A high tensile strength and corrosion resistant cable for offshore wind power

Abstract

This utility model discloses a high tensile strength and corrosion resistance cable for offshore wind power, comprising a cable core consisting of a central tensile rope and multiple moisture-proof insulated cores; the moisture-proof insulated cores are tangent to the central tensile rope; moisture-proof and water-blocking filler is used to fill the gaps in the cable core; a shielding aluminum-plastic composite tape is wrapped around the cable core; a corrosion-resistant composite layer is provided outside the shielding aluminum-plastic composite tape; a flexible buffer layer is extruded outside the corrosion-resistant composite layer; a steel tape armor layer is provided outside the flexible buffer layer; a PTFE film tape is overlapped and wrapped around the steel tape armor layer; and an outer sheath is extruded outside the PTFE film tape. By optimizing the cable structure and material selection, the tensile strength and corrosion resistance of the cable are improved, while maintaining the cable's flexibility and service life, to meet the high requirements of offshore wind farms for cables.

Description

Technical Field

[0001] This utility model relates to the field of power cables, specifically to a high tensile strength and corrosion resistance cable for offshore wind power. Background Technology

[0002] A wind power generation system is a combination of mechanical, electrical, and control equipment that converts wind energy into electrical energy. All components in a wind power generation system require corresponding cables for connection. The wind turbine generator, as the core energy conversion device in wind power generation, relies heavily on cables to transmit and convert energy. In the entire wind power generation system, cables are the blood vessels and nerves of the system, playing an irreplaceable and crucial role.

[0003] Wind turbine generators operate in harsh environments, and the rotation of the wind turbine blades is irregular and swings according to the wind direction. The cable must be frequently and randomly twisted, swung and pulled along with the direction of the wind turbine blades. The twisting speed and angle are uncertain. The cable must also oscillate and bend inside the wind turbine tower. The resulting swaying amplitude and pulling force are also uncertain, making it easy for the core to break and be damaged.

[0004] In offshore wind farms, cables also face the challenge of seawater corrosion, requiring excellent resistance to such corrosion. For example, wind power cables used in near-shore wind turbines must be able to withstand the erosion of salt and other substances in seawater to ensure long-term reliable operation. Furthermore, to accommodate the automatic yaw of wind turbines, wind power cables must meet the requirements of flexible and frequent torsion. For instance, cables used in special locations between the nacelle and the tower that require frequent twisting must possess excellent torsional and tensile strength.

[0005] With the increasing popularity of large wind turbine units, higher requirements have been placed on the electrical performance, dimensions, seawater corrosion resistance, and torsional angle resistance of cables. Existing cables cannot guarantee their safety performance and stability. Utility Model Content

[0006] To address the issues of poor corrosion resistance, torsional resistance, and tensile strength in existing offshore wind power cables, this invention provides a high-tensile-strength and corrosion-resistant cable for offshore wind power. This cable boasts high mechanical strength, excellent corrosion resistance, good torsional resistance, and a long service life, making it suitable for cable applications in environments characterized by strong chemical seawater corrosion and complex mechanical stress. It can ensure normal operation of the line for extended periods in harsh and complex environments, significantly improving the cable's service life.

[0007] To achieve the above objectives, this utility model provides a high tensile strength and corrosion resistance cable for offshore wind power, comprising a cable core, wherein the cable core is composed of a central tensile rope and multiple moisture-proof insulating cores; the moisture-proof insulating cores are tangent to the central tensile rope; moisture-proof and water-blocking filler is filled in the gaps of the cable core; a shielding aluminum-plastic composite tape is wrapped around the cable core; a corrosion-resistant composite layer is provided outside the shielding aluminum-plastic composite tape; a flexible buffer layer is extruded outside the corrosion-resistant composite layer; a steel tape armor layer is provided outside the flexible buffer layer; a PTFE film tape is overlapped and wrapped around the steel tape armor layer; and an outer sheath is extruded outside the PTFE film tape.

[0008] Preferably, the multiple moisture-proof insulated wire cores include a rare earth aluminum alloy conductor, a cross-linked polyethylene insulation layer extruded over the rare earth aluminum alloy conductor, multiple wire core tensile ropes provided inside and outside the cross-linked polyethylene insulation layer, a polyvinyl chloride plastic film wrapped around the cross-linked polyethylene insulation layer, and an ultra-smooth semi-conductive shielding layer extruded over the polyvinyl chloride plastic film.

[0009] Preferably, both the central tensile rope and the core tensile rope are woven from Kevlar fibers.

[0010] Preferably, the ratio of the diameter of the core tensile rope to the diameter of the rare earth aluminum alloy conductor is 0.6-0.8.

[0011] Preferably, the moisture-proof and water-blocking filler is made of glass fiber cloth and asphalt mastic coated on the glass fiber cloth.

[0012] Preferably, the corrosion-resistant composite layer includes a nano-ceramic coating, a waterproof and corrosion-resistant high-density polyethylene tape, and a fluororubber anti-corrosion layer. After the nano-ceramic coating is coated on the outer surface of the shielding aluminum-plastic composite tape, the waterproof and corrosion-resistant high-density polyethylene tape is wrapped around it, and the fluororubber anti-corrosion layer is extruded over the waterproof and corrosion-resistant high-density polyethylene tape.

[0013] Preferably, the flexible buffer layer is made of expanded thermoplastic polyurethane by extrusion molding.

[0014] Preferably, the outer sheath is made of ultra-high molecular weight polyethylene cable material through extrusion molding.

[0015] Compared with the prior art, the beneficial effects of this utility model are as follows:

[0016] 1. The cable using rare earth aluminum alloy conductors of this utility model has excellent electrical properties, creep resistance, heat resistance, wear resistance and corrosion resistance, making it safer and more reliable as a conductor; the selected rare earth elements can effectively improve the corrosion resistance and mechanical properties of aluminum alloys, showing significant advantages in conductivity, mechanical strength and corrosion resistance.

[0017] 2. This utility model enables the cable to have strong tensile strength by setting a central tensile rope and a core tensile rope, avoiding the problem of wire breakage when subjected to frequent pulling, swinging and torsion by wind force, and meeting the high tensile and high torsion requirements of offshore wind power.

[0018] 3. The moisture-proof and water-blocking filler of this utility model has a high closed-cell rate and a low water absorption rate, which makes the cable have a good waterproof effect. Moreover, the moisture-proof and water-blocking filler does not absorb water and will not reduce its strength due to saturation, so it can play a long-term moisture-proof and water-blocking role.

[0019] 4. The corrosion-resistant composite layer structure of this utility model can improve the corrosion resistance and corrosion resistance of the cable. It will not loosen or fall off after long-term use, has good flexibility, and can resist the erosion of sea waves.

[0020] 5. The flexible buffer layer of this utility model is made of expandable thermoplastic polyurethane. This flexible buffer layer tightly covers the outside of the anti-corrosion layer and has good elasticity and buffering performance. It can effectively absorb the stress generated by the cable during torsion and tension, and protect the safety of the internal structure of the cable. Moreover, the flexible buffer layer material has a small coefficient of thermal expansion, which can avoid the occurrence of cracking and local tensile fracture of the cable due to temperature changes.

[0021] 6. The steel strip armor layer structure of this utility model can not only effectively protect the cable from damage caused by animal gnawing, but also provide mechanical resistance and enhance wear resistance. In addition, the steel strip armor layer has a certain degree of corrosion resistance, thereby effectively extending its service life.

[0022] 7. The cable outer sheath is made of ultra-high molecular weight polyethylene, which has strong corrosion resistance and can maintain excellent flexibility even in low-temperature environments, greatly increasing the cable's corrosion resistance and mechanical properties and extending its service life. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of this utility model;

[0024] Figure 2 A schematic diagram of the structure of a moisture-proof insulated wire core. Detailed Implementation

[0025] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the present invention. After reading the present invention, any modifications of the present invention in various equivalent forms by those skilled in the art will fall within the scope defined by the appended claims.

[0026] like Figure 1-2As shown, this utility model provides a high tensile strength and corrosion resistance cable for offshore wind power, including a cable core, which is composed of a central tensile rope 1 and multiple moisture-proof insulating cores 2; and the moisture-proof insulating cores are tangent to the outer edge of the central tensile rope.

[0027] Among them, the moisture-proof insulated wire core 2 includes a rare earth aluminum alloy conductor 21, a cross-linked polyethylene insulation layer 23 extruded on the rare earth aluminum alloy conductor, multiple wire core tensile ropes 22 provided on the outside and inside of the cross-linked polyethylene insulation layer, a polyvinyl chloride plastic film 24 wrapped around the cross-linked polyethylene insulation layer, and an ultra-smooth semi-conductive shielding layer 25 extruded on the polyvinyl chloride plastic film.

[0028] In this embodiment, a rare earth aluminum alloy conductor is used, which has excellent electrical properties, creep resistance, heat resistance, wear resistance and corrosion resistance, making it safer and more reliable as a wire. The selected rare earth elements can effectively improve the corrosion resistance and mechanical properties of the aluminum alloy, showing significant advantages in conductivity, mechanical strength and corrosion resistance.

[0029] Both the central tensile rope 1 and the core tensile rope 22 are woven from Kevlar fiber, which is lightweight and has strong tensile strength. The tensile strength is 5 times that of steel wire. It is also resistant to high temperature and corrosion, avoiding the problem of wire breakage when subjected to frequent pulling, swinging and torsion by wind, thus meeting the high tensile and high torsion requirements of offshore wind power.

[0030] The ratio of the diameter of the core tensile rope to the diameter of the rare earth aluminum alloy conductor is 0.6-0.8, which provides sufficient mechanical support while reducing the weight of the cable, preventing the conductor from breaking under tension, bending or external pressure, without excessively restricting the bending radius of the cable, ensuring flexible bending in complex paths, and reducing internal stress concentration; while ensuring sufficient mechanical strength, it controls the overall size and weight of the cable, improves flexibility, optimizes conductivity, and reduces costs.

[0031] Furthermore, moisture-proof and water-blocking filler 3 is filled into the gaps in the cable core, shielding aluminum-plastic composite tape 4 is wrapped around the outside of the cable core, nano-ceramic coating 5 is applied to the outside of the shielding aluminum-plastic composite tape, and then waterproof and corrosion-resistant high-density polyethylene tape 6 is wrapped around it. Fluororubber anti-corrosion layer 7 is extruded on the outside of the waterproof and corrosion-resistant high-density polyethylene tape to form a corrosion-resistant composite layer.

[0032] It should be noted that the moisture-proof and water-blocking filler is made of fiberglass cloth and asphalt mastic coated on the fiberglass cloth. It has a high closed-cell rate and a low water absorption rate, which makes the cable have a good waterproof effect. Moreover, the moisture-proof and water-blocking filler does not absorb water and will not reduce its strength due to saturation, so it can play a long-term moisture-proof and water-blocking role.

[0033] In addition, the cable employs a corrosion-resistant composite layer internally. The inner layer uses a nano-ceramic coating, formed through a spraying process on the inner surface of the cable to create a dense nano-ceramic layer. Nano-ceramics possess extremely high hardness, wear resistance, and corrosion resistance, effectively preventing the intrusion of corrosive media. The middle layer uses waterproof and corrosion-resistant high-density polyethylene tape, exhibiting excellent chemical stability, waterproof performance, electrical insulation, and aging resistance. This layer further enhances the cable's corrosion resistance and waterproof performance while protecting the nano-ceramic layer. The outer layer uses a fluororubber (FKM) anti-corrosion layer. Fluororubber has excellent oil resistance, solvent resistance, high and low temperature resistance, and chemical stability. When in contact with harsh external environments, the outer fluororubber anti-corrosion layer provides a reliable anti-corrosion barrier for the cable, greatly enhancing its corrosion resistance and meeting the environmental requirements of marine cables.

[0034] Finally, a flexible buffer layer 8 is extruded over the corrosion-resistant composite layer, a steel strip armor layer 9 is provided over the flexible buffer layer, and a PTFE film tape 10 is overlapped and wrapped over the steel strip armor layer. This not only provides good flexibility and tensile strength, but also corrosion resistance, further improving the cable's ability to withstand frequent torsion. An outer sheath 11 is extruded over the PTFE film tape.

[0035] In this embodiment, the flexible buffer layer is made of intumescent thermoplastic polyurethane extrusion molding. The flexible buffer layer tightly covers the outside of the anti-corrosion layer and has good elasticity and buffering performance. It can effectively absorb the stress generated by the cable during torsion and tension, and protect the internal structure of the cable. Moreover, the flexible buffer layer material has a small coefficient of thermal expansion, which can avoid the occurrence of cracking and local tensile fracture of the cable due to temperature changes.

[0036] In this embodiment, the cable outer sheath is made of ultra-high molecular weight polyethylene, which has strong corrosion resistance and can maintain excellent flexibility even in low-temperature environments, greatly increasing the cable's corrosion resistance and mechanical properties and extending its service life.

[0037] In summary, this application aims to provide a high tensile strength and corrosion resistance cable for offshore wind power. By optimizing the cable structure and material selection, the tensile strength and corrosion resistance of the cable are improved, while maintaining the cable's flexibility and service life, so as to meet the high requirements of offshore wind farms for cable operation.

[0038] There are many specific applications of this utility model. The above description is only a preferred embodiment of this utility model. It should be noted that for those skilled in the art, several improvements can be made without departing from the principle of this utility model, and these improvements should also be considered within the protection scope of this utility model.

Claims

1. A high tensile strength and corrosion-resistant cable for offshore wind power, comprising a cable core, characterized in that... The cable core consists of a central tensile rope and multiple moisture-proof insulated cores; the moisture-proof insulated cores are tangent to the central tensile rope; moisture-proof and water-blocking filler is used to fill the gaps in the cable core; a shielding aluminum-plastic composite tape is wrapped around the cable core; a corrosion-resistant composite layer is provided outside the shielding aluminum-plastic composite tape; a flexible buffer layer is extruded outside the corrosion-resistant composite layer; a steel tape armor layer is provided outside the flexible buffer layer; a PTFE film tape is wrapped around the steel tape armor layer; and an outer sheath is extruded outside the PTFE film tape.

2. The high tensile strength and corrosion resistance cable for offshore wind power according to claim 1, characterized in that: The multiple moisture-proof insulated wire cores include a rare earth aluminum alloy conductor, a cross-linked polyethylene insulation layer extruded over the rare earth aluminum alloy conductor, multiple tensile ropes inside and outside the cross-linked polyethylene insulation layer, a polyvinyl chloride plastic film wrapped around the cross-linked polyethylene insulation layer, and an ultra-smooth semi-conductive shielding layer extruded over the polyvinyl chloride plastic film.

3. The high tensile strength and corrosion resistance cable for offshore wind power according to claim 2, characterized in that: Both the central tensile rope and the core tensile rope are made of Kevlar fiber.

4. A high tensile strength and corrosion-resistant cable for offshore wind power according to claim 2, characterized in that: The ratio of the diameter of the core tensile rope to the diameter of the rare earth aluminum alloy conductor is 0.6-0.

8.

5. A high tensile strength and corrosion-resistant cable for offshore wind power according to claim 2, characterized in that: The moisture-proof and water-blocking filler is made of glass fiber cloth and asphalt mastic coated on the glass fiber cloth.

6. A high tensile strength and corrosion-resistant cable for offshore wind power according to claim 2, characterized in that: The corrosion-resistant composite layer includes a nano-ceramic coating, a waterproof and corrosion-resistant high-density polyethylene tape, and a fluororubber anti-corrosion layer. After the nano-ceramic coating is coated on the outer surface of the shielded aluminum-plastic composite tape, the waterproof and corrosion-resistant high-density polyethylene tape is wrapped around it, and the fluororubber anti-corrosion layer is extruded over the waterproof and corrosion-resistant high-density polyethylene tape.

7. A high tensile strength and corrosion-resistant cable for offshore wind power according to claim 2, characterized in that: The flexible buffer layer is made by extrusion molding of expanded thermoplastic polyurethane.

8. A high tensile strength and corrosion-resistant cable for offshore wind power according to claim 2, characterized in that: The outer sheath is made of ultra-high molecular weight polyethylene cable material through extrusion molding.

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