Sensor wire with an interference-resistant structure

Abstract

The utility model discloses a sensor wire with anti -interference structure, including plug connector, and the wire of connecting plug connector, the wire includes a plurality of core line, a plurality of core line includes a power core line and a plurality of signal core line, the power core line sets up in the center position of wire, and a plurality of signal core line around power core line spiral twist and bind setting, the wire still includes: inner shielding layer, is wrapped in a plurality of core line outside, ground layer sets up in the inner shielding layer outside, outer shielding layer, is wrapped in ground layer outside, outer sheath layer, is wrapped in outer shielding layer outside. This sensor wire can effectively resist various electromagnetic interference, guarantees the stable transmission of sensor signal.

Description

Technical Field

[0001] This utility model relates to the field of sensor technology, and in particular to a sensor wire with an anti-interference structure. Background Technology

[0002] As a detection device, a sensor can sense the information being measured and transform the sensed information into electrical signals or other required forms of information output according to certain rules, so as to meet the requirements of information transmission, processing, storage, display, recording and control.

[0003] Sensor cables are a crucial component of sensor systems, used to connect sensors to control devices and transmit power and signals. Existing sensor cables typically consist of a connector and the wire connecting the connector, with power and signal cores embedded within the cable. However, industrial environments are rife with electromagnetic interference, which can affect the quality of sensor signal transmission through the cable, leading to measurement errors or even system malfunctions.

[0004] Currently, common anti-interference measures include single-layer shielding designs or simple core wire stranding. However, these measures have limited effectiveness in high-frequency signal transmission under complex electromagnetic environments and cannot meet the requirements of high-precision sensors. Therefore, a sensor wire structure with stronger anti-interference capabilities is needed. Utility Model Content The purpose of this invention is to overcome the shortcomings of insufficient anti-interference capability of existing sensor wires and to provide a sensor wire with an anti-interference structure that can effectively resist various electromagnetic interferences and ensure stable transmission of sensor signals.

[0005] The objective of this utility model is achieved through the following technical solution: A sensor cable with an anti-interference structure includes a connector and a cable connecting the connector. The cable includes a plurality of core wires, including a power core wire and a plurality of signal core wires. The cable also includes: An inner shielding layer is wrapped around the outside of the plurality of core wires; A grounding layer is disposed outside the inner shielding layer; An outer shielding layer is wrapped around the grounding layer. The outer sheath layer wraps around the outer shielding layer; The power core wire is located at the center of the wire, and several signal core wires are spirally twisted around the power core wire.

[0006] Furthermore, the inner shielding layer adopts an aluminum-magnesium alloy woven mesh structure with a weaving density of not less than 90%.

[0007] Furthermore, the grounding layer is composed of multiple strands of tin-plated copper wire, which are spirally wound along the length of the inner shielding layer, with a winding density of 4-6 turns per centimeter.

[0008] Furthermore, the outer shielding layer adopts a copper foil wrapping structure, the thickness of the copper foil is 0.03-0.05mm, and the wrapping overlap rate is 25%-35%.

[0009] Furthermore, the outer sheath is made of flame-retardant polyvinyl chloride material with a thickness of 0.5-1mm, and the Shore hardness of the outer sheath is 65-75D.

[0010] Furthermore, the signal core wire, from the inside out, includes a conductor, a high-density polyethylene insulation layer wrapped around the conductor, an independent shielding layer wrapped around the high-density polyethylene insulation layer, and a PVC inner sheath wrapped around the independent shielding layer.

[0011] Furthermore, the power core wire consists of a conductor and a PVC insulation layer wrapped around the conductor.

[0012] Furthermore, the conductors of both the power core wire and the signal core wire are made of multiple strands of silver-plated copper wire, with a single strand of copper wire having a diameter of 0.06-0.1mm.

[0013] Furthermore, high-strength, high-modulus, ultra-high molecular weight polyethylene fibers are filled between the power core wire and the signal core wire to separate the power core wire from each signal core wire.

[0014] Furthermore, the independent shielding layer adopts a copper wire braided structure with a braiding density of not less than 85%.

[0015] Furthermore, the pitch of the signal core wire spirally twisted around the power core wire is 10-20mm.

[0016] Furthermore, the number of signal core wires is 2-6, which are evenly distributed on the outer periphery of the power core wires.

[0017] The beneficial effects of this utility model are: This invention employs a multi-layer shielding structure consisting of an inner shielding layer, a grounding layer, and an outer shielding layer. The inner shielding layer effectively blocks electromagnetic interference between the internal core wires, the outer shielding layer resists electromagnetic interference from the external environment, and the grounding layer promptly discharges interference signals absorbed by the shielding layer, significantly improving the anti-interference capability of the wire.

[0018] The power core wire is located in the center, and the signal core wire is spirally twisted around it. This structure can reduce mutual interference between the power core wire and the signal core wire, and the spirally twisted signal core wire itself can also cancel out some electromagnetic interference.

[0019] The signal core wire is equipped with an independent shielding layer, which further enhances the anti-interference ability of individual signal transmission and ensures the stability and accuracy of signal transmission.

[0020] Each shielding and protective layer is designed with specific materials and parameters to ensure anti-interference performance while also taking into account the flexibility, durability and flame retardancy of the wire, thus extending the service life of the wire. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of an embodiment of the present utility model; Figure 2 This is a schematic diagram of the cross-sectional structure of the wire in an embodiment of this utility model; Reference numerals: 1. Connector; 2. Wire; 3. Power core wire; 31. Conductor; 32. PVC insulation layer; 4. Signal core wire; 41. Conductor; 42. High-density polyethylene insulation layer; 43. Independent shielding layer; 44. PVC inner sheath; 5. Inner shielding layer; 6. Grounding layer; 7. Outer shielding layer; 8. Outer sheath layer; 9. High-strength, high-modulus, ultra-high molecular weight polyethylene fiber. Detailed Implementation

[0022] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0023] In the description of this utility model, it should be noted that the terms "vertical direction," "up," "down," and "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, "first," "second," "third," and "fourth" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0024] In the description of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or a connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0025] like Figures 1 to 2 As shown, this embodiment of the utility model provides a sensor cable with an anti-interference structure, including a connector 1 and a cable 2 connected to the connector 1. The cable 2 includes several core wires, including a power core wire 3 and several signal core wires 4. The cable 2 also includes an inner shielding layer 5, a grounding layer 6, an outer shielding layer 7, and an outer sheath layer 8. In this embodiment, the several core wires include one power core wire 3 and four signal core wires 4. The connector 1 adopts a standard sensor-specific interface, and its internal pins are connected one-to-one with the power core wire 3 and the signal core wires 4. In this embodiment, the power core wire 3 is positioned at the center of the wire 2, and four signal core wires 4 are spirally twisted around the power core wire 3. Positioning the power core wire 3 at the center of the wire 2 is an optimal design that has been verified through numerous experiments. This arrangement ensures that the electromagnetic field generated by the power core wire 3 is evenly distributed around it, avoiding the problem of uneven electromagnetic interference to the signal core wires 4 caused by the offset position of the power core wire 3. The power core wire 3 consists of a conductor 31 and a PVC insulation layer 32 surrounding the conductor 31. The conductor 31 is made of 36 strands of silver-plated copper wire with a diameter of 0.08mm twisted together. The twisted structure of 22 copper wires gives the conductor 31 good flexibility, allowing it to adapt to bending and movement of the wire. The PVC insulation layer 32 is 0.3mm thick and has good insulation and aging resistance, ensuring electrical isolation between the power core wire 3 and other core wires. The signal core wire 4, from the inside out, comprises a conductor 41, a high-density polyethylene insulation layer 42 wrapped around the conductor 41, an independent shielding layer 43 wrapped around the high-density polyethylene insulation layer 42, and a PVC inner sheath 44 wrapped around the independent shielding layer 43. The conductor 41 is made of 22 strands of silver-plated copper wire with a diameter of 0.08mm, twisted together to ensure low signal loss and high stability during transmission. The high-density polyethylene insulation layer 42 is 0.2mm thick; the low and stable dielectric constant of high-density polyethylene reduces signal attenuation and distortion during transmission. The independent shielding layer 43 uses a copper wire braided structure with a braiding density of 88% and copper wire diameter of 0.05mm. This independent shielding layer 43 effectively blocks electromagnetic interference from other core wires to the signal core wire 4, ensuring independent signal transmission. The PVC inner sheath 44 is 0.15mm thick and uses the same material as the PVC insulation layer 32 of the power core wire 3, serving to protect the independent shielding layer 43 and provide further insulation. High-strength, high-modulus, ultra-high molecular weight polyethylene (UHMWPE) fiber 9 is filled between the power core wire 3 and the signal core wire 4. This UHMWPE fiber possesses extremely high strength and modulus, effectively separating the power core wire 3 from each signal core wire 4, maintaining their relative positional stability, and preventing friction and compression between the core wires when the wires are bent or subjected to external forces, thereby reducing interference caused by mechanical stress. Simultaneously, this fiber also exhibits good insulation properties and chemical corrosion resistance, and will not negatively impact the electrical performance of the core wires. There are four signal core wires 4, evenly distributed around the outer periphery of the power core wire 3. This even distribution ensures that the distance between each signal core wire 4 and the power core wire 3 is basically consistent, thereby reducing interference imbalance caused by distance differences. The four signal core wires 4 are spirally twisted around the power core wire 3 with a twist pitch of 15mm. This pitch parameter was determined after comprehensively considering anti-interference performance and wire flexibility. If the pitch is too small, it will increase the stiffness of the wire, which is not conducive to bending and installation; if the pitch is too large, it will reduce the anti-electromagnetic interference effect of the spiral twisting structure. By using a 15mm pitch, both good wire flexibility and symmetrical interference cancellation of the signal core wires 4 can be fully achieved during the twisting process. The inner shielding layer 5 wraps around several core wires and employs an aluminum-magnesium alloy braided mesh structure with a braiding density of 92%. Aluminum-magnesium alloy possesses excellent conductivity and mechanical strength, and its braided mesh structure forms a continuous conductive barrier, effectively blocking the outward radiation of electromagnetic interference generated between the internal core wires, while also preventing external interference from entering the internal core wire area. Testing has shown that the inner shielding layer 5 at this density achieves a shielding effectiveness of over 80 dB against internal electromagnetic interference. The grounding layer 6 is located outside the inner shielding layer 5 and consists of 10 strands of tin-plated copper wire with a diameter of 0.1 mm, spirally wound along the length of the inner shielding layer 5 at a winding density of 5 turns per centimeter. The tin-plated copper wire not only has good conductivity but also improves its oxidation resistance and solderability. The arrangement of 10 strands ensures that the grounding layer 6 has sufficient current-carrying capacity, enabling it to quickly conduct interference signals absorbed by the inner shielding layer 5 and the outer shielding layer 7 to the ground. The winding density of 5 turns per centimeter ensures tight contact between the grounding layer 6 and the inner shielding layer 5, reducing contact resistance and allowing interference signals to be smoothly conducted to the grounding terminal. The outer shielding layer 7 is wrapped around the grounding layer 6 and uses a copper foil wrapping structure. The copper foil is 0.04 mm thick and the wrapping overlap rate is 30%. The copper foil has extremely high conductivity and can effectively reflect and absorb high-frequency electromagnetic interference from the external environment. Tests have shown that the shielding effectiveness of this outer shielding layer 7 against external high-frequency electromagnetic interference can reach over 90 dB. The outer sheath layer 8, wrapped around the outer shielding layer 7, is made of flame-retardant polyvinyl chloride (PVC) material with a thickness of 0.8 mm and a Shore hardness of 70D. The flame-retardant PVC material has excellent flame-retardant properties, meeting the UL94V-0 flame-retardant standard, and is self-extinguishing upon contact with an open flame, reducing fire hazards. The 0.8 mm thickness provides the outer sheath layer 8 with sufficient mechanical strength to withstand external wear, compression, and impact, protecting the internal structure from damage.

[0026] The sensor cable in this embodiment has undergone rigorous performance testing. In an electromagnetic environment with a frequency range of 1MHz-1GHz, its signal-to-noise ratio can reach over 85dB, which is far higher than the 60dB of existing ordinary sensor cables, fully demonstrating its excellent anti-interference performance.

[0027] In summary, the sensor cable of this embodiment, through its multi-shielding structure, optimized core wire layout, and high-quality material selection, can effectively resist internal and external electromagnetic interference, ensuring stable transmission of sensor signals. It is suitable for sensor connections in various complex electromagnetic environments such as industrial automation, precision measurement, and medical equipment.

[0028] The above description merely illustrates the preferred technical solution of this utility model, and while the description is relatively specific and detailed, it should not be construed as limiting the scope of the utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and this utility model also intends to include these modifications and variations.

Claims

1. A sensor wire with an anti-interference structure, characterized in that: The cable includes a connector and a wire connecting the connector. The wire includes several core wires, including a power core wire and several signal core wires. The power core wire is located at the center of the wire, and the signal core wires are spirally twisted around the power core wire. The wire also includes: An inner shielding layer is wrapped around the outside of the plurality of core wires; A grounding layer is disposed outside the inner shielding layer; An outer shielding layer is wrapped around the grounding layer. The outer sheath layer is wrapped around the outside of the outer shielding layer.

2. The sensor wire with anti-interference structure according to claim 1, characterized in that: The inner shielding layer adopts an aluminum-magnesium alloy woven mesh structure with a weaving density of not less than 90%.

3. The sensor wire with anti-interference structure according to claim 1, characterized in that: The grounding layer is composed of multiple strands of tin-plated copper wire, which are spirally wound along the length of the inner shielding layer, with a winding density of 4-6 turns per centimeter.

4. The sensor wire with anti-interference structure according to claim 1, characterized in that: The outer shielding layer adopts a copper foil wrapping structure with a copper foil thickness of 0.03-0.05mm and a wrapping overlap rate of 25%-35%.

5. The sensor wire with an anti-interference structure according to claim 1, characterized in that: The outer sheath is made of flame-retardant polyvinyl chloride material with a thickness of 0.5-1mm and a Shore hardness of 65-75D.

6. The sensor wire with an anti-interference structure according to claim 1, characterized in that: The signal core wire, from the inside out, includes a conductor, a high-density polyethylene insulation layer wrapped around the conductor, an independent shielding layer wrapped around the high-density polyethylene insulation layer, and a PVC inner sheath wrapped around the independent shielding layer. The power core consists of a conductor and a PVC insulation layer wrapped around the conductor.

7. The sensor wire with an anti-interference structure according to claim 6, characterized in that: The conductors of both the power core and the signal core are made of multiple strands of silver-plated copper wire, with a single strand diameter of 0.06-0.1mm. Polyethylene fibers are filled between the power core wire and the signal core wire to separate the power core wire from each signal core wire.

8. The sensor wire with an anti-interference structure according to claim 6, characterized in that: The independent shielding layer adopts a copper wire braided structure with a braiding density of not less than 85%.

9. The sensor wire with anti-interference structure according to claim 1, characterized in that: The pitch of the signal core wire spirally twisted around the power core wire is 10-20mm.

10. The sensor wire with an anti-interference structure according to claim 1, characterized in that: The number of signal core wires is 2-6, which are evenly distributed on the outer periphery of the power core wires.

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