Cable stranding structure and method for cable production

Abstract

This invention relates to the field of cable production and processing technology, specifically to a cable stranding structure and method for cable production. The method involves selecting a conductor for constant-temperature aging and softening treatment, adjusting the stranding equipment and setting its parameters, passing the conductor through the stranding equipment, positioning and pulling it, and sequentially stranding each layer of conductor in the order of inner, middle, and outer layers, while releasing torsional stress step by step to obtain a complete stranded wire. The complete stranded wire is then fed into a shaping and compacting mechanism for compaction and shaping, and a protective shaping layer is applied to the outside of the shaped stranded wire to obtain the finished stranded wire. The finished stranded wire undergoes comprehensive inspection, rejecting defective products, and rewinding qualified products. This method, through precise control of layered tension regulation, step-by-step stress release, gradient compaction, and low-temperature curing, ensures that the stranded wire is free from loose strands, skipped strands, and broken wires. The design of reverse stranding of adjacent layers and layer-by-layer stress release can offset residual torsional stress during the stranding process, improving the structural stability of the cable stranded wire.

Description

Technical Field

[0001] This invention relates to the field of cable manufacturing and processing technology, and in particular to a cable strand structure and method for cable production. Background Technology

[0002] Cable stranding is a core process in cable production. It involves twisting multiple single-strand conductors together with a specific strand pitch and direction to form the cable core, which directly determines the cable's conductivity, tensile strength, bending resistance, and service life.

[0003] Currently, conventional cable stranding processes generally have many defects. First, the tension control of individual conductors is uneven during the stranding process, with some conductors being stretched too tightly and others being loosely stacked. This can easily lead to loose strands and strand skipping in the finished stranded cable, resulting in poor uniformity of the cable cross-section. Second, the torsional stress of stranding cannot be effectively released, leaving residual internal stress after the stranded cable is formed. This can easily lead to torsional deformation and wire breakage during later laying and bending processes. Summary of the Invention

[0004] The purpose of this invention is to provide a cable stranding structure and method for cable production, which aims to solve the problems of uneven tension control and ineffective stress release in conventional cable stranding processes.

[0005] To achieve the above objectives, in a first aspect, the present invention provides a method for producing stranded cable for cable manufacturing, comprising the following steps: Select conductors for isothermal aging softening treatment, debug the stranding equipment and set the stranding equipment parameters; The conductor is passed through the stranding device, positioned and pulled, and the conductors of each layer are stranded in the order of inner layer, middle layer and outer layer. The stress is released by twisting in steps to obtain the whole stranded wire. The integral stranded wire is fed into a shaping and compacting mechanism for compaction and shaping, and a protective shaping layer is wrapped around the outside of the shaped stranded wire to obtain the finished stranded wire. The finished stranded wire is subjected to comprehensive inspection of its appearance, roundness, strand pitch, and residual tension stress. Defective products are rejected, and qualified finished products are wound up.

[0006] The specific methods for selecting conductors for isothermal aging softening treatment, debugging stranding equipment, and setting stranding equipment parameters are as follows: The conductor alignment surface is selected for polishing and dust removal cleaning, and then the conductor is subjected to constant temperature aging softening. The treated conductor is subjected to unidirectional micro-pre-twisting straightening to correct single-strand conductors; Perform no-load test run calibration on the stranding equipment, and set the stranding equipment parameters and the layer stranding processing sequence.

[0007] The constant temperature aging softening treatment is at a temperature of 60-80℃, the holding time is 20-30 minutes, and the softening treatment is followed by natural cooling to room temperature.

[0008] The specific method for passing the conductor through the stranding device, positioning and pulling it, and sequentially stranding each layer of conductor in the order of inner layer, middle layer and outer layer, and releasing the stress step by step to obtain the whole stranded wire is as follows: The conductor is passed through the central channel of the stranding equipment, and the central conductor core is uniformly pulled and positioned using a front and rear dual traction mechanism. Complete the stranding of each conductor layer in the order of inner layer, middle layer and outer layer. After each conductor layer is completed, pause the stranding process and uniformly spray an antistatic insulating coating on the outer surface of the current stranded layer. The currently formed stranded layer is subjected to low-speed reverse twisting and slow-release treatment to obtain the whole stranded wire.

[0009] The antistatic insulating coating uses a water-based antistatic insulating paint, with a spray thickness of 0.02-0.05 mm, a spray temperature of 25-30℃, and is allowed to air dry for 1-2 minutes after spraying. The coating is uniform, without accumulation or missed areas, and the surface resistivity is controlled at 10 Ω·cm. 6 -10 9 Ω.

[0010] The specific method for feeding the integral stranded wire into the shaping and compacting mechanism for compaction and shaping, and then covering the outside of the shaped stranded wire with a protective shaping layer to obtain the finished stranded wire is as follows: The entire stranded wire is fed into a shaping and compaction mechanism, and a gradient annular compaction process is used to compact the entire stranded wire. The outer side of the shaped stranded wire is continuously coated with a flame-retardant buffer inner layer and a wear-resistant protective outer layer to form a complete protective shaping layer, thus obtaining a coated stranded wire. The coated stranded wire is subjected to segmented constant temperature cooling, and the cooled coated stranded wire is sent to a constant temperature aging chamber for low temperature stress setting treatment to obtain the finished stranded wire.

[0011] Secondly, the present invention also provides a cable stranding structure for cable production, applied to the cable stranding method for cable production as described in the first aspect above.

[0012] This invention discloses a method for producing stranded cable for cable manufacturing. The method involves selecting a conductor for constant-temperature aging and softening treatment, adjusting the stranding equipment and setting its parameters. The conductor is then passed through the stranding equipment, positioned and pulled, and stranded sequentially in the order of inner, middle, and outer layers. Stress is released step-by-step to obtain a complete stranded cable. The complete stranded cable is then fed into a shaping and compacting mechanism for compaction and shaping. A protective shaping layer is then applied to the outside of the shaped stranded cable to obtain the finished stranded cable. The finished stranded cable undergoes comprehensive inspection for appearance, roundness, strand pitch, and residual tension stress. Defective products are rejected, and qualified products are wound up. This method, through meticulous control of the entire process—layered tension regulation, step-by-step stress release, gradient compaction, and low-temperature curing—ensures that the stranded cable is free of loose strands. The issues of strand skipping and wire breakage are completely eliminated by the design of reverse twisting of adjacent layers and layer-by-layer stress release. This completely offsets the residual torsional stress during the stranding process, improves the structural stability of the cable strand, avoids torsional deformation and breakage during later laying and use, and extends the service life of the cable. In addition, three original core processes have been added: single conductor pre-twisting and straightening, interlayer anti-static isolation, and low-temperature aging and shaping. These processes have changed the industry's conventional simple process mode of "pre-treatment-stranding-shaping" and solved deep-seated technical problems that traditional processes cannot overcome, such as individual conductor differences, stranding misalignment, interlayer electrostatic interference, and later stress rebound. This solves the problems of uneven tension control and ineffective stress release in conventional cable stranding processes. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0014] Figure 1 This is a flowchart of a cable stranding method for cable production provided by the present invention.

[0015] Figure 2 This is a flowchart of step S1 of a cable stranding method for cable production provided by the present invention.

[0016] Figure 3 This is a flowchart of step S2 of a cable stranding method for cable production provided by the present invention.

[0017] Figure 4 This is a flowchart of step S3 of a cable stranding method for cable production provided by the present invention. Detailed Implementation

[0018] The embodiments of the present invention are described in detail below. Examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, but should not be construed as limiting the present invention.

[0019] Please see Figures 1 to 4In a first aspect, the present invention provides a method for producing stranded cable for cable manufacturing, comprising the following steps: S1 Selects the conductor for constant temperature aging softening treatment, debugs the stranding equipment and sets the stranding equipment parameters; Specific methods: S11 Select the conductor alignment surface for polishing, dust removal and cleaning, and then perform constant temperature aging softening on the conductor; In this embodiment of the invention, a central conductor core with matching specifications and multiple sets of single-strand stranded conductors are selected. All conductor surfaces are polished to remove oxidation and dust, and the oxide layer, burrs, dust and impurities on the conductor surface are removed. Then, the cleaned conductors are subjected to constant temperature aging softening treatment to eliminate the initial internal stress of the single-strand conductors. After the pretreatment is completed, they are classified and stored for later use. The polishing and oxidation removal process uses nano-grade polishing paste in conjunction with non-woven fabric for low-speed polishing at a speed of 300-500 r / min. After polishing, the material is ultrasonically cleaned with anhydrous ethanol for 3-5 min. The constant temperature aging softening treatment is carried out at a temperature of 60-80℃ for 20-30 min, followed by natural cooling to room temperature.

[0020] S12 performs unidirectional micro-pre-twisting straightening on the treated conductor to correct single-strand conductors; In this embodiment of the invention, each pre-treated stranded conductor undergoes unidirectional micro-pre-twisting straightening to correct natural bending and warping deformations generated during the production process, unify the initial curvature and stress state of all stranded conductors, and eliminate potential strand misalignment and loosening caused by individual differences in stranded conductors. The pre-twisting angle of the stranded conductor pre-twisting straightening is 3-5° / m, the pre-twisting speed is 100-150 r / min, and the pre-twisting direction is consistent with the formal stranding direction of the corresponding conductor layer. After pre-twisting, bidirectional straightening is performed using a straightening wheel set, and the straightness error of the straightened stranded conductor is ≤0.2mm / m.

[0021] S13 will perform no-load test run calibration of the stranding equipment and set the stranding equipment parameters and the layer stranding processing sequence.

[0022] In this embodiment of the invention, the stranding equipment is calibrated under no-load test run, and the equipment speed, traction speed, tension threshold, and strand pitch parameters are adjusted. According to the specifications of the cable to be processed, the corresponding strand pitch, stranding direction, and tension parameters of the inner, middle, and outer conductors are preset, and the layer stranding processing sequence is set to ensure that the parameters of each process are matched and consistent. The no-load test run calibration time of the equipment is 5-10 minutes. After calibration, the equipment speed error is controlled within ±2 r / min, and the traction speed error is controlled within ±0.2 m / min. The preset inner layer strand pitch is 15-20 mm, the middle layer strand pitch is 23-28 mm, and the outer layer strand pitch is 31-36 mm, and the difference between the strand pitches of adjacent layers is maintained at 8-12 mm.

[0023] S2 passes the conductor through the stranding device, positions and pulls it, and completes the stranding of each layer of conductor in the order of inner layer, middle layer and outer layer, and releases the stress step by step to obtain the whole stranded wire; Specific methods: S21 The conductor is passed through the central channel of the stranding device, and the central conductor core is uniformly pulled and positioned by a front and rear double traction mechanism. In this embodiment of the invention, the pre-treated central conductor core is passed through the central channel of the stranding equipment. The central conductor core is uniformly pulled and positioned using a front and rear dual traction mechanism. The traction speed of the central conductor core is controlled to be constant, keeping the central conductor core straight, without deviation, and without tensile deformation throughout the entire process, serving as the reference base for subsequent layer stranding.

[0024] S22 completes the stranding of each conductor layer in the order of inner layer, middle layer and outer layer. After each conductor layer is completed, the stranding process is paused and an antistatic insulating coating is evenly sprayed on the outer surface of the current stranded layer. In this embodiment of the invention, the conductor stranding of each layer is completed sequentially in the order of inner layer, middle layer, and outer layer. During the stranding process of each layer, an independent dynamic tension control + real-time visual correction mode is adopted to collect the tension data of single conductors and the stranding position deviation in real time, and dynamically fine-tune the conveying speed and arrangement position of each conductor to make the tension and arrangement of all single conductors in the same layer uniform and regular. Adjacent conductors are stranded in opposite directions to complete the ring-shaped uniform stranding layer by layer. After each conductor stranding is completed, the stranding process is paused, and an ultra-thin anti-static insulating coating is uniformly sprayed on the outer surface of the current stranded layer to form an anti-static isolation layer, filling the fine gaps between conductors, eliminating the electrostatic adsorption phenomenon caused by interlayer friction, isolating dust and impurities, and avoiding micro-contact discharge between interlayer conductors, thereby improving the insulation stability of the cable. During the stranding of each conductor layer, the conveying tension of the inner, middle, and outer single-strand conductors is controlled at 10-15N, 18-22N, and 25-30N respectively, with the tension difference between single-strand conductors in the same layer ≤1N. The inner layer uses right-hand stranding, the middle layer uses left-hand stranding, and the outer layer uses right-hand stranding, with the stranding speed increasing layer by layer from the inside out. The visual correction uses a high-speed industrial camera to acquire images of the stranded wire arrangement in real time, with a correction accuracy of ±0.1mm, correcting conductor misalignment in real time. The antistatic insulating coating uses water-based antistatic insulating paint, with a spray thickness of 0.02-0.05mm, a spray temperature of 25-30℃, and is allowed to air dry naturally for 1-2 minutes after spraying. The coating is uniform, without accumulation or missed areas, and the surface resistivity is controlled at 10. 6 -10 9 Ω.

[0025] S23 performs a low-speed reverse twisting and slow-release treatment on the currently formed stranded layer to obtain the overall stranded wire.

[0026] In this embodiment of the invention, the conductor is kept at a constant traction speed, and the currently formed stranded layer is subjected to a low-speed reverse twisting and release treatment to counteract the positive torsional stress generated during stranding, releasing residual internal stress layer by layer and avoiding stress accumulation. The twisting speed of the low-speed reverse twisting and release treatment is 1 / 5 to 1 / 3 of the stranding speed, and the twisting time is 2-4 minutes. During the twisting process, the stranded wire is kept at a constant traction speed. After the stress of a single layer is released, the next layer is stranded, preventing the accumulation of stress from multiple layers.

[0027] S3 feeds the integral stranded wire into the shaping and compacting mechanism for compaction and shaping, and then covers the outside of the shaped stranded wire with a protective shaping layer to obtain the finished stranded wire; Specific methods: S31 The integral stranded wire is fed into the shaping and compaction mechanism, and the entire stranded wire is compacted using a gradient annular compaction process. In this embodiment of the invention, the entire stranded wire is fed into a shaping and compaction mechanism. The entire stranded wire is compacted and shaped through a gradient annular compaction process to eliminate minute gaps between conductors, ensuring that each layer of conductors is tightly bonded and neatly arranged, thus guaranteeing the overall roundness and cross-sectional uniformity of the stranded wire. The gradient annular compaction process consists of three stages of compaction. The first stage compaction gap is 0.1-0.2 mm smaller than the theoretical outer diameter of the stranded wire, the second stage compaction gap is 0.05-0.1 mm smaller, and the third stage is precision calibration compaction with a compaction speed of 5-8 m / min. After compaction, the roundness error of the stranded wire is ≤0.3 mm.

[0028] S32 continuously wraps the outside of the shaped stranded wire with a flame-retardant buffer inner layer and a wear-resistant protective outer layer to form a complete protective shaping layer, thus obtaining a coated stranded wire. In this embodiment of the invention, a flame-retardant buffer inner layer and a wear-resistant protective outer layer are continuously wrapped around the outside of the compacted stranded wire to form a complete protective shaping layer. The flame-retardant buffer inner layer is made of flame-retardant elastic rubber material with a coating thickness of 0.3-0.5mm, and the wear-resistant protective outer layer is made of PVC wear-resistant material with a coating thickness of 0.8-1.2mm.

[0029] S33 performs segmented constant-temperature cooling on the coated stranded wire, and then sends the cooled coated stranded wire into a constant-temperature aging chamber for low-temperature stress setting treatment to obtain the finished stranded wire.

[0030] In this embodiment of the invention, after the coating is completed, the stranded wire is cooled at a uniform speed using a segmented constant temperature cooling method to avoid deformation stress caused by rapid cooling, thus completing the initial forming of the stranded wire. The cooled stranded wire is then sent to a constant temperature aging chamber for low-temperature stress setting treatment to solidify the overall structure of the stranded wire, eliminate residual hidden stress after forming, prevent stress rebound and deformation loosening during later use and storage, and improve the long-term stability of the stranded wire structure.

[0031] The segmented constant-temperature cooling is divided into three stages, with cooling temperatures of 45-50℃, 35-40℃, and 25-30℃ respectively. Each stage lasts for 4-6 minutes, and the uniform cooling rate is synchronized with the strand traction speed. The low-temperature aging and shaping treatment is performed at a temperature of 35-45℃, with a constant-temperature holding time of 15-20 minutes. The humidity inside the chamber is controlled at 40%-50%. Low-temperature shaping does not damage the conductor material, effectively solidifies the internal structure of the strand, eliminates hidden residual stress, and prevents the finished strand from rebounding, deforming, or loosening later.

[0032] S4 performs a comprehensive inspection of the appearance, roundness, strand pitch, and residual tension stress of the finished stranded wire, rejects defective products, and rewinds qualified finished products.

[0033] In this embodiment of the invention, the residual stress detection is performed using a stress tester for full-area detection. The residual stress value of the finished stranded wire is ≤5MPa; the strand pitch detection error is ≤±0.5mm; the appearance is free of defects such as loose strands, skipped strands, bulges, and scratches; after passing the inspection, constant tension winding is used, and the winding tension is controlled at 20-30N.

[0034] Secondly, the present invention also provides a cable stranding structure for cable production, applied to the cable stranding method for cable production as described in the first aspect above.

[0035] The above-disclosed embodiments are merely preferred embodiments of the cable strand structure and method for cable production according to this application, and should not be construed as limiting the scope of this application. Those skilled in the art can understand that all or part of the processes for implementing the above embodiments, and equivalent variations made in accordance with the claims of this application, still fall within the scope of this application.

Claims

1. A method for producing stranded cable for cable manufacturing, characterized in that, Includes the following steps: Select conductors for isothermal aging softening treatment, debug the stranding equipment and set the stranding equipment parameters; The conductor is passed through the stranding device, positioned and pulled, and the conductors of each layer are stranded in the order of inner layer, middle layer and outer layer. The stress is released by twisting in steps to obtain the whole stranded wire. The integral stranded wire is fed into a shaping and compacting mechanism for compaction and shaping, and a protective shaping layer is wrapped around the outside of the shaped stranded wire to obtain the finished stranded wire. The finished stranded wire is subjected to comprehensive inspection of its appearance, roundness, strand pitch, and residual tension stress. Defective products are rejected, and qualified finished products are wound up.

2. The cable stranding method for cable production as described in claim 1, characterized in that, The specific methods for selecting conductors for isothermal aging softening treatment, debugging stranding equipment, and setting stranding equipment parameters are as follows: The conductor alignment surface is selected for polishing and dust removal cleaning, and then the conductor is subjected to constant temperature aging softening. The treated conductor is subjected to unidirectional micro-pre-twisting straightening to correct single-strand conductors; Perform no-load test run calibration on the stranding equipment, and set the stranding equipment parameters and the layer stranding processing sequence.

3. The cable stranding method for cable production as described in claim 1, characterized in that, The constant temperature aging softening treatment is at a temperature of 60-80℃, and the holding time is 20-30 minutes. After the softening treatment, the material is allowed to cool naturally to room temperature.

4. The cable stranding method for cable production as described in claim 1, characterized in that, The specific method for passing the conductor through the stranding device, positioning and pulling it, and sequentially stranding each layer of conductor in the order of inner layer, middle layer and outer layer, and releasing the stress step by step to obtain the whole stranded wire is as follows: The conductor is passed through the central channel of the stranding equipment, and the central conductor core is uniformly pulled and positioned using a front and rear dual traction mechanism. Complete the stranding of each conductor layer in the order of inner layer, middle layer and outer layer. After each conductor layer is completed, pause the stranding process and uniformly spray an antistatic insulating coating on the outer surface of the current stranded layer. The currently formed stranded layer is subjected to low-speed reverse twisting and slow-release treatment to obtain the whole stranded wire.

5. The cable stranding method for cable production as described in claim 4, characterized in that, The anti-static insulating coating adopts water-based anti-static insulating paint, the spraying thickness is 0.02-0.05mm, the spraying temperature is 25-30℃, and the coating is naturally air-dried for 1-2min after spraying, the coating is uniform without accumulation and leakage, and the surface resistivity is controlled to be 10 6 -10 9 Ω.

6. The cable stranding method for cable production as described in claim 1, characterized in that, The specific method for feeding the integral stranded wire into the shaping and compacting mechanism for compaction and shaping, and then covering the outside of the shaped stranded wire with a protective shaping layer to obtain the finished stranded wire is as follows: The entire stranded wire is fed into a shaping and compaction mechanism, and a gradient annular compaction process is used to compact the entire stranded wire. The outer side of the shaped stranded wire is continuously coated with a flame-retardant buffer inner layer and a wear-resistant protective outer layer to form a complete protective shaping layer, thus obtaining a coated stranded wire. The coated stranded wire is subjected to segmented constant temperature cooling, and the cooled coated stranded wire is sent to a constant temperature aging chamber for low temperature stress setting treatment to obtain the finished stranded wire.

7. A cable stranding structure for cable production, applied to the cable stranding method for cable production as described in any one of claims 1-6.

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