Safety wire harness for electrical cabinet

Abstract

The utility model relates to a safety wire harness for an electrical cabinet. The wire harness comprises a conductor layer, a composite insulating layer, a gradient buffer layer, a multi-layer heterogeneous shielding layer and an outer sheath from inside to outside in sequence, wherein the gradient buffer layer adopts a silicone rubber / carbon fiber woven spiral spring structure and is used for absorbing vibration energy; the multi-layer heterogeneous shielding layer sequentially comprises an inner shielding layer, a middle wave absorbing layer and an outer layer from inside to outside and is used for shielding electromagnetic interference. The safe wire harness for the electrical cabinet is reasonable in design, solves the problems that an insulating material of an existing wire harness for the electrical cabinet is easy to age and layer, and shielding effectiveness is attenuated during high-frequency interference, can better adapt to complex working conditions, can better adapt to the complex working conditions in practical application of the electrical cabinet, and is high in practicability. And the stability of power transmission and signal transmission is ensured.

Description

Technical Field

[0001] This utility model relates to the field of wire harness technology, specifically to a safety wire harness for electrical cabinets. Background Technology

[0002] Electrical cabinets, as core equipment in industrial control systems, play a crucial role in numerous industries such as chemical, environmental protection, power systems, metallurgy, industry, nuclear power, fire safety monitoring, and transportation. Traditional electrical cabinets typically employ a layered structure for their internal wiring harnesses, consisting of a conductor layer, an insulation layer, a shielding layer, and an outer sheath. While this structure can meet basic power transmission and signal transmission requirements to a certain extent, it has gradually revealed many problems in complex industrial application environments.

[0003] Specifically: 1. Multi-stress coupling failure: In industrial settings, the wiring harnesses inside electrical cabinets must withstand the combined effects of various complex stresses, such as mechanical vibration, temperature shock, and chemical corrosion. Regarding mechanical vibration, many pieces of equipment in industrial production generate vibrations during operation, which are transmitted to the wiring harnesses inside the electrical cabinet. Long-term vibration causes repeated stretching and compression of the insulation material inside the wiring harness, leading to aging and delamination. Temperature shock is also a significant factor. Temperature variations can be large in different industrial environments. Drastic temperature changes alter the properties of the insulation material, accelerating its aging process. Chemical corrosion is equally important. In industries such as chemical manufacturing, electrical cabinets may be exposed to corrosive chemical environments, which can erode the insulation layer of the wiring harness, leading to a decline in insulation performance. 2. Electromagnetic compatibility vulnerability: Traditional single-layer braided shielding layers, when dealing with high-frequency interference, suffer from the skin effect. The skin effect reduces the shielding ability against high-frequency interference, significantly increasing the signal error rate.

[0004] Therefore, developing a new type of safety wiring harness for electrical cabinets is of great practical significance. Utility Model Content

[0005] Purpose of the utility model: In order to overcome the above shortcomings, the purpose of this utility model is to provide a safety wire harness for electrical cabinets. It is reasonably designed and solves the problems of easy aging and delamination of insulation materials and the attenuation of shielding effectiveness under high-frequency interference in existing electrical cabinet wire harnesses. It can better adapt to complex working conditions and ensure the stability of power transmission and signal transmission in the actual application of electrical cabinets. It has broad application prospects.

[0006] Technical solution: A safety wire harness for electrical cabinets, the wire harness comprising, from the inside out, a conductor layer, a composite insulation layer, a gradient buffer layer, a multi-layer heterogeneous shielding layer, and an outer sheath; wherein, the gradient buffer layer adopts a silicone rubber / carbon fiber braided helical spring structure to absorb vibration energy; the multi-layer heterogeneous shielding layer comprising, from the inside out, an inner shielding layer, an intermediate wave-absorbing layer, and an outer layer, to shield electromagnetic interference.

[0007] The safety wiring harness for electrical cabinets described in this invention possesses excellent vibration resistance and electromagnetic compatibility. The silicone rubber / carbon fiber braided helical spring structure of the gradient buffer layer absorbs vibration energy, reducing the impact of mechanical vibration on the internal structure and ensuring the mechanical reliability of the wiring harness in vibration environments. The multi-layer heterogeneous shielding design, through the synergistic effect of the inner shielding layer, the intermediate absorbing layer, and the outer layer, effectively shields against electromagnetic interference, reduces the signal error rate, and ensures signal integrity. It plays a crucial role in environments with severe high-frequency interference, such as power systems.

[0008] Furthermore, in the aforementioned electrical cabinet safety harness, the conductor layer is made of stranded silver-plated copper wire with a cross-sectional area of ​​0.5~10mm².

[0009] The conductor layer uses stranded silver-plated copper wire with controlled cross-sectional area, which reduces the skin effect, resulting in small high-frequency impedance fluctuations and ensuring the stability of power and signal transmission in high-frequency environments.

[0010] Furthermore, in the aforementioned electrical cabinet safety harness, the stranding parameters of the silver-plated copper wire in the conductor layer are: strand pitch is 12 times the wire diameter, and stranding direction is right-hand stranding on the outer layer and left-hand stranding on the inner layer.

[0011] By controlling the twist pitch to 12 times the wire diameter, high-frequency impedance fluctuations can be kept within <5%, improving the electrical performance stability of the harness in high-frequency environments and ensuring accurate power and signal transmission. The use of right-hand twisting on the outer layer and left-hand twisting on the inner layer eliminates torque accumulation, preventing deformation or damage to the harness due to torque during use, ensuring the stability and reliability of the harness structure, and extending its service life.

[0012] Furthermore, in the aforementioned electrical cabinet safety harness, the composite insulation layer comprises, from the inside out, a polytetrafluoroethylene coating and a substrate; the substrate is made of polyetheretherketone doped boron nitride nanosheets, and a polytetrafluoroethylene coating is coated inside the substrate, the thickness of the polytetrafluoroethylene coating being 30±5μm.

[0013] The substrate of the composite insulation layer is polyetheretherketone-doped boron nitride nanosheets to improve thermal conductivity and breakdown field strength. The inner layer is coated with polytetrafluoroethylene coating with a thickness of 30±5μm, which can provide reliable acid and alkali resistance protection for the insulation layer, prevent acid and alkali substances from corroding the insulation layer, and further improve the stability and reliability of the wire harness in harsh chemical environments.

[0014] Preferably, the doping amount of boron nitride nanosheets in the substrate is 5~15wt%.

[0015] Furthermore, in the aforementioned electrical cabinet safety wiring harness, the geometric parameters of the helical spring structure of the gradient buffer layer are as follows:

[0016] a) The outer diameter of the helical spring structure = wire harness diameter × 1.2;

[0017] b) The pitch of the helical spring structure = wire harness diameter × 0.8;

[0018] c) The silicone rubber / carbon fiber is orthogonally woven into a helical spring structure at 0° / 90°, and the threaded section is a circular arc thread.

[0019] The gradient buffer layer uses silicone rubber as the matrix and carbon fiber as reinforcement. The silicone rubber / carbon fiber is orthogonally woven into a helical spring structure at 0° / 90°. During installation, a 15% axial pre-compression is applied. By precisely controlling the geometric parameters and pre-compression of the helical spring structure, it can absorb 80% of the vibration energy in the frequency range of 20~2000Hz, effectively reducing the impact of mechanical vibration on the internal structure and improving the mechanical reliability of the wire harness.

[0020] Furthermore, the aforementioned electrical cabinet uses a safety-type wiring harness, wherein the inner shielding layer is a tin-plated copper braided layer, the middle absorbing layer is a ferrite / carbon nanotube absorbing film, and the outer layer is an aluminum foil Mylar.

[0021] The multi-layer heterogeneous shielding layer consists of an inner shielding layer made of tin-plated copper braid, an intermediate absorbing layer of ferrite / carbon nanotube absorbing film, and an outer layer of aluminum foil Mylar. The inner shielding layer effectively shields against low-frequency electromagnetic interference. The intermediate absorbing layer uses a ferrite / carbon nanotube absorbing film, with ferrite powder (particle size 2~5μm) and multi-walled carbon nanotubes (diameter 10~20nm) mixed at a mass ratio of 7:3. At a thickness of 0.1mm, the absorption loss is >15dB in the 1~6GHz frequency band, effectively absorbing high-frequency electromagnetic energy and further improving the electromagnetic compatibility of the harness. The outer aluminum foil Mylar layer works synergistically with the inner shielding layer and the intermediate absorbing layer to form a multi-layered protective structure, enhancing the shielding effect against electromagnetic interference and improving the stability and reliability of the harness in complex electromagnetic environments.

[0022] Furthermore, in the aforementioned electrical cabinet safety harness, the braiding density of the tin-copper braided layer should be ≥85%, the diameter of a single wire should be 0.08mm, the braiding angle should be 45°, and the thickness of the tin-copper braided layer should be 0.12±0.02mm.

[0023] The inner shielding layer, by controlling parameters such as braiding density, single filament diameter, braiding angle, and thickness, can ensure a shielding effectiveness of ≥65dB at 1MHz, effectively shielding low-frequency electromagnetic interference and ensuring the normal operation of the wire harness in low-frequency environments.

[0024] Furthermore, the aforementioned electrical cabinet uses a safety-type wiring harness, and the outer sheath is made of thermoplastic polyurethane, with a QR code laser-etched on the outer surface of the outer sheath.

[0025] The outer sheath is made of thermoplastic polyurethane, which is oil-resistant, UV-resistant, and flame-retardant. A QR code is laser-etched on the surface of the outer sheath, which can be scanned to obtain wire harness parameters and maintenance records, facilitating the management and maintenance of the wire harness and improving work efficiency.

[0026] The beneficial effects of this utility model are as follows: The safety wire harness for electrical cabinets described in this utility model is reasonably designed. The conductor layer uses stranded silver-plated copper wire with controlled cross-sectional area, reducing the skin effect and resulting in small high-frequency impedance fluctuations, ensuring the stability of power and signal transmission in high-frequency environments. The composite insulation layer improves thermal conductivity and breakdown field strength through polyetheretherketone doped boron nitride nanosheets, while the inner PTFE coating improves acid and alkali resistance, effectively preventing aging and delamination of the insulation material, improving insulation resistance, and extending the service life of the wire harness. The silicone rubber / carbon fiber braided helical spring structure of the gradient buffer layer can absorb vibration energy, reduce the impact of mechanical vibration on the internal structure, and ensure the mechanical reliability of the wire harness in vibration environments. The design of the multi-layer heterogeneous shielding layer, through the synergistic effect of the inner shielding layer, the middle absorbing layer, and the outer layer, effectively shields electromagnetic interference, reduces the signal error rate, and ensures signal integrity. The outer sheath is made of thermoplastic polyurethane, which has oil resistance, UV resistance, and flame retardant properties. At the same time, the QR code on the surface supports scanning to obtain wire harness parameters and maintenance records, facilitating the management and maintenance of the wire harness. Attached Figure Description

[0027] Figure 1 This is an overall sectional view of the safety wire harness for the electrical cabinet described in this utility model;

[0028] Figure 2 This is a cross-sectional view of the composite insulation layer of the safety wire harness for the electrical cabinet described in this utility model;

[0029] Figure 3 This is a cross-sectional view of the gradient buffer layer of the safety wire harness for the electrical cabinet described in this utility model;

[0030] Figure 4 This is a cross-sectional view of the multi-layer heterogeneous shielding layer of the safety wire harness for the electrical cabinet described in this utility model;

[0031] Figure 5 This is a cross-sectional view of the outer sheath of the safety wire harness for the electrical cabinet described in this utility model;

[0032] In the diagram: conductor layer 1, composite insulation layer 2, polytetrafluoroethylene coating 21, substrate 22, gradient buffer layer 3, multilayer heterogeneous shielding layer 4, inner shielding layer 41, intermediate absorbing layer 42, outer layer 43, outer sheath 5. Detailed Implementation

[0033] The following is in conjunction with the appendix Figure 1 , 2 Examples 1, 2, 3, 4, 5 and Examples 1 and 2 further illustrate this utility model.

[0034] Example 1

[0035] like Figure 1 As shown, the safety harness for electrical cabinets described in this utility model comprises, from the inside out, a conductor layer 1, a composite insulation layer 2, a gradient buffer layer 3, a multi-layer heterogeneous shielding layer 4, and an outer sheath 5.

[0036] The conductor layer 1 is made of stranded silver-plated copper wire with a cross-sectional area of ​​0.5~10mm², which is used to reduce the skin effect and make the high-frequency impedance fluctuation small.

[0037] like Figure 2 As shown, the substrate 22 of the composite insulating layer 2 is a polyetheretherketone-doped boron nitride nanosheet to improve the thermal conductivity and breakdown field strength, and the inner layer is coated with a polytetrafluoroethylene coating 21 to improve acid and alkali resistance.

[0038] like Figure 3 As shown, the gradient buffer layer 3 adopts a helical spring structure woven from silicone rubber / carbon fiber to absorb vibration energy.

[0039] like Figure 4 As shown, the multi-layer heterogeneous shielding layer 4 includes an inner shielding layer 41, a middle absorbing layer 42, and an outer layer 43, which are used to shield electromagnetic interference.

[0040] like Figure 5 As shown, the base material of the outer sheath 5 is thermoplastic polyurethane, which has the characteristics of oil resistance, UV resistance and flame retardancy. A QR code is laser-etched on the surface of the outer sheath 5, which supports scanning the code to obtain the wiring harness parameters and maintenance records.

[0041] In practical applications of electrical cabinets, the aforementioned safety-type wire harness can better adapt to complex working conditions. For example, in the chemical industry, due to the presence of corrosive chemicals, the composite insulation layer 2 and outer sheath 5 of the wire harness can prevent corrosion and extend its service life. In electrical cabinets in the transportation industry, such as the electrical control systems of subways and high-speed railways, the wire harness needs to have good mechanical reliability and electromagnetic compatibility. The structural design of this safety-type wire harness can meet these requirements and ensure the stable operation of the transportation system. Faced with complex working conditions such as mechanical vibration and high temperature, the gradient buffer layer 3 of the safety-type wire harness can absorb vibration energy, and the high thermal conductivity of the composite insulation layer 2 can effectively dissipate heat, ensuring the stable operation of the wire harness in complex environments.

[0042] Example 2

[0043] Based on the structural foundation of Embodiment 1 and above, such as Figure 1 , 2 As shown in Figures 3, 4, and 5.

[0044] The safety wire harness for electrical cabinets described in this utility model has the following conductor stranding parameters in conductor layer 1: the strand pitch is 12 times the wire diameter, so that the high-frequency impedance fluctuation is <5%; the stranding direction is right-hand stranding on the outer layer and left-hand stranding on the inner layer, which is used to eliminate torque accumulation.

[0045] Furthermore, in the composite insulating layer 2, the boron nitride nanosheets in the substrate 22 are doped with 5~15wt%, and the thickness of the polytetrafluoroethylene coating 21 is 30±5μm.

[0046] Furthermore, the helical spring structure of the gradient buffer layer 3 has the following geometric parameters: outer diameter of the helical spring structure = wire harness diameter × 1.2; pitch of the helical spring structure = wire harness diameter × 0.8; when installed, a 15% axial pre-compression is applied, which can absorb 80% of the vibration energy of 20~2000Hz; the silicone rubber / carbon fiber is orthogonally woven into a helical spring structure at 0° / 90°.

[0047] Furthermore, in the multilayer heterogeneous shielding layer 4, the inner shielding layer 41 is a tin-plated copper braided layer with a braiding density of ≥85%, a single wire diameter of 0.08mm, and a braiding angle of 45°, which can ensure a shielding effectiveness of ≥65dB at 1MHz. The thickness of the tin-plated copper braided layer is 0.12±0.02mm. The middle absorbing layer 42 is a ferrite / carbon nanotube absorbing film, in which ferrite powder (particle size 2~5μm) and multi-walled carbon nanotubes (diameter 10~20nm) are mixed at a mass ratio of 7:3. When its thickness is 0.1mm, the absorption loss in the 1~6GHz frequency band is >15dB. The outer layer is aluminum foil Mylar.

[0048] Furthermore, the fabrication of the safety wiring harness for the electrical cabinet described in this utility model includes the following steps:

[0049] (1) Preparation of conductor layer 1: Silver-plated copper wires are stranded according to specific stranding parameters to form a conductor layer with a cross-sectional area of ​​0.5~10mm²;

[0050] (2) Preparation of composite insulating layer 2: Polyether ether ketone doped boron nitride nanosheets are made into substrate 22, and polytetrafluoroethylene coating 21 is coated on the inner layer;

[0051] (3) Preparation of gradient buffer layer 3: Silicone rubber / carbon fiber is orthogonally woven into a helical spring structure at 0° / 90° and set according to specific geometric parameters and pre-compression amount;

[0052] (4) Preparation of multilayer heterogeneous shielding layer 4: In sequence, an inner shielding layer 414 of tin-plated copper braid, an intermediate absorbing layer 42 of ferrite / carbon nanotube absorbing film and an outer layer 43 of aluminum foil Mylar are prepared.

[0053] (5) Preparation of outer sheath 5: Thermoplastic polyurethane is used to make outer sheath 5, and a QR code is laser-etched on its surface;

[0054] (6) Assemble the above layers in sequence to form a safety harness for electrical cabinet.

[0055] The above description is only a preferred embodiment of the present utility model. It should be noted that for those skilled in the art, several improvements can be made without departing from the principle of the present utility model, and these improvements should also be considered within the protection scope of the present utility model.

Claims

1. A safety wiring harness for an electrical cabinet, characterized in that, The wire harness comprises, from the inside out, a conductor layer (1), a composite insulation layer (2), a gradient buffer layer (3), a multi-layer heterogeneous shielding layer (4), and an outer sheath (5); wherein, the gradient buffer layer (3) adopts a helical spring structure woven from silicone rubber / carbon fiber to absorb vibration energy; the multi-layer heterogeneous shielding layer (4) comprises, from the inside out, an inner shielding layer (41), a middle absorbing layer (42), and an outer layer (43) to shield electromagnetic interference.

2. The safety wiring harness for electrical cabinets according to claim 1, characterized in that, The conductor layer (1) is made of stranded silver-plated copper wire with a cross-sectional area of ​​0.5~10mm².

3. The safety wiring harness for electrical cabinets according to claim 2, characterized in that, The stranding parameters of the silver-plated copper wire in the conductor layer (1) are: the strand pitch is 12 times the wire diameter, and the stranding direction is right-hand stranding in the outer layer and left-hand stranding in the inner layer.

4. The safety wiring harness for electrical cabinets according to claim 1, characterized in that, The composite insulating layer (2) includes a polytetrafluoroethylene coating (21) and a substrate (22) from the inside to the outside. The substrate (22) is made of polyether ether ketone doped boron nitride nanosheets. The polytetrafluoroethylene coating (21) is coated inside the substrate (22), and the thickness of the polytetrafluoroethylene coating (21) is 30±5μm.

5. The safety wiring harness for electrical cabinets according to claim 1, characterized in that, The geometric parameters of the helical spring structure of the gradient buffer layer (3) are as follows: a) The outer diameter of the helical spring structure = wire harness diameter × 1.2; b) The pitch of the helical spring structure = wire harness diameter × 0.8; c) Silicone rubber / carbon fiber is orthogonally woven into a helical spring structure at 0° / 90°.

6. The safety wiring harness for electrical cabinets according to claim 1, characterized in that, The inner shielding layer (41) is made of tin-plated copper braided layer, the middle absorbing layer (42) is made of ferrite / carbon nanotube absorbing film, and the outer layer (43) is made of aluminum foil Mylar.

7. The safety wiring harness for electrical cabinets according to claim 6, characterized in that, The braiding density of the tin-copper braided layer should be ≥85%, the diameter of a single wire should be 0.08mm, the braiding angle should be 45°, and the thickness of the tin-copper braided layer should be 0.12±0.02mm.

8. The safety wiring harness for electrical cabinets according to claim 1, characterized in that, The outer sheath (5) is made of thermoplastic polyurethane, and a QR code is laser-etched on the outer surface of the outer sheath (5).

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