A bend-resistant sensor cable for high-speed trains

Abstract

The utility model belongs to cable technical field especially relates to a kind of bend-resistant sensor cable for high-speed train set, the cable with high elasticity fiber rope as center filling rope, filling rope outside evenly distributes multiple copper alloy conductors, conductor is covered in proper order insulating layer, first wrapping layer, shielding layer, second wrapping layer and sheath layer;Wherein insulating layer uses thermoplastic polyester elastomer, first wrapping layer is thin type flame-retardant cloth, shielding layer is composed of tinned copper wire and fiber silk, second wrapping layer is thin type non-woven fabric, sheath layer is crosslinking type polyurethane.The utility model by optimizing conductor material, insulation and sheath material selection and multilayer structure design, significantly improve the bend-resistant performance of cable, while having excellent electrical insulation, shielding anti-interference and flame retardancy, can long-term stable adapt to frequent bending, vibration and complex environment in high-speed train set operation, meet the reliable transmission demand of sensor signal.

Description

Technical Field

[0001] This utility model belongs to the field of cable technology, and in particular relates to a bend-resistant sensor cable for high-speed trains. Background Technology

[0002] High-speed trains, as the core equipment of modern rail transit, operate at high speeds in complex environments, placing extremely high demands on the reliability and durability of onboard equipment. Sensors, as core components monitoring critical parts of the train, require dedicated cables to connect to the control system. However, existing sensor cables for high-speed trains suffer from the following key problems in practical applications: insufficient bending resistance, poor electrical stability, inadequate environmental adaptability, and substandard flame retardancy. Therefore, developing a high-speed train sensor cable with excellent bending resistance, high shielding and anti-interference capabilities, wide temperature range adaptability, and reliable flame retardancy is crucial for addressing existing technological shortcomings and ensuring the safe and stable operation of high-speed trains. Utility Model Content

[0003] To address the problems of poor bending resistance, weak anti-interference ability, insufficient environmental adaptability, and substandard flame retardant performance of existing sensor cables used in high-speed trains, this utility model aims to propose a bending-resistant sensor cable for high-speed trains. By optimizing the structural design and material selection, the cable can achieve long-term reliable operation under frequent bending conditions, while meeting multiple performance requirements such as electrical insulation, anti-interference, high and low temperature resistance, and flame retardancy.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A bend-resistant sensor cable for high-speed trains comprises, from the inside out, a filler rope, a conductor, an insulation layer, a first wrapping layer, a shielding layer, a second wrapping layer, and a sheath layer. The specific design of each part is as follows: Filler rope: Located at the center of the cable, it is made of high-elasticity fiber rope. High-elasticity fiber rope has excellent tensile resilience and can absorb stress during cable bending, preventing conductor damage due to excessive stretching or compression. At the same time, its filling effect can make the conductor evenly distributed in the cable cross-section, ensuring the roundness of the cable structure and preventing conductor displacement during bending.

[0005] Conductor: Evenly distributed on the outside of the filler rope, arranged in a ring array. 100 tin-plated copper alloy monofilaments with a diameter of 0.08mm are stranded in layers at a pitch of 10-12 times, with the outermost layer stranded in the opposite direction at an angle of 35° to reduce bending stress.

[0006] Insulation layer: Covering the outside of each conductor, the material is thermoplastic polyester elastomer (TPEE). TPEE combines the elasticity of rubber with the rigidity of plastic. It can maintain excellent elasticity and insulation performance in the temperature range of -50℃ to 120℃. At the same time, it has excellent bending resistance and fatigue resistance. After 500,000 bends, the insulation layer shows no cracking or damage.

[0007] First wrapping layer: Covers the outside of all insulated conductors. The material is a thin flame-retardant cloth. The thin flame-retardant cloth not only binds the internal insulated conductors to prevent them from loosening when the cable is bent, but also has excellent flame-retardant properties, which can initially block the spread of flames and provide protection for the subsequent shielding and sheathing layers.

[0008] Shielding layer: Covering the outside of the first wrapping layer, it adopts a mixed weaving structure of "tinned copper wire + fiber wire", with a spiral winding of 0.18mm tinned copper alloy wire + 1600Dtex fiber wire woven mesh, and a coverage rate of ≥95%, which not only meets the anti-interference performance of shielding, but also meets the anti-bending ability under high frequency vibration and sway.

[0009] The second wrapping layer: wrapped around the outside of the shielding layer, made of thin non-woven fabric. Its main function is to isolate the shielding layer from the sheathing layer, prevent the high-temperature molten material from seeping into the braided gaps of the shielding layer during the extrusion process of the sheathing layer, and at the same time prevent the metal wires of the shielding layer from scratching the inner wall of the sheathing layer, thereby improving the integrity and stability of the overall cable structure.

[0010] Sheath layer: Covering the outside of the second wrapping layer, it is the outermost structure of the cable. The material is cross-linked polyurethane (TPU), with 40wt% nano aluminum hydroxide and 5% organosilicon modifier added. Cross-linked TPU has excellent wear resistance, oil resistance and high and low temperature resistance, and is also flame retardant. It does not release toxic fumes when burning, which can ensure the safety of the cable in the event of a fire.

[0011] This utility model has the following beneficial effects: 1. Significantly Improved Bending Resistance: This invention uses a highly elastic fiber rope as the core filler, combined with a copper alloy conductor and a thermoplastic polyester elastomer insulation layer, significantly enhancing the cable's flexibility and fatigue resistance. The conductor stranding structure and elastic filler material effectively disperse bending stress, allowing the cable to maintain structural integrity even in the environment of frequent vibrations in high-speed trains, solving the problems of easy breakage and insulation wear in traditional sensor cables.

[0012] 2. Excellent anti-interference capability: The cable shielding layer is made of a mixture of tinned copper wire and fiber filaments, with a coverage of up to 90%. This ensures excellent electromagnetic shielding performance while also taking into account flexibility and durability, ensuring stable and reliable signal transmission in strong electromagnetic interference environments and meeting the high-precision and low-error transmission requirements of high-speed trains for sensor signals.

[0013] 3. Strong environmental adaptability: The sheath layer is made of cross-linked polyurethane material, which has excellent wear resistance, oil resistance, weather resistance, and high and low temperature resistance, enabling long-term use under the complex operating conditions of high-speed trains. The insulation layer is made of thermoplastic polyester elastomer, which is resistant to hydrolysis and aging, giving the cable good overall mechanical strength and environmental adaptability.

[0014] 4. Flame-retardant and safe: The cable structure is equipped with a thin flame-retardant cloth as the first wrapping layer, and the sheath layer is made of cross-linked polyurethane flame-retardant material. The double-layer flame-retardant design effectively inhibits the spread of flames, ensuring that the cable does not spread flames under high temperature or short circuit conditions, and is low in smoke and non-toxic, thus ensuring the safety of personnel and equipment during vehicle operation. Attached Figure Description

[0015] Figure 1 This is a structural diagram of a bend-resistant sensor cable for high-speed trains proposed in this utility model.

[0016] Legend: 1. Conductor; 2. Insulation layer; 3. Filler rope; 4. First wrapping layer; 5. Shielding layer; 6. Second wrapping layer; 7. Sheath layer. Detailed Implementation

[0017] The present invention will be further described in detail below with reference to specific embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of the present invention.

[0018] Reference Figure 1 A bend-resistant sensor cable for high-speed trains includes a filler rope 3 at the center of the cable, a plurality of conductors 1 evenly distributed outside the filler rope 3, an insulation layer 2 covering the conductors 1, a first wrapping layer 4 covering the plurality of conductors 1, a shielding layer 5 covering the first wrapping layer 4, a second wrapping layer 6 covering the shielding layer 5, and a sheath layer 7 covering the second wrapping layer 6.

[0019] Reference Figure 1The filler rope 3 is a highly elastic fiber rope with excellent elastic recovery performance. It provides support when the cable is bent, reducing mutual compression and friction between conductors. It also quickly returns to its original shape when the cable recovers, maintaining the integrity of the cable structure. Conductor 1 is a copper alloy conductor. Compared to ordinary copper conductors, copper alloy conductors have higher strength and better fatigue resistance, making them less prone to breakage during frequent bending and ensuring the continuity of signal transmission. The insulation layer 2 is made of thermoplastic polyester elastomer, which has excellent flexibility and bending resistance, maintaining stable insulation performance when the cable is bent. The first wrapping layer 4 is a thin flame-retardant cloth, effectively blocking the spread of flames and improving the cable's fire resistance. The shielding layer 5 is made of tinned copper wire and fiber filaments. The tinned copper wire effectively shields against external electromagnetic interference, ensuring the stability of signal transmission; the fiber filaments increase the flexibility and bending resistance of the shielding layer, making it less prone to damage when the cable is bent. The second wrapping layer 6 is a thin non-woven fabric. Its excellent breathability and flexibility further protect the shielding layer and prevent it from sticking to the sheath layer during bending. The sheath layer 7 is made of cross-linked polyurethane, which has high strength, high abrasion resistance, oil resistance, and weather resistance. It effectively protects the internal structure of the cable from the influence of the external environment, and its good elasticity can adapt to frequent bending of the cable, extending the cable's service life.

[0020] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A bend-resistant sensor cable for high-speed trains, comprising a filler rope (3) at the center of the cable, characterized in that: The filling rope (3) has multiple conductors (1) evenly distributed on its outside. The conductors (1) are covered with an insulating layer (2). The multiple conductors (1) are covered with a first wrapping layer (4). The first wrapping layer (4) is covered with a shielding layer (5). The shielding layer (5) is covered with a second wrapping layer (6). The second wrapping layer (6) is covered with a sheath layer (7).

2. The bend-resistant sensor cable for high-speed trains according to claim 1, characterized in that: The filler rope (3) is a highly elastic fiber rope.

3. The bend-resistant sensor cable for high-speed trains according to claim 1, characterized in that: The conductor (1) is a copper alloy conductor, consisting of 100 tin-plated copper alloy monofilaments with a diameter of 0.08 mm, twisted in layers at a pitch of 10-12 times, with the outermost layer twisted in the opposite direction at an angle of 35°.

4. The bend-resistant sensor cable for high-speed trains according to claim 1, characterized in that: The insulating layer (2) is made of thermoplastic polyester elastomer.

5. A bend-resistant sensor cable for high-speed trains according to claim 1, characterized in that: The first wrapping layer (4) is a thin flame-retardant cloth.

6. The bend-resistant sensor cable for high-speed trains according to claim 1, characterized in that: The shielding layer (5) is made of tin-plated copper wire and fiber wire, with a spiral winding of 0.18mm tin-plated copper alloy wire + 1600Dtex fiber wire woven mesh, and a coverage rate of ≥95%.

7. A bend-resistant sensor cable for high-speed trains according to claim 1, characterized in that: The second wrapping layer (6) is a thin nonwoven fabric.

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