Composite tape systematized longitudinal wrapping process for cables and application

Abstract

The application discloses a cable composite tape systematic longitudinal wrapping process and application, solves the problem that a preformed horn mouth mold in the prior art is mainly selected by experience, has the beneficial effects of improving longitudinal wrapping quality and production efficiency, and specifically has the following scheme: a cable composite tape systematic longitudinal wrapping process, which comprises the following steps: determining a composite tape width according to a composite tape tensile compensation coefficient, a cable core outer diameter, a composite tape total thickness and a target lap rate; determining an outlet inner diameter of the preformed horn mouth mold according to the cable core outer diameter and the determined composite tape total thickness, determining an inlet width of the preformed horn mouth mold according to the determined composite tape width, determining a forming angle of the preformed horn mouth mold according to a composite tape bending strain, the composite tape total thickness and the outlet inner diameter of the preformed horn mouth mold, and determining a mold length of the preformed horn mouth mold; and forming a cable through a longitudinal wrapping forming device.

Description

Technical Field

[0001] This invention relates to the field of longitudinal wrapping technology of aluminum-plastic composite tape in cable production, and in particular to a systematic longitudinal wrapping process and application of composite tape for cables. Background Technology

[0002] Longitudinal wrapping of aluminum-plastic composite tape is a core protective process in cable production. By wrapping the aluminum-plastic composite tape longitudinally along the cable core and overlapping and pressing it tightly, it provides electromagnetic shielding, moisture resistance, and mechanical protection, directly determining the cable's service life and operational stability. Currently, the longitudinal wrapping process has the following problems: The design of the pre-forming flared die and the compaction die in the longitudinal wrapping forming device used for cable forming relies entirely on experience. The size selection of the pre-forming flared die largely depends on the personal experience of the operators, lacking scientific quantitative calculations, which can easily lead to uneven stress on the strip during deformation. Due to the differences in the width and thickness of aluminum-plastic composite tape, different specifications of cables correspond to aluminum-plastic composite tapes with different parameters. The experience-based selection method can easily lead to a mismatch between the two dies and the parameters of the aluminum-plastic composite tape. If the opening of the pre-forming flared die is too large, it will cause uneven stress on the aluminum-plastic composite tape during pre-forming, resulting in wrinkles and displacement. If the opening is too small, it will cause the aluminum-plastic composite tape to be overstretched, resulting in damage and breakage, affecting the longitudinal wrapping quality. When the size of the compaction die does not match the parameters of the aluminum-plastic composite tape, there will be poor longitudinal wrapping overlap, excessive gaps, or excessive tightness, leading to damage to the composite tape, which in turn reduces the insulation and moisture-proof performance of the cable, and even affects the service life of the cable. Summary of the Invention

[0003] To address the shortcomings of existing technologies, the purpose of this invention is to provide a systematic longitudinal wrapping process for composite tapes used in cables. This systematic longitudinal wrapping process for aluminum-plastic composite tapes for cables involves precisely selecting molds based on the width and thickness of the aluminum-plastic composite tape. This achieves precise matching between the flared end mold and the forming mold, solving the technical problems of inaccurate mold selection and unstable longitudinal wrapping quality in existing technologies, and improving the production efficiency of aluminum-plastic longitudinal wrapping tapes.

[0004] To achieve the above objectives, the present invention is implemented through the following technical solution: A systematic longitudinal wrapping process for composite tape used in cables includes the following: The total thickness of the composite tape is determined based on the outer diameter of the cable core, and the width of the composite tape is determined based on the tensile compensation coefficient of the composite tape, the outer diameter of the cable core, the total thickness of the composite tape, and the target overlap ratio. The outlet inner diameter of the preformed flared mold is determined based on the outer diameter of the cable core and the total thickness of the composite strip. The inlet width of the preformed flared mold is determined based on the width of the composite strip. The forming angle of the preformed flared mold is determined based on the bending strain of the composite strip, the total thickness of the composite strip, and the outlet inner diameter of the preformed flared mold. The mold length of the preformed flared mold is also determined. The inner diameter of the compression mold is determined based on the radial compression amount, the outer diameter of the cable core, and the total thickness of the composite tape. The pre-formed flared mold is manufactured according to the determined inlet width, outlet inner diameter, forming angle, and mold length of the pre-formed flared mold, and the compacting mold is manufactured according to the determined inner diameter of the compacting mold. The pre-formed flared mouth mold and the compaction and shaping mold, which have been manufactured, are installed on the longitudinal packaging forming device; The cable is formed using the aforementioned longitudinal forming device.

[0005] As described above, a systematic longitudinal wrapping process for composite tape used in cables includes a longitudinal wrapping forming device further comprising a visual inspection mechanism, a controller, and a tension adjustment mechanism. The visual inspection mechanism is used to acquire information about the composite strip and send it to the controller; The controller is used to adjust the wire tension of the tension adjustment mechanism according to the condition of the composite tape.

[0006] The longitudinal wrapping process of the composite tape for cables described above is used to determine the total thickness of the composite tape according to the following rules: When 2mm < the outer diameter of the cable core ≤ 10mm, the total thickness of the composite tape is between 0.08 and 0.12mm. When 10mm < the outer diameter of the cable core ≤ 30mm, the total thickness of the composite tape is between 0.12 and 0.18mm. When 30mm < the outer diameter of the cable core ≤ 60mm, the total thickness of the composite tape is between 0.18 and 0.25mm. When the outer diameter of the cable core is greater than 60 mm, the total thickness of the composite tape is greater than or equal to 0.25 mm.

[0007] The formula for calculating the width W of the composite tape in the systematic longitudinal wrapping process for cables described above is as follows: W=β*π(D c +2t) / (1-K) In the formula: t is the total thickness of the composite strip, K is the target overlap rate, the value of K ranges from 10% to 30%, β is the tensile compensation coefficient of the composite strip, and D... c The outer diameter of the cable core; The value of the composite tape tensile compensation coefficient is determined by the total thickness of the composite tape and the production line speed of the longitudinal wrapping forming device; When 2mm < the outer diameter of the cable core ≤ 30mm and the production line speed of the longitudinal wrapping forming device is greater than or equal to 35m / min, the value range of β is 1.04-1.12; When the outer diameter of the cable core is greater than 30 mm and the production line speed of the longitudinal wrapping forming device is less than or equal to 20 m / min, the value of β ranges from 1.01 to 1.08.

[0008] As described above, in a systematic longitudinal wrapping process for composite tape used in cables, the outlet inner diameter of the pre-formed flared die is D1. D1=D c +2t+Δ1 Where: t is the total thickness of the composite strip, Δ1 is the pre-formed gap, and D c The outer diameter of the cable core; The inlet width B of the pre-formed flared mold is based on the minimum inlet width B. min To confirm: B min =W+2δ B≥B min In the formula: W is the width of the composite strip, and δ is the lateral safety offset margin on one side, which is determined according to the variation of the total thickness of the composite strip: when the total thickness of the composite strip is ≤0.12mm, δ is 1.5~2.5mm; when the total thickness of the composite strip is 0.12~0.25mm, δ is 2.5~4mm; when the total thickness of the composite strip is ≥0.25mm, δ is 4~6mm; when the production line speed of the longitudinal packaging forming device is greater than 30m / min, δ is increased by 0.5~1mm; for thermoplastic polyester composite strips, δ is taken as the upper limit of the range.

[0009] In the systematic longitudinal wrapping process of the composite tape for cables described above, the relationship between the bending strain of the composite tape and the forming angle of the pre-formed flared die is as follows: ε=(2t*sin(A / 2)) / D1 In the formula: ε is the bending strain of the composite strip, t is the total thickness of the composite strip, and A is the forming angle of the pre-formed flared mold; When the outer diameter of the cable core is ≤30mm, the value of A is 25°~35°; when the outer diameter of the cable core is >30mm, the value of A is 35°~60°. The mold length L of the preformed flared mold is calculated according to the following formula: L = (B - D1) / tan(A / 2).

[0010] In the systematic longitudinal wrapping process of composite tape for cables described above, the formula for calculating the inner diameter D2 of the compression and shaping mold is as follows: D2=D c +2t-Δ2 Among them, D c Δt is the outer diameter of the cable core, t is the total thickness of the composite tape, and Δ2 is the radial compression amount.

[0011] The above-described systematic longitudinal wrapping process for composite tape used in cables, wherein the cable is formed using the longitudinal wrapping forming device, includes the following: Unwinding and feeding: Install the composite tape onto the unwinding mechanism, start the unwinding mechanism, and unwind the composite tape; Guiding and leveling: The unwound composite tape is fed into a guiding mechanism to level the composite tape; Preforming process: The leveled composite strip is fed into the preforming flared mold, so that the composite strip gradually forms an arc-shaped structure that matches the preforming flared mold, thus completing the preforming process; Hot melt pretreatment: The pre-formed composite strip is fed into the hot melt mechanism to heat the plastic layer of the overlapping area of ​​the composite strip; Longitudinal wrapping and compression molding: The heated composite tape is fed into the compression molding mold, and the composite tape and cable core are compressed by the compression molding mold. After compression, the plastic layer is shaped by cooling. After being pressed and fixed, the longitudinally wrapped cable is finely tensioned by the tension adjustment mechanism and then sent to the winding mechanism.

[0012] The systematic longitudinal wrapping process for composite tape in cables, as described above, also includes the following: The pre-formed flared mold is supported by a multi-dimensional motion mechanism, which is mounted on the frame of the longitudinal wrapping forming device. The visual inspection mechanism captures images of the composite belt and sends them to the controller. When the controller detects that the composite belt has an abnormal signal of overall eccentricity or serpentine shape, the controller controls the multi-dimensional motion mechanism to move to adjust the axial and radial positions of the preformed flared mold. The controller establishes a correlation logic between the overlap state and the thread tension. The controller acquires the gap width and the wrinkling status of the composite tape at the longitudinal overlap in real time: when the controller detects that the overlap is narrowing or a gap appears, the controller reduces the thread tension of the tension adjustment mechanism; when the controller detects that the composite tape is wrinkling, the controller reduces the thread tension of the tension adjustment mechanism; when the controller detects that the composite tape is slack or the overlap amount is greater than a set value, the controller increases the thread tension of the tension adjustment mechanism to achieve adaptive dynamic compensation of tension. After the position of the preformed flared mold is adjusted, the controller synchronously adjusts the tension parameters of the tension adjustment mechanism. When the controller detects that the composite belt is narrowing or has gaps, the controller controls the multi-directional motion mechanism and the tension adjustment mechanism to operate simultaneously.

[0013] Secondly, the present invention also provides an application of a systematic longitudinal wrapping process for composite tapes used in cables, specifically for the longitudinal wrapping process of aluminum-plastic composite tapes.

[0014] The beneficial effects of the present invention are as follows: This invention constructs a quantitative model linking "strip specifications, mold dimensions, and production conditions" to achieve coupling and matching of key parameters. First, the total thickness of the composite strip is obtained. Then, the width of the composite strip is determined based on the composite strip tension compensation coefficient, the outer diameter of the cable core, the total thickness of the composite strip, and the target overlap rate. Based on the outer diameter of the cable core, the total thickness of the composite strip, and the width of the composite strip, the outlet inner diameter, inlet width, forming angle, and mold length of the pre-forming flared mold are determined. Based on the radial compression amount, the outer diameter of the cable core, and the total thickness of the composite strip, the inner diameter of the compression mold is determined. In this way, the pre-forming flared mold and the compression mold are manufactured and applied to the longitudinal wrapping forming device. The longitudinal wrapping forming device shapes the cable, making up for the shortcomings of the traditional method that only considers thickness / width. It accurately matches the size of the corresponding composite strip, effectively avoiding excessive springback or overstretching, improving the stability of longitudinal wrapping quality, and ensuring that the composite strip can still perfectly overlap even after it narrows due to stretching during high-speed production. Detailed Implementation

[0015] It should be noted that the following detailed description is illustrative and intended to provide further explanation of the invention. Unless otherwise specified, all technical and scientific terms used in this invention have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0016] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of exemplary embodiments according to the invention. As used herein, unless otherwise expressly indicated by the invention, the singular form is also intended to include the plural form. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof. As introduced in the background art, the existing pre-formed flared end molds are mainly selected based on experience, which can easily lead to uneven stress on the composite tape during deformation. In order to solve the above technical problems, this invention proposes a systematic longitudinal wrapping process for composite tapes for cables.

[0017] In a typical embodiment of the present invention, a systematic longitudinal wrapping process for composite tape for cables, taking aluminum-plastic composite tape as an example, includes the following: 1) Select aluminum-plastic composite tape: For cables of different specifications, confirm the outer diameter D of the cable core to be longitudinally wrapped. c Select the width and thickness of the longitudinally wrapped aluminum-plastic composite strip. Method for selecting the strip material (composite strip): a. Selection of the total thickness of the composite strip: It should be noted that the total thickness of the composite tape is determined based on the outer diameter of the cable core. Specifically, the total thickness of the composite tape and the thickness of the aluminum layer in the composite tape are determined according to the following rules: When 2mm < cable core outer diameter D c When the thickness is ≤10mm, the total thickness of the composite strip is between 0.08 and 0.12mm. When 10mm < cable core outer diameter D c When the thickness is ≤30mm, the total thickness of the composite strip is between 0.12 and 0.18mm. When 30mm < cable core outer diameter D c When the thickness is ≤60mm, the total thickness of the composite strip is between 0.18 and 0.25mm. When the outer diameter of the cable core D c When the thickness is >60mm, the total thickness of the composite strip is ≥0.25mm; b. Width selection: Considering the thinning and stretching during the longitudinal wrapping process, the composite strip width is calculated based on the tensile compensation coefficient β of the production line speed V, taking into account the basic perimeter and overlap width. This ensures that the strip, after narrowing due to stretching during high-speed production, can still perfectly overlap. The formula for calculating the composite strip width W is: W=β*π(D c +2t) / (1-K) In the formula: t is the total thickness of the composite strip, K is the target overlap rate, the value of K ranges from 10% to 30%, and W is the width of the composite strip, which is the actual unfolded width of the aluminum-plastic composite strip selected. The value of β is determined by the total thickness t of the composite strip and the production line speed V (m / min) of the longitudinal wrapping forming device; When 2mm < cable core outer diameter ≤ 30mm and the production line speed of the longitudinal wrapping forming device is greater than or equal to 35m / min, the value range is 1.04-1.12; When the outer diameter of the cable core is greater than 30mm and the production line speed of the longitudinal wrapping forming device is less than or equal to 20m / min, a smaller β should be taken, with a value range of 1.01-1.08. It should be noted that during the material selection stage in the early stage of production, the optimal composite tape width is calculated by matching the corresponding composite tape tensile compensation coefficient β according to the outer diameter of the cable core and the preset production line speed. During the online production stage, the composite tape tensile compensation coefficient β is corrected in a closed loop by collecting the actual overlap rate in real time, and dynamic correction is performed to completely eliminate the unstable overlap defect caused by longitudinal wrapping tensile thinning.

[0018] The actual overlap rate is achieved through a vision inspection mechanism. This mechanism, equipped with a high-resolution industrial camera, a specific light source, and existing image processing software (installed on a computer), can clearly capture the texture of the aluminum-plastic strip surface and the details of the overlap boundary, identifying and locating the cable and overlap boundary in the image. After identifying the boundary, the computer calculates the pixel width of the overlap. Using the known actual cable diameter, strip width, and pixel diameter in the image, the actual overlap rate is finally calculated. When the overlap rate deviates from the target value, the computer sends a command to the controller of the longitudinal wrapping forming device to automatically adjust the parameters of the longitudinal wrapping forming device (such as the wire tension of the tension adjustment mechanism) so that the overlap rate returns to the set range in real time.

[0019] 2) Selection of pre-formed flared mouth mold: To ensure the pre-formed flared mold is compatible with the structural characteristics of the composite tape, based on the collected data on the composite tape width W, total composite tape thickness t, and cable core outer diameter D... c Collaborately calculate the outlet inner diameter D1, inlet width B, forming angle A, and mold length L of the preformed flared mold.

[0020] Determination of the inner diameter D1 and maximum width B of the preformed flared mouth mold outlet: The aluminum-plastic composite belt is pre-wrapped at the outlet. After the composite belt is wrapped, there are still overlap gaps and slight rebound wrinkles. It is not compressed and shaped. The outlet inner diameter D1 is obtained according to the following formula: D1=D c +2t+Δ1 In the formula: Δ1 is 0.2-0.5mm, and Δ1 is the pre-reserved gap for forming, which allows for a loose allowance for the composite belt to be gathered, and prevents the conical surface from scratching the aluminum-plastic belt.

[0021] Considering the lateral offset and edge flipping phenomena that occur during the high-speed conveying of aluminum-plastic composite belts, if the exit width of the pre-formed trumpet-shaped mold only matches the width of the composite belt, defects such as edge scraping, mold jamming, and aluminum foil tearing are likely to occur.

[0022] In this embodiment, the inlet width B of the pre-formed flared mold is based on the minimum inlet width B. min To confirm; B min =W+2δ B≥B min In the formula: δ is the lateral safety offset margin on one side of the composite belt, which is selected according to the change of the total thickness of the composite belt: when the total thickness of the composite belt is ≤0.12mm, δ is 1.5~2.5mm; when the total thickness of the composite belt is 0.12~0.25mm, δ is 2.5~4mm; when the total thickness of the composite belt is ≥0.25mm, δ is 4~6mm; when the production line speed of the longitudinal wrapping forming device is greater than 30m / min, δ is increased by 0.5~1mm; for thermoplastic polyester composite belts, δ is taken as the upper limit of the range.

[0023] In this embodiment, the determination of the forming angle A and the mold length L of the pre-formed flared mouth mold is as follows: The relationship between the bending strain ε of the composite belt and the forming angle A is as follows: ε=(2t*sin(A / 2)) / D1 The forming angle A can be deduced from the above relationship. In addition, it should be explained that the determination of the forming angle also follows the following rules: taking into account the mold length and forming angle of the pre-formed horn mold, the forming angle A is in the range of 25°~60°. If the calculated value of the above formula is not in this range, it should be selected from the following range: when Dc≤30mm, A is in the range of 25°~35°; when Dc>30mm, A is in the range of 35°~60°. The forming angle of the pre-formed horn mold is determined according to the above formula and the above rules, which effectively avoids defects such as thin strip wrinkles and aluminum foil stretching cracks.

[0024] Specifically, the mold length L is obtained according to the following formula: L = (B-D1) / tan(A / 2); It should be noted that, based on the uniform elongation of the composite strip (i.e., aluminum-plastic composite strip), the forming curvature of the mold, and the processing conditions, the value of the bending strain ε of the composite strip is taken as a reference: When the total thickness t of the composite tape is 0.08~0.12mm (applied to 2 <D c For cables ≤10mm thick, ε is taken as 0.002~0.008; When the total thickness t of the composite tape is 0.12~0.18mm (applied to 10 <D c For cables ≤30mm², ε is 0.002~0.006; When the total thickness t of the composite tape is 0.18~0.25mm (applied to 30... <D c For cables ≤60mm², ε is 0.002~0.005; When the total thickness t of the composite tape is ≥ 0.25 mm (applied to D) c For cables longer than 60mm, ε is 0.002 to 0.004.

[0025] 3) Determining the inner diameter of the compaction and shaping mold Calculation of the inner diameter D2 of the compression molding die: The radial compression amount is introduced to calculate the inner diameter of the compression molding die to ensure the overlap ratio. D2=D c +2t-Δ2 In the formula: D c t is the outer diameter of the cable core, t is the total thickness of the aluminum-plastic composite, and Δ2 is the radial compression amount (the value of Δ2 ranges from 0.1 to 0.3 mm).

[0026] The pre-forming flared mouth mold is manufactured according to the determined inlet width, outlet inner diameter, forming angle and mold length of the pre-forming flared mouth mold, and the compacting and shaping mold is manufactured according to the determined inner diameter of the compacting and shaping mold. The pre-formed flared mouth mold and the compaction and shaping mold are installed on the longitudinal wrapping forming device. The other structural components of the longitudinal wrapping forming device are all existing technologies and will not be described in detail. 4) Cables are formed using a longitudinal wrapping forming device: 4-1) Unwinding and feeding: Install the composite tape on the unwinding mechanism, adjust the unwinding tension to the preset range, match the total thickness of the composite tape (3-6N for thin tape, 6-10N for regular tape), start the unwinding mechanism to achieve stable unwinding of the aluminum-plastic composite tape; 4-2) Guiding and leveling: After unwinding, the aluminum-plastic composite strip is fed into the guiding mechanism. Through the coordinated action of the guide rollers and side guide baffles, the strip material (hereinafter referred to as strip material) is leveled and corrected to ensure that the edges of the strip material are neat and the conveying direction is consistent with the central axis of the subsequent mold. 4-3) Pre-forming process: The leveled composite strip is fed into the pre-forming flared mold. It is gently introduced through the straight buffer section of the mold and gradually tapered through the tapered forming section, so that the aluminum-plastic composite strip gradually forms an arc structure that matches the exit of the flared mold, thus completing the pre-forming process. 4-4) Hot melt pretreatment: The pre-formed composite strip is fed into the hot melt mechanism to precisely heat the plastic layer (PE / PET layer) of the overlapping area of ​​the strip. The heating temperature is controlled at 120-160℃ (for aluminum-plastic strip plastic layer materials, PE layer 120-140℃, PET layer 140-160℃), and the heating time is 1-3 seconds. During the heating process, the strip is kept stable to avoid uneven heating that may lead to sealing failure. 4-5) Longitudinal Wrapping and Compression Molding: The heated longitudinally wrapped composite tape is fed into a compression molding die. The compression molding die is used to uniformly and evenly press the composite tape and the cable core together at a constant speed. The compression pressure is controlled between 0.3 and 0.8 MPa. The surface of the compression molding die is decorated with high-temperature resistant and anti-slip textures. During the compression process, on the one hand, the composite tape and the cable core are compacted to eliminate the bonding gap and ensure the roundness of the longitudinal wrapping. On the other hand, the molten plastic layer in the overlapping area is compacted and fused a second time to further improve the sealing and bonding strength of the overlapping area. After compression, the plastic layer is shaped by natural cooling to ensure that the longitudinal wrapping structure does not loosen, delaminate, or spring back. 4-6) After the cable longitudinal wrapping is pressed and fixed, the tension is finely adjusted by the tension adjustment mechanism (to match the unwinding tension and pressing speed) and then sent to the winding mechanism. The speed is kept consistent with the unwinding, conveying and pressing speed through the synchronous control module to avoid the finished product being stretched, wrinkled or deformed due to speed difference; check the sealing performance, roundness, overlap rate and aluminum foil layer integrity of the longitudinal wrapping, and the finished product is neatly wound.

[0027] 5) Dynamic production fine-tuning mechanism: In high-speed production, fluctuations in strip tension and slight changes in the outer diameter of the cable core can cause wrinkling, cracking, or poor overlap of the aluminum-plastic strip. Existing equipment lacks a real-time online fine-tuning mechanism for the entire process. In this embodiment, a visual inspection mechanism is set up. The visual inspection mechanism acquires the condition of the composite strip and sends it to the controller. The controller adjusts the pay-off tension of the tension adjustment mechanism according to the condition of the composite strip, realizing real-time feedback control and achieving precise fine-tuning throughout the longitudinal wrapping production process. This effectively avoids defects such as overlap deviation, strip wrinkling, and eccentricity. The specific fine-tuning mechanism is as follows: 5-1) The pre-formed flared mold is supported by a multi-dimensional motion mechanism (an existing multi-directional motion mechanism that can move linearly along the X, Y, and Z axes and can be finely adjusted with a precision of ±0.05mm in the X / Y / Z three-axis directions). The longitudinal packaging forming device is equipped with a vision inspection mechanism, which is specifically a camera. The vision inspection mechanism takes pictures of the composite tape and sends them to the controller of the longitudinal packaging forming device. The controller includes a computer and the control center of the longitudinal packaging forming device (PLC controller or other type of controller). The computer has an image processing module to process the images sent by the vision inspection mechanism. The computer is connected to the controller. 5-2) When the controller receives an abnormal signal of the composite belt (longitudinal wrapping eccentricity, composite belt serpentine movement), it adjusts the axial and radial positions of the mold through the servo micro-motion screw to correct the composite belt conveying deviation, ensure the coaxiality of pre-forming and longitudinal wrapping, and avoid uneven overlap and belt damage caused by eccentricity.

[0028] 5-3) Adaptive tension fine-tuning: The controller has established a correlation logic between the overlapping state and the tension of the wire feeding. The controller can obtain the gap width at the longitudinal wrapping overlap and the wrinkling status of the composite tape in real time. When an abnormality in the composite tape overlap is detected (the overlap becomes narrower or gaps appear), the controller automatically reduces the tension of the tension adjustment mechanism and uses the elastic shrinkage characteristics of the aluminum-plastic composite tape to restore the overlap width to the design range. When wrinkling or excessive tension is detected in the strip (via the pressure sensor at the tension adjustment mechanism), the controller automatically reduces the unwinding tension of the tension adjustment mechanism to eliminate wrinkles. When strip slack or excessive overlap is detected, the tension of the tension adjustment mechanism is appropriately increased to ensure that the overlap rate meets the standard and achieve adaptive dynamic compensation of tension.

[0029] 5-4) Linkage and fine-tuning coordinated control: Each fine-tuning link does not operate independently, but is equipped with a vision inspection mechanism. The vision inspection mechanism obtains the condition of the composite tape and sends it to the controller. The controller adjusts the wire tension of the pre-forming flared die and the tension adjustment mechanism according to the condition of the composite tape, so as to realize real-time feedback control and form coordinated linkage. For example, after the mold displacement is fine-tuned, the controller simultaneously fine-tunes the tension parameters of the tension adjustment mechanism to ensure that the strip maintains constant tension in the new mold position; when the controller detects an abnormal overlap, it simultaneously triggers tension fine-tuning and mold fine-tuning, providing double protection for molding quality; all fine-tuning parameters are centrally controlled by the controller, and the fine-tuning accuracy can be adapted in real time according to the production line speed and strip specifications to ensure stability and consistency during high-speed and mass production.

[0030] Example 1: For small cross-section cables (outer diameter D of the cable core) c =5mm, flexible precision control cable) Application scenario: Industrial precision control cable, used for signal transmission in automated equipment, requiring no wrinkles in the longitudinal wrapping and no damage to the aluminum foil, production line speed V=25m / min, overlap rate K=15%, using PE plastic layer conventional aluminum foil composite tape.

[0031] Strip selection (1) Thickness selection: For small cross-section cables, aluminum-plastic composite tape with a total thickness t=0.10mm is selected (meeting 2 <D c (Thickness standard ≤10mm).

[0032] (2) Width selection: β=1.06 (thin strip, speed 25m / min), substituting into the formula W=β*π(D c +2t) / (1-K)=1.06×π×(5+2×0.10) / (1-0.15)≈20.4mm, and the actual selected strip is W=20.5mm, with a small margin reserved.

[0033] Mold selection (1) Pre-formed flared mouth mold: Δ1=0.3mm, D1=5+2×0.10+0.3=5.5mm; t=0.10mm, δ=2.0mm (single side), B=20.5+2×2.0=24.5mm; ε=0.005, substituting into ε=(2t×sin(A / 2)) / D1, we can inversely calculate A≈19° (which does not meet the requirement that when Dc≤30mm, the value of A is between 25° and 35°, therefore, considering the length and angle of the flared mouth mold, the forming angle A is within the range of 25°); L=(24.5-5.5) / tan(25° / 2)≈85.7mm, and L=86mm is actually selected.

[0034] (2) Pressing and shaping mold: Δ2=0.1mm, D2=5+2×0.10-0.1=5.1mm, and D2=5.1mm is actually selected.

[0035] Vertical wrapping and fine-tuning (1) Operating parameters: unwinding tension 4N (thin strip), hot melt temperature 130℃ (PE layer), heating time 1.5s, pressing pressure 0.4MPa, winding speed synchronized with unwinding and pressing speed (25m / min).

[0036] (2) Dynamic fine adjustment: During the production process, the vision module detects slight wrinkling of the strip (local wrinkles at the edge). The controller triggers tension fine adjustment, reducing the unwinding tension from 4N to 3.5N. At the same time, the Z-axis position of the pre-formed trumpet mouth mold is finely adjusted (+0.03mm), and the wrinkles are eliminated within 10s. When the overlap gap of 0.1mm is detected (slightly exceeding the standard), the controller automatically lowers the tension to 3.3N. By utilizing the elastic shrinkage of the strip, the overlap width is restored to the design range. There is no manual intervention throughout the process.

[0037] Implementation effect The finished product with longitudinal wrapping is free of wrinkles and aluminum foil damage, with an overlap rate of 14.8%-15.2%, meeting the standards. After bending test (repeated bending 50 times), the aluminum foil is free of breakage and the longitudinal wrapping is free of delamination. The production efficiency is increased by 25% compared with the traditional process, and the defect rate is reduced from 8% to 1.2%, which fully meets the requirements for use of precision control cables.

[0038] Example 2: Regarding the outer diameter D of the cable core c =20mm cable Application scenario: Transmission cables in buildings, requiring good longitudinal sealing performance, moisture and water resistance, production line speed V=35m / min, overlap rate K=18%, using PE plastic layer conventional aluminum foil composite tape, mass production.

[0039] Strip selection (1) Thickness selection: D c=20mm (10<Dc≤30mm), a conventional aluminum-plastic composite strip with a total thickness t=0.15mm is selected.

[0040] (2) Width selection: β=1.08 (conventional strip, speed 35m / min, unwinding tension is relatively high, β is increased by 0.01), substitute into the formula W=β*π(D c +2t) / (1-K) =1.08×π×(20+2×0.15) / (1-0.18)≈83.99mm, and a strip with W=84mm is actually selected.

[0041] Die Selection (1) Preforming bell mouth die: Δ1=0.4mm, D1=20+2×0.15+0.4=20.7mm; t=0.15mm, δ=3.0mm (one side), production line speed 35m / min (allowance is increased by 0.5mm), B=84+2×3.0=90mm; ε=0.004, back-calculate to get A≈32° (meeting the condition that Dc≤30mm, A takes a value in the range of 25°-35°); L=(90-20.7) / (tan(32° / 2)) ≈70.3 / (2×0.445)≈241.7mm, and L=242mm is actually selected.

[0042] (2) Compacting and shaping die: Δ2=0.2mm, D2=20+2×0.15-0.2 =20.1mm, and D2=20.1mm is actually selected.

[0043] Longitudinal Wrapping Operation and Fine Adjustment (1) Operation parameters: unwinding tension 8N (conventional strip), hot-melt temperature 135℃ (PE layer), heating time 2s, lamination pressure 0.6MPa, and winding speed synchronized with each link (35m / min).

[0044] (2) Dynamic fine adjustment: In mass production, due to the tiny fluctuation of the cable core outer diameter (±0.1mm), when the vision module detects slight eccentricity of the longitudinal wrapping (deviation 0.08mm), the controller automatically triggers the fine adjustment of the X / Y axis of the die (X axis -0.04mm, Y axis +0.03mm), and synchronously fine-adjusts the unwinding tension to 7.8N to ensure coaxiality; when detecting that the lap overlap amount is too large (lap rate 20%), the controller automatically increases the tension to 8.2N to correct the lap rate to about 18%, so as to realize the stability of mass production.

[0045] Implementation Effect The finished product has good roundness, tight overlap, and no gaps or wrinkles; the moisture-proof test (immersion for 24 hours) showed no water ingress, and the sealing performance met the standards; during mass production, the defect rate remained stable below 0.8%, the production efficiency was increased by 30% compared with the traditional process, one operator was reduced (no manual fine-tuning required), and the production cost was significantly reduced.

[0046] Example 3: Regarding the outer diameter D of the cable core c =70mm cable Application scenario: High-voltage power transmission cable (110kV), requiring high longitudinal mechanical strength and good electromagnetic shielding effect, minimum allowable bending radius R=350mm, production line speed V=20m / min, overlap rate K=20%, using PET plastic layer thickened reinforced aluminum-plastic tape (tensile resistance, high temperature resistance).

[0047] Strip selection (1) Thickness selection: D c =70mm (D) c (>60mm), a thickened and reinforced aluminum-plastic composite strip with a total thickness of t=0.28mm is selected, which meets the thickness standard.

[0048] (2) Width selection: β=1.05 (thickened strip, speed 20m / min, PET material, β increases by 0.02), substitute into the formula W=β*π(D c +2t) / (1-K) =1.05×π×(70+2×0.28) / (1-0.20)≈290.9mm, and the actual selected strip is W=291mm.

[0049] Mold selection (1) Pre-formed flared mouth mold: Δ1=0.5mm, D1=70+2×0.28+0.5=71.06mm; t=0.28mm (thickened), δ=5.0mm (single side), PET material (δ takes the upper limit of the range), B=291+2×5.0=301mm; ε=0.003 (thickened strip), back-calculated A≈45° (consistent with the value of A being between 35° and 60° when Dc>30mm); L=(301-71.06) / tan(45° / 2)≈558.55mm, actually selected L=559mm.

[0050] (2) Pressing and shaping mold: Δ2=0.2mm, D2=70+2×0.28-0.2=70.36mm, and D2=70.4mm is actually selected.

[0051] Vertical wrapping and fine-tuning (1) Operating parameters: unwinding tension 10N (thickened strip), adopt the "low tension start, gradual pressure increase" mode, hot melt temperature 150℃ (PET layer), heating time 3s, pressing pressure 0.8MPa, winding speed synchronized with each stage (20m / min), pressing roller selected with high temperature resistant anti-slip texture (suitable for PET layer).

[0052] (2) Dynamic fine adjustment: During the production process, if the vision module mechanism detects local wrinkles in the strip (due to the thickened strip shrinking too quickly), the controller will automatically trigger tension fine adjustment (from 10N to 9.5N) and simultaneously fine adjust the forming angle of the flared die (A is finely adjusted from 72° to 70°), eliminating the wrinkles within 20 seconds; if the overlap is not sealed properly (small gap), the controller will simultaneously trigger tension fine adjustment (increased to 9.8N) and pressing pressure fine adjustment (increased to 0.85MPa) to ensure sealing performance.

[0053] Implementation effect The finished product is free of wrinkles and damage, with tight overlaps and meeting mechanical strength standards (tensile strength ≥ 65 N / mm²). 2 It meets the requirements of high-voltage power cables; after bending test, the longitudinal wrapping structure is not loose or delaminated; the production process is stable and the defect rate is controlled below 0.5%, solving the industry pain points of longitudinal wrapping wrinkles and poor sealing of large cross-section cables.

[0054] The process provided in this embodiment is optimized in two directions for tear resistance of thin strips (≤0.12mm) and wrinkle resistance of thick strips (≥0.25mm): the pre-formed flared mold for thin strips is formed at a small angle to reduce stress; the forming angle and tension of thick strips are finely adjusted to reduce the excessively fast shrinkage of thick strips, thus solving the industry pain points from both structural and process perspectives.

[0055] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A systematic longitudinal wrapping process for composite tape used in cables, characterized in that, Includes the following: The total thickness of the composite tape is determined based on the outer diameter of the cable core, and the width of the composite tape is determined based on the tensile compensation coefficient of the composite tape, the outer diameter of the cable core, the total thickness of the composite tape, and the target overlap ratio. The outlet inner diameter of the preformed flared mold is determined based on the outer diameter of the cable core and the total thickness of the composite strip. The inlet width of the preformed flared mold is determined based on the width of the composite strip. The forming angle of the preformed flared mold is determined based on the bending strain of the composite strip, the total thickness of the composite strip, and the outlet inner diameter of the preformed flared mold. The mold length of the preformed flared mold is also determined. The inner diameter of the compression mold is determined based on the radial compression amount, the outer diameter of the cable core, and the total thickness of the composite tape. The pre-formed flared mold is manufactured according to the determined inlet width, outlet inner diameter, forming angle, and mold length of the pre-formed flared mold, and the compacting mold is manufactured according to the determined inner diameter of the compacting mold. The pre-formed flared mouth mold and the compaction and shaping mold, which have been manufactured, are installed on the longitudinal packaging forming device; The cable is formed using the aforementioned longitudinal forming device.

2. The systematic longitudinal wrapping process of composite tape for cables according to claim 1, characterized in that, The longitudinal packaging forming device is also equipped with a visual inspection mechanism, a controller and a tension adjustment mechanism; The visual inspection mechanism is used to acquire information about the composite strip and send it to the controller; The controller is used to adjust the wire tension of the tension adjustment mechanism according to the condition of the composite tape.

3. The systematic longitudinal wrapping process for composite tape in cables according to claim 1, characterized in that, The total thickness of the composite strip is determined according to the following rules: When 2mm < the outer diameter of the cable core ≤ 10mm, the total thickness of the composite tape is between 0.08 and 0.12mm. When 10mm < the outer diameter of the cable core ≤ 30mm, the total thickness of the composite tape is between 0.12 and 0.18mm. When 30mm < the outer diameter of the cable core ≤ 60mm, the total thickness of the composite tape is between 0.18 and 0.25mm. When the outer diameter of the cable core is greater than 60 mm, the total thickness of the composite tape is greater than or equal to 0.25 mm.

4. The systematic longitudinal wrapping process of composite tape for cables according to claim 1, characterized in that, The formula for calculating the width W of the composite strip is: W=β*π(D c +2t) / (1-K) In the formula: t is the total thickness of the composite strip, K is the target overlap rate, the value of K ranges from 10% to 30%, β is the tensile compensation coefficient of the composite strip, and D... c The outer diameter of the cable core; The value of the composite tape tensile compensation coefficient is determined by the total thickness of the composite tape and the production line speed of the longitudinal wrapping forming device; When 2mm < the outer diameter of the cable core ≤ 30mm and the production line speed of the longitudinal wrapping forming device is greater than or equal to 35m / min, the value range of β is 1.04-1.12; When the outer diameter of the cable core is greater than 30 mm and the production line speed of the longitudinal wrapping forming device is less than or equal to 20 m / min, the value of β ranges from 1.01 to 1.

08.

5. The systematic longitudinal wrapping process for composite tape in cables according to claim 1, characterized in that, The outlet inner diameter of the pre-formed flared mold is D1: D1=D c +2t+Δ1 Where: t is the total thickness of the composite strip, Δ1 is the pre-formed gap, and D c The outer diameter of the cable core; The inlet width B of the pre-formed flared mold is based on the minimum inlet width B. min To confirm: B min =W+2δ B≥B min In the formula: W is the width of the composite strip, and δ is the lateral safety offset margin on one side, which is determined according to the variation of the total thickness of the composite strip: when the total thickness of the composite strip is ≤0.12mm, δ is 1.5~2.5mm; when the total thickness of the composite strip is 0.12~0.25mm, δ is 2.5~4mm; when the total thickness of the composite strip is ≥0.25mm, δ is 4~6mm; when the production line speed of the longitudinal packaging forming device is greater than 30m / min, δ is increased by 0.5~1mm; for thermoplastic polyester composite strips, δ is taken as the upper limit of the range.

6. The systematic longitudinal wrapping process for composite tape in cables according to claim 5, characterized in that, The relationship between the bending strain of the composite strip and the forming angle of the pre-formed flared mold is as follows: ε=(2t*sin(A / 2)) / D1 In the formula: ε is the bending strain of the composite strip, t is the total thickness of the composite strip, and A is the forming angle of the pre-formed flared mold; When the outer diameter of the cable core is ≤30mm, the value of A is 25°~35°; when the outer diameter of the cable core is >30mm, the value of A is 35°~60°. The mold length L of the preformed flared mold is calculated according to the following formula: L = (B - D1) / tan(A / 2).

7. The systematic longitudinal wrapping process for composite tape in cables according to claim 1, characterized in that, The formula for calculating the inner diameter D2 of the compression molding die is as follows: D2=D c +2t-Δ2 Among them, D c Δt is the outer diameter of the cable core, t is the total thickness of the composite tape, and Δ2 is the radial compression amount.

8. The systematic longitudinal wrapping process of composite tape for cables according to claim 2, characterized in that, The process of forming the cable using the longitudinal wrapping forming device includes the following: Unwinding and feeding: Install the composite tape onto the unwinding mechanism, start the unwinding mechanism, and unwind the composite tape; Guiding and leveling: The unwound composite tape is fed into a guiding mechanism to level the composite tape; Preforming process: The leveled composite strip is fed into the preforming flared mold, so that the composite strip gradually forms an arc-shaped structure that matches the preforming flared mold, thus completing the preforming process; Hot melt pretreatment: The pre-formed composite strip is fed into the hot melt mechanism to heat the plastic layer of the overlapping area of ​​the composite strip; Longitudinal wrapping and compression molding: The heated composite tape is fed into the compression molding mold, and the composite tape and cable core are compressed by the compression molding mold. After compression, the plastic layer is shaped by cooling. After being pressed and fixed, the longitudinally wrapped cable is finely tensioned by the tension adjustment mechanism and then sent to the winding mechanism.

9. The systematic longitudinal wrapping process for composite tape in cables according to claim 8, characterized in that, It also includes the following: The pre-formed flared mold is supported by a multi-dimensional motion mechanism, which is mounted on the frame of the longitudinal wrapping forming device. The visual inspection mechanism captures images of the composite belt and sends them to the controller. When the controller detects that the composite belt has an abnormal signal of overall eccentricity or serpentine shape, the controller controls the multi-dimensional motion mechanism to move to adjust the axial and radial positions of the preformed flared mold. The controller establishes a correlation logic between the overlapping state and the thread tension. The controller obtains the gap width at the longitudinal overlap and the wrinkling status of the composite tape in real time. When the controller detects that the overlap is narrowing or a gap appears, the controller reduces the thread tension of the tension adjustment mechanism. When the controller detects wrinkling of the composite tape, the controller reduces the feeding tension of the tension adjustment mechanism; when the controller detects that the composite tape is slack and the overlap is greater than a set value, the controller increases the feeding tension of the tension adjustment mechanism to achieve adaptive dynamic compensation of tension. After the position of the preformed flared mold is adjusted, the controller synchronously adjusts the tension parameters of the tension adjustment mechanism. When the controller detects that the composite belt is narrowing or has gaps, the controller controls the multi-directional motion mechanism and the tension adjustment mechanism to operate simultaneously.

10. The application of the systematic longitudinal wrapping process for composite tape in cables according to any one of claims 1-9, characterized in that, The longitudinal wrapping process applied to aluminum-plastic composite belts.