Welding device for intermediate joint of power cable

Abstract

The utility model discloses a welding device for an intermediate joint of a power cable. The welding device comprises an electromagnetic induction heating machine, a melting cup and at least one set of welding die, the electromagnetic induction heating machine comprises an electromagnetic induction heating source and a heating coil; the melt cup comprises a crucible, and a blocking mechanism with an opening and closing type sealing structure is arranged at a discharge hole in the inner bottom of the crucible; the welding mold comprises a pair of half-and-half splicing mold bodies, a positioning cavity A, a welding cavity and a positioning cavity B are transversely formed in the splicing mold bodies in a penetrating mode in sequence, the middle of the welding cavity is upwards communicated with a feeding channel, and the upper end of the feeding channel is communicated with a material receiving positioning opening. The device is safe, reliable and pollution-free, and not only can ensure the consistency of the conductivity and resistivity of the cable joint before and after welding, but also can improve the welding efficiency.

Description

Technical Field

[0001] The utility model relates to the technical field of cable joint fusion welding, and more specifically to a fusion welding device for a medium joint of a power cable. Background Art

[0002] The core conductor of a power cable generally has three, and even more in some cases, and the vast majority of the materials are pure copper. The most core component in the fusion welding method of a power cable medium joint is a fusion welding die, which includes a pair of split dies. The split dies are transversely and sequentially provided with a positioning cavity A, a fusion welding cavity, and a positioning cavity B. The middle part of the fusion welding cavity is upwardly communicated with a feeding channel, and the upper end of the feeding channel is communicated with a fusion material cavity for containing a fusion material (solder), and the fusion material is pure copper. The two joints to be fusion welded of the core conductor are respectively inserted into the positioning cavity A and the positioning cavity B and directly enter the fusion welding cavity, but the two are kept at a separation distance. Then, the fusion material in the fusion material cavity is heated and liquefied and flows into the fusion welding cavity. After the fusion material cools and solidifies, the two joints of the core conductor are fusion welded into one body, and then enter the next grinding and polishing process, as well as the reset work of the insulating layer, shielding layer, and protective layer.

[0003] In the prior art, the process of heating and liquefying the fusion material in the fusion material cavity all adopts a chemical method, that is, a rapid heating method by the deflagration of heating powders such as gunpowder (there are many such videos on Douyin), that is, the fusion material and gunpowder are put into the fusion material cavity together, and the gunpowder is ignited to deflagrate and rapidly heat to liquefy the fusion material.

[0004] It is mentioned in the patent with application number 201921935089.5 and name of a fusion welded cable intermediate joint and a welding die for welding the same that the solder is a metal compound material containing copper powder. The solder can release a large amount of heat through a chemical reaction, thereby melting the copper powder and conducting the heat to the solder cavity to melt the cable conductor. The molten copper powder is in full contact with the molten cable conductor to form a conductor welding section.

[0005] It is mentioned in the patent with application number 202110665789.2 and name of a fusion welding process for a cable head that when using the fusion welding device, first insert the two cable heads into the fusion welding cavity from both ends of the fusion welding cavity and keep a certain distance, fix the positions of the cable heads with a fixing component, and then put the copper powder added with heating powder in the melting tank, ignite the heating powder, and the copper powder burns and melts into a liquid quickly, and the copper liquid flows into the fusion welding cavity.

[0006] The method of heating the fusion material with heating powder by chemical method has many drawbacks. For example, there is a hidden danger of burns or fire accidents caused by the flames of the deflagration of heating powders such as gunpowder; for another example, there is the pollution problem of harmful exhaust gases generated by the deflagration of heating powders such as gunpowder; for another example, the gunpowder burns incompletely and impurities enter the fusion material and finally solidify on the cable joint, resulting in poor conductivity and large resistivity. Utility Model Content

[0007] The purpose of the present utility model is to overcome the above defects of the prior art, and provide a power cable intermediate joint welding device that is safe, reliable, pollution-free, can not only ensure the conductivity and resistivity consistency of the cable joint before and after welding, but also improve the welding efficiency.

[0008] To achieve the above purpose, the present utility model is realized through the following technical solutions: A power cable intermediate joint welding device, characterized in that it includes an electromagnetic induction heating machine, a melting cup and at least one set of welding dies; the electromagnetic induction heating machine includes an electromagnetic induction heating source and a heating coil; the electromagnetic induction heating machine also includes a power cord and a handle gun, the heating coil is arranged at the free end of the handle gun, and the handle gun is connected to the electromagnetic induction heating source through the power cord;

[0009] The melting cup includes a crucible, and a blocking mechanism with an opening and closing sealing structure is arranged at the discharge port of the inner bottom of the crucible; the welding die includes a pair of split dies that are split in half, and a positioning cavity A, a welding cavity and a positioning cavity B are sequentially arranged horizontally and through the split dies, and a feeding channel communicates upward in the middle of the welding cavity;

[0010] Fill the melting cup containing the welding material into the heating coil. When the welding material in the crucible melts into a liquid state, then transport the melting cup containing the liquid welding material to the welding die, and the discharge port of the inner bottom of the crucible correspondingly extends into the feeding channel of the welding die.

[0011] The heating of the welding material of the present utility model adopts the method of electromagnetic induction heating, which is safe, reliable and pollution-free; it abandons the heating method of chemical methods such as gunpowder and other heating powders, without deflagration flames, without fire safety hazard problems, and without waste gas pollution problems.

[0012] After the welding material of the present utility model is heated and liquefied, there is no addition of impurities after combustion such as heating powder. The original material content remains the same after heating and liquefaction. For example, if it is 99.9% pure copper, then the pure copper ratio remains unchanged. In addition, if the material is taken on-site and a part of the core conductor of the cable to be joined is directly intercepted, then the composition of the welding material is the same as that of the core conductor of the cable to be joined, which can ensure the conductivity and resistivity consistency of the cable joint.

[0013] With the support of the power cord, the handle gun of the present utility model enables the staff to flexibly change positions in the field and can also go to high altitudes to directly weld joints; more importantly, a power cable often has at least three core conductors, so for one power cable welding, it needs to be welded three times. The present utility model can just perform continuous welding operations, greatly improving the welding efficiency.

[0014] Preferably, the electromagnetic induction heating source is specifically a high-frequency induction heating power supply.

[0015] Preferably, the discharge port at the inner bottom of the crucible is provided with a diversion conical opening that tapers downward. The diversion conical opening is for better discharging of the molten welding material.

[0016] Preferably, the blocking mechanism includes a flow-blocking rod, and a flow-blocking conical head that mates with the diversion conical opening is provided at the lower end of the flow-blocking rod. The upper end of the flow-blocking rod extends out of the crucible. Under the pressure of the molten welding material, the flow-blocking conical head can better close the discharge port of the crucible.

[0017] Preferably, a heat-preserving cup is sleeved outside the crucible, and a material-passing opening allowing the diversion conical opening to extend out is provided at the center of the inner bottom of the heat-preserving cup. The heat-preserving cup can prevent the crucible from losing temperature too quickly, can also play a role in heat collection during the heating of the crucible, and in addition, does not affect heating because for electromagnetic induction heating, it can directly avoid heating it to heat the interior.

[0018] Preferably, the crucible is specifically a graphite crucible, and the heat-preserving cup is specifically a quartz cup.

[0019] Preferably, an upper end of the feed channel communicates with a material-receiving positioning port, a lower end of the feed channel communicates with a welding cavity, a diameter of the welding cavity is larger than those of positioning cavity A and positioning cavity B, and diameters of the positioning cavity A and the positioning cavity B are the same.

[0020] Preferably, a discharge channel communicates downward from a middle part of the welding cavity, and a lower end of the discharge channel communicates with a waste cavity. The first-entering liquid welding material is used to preheat the welding material cavity and the core conductor inside the welding material cavity to better increase the bonding property between the joint and the solder (welding material). However, the first-entering liquid welding material cools down too quickly and is not suitable for use as solder, so it is discharged into the waste cavity.

[0021] Preferably, a pair of positioning holes and a pair of positioning posts are arranged on each of the split dies, and the two positioning holes and the two positioning posts are arranged in a matrix manner. The positioning holes and the positioning posts can better combine the split dies, and then an external tooling fixture is used to lock the split dies to form a welding die.

[0022] Advantageous effects: (1) The heating of the welding material in the present utility model adopts the electromagnetic induction heating method, which is safe, reliable and pollution-free; the heating method using chemical methods such as gunpowder heating powder is abandoned, there is no deflagration flame, no fire safety hazard problem, and no waste gas pollution problem.

[0023] (2) After the welding material of the utility model is heated and liquefied, there is no impurity added after combustion such as heating powder. The original material content remains the same after heating and liquefaction. For example, if it is 99.9% pure copper, the pure copper ratio remains unchanged. In addition, if the material is obtained on site and the part of the wire core conductor to be connected is directly cut off, the composition of the welding material is consistent with the wire core conductor to be connected, which can ensure the consistency of conductivity and resistivity of the cable joint.

[0024] (3) With the help of the power cord, the utility model can enable the staff to flexibly change positions in the venue and can also go up to high altitude to directly weld the joints; more importantly, a power cable usually has at least three core conductors, so a power cable welding must be welded three times. The utility model can perform continuous welding operations, greatly improving the welding efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the structure of the combination of the electromagnetic induction heating machine and the melting cup of the utility model;

[0026] Figure 2 This is a schematic diagram of the structure of the combination of the melting cup and the welding mold of the utility model;

[0027] Figure 3 This is a structural cross-sectional view of the melting cup of the utility model;

[0028] Figure 4 It is a structural schematic diagram of half of the welding mold of the utility model.

[0029] In the figure: 1-electromagnetic induction heating source, 2-handling gun, 3-power cord, 4-heating coil, 5-melting cup, 6-welding mold, 51-crucible, 52-blocking rod, 53-insulation cup, 54-flow guide cone, 55-blocking cone head, 56-feeding port, 61-positioning cavity A, 62-positioning cavity B, 63-welding cavity, 64-material receiving positioning port, 65-feeding channel, 66-waste cavity, 67-discharge channel, 68-positioning column, 69-positioning hole. DETAILED DESCRIPTION

[0030] In order to make the technical means, creative features and objectives of the present invention easy to understand, the present invention is further described below in conjunction with specific embodiments.

[0031] Embodiment: A power cable intermediate joint welding device includes an electromagnetic induction heater, a melting cup, and one or three sets of welding molds.

[0032] like Figure 1As shown, the electromagnetic induction heating machine includes an electromagnetic induction heating source 1, a heating coil 4, a power cord 3, and a hand-held gun 2. The hand-held gun 2 is internally provided with a transformer coil. The heating coil 4 is arranged at the free end of the hand-held gun 2. The heating coil 4 is connected to the transformer coil inside the hand-held gun 2. The transformer coil inside the hand-held gun 2 is connected to the electromagnetic induction heating source 1 through the power cord 3. Among them, the electromagnetic induction heating source 1 is specifically a high-frequency induction heating power supply.

[0033] As Figure 2 and Figure 3 shown, the melting cup 5 includes a crucible 51, a stopper rod 52, and a heat-insulating cup 53. The crucible 51 is specifically a graphite crucible, and the heat-insulating cup 53 is specifically a quartz cup.

[0034] A downwardly protruding diversion cone opening 54 is arranged at the inner bottom of the crucible 51. A stopper cone head 55 that cooperates with the diversion cone opening 54 is arranged at the lower end of the stopper rod 52. That is, the lower free end (stopper cone head 55) of the stopper rod 52 is detachably and sealingly inserted and matched with the inner bottom discharge port (diversion cone opening 54) of the crucible 51 (that is, the diversion cone opening 54, the stopper cone head 55, and the stopper rod 52 constitute a valve-type blocking mechanism); the upper end of the stopper rod 52 extends out of the crucible 51. The heat-insulating cup 53 is sleeved outside the crucible 51, and the two are independent but fitted. A material-passing port 56 allowing the diversion cone opening 54 to extend out is arranged at the center of the inner bottom of the heat-insulating cup 53.

[0035] As Figure 2 and Figure 4 shown, the welding mold 6 includes a pair of split molds that are split in half. A positioning cavity A61, a welding cavity 63, and a positioning cavity B62 are sequentially arranged horizontally and penetratingly in the split molds. A feeding channel 65 communicates upward in the middle of the welding cavity 63, and a material-receiving positioning port 64 communicates with the upper end of the feeding channel 65. The diameter of the welding cavity 63 is larger than that of the positioning cavity A61 and the positioning cavity B62, and the diameters of the positioning cavity A61 and the positioning cavity B62 are the same.

[0036] A discharging channel 67 communicates downward in the middle of the welding cavity 63, and a waste cavity 66 communicates with the lower end of the discharging channel 67. The diameter of the discharging channel 67 is smaller than that of the feeding channel 65, which can ensure that the welding material liquid fills the welding cavity.

[0037] A pair of positioning holes 69 and a pair of positioning posts 68 are arranged on each split mold, and the two positioning holes 69 and the two positioning posts 68 are arranged in a matrix.

[0038] Load the melting cup containing the welding material into the heating coil. When the welding material in the crucible melts into a liquid state, then transport the melting cup containing the liquid welding material to the welding mold, and the inner bottom discharge port of the crucible correspondingly extends into the feeding channel of the welding mold.

[0039] A welding process of a power cable intermediate joint welding device, characterized in that the welding steps of a set of welding molds are as follows:

[0040] (1) According to the number of core conductors of the power cable to be welded, the two joints to be welded of each core conductor are prepared by stripping the insulation layer, shielding layer and protective layer in sequence; at the same time, a set of reusable welding molds is prepared;

[0041] (2) Take a mold and place the two joints of a core conductor into the positioning cavity A and positioning cavity B of the former. The two joints need to be directly inserted into the welding cavity, but the two should be separated by a distance. Close the other mold and clamp it with a clamp.

[0042] (3) Prepare a crucible and insert it into the thermos cup. The blocking cone of the blocking rod seals the flow guide cone of the crucible. Then, put the amount of welding material into the melting cup. The material of the welding material is the material of the wire core conductor, which is generally pure copper. It can be prepared in advance or cut from the original wire core conductor.

[0043] (4) The staff holds a pistol and changes positions flexibly in the venue with the help of the power cord. First, the melting cup containing the welding material is filled into the heating coil. The lower part of the melting cup has a part exposed under the heating coil. The electromagnetic induction heating source is turned on. The heating coil generates an eddy current to quickly heat the crucible red, so that the welding material in the crucible melts into liquid.

[0044] (5) Use a pistol to transport the melting cup containing liquid welding material to the welding mold. The part of the melting cup that exposes the heating coil is inserted into the material receiving positioning port. The guide cone of the crucible extends into the feed channel accordingly. Then lift the blocking rod to introduce all the liquid welding material. This is divided into two processes. First, the liquid welding material that enters first passes through the feed channel, the welding chamber and the discharge channel in turn, and then flows into the waste chamber and fills the latter. This part of the liquid welding material that enters first is used to preheat the melting chamber and the wire core conductor inside the melting chamber. If it cools down too quickly, it is not suitable for use as solder, so it is discharged into the waste chamber. Secondly, the liquid welding material that enters later passes through the feed channel and stays in the welding chamber until it cools down and is used as solder. The cooling waiting or auxiliary cooling compression time;

[0045] (6) After the welding material cools and solidifies from the liquid state, release the clamp and unlock the welding mold. The welding work is completed, and then enter the next grinding and polishing process, as well as the reset work of the insulation layer, shielding layer and protective layer; at the same time, the welding mold returns to the second step and starts the welding work of the two joints to be welded of the next core conductor. Repeat the above steps until the welding work of all the core conductors of the power cable is completed.

[0046] A welding process of a power cable intermediate joint welding device, characterized in that the welding steps of multiple sets of welding dies are as follows:

[0047] (1) Prepare the same number of welding dies according to the number of wire core conductors of the power cable to be welded; at the same time, prepare the two welding joints of each wire core conductor by stripping the insulation layer, shielding layer and protective layer in sequence;

[0048] (2) Take a welding mold assembly, and place the two joints to be welded of a wire core conductor into the positioning cavity A and positioning cavity B of the former. The two joints to be welded need to be directly inserted into the welding cavity, but the two are kept separated. Close the other assembly of the welding mold and clamp it with a clamp; then assemble the next welding mold and the next wire core conductor, and complete the insertion of all wire core conductors into the welding mold in sequence;

[0049] (3) After all the wire core conductors to be welded are loaded into the corresponding welding mold and prepared, a crucible needs to be prepared in advance and inserted into the thermos cup. The flow blocking cone of the flow blocking rod seals the flow guide cone of the crucible; then, estimate the total amount of welding material for the welding joint, and put the amount of material exceeding the estimated total amount of welding material into the melting cup. The material of the welding material is the material of the wire core conductor, which can be prepared in advance or cut from the original wire core conductor;

[0050] (4) The staff holds a pistol and changes positions flexibly in the venue with the help of the power cord. First, the melting cup containing the welding material is filled into the heating coil. The lower part of the melting cup has a part exposed under the heating coil. The electromagnetic induction heating source is turned on. The heating coil generates an eddy current to quickly heat the crucible red, so that the welding material in the crucible melts into liquid.

[0051] (5) Use a pistol to transport the melting cup containing liquid welding material to the first welding mold containing the wire core conductor to be welded. The part of the melting cup that exposes the heating coil is inserted into the material positioning port. The guide cone of the crucible extends into the feed channel accordingly. Then, lift the blocking rod to introduce the liquid welding material. This is divided into two processes. First, the liquid welding material that enters first passes through the feed channel, the welding chamber and the discharge channel in turn, and then flows into the waste chamber and fills the latter. This part of the liquid welding material that enters first is used to preheat the melting chamber and the wire core conductor inside the melting chamber. If it cools down too quickly, it is not suitable for use as solder, so it is discharged into the waste chamber. Secondly, the liquid welding material that enters later passes through the feed channel and stays in the welding chamber until it cools down and is used as solder.

[0052] (6) When the liquid welding material can no longer flow in, plug the flow stopper back in, then lift the pistol and transfer it to the next welding die with the core conductor to be welded. Repeat the above process of filling the liquid welding material until all the welding dies are filled; after the welding material cools and solidifies from the liquid state, loosen the fixture and unlock the welding die, and the welding work is completed. Then, proceed to the next grinding and polishing process, as well as the reset work of the insulating layer, shielding layer, and protective layer.

Claims

1. A power cable intermediate joint welding device, characterized in that: The invention comprises an electromagnetic induction heating machine, a melting cup and at least one set of welding molds; the electromagnetic induction heating machine comprises an electromagnetic induction heating source and a heating coil; the electromagnetic induction heating machine also comprises a power cord and a handgun, the heating coil is arranged on the free end of the handgun, and the handgun is connected to the electromagnetic induction heating source through the power cord; The melting cup comprises a crucible, and a plugging mechanism with an opening and closing sealing structure is arranged at the inner bottom discharge port of the crucible; the welding mold comprises a pair of half-opened molds, and a positioning cavity A, a welding cavity and a positioning cavity B are arranged in a transverse through sequence of the molds, and a feeding channel is connected upwardly in the middle of the welding cavity; The melting cup containing the welding material is filled into the heating coil. When the welding material in the crucible melts into liquid, the melting cup containing the liquid welding material is transported to the welding mold, and the inner bottom discharge port of the crucible extends into the feed channel of the welding mold accordingly.

2. The power cable intermediate joint welding device according to claim 1, characterized in that: The electromagnetic induction heating source is specifically a high-frequency induction heating power source.

3. The power cable intermediate joint welding device according to claim 1, characterized in that: The inner bottom discharge port of the crucible is configured as a downwardly closing flow guide cone.

4. The power cable intermediate joint welding device according to claim 3, characterized in that: The blocking mechanism comprises a flow blocking rod, the lower end of which is provided with a flow blocking cone head matched with the flow guide cone mouth, and the upper end of the flow blocking rod extends out of the crucible.

5. The power cable intermediate joint welding device according to claim 3 or 4, characterized in that: The outer shell of the crucible is provided with a thermos cup, and the center of the inner bottom of the thermos cup is provided with a material passing port for allowing the guide cone to extend out.

6. The power cable intermediate joint welding device according to claim 5, characterized in that: The crucible is specifically a graphite crucible, and the thermos cup is specifically a quartz cup.

7. The power cable intermediate joint welding device according to claim 1, characterized in that: The upper end of the feed channel is connected to a material receiving positioning port, and the lower end of the feed channel is connected to a welding chamber. The diameter of the welding chamber is larger than the positioning chamber A and the positioning chamber B. The diameters of the positioning chamber A and the positioning chamber B are the same.

8. The power cable intermediate joint welding device according to claim 1 or 7, characterized in that: The middle part of the welding cavity is downwardly connected with a material discharge channel, and the lower end of the material discharge channel is connected with a waste cavity.

9. The power cable intermediate joint welding device according to claim 1, characterized in that: A pair of positioning holes and a pair of positioning posts are arranged on each of the mold blocks, and the two positioning holes and the two positioning posts are arranged in a matrix manner.

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