Long life silicone rubber insulated motor lead cable

Abstract

The utility model discloses a long -lived silicon rubber insulation motor lead cable, and the conductor is wrapped with high temperature resistance polyester tape, semiconductive silicon rubber shielding layer, silicon rubber insulation layer, multiple wrapping and weaving layer and silicon aluminum sol coating layer in proper order. Among them, the first weaving layer of conductive carbon fiber weaving has the function of electric conduction and electromagnetic shielding. The utility model effectively solves the problems of poor insulation, low temperature resistance, low mechanical strength and insufficient weather resistance of the existing cable, not only can evenly distribute the electric field, inhibit electrical fault, but also can operate stably under 180 DEG C high temperature, and the multilayer protection can resist external damage and severe environment erosion, providing reliable guarantee for the stable operation of the wind power generation system.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, specifically, to a long-life silicone rubber insulated motor lead cable. Background Technology

[0002] With the increasing global demand for clean energy, the wind power industry has experienced rapid development. Wind turbines operate in harsh environments, including extreme temperatures, high humidity, and salt spray. Silicone rubber motor lead wires are crucial for the reliable operation of wind turbines.

[0003] Ordinary motor lead cables may experience performance degradation in wind power environments. Under extreme conditions, their insulation performance deteriorates drastically, and their weather resistance is severely insufficient. This is especially true in offshore wind power projects, where salt spray corrosion and drastic temperature and humidity fluctuations can easily lead to cracking and power transmission interruptions. While existing silicone rubber insulated cables for wind turbines are widely used, they still have several problems. From an electrical performance perspective, although the cables provide insulation and can withstand high-voltage corona and arc discharge, ensuring electrical safety, their electrical performance gradually deteriorates under long-term operation at 180°C, causing the cables to smoke, age, and even burn out the motor, leading to turbine shutdown and significant economic losses. Furthermore, due to the soft nature of silicone rubber, the cables are easily damaged by external impacts and friction during installation and daily use, resulting in loss of power transmission function and rendering the cables unusable.

[0004] Therefore, how to solve the existing deficiencies and shortcomings by using motor lead cables with long lifespan characteristics is the direction that those engaged in this industry urgently want to improve. Utility Model Content

[0005] The purpose of this invention is to address the above-mentioned problems by providing a long-life silicone rubber insulated motor lead cable.

[0006] The technical solution of this utility model is as follows: a long-life silicone rubber insulated motor lead cable, comprising: a conductor, wherein the conductor is wrapped from the inside out with a high-temperature resistant polyester tape, a shielding layer, an insulating layer, a first wrapping layer, a first braided layer, a second wrapping layer, a second braided layer, and a coating layer; the shielding layer is a semi-conductive silicone rubber shielding material, the insulating layer is a silicone rubber insulating material; the first braided layer is woven from conductive carbon fiber, and the coating layer is made of aluminosilicate sol.

[0007] According to the present invention, a long-life silicone rubber insulated motor lead cable is provided, wherein the volume resistivity of the insulation layer is ≥10. 16 Ω·m.

[0008] According to the present invention, a long-life silicone rubber insulated motor lead cable is provided, wherein the resistivity of the first braided layer is 10 Ω·cm. -4 Ω·m.

[0009] According to the present invention, a long-life silicone rubber insulated motor lead cable is provided, wherein the conductive carbon fiber is a surface-metallized carbon fiber.

[0010] According to the present invention, a long-life silicone rubber insulated motor lead cable is provided, wherein the second braided layer is woven from 1500D aramid yarn.

[0011] According to the present invention, a long-life silicone rubber insulated motor lead cable is provided, wherein the braiding density of the 1500D aramid yarn is ≥85%.

[0012] According to the present invention, a long-life silicone rubber insulated motor lead cable is provided, wherein the material of the first wrapping layer is a semi-conductive nylon tape.

[0013] According to the present invention, a long-life silicone rubber insulated motor lead cable is provided, wherein the conductor is a Class 5 tin-plated copper conductor.

[0014] According to the present invention, a long-life silicone rubber insulated motor lead cable is provided, wherein the diameter of the tinned copper conductor monofilament is 0.3 to 0.51 mm.

[0015] According to the present invention, a long-life silicone rubber insulated motor lead cable is provided, wherein the metal on the surface of the conductive carbon fiber is one of nickel-plated carbon fiber, copper-plated carbon fiber, silver-plated carbon fiber, platinum-plated carbon fiber, and aluminum-plated carbon fiber.

[0016] The advantages of the long-life silicone rubber insulated motor lead cable provided by this utility model are:

[0017] 1. The shielding layer uses semi-conductive silicone rubber shielding material, which can effectively and uniformly distribute the electric field, suppress corona and partial discharge phenomena, and greatly reduce the probability of electrical faults such as leakage and short circuit; the first braided layer is woven from conductive carbon fiber, which not only enhances the overall conductivity of the cable, but also forms a good electromagnetic shielding effect, reduces the impact of electromagnetic interference on the internal signal transmission of the cable, and ensures the stability and safety of power transmission.

[0018] 2. High-temperature resistant polyester tape has good heat resistance and can operate stably for a long time in environments with temperatures of 180℃ or even higher. It effectively isolates the conductor and insulation layer, improves the high-temperature aging resistance of the cable, and extends the service life of the cable.

[0019] 3. Multiple wrapping and braiding layers enhance the overall mechanical strength of the cable. The first and second braiding layers not only resist damage from external impacts and friction, but also limit the deformation of the silicone rubber material caused by external forces, solving the problem of the soft and easily damaged nature of silicone rubber material; the coating layer uses aluminosilicate material to form a dense protective film, effectively resisting the corrosion of harsh environments such as salt spray and high humidity, and greatly improving the weather resistance of the cable. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the long-life silicone rubber insulated motor lead cable described in this utility model.

[0021] Wherein: 1-conductor, 2-high temperature resistant polyester tape, 3-shielding layer, 4-insulating layer, 5-first wrapping layer, 6-first braided layer, 7-second wrapping layer, 8-second braided layer, 9-coating layer. Detailed Implementation

[0022] The present invention will now be described in detail with reference to the specific embodiments shown in the accompanying drawings. However, these embodiments do not limit the present invention, and any structural, methodological, or functional modifications made by those skilled in the art based on these embodiments are included within the protection scope of the present invention.

[0023] If the description of this utility model involves directions (e.g., up, down, left, right, front, back, outside, inside, etc.), then the directions involved need to be defined.

[0024] The scope of embodiments described herein includes the entire scope of the claims and all available equivalents thereof. Throughout this document, the terms “first,” “second,” etc., are used only to distinguish one element from another without requiring or implying any actual relationship or order between the elements. Indeed, a first element can also be referred to as a second element, and vice versa. Furthermore, the terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a structure, apparatus, or device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a structure, apparatus, or device. Without further limitation, an element defined by the phrase “comprising one…” does not exclude the presence of other identical elements in the structure, apparatus, or device that includes said element.

[0025] This utility model provides a long-life silicone rubber insulated motor lead cable, such as... Figure 1As shown, the long-life silicone rubber insulated motor lead cable includes a conductor 1, which is wrapped from the inside out with a high-temperature resistant polyester tape 2, a shielding layer 3, an insulation layer 4, a first wrapping layer 5, a first braided layer 6, a second wrapping layer 7, a second braided layer 8, and a coating layer 9. The shielding layer 3 is a semi-conductive silicone rubber shielding material, and the insulation layer 4 is a silicone rubber insulating material. The volume resistivity of the insulation layer 4 is ≥10 Ω·cm. 16 Ω·m; The first braided layer 6 is woven from conductive carbon fibers, and the resistivity of the first braided layer 6 is 10 Ω·m. -4 The coating layer 9 is made of aluminosilicate sol with a strength of Ω·cm.

[0026] In this embodiment, the silica-alumina sol is prepared by mixing organosilicon resin and aluminum sol in a ratio of 15:1 to 20:1. Preferably, the ratio of organosilicon resin to aluminum sol in the silica-alumina sol of this invention is 17:1. Experiments have shown that the bonding strength of the coating layer at this ratio can reach 3.5 MPa, which is significantly improved compared to silica-alumina sols obtained with other ratios. This demonstrates that this not only forms a dense protective film on the cable surface but also significantly enhances wear resistance and weather resistance, enabling it to withstand harsh environmental corrosion such as salt spray and high humidity.

[0027] In this embodiment, the first braided layer 6 is woven from conductive carbon fiber. The conductive carbon fiber is a carbon fiber with surface metallization treatment. The metal on the surface of the conductive carbon fiber is one of nickel-plated carbon fiber, copper-plated carbon fiber, silver-plated carbon fiber, platinum-plated carbon fiber, and aluminum-plated carbon fiber. The tensile strength reaches 4-7 GPa, which can provide electromagnetic shielding function while withstanding axial tensile force of ≥500N, thus avoiding damage to the internal structure when the cable is bent.

[0028] In this embodiment, the second braided layer 8 is made of 1500D aramid yarn interwoven at a braiding density of ≥85%, using a twill weave process, with an overlap rate controlled at 15%-20%. The aramid yarn has a tensile strength of ≥3GPa, a high temperature resistance of up to 260℃, and a breaking elongation of 3.5%-4.0%. It can be understood that the second braided layer 8 can effectively buffer external impact forces, resist mechanical damage such as collisions and friction during cable laying and installation, and at the same time limit the deformation of the silicone rubber insulation layer, thereby improving the overall structural stability.

[0029] In this embodiment, the first wrapping layer 5 is made of semi-conductive nylon tape, which is wound around the outer surface of the insulation layer with an overlap rate of 35%-45%. This not only uniformly disperses the electric field on the surface of the insulation layer, but also acts as a buffer layer to prevent broken carbon fiber filaments in the first braided layer from piercing the insulation layer.

[0030] In this embodiment, the conductor 1 is a Class 5 tin-plated copper conductor with a single wire diameter of 0.3-0.51 mm and an elongation at break of ≥20%. After being bundled, it is processed by regular stranding. The stranding pitch ratio from the inside to the outside is controlled to be 18-20 times, 14-16 times, and 10-12 times respectively. The stranding direction is the same and the layers are tightly pressed to ensure that the conductor structure is compact and the outer diameter tolerance is ≤±0.1 mm, which is suitable for the uniform extrusion process of the subsequent shielding layer and insulation layer.

[0031] In this embodiment, the high-temperature resistant polyester tape 2 can be made of polyethylene terephthalate modified material, with a temperature resistance rating of 180℃ and a heat shrinkage rate of ≤1.5% under long-term use. It can effectively isolate the conductor and the shielding layer and prevent the oxides on the surface of the tin-plated copper wire from affecting the electric field distribution.

[0032] In this embodiment, the shielding layer 3 is a semi-conductive silicone rubber shielding material. The semi-conductive silicone rubber shielding material can be a modified vinyl silicone rubber-based semi-conductive shielding material, which is coated onto the conductor surface by an extrusion process. The thickness is controlled at 0.3-0.5 mm, which can eliminate the micro-unevenness of the conductor surface, homogenize the electric field distribution, and suppress the partial discharge phenomenon.

[0033] In this embodiment, the insulation layer 4 is made of silicone rubber insulation material, which can be high-temperature resistant methyl vinyl silicone rubber insulation material. It is formed by high-temperature vulcanization extrusion process, with an extrusion temperature of 120-140℃, a steam pressure of 1.1-1.3MPa, a wire speed of 3-6m / min, and the insulation layer thickness is adjusted to 2.5-4mm according to the voltage level to ensure the electrical insulation reliability under long-term operation at 180℃.

[0034] In this embodiment, the second wrapping layer 7 is a reinforced nonwoven fabric, which can fix the first braided layer and provide a smooth base for the second braided layer, avoiding stress concentration during aramid yarn weaving. The second wrapping layer 7 can be a reinforced nonwoven fabric blended with aramid and polyester fibers, with a basis weight of 80-100 g / m². 2 Longitudinal and transverse tensile strength ≥50N / mm 2 The heat shrinkage rate is ≤5%. The non-woven fabric surface is impregnated with silicone resin to form a 0.05-0.1mm thick coating, which enhances the interfacial bonding with the silicone rubber insulation layer. The wrapping process can adopt overlapping wrapping, with an overlap rate controlled at 20%-30%, tension of 5-8N, and linear speed of 15-20m / min. It can be understood that the second wrapping layer 7 can effectively fix the conductive carbon fiber braided layer, avoid stress concentration caused by uneven contact during aramid yarn braiding, and ensure that the braided layer wire breakage rate is ≤1% under the condition of bending radius ≥6D, thereby improving the overall flexibility and reliability of the cable.

[0035] This utility model provides a long-life silicone rubber insulated motor lead cable, which consists of a conductor 1 wrapped with a high-temperature resistant polyester tape 2, a shielding layer 3, an insulation layer 4, a first wrapping layer 5, a first braided layer 6, a second wrapping layer 7, a second braided layer 8, and a coating layer 9. The shielding layer 3 homogenizes the electric field, preventing distortion of the electric field on the conductor 1 surface; the first braided layer 6 effectively shields electromagnetic interference and grounds the cable; the second braided layer 8 enhances mechanical protection; and the coating layer 9 improves wear resistance and weather resistance. This allows the cable to operate stably at 180℃ for extended periods and adapt to environments ranging from -60℃ to +60℃, effectively solving problems such as poor insulation and low high-temperature resistance, ensuring reliable operation of wind power generation systems, and extending service life.

[0036] The embodiments of the present invention have been described above. These descriptions are exemplary and not exhaustive, and are not limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles of the embodiments, their practical application, or technological improvements in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A long-life silicone rubber insulated motor lead cable, comprising: The conductor (1) is characterized in that, from the inside out, the conductor (1) is wrapped with a high-temperature resistant polyester tape (2), a shielding layer (3), an insulating layer (4), a first wrapping layer (5), a first braided layer (6), a second wrapping layer (7), a second braided layer (8), and a coating layer (9); the shielding layer (3) is a semi-conductive silicone rubber shielding material, the insulating layer (4) is a silicone rubber insulating material; the first braided layer (6) is woven from conductive carbon fiber, and the coating layer (9) is made of aluminosilicate sol.

2. The long-life silicone rubber insulated motor lead cable according to claim 1, characterized in that, The volume resistivity of the insulating layer (4) is ≥10. 16 Ω·m.

3. The long-life silicone rubber insulated motor lead cable according to claim 2, characterized in that, The resistivity of the first braided layer (6) is 10. -4 Ω·m.

4. The long-life silicone rubber insulated motor lead cable according to claim 1, characterized in that, The conductive carbon fiber is a surface-metallized carbon fiber.

5. The long-life silicone rubber insulated motor lead cable according to claim 1, characterized in that, The second woven layer (8) is woven from 1500D aramid yarn.

6. The long-life silicone rubber insulated motor lead cable according to claim 5, characterized in that, The weaving density of the 1500D aramid yarn is ≥85%.

7. The long-life silicone rubber insulated motor lead cable according to claim 1, characterized in that, The material of the first wrapping layer (5) is a semi-conductive nylon tape.

8. The long-life silicone rubber insulated motor lead cable according to claim 1, characterized in that, The conductor (1) is a Class 5 tin-plated copper conductor.

9. The long-life silicone rubber insulated motor lead cable according to claim 8, characterized in that, The diameter of the tin-plated copper conductor monofilament is 0.3 to 0.51 mm.

10. The long-life silicone rubber insulated motor lead cable according to claim 4, characterized in that, The metal on the surface of the conductive carbon fiber is one of nickel-plated carbon fiber, copper-plated carbon fiber, silver-plated carbon fiber, platinum-plated carbon fiber, and aluminum-plated carbon fiber.

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