An industrial-grade compact high-integration power control integrated cable
By using a three-core tangential reinforcement design and a multi-layer shielding structure, the problems of loose outer diameter and poor mechanical properties of traditional cables are solved, achieving a compact and efficient cable design and improving the mechanical stability and signal transmission reliability of the cable.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- BEIJING VIBROFLOTATION ENG
- Filing Date
- 2025-07-25
- Publication Date
- 2026-05-29
Smart Images
Figure CN224304383U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of cable technology, and in particular to an industrial-grade compact, highly integrated power control cable. Background Technology
[0002] In industries such as manufacturing, construction, and new energy, cables serve as crucial carriers for power transmission and signal control. Their structural rationality and performance stability directly impact the overall system's operational efficiency and safety. However, traditional cables suffer from several structural design shortcomings: Firstly, the loose arrangement of the conductors, with large gaps between power conductors, control conductors, and other components, necessitates the use of a large amount of filler material to ensure structural stability. This results in a larger overall cable diameter, occupying more installation space, increasing wiring difficulty, and raising cable weight and manufacturing costs due to excessive filler material usage. Secondly, their mechanical properties are insufficient to meet the demands of complex operating conditions. The outer sheath is often a single-layer design with limited torsional resistance, abrasion resistance, and oil resistance, and lacks effective tensile reinforcement. Under frequent movement, bending, or tensile stress, sheath damage and conductor breakage are common, shortening service life. Furthermore, some cables suffer from poor electromagnetic shielding between control and power conductors, making signal transmission susceptible to interference. Inadequate insulation design also poses a potential risk of short circuits between conductors, making them unsuitable for demanding electrical environments. These issues mean that traditional cables have room for improvement in terms of compactness, economy, mechanical strength, and transmission stability, and there is an urgent need for a cable with a more optimized structure to solve these problems. Utility Model Content
[0003] The purpose of this invention is to provide an industrial-grade, compact, highly integrated power control cable that solves the aforementioned problems.
[0004] This utility model is achieved through the following technical solution:
[0005] An industrial-grade compact, highly integrated power control cable includes an outer sheath, an inner sheath, a fiber braided reinforcement layer, a filler layer, three power conductors, a reinforcement conductor, and three control conductors.
[0006] The cable consists of, from the outside in, an outer sheath, a fiber braided reinforcement layer, an inner sheath, and a wrapping tape.
[0007] The three power cores are placed inside the wrapping tape and are tangent to each other and also to the outer wrapping tape. A reinforcing core is set at the center of the three power cores due to their tangency. The three control lines are respectively set at the edge gaps of the three power cores and are tangent to the wrapping tape and the two power cores.
[0008] Furthermore,
[0009] The reinforcing conductor is made of soft steel wire rope with non-woven fabric or soft steel wire rope with extruded ethylene propylene rubber insulation, and is placed in the center gap of the three main insulated conductors.
[0010] Furthermore,
[0011] The filler layer is located in the gap between the power core, the reinforcing core, the control wire, and the wrapping tape, and is filled with insulating material.
[0012] Furthermore,
[0013] The control line includes a control cable core and a metal shielding layer. Each control line is formed by twisting two or more control cable cores together, and a metal shielding layer is wrapped around the twisted control cable cores.
[0014] Furthermore,
[0015] The power core includes a power core insulation layer and a soft copper conductor. The soft copper conductor is formed by twisting multiple copper wires together and is wrapped with a power core insulation layer on the outside.
[0016] Furthermore,
[0017] The metal shielding layer is made of polyester tape wrapped with tinned copper wire braided with polyester tape or loosely wrapped copper wire with semi-conductive nylon tape.
[0018] The beneficial effects of this utility model are:
[0019] 1. This utility model uses a tight arrangement of three power cores that are tangent to each other and attached to the wrapping tape, a reinforcing core in the center, and control wires placed in the side gaps. Combined with the filling layer filling the blank spaces, it minimizes the internal gaps and makes the overall cable structure more compact. This not only reduces the outer diameter of the cable and saves installation space, but also reduces the use of filling layer material, thus reducing the weight and cost of the cable.
[0020] 2. The cable's outer layer adopts a double-layer sheath (outer sheath and inner sheath) with a fiber braided reinforcement layer in the middle, giving the cable excellent anti-torsion, wear resistance and oil resistance; the central reinforcing core uses soft steel wire rope, which enhances the cable's tensile strength, effectively resists the stress caused by tension and bending, improves the cable's mechanical stability during moving or fixed installation, and extends its service life under complex working conditions. Attached Figure Description
[0021] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present invention and form part of this application, do not constitute a limitation thereof. In the drawings:
[0022] Figure 1 This is a schematic diagram of the structure of this utility model.
[0023] The attached diagram shows the markings and corresponding component names:
[0024] 1-Outer sheath, 2-Fiber braided reinforcing layer, 3-Inner sheath, 4-Filling layer, 5-Power core, 50-Power core insulation layer, 51-Soft copper conductor, 6-Reinforcing core, 60-Soft steel wire rope, 61-Non-woven fabric or EPDM rubber insulation, 7-Control wire, 70-Control core, 71-Metallic shielding layer, 8-Wrapping tape. Detailed Implementation
[0025] The present invention will be further described in detail below with reference to the embodiments and accompanying drawings, but the implementation of the present invention is not limited thereto.
[0026] In the description of this utility model, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "longitudinal", "lateral", "horizontal", "inner", "outer", "front", "rear", "top", "bottom", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.
[0027] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set up," "have," "install," "connect," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.
[0028] See the example. Figure 1 :
[0029] An industrial-grade compact, highly integrated power control cable includes an outer sheath 1, an inner sheath 3, a fiber braided reinforcement layer 2, a filler layer 4, three power conductors 5 and a reinforcement conductor 6, and three control conductors 7.
[0030] The cable consists of, from the outside in, an outer sheath 1 layer, a fiber braided reinforcement layer 2, an inner sheath 3, and a wrapping tape 8;
[0031] The three power cores 5 are placed inside the wrapping tape 8 and are tangent to each other and also to the outer wrapping tape 8. A reinforcing core 6 is set at the center of the three power cores 5 due to their tangency. The three control lines 7 are respectively set at the edge gaps of the three power cores 5 and are tangent to the wrapping tape 8 and the two power cores 5.
[0032] Furthermore,
[0033] The reinforcing core 6 is made of soft steel wire rope 60 plus non-woven fabric or soft steel wire rope 60 plus extruded ethylene propylene rubber insulation, and is placed at the center gap of the three main insulated cores.
[0034] The soft steel wire rope 60 itself has high mechanical strength. When combined with non-woven fabric or ethylene propylene rubber insulation 61, it can enhance the stability of the overall cable structure through the support at the center position, resist the stress caused by tension and bending, and avoid electrical interference with the surrounding wire cores through the insulation material, thereby improving the durability and safety of the cable under complex working conditions.
[0035] In one embodiment, the reinforcing core 6 of the cable adopts a combination structure of soft steel wire rope 60 plus non-woven fabric or soft steel wire rope 60 plus extruded ethylene propylene rubber insulation, specifically placed in the central gap surrounded by the three main insulated cores. This design, through material combination and location selection, utilizes the high strength characteristics of the soft steel wire rope 60 to fill the central space, while ensuring electrical isolation between it and the surrounding cores through the non-woven fabric or ethylene propylene rubber insulation 61, achieving a combination of structural filling and functional reinforcement.
[0036] Furthermore,
[0037] The filling layer 4 is located in the gap between the power core 5, the reinforcing core 6, the control line 7 and the wrapping tape 8, and is filled with insulating material.
[0038] Filling the gaps with insulating material can eliminate internal gaps, ensuring a tight fit between each conductor and the wrapping tape 8, preventing wear caused by shaking and friction during cable movement or bending. On the other hand, the insulating material itself can enhance the overall insulation performance, reducing the risk of short circuits between conductors. At the same time, the tangential relationship between the power conductor 5, reinforcing conductor 6, control conductor 7, and wrapping tape 8 reduces the number of gaps that need to be filled, making the cable structure more compact, reducing the overall outer diameter, reducing the amount of filler required, reducing cable weight, and lowering costs.
[0039] In one embodiment, the filler layer 4 is disposed in the blank area between the power core 5, the reinforcing core 6, the control wire 7, and the wrapping tape 8, and is made of insulating material. This is achieved by completely covering the gaps between the internal cores and the wrapping tape 8 with the insulating material, so that each component forms a tightly fitted whole within the wrapping tape 8, avoiding structural loosening due to gaps.
[0040] Furthermore,
[0041] The control line 7 includes a control cable core and a metal shielding layer 71. Each control line 7 is formed by twisting two or more control cable cores together, and a metal shielding layer 71 is wrapped around the twisted control cable cores.
[0042] The control cable core is formed by twisting, which can cancel the electromagnetic interference of adjacent cable cores and reduce signal transmission loss; the outer metal shielding layer 71 can isolate the interference of the external electromagnetic environment. The dual design ensures the stable transmission of control signals in complex electrical environments and guarantees the reliability of the cable's control function.
[0043] In one embodiment, the control cable core adopts a 16×1.5 specification. Its control core 70 is composed of a tinned soft copper conductor 51 conforming to IEC60228 Type 5 and extruded ethylene propylene rubber insulation. The insulation is white and printed with black numbers (natural numbers starting from 1) for identification. The 16×1.5 control core 70 is divided into three twisted pairs in numerical order, namely 1~5, 6~10, and 11~15. Each twisted pair is provided with a metal shielding layer 71 after twisting. Different colored yarns can also be added to each twisted pair to distinguish different twisted pairs.
[0044] Furthermore,
[0045] The power core 5 includes a power core insulation layer 50 and a soft copper conductor 51. The soft copper conductor 51 is formed by twisting multiple copper wires together and is wrapped with a power core insulation layer 50 on the outside.
[0046] The soft copper conductor 51, formed by multiple twisted copper wires, is more flexible than a single hard conductor, making it easier to bend the cable during moving or fixed installation and reducing the risk of conductor breakage due to bending. The outer power core insulation layer 50 effectively isolates the conductor from the outside environment, preventing leakage and ensuring the safety of power transmission.
[0047] In one embodiment, the nominal thickness of the power conductor insulation layer 50 is 1.8 mm, with the thinnest point being 1.5 mm.
[0048] Furthermore,
[0049] The metal shielding layer 71 is made of polyester tape wrapping + tinned copper wire braiding + polyester tape wrapping or loosely wrapped copper wire + semi-conductive nylon tape.
[0050] The three-layer structure of "polyester tape wrapping + tinned copper wire braiding + polyester tape wrapping" has a clear division of labor. The inner polyester tape protects and controls the cable core from wear of the braided layer, the middle tinned copper wire braided layer achieves efficient electromagnetic shielding through the conductivity of metal, and the outer polyester tape fixes the braided layer and enhances its corrosion resistance. The multi-layer synergy improves the shielding effect while extending the service life of the shielding layer.
[0051] In one embodiment, each layer of polyester tape is wrapped in two layers, and the tinned copper wire is woven with a weaving density of not less than 85%, which has a better isolation effect.
[0052] The method of using this utility model is as follows:
[0053] The cable of this invention achieves stable operation and durability during use. Structurally, the cable forms a multi-layered protection system consisting of an outer sheath 1, a fiber braided reinforcing layer 2, an inner sheath 3, and a wrapping tape 8. The outer sheath provides waterproof, wear-resistant, and oil-resistant properties, while the middle fiber braided layer enhances torsional and tensile strength. Combined with the double-layer design of the inner and outer sheaths 1, it can withstand mechanical and chemical corrosion in complex environments. The three internal power cores 5 are tangent to each other and attached to the wrapping tape 8. A reinforcing core 6 is located in the center, and control lines 7 are placed in the gaps at the edges. The tight arrangement eliminates unnecessary gaps, achieving efficient space utilization and reducing the use of the filler layer 4 (insulation material), thus reducing the weight and cost of the cable while meeting compactness requirements.
[0054] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of this utility model. It should be understood that the above description is only a specific embodiment of this utility model and is not intended to limit the scope of protection of this utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the scope of protection of this utility model.
Claims
1. An industrial-grade, compact, highly integrated power control cable, characterized in that, It includes an outer sheath (1), an inner sheath (3), a fiber braided reinforcement layer (2), a filling layer (4), three power cores (5) and a reinforcement core (6), and three control lines (7); The cable consists of an outer sheath (1) layer, a fiber braided reinforcement layer (2) layer, an inner sheath (3) layer, and a wrapping tape (8) layer from the outside to the inside. The three power cores (5) are placed inside the wrapping tape (8) and are tangent to each other and also tangent to the outer wrapping tape (8). A reinforcing core (6) is set at the center of the three power cores (5) due to their tangency. The three control lines (7) are respectively set at the edge gap of the three power cores (5) and are tangent to the wrapping tape (8) and the two power cores (5).
2. The industrial-grade compact, highly integrated power control cable according to claim 1, characterized in that, The reinforcing core (6) is made of soft steel wire rope (60) plus non-woven fabric or soft steel wire rope (60) plus extruded ethylene propylene rubber insulation, and is placed at the center gap of the three main insulated cores.
3. The industrial-grade compact, highly integrated power control cable according to claim 1, characterized in that, The filler layer (4) is located in the gap between the power core (5), the reinforcing core (6), the control line (7) and the wrapping tape (8), and is filled with insulating material.
4. The industrial-grade compact, highly integrated power control cable according to claim 2, characterized in that, The control line (7) includes a control cable core and a metal shielding layer (71). Each control line (7) is formed by twisting two or more control cable cores together, and a metal shielding layer (71) is wrapped around the twisted control cable core.
5. The industrial-grade compact, highly integrated power control cable according to claim 1, characterized in that, The power core (5) includes a power core insulation layer (50) and a soft copper conductor (51). The soft copper conductor (51) is formed by twisting multiple copper wires together and is wrapped with a power core insulation layer (50) on the outside.
6. The industrial-grade compact, highly integrated power control cable according to claim 4, characterized in that, The metal shielding layer (71) is made of polyester tape wrapping + tinned copper wire braiding + polyester tape wrapping or loosely wrapped copper wire + semi-conductive nylon tape.