An apparatus for manufacturing a composite logging cable

Abstract

The utility model provides a kind of manufacturing equipment of composite material well logging cable, including yarn frame (101) arranged in turn, week preheater (102), infiltration device (103), pultrusion mould (104), post-curing oven (105), traction machine (106) and take-off mechanism (107);Wherein, pultrusion mould (104) includes core mould (401), outer mould (402), tubular heating element (403), cable core passage (404) and multiple fiber composite material passages (405,406);Wherein, core mould (401) is located inside outer mould (402), the cable core passage (404) is located the center of the core mould, and the multiple fiber composite material passages (405,406) are sequentially arranged outside cable core passage (404) along circumference.The utility model can realize the good combination of resin and fiber by the multi-channel zoning design and precision temperature control of pultrusion mould, and significantly improve the comprehensive performance of cable.

Description

Technical Field

[0001] This application relates to the field of cable manufacturing technology, and in particular to a manufacturing device for a composite material logging cable. Background Technology

[0002] Logging cables are indispensable specialized cables in oil and gas field development. To withstand the high temperatures and corrosive environments downhole, protective or shielding layers are typically added to improve the cable's strength and corrosion resistance. Fiber composite cables are lightweight, corrosion-resistant, and high-strength, making them particularly suitable for harsh environments and demanding performance requirements.

[0003] Although fiber composite cables offer numerous performance advantages, they also suffer from some significant drawbacks due to limitations in manufacturing processes and other factors. For instance, an improperly designed resin impregnation system for the prepreg can result in insufficient interfacial bonding strength between the fiber and resin. Furthermore, during the pultrusion molding process, the equipment's ability to dynamically control temperature and pressure is limited, easily leading to incomplete or over-curing of the resin. This can cause interfacial peeling and softening during cable use, affecting the overall performance and service life of the cable. Utility Model Content

[0004] To address the aforementioned issues, this invention provides a manufacturing device for composite material logging cables. Through the multi-channel partition design of the pultrusion die and precise temperature control, it enables a good combination of resin and fiber, significantly improving the overall performance of the cable.

[0005] This utility model provides a manufacturing equipment for composite material logging cables, including a yarn frame, a frequency preheater, an impregnation device, a pultrusion die, a post-curing oven, a traction machine, and a take-up and delivery mechanism arranged in sequence. The pultrusion die includes a core die, an outer die, a tubular heating element, a cable core channel, and multiple fiber composite material channels. The core die is located inside the outer die, the cable core channel is located at the center of the core die, and the multiple fiber composite material channels are arranged sequentially around the outer side of the cable core channel.

[0006] Furthermore, the tubular heating element can be provided in multiple groups, preferably 3-5 groups.

[0007] Furthermore, multiple sets of tubular heating elements can be respectively installed in the inlet section, forming section and outlet section of the outer mold.

[0008] Furthermore, the impregnation device includes an impregnation tank and a wire mechanism.

[0009] Furthermore, the impregnation tank adopts a semi-open groove structure design, with a depth of 150-200mm and a width of 50-100mm. Preferably, a wedge-shaped guide plate is provided at the bottom of the impregnation tank, with the guide plate at an angle of 15-20° to the horizontal plane.

[0010] Furthermore, the yarn guiding mechanism comprises an inlet yarn guide, a tension adjusting roller group, and an impregnating yarn guide plate. Preferably, the inlet yarn guide adopts a comb-like structure with a tooth spacing of 5-8 mm.

[0011] Furthermore, the post-curing oven is equipped with multiple temperature control zones, preferably four. The length of each temperature control zone is 80-120cm, preferably 100cm. The heating temperature of the four zones is controlled according to the characteristics of the resin. The temperature of each temperature control zone can be adjusted according to requirements.

[0012] The superior effects of this utility model are as follows: 1. The impregnation tank of this utility model can ensure that the fiber composite material is fully impregnated in the impregnation tank, so as to achieve a good bond between the resin and the fiber.

[0013] 2. The pultrusion die features a multi-channel partition design and a precision temperature control system. The multi-channel partition design enables the coating of multiple layers of fiber composite material onto the cable core, while the precision temperature control system enables the synergistic molding of the fiber composite material and the built-in cable core, precisely controlling the initial curing state of the composite logging cable.

[0014] 3. The segmented temperature-controlled post-curing process can promote further cross-linking and curing of the resin inside the material, completing the transformation from the initial cured state to the final product, and significantly improving the overall performance of the cable. Attached Figure Description

[0015] Figure 1 This is a structural schematic diagram of the composite material logging cable manufacturing equipment of this utility model; Figure 2 This is a schematic diagram of the immersion device of this utility model; Figure 3 This is a cross-sectional view of the pultrusion die structure of this utility model.

[0016] Explanation of reference numerals in the attached figures: 101. Yarn rack; 102. Frequency preheater; 103. Impregnation tank; 104. Pultrusion die; 105. Post-curing oven; 106. Traction machine; 107. Take-up and untake-down mechanism; 201. Impregnation tank body; 202. Wire guiding mechanism; 203. Pultrusion die; 401. Core mold; 402. Outer mold; 403. Tubular heating element; 404. Cable core channel; 405. First fiber composite material channel; 406. Second fiber composite material channel. Detailed Implementation

[0017] The manufacturing equipment for the composite material logging cable of this utility model will be further described in detail below with reference to the accompanying drawings.

[0018] like Figure 1 As shown, this embodiment provides a composite material logging cable manufacturing equipment, which includes: a yarn rack 101 for arranging and placing fiber composite materials; a frequency preheater 102 for dehumidifying and pre-treating the fiber composite materials; an impregnation device 103 with a traction function and capable of uniformly impregnating the fiber composite materials; a pultrusion die 104 for initially shaping the composite material logging cable; a post-curing oven 105 for curing after pultrusion; a traction machine 106 for traction of the finished composite material logging cable; and a take-up and untake-down mechanism 107 for storing the finished composite material logging cable.

[0019] When the composite logging cable includes multiple fiber composite materials, multiple yarn frames 101 can be provided. These multiple yarn frames can be arranged side-by-side, and the fiber composite materials placed on each yarn frame can be the same or different. The fiber composite materials include carbon fiber composite materials, glass fiber composite materials, aramid fiber composite materials, etc.

[0020] like Figure 2 As shown, this embodiment discloses an impregnation device that achieves efficient impregnation and shaping of fiber materials through a special structural design. The impregnation device includes an impregnation tank 201 and a fiber guiding mechanism 202. The impregnation tank 201 adopts a semi-open groove structure design with a depth of 150-200mm and a width adjusted to 50-100mm according to the fiber bundle width. The inner wall of the tank is mirror-polished with a surface roughness Ra≤0.8μm to reduce resin flow resistance. A wedge-shaped guide plate is installed at the bottom of the tank, with an inclination angle of 15-20° to the horizontal plane, guiding the resin to form a self-circulating flow path and ensuring uniform resin concentration within the tank. The fiber guiding mechanism 202 consists of an inlet yarn guide, a tension adjusting roller group, and an impregnation guide plate. The inlet yarn guide adopts a comb-like structure with a tooth spacing of 5-8mm, which can evenly separate multiple fiber bundles and prevent yarn tangling. The surface of the yarn guide is hard chrome plated with a hardness ≥60HRC to improve wear resistance.

[0021] Figure 3 The structure of a pultrusion die according to this application is disclosed. The pultrusion die includes: a core die 401, an outer die 402, a tubular heating element 403, a cable core channel 404, a first fiber composite material channel 405, and a second fiber composite material channel 406. This die, through a multi-channel partitioned design and a precision temperature control system, achieves the coordinated molding of the fiber composite material and the embedded cable core.

[0022] The core mold 401 serves as the central support structure for forming the central cable core channel and the internal fiber arrangement space. The outer mold 402, located outside the core mold 401, cooperates with it to form a fiber composite material molding cavity, controlling the outer contour dimensions and layer distribution of the composite logging cable. Tubular heating elements 403 are mounted on the mold sleeve to heat the mold. Three to five sets of tubular heating elements 403 are respectively positioned at the inlet, forming, and outlet sections of the outer mold 402. These tubular heating elements can be resistance heating wires. The core mold 401 has three independent channels, serving as channels for the cable core and fiber composite material, respectively. A cable core channel 404 is located at the center of the core mold, with a flared guide at the inlet to prevent scratching the cable sheath. The cable core can be a power cable, signal cable, or optical fiber. A first fiber composite material channel 405, with a circular cross-section, is arranged around the outer side of the cable core channel and is evenly distributed along the circumference of the mold. A guide cone is located at the channel inlet to guide the fiber bundles to disperse evenly. A second fiber composite material channel 406 is also provided on the outside of the first fiber composite material channel to form a multi-layer fiber structure for the cable.

[0023] The post-curing oven 105 is located behind the pultrusion die 104 and is used to cure the composite logging cable after pultrusion. The post-curing oven has multiple temperature control zones, preferably four. The length of each temperature control zone is 80-120cm, preferably 100cm. The heating temperature of the four zones is controlled according to the characteristics of the resin. Each temperature control zone can be set to a different temperature as needed.

[0024] The manufacturing process of the composite material logging cable according to this utility model is as follows: First, the position of the rollers on the yarn frame 101 is precisely controlled. Using a high-precision positioning device and calibration system, the fiber composite material is neatly arranged on the yarn frame rollers in a predetermined order. Each fiber composite material thread is pulled through the limiting device. To avoid the threads from tangling and rubbing against each other, affecting the material properties, the spacing between each pulling thread on the limiting device must be maintained at more than 5mm. Subsequently, the threads are pulled by the winding device and orderly enter the frequency preheater 102 for dehumidification treatment at the preheating temperature. The preheating temperature can be determined according to the thermal stability and moisture evaporation characteristics of the composite material threads. This step can effectively remove the moisture contained in the material stored in the warehouse for a long time, preventing moisture from causing defects such as bubbles and delamination during the subsequent molding process, which would affect the quality of the product.

[0025] Next, using the wire unwinding mechanism, the dehumidified fiber composite material is introduced into the impregnation tank 103. Operators must use a liquid level sensor and a resin quality monitoring system to strictly control the resin level and freshness within the impregnation tank, ensuring the resin level is 3-5 cm above the material immersion position. This liquid level control ensures the glass fiber and carbon fiber composite material is fully impregnated in the impregnation tank, achieving good bonding between the resin and fiber, laying the foundation for the mechanical properties of the product. With the precise traction function of the wire unwinding mechanism, the uniformly impregnated fiber composite material slowly enters the pultrusion die 104 at a constant rate of approximately 0.5 m / min. This traction rate has been verified through extensive process testing, ensuring sufficient impregnation within the die while avoiding uneven resin distribution or insufficient impregnation due to excessive speed. Inside the pultrusion die 104, the material undergoes shaping and curing under the combined effects of high temperature and the pultrusion process. Through the specific cavity design of the mold, the product can be given precise external dimensions; at the same time, by using the temperature gradient control system inside the mold, the temperature of different areas can be precisely adjusted, so that the material gradually forms the initial solidified form of the composite logging cable.

[0026] Next, to further improve the mechanical properties and dimensional stability of the product, the newly pultruded composite logging cable undergoes post-curing treatment. The material passes through the post-curing oven 105, located behind the pultrusion die 104, at a uniform speed. The post-curing oven 105 employs a four-segment temperature control structure, with each segment having an effective heating length of 1m. The heating temperature range is 20-300℃, and the heating temperature of the four segments is controlled according to the characteristics of the resin. The heating temperatures of the four segments differ, gradually increasing as the composite logging cable moves. For example, the temperature in the first segment of the oven is set at 140℃, the second at 180℃, the third at 205℃, and the fourth at 220℃. The entire post-curing process takes 6-10 minutes. This segmented heating and isothermal control post-curing process is designed based on the resin's curing reaction kinetics, which promotes further cross-linking and curing of the resin within the material, completing the transformation from the initial cured state to the final product and significantly improving the overall performance of the product.

[0027] Finally, the carbon composite logging cable is precisely wound onto the reel of the take-up and unwinding mechanism 107 under the traction of the traction machine 106. During this process, the product is fixed and the tension is adjusted through the coordinated action of the positioning clamp and the tension control system, ensuring that the wound product is neat and tight, avoiding problems such as loosening and deformation, and ensuring the appearance quality and packaging and transportation requirements of the product.

[0028] The above embodiments are merely preferred embodiments of the present utility model and are not intended to limit the scope of the present utility model. Various modifications and improvements made by those skilled in the art to the technical solutions of the present utility model without departing from the spirit of the present utility model should fall within the protection scope defined by the claims of the present utility model.

Claims

1. A manufacturing equipment for composite logging cables, comprising a yarn rack (101), a frequency preheater (102), an impregnation device (103), a pultrusion die (104), a post-curing oven (105), a traction machine (106), and a take-up and release mechanism (107) arranged in sequence. in, The pultrusion die (104) includes a core die (401), an outer die (402), a tubular heating element (403), a cable core channel (404), and multiple fiber composite material channels (405, 406); wherein, the core die (401) is located inside the outer die (402), the cable core channel (404) is located at the center of the core die, and the multiple fiber composite material channels (405, 406) are arranged sequentially on the outside of the cable core channel (404) along the circumference.

2. The manufacturing equipment according to claim 1, wherein, The tubular heating element (403) is configured in multiple groups.

3. The manufacturing equipment according to claim 2, wherein, The tubular heating elements (403) are configured in groups of 3-5.

4. The manufacturing equipment according to claim 2, wherein, Multiple sets of tubular heating elements (403) are respectively installed in the inlet section, forming section and outlet section of the outer mold (402).

5. The manufacturing equipment according to claim 1, wherein, The impregnation device (103) includes an impregnation tank body (201) and a wire guide mechanism (202).

6. The manufacturing equipment according to claim 5, wherein, The impregnation tank (201) adopts a semi-open groove structure design with a depth of 150-200mm and a width of 50-100mm.

7. The manufacturing equipment according to claim 5, wherein, The bottom of the impregnation tank (201) is provided with a wedge-shaped guide plate, which is inclined at an angle of 15-20° to the horizontal plane.

8. The manufacturing equipment according to claim 5, wherein, The yarn guide mechanism (202) consists of an inlet yarn guide, a tension adjusting roller group, and an impregnated yarn guide plate.

9. The manufacturing equipment according to claim 8, wherein, The inlet yarn guide adopts a comb-like structure with a tooth spacing of 5-8mm.

10. The manufacturing equipment according to claim 1, wherein, The post-curing oven (105) is equipped with multiple temperature control zones.

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