad and buffer pad. Combined with the monitoring and early warning system, the real-time collection and abnormal early warning of core temperature, surface temperature and moisture status can be realized, thereby improving the safety of cable operation and the efficiency of operation and maintenance response. Attached Figure Description

[0023] Figure 1 This is a partial perspective view of the present invention;

[0024] Figure 2 for Figure 1 Schematic diagram of the structure at point A;

[0025] Figure 3 This is a cross-sectional view of the present invention;

[0026] Figure 4 for Figure 3 Schematic diagram of the structure at point B;

[0027] Figure 5 This is a top view of the present invention;

[0028] Figure 6 This is a schematic diagram showing the connection between the external wiring ring and the reinforcing strip of the present invention;

[0029] Figure 7 This is a partial cross-sectional schematic diagram of the reinforcing strip according to the second embodiment of the present invention;

[0030] Figure 8 This is a system connection block diagram of the present invention.

[0031] Explanation of markings in the diagram:

[0032] 1. Wire core harness; 2. Buffer tubing; 21. C-type sleeve; 22. Composite reinforced wire; 3. Composite shielding layer; 4. Outer protective frame; 5. Reinforcing strip; 51. Hollow strip; 52. Strain indicator strip; 53. Thermal conductive pad layer; 6. Outer insulation layer; 7. Segmented sleeve; 71. External connection ring. Detailed Implementation

[0033] The technical solutions will now be clearly and completely described with reference to the accompanying drawings in the embodiments of the present invention.

[0034] First implementation method:

[0035] Please see Figures 1-6 A high-strength cross-linked polyethylene insulated overhead cable includes a core bundle 1, an inner buffer skeleton surrounding the outer end of the core bundle 1, the inner buffer skeleton including multiple evenly distributed buffer lines 2, a composite shielding layer 3 covering the outer end of the inner buffer skeleton, and a flame-retardant pad layer filled between the composite shielding layer 3 and the multiple buffer lines 2, the flame-retardant pad layer being composed of a blend of aluminum hydroxide and polyethylene.

[0036] The outer end of the composite shielding layer 3 is fitted with an outer protective frame 4. The outer end of the outer protective frame 4 has multiple strip grooves, and reinforcing strips 5 are embedded in the strip grooves. A strip cavity is provided between two adjacent strip grooves. A buffer pad is filled between the strip cavity and the composite shielding layer 3. The outer end of the outer protective frame 4 is covered with an outer insulating layer 6. The convex surface of the outer protective frame 4 is bonded to the outer insulating layer 6.

[0037] The reinforcing strip 5 includes a hollow strip 51, the surface of which is provided with multiple strain indicator strips 52 (in this embodiment, the strain indicator strips 52 are directly laid on the surface of the hollow strip 51). The strain indicator strips 52 are used to mark areas subjected to excessive temperature or pressure. The strain indicator strips 52 change color when subjected to pressure or high temperature. The strain indicator strips 52 include pressure strain strips and thermochromic strips. The pressure strain strips are made of pressure-sensitive color-changing material, and their color change threshold pressure is 0.5-3.0 MPa. The thermochromic strips are made of thermochromic material, and their color change initiation temperature is 80℃, and their complete color change temperature is 120℃. The surface of the outer insulation layer 6 is coated with an indicator strip that matches the position of the reinforcing strip 5. Multiple evenly distributed observation holes are opened at the indicator strips. The observation holes are sealed with transparent resin. Optionally, multiple reinforcing strips 5 can also be installed in series in the strip groove.

[0038] The design of the reinforcing strip 5 enhances the radial compressive strength of the cable, while the strain gauge strip 52 on its surface identifies areas of excessive pressure and overheating, facilitating identification by maintenance personnel. Additionally, the buffer pads filling the cavities between adjacent slots absorb external impacts and enhance heat dissipation through silicon carbide particles, preventing localized temperature buildup. Furthermore, the slot design facilitates replacement of the reinforcing strip 5 during cable maintenance. Simply open the outer insulation layer 6 (cut along the edge of the marking strip), pry the reinforcing strip 5 out of the slot to remove it, insert the new reinforcing strip 5 into the slot, and finally close the opened outer insulation layer 6.

[0039] Multiple evenly distributed segmented sleeves 7 are installed on the outer insulation layer 6. The inner end of the segmented sleeve 7 is equipped with an inner connecting ring that matches multiple buffer lines 2. The buffer line 2 includes a C-shaped sleeve 21 that is fixedly connected to the wire core bundle 1. The C-shaped sleeve 21 plays a major buffering role. When the cable is subjected to strong external force, the force can be effectively dispersed and buffered through the C-shaped sleeve 21.

[0040] The C-shaped sleeve 21 is internally fitted with a composite reinforcing wire 22; the composite reinforcing wire 22 includes a temperature detection wire and a structural reinforcing wire; the cross-section of the C-shaped sleeve 21 is C-shaped, the C-shaped sleeve 21 is made of elastic thermally conductive material, and multiple uniformly distributed temperature detection units are provided on the temperature detection wire, and the sensing end of the temperature detection unit is in contact with the wire core bundle 1.

[0041] The segmented unit 7 is equipped with a data transmission module, which transmits the temperature data collected by the temperature detection unit to an external monitoring system via a data transmission device.

[0042] The strip groove has multiple pairs of through holes, which connect the strip groove and the strip cavity. The buffer pad is made of porous polyethylene foam material and contains silicon carbide microparticles to enhance thermal conductivity. The through holes on the strip groove connect the strip groove and the strip cavity, and the silicon carbide microparticles enhance thermal conductivity, which helps to transfer and diffuse heat outward through the through holes, thus improving the heat dissipation effect.

[0043] When the wire core harness 1 is powered on, it generates heat. The temperature detection unit on the temperature detection line in the C-type sleeve 21 monitors the temperature changes at various locations of the wire core harness 1 in real time. When the temperature of the wire core harness 1 rises or it comes into contact with a flame, the flame-retardant pad layer decomposes through heat absorption to form a flame-retardant barrier, which can delay the spread of fire. At the same time, the thermal conductivity of the C-type sleeve 21 transfers the heat of the wire core to the flame-retardant pad layer, preventing local overheating.

[0044] Meanwhile, the composite reinforcing wire 22 inside the C-type sleeve includes a temperature sensing wire, whose temperature sensing unit is closely fitted with the wire core bundle to monitor changes in wire core temperature in real time. The structural reinforcing wire further enhances the mechanical strength around the wire core, preventing damage to the wire core from external forces;

[0045] When the outer protective frame 4 is subjected to external pressure, the pressure is transmitted to the reinforcing strip 5 through the outer insulation layer 6. The pressure strain gauge in the reinforcing strip 5 changes color when the pressure reaches the threshold pressure of 0.5-3.0 MPa. At the same time, if the local temperature of the cable rises to 80℃, the temperature-changing strip begins to change color, and it completely changes color when the temperature reaches 120℃. Maintenance personnel can observe the color change of the strain gauge 52 through the observation hole at the marking strip on the surface of the outer insulation layer 6, so as to promptly detect areas that are overheated or subjected to excessive pressure.

[0046] The inner connecting ring at the inner end of the segmented sleeve 7 matches the buffer pipeline 2, which can further fix the position of the buffer pipeline 2 and ensure that it can stably play its role in buffering and heat conduction.

[0047] Second implementation method:

[0048] The difference between this embodiment and the first embodiment is that:

[0049] Please see Figures 1-3 and Figures 5-7 A thermally conductive pad 53 with a closed opening end of the strip cavity is laid between the strain indicator strip 52 and the hollow strip 51. In this embodiment, the strain indicator strip 52 is connected to the surface of the hollow strip 51 through the thermally conductive pad 53.

[0050] A fiber optic temperature sensor and a moisture sensor are installed inside the strain indicator strip 52. The sensing end of the fiber optic temperature sensor is connected to the thermal pad layer 53. Both ends of the segmented sleeve 7 are provided with external wiring rings 71 for wiring the fiber optic temperature sensor. The external wiring rings 71 are provided with multiple interfaces that match the reinforcing strip 5. When the interfaces are not in use, they are sealed with rubber plugs.

[0051] This embodiment enables the reinforcing strip 5 to monitor the cable surface temperature through the thermally conductive pad layer 53 and the fiber optic temperature sensor. By detecting the cable surface temperature, the data is fed back to the intelligent operation and maintenance platform in real time. Combined with the moisture sensor data, the risk of cable moisture can be identified simultaneously. The thermally conductive pad layer 53 not only improves the temperature conduction efficiency but also provides physical protection for the optical fiber, ensuring monitoring accuracy and long-term stability. The modular interface design of the external connection ring 71 supports quick plugging and unplugging and multi-point expansion, adapting to the distributed monitoring needs of cable segments of different lengths.

[0052] The third implementation method:

[0053] Please see Figure 8 This solution also includes a monitoring and early warning system, which comprises a data acquisition module, a data processing module, and an early warning output module.

[0054] The data acquisition module is used to collect various monitoring data during the operation of the cable in real time. The monitoring data includes temperature data of each position of the core bundle collected by the temperature detection unit on the temperature detection line, surface temperature data of the cable collected by the fiber optic temperature sensor laid in the reinforcing strip, and moisture data of the cable collected by the moisture sensor.

[0055] The data processing module receives monitoring data transmitted from the data acquisition module and analyzes and processes it. This module compares the acquired temperature data with preset temperature thresholds (such as 120℃ for complete color change of the temperature-sensitive strip), compares the moisture data with preset moisture risk thresholds, and combines this with information on color changes in the pressure strain gauge and pressure exceeding 0.5-3.0 MPa obtained through the observation hole to comprehensively determine whether the cable exhibits abnormal conditions such as overheating, overpressure, or moisture absorption.

[0056] The early warning output module is used to issue an early warning signal in a timely manner when the data processing module determines that there is an abnormality in the cable. The early warning signal can be output in a variety of ways, such as sending alarm information to an external monitoring system or intelligent operation and maintenance platform, so that operation and maintenance personnel can be aware of the abnormality of the cable in a timely manner, and take corresponding maintenance and handling measures to prevent the fault from escalating further.

[0057] This implementation method enables comprehensive, real-time, and intelligent monitoring and early warning of cable operating status. It can quickly identify potential risks such as overheating, overvoltage, or moisture in the cable. Once an abnormality is detected, the early warning output module will respond rapidly by sending alarm information to external monitoring systems or intelligent operation and maintenance platforms. This ensures that maintenance personnel can grasp the cable's operational problems as soon as possible and take effective maintenance and handling measures to prevent further escalation of the fault, ensure the safe and stable operation of the cable system, and improve the reliability and security of the entire power transmission network.

[0058] The above description is merely a preferred embodiment of the present invention; it encompasses all the protection scope of the present invention. Any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in the present invention, based on the technical solutions and improved concepts of the present invention, should be covered within the protection scope of the present invention.

Claims

1. A high-strength cross-linked polyethylene insulated overhead cable, comprising a core bundle (1), characterized in that: The outer end of the wire core bundle (1) is surrounded by an inner buffer skeleton, which includes multiple evenly distributed buffer lines (2). The outer end of the inner buffer skeleton is covered with a composite shielding layer (3). The outer end of the composite shielding layer (3) is fitted with an outer protective skeleton (4). The outer end of the outer protective skeleton (4) is provided with multiple strip grooves, and reinforcing strips (5) are embedded in the strip grooves. A strip cavity is provided between two adjacent strip grooves. A buffer pad is filled between the strip cavity and the composite shielding layer (3). The outer end of the outer protective skeleton (4) is covered with an outer insulation layer (6). The buffer pipeline (2) includes a C-shaped sleeve (21) fixedly connected to the wire core bundle (1), and a composite reinforcing wire (22) is threaded inside the C-shaped sleeve (21). The composite reinforcing wire (22) includes a temperature detection wire and a structural reinforcing wire. The reinforcing strip (5) includes a hollow strip (51), and the surface of the hollow strip (51) is provided with multiple strain marking strips (52), which change color when subjected to pressure or high temperature; Multiple evenly distributed segmented sleeves (7) are installed on the outer insulation layer (6), and the inner end of the segmented sleeves (7) is equipped with an inner connecting ring that matches multiple buffer lines (2).

2. The high-strength cross-linked polyethylene insulated overhead cable according to claim 1, characterized in that: A thermally conductive pad (53) with a closed strip cavity opening is laid between the strain indicator strip (52) and the hollow strip (51). An optical fiber temperature sensor and a moisture sensor are installed inside the strain indicator strip (52). The sensing end of the optical fiber temperature sensor is connected to the thermally conductive pad (53). Both ends of the segmented sleeve (7) are provided with external wiring rings (71) for wiring with the optical fiber temperature sensor. The external wiring rings (71) are provided with multiple interfaces that match the reinforcing strip (5).

3. The high-strength cross-linked polyethylene insulated overhead cable according to claim 1, characterized in that: The C-shaped sleeve (21) has a C-shaped cross section and is made of elastic thermally conductive material. Multiple temperature detection units are evenly distributed on the temperature detection line, and the sensing end of the temperature detection unit is attached to the wire core bundle (1).

4. A high-strength cross-linked polyethylene insulated overhead cable according to claim 1, characterized in that: A flame-retardant pad is filled between the composite shielding layer (3) and the multiple buffer pipelines (2), and the flame-retardant pad is composed of a blend of aluminum hydroxide and polyethylene.

5. A high-strength cross-linked polyethylene insulated overhead cable according to claim 1, characterized in that: The strain gauge (52) includes a pressure strain gauge and a temperature-sensitive strain gauge. The pressure strain gauge is made of a pressure-sensitive color-changing material, and its color change threshold pressure is 0.5-3.0 MPa. The temperature-sensitive strain gauge is made of a thermochromic material, and its color change initiation temperature is 80℃ and its complete color change temperature is 120℃.

6. A high-strength cross-linked polyethylene insulated overhead cable according to claim 1, characterized in that: The strip groove has multiple pairs of through holes, which are used to connect the strip groove and the strip cavity.

7. A high-strength cross-linked polyethylene insulated overhead cable according to claim 1, characterized in that: The surface of the outer insulation layer (6) is coated with an identification strip that matches the position of the reinforcing strip (5). Multiple evenly distributed observation holes are provided at the identification strip, and the observation holes are sealed with transparent resin.

8. A high-strength cross-linked polyethylene insulated overhead cable according to claim 1, characterized in that: The cushioning layer is made of porous polyethylene foam material, and silicon carbide microparticles are incorporated into the cushioning layer to enhance thermal conductivity.

9. A high-strength cross-linked polyethylene insulated overhead cable according to claim 1, characterized in that: It also includes a monitoring and early warning system, which comprises a data acquisition module, a data processing module, and an early warning output module. The data acquisition module is used to collect various monitoring data during the cable operation process in real time. The data processing module is used to receive the monitoring data transmitted by the data acquisition module, analyze and process it, and comprehensively determine whether there is any abnormality in the cable. The early warning output module is used to issue an early warning signal in a timely manner when the data processing module determines that there is an abnormality in the cable.

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