An energy-saving steel-cored aluminum stranded conductor for extra-high voltage and a preparation device and process thereof

Abstract

The application discloses an energy-saving steel-cored aluminum stranded wire for extra-high voltage and a preparation device and process thereof, and relates to the technical field of steel-cored aluminum stranded wires, which comprises a frame stranding machine, the frame stranding machine comprises a shell, a rotating disc is rotatably connected to the shell, a main shaft is arranged at the shaft center of the rotating disc, a wire guide roller assembly and a wire penetrating hole penetrating through the rotating disc are arranged on the sidewall of the rotating disc. The wire guide roller assembly, the compensation assembly and the wire penetrating hole are arranged, on one hand, the second elastic member absorbs the impact force and guides the aluminum single wire to return to the correct path, preventing the aluminum single wire from directly sliding and rubbing with the wire penetrating hole wall; on the other hand, the pressure sensor detects the contact pressure in real time, and the signal of the displacement sensor is combined to realize the online automatic determination of whether the first elastic member is attenuated and whether the main guide wheel is worn.

Description

Technical Field

[0001] This invention relates to the field of steel-cored aluminum stranded wire technology, and in particular to an energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications, as well as its preparation apparatus and process. Background Technology

[0002] With the development of ultra-high voltage power transmission technology, the requirements for the smoothness and roundness of conductor surfaces are becoming increasingly stringent. Large-section steel-cored aluminum stranded wires are used in 500kV and above ultra-high voltage transmission lines, and their smoothness and roundness have a decisive impact on corona performance. The frame stranding machine is the core equipment in the production of steel-cored aluminum stranded wires. Its wire-passing system (including wire-passing holes, wire-passing guide rollers, paralleling molds, etc.) is in direct contact with the high-speed moving aluminum single wire. Therefore, the quality of the wire-passing system directly affects the corona characteristics of steel-cored aluminum stranded wires.

[0003] In some existing technologies, the guide roller is directly fixed to the mounting bracket (distributor or support), and there is rigid contact between the guide roller and the aluminum wire. However, during the stranding process of the wire stranding machine, when the aluminum wire passes through the guide roller after being released from the reel, it inevitably bounces up and down due to various factors such as tension fluctuations, decreasing reel radius, and centrifugal force generated by the rotation of the winding cage. Rigid contact not only causes wear and scratches on the grooves of the guide roller but also scratches on the surface of the aluminum wire. Therefore, some existing technologies use elastic elements at the ends of the guide roller to prevent this. The wire guide roller and the aluminum wire are in elastic contact. When the aluminum wire bounces up and down, this impact force acts on the elastic element through the wire guide roller, causing the elastic element to compress and absorb the impact force. However, when the guide roller retracts due to the compression of the elastic element, the spatial position of the guide roller changes, causing the axis of the aluminum single wire downstream of the guide roller to shift. When the axis shift exceeds the design gap between the guide roller and the downstream wire hole, the aluminum single wire comes into direct contact with the wall of the wire hole, generating sliding friction. This not only causes wear on the surface of the aluminum single wire, but also generates a large amount of particulate aluminum chips, which in turn exacerbates the deterioration of the surface quality.

[0004] Furthermore, under continuous cyclic loads, the elastic element will experience elasticity decay or permanent deformation, leading to a gradual degradation of its stiffness and a gradual loss of pre-compression. Creep of the elastic element will cause the working position of the guide wheel to gradually drift, and the contact state between the aluminum single wire and the guide wheel will continue to deteriorate, ultimately resulting in the loss of control over the surface quality of the steel-cored aluminum stranded wire. At the same time, when the aluminum single wire passes through the guide wheel at high speed, the impact force of the up-and-down jumping and the friction force of high-speed movement will cause wear or grooving on the surface of the guide wheel groove. When the aluminum wire passes through the damaged guide wheel, it will also affect its surface quality.

[0005] The inspection of whether the elastic element has creeped and whether the guide wheel groove is worn usually requires a special maintenance period. The operator has to stop the machine and carry out manual inspection. With dozens of wire guide wheels in the frame stranding machine, this inspection method is not only time-consuming and labor-intensive, but also seriously affects the production efficiency of steel-cored aluminum stranded wire.

[0006] To address these issues, this invention proposes an energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications, along with its preparation apparatus and process. Summary of the Invention

[0007] The purpose of this invention is to provide an energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications, as well as its preparation apparatus and process, to solve the technical problems mentioned in the background art.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a device for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage, comprising a frame stranding machine, the frame stranding machine comprising a housing, a turntable rotatably connected to the housing, a main shaft being provided at the axis of the turntable, and a wire guide wheel assembly and a wire through hole being provided on the side wall of the turntable; The wire guide roller assembly includes a first elastic element and a displacement sensor. The wire guide roller assembly can absorb the jumping impact force of the aluminum single wire. A compensation component is provided in the wire hole. The compensation component includes a second elastic element and a pressure sensor. When the aluminum single wire deviates from its axis, the compensation component can compensate and guide the aluminum single wire.

[0009] Preferably, the guide wheel assembly further includes a connecting frame that is slidably connected to the side wall of the turntable, a main guide wheel is rotatably connected to the end of the connecting frame, a limit plate is fixedly connected to the side wall of the turntable, the first elastic element is located between the limit plate and the connecting frame, a limit rod that penetrates the limit plate is fixedly connected to the connecting frame, and a displacement sensor is installed on the limit plate to monitor the displacement of the limit rod.

[0010] Preferably, the wire hole is an oblong groove, and the compensation component further includes a mounting groove formed inside the wire hole. A connecting block is slidably connected in the mounting groove. The pressure sensor is disposed at the end of the mounting groove. A pressure block is disposed on one side of the pressure sensor. The second elastic element is located between the pressure block and the connecting block. A limiting groove is formed on the side wall of the mounting groove. A protrusion matching the limiting groove is disposed on the side wall of the connecting block. A mounting bracket is disposed on the side of the connecting block away from the second elastic element. A compensation guide wheel is rotatably connected to the mounting bracket. A compensation gap is formed between the contact surface of the compensation guide wheel and the aluminum single wire.

[0011] Preferably, the turntable is further provided with a control unit, which is electrically connected to the displacement sensor and pressure sensor in the multiple wire guide wheel assemblies and multiple compensation assemblies, and adjacent displacement sensors and pressure sensors form a detection group, each of which is used to detect a single aluminum wire.

[0012] Preferably, the control unit determines the fault status of the guide roller assembly based on the real-time signals from the displacement sensor and pressure sensor in the same detection group in the following manner: When the displacement sensor's detection value continues to increase and cannot be reset, and the pressure sensor's detection value also continues to increase, the control unit determines that the first elastic element has experienced elastic force attenuation. When the pressure sensor reading increases while the displacement sensor reading remains unchanged, the control unit determines that the drive wheel is worn.

[0013] Preferably, the connecting block is provided with a sliding groove, the mounting frame is provided with a slide rail that is slidably connected to the connecting block, and a telescopic component is provided at the end of the slide rail away from the main guide wheel. The telescopic component is externally connected to a hydraulic drive component through a pipe. The hydraulic drive component can drive the mounting frame and the compensating guide wheel to move along the axis of the main shaft through the telescopic component.

[0014] Preferably, the connecting frame is provided with an inclined surface, and the mounting frame is provided with two symmetrically distributed connecting rods at the end near the main guide wheel. The end of the connecting rod away from the mounting frame is in contact with the inclined surface. When the telescopic component drives the mounting frame to move to one side of the main guide wheel, the connecting frame can move towards the direction of the limiting plate under the action of the inclined surface and the connecting rods.

[0015] Preferably, the turntable is provided with a plurality of circumferentially distributed feeding grooves, and a plurality of equidistant feeding positions are provided in the feeding grooves. A material cylinder wound with aluminum single wire is installed in each of the plurality of feeding positions. Multiple material discharge positions located in the same axial position form a control group. The hydraulic drive includes a hydraulic cylinder fixedly connected to the frame winch. A piston rod is slidably connected inside the hydraulic cylinder. A hydraulic rod is fixedly connected to one end of the piston rod that extends out of the hydraulic cylinder. Multiple connecting pipes are provided on the circumferential side of the hydraulic cylinder. Each connecting pipe is equipped with a valve. Each valve is connected to multiple telescopic components in the same control group through a pipe.

[0016] A manufacturing process for energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications includes the following steps: S100: Galvanized steel wire is drawn and heat-treated to form a steel core; S200: Electrical aluminum ingots are continuously cast and rolled into aluminum rods, and then drawn and annealed to produce aluminum single wires. S300: Install multiple barrels wound with aluminum single wire in a frame stranding machine, and pass the steel core through the center of the main shaft of the frame stranding machine; S400: Lead the aluminum single wire out from the barrel and pass it through the wire guide roller assembly and the wire hole set on the frame stranding machine in sequence; S500: Based on the real-time signals from the displacement sensor and pressure sensor, determine the current fault status of the wire guide wheel assembly to provide feedback on the surface damage status of the aluminum wire. S600: The aluminum single wire, after being compensated and guided, is led to the area around the steel core through a distribution plate, and then subjected to multi-layer concentric stranding under the action of a frame stranding machine to obtain energy-saving steel-core aluminum stranded wire for ultra-high voltage applications.

[0017] An energy-saving steel-cored aluminum stranded wire for ultra-high voltage is prepared using the aforementioned preparation process for an energy-saving steel-cored aluminum stranded wire for ultra-high voltage.

[0018] The beneficial effects of this invention are: This invention utilizes a guide roller assembly, a compensation component, and a threading hole. The compensation component is installed within the threading hole. Under normal conditions, the compensation guide roller in the compensation component forms a compensation gap with the aluminum wire, preventing contact between the guide roller and the aluminum wire during normal passage. This avoids daily wear caused by prolonged contact and prevents the guide roller from causing additional scratches or friction damage to the aluminum wire surface. Only when the axial offset of the aluminum wire exceeds the compensation gap due to fluctuations in wire tension or creep of the elastic element does the compensation guide roller contact the aluminum wire. This allows the second elastic element to absorb the impact force and guide the aluminum wire back to its normal position. The correct path prevents the aluminum wire from sliding and rubbing directly against the hole wall, thus avoiding aluminum chips and surface wear. The dual guidance of the main guide wheel and the compensating guide wheel prevents excessive axial offset of the aluminum wire. Furthermore, a pressure sensor monitors the contact pressure in real time, and combined with signals from a displacement sensor, enables online automatic determination of whether the first elastic element has experienced elasticity decay and whether the main guide wheel has worn. This achieves online real-time monitoring and automatic fault diagnosis of the wire guide wheel assembly, significantly shortening the fault detection time and preventing the continuous deterioration of the aluminum wire surface due to undetected creep of the elastic element or wear of the guide wheel. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the frame stranding machine of the present invention.

[0020] Figure 2 This is a three-dimensional structural diagram of the frame stranding machine of the present invention.

[0021] Figure 3 This is a cross-sectional schematic diagram of the guide wheel assembly and compensation assembly of the present invention.

[0022] Figure 4 for Figure 3 A magnified view of a portion of point A in the middle.

[0023] Figure 5 This is a schematic diagram showing the fit between the connecting rod and the inclined surface of the present invention.

[0024] Figure 6This is a cross-sectional schematic diagram of the structure after the compensating guide wheel replaces the main guide wheel in this invention.

[0025] Figure 7 for Figure 6 A magnified view of a portion of point B in the middle.

[0026] Figure 8 This is a schematic diagram of the structure of the hydraulic drive component of the present invention.

[0027] The attached figures are labeled as follows: 1. Aluminum single wire; 2. Frame stranding machine; 21. Housing; 22. Turntable; 23. Main shaft; 24. Feed chute; 3. Guide roller assembly; 31. First elastic element; 32. Displacement sensor; 33. Connecting frame; 331. Inclined surface; 34. Main guide roller; 35. Limiting plate; 36. Limiting rod; 4. Threading hole; 5. Compensation component; 51. Second elastic element; 52. Pressure sensor; 53. Mounting groove; 54. Connecting block; 55. Pressure block; 56. Mounting bracket; 561. Slide rail; 57. Compensation guide wheel; 58. Connecting rod; 6. Telescopic components; 7. Hydraulic drive components; 71. Hydraulic cylinder; 72. Hydraulic rod; 73. Valve. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example 1

[0029] During the stranding process of a frame stranding machine, when the aluminum single wire passes through the guide roller after being released from the wire reel, it inevitably bounces up and down due to various factors such as fluctuations in wire tension, decreasing reel radius, and centrifugal force generated by the rotation of the winding cage. Rigid contact not only causes wear and scratches on the grooves of the guide roller, but also scratches on the surface of the aluminum wire. Therefore, some existing technologies use elastic elements at the end of the guide roller to make elastic contact between the guide roller and the aluminum wire. When the aluminum wire bounces up and down, the impact force acts on the elastic element through the guide roller, causing the elastic element to compress and absorb the impact force. However, when the guide roller retracts due to the compression of the elastic element, the spatial position of the guide roller changes, causing the axis of the aluminum single wire downstream of the guide roller to shift. When the axis shift exceeds the design gap between the guide roller and the downstream wire hole, the aluminum single wire comes into direct contact with the wall of the wire hole, generating sliding friction. This not only causes wear on the surface of the aluminum single wire, but also generates a large amount of particulate aluminum chips, which further exacerbates the deterioration of surface quality.

[0030] Furthermore, under continuous cyclic loads, the elastic element will experience elasticity decay or permanent deformation, leading to a gradual degradation of its stiffness and a gradual loss of pre-compression. Creep of the elastic element will cause the working position of the guide wheel to gradually drift, and the contact state between the aluminum single wire and the guide wheel will continue to deteriorate, ultimately resulting in the loss of control over the surface quality of the steel-cored aluminum stranded wire. At the same time, when the aluminum single wire passes through the guide wheel at high speed, the impact force of the up-and-down jumping and the friction force of high-speed movement will cause wear or grooving on the surface of the guide wheel groove. When the aluminum wire passes through the damaged guide wheel, it will also affect its surface quality.

[0031] The inspection of whether the elastic element has creeped and whether the guide wheel groove is worn usually requires a special maintenance period. The operator has to stop the machine and carry out manual inspection. With dozens of wire guide wheels in the frame stranding machine, this inspection method is not only time-consuming and labor-intensive, but also seriously affects the production efficiency of steel-cored aluminum stranded wire.

[0032] This embodiment was invented to solve the above problems.

[0033] Please see Figures 1 to 8 As shown, an embodiment of the present invention provides a device for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications, including a frame stranding machine 2. The frame stranding machine 2 includes a housing 21, a turntable 22 rotatably connected to the housing 21, a main shaft 23 disposed at the axis of the turntable 22, and a wire guide wheel assembly 3 and a wire through hole 4 penetrating the turntable 22 disposed on the side wall of the turntable 22. The wire guide wheel assembly 3 includes a first elastic element 31 and a displacement sensor 32. The wire guide wheel assembly 3 can absorb the jumping impact force of the aluminum single wire 1. The wire hole 4 is provided with a compensation component 5. The compensation component 5 includes a second elastic element 51 and a pressure sensor 52. When the aluminum single wire 1 deviates from its axis, the compensation component 5 can compensate and guide the aluminum single wire 1.

[0034] Furthermore, a through groove is provided in the main shaft 23, and a steel core is inserted through the through groove. The turntable 22 includes two symmetrically arranged discs and a plurality of mounting plates fixedly arranged between the two discs. The plurality of mounting plates are evenly distributed around the axis of the main shaft, and a plurality of evenly distributed feeding grooves 24 are formed between the plurality of mounting plates. A plurality of equidistant feeding positions are provided in the feeding grooves 24, and a material cylinder wound with aluminum single wire 1 is installed in each feeding position. The structure of the above frame stranding machine 2 is all prior art and will not be described in detail.

[0035] Furthermore, the guide wheel assembly 3 also includes a connecting frame 33 that is slidably connected to the side wall of the disc. A connecting groove is provided on the side wall of the turntable 22. A card plate matching the connecting groove is provided on the connecting frame 33. A main guide wheel 34 is rotatably connected to the end of the connecting frame 33. A limiting plate 35 is fixedly connected to the side wall of the turntable 22. The first elastic element 31 is located between the limiting plate 35 and the connecting frame 33. A limiting rod 36 that penetrates the limiting plate 35 is fixedly connected to the connecting frame 33. The displacement sensor 32 is installed on the limiting plate 35 to monitor the displacement of the limiting rod 36.

[0036] The threading hole 4 is an oblong groove. The compensation component 5 also includes a mounting groove 53 opened inside the threading hole 4. A connecting block 54 is slidably connected in the mounting groove 53. The pressure sensor 52 is disposed at the end of the mounting groove 53. A pressure block 55 is disposed on one side of the pressure sensor 52. The second elastic member 51 is located between the pressure block 55 and the connecting block 54. A limiting groove is opened on the side wall of the mounting groove 53. A protrusion matching the limiting groove is disposed on the side wall of the connecting block 54. A mounting bracket 56 is disposed on the side of the connecting block 54 away from the second elastic member 51. A compensation guide wheel 57 is rotatably connected to the mounting bracket 56. A compensation gap is formed between the contact surface of the compensation guide wheel 57 and the aluminum single wire 1.

[0037] The turntable 22 is also equipped with a control unit, which is electrically connected to the displacement sensor 32 and pressure sensor 52 in the multiple wire guide roller assemblies 3 and multiple compensation assemblies 5, respectively. Adjacent displacement sensors 32 and pressure sensors 52 form a detection group, and each detection group is used to detect a single aluminum wire 1.

[0038] The control unit determines the fault status of the guide roller assembly 3 based on the real-time signals from the displacement sensor 32 and pressure sensor 52 in the same detection group in the following manner: When the detection value of displacement sensor 32 continues to increase and cannot be reset, and the detection value of pressure sensor 52 also continues to increase, the control unit determines that the elastic element 31 has experienced elastic force attenuation. When the detection value of pressure sensor 52 increases while the detection value of displacement sensor 32 does not change significantly, the control unit determines that the main drive wheel 34 is worn.

[0039] During use, the aluminum single wire 1 is led out from the barrel and passes through the main guide wheel 34 and the wire threading hole 4 in sequence. Under normal wire feeding conditions, the aluminum single wire 1 passes smoothly through the wire threading hole 4 under the guidance of the main guide wheel 34. At this time, there is a compensation gap between the compensation guide wheel 57 and the aluminum single wire 1, and the compensation guide wheel 57 does not contact the aluminum single wire 1. When the turntable 22 starts to rotate, the pressure sensor 52 measures the initial pressure value.

[0040] When the aluminum single wire 1 bounces up and down due to fluctuations in wire tension, a decrease in the radius of the wire spool, or centrifugal force generated by the rotation of the winch, the impact force is transmitted to the connecting frame 33 through the main guide wheel 34. This causes the connecting frame 33 to overcome the elastic force of the first elastic element 31 and move radially along the turntable 22. The first elastic element 31 is compressed to absorb the impact energy. At the same time, the limiting rod 36 moves synchronously with the connecting frame 33, and the displacement sensor 32 monitors the displacement of the limiting rod 36 in real time. When the bounce amplitude of the aluminum single wire 1 is small and the axial offset does not exceed the compensation gap, the compensation guide wheel 57 does not contact the aluminum single wire 1, and the reading of the pressure sensor 52 remains unchanged at its initial value.

[0041] When the aluminum single wire 1 jumps a large amplitude, or when the elasticity of the first elastic element 31 decreases due to long-term use, causing the working position of the main guide wheel 34 to gradually drift, the axial offset of the aluminum single wire 1 increases until it exceeds the compensation gap. The aluminum single wire 1 contacts the compensation guide wheel 57 and pushes the compensation guide wheel 57, the mounting bracket 56 and the connecting block 54 to move inward to the mounting groove 53. The connecting block 54 transmits the contact pressure to the pressure sensor 52 through the second elastic element 51 and the pressure block 55. The pressure sensor 52 measures that the contact pressure has increased. The contact pressure at this time is the current pressure value minus the initial pressure value.

[0042] The control unit determines the fault status of the guide roller assembly 3 based on the real-time signals from the displacement sensor 32 and pressure sensor 52 in the same detection group in the following manner: When the detection value of displacement sensor 32 continues to increase and cannot be reset to the initial position after aluminum single wire 1 stops jumping, and the detection value of pressure sensor 52 also continues to increase, the control unit determines that the elastic element 31 has experienced elasticity attenuation. At this time, the first alarm signal is issued to prompt the operator to replace the first elastic element 31. When the detection value of pressure sensor 52 increases while the detection value of displacement sensor 32 does not change significantly, the control unit determines that the groove of the main guide wheel 34 is worn. At this time, a second alarm signal is issued to prompt the operator to check or replace the main guide wheel 34.

[0043] Based on the alarm signal, the operator will arrange a shutdown for maintenance at the appropriate time, replace the damaged first elastic element 31 or the main guide wheel 34, and restore the normal working condition of the guide wheel assembly 3, thereby ensuring the surface quality and production efficiency of the energy-saving steel-cored aluminum stranded wire for ultra-high voltage.

[0044] In summary, this invention, through the arrangement of the wire guide wheel assembly 3, the compensation assembly 5, and the wire hole 4, etc., provides a compensation assembly 5 within the wire hole 4. Under normal conditions, the compensation guide wheel 57 in the compensation assembly 5 forms a compensation gap with the aluminum wire 1, ensuring that the compensation guide wheel 57 does not contact the aluminum wire 1 during normal passage. This avoids daily wear caused by long-term contact and prevents the compensation guide wheel 57 from causing additional scratches or friction damage to the surface of the aluminum wire 1. Only when the axial offset of the aluminum wire 1 exceeds the compensation gap due to fluctuations in the wire tension or creep of the elastic element does the compensation guide wheel 57 contact the aluminum wire 1. This allows the second elastic element 51 to absorb the impact force and guide the aluminum wire 1 back to the correct path, preventing the aluminum wire 1 from directly contacting the wall of the wire hole 4. The aluminum wire 1 experiences sliding friction, resulting in aluminum chips and surface wear. The dual guidance of the main guide wheel 34 and the compensating guide wheel 57 prevents excessive axial offset of the aluminum single wire 1. Furthermore, the pressure sensor 52 monitors the contact pressure in real time, and combined with the signal from the displacement sensor 32, automatically determines whether the first elastic element 31 experiences elasticity decay and whether the main guide wheel 34 is worn. This enables real-time online monitoring and automatic fault diagnosis of the wire guide wheel assembly 3, significantly shortening fault detection time and preventing the continuous deterioration of the aluminum single wire 1 surface due to undetected creep of the elastic element or wear of the guide wheel. This effectively ensures the surface quality and corona performance of the energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications, while reducing unnecessary downtime for inspections and improving production efficiency. Example 2

[0045] In actual use, it was found that even if the first elastic element 31 showed signs of elasticity decay or the main guide wheel 34 showed significant wear, the machine still needed to be stopped for maintenance. However, the machine stoppage not only affected production efficiency, but also may interfere with the un-twisted aluminum single wire 1 and steel core during the maintenance process. For example, the sudden change in wire tension at the moment of machine stoppage may cause the aluminum single wire 1 to loosen or be overstretched, and the position of the aluminum single wire 1 that has passed through the wire divider may shift. When restarting the machine, it is necessary to readjust the tension and twisting pitch of each single wire, which not only consumes a lot of time, but is also prone to uneven twisting due to human adjustment errors, affecting the surface roundness and corona performance of the steel core aluminum stranded wire.

[0046] In addition, the frame stranding machine 2 has dozens of wire guide rollers. Checking and replacing them one by one takes a long time. If only a single worn main guide roller 34 is replaced, other main guide rollers 34 in the same group that have not yet shown obvious wear but have early grooves may still cause surface quality problems again in the near future, leading to frequent shutdowns and further reducing production efficiency.

[0047] Further improvements were made based on the above embodiments.

[0048] Please see Figures 4 to 8 As shown, the connecting block 54 has a sliding groove, and the mounting bracket 56 is provided with a slide rail 561 that is slidably connected to the connecting block 54. The end of the slide rail 561 away from the main guide wheel 34 is provided with a telescopic member 6. The end of the telescopic member 6 is slidably engaged with the slide rail 561, that is, the side wall of the slide rail 561 has a vertical slot, and the end of the telescopic member 6 is provided with a locking block that is slidably connected to the slot. The telescopic member 6 is externally connected to a hydraulic drive member 7 through a pipe. The hydraulic drive member 7 can drive the mounting bracket 56 and the compensating guide wheel 57 to move along the axial direction of the main shaft 23 through the telescopic member 6.

[0049] In this embodiment, the telescopic component 6 adopts a multi-stage telescopic sleeve, which is composed of multiple sealed sliding sleeves.

[0050] The connecting frame 33 is provided with an inclined surface 331. The mounting frame 56 is provided with two symmetrically distributed connecting rods 58 at one end near the main guide wheel 34. The end of the connecting rod 58 away from the mounting frame 56 contacts the inclined surface 331. When the telescopic member 6 drives the mounting frame 56 to move to one side of the main guide wheel 34, the connecting frame 33 can move towards the limiting plate 35 under the action of the inclined surface 331 and the connecting rods 58.

[0051] Multiple material discharge positions located in the same axial position form a control group. The hydraulic drive component 7 includes a hydraulic cylinder 71 fixedly connected to the frame winch 2. A piston rod is slidably connected inside the hydraulic cylinder 71. A hydraulic rod 72 is fixedly connected to one end of the piston rod that extends out of the hydraulic cylinder 71. Multiple connecting pipes are provided on the circumferential side of the hydraulic cylinder 71. Each connecting pipe is provided with a valve 73. Each valve 73 is connected to multiple telescopic components 6 in the same control group through a hose.

[0052] Based on the above embodiments, during use, the control unit determines the fault according to the real-time signals of the displacement sensor 32 and the pressure sensor 52 in the same detection group. When the control unit determines that the main drive wheel 34 is worn, the control unit sends a switching command to the hydraulic drive component 7. The hydraulic drive component 7 drives the piston rod to move in the hydraulic cylinder 71 through the hydraulic rod 72, so that the hydraulic oil in the hydraulic cylinder 71 enters the corresponding telescopic component 6 through the connecting pipe and the valve 73. The telescopic component 6 extends and pushes the mounting bracket 56 to move along the slide rail 561 towards the main drive wheel 34.

[0053] When the mounting bracket 56 moves, the connecting rod 58 on it moves accordingly. The end of the connecting rod 58 away from the mounting bracket 56 contacts the inclined surface 331 on the connecting bracket 33 and slides along the inclined surface 331. Since the inclined surface 331 is inclined towards the limiting plate 35 along the connecting bracket 33, the connecting rod 58 generates a component force perpendicular to the inclined surface 331 when sliding on the inclined surface 331. This component force pushes the connecting bracket 33 to overcome the elastic force of the first elastic element 31 and move towards the limiting plate 35, thereby causing the main guide wheel 34 to retract together with the connecting bracket 33 and disengage from the aluminum single wire 1.

[0054] At the same time, the compensating guide wheel 57 on the mounting frame 56 moves towards the main guide wheel 34 along with the mounting frame 56, gradually enters the travel path of the aluminum single wire 1, replaces the main guide wheel 34 to contact the aluminum single wire 1, and continues to guide the aluminum single wire 1 smoothly through the wire hole 4. Thus, the compensating guide wheel 57 successfully replaces the worn main guide wheel 34, realizing automatic switching under non-stop conditions.

[0055] For the control group setup, multiple feeding positions of the cylinders located in the same axial position form a control group. The telescopic components 6 corresponding to multiple wire guide roller assemblies 3 in the control group are connected to the same valve 73 of the hydraulic drive component 7 through pipes. When the control unit determines that the main guide wheel 34 corresponding to any detection group in the control group is worn, the control unit controls the valve 73 to open, so that all telescopic components 6 in the same control group move synchronously, driving all corresponding compensation guide rollers 57 to replace their respective main guide wheels 34 at the same time. This is because the contact angle between the cylinders and the main guide wheels 34 in the same axial position is the same, and the wear pattern of the aluminum single wire 1 on the main guide wheels 34 is similar. When one main guide wheel 34 is determined to be worn, the other main guide wheels 34 in the same group may also have early wear or grooves. Synchronous switching can eliminate hidden dangers in advance and further improve the stability of the surface quality of the conductor.

[0056] Furthermore, the final position of the compensating guide wheel 57 after axial movement is not completely coincident with the original position of the main guide wheel 34, but slightly closer to the wire hole 4. This results in a smaller contact angle when the aluminum single wire 1 coming out of the same barrel comes into contact with the compensating guide wheel 57, and a smaller friction force between the aluminum single wire 1 and the compensating guide wheel 57. Consequently, the compensating guide wheel 57 has a longer service life and can handle multiple emergency compensation tasks for the main guide wheel 34.

[0057] It should be noted that when the compensating guide wheel 57 replaces the main guide wheel 34, the second elastic element 51 is used to absorb the jumping impact force generated by the aluminum single wire 1, and the detection signals of the pressure sensor 52 and displacement sensor 32 in this detection group will no longer have the effect of detection feedback. Instead, the sensors in the detection group will start working again after the aluminum single wire 1 in the barrel is completely twisted with the steel core or the current steel core twisting task is completed, the main guide wheel 34 or the first elastic element 31 is replaced and the compensating guide wheel 57 is reset.

[0058] In summary, this invention, through the design of the telescopic component 6, hydraulic drive component 7, connecting rod 58, and inclined surface 331, allows the hydraulic drive component 7 to extend the telescopic component 6 after the control unit determines that the main guide wheel 34 is worn. This causes the mounting frame 56 and the compensating guide wheel 57 to move towards the main guide wheel 34. Simultaneously, the connecting rod 58 slides along the inclined surface 331 on the connecting frame 33, pushing the connecting frame 33 and the main guide wheel 34 to retract and disengage from the aluminum single wire 1. The compensating guide wheel 57 then automatically replaces the main guide wheel 34 to continue guiding the aluminum single wire 1. This achieves automatic switching of the main guide wheel 34 without stopping the machine. Compared to the method of stopping the machine for maintenance after detecting a fault, this invention avoids problems such as the aluminum single wire 1 becoming loose or overstretched due to sudden changes in wire tension during shutdown, and the position of the aluminum single wire 1 that has passed through the splitter reel shifting. It also eliminates the tedious process of adjusting the tension of each single wire and the stranding pitch when restarting the machine, and eliminates the impact of human adjustment errors on the stranding uniformity. This significantly improves the continuous production capacity and surface roundness of steel-cored aluminum stranded wire.

[0059] Furthermore, since the contact angle between the barrel and the main guide wheel 34 at the same axial position is the same, the wear patterns of the aluminum single wire 1 and the main guide wheel 34 are similar. When the control unit determines that the main guide wheel 34 corresponding to any detection group in the control group is worn, the other main guide wheels 34 in the same group may also have early wear or grooves. The control unit controls the valve 73 to open, so that all the telescopic parts 6 in the same control group move synchronously, driving all the corresponding compensation guide wheels 57 to replace their respective main guide wheels 34 at the same time. This synchronous switching can eliminate hidden dangers in advance and avoid frequent shutdowns caused by the replacement of a single main guide wheel 34 and the subsequent failure of other main guide wheels 34 in the same group in a short period of time. This further improves the stability of the conductor surface quality and the overall operating efficiency of the equipment. Example 3

[0060] This embodiment also provides a manufacturing process for energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications, including the following steps: S100: Galvanized steel wire is drawn and heat-treated to form a steel core.

[0061] S200, Aluminum rods are made from electrical aluminum ingots through continuous casting and rolling, and then aluminum single wires are made through wire drawing and annealing.

[0062] S300. Install multiple cylinders wound with aluminum single wire 1 in the frame stranding machine 2, and pass the steel core through the center of the main shaft 23 of the frame stranding machine 2.

[0063] S400, the aluminum single wire 1 is led out from the barrel and passes through the wire guide roller assembly 3 and the wire hole 4 set on the frame stranding machine 2 in sequence.

[0064] S500: Based on the real-time signals from displacement sensor 32 and pressure sensor 52, determine the current fault status of the wire guide wheel assembly 3 to provide feedback on the surface damage status of the aluminum single wire 1.

[0065] S600, the aluminum single wire 1 after compensation and guidance is led to the steel core through the distribution plate, and multi-layer concentric stranding is carried out under the action of the frame stranding machine 2 to obtain the energy-saving steel core aluminum stranded wire for ultra-high voltage.

[0066] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A device for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications, comprising a frame stranding machine, characterized in that, The frame stranding machine includes a housing, a turntable rotatably connected to the housing, a main shaft at the axis of the turntable, and a wire guide wheel assembly and a wire through hole penetrating the turntable on the side wall of the turntable. The wire guide roller assembly includes a first elastic block and a displacement sensor. The wire guide roller assembly can absorb the jumping impact force of the aluminum single wire. A compensation component is provided in the wire hole. The compensation component includes a second elastic element and a pressure sensor. When the aluminum single wire deviates from its axis, the compensation component can compensate and guide the aluminum single wire.

2. The apparatus for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications according to claim 1, characterized in that, The guide wheel assembly further includes a connecting frame that is slidably connected to the side wall of the turntable. A main guide wheel is rotatably connected to the end of the connecting frame. A limit plate is fixedly connected to the side wall of the turntable. The first elastic element is located between the limit plate and the connecting frame. A limit rod that penetrates the limit plate is fixedly connected to the connecting frame. The displacement sensor is installed on the limit plate to monitor the displacement of the limit rod.

3. The apparatus for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications according to claim 1, characterized in that, The wire-passing hole is an oblong groove. The compensation component also includes a mounting groove inside the wire-passing hole. A connecting block is slidably connected in the mounting groove. The pressure sensor is located at the end of the mounting groove. A pressure block is provided on one side of the pressure sensor. The second elastic element is located between the pressure block and the connecting block. A limiting groove is provided on the side wall of the mounting groove. A protrusion matching the limiting groove is provided on the side wall of the connecting block. A mounting bracket is provided on the side of the connecting block away from the second elastic element. A compensation guide wheel is rotatably connected to the mounting bracket. A compensation gap is formed between the contact surface of the compensation guide wheel and the aluminum single wire.

4. The apparatus for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications according to claim 1, characterized in that, The turntable is also equipped with a control unit, which is electrically connected to the displacement sensors and pressure sensors in the multiple wire guide roller assemblies and multiple compensation assemblies. Adjacent displacement sensors and pressure sensors form a detection group, and each detection group is used to detect a single aluminum wire.

5. The apparatus for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications according to claim 4, characterized in that, The control unit determines the fault status of the guide roller assembly based on the real-time signals from the displacement sensor and pressure sensor in the same detection group in the following manner: When the displacement sensor's detection value continues to increase and cannot be reset, and the pressure sensor's detection value also continues to increase, the control unit determines that the first elastic element has experienced elastic force attenuation. When the pressure sensor reading increases while the displacement sensor reading remains unchanged, the control unit determines that the drive wheel is worn.

6. The apparatus for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications according to claim 3, characterized in that, The connecting block is provided with a sliding groove, and the mounting frame is provided with a slide rail that is slidably connected to the connecting block. The end of the slide rail away from the main guide wheel is provided with a telescopic component. The telescopic component is externally connected to a hydraulic drive component through a pipe. The hydraulic drive component can drive the mounting frame and the compensating guide wheel to move along the axis of the main shaft through the telescopic component.

7. The apparatus for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications according to claim 6, characterized in that, The connecting frame is provided with an inclined surface, and the mounting frame is provided with two symmetrically distributed connecting rods at the end near the main guide wheel. The end of the connecting rod away from the mounting frame is in contact with the inclined surface. When the telescopic component drives the mounting frame to move to one side of the main guide wheel, the connecting frame can move towards the direction of the limiting plate under the action of the inclined surface and the connecting rods.

8. The apparatus for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications according to claim 6, characterized in that, The turntable is provided with multiple circumferentially distributed feeding grooves, and multiple equidistant feeding positions are provided in the feeding grooves. Each of the multiple feeding positions is equipped with a material cylinder wound with aluminum single wire. Multiple material discharge positions located in the same axial position form a control group. The hydraulic drive includes a hydraulic cylinder fixedly connected to the frame winch. A piston rod is slidably connected inside the hydraulic cylinder. A hydraulic rod is fixedly connected to one end of the piston rod that extends out of the hydraulic cylinder. Multiple connecting pipes are provided on the circumferential side of the hydraulic cylinder. Each connecting pipe is equipped with a valve. Each valve is connected to multiple telescopic components in the same control group through a pipe.

9. A process for preparing energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications, comprising stranding steel-cored aluminum stranded wire using the preparation apparatus described in any one of claims 1-8, characterized in that... Includes the following steps: S100: Galvanized steel wire is drawn and heat-treated to form a steel core; S200: Electrical aluminum ingots are continuously cast and rolled into aluminum rods, and then drawn and annealed to produce aluminum single wires. S300: Install multiple barrels wound with aluminum single wire in a frame stranding machine, and pass the steel core through the center of the main shaft of the frame stranding machine; S400: Lead the aluminum single wire out from the barrel and pass it through the wire guide roller assembly and the wire hole set on the frame stranding machine in sequence; S500: Based on the real-time signals from the displacement sensor and pressure sensor, determine the current fault status of the wire guide wheel assembly to provide feedback on the surface damage status of the aluminum wire. S600: The aluminum single wire, after being compensated and guided, is led to the area around the steel core through a distribution plate, and then subjected to multi-layer concentric stranding under the action of a frame stranding machine to obtain energy-saving steel-core aluminum stranded wire for ultra-high voltage applications.

10. An energy-saving steel-cored aluminum stranded wire for ultra-high voltage applications, prepared using the manufacturing process described in claim 9.

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