High durability coal mining machine optical fiber composite rubber jacketed flexible cable

Abstract

The utility model discloses a kind of high durability coal cutter optical fiber composite rubber jacketed flexible cable, including power line core group, control line core group and light unit group;The power line core group includes power line core conductor, power line core semi-conductive layer, power line core insulating layer and power line core hybrid braiding layer sequentially arranged from inside to outside;The control line core group includes control line core conductor, control line core insulating layer, control line core braided shielding layer and control line core cladding layer sequentially arranged from inside to outside.The high durability coal cutter optical fiber composite rubber jacketed flexible cable is mainly used for fully mechanized coal face special purpose, and power transmission, control signal transmission and communication signal transmission can be realized.It has excellent physical and mechanical properties, control line core has excellent electromagnetic compatibility and transmission stability, and light unit group is simultaneously arranged, so that communication signal transmission can be realized.

Description

Technical Field

[0001] This utility model relates to the field of power cables, specifically to a high-durability fiber optic composite rubber-sheathed flexible cable for coal mining machines. Background Technology

[0002] Traditional extensive coal production methods not only require a large amount of human resources but also cause serious environmental damage. Accelerating the transformation of coal production methods to achieve safe, efficient, and green mining with reduced manpower and automation, as well as clean, efficient, and low-carbon utilization, is an urgent requirement of the coal revolution. Clearly, under the wave of intelligent industrial manufacturing, the coal industry, as an important energy sector in my country, must actively engage in intelligent construction; this is both an inevitable trend and a requirement for coal mining enterprises to implement innovation-driven and value-creation strategies.

[0003] Driving high-quality development through technological innovation is undoubtedly key for the coal industry to implement the new development philosophy and solve industry challenges. At the same time, it is important to note that the construction of intelligent coal mines is an ongoing process. We must look to the future, maintain confidence, and accelerate the promotion and application of these technologies, while also being grounded in reality, continuously overcoming technological bottlenecks, accelerating talent cultivation, seizing opportunities, and acting in accordance with the trend to take the initiative strategically.

[0004] Intelligent coal mining is a core technological support for the high-quality development of the coal industry. It deeply integrates artificial intelligence, industrial Internet of Things, cloud computing, big data, robots, and intelligent equipment with modern coal development and utilization to form an intelligent system that enables comprehensive perception, real-time interconnection, analysis and decision-making, autonomous learning, dynamic prediction, and collaborative control. This is of great significance for improving the level of safe production in coal mines and ensuring a stable supply of coal.

[0005] With the continuous introduction of safety policies for coal production, coal mine cable manufacturing projects, as a type of safety assurance equipment in the coal mining industry, will be widely used in the coal mining industry. Various types of mining cables that are used in conjunction with these cables will have a broader market prospect and can obtain good economic benefits.

[0006] Mining rubber-sheathed cables are not only an indispensable part of industrial enterprises and construction, but also one of the main materials driving my country's rapid social development. They come in many varieties, and their applications extend beyond the power industry to include construction, communications, manufacturing, and other sectors. In recent years, the mining rubber-sheathed cable industry has experienced rapid growth. While a supporting industry, it is the second largest in the electrical engineering sector after the automotive industry, accounting for 25% of the industry's output value, with a market share exceeding 90%. In recent years, the number of manufacturers of similar mining rubber-sheathed cables has been increasing. Survey data shows that over 40% of companies in the mining rubber-sheathed cable industry have experienced unfair competition, such as winning bids below cost or malicious price-cutting by competitors. As the global market for mining rubber-sheathed cables continues to mature, the development of the mining rubber-sheathed cable manufacturing industry has slowed down, with relatively small growth rates, declining demand, relative overcapacity among cable companies, lower prices, fierce competition among companies, and a sharp rise in raw material prices. As a result, many mining rubber-sheathed cable companies are struggling to survive, and some small and medium-sized mining rubber-sheathed cable companies or non-specialized mining rubber-sheathed cable factories have exited the market.

[0007] With continuous economic development and changes in economic models, the coal industry is also facing a huge transformation, shifting from extensive to intensive and refined operations. At present, most coal mines still rely on underground workers for mining, which is a harsh and dangerous environment. Hundreds of miners lose their lives every year. Therefore, Internet-based intelligent mining has become the development direction and inevitable trend for safe and efficient coal mining.

[0008] Currently, coal mining primarily relies on deep-shaft mining. Coal mines contain numerous chemical elements, and varying levels of methane gas are often present deep underground. In the relatively confined space of a deep mine, methane gas can easily explode upon encountering an open flame or high-temperature heat source, causing casualties and requiring subsequent emergency response, severely impacting mining progress. Workers also suffer adverse physical and mental health effects from prolonged exposure to the harsh environment. Although coal mining equipment consists of mining machines, manual operation is still necessary during actual mining operations. To mitigate potential casualties during mining, researchers are actively developing advanced technologies.

[0009] The development direction of intelligent coal mining technology lies in enabling the system to perceive the underground environment using preset programs and instructions, and to transmit information to the ground control terminal via internet technology. This allows workers to quickly understand the specific underground conditions without going deep underground, and design the best mining plan based on the actual situation. The fully mechanized longwall face is a key link in modern coal mine production, and it is the system with the most equipment, the harshest environment, and the most complex operation in coal mine production. To date, it has been a subject of intensive research in various countries.

[0010] The intelligent fully mechanized mining face control system realizes automated control and remote control of coal mining operations. Through the coal mining machine's memory cutting adjustment control, the overall coordinated control technology of the coal mining machine, support electro-hydraulic control, and transportation system, it realizes local / centralized / remote three-level network management of equipment. The system can automatically adjust the production capacity of the coal mining machine according to the load of the transportation system. Through wireless network coverage, it realizes reliable communication between mobile devices and the coal mining machine in the working environment. Video, voice, and data network video automatic tracking and monitoring, based on the Internet of Things technology of sensors between equipment, realizes the attitude recognition of related equipment and early warning of faults, and realizes coordinated, safe and reliable production. The technology of the entire project has reached the international advanced level and solved the communication bottleneck of the entire working face.

[0011] Currently, the special cable used in intelligent fully mechanized coal mining machines, the "coal mining machine fiber optic composite rubber-sheathed flexible cable," suffers from defects such as poor mechanical performance, low insulation and sheath mechanical performance, poor control core transmission stability, poor control core transmission electromagnetic compatibility, poor fiber bending resistance, and short overall cable life. These defects directly affect the utilization and development of intelligent coal mining equipment. Utility Model Content

[0012] The purpose of this utility model is to apply for a high-durability fiber optic composite rubber-sheathed flexible cable for coal mining machines. This high-durability fiber optic composite rubber-sheathed flexible cable is mainly used in fully mechanized coal mining machines and can realize the transmission of power, control signals, and communication signals. It has excellent physical and mechanical properties, the control core has excellent electromagnetic compatibility and transmission stability, and it is equipped with optical unit groups to realize the transmission of communication signals.

[0013] To achieve the above objectives, the present invention adopts the following technical solution:

[0014] A high-durability fiber optic composite rubber-sheathed flexible cable for coal mining machines includes a power core group, a control core group, and an optical unit group. The power core group includes, from the inside out, a power core conductor, a power core semi-conductive layer, a power core insulation layer, and a power core hybrid braided layer. The control core group includes, from the inside out, a control core conductor, a control core insulation layer, a control core braided shielding layer, and a control core covering layer.

[0015] Preferably, the power core group, control core group, and optical unit group are all covered by an integrated sheath inner layer, an aramid braided reinforcement layer, and an integrated sheath outer layer arranged sequentially from the inside out.

[0016] Preferably, both the power conductor and the control conductor are Class 5 tin-plated soft copper conductors with bundled and twisted wires, and the bundled and twisted wire pitch is 8 times the outer diameter of the conductor.

[0017] Preferably, the semi-conductive layer of the power core is a semi-conductive nylon tape, the wrapping direction of the semi-conductive nylon tape is opposite to the twisting direction of the conductor, and the overlap rate is controlled at 15%.

[0018] Preferably, the insulation layer of the power conductor is a double-layer co-extruded structure of ethylene propylene rubber and semi-conductive rubber.

[0019] Preferably, the power core hybrid braided layer is a hybrid braided structure of tin-plated copper wire and polyester wire.

[0020] Preferably, the braided shielding layer of the control wire core has a twisted pair structure.

[0021] Preferably, the power core group, control core group, and optical unit group are twisted into a cable, and the center of the cable core is filled with a filler strip formed by extruding semi-conductive rubber with aramid yarn twisted rope.

[0022] Preferably, the cable pitch ratio of the aramid braided reinforcing layer is no greater than 9 times the cable outer diameter.

[0023] The beneficial effects of this utility model are as follows:

[0024] 1. This utility model strands the power core, control core assembly, and optical unit assembly into a cable. The center of the cable core is filled with a filler strip formed by twisting aramid fibers and extruding semi-conductive rubber. The filler strip undergoes vulcanization treatment. This significantly improves the overall tensile strength and bending resistance of the cable. The design of a cable section diameter ratio not exceeding 9 times the cable outer diameter ensures optimal bending resistance.

[0025] 2. The composite sheath layer undergoes continuous vulcanization treatment, achieving the following post-vulcanization parameters: tensile strength ≥12MPa, elongation at break ≥300%. An aramid fiber braided reinforcement layer is installed outside the inner sheath, with a braiding density of 20% to maintain tensile strength and a tight fit between the inner and outer sheaths. The outer sheath is a single-layer structure made of black high-strength rubber material. It also undergoes continuous vulcanization treatment, achieving a post-vulcanization tensile strength ≥18.5MPa and elongation at break ≥400%. The composite sheath's structural design and the selection of high-strength rubber material enhance the cable's overall tensile and bending resistance, effectively protecting the internal insulated cores from stress and external stresses, thus extending the cable's service life. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0028] 1. Power conductor core; 2. Power conductor core semiconductive layer; 3. Power conductor core insulation layer; 4. Power conductor core hybrid braided layer; 5. Filler strip; 6. Optical unit group; 7. Control conductor core; 8. Control conductor core insulation layer; 9. Control conductor core braided shielding layer; 10. Control conductor core covering layer; 11. Inner layer of composite sheath; 12. Aramid braided reinforcement layer; 13. Outer layer of composite sheath. Detailed Implementation

[0029] To make the objectives, features, and advantages of this utility model more apparent and understandable, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings of the specific embodiments. Obviously, the embodiments described below are only some embodiments of this utility model, and not all embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0030] This utility model discloses a method such as Figure 1 The cable shown is a high-durability fiber optic composite rubber-sheathed flexible cable for coal mining machines. The cable includes a power core group, a control core group, and an optical unit group 6. The power core group comprises, from the inside out, a power core conductor 1, a power core semi-conductive layer 2, a power core insulation layer 3, and a power core hybrid braided layer 4. The control core group comprises, from the inside out, a control core conductor 7, a control core insulation layer 8, a control core braided shielding layer 9, and a control core covering layer 10. Filler strips 5 are provided between adjacent core groups. All core groups and filler strips are collectively covered by, from the inside out, a composite inner sheath layer 11, an aramid braided reinforcement layer 12, and a composite outer sheath layer 13.

[0031] The power conductor 1 adopts a Class 5 tin-plated soft copper conductor with bundled and twisted wires. To avoid stress concentration, the conductor adopts a bundled and twisted wire structure design, and the bundled wire and twisting pitch is controlled at 8 times the outer diameter of the conductor. To maintain the flexibility of the conductor, the bundled wires adopt the same bundled wire direction to prevent loosening during the twisting process. The twisting direction is the same and opposite to the bundled wire direction.

[0032] The power core conductor is composed of a semi-conductive layer 2, which is formed by overlapping and wrapping semi-conductive nylon tape around the outside of the power core conductor. The wrapping direction of the semi-conductive nylon tape is opposite to the twisting direction of the conductor, and the overlap rate is controlled at 15%.

[0033] The insulation layer 3 of the power wire core is produced by continuous vulcanization using a double-layer co-extrusion process with high-strength ethylene propylene rubber and semi-conductive rubber. Continuous vulcanization is carried out using a saturated steam pressure of 1.0 MPa. After vulcanization, the tensile strength is ≥12 MPa and the elongation at break is ≥300%.

[0034] The power core is uniformly braided with a mixture of tinned copper wire and polyester wire, forming a hybrid braided layer 4. This layer is continuously braided using a 48-spindle braiding machine, with the braiding density controlled at 80%. The design of the braided monofilaments fulfills the function of the braided shielding layer as a grounding wire.

[0035] The control conductor 7 uses a Class 5 tin-plated soft copper conductor. To avoid stress concentration, the conductor adopts a bundled and twisted structure design, with the bundle and twisting pitch controlled at 8 times the conductor's outer diameter. To maintain the conductor's flexibility, the bundled wires are in the same direction to prevent loosening during the twisting process, and the twisting direction is the same but opposite to the bundled wire direction. Simultaneously, a tensile load-bearing core is set at the center of the control conductor, using a multi-strand aramid fiber twisted structure. The control conductor insulation uses a high-strength ethylene propylene rubber compound. After extrusion, it undergoes continuous vulcanization at a saturated steam pressure of 1.0 MPa. After vulcanization, the cross-linking properties are: tensile strength ≥12 MPa, elongation at break ≥300%, significantly improving the physical and mechanical properties of the cable insulation.

[0036] Control core insulation layer 8: Made of high-strength ethylene propylene rubber compound. After extrusion, it is continuously vulcanized and cross-linked. After vulcanization, the tensile strength is ≥12MPa and the elongation at break is ≥300%. Vulcanization significantly improves the physical and mechanical properties of the cable insulation.

[0037] The control wire core adopts a twisted pair structure design. In the twisted pair structure design, the electromagnetic waves generated during the transmission of one wire core are canceled out by the electromagnetic waves generated by the other wire core. At the same time, a braided shielding layer 9 made of tinned copper wire is set outside the control wire core group. The twisted pair structure and the structure of the braided layer give the control wire core excellent electromagnetic compatibility and make the transmitted signal more stable.

[0038] When the cable is bent, the difference in diameter between the cable cores can cause uneven stress on the cores. To maintain uniform stress, a high-strength control core sheath layer 10 is installed outside the control core group. The thickness is designed so that the outer diameter of the control core group reaches 80% of the outer diameter of the power core. This layer uses high-strength rubber sheath material. After extrusion, it undergoes continuous vulcanization. After vulcanization, the tensile strength is ≥18.5MPa and the elongation at break is ≥400%.

[0039] The optical unit group adopts a flexible armored reinforced fiber unit group.

[0040] The inner sheath of the cable is made of high-strength ethylene propylene rubber insulation. It undergoes continuous vulcanization treatment, and the vulcanization results in the following properties: tensile strength ≥12MPa, elongation at break ≥300%.

[0041] The control core 7 adopts a twisted-pair structure design, with the twisted-pair pitch ratio controlled at 8 times the outer diameter of the twisted pair. Adjacent twisted pairs use different twisting pitches. After twisting, the control core groups are cabled, and a tinned copper wire braided shielding layer is set outside the control core groups. The braiding angle of the tinned copper wire braided shielding layer is 45°, and the braiding density is greater than 80%. A high-strength rubber sheath layer is set outside the control core groups, and the thickness of the sheath layer is designed so that the outer diameter of the control core group reaches 80% of the outer diameter of the power core. The sheath layer uses high-strength rubber sheath material. After extrusion, it undergoes continuous vulcanization at a saturated vapor pressure of 1.2MPa. After vulcanization, the tensile strength is ≥18.5MPa, and the elongation at break is ≥400%.

[0042] The power core, control core group, and optical unit group are stranded into a cable. The center of the cable core is filled with a filler strip formed by twisting aramid yarn and extruding semi-conductive rubber. The filler strip is vulcanized. The control core group and optical unit group are placed in the gaps between the cable cores, with the cable forming direction being right-handed. The gaps between the cable cores are filled with rubber filler strips. The rubber filler strips in the edge gaps are made by extruding filler rubber with central hemp rope and vulcanizing the filler strips. One layer of reinforcing non-woven fabric tape is overlapped around the outside of the cable core, and the cable pitch ratio is no more than 9 times the outer diameter of the cable.

[0043] The inner layer 11 of the composite sheath is made of high-strength ethylene propylene rubber insulation material. It undergoes continuous vulcanization treatment, and the vulcanized properties are: tensile strength ≥12MPa, elongation at break ≥300%. An aramid fiber braided reinforcement layer 12 is installed outside the inner sheath. To maintain tensile strength and a tight fit between the inner and outer sheaths, the braiding density is set at 20%. The outer layer 13 of the composite sheath has a single-layer structure and uses black high-strength rubber sheath material. It also undergoes continuous vulcanization treatment, and the vulcanized tensile strength is ≥18.5MPa, elongation at break ≥400%.

[0044] Although the present invention has been described in detail with reference to the accompanying drawings and preferred embodiments, the present invention is not limited thereto. Various equivalent modifications or substitutions can be made to the embodiments of the present invention by those skilled in the art without departing from the spirit and essence of the present invention, and such modifications or substitutions should all be within the scope of the present invention. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should also be included within the protection scope of the present invention.

Claims

1. A high durability coal mining machine fiber optic composite rubber jacketed flexible cable characterized by, It includes a power core assembly, a control core assembly, and an optical unit assembly; the power core assembly includes, from the inside out, a power core conductor, a power core semiconducting layer, a power core insulation layer, and a power core hybrid braided layer; the control core assembly includes, from the inside out, a control core conductor, a control core insulation layer, a control core braided shielding layer, and a control core covering layer.

2. A high durability coal cutter optical fiber composite rubber jacketed flexible cable as claimed in claim 1, wherein, The power core group, control core group, and optical unit group are all covered by an inner layer of integrated sheath, an aramid braided reinforcement layer, and an outer layer of integrated sheath arranged sequentially from the inside out.

3. A high durability coal cutter optical fiber composite rubber jacketed flexible cable as claimed in claim 2, wherein, Both the power conductor and the control conductor are Class 5 tin-plated soft copper conductors with bundled and twisted wires, and the bundled and twisted wire pitch is 8 times the outer diameter of the conductor.

4. A high durability coal cutter optical fiber composite rubber jacketed flexible cable as claimed in claim 2, wherein, The semi-conductive layer of the power core is a semi-conductive nylon tape, with the wrapping direction of the semi-conductive nylon tape opposite to the twisting direction of the conductor, and the overlap rate is controlled at 15%.

5. A high durability coal cutter optical fiber composite rubber jacketed flexible cable as claimed in claim 2, wherein, The insulation layer of the power conductor is a double-layer co-extruded structure of ethylene propylene rubber and semi-conductive rubber.

6. The high-durability fiber optic composite rubber-sheathed flexible cable for coal mining machines according to claim 2, characterized in that, The power core hybrid braided layer is a hybrid braided structure of tin-plated copper wire and polyester wire.

7. A high durability coal cutter optical fiber composite rubber jacketed flexible cable as claimed in claim 2, wherein, The control wire core braided shielding layer has a twisted pair structure.

8. A high durability coal cutter optical fiber composite rubber jacketed flexible cable as claimed in claim 2, wherein, The power core group, control core group, and optical unit group are twisted together to form a cable, and the center of the cable core is filled with a filler strip formed by extruding semi-conductive rubber with aramid yarn twisted rope.

9. A high durability coal cutter optical fiber composite rubber jacketed flexible cable as claimed in claim 2, wherein, The cable pitch ratio of the aramid braided reinforcement layer is no greater than 9 times the outer diameter of the cable.

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