Mining tensile wear-resistant trailing cable and processing technology thereof

Abstract

The application belongs to the technical field of cables and specifically relates to a mining tensile wear-resistant trailing cable and a processing technology thereof, which comprises a core, and an inner sheath and an outer sheath are arranged outside the core; the inner sheath comprises chlorinated polyethylene, neoprene, magnesium oxide, zinc oxide, lead disulfate, lead trisulfate and high wear-resistant carbon black mixed at a weight ratio of 60-80:10-20:3-5:2-4:1-3:1-2:10-15; and the outer sheath comprises polyether type thermoplastic polyurethane elastomer, polytetrafluoroethylene and nano silicon dioxide mixed at a weight ratio of 100:8-12:5-10:3-6:1-3:0.5-1.5:1-2:8-15. The application uniformly heats the stable rotational flow field formed by the insulated core, so that the insulated layer and the sheath are more closely combined, and the uneven problems of the properties such as the internal fixed extension stress, resilience and wear resistance of the cable insulated layer are solved.

Description

Technical Field

[0001] This invention belongs to the field of cable technology, specifically relating to a mining tensile and wear-resistant drag cable and its processing technology. Background Technology

[0002] Tensile and abrasion-resistant drag cables, based on the traditional cable structure, incorporate a cross-linked polyethylene insulation inner layer and an outer sheath, thus possessing excellent tensile, torsional, abrasion, and cut resistance properties, making them widely applicable to harsh working conditions such as mines. Through anti-torsion stranding design and reinforcing layers, existing cables effectively prevent twisting and deformation during repeated winding, thereby stably supplying power to mining equipment such as loaders and electric shovels.

[0003] Existing cables adopt an inner and outer layered structure: the outer sheath relies on its own material properties to resist external pulling and torsion; the inner insulation layer is vulcanized to significantly improve the tensile strength, tensile stress, resilience and wear resistance of the rubber, while reducing permanent deformation, thus enabling it to withstand the mechanical stress generated during cable laying, bending and operation.

[0004] In the cable production process, the conductor is led out by the unloading device, preheated, and then enters the extruder head, where it is coated with ethylene propylene rubber to form an insulation layer. Subsequently, the insulated cable enters the vulcanization pipe to begin the cross-linking reaction.

[0005] When steam is used as the heat medium in the vulcanization pipeline, the steam is distributed to the outside of the insulation layer through a pre-designed flow channel. However, due to limitations imposed by the flow channel structure and steam flow state, it is difficult for the steam to form a uniform and stable swirling flow field around the insulation layer, resulting in uneven temperature distribution on the insulation layer surface. This uneven temperature distribution may further cause differences in the degree of local cross-linking, inducing unevenness on the insulation layer surface, leading to problems with the uniformity of properties such as tensile stress, resilience, and abrasion resistance within the cable insulation layer. Summary of the Invention

[0006] The purpose of this invention is to provide a mining tensile and wear-resistant drag cable and its processing technology, which can form a stable swirling field to uniformly heat the insulated core, making the insulation layer and sheath more tightly bonded, and solving the problem of uneven performance of the cable insulation layer in terms of tensile stress, resilience and wear resistance.

[0007] The specific technical solution adopted by this invention is as follows: A mining tensile and wear-resistant drag cable and its processing technology, comprising a conductor core, wherein the conductor core is provided with an inner sheath and an outer sheath. The inner sheath comprises chlorinated polyethylene, chloroprene rubber, magnesium oxide, zinc oxide, dibasic lead sulfate, tribasic lead sulfate, and high abrasion-resistant carbon black, mixed in a weight ratio of 60-80:10-20:3-5:2-4:1-3:1-2:10-15; the outer sheath comprises polyether thermoplastic polyurethane elastomer, polytetrafluoroethylene, nano-silica, nano-silicon carbide, coupling agent, antioxidant, lubricant, and carbon black, mixed in a weight ratio of 100:8-12:5-10:3-6:1-3:0.5-1.5:1-2:8-15.

[0008] A processing technology for a mining tensile and abrasion-resistant drag cable, the processing technology being used to prepare the cable as described above, the processing technology comprising the following steps: Tinned soft copper wire is twisted with aramid fiber rope to form a composite conductor core; Ethylene propylene rubber is extruded onto the outer surface of the composite conductor core using an extruder to obtain an insulated core. The insulated core is then sent to a vulcanization device for vulcanization treatment to obtain the treated insulated core. Semi-conductive nylon tape is wrapped around the outside of the treated insulated core, and a shielding layer of tinned copper wire and polyester wire is braided after wrapping to obtain a shielded insulated core. The power core, ground core, and monitoring core are twisted together around the shielded and insulated core to form a cable core. After cabling, a semi-conductive nylon tape is wrapped around the outside of the cable core to obtain a wrapped cable core; The modified chlorinated polyethylene composite material is extruded onto the outer surface of the cable core using an extruder to form an inner sheath layer; Aramid fiber braided tape is combined with a spiral metal compression core to form a composite tape. The composite tape is then wrapped around the outer surface of the inner sheath to form a composite tensile-strengthened cable core. Nano-modified polyether polyurethane composite material is extruded onto the outer surface of the composite tensile-strengthened cable core using an extruder to form an outer sheath layer; A composite coating material of liquid silicone rubber and nano-ceramic particles is uniformly coated on the outer surface of the outer sheath layer, and then cured by heating to form a wear-resistant coating, thereby obtaining the cable as described above.

[0009] A cable vulcanizing device, used for vulcanizing treatment in the processing described in claim , includes an extruder body and a die head, wherein the die head outlet is connected to a vulcanizing channel for circulating high-temperature steam to the insulated wire core, and further includes: The first swirl channel and the second swirl channel are disposed inside the vulcanization channel. The first swirl channel is provided with a first guiding fin along the tangential direction of the insulated wire core. The first guiding fin is used to guide high-temperature steam to form a swirling field around the insulated wire core inside the first swirl channel and the second swirl channel. A flow guide rotor is disposed inside the first swirling channel. The flow guide rotor includes a heating cylinder and a preheating cylinder welded together. A through hole is provided on the heating cylinder along the tangential direction of the insulated wire core. The swirling flow field flows along the first swirling channel, through hole, heating cylinder, second swirling channel and preheating cylinder, and its own pressure decreases during this flow process, so that the swirling flow field heats the insulated wire core uniformly. At the same time, the swirling flow field drives the guide rotor and the second swirling channel to rotate around the insulated wire core, thereby reducing the impact force of the swirling flow field on the insulated wire core.

[0010] As an alternative, the second swirl channel includes an arc-shaped base plate, a bent portion, and an arc-shaped movable guide plate welded sequentially to the inner wall of the heating cylinder, wherein a heat-sensitive elastic deformation member is welded between the bent portion and the adjacent arc-shaped movable guide plate; When the temperature of the heated elastic deformation part is lower than the preset vulcanization temperature, the distance between the arc-shaped substrate and the adjacent arc-shaped movable guide plate is used to limit the flow rate of the swirling field in contact with the insulated wire core. When the temperature of the heated elastic deformation member is not lower than the preset vulcanization temperature, the heated elastic deformation member expands and deforms, increasing the distance between the arc-shaped substrate and the adjacent arc-shaped movable guide plate, thereby increasing the flow rate of the swirling field in contact with the insulated wire core, and the temperature of the swirling field is not lower than the preset vulcanization temperature.

[0011] As an alternative, the preheating cylinder is funnel-shaped with its inner diameter increasing in the order away from the heating cylinder. The funnel-shaped inner cavity of the preheating cylinder is used to reduce the pressure of the swirling flow field and to guide the sulfide residue to slide into a designated area.

[0012] As an optional solution, the vulcanization channel includes a detachably connected feed cylinder and a discharge cylinder, wherein a first sealing gasket is embedded in the feed inlet of the feed cylinder and a second sealing gasket is embedded in the discharge outlet of the discharge cylinder. The feed cylinder is used for heating and preheating the insulated wire core, and the discharge cylinder is used for cooling the insulated wire core.

[0013] As an alternative, the first swirl channel includes a first partition, a second partition, and a heat insulation cover that are welded at intervals to the inner wall of the vulcanization channel; The first baffle, the second baffle, and the guide rotor form a closed space for the flow of the swirling flow field.

[0014] As an optional solution, the inside of the feed cylinder is provided with a slag receiving groove for receiving sulfide residue sliding down from the preheating cylinder, and an air inlet pipe and an exhaust pipe are connected through the feed cylinder. The slag receiving trough is connected to the exhaust pipe, and the air inlet pipe extends into the first vortex channel and is tangentially oriented towards the first guide fin along the insulating wire core.

[0015] As an optional solution, a third sealing gasket for straightening the insulated wire core is rotatably installed in the middle of the heating cylinder. The third sealing gasket has a frustum-shaped protrusion facing the outlet of the vulcanization channel, and the frustum-shaped protrusion of the third sealing gasket is used to guide cooling water away from the heating cylinder.

[0016] As an alternative, the thermo-elastic deformation component includes shape memory polyurethane and thermally expanded microspheres embedded in shape memory polyurethane; The thermally expandable microspheres include a thermoplastic resin shell and a foaming agent filler, wherein the foaming agent filler is at least one of liquid n-hexane, cyclohexane, isobutane, or isopentane.

[0017] The technical effects achieved by this invention are as follows: This invention provides a cable. This cable, through a multi-layered synergistic structural design consisting of a central aramid reinforcing core, a composite conductor, an aramid / metal composite tensile layer, a nano-modified polyether-type polyurethane outer sheath, and a ceramic particle wear-resistant coating, significantly outperforms ordinary mining drag cables in key indicators such as tensile strength, wear resistance, scratch resistance, and bending fatigue life, thus meeting the requirements for long-term use under harsh mining conditions.

[0018] This invention provides a cable processing technology. This technology, through the configuration of an outer sheath material, an inner sheath material, and a wear-resistant coating, produces a cable with a tensile strength of not less than 180 N / mm². 2 Scratch resistance not less than 1200 cycles, bending fatigue life not less than 8×10 4 This type of cable is designed to meet the long-term needs of harsh mining conditions. It addresses the issue of uneven performance in cable insulation, including variations in tensile stress, resilience, and abrasion resistance.

[0019] This invention provides a vulcanization device for cable processing. During vulcanization, high-temperature steam is dispersed through a dual-swirling channel to form a stable swirling field, which uniformly heats the insulated wire core, thus solving the problem of uneven performance in the cable insulation layer, such as tensile stress, resilience, and abrasion resistance.

[0020] This invention provides a vulcanization device for cable processing. During vulcanization, a heat-deformation structure is set in a dual-swirling channel, and the swirling flow field acts on the insulated wire core, increasing its flow rate, thereby achieving adaptive incremental adjustment of the high-temperature vulcanizing steam. At the same time, the swirling flow field, which has reached the preset vulcanization temperature, is arranged close to the insulated wire core to improve the uniformity of heating of the insulated wire core, thereby enhancing the operability of the vulcanization process.

[0021] This invention provides a vulcanization device for cable processing. During the vulcanization process, the funnel-shaped structure inside the swirling channel can reduce the pressure of the swirling field and can also be used to guide the sulfide residue to slide into a designated area. Attached Figure Description

[0022] Figure 1 This is a first cross-sectional view of a mining tensile and wear-resistant drag cable according to Embodiment 1 of the present invention; Figure 2 This is the invention Figure 1 A second cross-sectional view of a type of mining tensile and abrasion-resistant drag cable; Figure 3 This is a flowchart of the processing technology of a mining tensile and wear-resistant drag cable according to the present invention; Figure 4 This is a schematic diagram of the structure of a cable vulcanizing device according to Embodiment 5 of the present invention; Figure 5 This is the invention Figure 4 Schematic diagram of the structure of the sulfidation channel; Figure 6 This is the invention Figure 4 First cross-sectional view of the central vulcanization channel; Figure 7 This is the invention Figure 4 Second cross-sectional view of the vulcanization channel; Figure 8 This is the invention Figure 4 Exploded view of the sulfidation channel; Figure 9 This is the invention Figure 8 Schematic diagram of the structure of the central guide rotor; Figure 10 This is the invention Figure 8 Schematic diagram of the structure of the second vortex channel in the middle; Figure 11 This is the invention Figure 10 A schematic diagram of the structure of a heat-sensitive elastically deformable component.

[0023] The attached diagram lists the components represented by each number as follows: 101. First conductor core; 102. Second conductor core; 103. Insulation layer; 104. Semi-conductive shielding layer; 105. Inner sheath; 106. Third conductor core; 107. Reinforcing layer; 108. Outer sheath; 2. Extruder body; 201. Hopper; 202. Heated auger conveyor cylinder; 203. Extruder head; 3. Vulcanizing channel; 301. Feed cylinder; 302. First sealing gasket; 303. Air inlet pipe; 304. Exhaust pipe; 305. Discharge cylinder; 306. Second sealing gasket; 307. Slag receiving trough; 4. First swirl channel; 401. First baffle; 402. Second baffle; 403. First guide fins; 404. Heat insulation cover; 5. Guide rotor; 501. Heating cylinder; 502. Third sealing gasket; 503. Through hole; 504. Preheating cylinder; 6. Second vortex channel; 601. Arc-shaped substrate; 602. Bending part; 603. Arc-shaped movable guide plate; 604. Heat-sensitive elastic deformation part. Detailed Implementation

[0024] To make the objectives and advantages of this invention clearer, the invention will be specifically described below with reference to embodiments. It should be understood that the following text is merely used to describe one or more specific embodiments of the invention and does not strictly limit the scope of protection specifically claimed by the invention.

[0025] Example 1:

[0026] like Figures 1-2 As shown, a mining tensile and wear-resistant drag cable includes a first conductor 101, a second conductor 102, and a third conductor 106 twisted together. Before twisting, the first conductor 101, the second conductor 102, and the third conductor 106 are all covered with an insulation layer 103 by extrusion, and a semi-conductive shielding layer 104 is wrapped around the insulation layer 103. Then, the first conductor 101, the second conductor 102, and the third conductor 106 are twisted together to form a conductor core. The conductor core is then covered with an inner sheath 105 by extrusion, and a reinforcing layer 107 is wrapped around the inner sheath 105. Finally, an outer sheath 108 is extruded around the reinforcing layer 107 to obtain the tensile and wear-resistant drag cable.

[0027] See attached document Figure 1 and Figure 2 The first conductor 101 is configured as a power conductor. The power conductor consists of a tin-plated soft copper conductor, a semi-conductive rubber, an ethylene propylene rubber and an insulating shielding layer from the inside out. There are three first conductors 101, and the three first conductors 101 surround a central tensile reinforcing core. The reinforcing core is made of high-strength aramid fiber rope and tin-plated soft copper wire twisted together.

[0028] See attached document Figure 1 and Figure 2 The second conductor 102 is configured as a control conductor, used as a ground wire, and is twisted with a third conductor 106 for monitoring conductors.

[0029] See attached document Figure 1 and Figure 2 The semi-conductive shielding layer 104 is wrapped with a semi-conductive nylon tape around the outside of the cable core, and the semi-conductive shielding layer 104 is in direct contact with the insulation layer 103.

[0030] See attached document Figure 1 and Figure 2 The inner sheath 105 is made of a special modified chlorinated polyethylene material, which gives it wear-resistant properties.

[0031] See attached document Figure 2 The reinforcing layer 107 adopts, for example Figure 2 The aramid fiber braided tape shown by the dotted line is formed by the composite weaving of the spiral metal pressure-resistant core, which has both tensile and torsional resistance functions. When the cable is under tension, the spiral metal pressure-resistant core absorbs tensile energy through spiral extension, while preventing torsional damage to the cable during the winding process.

[0032] See attached document Figure 1 The reinforcing layer 107 adopts, for example Figure 1 The wrapping material shown in the line, the reinforcing layer 107 can be used as a ground wire.

[0033] See attached document Figure 1 and Figure 2 The outer sheath 108 is made of nano-modified polyether polyurethane (TPU) composite material, and the wear of nano-modified polyether polyurethane can be less than 10mm. 3 It can withstand long-term friction from ore without damage. The outer sheath 108 is coated with a composite coating of liquid silicone rubber and nano-ceramic particles. The liquid silicone rubber and nano-ceramic particle composite coating reduces the frictional resistance between the cable and the ground and equipment by utilizing the low coefficient of friction (≤0.3) of liquid silicone rubber. On the other hand, the nano-ceramic particles greatly improve the surface hardness and scratch resistance.

[0034] Example 2:

[0035] like Figure 3 As shown, a processing technology for a mining tensile and abrasion-resistant drag cable includes the following steps: Conductor and tensile core preparation: 99.99% annealed oxygen-free tin-plated soft copper wire is bundled together, and aramid fiber rope is stranded together as a central reinforcing element to form a composite conductor core of "aramid fiber rope + copper strand". In this process, aramid fiber rope is used as the central strand, and 4 to 8 strands of tin-plated soft copper wire are bundled around the central strand. The bundled pitch ratio is controlled between 10 and 14. After bundling, the wire is annealed in an annealing furnace at a temperature of 200℃ to 250℃ for 30 minutes to obtain the composite conductor core. Extrusion and vulcanization of insulation layer 103: Ethylene propylene rubber is extruded onto the outer surface of the composite conductor core through an extruder to form insulation layer 103, thus obtaining an insulated conductor core. The insulated conductor core is then sent to a vulcanization device for vulcanization treatment to obtain the treated insulated conductor core. Shielding layer preparation: A semi-conductive nylon tape is wrapped around the insulation layer of the treated insulated core to form a semi-conductive shielding layer 104 outside the insulation layer 103. A mixed shielding layer of tin-plated copper wire and polyester wire is then woven around the semi-conductive shielding layer 104 after wrapping. Cable core cabling: Three power cores, three ground cores and one monitoring core are twisted together around the composite conductor core to form a cable. The cable section diameter ratio is controlled between 8 and 10. Semi-conductive filler material is filled between each core to obtain the cable core. Among them, the power core, ground core and monitoring core are all formed by extruding and vulcanizing the insulation layer 103 and preparing the shielding layer, forming the insulation layer 103, semi-conductive nylon tape, tinned copper wire and polyester wire mixed shielding layer; Wadding preparation: A semi-conductive nylon tape is wrapped around the outside of the cable core after cabling. Inner sheath 105 extrusion: Modified chlorinated polyethylene composite material is extruded onto the outer surface of the wrapping layer using an extruder to form an inner sheath layer; The preparation method of the modified chlorinated polyethylene composite material is as follows: Step S101: Place 60 parts of chlorinated polyethylene and 10 parts of chloroprene rubber into a mixer at 75°C and plasticize for 2 to 3 minutes. Step S102: Add 3 parts magnesium oxide, 2 parts zinc oxide, 1 part dibasic lead sulfate, 1 part tribasic lead sulfate, and 10 parts high abrasion-resistant carbon black to the internal mixer, and continue mixing for 5 min to 8 min until uniform to obtain the compound. Step S103: Pass the compounded rubber compound through a two-roll mill 3 to 5 times, then sheet and cool to obtain the modified chlorinated polyethylene composite material. Composite tensile reinforcement layer 107 weaving: Aramid fiber filament braided tape and spiral metal pressure-resistant core are compositely woven to form a composite tape. The composite tape is wrapped around the outer wall of the inner sheath layer to form composite tensile reinforcement layer 107. Outer sheath 108 extrusion: Nano-modified polyether polyurethane composite material is extruded onto the outer surface of composite tensile reinforcing layer 107 using an extruder to form an outer sheath layer; The preparation method of the nano-modified polyether polyurethane composite material is as follows: Step S201: Add 100 parts of polyether thermoplastic polyurethane elastomer, 8 parts of polytetrafluoroethylene micro powder, 5 parts of nano silica, 3 parts of nano silicon carbide, 1 part of KH-550 coupling agent, 0.5 parts of 1010 antioxidant, 1 part of zinc stearate lubricant, and 8 parts of carbon black into a high-speed mixer. Stir the mixture at 800 rpm for 15 minutes at room temperature to ensure that all components are fully and evenly mixed to obtain a mixture. Step S202: The mixture is melt-blended and extruded through a twin-screw extruder at a temperature of 170℃~190℃ and granulated to obtain nano-modified polyether polyurethane composite material particles; Abrasion-resistant coating: Liquid silicone rubber and nano-ceramic particle composite coating material are uniformly coated on the outer surface of the outer sheath layer, and then cured by heating to form an abrasion-resistant coating, thereby obtaining the cable in Example 1; The preparation method of the wear-resistant coating is as follows: Step S301: Add 100 parts of liquid silicone rubber, 10 parts of nano alumina ceramic particles (particle size ≤ 50nm), 2 parts of crosslinking agent, and 0.5 parts of catalyst into a mixing tank, and stir the mixing tank at 500rpm for 20min at 25℃ to obtain a uniform composite coating slurry. Step S302: Apply the composite coating slurry evenly to the surface of the outer sheath layer by spraying or dipping, and control the coating thickness to be between 50μm and 100μm; Step S303: Transfer the cable with the composite coating paste to an oven at 120°C and cure for 30 minutes to allow the wear-resistant coating to form on the cable surface.

[0036] Example 3:

[0037] It is basically the same as Example 2, and the similarities are the same as in Example 2. The difference is that: The preparation method of modified chlorinated polyethylene composite material is as follows: Step M101: Place 70 parts of chlorinated polyethylene and 15 parts of chloroprene rubber into an internal mixer at 75°C and plasticize for 2 to 3 minutes. Step M102: Add 4 parts magnesium oxide, 3 parts zinc oxide, 2 parts dibasic lead sulfate, 1.5 parts tribasic lead sulfate, and 12.5 parts high abrasion-resistant carbon black to the internal mixer, and continue mixing for 5 to 8 minutes until uniform to obtain the compound. The preparation method of nano-modified polyether polyurethane composite material is as follows: Step M201: Add 100 parts of polyether thermoplastic polyurethane elastomer, 10 parts of polytetrafluoroethylene micro powder, 7.5 parts of nano silica, 4.5 parts of nano silicon carbide, 2 parts of KH-550 coupling agent, 1 part of 1010 antioxidant, 1.5 parts of zinc stearate lubricant, and 11.5 parts of carbon black into a high-speed mixer. Stir the mixture at 800 rpm for 15 minutes at room temperature to ensure that all components are fully and evenly mixed to obtain a mixture. The preparation method of the wear-resistant coating is as follows: Step M301: Add 100 parts of liquid silicone rubber, 15 parts of nano alumina ceramic particles (particle size ≤ 50nm), 3.5 parts of crosslinking agent, and 0.75 parts of catalyst into a mixing tank, and stir the mixing tank at 25°C and 500rpm for 20min to obtain a uniform composite coating slurry.

[0038] Example 4:

[0039] It is basically the same as Example 2, and the similarities are the same as in Example 2. The difference is that: The preparation method of modified chlorinated polyethylene composite material is as follows: Step N101: Place 80 parts of chlorinated polyethylene and 20 parts of chloroprene rubber into an internal mixer at 75°C and plasticize for 2 to 3 minutes. Step N102: Add 5 parts magnesium oxide, 4 parts zinc oxide, 3 parts dibasic lead sulfate, 2 parts tribasic lead sulfate, and 15 parts high abrasion-resistant carbon black to the internal mixer, and continue mixing for 5 to 8 minutes until uniform to obtain the compound. The preparation method of nano-modified polyether polyurethane composite material is as follows: Step N201: Add 100 parts of polyether thermoplastic polyurethane elastomer, 12 parts of polytetrafluoroethylene micro powder, 10 parts of nano silica, 6 parts of nano silicon carbide, 3 parts of KH-550 coupling agent, 1.5 parts of 1010 antioxidant, 2 parts of zinc stearate lubricant, and 15 parts of carbon black into a high-speed mixer. Stir the mixture at 800 rpm for 15 minutes at room temperature to ensure that all components are fully and evenly mixed to obtain a mixture. The preparation method of the wear-resistant coating is as follows: Step N301: Add 100 parts of liquid silicone rubber, 20 parts of nano alumina ceramic particles (particle size ≤ 50nm), 5 parts of crosslinking agent, and 1 part of catalyst into a mixing tank, and stir the mixing tank at 25℃ and 500rpm for 20min to obtain a uniform composite coating slurry.

[0040] To verify the tensile and abrasion resistance of the cables processed according to the above processing technology, the present invention took the cables processed in Examples 2 to 4 (at least 500 mm in length, with clamps installed at both ends) as samples A, B and C respectively. At the same time, commercially available ordinary mining drag cable was purchased as sample D (traditional neoprene rubber sheath + ordinary copper conductor structure). Tensile performance test, abrasion resistance test, scratch resistance test and bending fatigue test were carried out in sequence.

[0041] (a) Tensile property test Referring to GB / T 228.1 "Tension Test of Metallic Materials" and relevant standards for mining cables, a universal testing machine was used to conduct tensile tests on the cable samples. The tensile speed was 20 mm / min, and the maximum tensile force and elongation at break were recorded. Each group of samples was tested 5 times, and the average value was taken. The tensile performance test results are recorded in Table 1 below.

[0042] Table 1. Tensile property test results

[0043] (II) Wear resistance test Referring to GB / T 9867 "Determination of Abrasion Resistance of Vulcanized Rubber or Thermoplastic Rubber" and the abrasion resistance test standard for mining cables, the Taber abrasion tester was used for testing. Circular specimens with a diameter of 100 mm were cut from the outer sheath of the cable sample. For each specimen, a CS-10 grinding wheel was used to rub against it with a load of 500 g, a rotation speed of 60 r / min, and a total of 1000 revolutions. The mass loss before and after abrasion was calculated, and the test results of abrasion resistance were recorded in Table 2 below.

[0044] Table 2. Test results of wear resistance performance

[0045] (III) Scratch resistance test Referring to the scratch resistance test method for mining cables, a reciprocating scratch tester was used. The scratch head was a steel needle with a diameter of 1 mm, the load was 5 N, and the reciprocating frequency was 30 times / min. The number of reciprocating strokes until the sheath was damaged and the cable core was exposed was calculated. The test results of scratch resistance performance are recorded in Table 3 below.

[0046] Table 3. Results of scratch resistance test

[0047] (iv) Bending fatigue test Referring to the test standard for bending resistance of mining cables, repeated bending tests were conducted. For each sample, the bending radius was 10 times the outer diameter of the cable, the bending angle was ±90°, and the bending frequency was 30 times / min. The number of bends until the conductor broke or the sheath cracked was counted. The bending fatigue test results are recorded in Table 4 below.

[0048] Table 4 Results of Bending Fatigue Test

[0049] The experimental data above show that the present invention, through its multi-layered synergistic structural design of "central aramid reinforcing core + composite conductor + aramid / metal composite tensile layer + nano-modified TPU outer sheath + ceramic particle wear-resistant coating", significantly outperforms ordinary mining drag cables in key indicators such as tensile strength, wear resistance, scratch resistance, and bending fatigue life. In particular, the modified chlorinated polyethylene composite material, nano-modified polyether polyurethane composite material, and wear-resistant coating configured in the mass ratio of Example 3 enable the cable to have optimal performance and meet the requirements for long-term use under harsh mining conditions.

[0050] Example 5:

[0051] like Figures 4-11 As shown, a cable vulcanizing device is used for the vulcanization treatment of the insulated wire core in Examples 2 to 4, particularly for the vulcanization treatment of the insulation layer 103. The vulcanizing device includes an extruder body 2, which comprises a hopper 201, a heated auger conveyor cylinder 202, and a die head 203 connected in sequence. During cable processing, the composite conductor wire core is pulled through the die head 203, and ethylene propylene rubber granules are poured into the hopper 201 for heating and melting. The molten material is conveyed by an electric auger in the heated auger conveyor cylinder 202. Ethylene propylene rubber is melted and wrapped around the composite conductor core in the die head 203. The discharge port of the die head 203 is connected to a vulcanization channel 3 for circulating high-temperature steam to the insulated core. Under the action of high-temperature steam, the temperature of the insulation layer 103 in the vulcanization channel 3 is heated to a preset vulcanization temperature of 160°C or higher, so that the ethylene propylene rubber completes the cross-linking reaction. The pressure of the high-temperature steam in the vulcanization channel 3 is above 0.2 MPa. Under the action of high temperature and vulcanizing agent, cross-linking bonds are formed between the molecular chains of ethylene propylene rubber, forming a three-dimensional network structure.

[0052] As an optional embodiment, the vulcanization temperature is usually controlled at around 160°C to 180°C.

[0053] like Figure 4 and Figure 6 As shown, the vulcanization channel 3 is equipped with a first swirling channel 4, a guide rotor 5, and a second swirling channel 6. The guide rotor 5 draws in high-temperature steam, causing a swirling field to form inside the first swirling channel 4 and the second swirling channel 6, surrounding the insulated wire core. During operation, the swirling field flows along the first swirling channel 4, the guide rotor 5, and the second swirling channel 6, and its own pressure decreases during this flow. Thus, the swirling field uniformly heats the insulated wire core. At the same time, the swirling field drives the guide rotor 5 and the second swirling channel 6 to rotate around the insulated wire core, thereby reducing the impact force of the swirling field on the insulated wire core.

[0054] like Figure 5 , Figure 6 and Figure 8As shown, the vulcanization channel 3 includes a detachably connected feed cylinder 301 and discharge cylinder 305. A first sealing gasket 302 is embedded in the feed inlet of the feed cylinder 301, and a second sealing gasket 306 is embedded in the discharge outlet of the discharge cylinder 305. During operation, the extruded insulated wire core is passed laterally through the feed cylinder 301, the first sealing gasket 302, the discharge cylinder 305, and the second sealing gasket 306. High-temperature steam is introduced into the feed cylinder 301 to allow the ethylene propylene rubber to complete the cross-linking reaction. The feed cylinder 301 is used for heating and preheating the insulated wire core, and the discharge cylinder 305 is used for cooling the insulated wire core.

[0055] like Figure 5 , Figure 7 and Figure 9 As shown, the feed cylinder 301 has a slag receiving groove 307 inside for receiving sulfide residue that slides off the insulated wire core. An air inlet pipe 303 and an exhaust pipe 304 are connected through the feed cylinder 301. The slag receiving groove 307 is connected to the exhaust pipe 304. The air inlet pipe 303 extends into the first vortex channel 4 and is tangential to the insulated wire core.

[0056] like Figure 6 , Figure 8 and Figure 9 As shown, the first swirling channel 4 includes a first partition 401, a second partition 402, and a heat insulation cover 404, which are welded at intervals to the inner wall of the vulcanization channel 3. A first guide fin 403, which is welded to the guide rotor 5, is inserted tangentially between the first partition 401 and the second partition 402 along the insulating core. During operation, the first guide fin 403 is used to guide high-temperature steam to form a swirling field around the insulating core inside the first swirling channel 4 and the second swirling channel 6, thus preventing high-temperature steam from directly spraying onto the insulating core and causing unevenness on the surface of the insulation layer 103. At the same time, the first guide fin 403 drives the guide rotor 5 to rotate synchronously under the driving action of the high-temperature steam. In addition, the 12 first guide fins 403 are evenly distributed on the outside of the guide rotor 5, so that the swirling field is evenly distributed at the intervals of the first guide fins 403. Thus, the evenly distributed swirling field can evenly heat the insulating core, solving the problem of unevenness in the tensile stress, resilience, and wear resistance of the cable insulation layer 103.

[0057] According to the above structure, the first partition 401, the second partition 402, the heat insulation cover 404 and the guide rotor 5 form a closed space for the flow of the swirling field, so that the swirling field is accurately distributed in the first swirling channel 4 and the second swirling channel 6.

[0058] It should be noted that the first flow-guiding fin 403 is connected to the first partition 401 and the second partition 402 via an annular slide rail. The heat insulation cover 404 is made of materials such as rock wool and vacuum plate, which can reduce the heat loss from the swirling flow field to the outside.

[0059] like Figure 6 , Figure 8 and Figure 9 As shown, the guide rotor 5 includes a heating cylinder 501 and a preheating cylinder 504 welded together. During installation, the heating cylinder 501 is embedded in the middle of the first partition 401 and the second partition 402 through a sealed bearing. The second swirling channel 6 is disposed inside the heating cylinder 501. During operation, the swirling field provides thrust, causing the heating cylinder 501, the preheating cylinder 504, and the second swirling channel 6 to rotate synchronously, maintaining the swirling field around the insulated wire core, and applying centrifugal force to the sulfide residue that falls off the insulated wire core. As a result, the sulfide residue slides along the preheating cylinder 504 into the slag receiving groove 307 for centralized collection.

[0060] like Figure 6 , Figure 8 and Figure 9 As shown, the preheating cylinder 504 is funnel-shaped and its inner diameter increases in order away from the heating cylinder 501. The internal volume of the heating cylinder 501 is smaller than the internal volume of the preheating cylinder 504, so that the swirling flow field gradually disperses after entering the preheating cylinder 504 from the heating cylinder 501. This allows the funnel-shaped inner cavity of the preheating cylinder 504 to reduce the pressure of the swirling flow field. The funnel-shaped inner cavity of the preheating cylinder 504 can also be used to guide the sulfide residue to slide into the designated area.

[0061] like Figure 6 , Figure 8 and Figure 9 As shown, a third sealing washer 502 for straightening the insulated wire core is rotatably installed in the middle of the heating cylinder 501. During operation, the insulated wire core passes through the middle of the third sealing washer 502. At the same time, the third sealing washer 502 protrudes in a frustum shape towards the outlet of the vulcanization channel 3. The frustum-shaped protrusion of the third sealing washer 502 is used to divert cooling water away from the heating cylinder 501 and prevent condensate from seeping into the second vortex channel 6 along the middle hole of the third sealing washer 502.

[0062] like Figure 6 , Figure 10 and Figure 11 As shown, the second swirl channel 6 includes an arc-shaped base plate 601, a bent portion 602, and an arc-shaped movable guide plate 603, which are sequentially welded to the inner wall of the heating cylinder 501. A heat-sensitive elastic deformation member 604 is welded between the bent portion 602 and the adjacent arc-shaped movable guide plate 603. During installation, the arc-shaped base plate 601, made of alloy steel, is first welded to the inner wall of the heating cylinder 501. Then, the bent portion 602 and the arc-shaped movable guide plate 603, made of shape memory alloy, are sequentially welded to the end face of the arc-shaped base plate 601. When welding the heat-sensitive elastic deformation member 604, each arc-shaped movable guide plate 603 needs to be pressed with the same constant force to achieve the minimum adjustment of the swirl flow field at the interval of the arc-shaped movable guide plate 603. When the temperature of the heat-exposed elastic deformation member 604 is lower than the preset vulcanization temperature, the distance between the arc-shaped substrate 601 and the adjacent arc-shaped movable guide plate 603 remains small, which can limit the flow rate of the swirling field in contact with the insulated wire core. When the temperature of the heat-exposed elastic deformation member 604 is not lower than the preset vulcanization temperature, the heat-exposed elastic deformation member 604 expands and deforms, increasing the distance between the arc-shaped substrate 601 and the adjacent arc-shaped movable guide plate 603, thereby increasing the flow rate of the swirling field in contact with the insulated wire core, and the temperature of the swirling field is not lower than the preset vulcanization temperature.

[0063] like Figure 6 , Figure 10 and Figure 11 As shown, the heat-sensitive elastic deformable component 604 includes shape memory polyurethane and thermally expanded microspheres embedded in the shape memory polyurethane. During production, the shape memory polyurethane is molded into a cage structure using a mold. This cage structure is used to hold the thermally expanded microspheres. The thermally expanded microspheres include a thermoplastic resin shell and a foaming agent filler. The foaming agent filler is at least one of liquid n-hexane, cyclohexane, isobutane, or isopentane. When the high-temperature steam temperature reaches 160°C, the foaming agent filler inside the thermally expanded microspheres expands and deforms by about 5 times, causing the shape memory polyurethane to elongate and deform. This reduces the tension of the heat-sensitive elastic deformable component 604 on the adjacent arc-shaped movable guide plate 603, increases the distance between the arc-shaped base plate 601 and the adjacent arc-shaped movable guide plate 603, and the swirling flow field acts on the insulated wire core, increasing its flow rate, thereby achieving adaptive incremental adjustment of the high-temperature steam for vulcanization. At the same time, the swirling flow field, which has reached the preset vulcanization temperature, is arranged close to the insulated wire core to improve the uniformity of heating of the insulated wire core, thereby enhancing the operability of the vulcanization treatment of the insulated wire core.

[0064] As an optional embodiment, a screen is welded inside the through hole 503, which can reduce the steam impact force and also block the sulfides from falling cables.

[0065] The above description is merely an optional embodiment of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described or explained in this invention, unless otherwise specified or limited, shall be implemented according to conventional means in the art.

Claims

1. A mining tensile and abrasion-resistant drag cable, comprising a conductor, characterized in that: The conductor is provided with an inner sheath (105) and an outer sheath (108). The inner sheath (105) comprises chlorinated polyethylene, chloroprene rubber, magnesium oxide, zinc oxide, dibasic lead sulfate, tribasic lead sulfate, and high abrasion-resistant carbon black in a weight ratio of 60-80:10-20:3-5:2-4:1-3:1-2:10-15; the outer sheath (108) comprises polyether thermoplastic polyurethane elastomer, polytetrafluoroethylene, nano-silica, nano-silicon carbide, coupling agent, antioxidant, lubricant, and carbon black in a weight ratio of 100:8-12:5-10:3-6:1-3:0.5-1.5:1-2:8-15.

2. A processing technology for a mining tensile and wear-resistant drag cable, characterized in that, The processing technology is used to manufacture the cable as described in claim 1, and the processing technology includes the following steps: Tinned soft copper wire is twisted with aramid fiber rope to form a composite conductor core; Ethylene propylene rubber is extruded onto the outer surface of the composite conductor core using an extruder to obtain an insulated core. The insulated core is then sent to a vulcanization device for vulcanization treatment to obtain the treated insulated core. Semi-conductive nylon tape is wrapped around the outside of the treated insulated core, and a shielding layer of tinned copper wire and polyester wire is braided after wrapping to obtain a shielded insulated core. The power core, ground core, and monitoring core are twisted together around the shielded and insulated core to form a cable core. After cabling, a semi-conductive nylon tape is wrapped around the outside of the cable core to obtain a wrapped cable core; The modified chlorinated polyethylene composite material is extruded onto the outer surface of the cable core using an extruder to form an inner sheath layer; Aramid fiber braided tape is combined with a spiral metal compression core to form a composite tape. The composite tape is then wrapped around the outer surface of the inner sheath to form a composite tensile-strengthened cable core. Nano-modified polyether polyurethane composite material is extruded onto the outer surface of the composite tensile-strengthened cable core using an extruder to form an outer sheath layer; A composite coating material of liquid silicone rubber and nano-ceramic particles is uniformly coated on the outer surface of the outer sheath layer, and then cured by heating to form a wear-resistant coating, thereby obtaining the cable as described in claim 1.

3. A cable vulcanizing device, according to claim 1, a mining tensile and wear-resistant drag cable and its processing technology, wherein the vulcanizing device is used for vulcanizing treatment in the processing technology as described in claim 2, comprising an extruder body (2) and a die head (203), wherein the discharge port of the die head (203) is connected to a vulcanizing channel (3) for circulating high-temperature steam to the insulated wire core, characterized in that, Also includes: The first swirling channel (4) and the second swirling channel (6) are disposed inside the vulcanization channel (3). The first swirling channel (4) is provided with a first guiding fin (403) tangentially installed inside the first swirling channel (4) along the insulating core. The first guiding fin (403) is used to guide high-temperature steam to form a swirling field around the insulating core inside the first swirling channel (4) and the second swirling channel (6). A flow guide rotor (5) is disposed inside the first swirling channel (4). The flow guide rotor (5) includes a heating cylinder (501) and a preheating cylinder (504) welded together. A through hole (503) is provided on the heating cylinder (501) along the tangential direction of the insulated wire core. The swirling flow field flows along the first swirling channel (4), through hole (503), heating cylinder (501), second swirling channel (6) and preheating cylinder (504), and its own pressure is reduced during this flow process, so that the swirling flow field heats the insulating wire core uniformly. At the same time, the swirling flow field drives the guide rotor (5) and the second swirling channel (6) to rotate around the insulating wire core, thereby reducing the impact force of the swirling flow field on the insulating wire core.

4. The cable vulcanizing equipment according to claim 3, characterized in that: The second vortex channel (6) includes an arc-shaped base plate (601), a bent portion (602) and an arc-shaped movable guide plate (603) welded sequentially to the inner wall of the heating cylinder (501). A heat-sensitive elastic deformation member (604) is welded between the bent portion (602) and the adjacent arc-shaped movable guide plate (603). When the temperature of the heat-exposed elastic deformation member (604) is lower than the preset vulcanization temperature, the distance between the arc-shaped substrate (601) and the adjacent arc-shaped movable guide plate (603) is used to limit the flow rate of the swirling field in contact with the insulated wire core. When the temperature of the heat-exposed elastic deformation member (604) is not lower than the preset vulcanization temperature, the heat-exposed elastic deformation member (604) expands and deforms, increasing the distance between the arc-shaped substrate (601) and the adjacent arc-shaped movable guide plate (603), thereby increasing the flow rate of the swirling field in contact with the insulated wire core, and the temperature of the swirling field is not lower than the preset vulcanization temperature.

5. The cable vulcanizing equipment according to claim 3, characterized in that: The preheating cylinder (504) is funnel-shaped and its inner diameter increases in order away from the heating cylinder (501). The funnel-shaped inner cavity of the preheating cylinder (504) is used to reduce the pressure of the swirling flow field and to guide the sulfide residue to slide into the designated area.

6. The cable vulcanizing equipment according to claim 3, characterized in that: The vulcanization channel (3) includes a detachably connected feed cylinder (301) and a discharge cylinder (305). A first sealing gasket (302) is embedded in the feed port of the feed cylinder (301), and a second sealing gasket (306) is embedded in the discharge port of the discharge cylinder (305). The feed cylinder (301) is used for heating and preheating the insulated wire core, and the discharge cylinder (305) is used for cooling the insulated wire core.

7. The cable vulcanizing equipment according to claim 3, characterized in that: The first swirl channel (4) includes a first partition (401), a second partition (402) and a heat shield (404) welded at intervals to the inner wall of the vulcanization channel (3). The first partition (401), the second partition (402), and the guide rotor (5) form a closed space for the flow of the swirling flow field.

8. The cable vulcanizing equipment according to claim 6, characterized in that: The feed cylinder (301) has a slag receiving groove (307) for receiving sulfide residues that slide down from the preheating cylinder (504). An air inlet pipe (303) and an exhaust pipe (304) are connected through the feed cylinder (301). The slag receiving groove (307) is connected to the exhaust pipe (304), and the air inlet pipe (303) extends into the interior of the first vortex channel (4) and is tangentially oriented toward the first guide fin (403) along the insulating core.

9. The cable vulcanizing equipment according to claim 3, characterized in that: A third sealing gasket (502) for straightening the insulated wire core is rotatably installed in the middle of the heating cylinder (501). The third sealing gasket (502) is convex in the shape of a frustum facing the outlet of the vulcanization channel (3). The frustum-shaped protrusion of the third sealing gasket (502) is used to guide cooling water away from the heating cylinder (501).

10. A cable vulcanizing device according to claim 4, characterized in that: The heat-sensitive elastic deformation component (604) includes shape memory polyurethane and thermally expanded microspheres embedded in shape memory polyurethane; The thermally expandable microspheres include a thermoplastic resin shell and a foaming agent filler, wherein the foaming agent filler is at least one of liquid n-hexane, cyclohexane, isobutane, or isopentane.

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