Low-temperature-resistant flexible cable structure for robot

Abstract

The utility model belongs to the field of cables, and provides a low temperature resistant flexible cable structure for a robot, which comprises a cable core formed by twisting a plurality of insulating wire cores and a filling layer, each insulating wire core is provided with a twisted conductor, an insulating layer and a tensile reinforcing layer from inside to outside, the insulating layer is coated on the surface of the conductor, carbon fibers are woven outside the insulating layer, and the tensile reinforcing layer is coated on the surface of the cable core. The tensile reinforcing layer is used for improving the overall strength and toughness of the cable; polyester fibers are filled among the plurality of insulating wire cores to form a filling layer. Compared with the prior art, the utility model has the advantages that the high-strength carbon fibers are woven outside the outer insulating layer, so that excellent tensile strength is provided, and high strength and high toughness can still be kept at the low temperature of-100 DEG C; and the outer sheath made of wear-resistant, oil-resistant and low-temperature-resistant modified polyvinyl chloride (PVC) is matched, so that the cable has excellent chemical corrosion resistance, wear resistance and flexibility, the electrical performance is improved, and the service life is prolonged at the same time.

Description

Technical Field

[0001] This utility model belongs to the field of cables, specifically relating to a low-temperature resistant flexible cable structure for robots. Background Technology

[0002] With the rapid development of robotics technology, the application scenarios of robots have expanded from conventional environments to polar exploration, deep-sea operations, and cryogenic industrial environments. Robots operating in these extreme conditions face a series of unique challenges, among which the performance of cables, as key components for transmitting power and signals, is particularly critical. However, due to material and technological limitations, traditional cables exhibit numerous problems in extreme low-temperature environments:

[0003] 1. Embrittlement and fracture: Most traditional cables use materials that harden and become brittle at low temperatures, making them prone to breakage, especially in applications involving frequent movement or bending, such as the joints of robots.

[0004] 2. Decreased electrical performance: Low temperatures can affect the contact resistance between the conductor and insulation layer inside the cable, increasing the resistance value and leading to greater power loss. It may even affect the stability of signal transmission, which is fatal for advanced robots that rely on precise data transmission.

[0005] 3. Insufficient durability: Traditional cables that are exposed to low temperatures for a long time may experience rapid aging, which not only shortens the service life of the cable itself, but also indirectly reduces the reliability and maintenance cost-effectiveness of the entire robot. Utility Model Content

[0006] The purpose of this invention is to address the aforementioned problems in the existing technology by proposing a low-temperature resistant flexible cable structure for robots that is simple in structure and can maintain high flexibility and durability in extreme low-temperature environments.

[0007] The objective of this utility model can be achieved through the following technical solution: A low-temperature resistant flexible cable structure for robots is proposed, comprising: a cable core formed by stranding several insulated cores and a filler layer, wherein each insulated core is provided with a stranded conductor, an insulation layer, and a tensile reinforcement layer from the inside out; the insulation layer covers the surface of the conductor, and carbon fiber is woven outside the insulation layer to form the tensile reinforcement layer, which is used to improve the overall strength and toughness of the cable; a filler layer is formed by filling the spaces between the several insulated cores with polyester fiber, which is used to enhance the tensile strength and torsional resistance of the cable.

[0008] The wrapping layer is formed by overlapping a layer of polyester tape around the outside of the cable core, which makes the cable core compact and round.

[0009] A braided shielding layer is wrapped around the polyester tape. The braided shielding layer is used to improve the resistance to electromagnetic interference, so that the cable has both conductivity and flexibility.

[0010] The outer sheath is made of wear-resistant, oil-resistant, and low-temperature-resistant modified polyvinyl chloride material, which is coated on the outside of the woven shielding layer through an extrusion process.

[0011] In the aforementioned low-temperature resistant flexible cable structure for robots, the insulation layer is made of polytetrafluoroethylene material uniformly coated on the surface of the conductor through an extrusion process.

[0012] In the aforementioned low-temperature resistant flexible cable structure for robots, the thickness of the insulation layer is 0.5mm-1.0mm.

[0013] In the aforementioned low-temperature resistant flexible cable structure for robots, the braiding density of the carbon fiber is over 90%, ensuring that the overall tensile strength of the cable meets the application requirements.

[0014] In the aforementioned low-temperature resistant flexible cable structure for robots, the conductor layer is made of oxygen-free copper material, and the purity of the oxygen-free copper is above 99.99%.

[0015] In the aforementioned low-temperature resistant flexible cable structure for robots, a nano-diamond composite coated stranding compression mold is used when the conductors are stranded.

[0016] In the aforementioned low-temperature resistant flexible cable structure for robots, the overlap rate of the polyester tape is 20% or more.

[0017] In the aforementioned low-temperature resistant flexible cable structure for robots, the braided shielding layer material is made of φ0.1mm tin-plated copper wire.

[0018] In the aforementioned low-temperature resistant flexible cable structure for robots, the braided shielding layer has a braiding density of 80% or higher.

[0019] In the aforementioned low-temperature resistant flexible cable structure for robots, the nanodiamond composite coated strand compaction mold can form a nano-coating-level protective film on the conductor surface to enhance the cable's corrosion resistance.

[0020] Compared with the prior art, the present invention has the following beneficial effects:

[0021] (1) The low-temperature resistant flexible cable structure for robots of this utility model provides excellent tensile strength by weaving high-strength carbon fiber on the outer insulation layer, and can still maintain high strength and high toughness at a low temperature of -100℃; combined with the outer sheath made of wear-resistant, oil-resistant and low-temperature resistant modified polyvinyl chloride (PVC), the cable has excellent chemical corrosion resistance, wear resistance and flexibility, improved electrical performance, and extended service life.

[0022] (2) When stranding conductors, a nano-diamond composite coating stranding compaction die is used. Using this die, a nano-coating-level protective film is formed on the conductor surface, which enhances the corrosion resistance. The working surface of the die has a high smoothness that remains unchanged. The surface is smooth and the friction coefficient is low, which is beneficial to improving the withstand voltage level and partial discharge performance of the cable.

[0023] (3) The low-temperature resistant insulation layer material is polytetrafluoroethylene. The low-temperature resistance and high insulation resistance of this material further enhance the applicability of the cable in extreme low-temperature environments. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the overall structure of this application.

[0025] In the diagram, 1 is the cable core; 10 is the insulated core; 100 is the conductor; 101 is the insulation layer; 102 is the tensile reinforcement layer; 11 is the filler layer; 2 is the wrapping tape layer; 3 is the braided shielding layer; and 4 is the outer sheath. Detailed Implementation

[0026] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings. However, the present invention is not limited to these embodiments.

[0027] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0028] like Figure 1 As shown, the present invention discloses a low-temperature resistant flexible cable structure for robots, comprising a cable core 1 formed by twisting several insulated wire cores 10 and a filling layer 11, a wrapping layer 2, a braided shielding layer 3, and an outer sheath 4 that are sequentially wrapped around the cable core 1 from the inside out.

[0029] Each insulated core 10 consists of a stranded conductor 100, an insulation layer 101, and a tensile reinforcement layer 102, arranged from the inside out. The insulation layer 101 covers the surface of the conductor 100, and carbon fiber is woven around the insulation layer 101 to form the tensile reinforcement layer 102, which is used to improve the overall strength and toughness of the cable. Polyester fiber is used to fill the spaces between several insulated cores 10 to form a filler layer 11, which is used to enhance the tensile strength and torsional performance of the cable. A wrapping layer 2 is formed by overlapping a layer of polyester tape around the cable core 1, which makes the cable core 1 tight and round. A braided shielding layer 3 is wrapped around the polyester tape, which is used to improve the electromagnetic interference resistance and make the cable both conductive and flexible. An outer sheath 4 is made of wear-resistant, oil-resistant, and low-temperature resistant modified polyvinyl chloride material and is wrapped around the braided shielding layer 3 by an extrusion process.

[0030] In this embodiment, multiple conductive copper wires are twisted together at a certain pitch to form a conductor 100, thereby improving flexibility and mechanical strength. A layer of high-performance insulating material is then extruded onto the surface of the conductor 100 to ensure safe current transmission during cable operation. Notably, this embodiment incorporates (high-strength) carbon fiber woven around the insulation layer 101 to form the required tensile strength reinforcement layer. The high-strength carbon fiber exhibits the following performance indicators: tensile strength ≥3000MPa, elastic modulus ≥70GPa, and maintains high strength and toughness at -100℃, thus significantly improving the overall strength and toughness of the cable. A filling layer 11 is formed by filling the spaces between multiple insulated cores 10 with (high-strength) polyester fiber. This not only enhances the cable's tensile strength and torsional resistance but also helps maintain the circular structure of the core 1. Furthermore, this embodiment also overlaps and wraps a layer of polyester tape around the core 1, making it more compact and round. This effectively prevents the internal cores from loosening and reduces relative displacement between cores, preventing wear due to friction and ensuring smooth progress in subsequent processing steps. The polyester tape is surrounded by a braided shielding layer 3. This braided structure, compared to longitudinal wrapping, is better suited to adapting to dynamic bending, effectively shielding against external electromagnetic interference (EMI) while ensuring signal transmission stability, thus maintaining the cable's good flexibility and bendability. Finally, this embodiment uses abrasion-resistant, oil-resistant, and low-temperature-resistant modified polyvinyl chloride (PVC) material, which is extruded over the shielding layer to form the outermost protective layer. The modified PVC possesses excellent weather resistance, maintaining flexibility in low-temperature environments and exhibiting strong abrasion resistance, making it suitable for frequent robot movement. Therefore, this cable structure fully considers the robot's requirements for high flexibility, high durability, and good electromagnetic compatibility in practical applications, enabling it to maintain normal operation in extreme low-temperature environments while also possessing the necessary tensile strength and flexibility.

[0031] It should be noted that the performance indicators of the modified polyvinyl chloride (PVC) material referred to in this embodiment can be referenced as follows: temperature resistance range -100℃ to +150℃, tensile strength ≥20 MPa, elongation ≥300%, abrasion resistance: Taber abrasion test, weight loss ≤10 mg / 1000 cycles; chemical corrosion resistance: acid and alkali resistant, oil resistant, and solvent resistant. This embodiment also includes surface treatment of the outer sheath 4: the extruded outer sheath 4 is inlaid with polytetrafluoroethylene material on the working surface of the die sleeve. After extrusion, the sheath has a glossy surface and is treated with anti-slip properties to improve operational convenience. The sheath protects the internal structure from mechanical damage and chemical corrosion, extending its service life.

[0032] like Figure 1 As shown, in this embodiment, polytetrafluoroethylene (PTFE) material is uniformly coated onto the surface of conductor 100 through an extrusion process to form an insulating layer 101. During the extrusion process, the wall thickness and concentricity are precisely controlled to ensure that the insulating layer 101 has a consistent thickness and a rounded shape. Similarly, the low-temperature resistant insulating layer 101 is made of PTFE, and its performance indicators are as follows: temperature resistance range -100℃ to +250℃, insulation resistance ≥10^14 Ω·cm, dielectric strength ≥20 kV / mm, and low-temperature flexibility (can be bent 180° at -100℃ without cracking).

[0033] Preferably, in this embodiment, the thickness of the insulation layer 101 ranges from 0.5mm to 1.0mm. This thickness can be adjusted adaptively according to the cable specifications used in practice. This thickness range provides sufficient protection without sacrificing flexibility. Even in an environment of -200℃, this thickness of PTFE can still maintain good flexibility and insulation performance, helping to extend the cable's service life and reduce failures caused by insulation wear.

[0034] More preferably, in this embodiment, the braiding density of the high-strength carbon fiber is not less than 90%, ensuring that the overall tensile performance of the cable meets the application requirements. By using a dedicated braiding machine (such as a circular loom or multi-axis braiding equipment), setting parameters such as the braiding angle (generally ±45°), yarn tension, and pitch, and adjusting the braiding speed and density, it is possible to ensure that the final braiding density reaches more than 90%. It should be noted that high-strength carbon fiber has extremely high tensile strength (up to 3500 MPa or more). When the braiding density is ≥90%, it not only provides good structural support for the cable, reducing internal conductor deformation and insulation damage during repeated bending and torsion of the cable, but also effectively disperses external tensile force throughout the reinforcing layer, significantly improving the cable's ability to withstand dynamic tensile loads, making it suitable for scenarios involving frequent robot movement and traction.

[0035] More preferably, in this embodiment, a layer of polyester tape is wrapped around the outside of the cable core 1 in an overlapping manner, and the overlap rate is not less than 20%. The polyester tape has good tensile strength and elastic modulus, and the dense structure formed by the overlapping wrapping can provide support when subjected to external pressure or torsion, effectively preventing the internal insulated core 10 from shifting or deforming during subsequent processing or use.

[0036] More preferably, the polyester tape in this embodiment is covered by a braided shielding layer 3. The braided shielding layer 3 is made of φ0.1mm tin-plated copper wire, which provides electromagnetic interference (EMI) protection. The tin-plated copper wire is resistant to oxidation and moisture, and can be stably maintained in various environments. It is suitable for complex industrial scenarios such as high temperature, low temperature, oil, and dust. Preferably, the braiding density of the braided shielding layer 3 is more than 80%, which helps to improve the anti-electromagnetic interference capability, and has high conductivity and flexibility.

[0037] More preferably, in this embodiment, the conductor 100 layer is made of high-purity oxygen-free copper (OFC) material. This involves drawing high-purity oxygen-free copper into the required diameter, testing the resistivity, mechanical properties, and surface finish of the copper wire to ensure compliance with standards. Preferably, in this embodiment, the purity of the oxygen-free copper is above 99.99%, and it undergoes surface treatment: when stranding the conductor 100, a nano-diamond composite coated stranding die is used. This die forms a nano-coating-level protective film on the surface of the conductor 100, enhancing corrosion resistance. The die's working surface has a high and consistent finish, a smooth surface, and a low coefficient of friction, which is beneficial for improving the cable's withstand voltage and partial discharge performance. The structural performance parameters are as follows: single-wire conductivity ≥101% IACS (International Annealed Copper Standard), single-wire tensile strength ≥200 MPa, single-wire elongation ≥30%, low-temperature brittleness: no embrittlement at -100℃.

[0038] Finally, the finished cables undergo mechanical, electrical, and service life tests at low temperatures to ensure they meet design requirements. Cable temperature adaptability: Temperature range: -100℃ to +150℃. Service life: ≥10 years in extreme low-temperature environments. Testing standards: Meets international standards such as IEC 60811 and IEC 60227.

[0039] It should be noted that in this invention, the use of terms such as "first," "second," and "a" is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified. The terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two elements or the interaction between two elements, unless otherwise explicitly specified. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0040] Furthermore, the technical solutions of the various embodiments of the present invention can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by the present invention.

[0041] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A low-temperature resistant flexible cable structure for robots, characterized in that, include: The cable core is composed of several insulated wire cores and a filler layer twisted together. Each of the insulated wire cores is provided with a stranded conductor, an insulation layer and a tensile reinforcement layer from the inside out. The insulation layer covers the surface of the conductor, and carbon fiber is woven outside the insulation layer to form the tensile reinforcement layer, which is used to improve the overall strength and toughness of the cable. Polyester fiber is used to fill the spaces between the several insulated wire cores to form a filler layer, which is used to enhance the tensile strength and torsional resistance of the cable. The wrapping layer is formed by overlapping a layer of polyester tape around the outside of the cable core, which makes the cable core compact and round. A braided shielding layer is wrapped around the polyester tape. The braided shielding layer is used to improve the resistance to electromagnetic interference, so that the cable has both conductivity and flexibility. The outer sheath is made of wear-resistant, oil-resistant, and low-temperature-resistant modified polyvinyl chloride material, which is coated on the outside of the woven shielding layer through an extrusion process.

2. The low-temperature resistant flexible cable structure for robots according to claim 1, characterized in that, The insulating layer is made of polytetrafluoroethylene material and is uniformly coated on the surface of the conductor through an extrusion process.

3. The low-temperature resistant flexible cable structure for robots according to claim 2, characterized in that, The thickness of the insulating layer is 0.5mm-1.0mm.

4. The low-temperature resistant flexible cable structure for robots according to claim 1, characterized in that, The braiding density of the carbon fiber is over 90%, which ensures that the overall tensile strength of the cable meets the usage requirements.

5. The low-temperature resistant flexible cable structure for robots according to claim 1, characterized in that, The conductor layer is made of oxygen-free copper material with a purity of 99.99% or higher.

6. A low-temperature resistant flexible cable structure for robots according to claim 1 or 5, characterized in that, The conductors are stranded using a nano-diamond composite coated wire clamping die.

7. The low-temperature resistant flexible cable structure for robots according to claim 1, characterized in that, The overlap rate of the polyester tape is 20% or more.

8. The low-temperature resistant flexible cable structure for robots according to claim 1, characterized in that, The braided shielding layer material is made of φ0.1mm tin-plated copper wire.

9. A low-temperature resistant flexible cable structure for robots according to claim 1 or 8, characterized in that, The braided shielding layer has a braiding density of 80% or higher.

10. A low-temperature resistant flexible cable structure for robots according to claim 6, characterized in that, The nanodiamond composite coated stranded wire compression mold can form a nano-coating-level protective film on the conductor surface to enhance the cable's corrosion resistance.

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