High performance thin wall locomotive interior connecting cable

Abstract

This utility model discloses a high-performance cable for internal connections in thin-walled locomotives, relating to the field of cable manufacturing technology, including a cable core. This application provides a high-performance cable for internal connections in thin-walled locomotives. Based on the traditional copper conductor structure, this application innovates by adding a high-strength bulletproof wire stranded layer outside the third stranded layer, employing a spiral stranded structure of copper conductor and bulletproof wire. This composite structure fully utilizes the conductivity of copper and the high strength of aramid fiber, improving tensile strength while maintaining good flexibility and bending resistance. It is particularly suitable for applications requiring high mechanical stress. Furthermore, the stranding process is optimized and improved, employing a three-layer differentiated stranding direction design. The first and third stranded layers use standard left-hand stranding, while the second stranded layer uses right-hand stranding. This alternating stranding method forms a balanced torque structure, effectively offsetting the residual stress generated by unidirectional stranding.

Description

Technical Field

[0001] This utility model relates to the field of cable manufacturing technology, specifically to a high-performance thin-walled cable for internal connections in locomotives. Background Technology

[0002] The existing thin-walled locomotive and rolling stock wires generally consist of a conductor and an insulation layer. They have an uneven appearance and often exhibit single-wire skipping, causing the conductor's outer diameter to frequently exceed the upper limit. The insulation layer thickness is generally above 0.3mm, and the material strength is not high, typically around 22N / mm2. They also have poor oil and wear resistance, resulting in a persistently high outer diameter of the finished wires. Consequently, their performance, safety, and reliability are weak, failing to meet the requirements for energy conservation and high efficiency.

[0003] For example, patent CN208521626U discloses a high-strength, thin-walled wire for locomotives and rolling stock. Compared with one-time opposite-direction stranding, this patent uses a three-layer, co-directional stranding method, resulting in a very smooth and round conductor appearance and significantly improved flexibility. The conductor roundness is improved by 40%, and the outer diameter can be controlled within the lower deviation range, providing a basis for reducing the outer diameter of wire products. However, although the three-layer stranding structure improves tensile strength, it does not consider the metal fatigue problem under dynamic bending conditions. After the tinned copper wire is stranded, there is still micro-friction between the individual wires, which can easily lead to wire breakage due to long-term vibration. Furthermore, the 0.2mm thin-walled insulation layer may affect heat dissipation efficiency in high-temperature scenarios (such as locomotive engine compartments). The upper limit of the long-term working temperature of polyolefin materials is 105℃, which is lower than the 250℃ temperature resistance rating of the new polyether ether ketone (PEEK). Utility Model Content

[0004] The purpose of this invention is to provide a high-performance thin-walled locomotive internal connection cable to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, this utility model provides the following technical solution: a high-performance thin-walled locomotive internal connection cable, comprising a cable core, wherein the cable core includes a first stranded layer disposed at the center, a second stranded layer disposed outside the first stranded layer, and a third stranded layer disposed outside the second stranded layer, wherein the first stranded layer and the third stranded layer are standard left-hand stranded, and the second stranded layer is right-hand stranded, wherein a bulletproof wire stranded layer is additionally provided outside the third stranded layer, and the bulletproof wire stranded layer is made of aramid fiber material.

[0006] Furthermore, the first stranded layer is located at the center and consists of seven tin-plated copper wires, and six of the tin-plated copper wires in the first stranded layer are arranged in a concentric array around the central tin-plated copper wire.

[0007] Furthermore, the second stranded layer consists of twelve tin-plated copper wires arranged concentrically.

[0008] Furthermore, the third stranded layer consists of eighteen tin-plated copper wires arranged concentrically.

[0009] Furthermore, the outer side of the cable core is wrapped with a protective layer, which includes an inner layer disposed on the inner side, and the inner layer is precisely wrapped with a 0.05mm ultrathin polyimide film.

[0010] Furthermore, the protective layer also includes an intermediate layer disposed on the outer side of the inner layer, and the intermediate layer is made of 0.1mm high-density irradiated cross-linked polyolefin material.

[0011] Furthermore, the protective layer also includes an outer layer disposed outside the intermediate layer, and the outer layer is coated with a 0.05mm fluorinated ethylene propylene copolymer.

[0012] Compared with the prior art, the present invention has the following beneficial effects: 1. This utility model innovates upon the traditional copper conductor structure by adding a high-strength bulletproof wire stranded layer outside the third stranded layer. It employs a spiral stranded structure of copper conductor and bulletproof wire, which fully utilizes the conductivity of copper and the high strength of aramid fiber. This enhances tensile strength while maintaining good flexibility and bending resistance, making it particularly suitable for applications requiring high mechanical stress. Furthermore, the stranding process is optimized and improved by adopting a three-layer differentiated stranding direction design. The first and third stranded layers use standard left-hand stranding, while the second stranded layer uses right-hand stranding. This alternating stranding method forms a balanced torque structure, effectively offsetting residual stress generated by unidirectional stranding, reducing self-torsion during use, and significantly improving cable stability and service life.

[0013] 2. This utility model adopts an innovative three-layer composite structure to replace the traditional single polyolefin protective layer. The inner layer is made of 0.05mm ultra-thin polyimide film precision wrapping, which has excellent high temperature resistance and effectively prevents the internal conductor from overheating and breaking down. The middle layer is made of 0.1mm high-density irradiated cross-linked polyolefin material, which provides excellent tensile and compressive mechanical protection for the cable. The outer layer is made of 0.05mm fluorinated ethylene propylene copolymer coating, which has inert chemical properties and can resist harsh environmental factors such as acid and alkali corrosion and solvent penetration. It achieves gradient optimization of temperature resistance, mechanical strength and chemical stability while reducing the outer diameter of the wire product. Attached Figure Description

[0014] Figure 1 This is a schematic cross-sectional view of the cable structure of this utility model; Figure 2 This utility model Figure 1 Enlarged structural diagram at point A in the middle; Figure 3This is a schematic diagram of the external structure of the cable of this utility model.

[0015] In the diagram: 1. Cable core; 101. First stranded layer; 102. Second stranded layer; 103. Third stranded layer; 104. Bulletproof wire stranded layer; 2. Protective layer; 201. Inner layer; 202. Middle layer; 203. Outer layer. Detailed Implementation

[0016] The embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this utility model, but should not be used to limit the scope of this utility model.

[0017] like Figures 1 to 3 As shown, a high-performance thin-walled locomotive internal connection cable includes a cable core 1. The cable core 1 includes a first stranded layer 101 disposed at the center, a second stranded layer 102 disposed outside the first stranded layer 101, and a third stranded layer 103 disposed outside the second stranded layer 102. The first stranded layer 101 and the third stranded layer 103 are standard left-hand stranded, while the second stranded layer 102 is right-hand stranded. An additional bulletproof wire stranded layer 104 is provided outside the third stranded layer 103, and the bulletproof wire stranded layer 104 is made of aramid fiber. The first stranded layer 101 is located at the center and consists of seven tin-plated copper wires, and six of the tin-plated copper wires in the first stranded layer 101 are arranged concentrically around the central tin-plated copper wire. The second stranded layer 102 has twelve tin-plated copper wires arranged concentrically, and the third stranded layer 103 has eighteen tin-plated copper wires arranged concentrically. The specific operation is as follows: This application innovates on the basis of traditional copper conductor structure by adding a high-strength bulletproof wire stranded layer 104 outside the third stranded layer 103. The spiral stranded structure of copper conductor and bulletproof wire is adopted. This composite structure gives full play to the conductivity of copper and the high strength of aramid fiber, improving tensile strength while maintaining good flexibility and bending resistance. It is particularly suitable for application scenarios that need to withstand large mechanical stress. Furthermore, the stranding process is optimized and improved by adopting a three-layer differentiated stranding direction design. The first stranded layer 101 and the third stranded layer 103 adopt standard left-hand stranding, while the second stranded layer 102 adopts right-hand stranding. This alternating stranding method forms a balanced torque structure, which can effectively offset the residual stress generated by unidirectional stranding, reduce self-torsion during use, and significantly improve the stability and service life of the cable. like Figures 1 to 3As shown, the outer side of the cable core 1 is wrapped with a protective layer 2. The protective layer 2 includes an inner layer 201 disposed on the inner side, and the inner layer 201 is precisely wrapped with a 0.05mm ultrathin polyimide film. The protective layer 2 also includes an intermediate layer 202 disposed on the outer side of the inner layer 201, and the intermediate layer 202 is made of a 0.1mm high-density irradiated cross-linked polyolefin material. The protective layer 2 also includes an outer layer 203 disposed on the outer side of the intermediate layer 202, and the outer layer 203 is coated with a 0.05mm fluorinated ethylene propylene copolymer. The specific operation is as follows: This application adopts an innovative three-layer composite structure to replace the traditional single polyolefin protective layer 2. The inner layer 201 is made of 0.05mm ultra-thin polyimide film precision wrapping, which has excellent high temperature resistance and effectively prevents the internal conductor from overheating and breaking down. The middle layer 202 is made of 0.1mm high-density irradiated cross-linked polyolefin material, which provides excellent tensile and compressive mechanical protection for the cable. The outer layer 203 is made of 0.05mm fluorinated ethylene propylene copolymer coating, which has inert chemical properties and can resist harsh environmental factors such as acid and alkali corrosion and solvent penetration. Under the premise of reducing the outer diameter of the wire product, the temperature resistance, mechanical strength and chemical stability are optimized in a gradient.

[0018] It should be noted that the three-stranded structure of this application is the same as that of Chinese Patent No. CN208521626U, and has the same function. Both can meet the requirements of wires for locomotives and rolling stock. The difference is that the stranding process is optimized and improved, and a high-strength bulletproof wire stranded layer 104 is added outside the third stranded layer 103. At the same time, while maintaining the thickness of the protective layer 2, the temperature resistance, mechanical strength and chemical stability are optimized by means of an innovative three-layer composite structure.

[0019] Working Principle: This application innovates upon the traditional copper conductor structure by adding a high-strength bulletproof wire stranded layer 104 outside the third stranded layer 103. It employs a spiral stranded structure of copper conductor and bulletproof wire. This composite structure fully utilizes the conductivity of copper and the high strength of aramid fiber, improving tensile strength while maintaining good flexibility and bending resistance. It is particularly suitable for applications requiring high mechanical stress. Furthermore, the stranding process is optimized and improved, employing a three-layer differentiated stranding direction design. The first stranded layer 101 and the third stranded layer 103 use standard left-hand stranding, while the second stranded layer 102 uses right-hand stranding. This alternating stranding method forms a balanced torque structure, effectively offsetting the residual torque generated by unidirectional stranding. This application employs an innovative three-layer composite structure to replace the traditional single polyolefin protective layer 2, which reduces stress and self-torsion during use, significantly improving cable stability and service life. The inner layer 201 is made of 0.05mm ultra-thin polyimide film with excellent high-temperature resistance, effectively preventing overheating and breakdown of the internal conductor. The middle layer 202 is made of 0.1mm high-density irradiated cross-linked polyolefin material, providing excellent tensile and compressive mechanical protection for the cable. The outer layer 203 is made of 0.05mm fluorinated ethylene propylene copolymer coating, which has inert chemical properties and can resist harsh environmental factors such as acid and alkali corrosion and solvent penetration. This achieves gradient optimization of temperature resistance, mechanical strength and chemical stability while reducing the outer diameter of the wire product.

[0020] The embodiments of this utility model are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the utility model to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described in order to better illustrate the principles and practical applications of this utility model, and to enable those skilled in the art to understand this utility model and design various embodiments with various modifications suitable for a particular purpose.

Claims

1. A high-performance, thin-walled locomotive internal connection cable, comprising a cable core (1), characterized in that, The cable core (1) includes a first stranded layer (101) disposed at the center, a second stranded layer (102) disposed outside the first stranded layer (101), and a third stranded layer (103) disposed outside the second stranded layer (102). The first stranded layer (101) and the third stranded layer (103) are standard left-hand stranded, while the second stranded layer (102) is right-hand stranded. An additional bulletproof wire stranded layer (104) is provided outside the third stranded layer (103), and the bulletproof wire stranded layer (104) is made of aramid fiber.

2. The high-performance thin-walled locomotive internal connection cable according to claim 1, characterized in that, The first stranded layer (101) is located at the center and is composed of seven tin-plated copper wires, and six of the tin-plated copper wires in the first stranded layer (101) are arranged in a concentric array around the central tin-plated copper wire.

3. The high-performance thin-walled locomotive internal connection cable according to claim 2, characterized in that, The second stranded layer (102) has twelve tin-plated copper wires arranged concentrically.

4. A high-performance thin-walled locomotive internal connection cable according to claim 3, characterized in that, The third stranded layer (103) consists of eighteen tin-plated copper wires arranged concentrically.

5. A high-performance thin-walled locomotive internal connection cable according to claim 4, characterized in that, The cable core (1) is wrapped with a protective layer (2) on the outside. The protective layer (2) includes an inner layer (201) disposed on the inside, and the inner layer (201) is precisely wrapped with a 0.05mm ultra-thin polyimide film.

6. A high-performance thin-walled locomotive internal connection cable according to claim 5, characterized in that, The protective layer (2) also includes an intermediate layer (202) disposed outside the inner layer (201), and the intermediate layer (202) is made of 0.1 mm high-density irradiated cross-linked polyolefin material.

7. A high-performance thin-walled locomotive internal connection cable according to claim 6, characterized in that, The protective layer (2) further includes an outer layer (203) disposed outside the intermediate layer (202), and the outer layer (203) is coated with a 0.05 mm fluorinated ethylene propylene copolymer.

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