Electric wire with D-shaped core wire structure, D-shaped eye mold and D-shaped stranding cabling mold

Abstract

The utility model discloses an electric wire with a D-shaped core wire structure, a D-shaped eye mold and a D-shaped stranding cabling mold, which comprise a wire core, the wire core is D-shaped, the wire core is formed by pressing a plurality of strands of conductors, an insulating layer is formed outside the wire core through extrusion molding, the insulating layer is extruded into a D shape, the insulating layer is provided with a plane and an arc-shaped surface, and the arc-shaped surface is arranged on the plane. The planes of the two insulating layers are attached to each other, the two strands of insulating layers are stranded, and after the two strands of insulating layers are stranded, a sheath is formed outside the two strands of insulating layers through extrusion molding; as the core wire is of a D-shaped structure and is circular after being twisted into a cable, the concentricity can reach more than 90% when an outer sheath is extruded, the appearance of the cable is smooth and full, the error of the wire diameter can be controlled within + / -0.1, the distance from a sheath to the wire core is highly consistent, and the condition of wire damage caused by non-uniform wall thickness of the sheath during later sheath stripping operation is avoided.

Description

Technical Field

[0001] This utility model relates to a wire with a D-shaped core wire structure, a D-shaped eye mold, and a D-shaped stranded cable mold. Background Technology

[0002] Currently, conventional structural electrical wires generally use round core wires.

[0003] The current round core wire structure has a large difference in sheath thickness when making two-core sheathed wires. During the sheath stripping operation, there are problems such as scratching the core wire insulation or uneven stripping. Utility Model Content

[0004] The purpose of this utility model is to provide a wire with a D-shaped core wire structure, a D-shaped eye mold, and a D-shaped stranded cable mold.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A wire with a D-shaped core structure includes a core, the core being "D"-shaped, the core being formed by pressing together multiple conductors, and an insulation layer being extruded onto the outside of the core. The insulation layer is extruded into a "D" shape and has a planar surface and an arc-shaped surface. The planar surfaces of the two insulation layers are attached to each other, and the two strands of the insulation layer are twisted together. After twisting, a sheath is extruded onto the outside of the two strands of the insulation layer.

[0007] Preferably, the wire core is formed by extrusion using a wire pressing machine.

[0008] Preferably, the conductor is made of annealed bare copper conductor and bonded with 1000D Kevlar.

[0009] Preferably, the diameter of a single annealed bare copper conductor is 0.12 mm.

[0010] Preferably, the diameter of the two strands of insulation after twisting is 3.6 mm ± 0.1 mm.

[0011] Preferably, the diameter of the sheath after molding is 4.91mm ± 0.1mm.

[0012] A D-type eye mold includes an eye mold body having a D-shaped hole for extruding an insulating layer.

[0013] A D-type stranding cable mold includes a mold having two symmetrical D-type through-holes. Two insulating layers wrapped with wire cores pass through the D-type through-holes and are fed into a stranding machine, where they are stranded and then conveyed to an extruder.

[0014] Compared with the prior art, the beneficial effects of this utility model are:

[0015] Because the core wire has a D-shaped structure, the structure after stranding into a cable is circular. When the outer sheath is extruded, the concentricity can reach more than 90%, and the cable appearance is smooth and full. The wire diameter error can be controlled within ±0.1. The distance between the sheath and the core wire remains highly consistent. During the later sheath stripping operation, the wire damage caused by uneven sheath wall thickness is avoided. Attached Figure Description

[0016] Figure 1 This is a cross-sectional view of the wire;

[0017] Figure 2 This is a structural diagram of a D-type eye mold;

[0018] Figure 3 This is a structural diagram of a D-type stranded cable mold;

[0019] Figure 4 This is a flowchart of the wire production process. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0021] Please refer to Figure 1 As shown, this utility model is a wire with a D-shaped core wire structure, including a wire core 1, which is D-shaped and formed by pressing multiple conductors 11 together. An insulation layer 2 is extruded on the outside of the wire core 1. The insulation layer 2 is extruded into a D-shape and has a flat surface 21 and an arc-shaped surface 22. The flat surfaces 21 of the two insulation layers 2 are attached to each other, and the two strands of the insulation layer 2 are twisted together. After twisting, a sheath 3 is extruded on the outside of the two strands of the insulation layer 2.

[0022] The core wire 1 is formed by extrusion using a wire pressing machine.

[0023] The conductor 11 is made of annealed bare copper conductor and bonded with 1000D Kevlar.

[0024] The diameter of a single annealed bare copper conductor is 0.12 mm.

[0025] The conductor 11 in this technical solution is more resistant to swinging and can withstand greater tensile force than conventional wires.

[0026] The diameter of the two strands of insulation after twisting is 3.6mm ± 0.1mm. This is about 0.7mm smaller than the conventional two-core round cable with a diameter of Ø4.3mm.

[0027] The diameter of the formed sheath 3 is 4.91mm ± 0.1mm. This is about 0.7mm smaller than the traditional two-core round power cable Ø5.6mm ± 0.1mm. By calculating the amount of material used in the sheath, it saves about 50% of the sheath material.

[0028] A D-type eye mold includes an eye mold body 4, the eye mold body 4 having a D-shaped hole 41 for extruding an insulating layer 2.

[0029] A D-type stranding cable mold includes a mold 5, which has two symmetrical D-type through-holes 51. Two insulating layers 2 wrapped with wire cores 1 pass through the D-type through-holes 51 and are fed into a stranding machine, which strands the wires into a cable and then conveys it to an extruder.

[0030] The processing steps for this product are as follows:

[0031] 01. Stranded Copper Wire: First, arrange the 67 spools of individual copper wires sequentially through the pay-off frame and tension gun. Using the 7-hole wiring method, arrange the individual copper wires sequentially through the wire dividers, adjusting the spacing between each divider. Pass the wires through the eyepiece, and then, according to equipment requirements, pass the bundled copper wires through the bow and internal take-up reel, winding them onto the internal take-up spool. After installing the wires, adjust the pay-off tension, ensuring the tension of the tension gun is even. After adjusting the equipment parameters, adjust the internal take-up tension, the width of the wires, and the spacing between the wires; then you can begin bundling the wires.

[0032] 02 Core Insulation Shaping: Core 1 is made by rolling and shaping copper conductors using a special rolling mill. The height of the shaped copper conductor after rolling and shaping needs to be controlled within 0.72mm ± 0.1mm, and the width needs to be controlled within 2.08mm ± 0.1mm. Then, a TPE wire extrusion machine is used, employing a combination of proprietary shaped extrusion inner and outer dies. The inner die size is required to be 0.95mm x 2.4mm, and the outer die size is required to be 1.75mm x 3.7mm. The two work together to obtain a D-shaped core wire that meets the requirement of 1.7mm x 3.45mm ± 0.1mm.

[0033] 03 Core wire insulation pressing: The core wires coming out of the wire tying machine are already wrapped with insulation layer 2, enter the cooling mechanism, and then wind around to the automatic wire storage device. The wire diameter measuring equipment of the wire storage device measures whether the wire diameter meets 1.75mm x 3.7mm; if it meets the requirement, the wire is automatically taken back, and the insulation pressing is completed.

[0034] 04. Stranding Insulated Cores into Cables: Place the cores to be stranded on the internal rotating cradle and adjust the core tension. Mount the cores from the untwisting shaft and pass them through the guide rollers. Wind the cores sequentially onto the tension guide rollers. Pass the cores through the distribution reel according to the core arrangement order required by the cabling parameter table. Twist the cores together and pass them through the D-type port into the main unit. Mold 5 needs to be fixed with tools. The front is for dragging and the back is for wrapping. Select the appropriate wrapping tape specification according to the product parameter table. Adjust the empty and full reel tension parameters of the wrapping tape. The forward / reverse direction of the wrapping tape must be set according to the corresponding product cabling parameter table. Begin cabling.

[0035] 05 Sheath Pressing: Use power pay-off and check the pay-off tension. Push the semi-finished spool into the pay-off frame and use the lifting operation to make the spool center parallel to the pay-off main shaft center. Then lock the central shaft of the pay-off frame and lower the lifting tray. Wind the semi-finished wire onto the tension guide roller according to the winding sequence. Adjust the appropriate tension air pressure of the tension guide roller. Place the TPE raw material in a special drying machine for drying and dehumidification treatment (required temperature 80 degrees Celsius for 2-4 hours). Turn on the preheater and powder sifter in advance. Pass the core wire and conductor copper wire through the machine head eyepiece and start the main machine at a slow speed, and adjust the wire concentricity. Install the printing wheel and adjust the ink and scraper. The pressing wheel and the fixed guide rollers on both sides should be aligned before printing. After printing, the wire production is complete.

[0036] 06 Performance Testing: After the outer sheath of the wire is extruded, it enters the wire outer diameter measuring instrument. The actual outer diameter of the wire is measured by the central infrared sensor of the measuring instrument. The 3D measurement is performed according to the extruded outer sheath of 4.91mm. If it meets the OD, the high-frequency spark tester uses high-voltage electric shock to detect whether the wire core has exposed copper or the insulation is too thin. Marks are made on the parts that are below the minimum insulation thickness. The take-up coil is adjusted for pitch and arrangement, and the wire is taken up according to the outer diameter of 4.91mm.

[0037] The purpose of the above process is to improve the problems of low space utilization, large amount of outer sheath material, unstable extrusion dimensions of the outer sheath, and low yield of wire cutting after forming in traditional two-core power cords. This invention uses a cold rolling wheel for one-time forming during core wire extrusion, and the D-shaped structure greatly improves space utilization. The concentricity of the extruded outer sheath section is high, and the amount of outer sheath material used is far less than that of traditional two-core power cords, eliminating the need for filling. The high concentricity of the core wire forming results in greater controllability in subsequent processing, stronger stability after cabling, and easier outer sheath extrusion. The overall structure is more stable, which not only reduces the amount of insulation material used and reduces costs, but also greatly reduces rework costs due to improved dimensional stability at the stripping and wire forming stations in subsequent processing.

[0038] The contents not described in detail in this specification are existing technologies known to those skilled in the art.

[0039] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A wire with a D-type core wire structure, characterized in that, Includes a wire core (1), which is "D" shaped. The wire core (1) is formed by pressing multiple conductors (11) together. An insulation layer (2) is extruded on the outside of the wire core (1). The insulation layer (2) is extruded into a "D" shape. The insulation layer (2) has a plane (21) and an arc surface (22). The planes (21) of the two insulation layers (2) are attached to each other. The two insulation layers (2) are twisted together. After twisting, a sheath (3) is extruded on the outside of the two insulation layers (2).

2. The wire with a D-type core wire structure according to claim 1, characterized in that, The core wire (1) is formed by extrusion using a wire pressing machine.

3. The wire with a D-type core wire structure according to claim 1, characterized in that, The conductor (11) is made of annealed bare copper conductor and bonded with 1000D Kevlar.

4. The wire with a D-type core wire structure according to claim 3, characterized in that, The diameter of a single annealed bare copper conductor is 0.12 mm.

5. The wire with a D-type core wire structure according to claim 3, characterized in that, The diameter of the two insulating layers (2) after twisting is 3.6mm ± 0.1mm.

6. The wire with a D-type core wire structure according to claim 5, characterized in that, The diameter of the sheath (3) after molding is 4.91mm ± 0.1mm.

7. A D-type eye mold for a wire with a D-type core wire structure as described in any one of claims 1 to 6, characterized in that, Includes an eye mold body (4), which has a D-shaped hole (41) for extruding an insulating layer (2).

8. A D-type stranding cable mold for a wire with a D-type core wire structure as described in any one of claims 1 to 6, characterized in that, Includes a mold (5), which has two symmetrical D-shaped ports (51). Two insulating layers (2) wrapped with wire cores (1) pass through the D-shaped ports (51) and are fed to a cable stranding machine, which strands them into shape and then conveys them to an extruder.

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