Integrated flexible cable for wind power generation

Abstract

The utility model discloses an integrated flexible cable for wind power generation, which comprises a longitudinally extending cable core, and a belting layer and an outer sheath which are arranged outside the cable core, and the cable core comprises a power transmission unit, a control unit, a signal transmission unit and a communication unit; the power transmission unit comprises a power transmission unit wire core, and a power transmission unit inner protection layer and a power transmission unit shielding layer which are arranged outside the power transmission unit wire core; the control unit comprises a control unit wire core, and a control unit inner protection layer and a control unit shielding layer which are arranged outside the control unit wire core; the signal transmission unit comprises a signal transmission unit wire core, and a signal transmission unit inner protection layer and a signal transmission unit shielding layer which are arranged outside the signal transmission unit wire core; the communication unit comprises a communication unit wire core, and a communication unit inner protection layer and a communication unit shielding layer which are arranged outside the communication unit wire core. The cable provided by the utility model solves the technical problem that the traditional cable for wind power generation does not meet the multifunctional integration requirement.

Description

Technical Field

[0001] The utility model belongs to the technical field of wire and cable, and particularly relates to an integrated flexible cable for wind power generation. Background Art

[0002] In 2023, the installed capacity of renewable energy power generation in China historically exceeded that of thermal power for the first time, and the newly installed capacity throughout the year exceeded half of the global total. At present, there is huge room for development in China's wind power industry. The demand for cables for wind power generation remains strong. Moreover, with the increase in the single-unit installed capacity, new requirements are continuously put forward for the design and development of cables. There are not only higher and higher requirements for the voltage level, but also the demand for the integration of units such as power lines and control lines, so as to save costs and installation space, and thus meet the special operating conditions requirements of wind turbines.

[0003] The Chinese utility model patent authorization announcement number CN205038988U discloses a torsion-resistant flexible cable for wind power generation, which includes a plurality of conductors, an insulating layer, a shielding layer and a sheath. An isolation layer is wound around the conductor, and an insulating layer is arranged outside the isolation layer to form an insulated wire core. Fillers are arranged between the insulated wire cores, and a plurality of insulated wire cores form a cable core. A tape layer, a shielding layer and a sheath are sequentially arranged on the cable core from inside to outside. The flexible cable of this utility model has the characteristics of being torsion-resistant, cold-resistant, salt spray-resistant, ultraviolet-resistant, and excellent electrical and mechanical physical properties. However, this flexible cable has only a single function and does not meet the requirement of multi-functional integration. Summary of the Utility Model

[0004] Aiming at the existing technical problems, the utility model aims to provide an integrated flexible cable for wind power generation, which can solve the technical problem that the traditional cable for wind power generation does not meet the requirement of multi-functional integration.

[0005] In order to achieve the above purpose, the technical solution adopted by the utility model is as follows:

[0006] An integrated flexible cable for wind power generation includes a longitudinally extending cable core, a tape layer and an outer sheath sequentially arranged outside the cable core. Its structural characteristics are: the cable core includes a power transmission unit, a control unit, a signal transmission unit and a communication unit; the power transmission unit includes a power transmission unit wire core, a power transmission unit inner sheath and a power transmission unit shielding layer sequentially arranged outside the power transmission unit wire core; the control unit includes a control unit wire core, a control unit inner sheath and a control unit shielding layer sequentially arranged outside the control unit wire core; the signal transmission unit includes a signal transmission unit wire core, a signal transmission unit inner sheath and a signal transmission unit shielding layer sequentially arranged outside the signal transmission unit wire core; the communication unit includes a communication unit wire core, a communication unit inner sheath and a communication unit shielding layer sequentially arranged outside the communication unit wire core.

[0007] The soft cable of the present application divides each combined unit according to functions. The internal structures of each combined unit are designed separately and then twisted into a cable as a whole. This not only ensures a clear distinction between each functional unit but also forms a combined integrated structure, reducing the overall material consumption and installation and laying space. After each functional unit is independently twisted into a cable, an inner sheath is extruded on each of them, and then a shielding layer is wrapped around the inner sheath to reduce the mutual electromagnetic interference between each unit.

[0008] Preferably, a filling strip is provided at the center of both the power transmission unit and the signal transmission unit. The setting of the filling strip can effectively improve the tensile and anti-torsion performance of the conductor.

[0009] Preferably, filling strips are filled at the center and around the cable core. The setting of the filling strip can effectively improve the tensile and anti-torsion performance of the cable.

[0010] Preferably, the filling strip is a reinforced high-elastic rubber strip.

[0011] Specifically, the power transmission unit core includes multiple power transmission unit conductors, and power transmission unit insulating layers are provided outside each of these power transmission unit conductors; the control unit core includes multiple control unit conductors, and control unit insulating layers are provided outside each of these control unit conductors; the signal transmission unit core has two groups, and each group of signal transmission unit cores includes multiple signal transmission unit conductors, and signal transmission unit insulating layers are provided outside each of these signal transmission unit conductors; the communication unit core has two groups, and each group of communication unit cores includes multiple communication unit core conductors, and communication unit insulating layers are provided outside each of these communication unit core conductors.

[0012] Preferably, the inner sheaths of the power transmission unit, the control unit, the signal transmission unit, and the communication unit are all made of a halogen-free flame-retardant TPE sheath material with a temperature resistance of -40°C to 105°C, and the insulating layers of the power transmission unit, the control unit, the signal transmission unit, and the communication unit are all made of a halogen-free flame-retardant TPE elastomer insulating material with a temperature resistance of -40°C to 105°C. The use of special soft halogen-free flame-retardant TPE insulating materials and inner sheath materials with a temperature resistance of -40°C to 105°C meets the performance requirements of the product for high and low temperature resistance, salt spray resistance, flame retardancy, etc.

[0013] Preferably, an isolation layer is provided outside the shielding layers of the power transmission unit, the control unit, the signal transmission unit, and the communication unit. The isolation layer is made of a non-woven fabric tape or a polyester tape. The setting of the isolation layer can effectively isolate the mutual friction of the braided wires between each functional unit during the twisting process of the cable and reduce the risk of broken braided wires.

[0014] Specifically, the shielding layers of the power transmission unit, the control unit, and the signal transmission unit are all woven with tinned copper wires, and the braiding density is not less than 80%.

[0015] Specifically, the shielding layer of the communication unit includes an aluminum-plastic composite tape and a tinned copper wire braided layer arranged in sequence from the inside to the outside. The aluminum surface of the aluminum-plastic composite tape is in contact with the tinned copper wire braided layer, and the braiding density of the shielding layer of the communication unit is not less than 85%.

[0016] Preferably, the outer sheath is made of a flame-retardant TPU material with a temperature resistance of -40°C to 105°C. The flame-retardant TPU outer sheath material with a temperature resistance of -40°C to 105°C meets the performance requirements of the product for high and low temperature resistance, salt spray resistance, flame retardancy, etc.

[0017] Compared with the prior art, the beneficial effects of the present utility model are as follows:

[0018] 1. For the integrated flexible cable for wind power generation of the present utility model, the cable divides each combined unit according to functions, and the internal structures of each combined unit are designed separately and then integrally stranded into a cable. This not only ensures the clear distinction of each functional unit but also forms a combined integrated structure, reducing the overall material consumption and installation and laying space.

[0019] 2. For the integrated flexible cable for wind power generation of the present utility model, after each functional unit is independently stranded into a cable, an inner sheath is extruded on each of them, and then a shielding layer is wrapped around the inner sheath, reducing the mutual electromagnetic interference between each unit.

[0020] 3. For the integrated flexible cable for wind power generation of the present utility model, a torsion-resistant conductor structure and a cable core structure are designed, and a strengthened filling is provided, which can effectively improve the tensile and torsion-resistant performance of the cable.

[0021] 4. For the integrated flexible cable for wind power generation of the present utility model, by providing an isolation layer, the mutual friction of the braided wires between each unit during the torsion process of the cable can be effectively isolated, reducing the risk of broken braided wires.

[0022] 5. For the integrated flexible cable for wind power generation of the present utility model, a special soft halogen-free flame-retardant TPE insulating material and inner sheath material with a temperature resistance of -40°C to 105°C, as well as a flame-retardant TPU outer sheath material with a temperature resistance of -40°C to 105°C, meet the performance requirements of the product for high and low temperature resistance, salt spray resistance, flame retardancy, etc. Description of the Drawings

[0023] Figure 1 is a schematic structural diagram of the integrated flexible cable for wind power generation of the present utility model;

[0024] Figure 2 is Figure 1 a schematic structural diagram of the power transmission unit in

[0025] Figure 3 is Figure 1 a schematic structural diagram of the control unit in

[0026] Figure 4 is Figure 1 Schematic diagram of the signal transmission unit structure in

[0027] Figure 5 is Figure 1 Schematic diagram of the communication unit structure in

[0028] Figure 6 is Figure 1 Flow chart of the production process of the cable product of

[0029] In the figure

[0030] 1 - Power transmission unit, 11 - Core of power transmission unit, 111 - Conductor of power transmission unit, 112 - Insulation layer of power transmission unit, 12 - Inner sheath of power transmission unit, 13 - Shielding layer of power transmission unit, 14 - Tape layer of power transmission unit, 2 - Control unit, 21 - Core of control unit, 211 - Conductor of control unit, 212 - Insulation layer of control unit, 22 - Inner sheath of control unit, 23 - Shielding layer of control unit, 24 - Tape layer of control unit, 3 - Signal transmission unit, 31 - Core of signal transmission unit, 311 - Conductor of signal transmission unit, 312 - Insulation layer of signal transmission unit, 32 - Inner sheath of signal transmission unit, 33 - Shielding layer of signal transmission unit, 34 - Tape layer of signal transmission unit, 4 - Communication unit, 41 - Core of communication unit, 411 - Conductor of communication unit, 412 - Insulation layer of communication unit, 42 - Inner sheath of communication unit, 43 - Shielding layer of communication unit, 44 - Tape layer of communication unit, 5 - Tape layer, 6 - Outer sheath, 7 - Filler strip, 8 - Isolation layer. Specific embodiments

[0031] The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with embodiments. It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other. For the convenience of description, words such as "upper", "lower", "left", and "right" hereinafter only indicate the same directions as the upper, lower, left, and right directions of the accompanying drawings themselves, and do not limit the structure.

[0032] As Figure 1 shown, an integrated flexible cable for wind power generation provided in this embodiment includes a longitudinally extending cable core, and a tape layer 5 and an outer sheath 6 sequentially arranged outside the cable core. The cable core includes a power transmission unit 1, a control unit 2, two groups of signal transmission units 3 and two groups of communication units 4, and filler strips 7 are filled in the center and around the cable core.

[0033] As Figure 2As shown, the power transmission unit 1 includes a power transmission unit core 11, and a power transmission unit tape layer 14, a power transmission unit inner sheath 12, a power transmission unit shielding layer 13, and an isolation layer 8 that are sequentially arranged outside the power transmission unit core 11. A filling strip 7 is provided at the center of the power transmission unit 1. The power transmission unit core 11 includes six power transmission unit conductors 111, and power transmission unit insulation layers 112 are arranged outside each of the power transmission unit conductors 111. The filling strip 7 is arranged at the center of the six power transmission unit conductors 111. As Figure 3 shown, the control unit 2 includes a control unit core 21, and a control unit tape layer 24, a control unit inner sheath 22, a control unit shielding layer 23, and an isolation layer 8 that are sequentially arranged outside the control unit core 21. The control unit core 21 includes four control unit conductors 211, and control unit insulation layers 212 are arranged outside each of the control unit conductors 211. As Figure 4 shown, the signal transmission unit 3 includes a signal transmission unit core 31, and a signal transmission unit tape layer 34, a signal transmission unit inner sheath 32, a signal transmission unit shielding layer 33, and an isolation layer 8 that are sequentially arranged outside the signal transmission unit core 31. Filling strips 7 are provided at the centers of the signal transmission unit 3. The signal transmission unit core 31 includes six signal transmission unit conductors 311, and signal transmission unit insulation layers 312 are arranged outside each of the signal transmission unit conductors 311. The filling strip 7 is arranged at the center of the six signal transmission unit conductors 311. As Figure 5 shown, the communication unit 4 includes a communication unit core 41, and a communication unit tape layer 44, a communication unit inner sheath 42, a communication unit shielding layer 43, and an isolation layer 8 that are sequentially arranged outside the communication unit core 41. The communication unit core 41 includes four communication unit core conductors 411, and communication unit insulation layers 412 are arranged outside each of the communication unit core conductors 411. The filling strips 7 are all made of reinforced high-elastic rubber strips, and the isolation layers 8 are all made of non-woven fabric tapes or polyester tape wraps. The power transmission unit insulation layer 112, the control unit insulation layer 212, the signal transmission unit insulation layer 312, and the communication unit insulation layer 412 are all extruded with a halogen-free flame-retardant TPE elastomer insulating material with a temperature resistance of 105°C. The power transmission unit inner sheath 12, the control unit inner sheath 22, the signal transmission unit inner sheath 32, and the communication unit inner sheath 42 are all extruded with a halogen-free flame-retardant TPE elastomer sheath material with a temperature resistance of 105°C, and the surface of the inner sheath is smooth and round. The power transmission unit shielding layer 13, the control unit shielding layer 23, and the signal transmission unit shielding layer 33 are all woven with tinned copper wires, and the weaving density is not less than 80%. The communication unit shielding layer 43 includes an aluminum-plastic composite tape and a tinned copper wire braided layer arranged in sequence from the inside to the outside. The aluminum surface of the aluminum-plastic composite tape is in contact with the tinned copper wire braided layer, and the weaving density of the communication unit shielding layer 43 is not less than 85%. The outer sheath 6 is made of a special polyurethane TPU material for flame-retardant wind power products, and the surface of the sheath is preferably a bright surface.

[0034] As Figure 6 shown, the production process of the integrated flexible cable product for wind power generation in this embodiment mainly includes the following steps:

[0035] 1) The φ8.0mm copper rod is drawn into copper wires with a diameter of 0.15 - 0.41mm by a wire drawing device;

[0036] 2) Conductor stranding: The drawn copper wires are stranded into strands to respectively manufacture the power transmission unit conductor 111, the control unit conductor 211, the signal transmission unit conductor 311, and the communication unit conductor 411. The stranding direction can be left - hand or right - hand. Optionally, the specifications of the power transmission unit conductor 111 can be selected as 10 - square and 16 - square cross - section conductors according to the actual current - carrying capacity requirements. For the 16 - square conductor, it needs to be further re - stranded. The bunch strands are further combined and stranded in a 1 + 6 arrangement to achieve the required cross - section size of the conductor. In particular, the re - stranding direction of the power transmission unit conductor 111 needs to be consistent with the stranding direction;

[0037] 3) Insulation extrusion is performed on the power transmission unit conductor 111, the control unit conductor 211, the signal transmission unit conductor 311, and the communication unit conductor 411;

[0038] 4) Cabling of the power transmission unit core 11: Six insulated power transmission unit conductors 111 are stranded into one strand by a cabling device, and the lay ratio is controlled between 9 and 10. Cabling of the control unit core 21: Four insulated control unit conductors 211 are stranded into one strand by a cabling device, and the lay ratio is controlled between 9 and 10. Cabling of the signal transmission unit core 31: Six insulated signal transmission unit conductors 311 are stranded into one strand by a cabling device, and the lay ratio is controlled between 9 and 10. Cabling of the communication unit core 41: The insulated communication unit conductor 411 is pairwise twisted. The lay ratios of the two twisted pairs are respectively controlled between 13 and 14 and between 12 and 13. Then, the cores of the two twisted pairs are stranded into one strand by a cabling device, and the lay ratio is controlled between 9 and 10;

[0039] 5) After wrapping the cabled cores of the power transmission unit core 11, the control unit core 21, the signal transmission unit core 31, and the communication unit core 41, an inner sheath is extruded on each respectively, and the surface of each inner sheath should be smooth and round;

[0040] 6) Tin-plated copper wires are used to braid outside the inner sheath 12 of the power transmission unit to form the power transmission unit shielding layer 13, and the braiding density is not less than 80%; tin-plated copper wires are used to braid outside the inner sheath 22 of the control unit to form the control unit shielding layer 23, and the braiding density is not less than 80%; tin-plated copper wires are used to braid outside the inner sheath 32 of the signal transmission unit to form the signal transmission unit shielding layer 33, and the braiding density is not less than 80%; for the inner sheath 42 of the communication unit, an aluminum-plastic composite tape is wrapped around it, and then tin-plated copper wires are used to braid to form a communication unit shielding layer 43 with a structure of aluminum-plastic composite tape + tin-plated copper wire braiding. The aluminum surface of the aluminum-plastic composite tape is in contact with the braided layer, and the braiding density is not less than 85%;

[0041] 7) An isolation tape is wrapped around the power transmission unit shielding layer 13, the control unit shielding layer 23, the signal transmission unit shielding layer 33 and the communication unit shielding layer 43;

[0042] 8) Assembly stranding and wrapping: The power transmission unit 1, the control unit 2, the signal transmission unit 3, and the communication unit 4 are stranded once, and the stranding pitch diameter ratio is controlled between 9 and 10. The cable core should be round and straight, and the filling should be compact; in particular, the stranding direction of the assembled cable is the same as that of each unit's individual cable stranding;

[0043] 9) Extrusion of the outer sheath: An outer sheath 6 is extruded on the assembled cable core. The sheath material uses a special polyurethane TPU material for flame-retardant wind power products, and the surface of the sheath is preferably shiny.

[0044] The content clarified in the above embodiments should be understood that these embodiments are only used to more clearly illustrate the present invention, rather than to limit the scope of the present invention. After reading the present invention, various equivalent forms of modification of this embodiment by those skilled in the art all fall within the scope defined by the appended claims of the present invention.

Claims

1. An integrated flexible cable for wind power generation, comprising a cable core extending longitudinally, and a tape layer (5) and an outer sheath (6) sequentially arranged outside the cable core, characterized in that: The cable core comprises a power transmission unit (1), a control unit (2), a signal transmission unit (3) and a communication unit (4); The power transmission unit (1) comprises a power transmission unit wire core (11), and a power transmission unit inner protective layer (12) and a power transmission unit shielding layer (13) which are sequentially arranged outside the power transmission unit wire core (11); The control unit (2) comprises a control unit wire core (21), and a control unit inner sheath (22) and a control unit shielding layer (23) which are sequentially arranged outside the control unit wire core (21); The signal transmission unit (3) comprises a signal transmission unit wire core (31), and a signal transmission unit inner sheath (32) and a signal transmission unit shielding layer (33) which are sequentially arranged outside the signal transmission unit wire core (31); The communication unit (4) comprises a communication unit wire core (41), and a communication unit inner sheath (42) and a communication unit shielding layer (43) which are sequentially arranged outside the communication unit wire core (41).

2. The integrated flexible cable for wind power generation according to claim 1, characterized in that: Filling strips (7) are provided at the centres of the power transmission unit (1) and the signal transmission unit (3).

3. The integrated flexible cable for wind power generation according to claim 2, characterized in that: The center and surrounding areas of the cable core are filled with filling strips (7).

4. The integrated flexible cable for wind power generation according to claim 3, characterized in that: The filling strip (7) is a reinforced high-elastic rubber strip.

5. The integrated flexible cable for wind power generation according to claim 1, characterized in that: The power transmission unit core (11) comprises a plurality of power transmission unit conductors (111), and a power transmission unit insulation layer (112) is disposed outside the power transmission unit conductors (111); the control unit core (21) comprises a plurality of control unit conductors (211), and a control unit insulation layer (212) is disposed outside the control unit conductors (211); the signal transmission unit core (31) is provided with two groups, and each group of signal transmission unit cores (31) comprises a plurality of signal transmission unit conductors (311), and a signal transmission unit insulation layer (312) is disposed outside the signal transmission unit conductors (311); the communication unit core (41) is provided with two groups, and each group of communication unit cores (41) comprises a plurality of communication unit core conductors (411), and a communication unit insulation layer (412) is disposed outside the communication unit core conductors (411).

6. The integrated flexible cable for wind power generation according to claim 5, characterized in that: The power transmission unit inner protective layer (12), the control unit inner protective layer (22), the signal transmission unit inner protective layer (32) and the communication unit inner protective layer (42) are all made of a halogen-free flame-retardant TPE sheath material with a temperature resistance of -40°C to 105°C, and the power transmission unit insulation layer (112), the control unit insulation layer (212), the signal transmission unit insulation layer (312) and the communication unit insulation layer (412) are all made of a halogen-free flame-retardant TPE elastomer insulation material with a temperature resistance of -40°C to 105°C.

7. The integrated flexible cable for wind power generation according to claim 1, characterized in that: An isolation layer (8) is arranged outside the power transmission unit shielding layer (13), the control unit shielding layer (23), the signal transmission unit shielding layer (33) and the communication unit shielding layer (43), and the isolation layer (8) is made of non-woven fabric or polyester tape.

8. The integrated flexible cable for wind power generation according to claim 1, characterized in that: The power transmission unit shielding layer (13), the control unit shielding layer (23) and the signal transmission unit shielding layer (33) are all woven from tinned copper wires, with a weaving density of not less than 80%.

9. The integrated flexible cable for wind power generation according to claim 1, characterized in that: The communication unit shielding layer (43) comprises an aluminum-plastic composite tape and a tinned copper wire braided layer arranged in sequence from the inside to the outside, the aluminum surface of the aluminum-plastic composite tape is in contact with the tinned copper wire braided layer, and the braiding density of the communication unit shielding layer (43) is not less than 85%.

10. The integrated flexible cable for wind power generation according to claim 1, characterized in that: The outer sheath (6) is made of flame-retardant TPU material with a temperature resistance of -40°C to 105°C.

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