Anti-torsion wind energy cable

Abstract

The utility model provides an anti-torsion wind energy cable, comprising a cable core, the outer side of the cable core is sequentially provided with an aluminum foil Mylar separation belt layer, a silicone rubber outer sheath and a synthetic fiber braided layer from inside to outside, and the braiding density of the synthetic fiber braided layer is greater than or equal to 85%; the technical problems that a traditional wind energy cable is poor in torsion resistance, prone to breakage, aging and damage and the like are solved, the torsion resistance of the wind energy cable is improved, the problems that the cable is prone to breakage, aging and damage and the like are effectively avoided, the operation stability of the wind energy cable in a severe working environment is ensured, and the service life of the wind energy cable is prolonged. In addition, potential safety hazards caused by line aging or breakage are greatly reduced, and the maintenance cost is reduced.

Description

Technical Field

[0001] The utility model relates to the technical field of wind energy cables, and particularly relates to a wind energy cable with anti-torsion performance. Background Art

[0002] Wind energy, as a clean and renewable energy source, has received extensive attention and application globally. As the main form of wind energy utilization, the stability and reliability of wind power generation systems play a crucial role in the continuity of energy supply and environmental protection. In wind power generation systems, cables, as key components connecting wind turbines to the power grid, directly affect the operating efficiency and safety of the entire system in terms of their performance.

[0003] However, despite the significant progress made in wind power generation technology, there are still some obvious defects and deficiencies in existing wind energy cables.

[0004] Firstly, in terms of material selection, traditional wind energy cables are mostly made of cross-linked polyethylene or ethylene propylene rubber insulation and various elastomer sheaths. Although the above materials have excellent electrical properties and material price advantages, their resistance to climate, abrasion, high and low temperatures, UV, torsion, and aging is relatively weak in complex and changeable wind environments. Since wind resources are abundant in the north of China, wind farms are usually located in remote areas in the northwest, with harsh environmental conditions, strong winds, a lot of dust, and large temperature fluctuations. These factors will cause varying degrees of damage to the cables, leading to cable aging, breakage, and even safety accidents.

[0005] Secondly, the anti-torsion performance of traditional wind energy cables is weak. Wind turbines rotate and sway frequently during operation, which poses high requirements for the anti-torsion performance of cables. However, existing cables often struggle to withstand this frequent torsion and are prone to problems such as fracture and breakage. This not only affects the normal operation of the wind power system but also increases maintenance costs and reduces the economic benefits of the system. Summary of the Utility Model

[0006] In order to solve the technical problems of the weak anti-torsion performance of traditional wind energy cables and the easy fracture, aging, and breakage of traditional wind energy cables, the utility model proposes a wind energy cable with anti-torsion performance, which solves the technical problems of the weak anti-torsion performance, easy fracture, aging, and breakage of traditional wind energy cables, improves the anti-torsion performance of wind energy cables, effectively avoids the occurrence of problems such as easy fracture, aging, and breakage of cables, which not only ensures the operation stability of wind energy cables in harsh working environments but also greatly reduces the safety hazards caused by line aging or fracture and reduces maintenance costs.

[0007] To achieve the above purpose, the technical solution of the utility model is as follows:

[0008] On the one hand, the present utility model provides a wind energy cable with anti-torsion performance, comprising: a cable core, an aluminum foil mylar separator layer, a silicone rubber outer sheath and a synthetic fiber braided layer are sequentially arranged outside the cable core from inside to outside, and the braiding density of the synthetic fiber braided layer is ≥85%.

[0009] The wind energy cable with anti-torsion performance provided by the present utility model solves the technical problems of weak anti-torsion performance, easy fracture, aging and damage of traditional wind energy cables, improves the anti-torsion performance of the wind energy cable, effectively avoids the occurrence of problems such as easy fracture, aging and damage of the cable, which not only ensures the operation stability of the wind energy cable in harsh working environments, but also greatly reduces the potential safety hazards caused by line aging or fracture, and reduces the maintenance cost.

[0010] As a preferred technical solution, the overlapping rate of every two adjacent aluminum foil mylar separator layers in the aluminum foil mylar separator layer is ≥20%.

[0011] As a preferred technical solution, the cable core comprises: a plurality of wire groups, and the plurality of wire groups are stranded to form a cable core.

[0012] As a preferred technical solution, the wire group comprises: a conductor, and a mylar wrapping protection layer and a silicone rubber insulating layer are sequentially arranged outside the conductor from inside to outside.

[0013] As a preferred technical solution, the gap of the cable core is filled with a flexible flame-retardant filler.

[0014] As a preferred technical solution, the conductor comprises: a plurality of copper wires or tinned copper wires, and the copper wires or the tinned copper wires are in a multi-strand composite stranding form to form a prefabricated conductor.

[0015] As a preferred technical solution, the prefabricated conductor is filled with a conductor filler, and the conductor filler comprises any one of Kevlar fibers, copper foil wires and nylon wires.

[0016] As a preferred technical solution, the thickness of the thinnest point of the silicone rubber insulating layer is ≥0.8 mm.

[0017] As a preferred technical solution, the thickness of the thinnest point of the silicone rubber outer sheath is ≥1.0 mm.

[0018] As a preferred technical solution, the flexible flame-retardant filler comprises any one of a flame-retardant PP filling rope, a flame-retardant cotton thread, a glass fiber rope and an expanded polypropylene filler.

[0019] The wind energy cable with anti-torsion performance provided by the present utility model has the following beneficial effects:

[0020] 1) It solves the technical problems of traditional wind energy cables, such as weak anti-torsion performance, easy fracture, aging and damage, improves the anti-torsion performance of wind energy cables, effectively avoids the occurrence of problems such as easy fracture, aging and damage of cables, which not only ensures the operation stability of wind energy cables in harsh working environments, but also greatly reduces the safety hazards caused by line aging or fracture and reduces the maintenance cost.

[0021] 2) This application purposefully selects an aluminum foil mylar separator layer, which mainly plays a role in protecting the silicone rubber insulation layer and electromagnetic shielding, and can effectively block external interference signals to ensure the normal operation of the equipment;

[0022] This application purposefully selects a silicone rubber outer sheath, which has functions of weather resistance, abrasion resistance, high and low temperature resistance, UV resistance, anti-aging, anti-torsion, low density, high flexibility and corrosion resistance. Moreover, the silicone rubber outer sheath is environmentally friendly and pollution-free and suitable for the operating temperature of the cable, effectively avoiding the occurrence of problems such as easy fracture, aging and damage of the cable, improving the service life of the cable in harsh environments and reducing the maintenance cost;

[0023] This application purposefully selects a synthetic fiber braided layer, which makes the cable have high mechanical strength and mainly plays a role in protecting the silicone rubber outer sheath and improving the anti-torsion performance. The braiding density of the synthetic fiber braided layer is ≥85%, further making the cable have high mechanical strength and playing a role in protecting the silicone rubber outer sheath and improving the anti-torsion performance.

[0024] 3) A mylar wrapping protection layer and a silicone rubber insulation layer are provided on the outside of the conductor from the inside to the outside;

[0025] This application purposefully selects a silicone rubber insulation layer, which has high softness, improves the anti-torsion performance of the cable, and the working temperature meets -55~180°C, meeting the requirements of the cable for use in different high and low temperature environments;

[0026] This application purposefully selects a mylar wrapping protection layer, which is wrapped with a mylar wrapping protection tape, mainly playing a role in fixing the conductor from loosening, thereby achieving the effect of improving the roundness of the conductor and facilitating processing and peeling.

[0027] 4) The prefabricated conductor is filled with a conductor filler, and the conductor filler includes any one of Kevlar fiber, copper foil wire and nylon wire. The main function of the conductor filler is to enhance the tensile strength and anti-torsion of the cable.

[0028] 5) The standard rated temperature of this cable can reach -55~180°C, the rated voltage can reach 0.6~1KV, and the finished cable withstands an alternating current of 50HZ, a test voltage of 3.5kV, and the insulation does not break down for 5 minutes;

[0029] The rated voltage of this cable can reach 0.6 KV to 1 KV, which means the cable is designed to operate safely at voltages not exceeding 600 - 1000 volts. The rated voltage is a key parameter in the design and use of the cable, ensuring that the cable can operate for a long time under the rated voltage without damage, and improving the safe operating ability of the cable under the rated voltage;

[0030] The cable withstands an AC of 50 HZ, a test voltage of 3.5 kV, and the insulation does not break down for 5 minutes. This is a specific manifestation of the electrical strength (also known as insulation performance) of the cable; this test shows that under a high voltage of 3500 volts for 5 minutes, the silicone rubber insulation layer of the cable can still remain intact without breakdown; this is an important indicator of the cable's insulation performance, reflecting the safety, reliability, and stability of the cable under high - voltage conditions. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 Schematic diagram of the structure of a wind - energy cable with anti - torsion provided for Embodiment 1;

[0032] Figure 2 Schematic diagram of the structure of a wind - energy cable with anti - torsion provided for Embodiment 2;

[0033] Among them, 1 - aluminum foil mylar separator layer; 2 - silicone rubber outer sheath; 3 - synthetic fiber braided layer; 4 - conductor; 5 - conductor filler; 6 - mylar wrapped protection layer; 7 - silicone rubber insulation layer; 8 - flexible flame - retardant filler; 9 - wire group. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0034] The following will describe in detail the preferred embodiments of the present utility model with reference to the accompanying drawings.

[0035] The present utility model provides a wind - energy cable with anti - torsion, including: a cable core, and an aluminum foil mylar separator layer 1, a silicone rubber outer sheath 2, and a synthetic fiber braided layer 3 are sequentially arranged from the inside to the outside of the cable core, and the braiding density of the synthetic fiber braided layer 3 is ≥85%.

[0036] The wind - energy cable with anti - torsion provided by the present utility model solves the technical problems of weak anti - torsion performance, easy fracture, aging, and damage of traditional wind - energy cables, improves the anti - torsion performance of the wind - energy cable, effectively avoids problems such as easy fracture, aging, and damage of the cable, which not only ensures the operating stability of the wind - energy cable in harsh working environments, but also greatly reduces the safety hazards caused by line aging or fracture, and reduces the maintenance cost.

[0037] The aluminum foil mylar separator layer 1 is purposefully selected in this application. The aluminum foil mylar separator layer 1 mainly plays a role in protecting the silicone rubber insulation layer 7 and electromagnetic shielding, and can effectively block external interference signals to ensure the normal operation of the equipment;

[0038] This application purposefully selects the silicone rubber outer sheath 2. The silicone rubber outer sheath 2 has the functions of weather resistance, abrasion resistance, high and low temperature resistance, UV resistance, anti-aging, anti-torsion, low density, high flexibility, and corrosion resistance, effectively avoiding problems such as easy fracture, aging, and damage of the cable, improving the service life of the cable in harsh environments, reducing the maintenance cost, and the silicone rubber outer sheath 2 is preferably a halogen-free and antimony-free silicone rubber outer sheath, which also meets the two environmental protection requirements of RoHS and REACH formulated by the European Union, is environmentally friendly and pollution-free and suitable for the operating temperature of the cable;

[0039] This application purposefully selects the minimum thickness of the silicone rubber outer sheath 2 to be ≥1.0 mm, reducing the wall thickness and weight of the traditional cable, which is beneficial to the transportation and storage of the cable;

[0040] This application purposefully selects the synthetic fiber braided layer 3. The synthetic fiber braided layer 3 makes the cable have high mechanical strength, mainly playing the role of protecting the silicone rubber outer sheath 2 and improving the anti-torsion performance. The braiding density of the synthetic fiber braided layer 3 is ≥85%, further making the cable have high mechanical strength, mainly playing the role of protecting the silicone rubber outer sheath 2 and improving the anti-torsion performance.

[0041] Preferably, the overlap rate of every two adjacent aluminum foil mylar separator belts in the aluminum foil mylar separator belt layer 1 is ≥20%; the aluminum foil mylar separator belt layer 1 mainly plays the role of protecting the silicone rubber insulation layer 7 and electromagnetic shielding, and can effectively block external interference signals to ensure the normal operation of the equipment. The overlap rate of the aluminum foil mylar separator belt layer 1 is ≥20%, further improving the electromagnetic shielding performance of the cable.

[0042] Preferably, the cable core includes: a plurality of wire groups 9, and the plurality of wire groups 9 are stranded to form a cable core.

[0043] Preferably, the wire group 9 includes: a conductor 4, and a mylar wrapped protection belt layer 6 and a silicone rubber insulation layer 7 are sequentially arranged on the outside of the conductor 4 from the inside to the outside;

[0044] This application purposefully selects the silicone rubber insulation layer 7. The silicone rubber insulation layer 7 has high flexibility, improves the anti-torsion performance of the cable, and the working temperature meets -55~180℃, meeting the requirements for use of the cable in different high and low temperature environments;

[0045] This application purposefully selects the silicone rubber insulation layer 7, and its performance meets the national standard of GB / T29631-2013 for wind power generation with a rated voltage of 1.8 / 3 kV and below and resistant to distortion soft cables, and also meets the two environmental protection requirements of RoHS and REACH formulated by the European Union, minimizing the impact on the environment during the production and use of the cable and improving the environmental friendliness of the cable;

[0046] The silicone rubber insulating layer 7 is tightly extruded and coated on the conductor 4. The surface of the silicone rubber insulating layer 7 is smooth, flat, with uniform color, and has no defects such as bubbles and sand holes visible to the naked eye on the cross-section;

[0047] In this application, the silicone rubber insulating layer 7 is purposefully selected, and its performance complies with the national standard of GB / T29631-2013 for wind power generation withstanding torsion flexible cables with rated voltage of 1.8 / 3 kV and below. The minimum thickness requirement of the thinnest point is ≥0.8 mm, reducing the wall thickness and weight of traditional cables, which is beneficial to the transportation and storage of cables;

[0048] This anti-torsion wind energy cable also has excellent electrical properties. The dielectric strength of the silicone rubber insulating layer 7 is tested to be 25 - 30 KV / mm, which is much better than other materials. It can effectively transmit electric energy to ensure the normal operation of the wind energy power generation system; at the same time, the low-resistance and low-loss structural characteristics of the silicone rubber insulating layer 7 also help to improve the conversion and transportation of electric energy and reduce energy waste;

[0049] In this application, the Mylar wrapping protection tape layer 6 is purposefully selected and wrapped with the Mylar wrapping protection tape, which mainly plays a role in fixing the conductor 4 from loosening, thus improving the roundness of the conductor 4 and facilitating the processing of peeling the skin.

[0050] Preferably, the gap of the cable core is filled with a flexible flame-retardant filler 8.

[0051] Preferably, the flexible flame-retardant filler 8 includes any one of a flame-retardant PP filling rope, flame-retardant cotton thread, glass fiber rope, and expanded polypropylene filler; it further plays a role in strengthening the tensile strength and torsion resistance of the cable.

[0052] Preferably, the conductor 4 includes: multiple copper wires or tinned copper wires, and the copper wires or the tinned copper wires are in a multi-strand composite stranded form to form a prefabricated conductor; it conforms to the Class 6 conductor structure in GB / T3956-2008, providing clear technical requirements and quality assurance for the production and use of conductors for power cables and flexible cords. Its composition, performance, resistance, and appearance comply with the provisions of the GB / T3956-2008 standard, ensuring that the conductor has good electrical conductivity.

[0053] Preferably, the prefabricated conductor is filled with a conductor filler 5, and the conductor filler 5 includes any one of Kevlar fibers, copper foil wires, and nylon wires; the main function of the conductor filler 5 is to strengthen the tensile strength and torsion resistance of the wire.

[0054] Preferably, the surface of the conductor 4 is smooth, free of oil stains, burrs that damage the insulation, and single wires with sharp edges. The surface of the conductor 4 has no raised or broken single wires.

[0055] Example 1

[0056] As Figure 1 shown, the present utility model provides a wind energy cable with anti-torsion performance, comprising: two wire groups 9, wherein the wire group 9 includes: a conductor 4, and the conductor 4 includes: multiple copper wires, and the multiple copper wires are in a multi-strand composite stranded form to form a prefabricated conductor. The prefabricated conductor is filled with Kevlar fiber conductor filler inside to form the conductor 4. A mylar wrapping protection tape layer 6 and a silicone rubber insulation layer 7 are provided on the outside of the conductor 4 from the inside to the outside to form the wire group 9. The two wire groups 9 are stranded to form a cable core. A flexible flame-retardant filler 8 made of flame-retardant PP filling cord is filled in the cable core gap. An aluminum foil mylar separation tape layer 1, a silicone rubber outer sheath 2, and a synthetic fiber braided layer 3 are sequentially provided on the outside of the cable core from the inside to the outside. The braiding density of the synthetic fiber braided layer 3 is 85%. This wind energy cable with anti-torsion performance solves the technical problems of weak anti-torsion performance, easy breakage, aging, and damage of traditional wind energy cables, improves the anti-torsion performance of the wind energy cable, effectively avoids the occurrence of problems such as easy breakage, aging, and damage of the cable, which not only ensures the operation stability of the wind energy cable in harsh working environments, but also greatly reduces the safety hazards caused by line aging or breakage, and reduces the maintenance cost.

[0057] Embodiment 2

[0058] As Figure 2 shown, the present utility model provides a wind energy cable with anti-torsion performance, comprising: four wire groups 9, wherein the wire group 9 includes: a conductor 4, and the conductor 4 includes: multiple tinned copper wires, and the multiple tinned copper wires are in a multi-strand composite stranded form to form a prefabricated conductor. The prefabricated conductor is filled with copper foil wire conductor filler inside to form the conductor 4. A mylar wrapping protection tape layer 6 and a silicone rubber insulation layer 7 are provided on the outside of the conductor 4 from the inside to the outside to form the wire group 9. The four wire groups 9 are stranded to form a cable core. A flexible flame-retardant filler 8 made of flame-retardant cotton thread is filled in the cable core gap. An aluminum foil mylar separation tape layer 1, a silicone rubber outer sheath 2, and a synthetic fiber braided layer 3 are sequentially provided on the outside of the cable core from the inside to the outside. The braiding density of the synthetic fiber braided layer 3 is 90%. This wind energy cable with anti-torsion performance solves the technical problems of weak anti-torsion performance, easy breakage, aging, and damage of traditional wind energy cables, improves the anti-torsion performance of the wind energy cable, effectively avoids the occurrence of problems such as easy breakage, aging, and damage of the cable, which not only ensures the operation stability of the wind energy cable in harsh working environments, but also greatly reduces the safety hazards caused by line aging or breakage, and reduces the maintenance cost.

[0059] It can be understood that the present utility model is described through some embodiments. Those skilled in the art know that without departing from the spirit and scope of the present utility model, various changes or equivalent replacements can be made to these features and embodiments. Additionally, under the teaching of the present utility model, these features and embodiments can be modified to adapt to specific circumstances and materials without departing from the spirit and scope of the present utility model. Therefore, the present utility model is not limited by the specific embodiments disclosed herein, and all changes or equivalent replacements that fall within the scope of the claims of this application. Additionally, under the teaching of the present utility model, these features and embodiments can be modified to adapt to specific circumstances and materials without departing from the spirit and scope of the present utility model. Therefore, the present utility model is not limited by the specific embodiments disclosed herein, and all embodiments that fall within the scope of the claims of this application belong to the scope protected by the present utility model.

Claims

1. A torsion-resistant wind power cable, characterized in that: include: The cable core has an aluminum foil Mylar separation tape layer, a silicone rubber outer sheath and a synthetic fiber braided layer arranged on its outer side from inside to outside, and the braiding density of the synthetic fiber braided layer is ≥85%.

2. The torsion-resistant wind power cable according to claim 1, characterized in that The overlap rate of each two adjacent groups of aluminum foil Mylar separator tape layers in the aluminum foil Mylar separator tape layers is ≥20%.

3. The torsion-resistant wind power cable according to claim 1, characterized in that The cable core includes: a plurality of wire groups, and a plurality of the wire groups are twisted to form the cable core.

4. The torsion-resistant wind power cable according to claim 3, characterized in that The wire group comprises: a conductor, and the outer side of the conductor is provided with a Mylar wrapping protection tape layer and a silicone rubber insulation layer in sequence from the inside to the outside.

5. The torsion-resistant wind power cable according to claim 4, characterized in that The gaps in the cable core are filled with flexible flame-retardant fillers.

6. The torsion-resistant wind power cable according to claim 4, characterized in that The conductor comprises: a plurality of copper wires or tinned copper wires, wherein the copper wires or the tinned copper wires are in a multi-strand composite twisted form to form a prefabricated conductor.

7. The torsion-resistant wind power cable according to claim 6, characterized in that The prefabricated conductor is filled with a conductor filler, and the conductor filler includes: any one of Kevlar fiber, copper foil wire and nylon wire.

8. The torsion-resistant wind power cable according to claim 4, characterized in that The thinnest point thickness of the silicone rubber insulating layer is ≥0.8 mm.

9. The torsion-resistant wind power cable according to claim 1, characterized in that The thinnest point thickness of the silicone rubber outer sheath is ≥1.0 mm.

10. The torsion-resistant wind power cable according to claim 5, characterized in that The flexible flame retardant filler comprises any one of: a flame retardant PP filling rope, a flame retardant cotton thread, a glass fiber rope and an expanded polypropylene filler.

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