Cold-resistant and twist-resistant wind power cable

Abstract

This utility model discloses a cold-resistant and torsion-resistant wind power flexible cable, relating to the field of flexible cable technology. It solves the problems of poor overall strength and short service life in existing wind power flexible cables. The cable includes an inner layer structure comprising a conductor layer, an insulation layer wrapped around the conductor layer, and a shielding layer wrapped around the insulation layer. It also includes a sheath structure comprising an outer sheath, a filler layer, an inner interlayer, and an armor layer. The filler layer is disposed in the gap between the shielding layer and the conductor layer. The armor layer wraps around the outside of the shielding layer, the outer sheath wraps around the armor layer, and the inner interlayer is disposed between the outer sheath and the armor layer. This utility model's cable design ensures conductivity, enhances fatigue resistance, prevents breakage due to repeated bending, improves the cable's load-bearing capacity, and prevents deformation due to torsion and tension.

Description

Technical Field

[0001] This utility model belongs to the field of flexible cable technology, and in particular relates to a cold-resistant and torsion-resistant wind power flexible cable. Background Technology

[0002] With the booming development of the wind power industry, the demand for cables used in wind power generation is increasing day by day, among which torsion-resistant power cables rank first in usage. Given that wind farms are mostly located in harsh environments and wind turbines have a long service life, this places extremely stringent requirements on the performance of cables.

[0003] Currently, while existing wind power flexible cables utilize insulation and sheathing materials to protect the cable core, they have several shortcomings. The overall strength of existing wind power flexible cables is insufficient, and they lack a specific structural design to prevent axial torsion. In practical applications, the cable is highly susceptible to axial torsion, which can destabilize the internal structure, leading to damage and ultimately significantly shortening the service life of the wind power flexible cable.

[0004] In summary, existing wind power flexible cables suffer from poor overall strength and short service life. Utility Model Content

[0005] This invention provides a cold-resistant and torsion-resistant wind power flexible cable, which can solve the problems of poor overall strength and short service life of existing wind power flexible cables.

[0006] To achieve the above objectives, a cold-resistant and torsion-resistant wind power flexible cable is proposed according to an embodiment of the first aspect of the present invention, comprising an inner layer structure, wherein the inner layer structure comprises a conductor layer, an insulation layer wrapped around the conductor layer, and a shielding layer wrapped around the insulation layer.

[0007] Also includes:

[0008] The protective layer structure includes an outer protective layer, a filler layer, an inner interlayer, and an armor layer. The filler layer is disposed in the gap between the shielding layer and the conductor layer. The armor layer wraps around the outside of the shielding layer. The outer protective layer wraps around the outside of the armor layer. The inner interlayer is disposed between the outer protective layer and the armor layer.

[0009] A further improvement is that the conductor layer is made of multiple strands of fine tin-plated copper wire twisted together.

[0010] A further improvement is that the insulating layer is made of a cold-resistant elastomer material, which is one of cross-linked polyethylene, ethylene propylene rubber, and thermoplastic elastomer.

[0011] A further improvement is that the shielding layer is made of a mixture of tin-plated copper wire and aramid fiber.

[0012] A further improvement is that the filling layer is an elastic cushioning material, which is one of silicone rubber, polyurethane foam, and fiberglass rope.

[0013] A further improvement is that the armor layer is made of stainless steel strip spirally wrapped or non-magnetic alloy wire woven together.

[0014] A further improvement is that a rubber strip is provided between the armor layer and the inner interlayer, and the rubber strip is wrapped around the outside of the armor layer.

[0015] A further improvement is that the inner interlayer is composed of a polyurethane material and a filling rope, and the outer protective layer is made of cold-resistant rubber.

[0016] A further improvement is that the outer surface of the outer protective layer is coated with a fluorocarbon resin coating and an organic ultraviolet absorber.

[0017] A further improvement is that the protective layer structure also includes a reinforcing layer disposed between the inner interlayer and the outer protective layer, the reinforcing layer being woven from aramid fiber filaments.

[0018] Compared with the prior art, the beneficial effects of this utility model are:

[0019] (1) This utility model uses a cold-resistant elastomer material for the insulation layer of the inner layer structure of the cable, and designs the outer sheath of the cable's outer sheath structure as cold-resistant rubber. The inner interlayer of the sheath structure is designed to be composed of polyurethane material and filler rope. The filler rope has flame-retardant and corrosion-resistant properties, which can improve the flame-retardant effect and torsion resistance of the cable. During the use of the cable, the polyurethane material forms an outer cold-resistant layer, which, together with the insulation layer, improves the overall cold resistance, allowing the cable to maintain ≥200% elongation at break at low temperatures, preventing the insulation layer from becoming brittle and cracking, thus possessing strong flexibility, durability, and impact resistance. A rubber strip is set between the armor layer and the inner interlayer, and the rubber strip is wrapped around the outside of the armor layer. When the cable is in use, the rubber strip expands when it comes into contact with water, forming a longitudinal water barrier, improving the waterproof performance, and making it suitable for humid environments.

[0020] (2) This utility model designs an armor layer in the outer sheath structure, which is made of stainless steel spiral wrapping or non-magnetic alloy wire braiding. This provides rodent and ant protection and lateral pressure resistance while maintaining bending performance. A filling layer is designed in the outer sheath structure. The filling layer is an elastic buffer material, which is one of silicone rubber, polyurethane foam, and fiberglass rope. This material can absorb the stress generated by torsion and prevent core displacement. A reinforcing layer is also designed in the sheath structure. The reinforcing layer is made of aramid fiber braiding. Because the strength of aramid fiber is 5-6 times that of steel wire and the modulus is 2-3 times that of steel wire or fiberglass, the tensile strength and rigidity of the cable can be significantly improved after braiding. Moreover, the density of aramid fiber is only 1 / 5 that of steel wire, and the weight of the cable is greatly reduced after braiding, while maintaining flexibility and facilitating installation and maintenance. In summary, the cable design of this new model not only ensures conductivity but also enhances fatigue resistance, prevents breakage caused by repeated bending, improves the load-bearing capacity of the cable, and prevents deformation caused by torsion and tension. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the inner layer structure of this utility model;

[0022] Figure 2 This is a cross-sectional schematic diagram of the inner layer structure and sheath structure of the entire cable of this utility model.

[0023] Marked in the image:

[0024] 1. Inner layer structure; 11. Conductor layer; 12. Shielding layer; 13. Insulating layer;

[0025] 2. Protective layer structure; 21. Outer protective layer; 211. Fluorocarbon resin coating; 212. Organic ultraviolet absorber; 22. Filler layer; 23. Inner interlayer; 24. Armor layer; 25. Rubber strip; 26. Reinforcing layer. Detailed Implementation

[0026] The technical solution of this utility model will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0027] like Figures 1 to 2 As shown, a cold-resistant and torsion-resistant wind power flexible cable includes:

[0028] The inner layer structure 1 includes a conductor layer 11, an insulating layer 13 wrapped around the conductor layer 11, and a shielding layer 12 wrapped around the insulating layer 13.

[0029] Specifically, the conductor layer 11 is made of multiple strands of fine tin-plated copper wire. This design not only ensures conductivity but also enhances fatigue resistance and prevents breakage caused by repeated bending.

[0030] Specifically, the insulation layer 13 is made of a cold-resistant elastomer material, which is one of cross-linked polyethylene, ethylene propylene rubber and thermoplastic elastomer. In this embodiment, ethylene propylene rubber is used as an example. This design allows the flexible cable to maintain its elasticity at low temperatures and prevents the insulation layer 13 from becoming brittle and cracking.

[0031] Specifically, the shielding layer 12 is made of tin-plated copper wire and aramid fiber. This design can have both electromagnetic shielding and mechanical reinforcement functions, and the high modulus characteristics of aramid fiber can significantly improve torsional resistance.

[0032] Sheath structure 2 includes an outer sheath 21, a filler layer 22, an inner interlayer 23, and an armor layer 24. The filler layer 22 is disposed in the gap between the shielding layer 12 and the conductor layer 11. The armor layer 24 is wrapped around the outside of the shielding layer 12. The outer sheath 21 is wrapped around the outside of the armor layer 24. The inner interlayer 23 is disposed between the outer sheath 21 and the armor layer 24.

[0033] Specifically, the filling layer 22 is an elastic cushioning material, which is one of silicone rubber, polyurethane foam and fiberglass rope, and can absorb the stress generated by torsion and prevent the core from shifting.

[0034] Specifically, the armor layer 24 is made of stainless steel strip spiral wrapping or non-magnetic alloy wire weaving, which can provide rodent and ant protection and lateral pressure resistance while maintaining bending performance;

[0035] Specifically, the inner layer 23 is composed of a polyurethane material and a filler rope. The polyurethane material forms the outer cold-resistant layer, which, in conjunction with the insulation layer 13, improves the overall cold resistance. The filler rope has flame-retardant and corrosion-resistant properties, enhancing the internal flame-retardant effect and torsion resistance of the cable.

[0036] Specifically, the outer sheath 21 is made of cold-resistant rubber, which is based on chlorosulfonated polyethylene or hydrogenated nitrile rubber, with added plasticizers and antioxidants. This material design allows the cable to maintain an elongation at break of ≥200% at low temperatures, thus possessing strong flexibility, durability, and impact resistance.

[0037] As a preferred embodiment, a rubber strip 25 is disposed between the armor layer 24 and the inner interlayer 23, and the rubber strip 25 wraps around the outside of the armor layer 24. When the cable is in use, the rubber strip 25 expands when it comes into contact with water, forming a longitudinal water-blocking barrier, improving waterproof performance, and making it suitable for humid environments.

[0038] As a preferred embodiment, the outer surface of the outer protective layer 21 is coated with a fluorocarbon resin coating 211, which can resist abrasion from sand and gravel and corrosion from oil.

[0039] As a preferred embodiment, the outer surface of the outer protective layer 21 is coated with an organic ultraviolet absorber 212, which can extend its service life in strong ultraviolet environments such as plateaus and islands.

[0040] As a preferred embodiment, the sheath structure 2 further includes a reinforcing layer 26 disposed between the inner interlayer 23 and the outer sheath 21. The reinforcing layer 26 is woven from aramid fiber filaments. Because the strength of aramid fiber is 5-6 times that of steel wire and its modulus is 2-3 times that of steel wire or glass fiber, weaving it can significantly improve the tensile strength and rigidity of the cable. Moreover, the density of aramid fiber is only 1 / 5 that of steel wire, and the weight of the cable is greatly reduced after weaving, while maintaining flexibility, making it easy to install and maintain. In summary, this further improves the load-bearing capacity of the cable and prevents deformation caused by torsion and tension.

[0041] like Figures 1 to 2 As shown in the illustration, it should also be noted that the flexible cable in this embodiment is manufactured using existing equipment and the manufacturing process is prior art. The working principle has been disclosed and is omitted in this embodiment. Furthermore, it should be noted that this application only addresses the shortcomings of existing wind power flexible cables, such as poor overall strength and short service life, and does not involve other aspects. The working principle of this cold-resistant and torsion-resistant wind power flexible cable is described below:

[0042] In this novel design, the insulation layer 13 of the inner structure 1 of the cable is made of a cold-resistant elastomer material, and the outer sheath 21 of the outer sheath structure 2 is designed to be made of cold-resistant rubber. The inner interlayer 23 of the sheath structure 2 is designed to be composed of polyurethane material and filler rope. The filler rope has flame-retardant and corrosion-resistant properties, which can improve the flame-retardant effect and torsion resistance of the cable. During cable use, the polyurethane material forms an outer cold-resistant layer, which, together with the insulation layer 13, improves the overall cold resistance, allowing the cable to maintain an elongation at break of ≥200% at low temperatures, preventing the insulation layer 13 from becoming brittle and cracking, thus providing strong flexibility, durability, and impact resistance. A rubber strip 25 is placed between the armor layer 24 and the inner interlayer 23, wrapping around the outside of the armor layer 24. When the cable is in use, the rubber strip 25 expands when it comes into contact with water, forming a longitudinal water-blocking barrier, improving waterproof performance, and making it suitable for humid environments.

[0043] Furthermore, by designing an armor layer 24 within the outer sheath structure 2, which is made of stainless steel spiral wrapping or non-magnetic alloy wire braiding, it provides rodent and termite protection and lateral pressure resistance while maintaining bending performance. A filler layer 22, an elastic cushioning material selected from silicone rubber, polyurethane foam, and fiberglass rope, is also incorporated into the outer sheath structure 2. This filler layer absorbs torsional stress and prevents core displacement. Additionally, a reinforcing layer 26, woven from aramid fiber filaments, is designed within the sheath structure 2. Aramid fiber has a strength 5-6 times that of steel wire and a modulus 2-3 times that of steel wire or fiberglass, significantly improving the cable's tensile strength and rigidity after braiding. Moreover, the density of aramid fiber is only 1 / 5 that of steel wire, resulting in a substantial reduction in cable weight while maintaining flexibility for easy installation and maintenance. In summary, this novel cable design ensures conductivity, enhances fatigue resistance, prevents breakage due to repeated bending, improves the cable's load-bearing capacity, and prevents deformation due to torsion and tension.

[0044] The above embodiments are only used to illustrate the technical methods of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical methods of this utility model without departing from the spirit and scope of the technical methods of this utility model.

Claims

1. A cold-resistant and torsion-resistant wind power flexible cable, comprising an inner layer structure (1), wherein the inner layer structure (1) comprises a conductor layer (11), an insulation layer (13) wrapped around the conductor layer (11), and a shielding layer (12) wrapped around the insulation layer (13). Its features are, Also includes: The sheath structure (2) includes an outer sheath (21), a filler layer (22), an inner interlayer (23), and an armor layer (24). The filler layer (22) is disposed in the gap between the shielding layer (12) and the conductor layer (11). The armor layer (24) is wrapped around the outside of the shielding layer (12). The outer sheath (21) is wrapped around the outside of the armor layer (24). The inner interlayer (23) is disposed between the outer sheath (21) and the armor layer (24).

2. The cold-resistant and torsion-resistant wind power flexible cable according to claim 1, characterized in that, The conductor layer (11) is made of multiple strands of fine tin-plated copper wire twisted together.

3. The cold-resistant and torsion-resistant wind power flexible cable according to claim 1, characterized in that, The insulating layer (13) is made of a cold-resistant elastomer material, which is one of cross-linked polyethylene, ethylene propylene rubber and thermoplastic elastomer.

4. The cold-resistant and torsion-resistant wind power flexible cable according to claim 1, characterized in that, The shielding layer (12) is made of tin-plated copper wire and aramid fiber.

5. The cold-resistant and torsion-resistant wind power flexible cable according to claim 1, characterized in that, The filling layer (22) is an elastic cushioning material, which is one of silicone rubber, polyurethane foam and fiberglass rope.

6. The cold-resistant and torsion-resistant wind power flexible cable according to claim 1, characterized in that, The armor layer (24) is made of stainless steel strip spiral wrapping or non-magnetic alloy wire weaving.

7. The cold-resistant and torsion-resistant wind power flexible cable according to claim 6, characterized in that, A rubber strip (25) is provided between the armor layer (24) and the inner interlayer (23), and the rubber strip (25) is wrapped around the outside of the armor layer (24).

8. The cold-resistant and torsion-resistant wind power flexible cable according to claim 7, characterized in that, The inner interlayer (23) is composed of polyurethane material and filler rope, and the outer protective layer (21) is cold-resistant rubber.

9. A cold-resistant and torsion-resistant wind power flexible cable according to claim 6, characterized in that, The outer surface of the outer protective layer (21) is coated with a fluorocarbon resin coating (211) and an organic ultraviolet absorber (212).

10. A cold-resistant and torsion-resistant wind power flexible cable according to claim 7, characterized in that, The protective layer structure (2) further includes a reinforcing layer (26) disposed between the inner interlayer (23) and the outer protective layer (21), the reinforcing layer (26) being woven from aramid fiber filaments.

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