Low-deviation flat transposed cable for extra-high voltage matching reactor, and manufacturing process

Abstract

A low-deviation flat transposed cable for an extra-high voltage matching reactor, and a manufacturing process. The low-deviation flat transposed cable for an extra-high voltage matching reactor comprises a flat transposed wire strand and a lapped insulating layer, wherein the flat transposed wire strand comprises n (n is an even number and n≥6) film-wrapped single round wires, which are formed into a dual-layer arrangement structure by means of stranding, transposition and compression according to a certain pitch, a certain stranding direction and a certain angle. Stranding, transposition and compression process equipment comprises three device modules such as a stranding and transposition device, a cam pre-loading device and a four-roller compression device, which are sequentially arranged in series and respectively complete an initial forming process, a pre-setting process and a final shaping process of the flat transposed wire strand during the processing and forming process of the flat transposed cable. Taking into consideration the structural characteristics and product requirements of the low-deviation flat transposed cable for an extra-high voltage matching reactor, a targeted manufacturing process and targeted process equipment are designed, wherein the process principle is scientific, the equipment is prominently advanced, and the production line has a relatively strong flexible manufacturing capacity.

Description

A low-deviation flat transposed conductor for ultra-high voltage supporting reactor and its manufacturing process Technical Field

[0001] The present invention relates to the high-end technical field of ultra-high voltage equipment, and in particular to a low-deviation flat transposed conductor for an ultra-high voltage matching reactor and a manufacturing process thereof. Background Art

[0002] my country has made significant progress in UHV equipment manufacturing, particularly in UHV transmission technology, which has become China's third high-tech trademark worldwide, following high-speed rail and nuclear power. Reactors, as a core component of UHV transmission systems, play a crucial role in reactive power compensation, current limiting, filtering, and overvoltage protection. Dry-type reactors, due to their lack of auxiliary operating systems and virtually maintenance-free operation, are increasingly widely used in UHV transmission. The core component of dry-type reactors is the coil winding, and flat transposed conductors are a key component in manufacturing the coil windings for UHV dry-type reactors.

[0003] As the capacity of ultra-high voltage transmission continues to increase, the capacity and volume of dry-type reactors are also getting larger and larger, and the size of coil windings and the specifications of winding wires are also getting larger and larger. In order to reduce the eddy current loss of the winding, it is necessary to replace a winding wire with a larger cross-section with multiple winding wires with smaller cross-sections. The traditional coil winding process adopts a multi-parallel winding method. A large number of theories and experiments have confirmed that this winding method not only has high requirements on equipment and winding technology, but also has low winding efficiency and winding filling factor. Moreover, when the number of parallel windings is greater than 2, it is difficult to achieve complete coil winding replacement only through the optimization of the winding process, resulting in an increase in the winding wire length error of the parallel wound winding coil, which leads to an increase in the circulating current of the reactor during operation, thereby increasing losses and posing a safety hazard.

[0004] The flat transposed conductor transposes and twists multiple film-wrapped round single-wire winding wires together. Its appearance is no different from a solid flat winding wire. The simplest continuous winding process can achieve a full transposition effect. The winding efficiency, winding quality, and winding strength are significantly improved, and the conduction surface area of ​​the winding wire is greatly increased, effectively reducing the eddy current loss and harmonic impedance of the reactor. Compared with the winding formed by winding multiple round single-wire winding wires, the winding wound with flat transposed conductors has a higher filling factor, the structure of the reactor is more compact, and the cost reduction and efficiency improvement effect are significant.

[0005] In fact, reactors play a key role in the stability and reliability of UHV system operation. Flat transposed conductor windings can certainly address the inherent shortcomings of traditional windings, but the manufacturing process of flat transposed conductors is complex, and the requirements for technical indicators such as appearance, structural dimensions, electrical insulation performance, and consistency of film-wrapped single wires are very strict. In particular, higher requirements are placed on the low deviation characteristics between each film-wrapped single wire of the flat transposed conductor. This low deviation characteristic is mainly reflected in the DC resistance deviation rate and core-to-core insulation resistance index of each film-wrapped single wire. For example, the DC resistance deviation rate of each film-wrapped single wire cannot exceed ±1%. That is, the unit resistivity error and length error of each film-wrapped single wire should be controlled within a relatively narrow digital range. The unit resistivity error is related to the conductor material and conductor deformation differences. The length error is related to the twisting stability, transposition accuracy, and pitch uniformity of the flat transposed conductor. The core-to-core insulation resistance index is related to the integrity of the film-wrapped insulation. All of these place very high demands on the manufacturing process of flat transposed conductors. Furthermore, flat transposed conductors are custom products. As the number of film-wrapped individual conductors increases and the width-to-thickness ratio rises, controlling the technical specifications of the finished product becomes increasingly difficult. Existing similar products and their manufacturing processes fall significantly short of these requirements, particularly in terms of the scientific nature, sophistication, and reliability of the manufacturing process. These processes suffer from low equipment precision, high operational difficulty, a narrow scope of application, and poor stability.

[0006] To sum up, it is necessary for the industry to upgrade the key components and process technologies of UHV supporting reactors, improve the technical level of domestic high-end equipment manufacturing of high-power devices, and continuously promote the high-quality development of my country's UHV equipment.

[0007] Summary of the Invention

[0008] The technical solution of the present invention addresses the technical problem that the existing technical solutions are too single, and provides a solution that is significantly different from the existing technology. The embodiment of the present invention provides a low-deviation flat transposed conductor and a manufacturing process for ultra-high voltage supporting reactors to solve the existing technical problems.

[0009] The embodiment of the present invention adopts the following technical solution: a low-deviation flat transposed conductor for an ultra-high voltage supporting reactor, comprising a flat transposed stranded wire and a wrapped insulating layer;

[0010] The flat transposed stranded wire comprises n membrane-wrapped round single wires, wherein n is an even number and n≥6, the outer diameter of the membrane-wrapped round single wires is d, and each membrane-wrapped round single wire forms a double-layer arrangement structure, wherein the membrane-wrapped round single wires are provided with a metal round single wire and a membrane wrapping layer, and the wrapping direction of the membrane wrapping layer is in the same direction as the twisting direction of the flat transposed stranded wire;

[0011] The wrapped insulation layer includes two film wrapping layers and one film fiber composite cloth wrapping layer. The wrapping direction of the film wrapping layer is the same as the twisting direction of the flat transposed stranded wire, and the wrapping direction of the film fiber composite cloth wrapping layer is opposite to the wrapping direction of the film wrapping layer.

[0012] A manufacturing process for a low-deviation flat transposed conductor for an ultra-high voltage supporting reactor, comprising the following specific steps:

[0013] Step 1, round single wire drawing: First, select the base material for making round single wire, that is, metal rod. Then, use the wire drawing machine to draw the metal rod into metal round single wire. The wire drawing machine should be equipped with an eddy current flaw detection online inspection point. The metal round single wire passes the defect screening before closing. The defects include cracks, invisible fractures, hidden seams, inclusions, pores, etc.

[0014] Step 2, round single wire film wrapping: take the metal round single wire in step 1, and pass it through a film wrapping production line to obtain a film-wrapped round single wire, wherein the film wrapping production line includes a disc-moving and centering pay-off device, a surface decontamination and cleaning device, a half-cut taping head, a traction wheel, a negative pressure dust removal device, a spark machine, and a disc-moving and centering take-up device;

[0015] Step 3, twisting, transposing, and press-forming: Take the film-wrapped single wire in step 2, and complete it through a twisting, transposing, and press-forming production line to obtain a low-deviation flat transposed conductor for ultra-high voltage supporting reactors. The twisting, transposing, and press-forming production line includes a twisting cage, twisting, transposing, and press-forming process equipment, a No. 1 wrapping machine, a No. 2 wrapping machine, a crawler traction machine, a spark machine, and a gantry ground rail wire take-up and arrangement machine.

[0016] The twisting transposition and profiling process equipment of the twisting transposition and profiling wrapping production line in the above-mentioned manufacturing process includes a twisting transposition device, a cam pre-pressing device, and a four-roller profiling device;

[0017] The twisting transposition device includes a first base, an up-down displacement assembly, a front-back displacement assembly, a left-right displacement assembly, a mold box assembly, a mold assembly and a twisting cage, and four threaded holes are provided on the plane of the first base;

[0018] The upper and lower displacement components of the twisted transposition device include a platform and four groups of fasteners, each group of fasteners includes a first bolt fastener and a second bolt fastener, a group of first threaded holes, a group of second threaded holes and a group of threaded holes are provided in the platform, the first bolt fasteners connect the platform to the connecting threaded holes of the base plane through the threaded holes of the platform, and the bolt fasteners are supported on the upper surface of the platform through the threaded holes of the platform;

[0019] The front-rear displacement assembly of the twisted transposition device includes two sets of linear guide rails and a set of lead screw assemblies, each set of the linear guide rails includes two sliders and an optical axis guide rail, the lead screw assembly includes a second base, a lead screw, a trapezoidal nut, a third base and a first hand wheel, the linear guide rails are arranged on both sides of the lead screw assembly, the optical axis guide rail is connected to the second threaded hole in the platform through a threaded fastener, the second base is connected to the third threaded hole in the platform through a threaded fastener, and the third base is connected to the first threaded hole in the platform through a threaded fastener, one end of the lead screw is fixed to the second base, and the other end of the lead screw passes through the third base and is connected to the first hand wheel;

[0020] The left and right displacement components of the twisted transposition device include a square tray, an optical axis, a first lead screw, and a second hand wheel. The bottom of the square tray is provided with four sets of fifth threaded holes and a fourth threaded hole. The fifth threaded holes are connected to the slider of the linear guide rail of the front-to-back displacement component through threaded fasteners, and the fourth threaded holes are connected to the trapezoidal nut of the lead screw assembly of the front-to-back displacement component through threaded fasteners.

[0021] The mold box assembly of the twisted displacement device includes a mold box body, an end cover, a tightening bolt and a locking assembly. The upper part of the mold box body and the end cover form a cavity. The bottom of the mold box body is provided with first through holes on both sides. The bottom of the mold box body is provided with a sixth threaded hole in the middle. The sixth threaded hole is matched with the optical axis of the left and right displacement assembly, and the sixth threaded hole is matched with the first lead screw of the left and right displacement assembly.

[0022] The mold assembly of the twisting transposition device includes a mold sleeve, a mold core, a first shaft, an elastic coupling and a second shaft. A straight slot gradually tapered through hole is provided in the mold sleeve, one end of the mold core is a straight slot gradually tapered tongue, and the other end of the mold core is connected to the first shaft, the flexible coupling and the second shaft in sequence. The mold sleeve is fixed in the mold box assembly cavity by a locking assembly and a tightening bolt. A straight slot gradually tapered ring body transposition channel is formed between the straight slot gradually tapered through hole of the mold sleeve and the straight slot gradually tapered tongue of the mold core.

[0023] The cam preload device includes an arc-shaped roller shaft, a bracket, a connecting bearing, a third shaft, a fastening bolt, and a fastening screw. The arc-shaped roller shaft is provided with bearing holes on both sides, the bracket is provided with second through holes on both sides of the lower end, and the bracket is provided with slot-shaped through holes on both sides of the upper end. The outer ring of the connecting bearing is assembled in the bearing hole of the arc-shaped roller shaft, and the third shaft is assembled in the inner ring of the connecting bearing. The two ends of the third shaft are fixed to the slot-shaped through holes by fastening bolts. The two sets of arc-shaped roller shafts form a minimum spacing T3 between the outer arc surfaces.

[0024] The four-roll forming device includes a roll forming device and a base, the roll forming device includes a housing assembly, a roll forming assembly and a control assembly, the housing assembly includes a housing bottom plate, a housing side plate and a housing panel, the housing panel and the housing bottom plate are both provided with a cross-shaped opening, the housing bottom plate is provided with four rows of seventh threaded holes, the upper, lower, right and left end surfaces of the housing side plates are each provided with a third through hole, and the upper left, lower right, upper right and lower left end surfaces of the housing side plates are each provided with a notch;

[0025] The rolling assembly includes a roller, a bearing group, a connecting shaft, a third sleeve, a roller clamping displacement member, an upper displacement workpiece, a linear guide rail No. 1 and a linear guide rail No. 2. There are four sets of the rolling assembly. The linear guide rail No. 1 includes a guide rail slider No. 1, a sliding guide rail No. 1, a track fastening screw No. 1 and a slider fastening screw No. 1. The sliding guide rail No. 1 is fixed to the seventh threaded hole of the bottom plate of the shell by a track fastening screw No. 1, and a guide rail slider No. 1 is slidably connected to one side of the sliding guide rail No. 1, and the guide rail slider No. 1 is fixed to the upper displacement workpiece by a slider fastening screw No. 1. A fourth through hole is provided on the bottom surface of the upper displacement workpiece, and a second threaded guide hole is provided on the side surface of the upper displacement workpiece. The linear guide rail No. 2 includes a guide rail slider No. 2, a sliding guide rail No. 2, a track fastening screw No. 2, and a slider fastening screw No. 2. The sliding guide rail No. 2 is connected to the upper displacement workpiece by a track fastening screw No. 2, and a guide rail slider No. 2 is slidably connected to the outer wall of the sliding guide rail No. 2, and the guide rail slider No. 2 is connected to the roller clamping displacement member by a slider fastening screw No. 2;

[0026] Bearing holes are provided on both sides of the roller, and the bearing group includes a first bearing and a second bearing. The outer rings of the first bearing and the second bearing are tightly fitted in the bearing holes, and the connecting shaft is tightly fitted to the inner rings of the first bearing and the second bearing. Two first bearing retaining rings are provided on the outer sides of the first bearing and the second bearing respectively. The two sides of the roller clamping displacement member are connected to the third sleeve by sleeve fastening screws;

[0027] The control component includes a third handwheel, a bearing sleeve, a fourth bearing, a second lead screw, a second bearing retaining ring, a key block and a bearing sleeve fastening screw. The control component is provided with a total of eight sets, and every two sets of control components correspond to the rolling components, wherein the second lead screw on one group of control components passes through the third through hole and engages with the second threaded guide hole, the bearing sleeve on one group of control components is fixed to the outer wall of the shell side plate by the bearing sleeve fastening screw, and the bearing sleeve corresponds to the position of the third through hole, the bearing sleeve on another group of the control components is fixed to the bottom of the upper displacement workpiece by the bearing sleeve fastening screw, and the bearing sleeve corresponds to the position of the fourth through hole, the second lead screw on another group of the control components engages with the first threaded guide hole, the second lead screw is rotatably connected to the bearing sleeve through the fourth bearing, the outer wall of the second lead screw is provided with a key block by opening a keyway, and the key block is connected to the third handwheel on one side, and the second bearing retaining ring is sleeved on the outside of the second lead screw and fixed to the bottom of the fourth bearing by bolts.

[0028] Furthermore, the twisting transposition device, cam preloading device and four-roller profiling device are arranged in series in sequence, the distance d1 between the twisting transposition device and the cam preloading device is controlled within 50mm-500mm, and the distance d2 between the cam preloading device and the four-roller profiling device is controlled within 100mm-3000mm.

[0029] Furthermore, the shaft of the mold assembly in the stranding transposition device is connected to the central tube of the stranding cage, and the relative positions between the mold sleeve and the mold core are fixed after the straight slot gradually tapered ring body transposition channel is formed.

[0030] Furthermore, the outer circumferential width of the roller of the roll forming device is T1, the distance from the outer circumferential surface of the roller to the end of the shaft hole side of the roller clamping displacement member is T2, and the width of T1 ≤ the width of T2.

[0031] Furthermore, the outer circumferential surfaces of the four rollers of the roll-forming device together form a rectangular roll-forming die opening, and the four rollers correspond to the cross-shaped opening.

[0032] Furthermore, the elastic coupling of the mold assembly should be a spring coupling, a slit coupling or a parallel groove coupling.

[0033] Furthermore, the quantitative relationship between the sizing zone length L, sizing zone height h, and sizing zone width w of the straight slot gradually tapered through hole of the mold sleeve should be: 2h≤L and 0.5w≤L≤1.5w, the quantitative relationship between the sizing zone height h of the straight slot gradually tapered through hole of the mold sleeve and the number n of membrane-wrapped round single wires, the outer diameter d of the membrane-wrapped round single wires, and the twisting angle θ of the flat transposed stranded wire is: h=d(1+1 / cos(θ))+x, x is an adjustment parameter with a value range of 0∽0.5d, the quantitative relationship between the sizing zone width w of the straight slot gradually tapered through hole of the mold sleeve and the number n of membrane-wrapped round single wires, the outer diameter d of the membrane-wrapped round single wires, and the twisting angle θ of the flat transposed stranded wire is: w=0.5nd / cos(θ)+(0.5n-1)y, y is an adjustment parameter with a value range of 0∽0.2.

[0034] Furthermore, the angles after the membrane-wrapped single line and the straight-notch gradually tapered ring body transposition channel are matched are α and β, the angles of the straight-notch gradually tapered through hole of the mold sleeve are α1 and β1, and the angles of the straight-notch gradually tapered tongue of the mold core are α2 and β2. The quantitative relationship between α, β, α1, β1, α2 and β2 is: α≥α1, β≥β1, α1=α2+(1°∽10°), β1=β2+(1°∽10°).

[0035] The low-deviation flat transposed conductor for the UHV supporting reactor of the present invention has the following characteristics:

[0036] First, the wrapping direction of the film-wrapped round single wire is the same as the twisting direction of the flat transposed stranded wire. During the transposition stranding process, the wrapping overlap of the film-wrapped round single wire can avoid head-on friction with the inner surface of the die sleeve of the stranding transposition device, reducing defects such as curling and cracking of the film-wrapped round single wire, ensuring the insulation strength of the film-wrapped round single wire and improving the voltage resistance and corona resistance of the reactor.

[0037] Secondly, the wrapping direction of the film-wrapped insulation layer is in the same direction as the twisting direction of the flat transposed stranded wire, which avoids the reverse twisting of the wrapping causing the stranded wire to become loose and twisted, thereby improving the compactness and dimensional stability of the flat transposed stranded wire;

[0038] Third, the round single wire drawing process is equipped with an online eddy current flaw detection point to screen the physical defects of the metal round single wire, significantly reducing the quality defects of the conductor material and improving the consistency of the film-wrapped round single wire;

[0039] Fourthly, the advantages of the reel-moving and centering pay-off (rewinding) device in the round single-wire film wrapping process are as follows: The common pay-off and rewinding feature in the industry is that the reel only rotates, and the single wire moves back and forth with the guide frame when winding it out (or in), causing the single wire to deflect within a certain angle range on the guide frame. This leads to large fluctuations in the single wire tension, which not only affects the stability of the wrapping, but also easily destroys the regularity of the wire arrangement, and also increases friction defects on the single wire surface.

[0040] The manufacturing device used in this manufacturing process has the following features when used:

[0041] 1. Scientific process principles and outstanding advancement; 2. Strong flexibility; 3. Lightweight and high space utilization; 4. Good operability, maintainability and repairability. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] In order to more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the specific embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0043] FIG1 is a schematic diagram of the structure of a low-deviation flat transposed conductor for a UHV supporting reactor according to the present invention;

[0044] FIG2 is a schematic diagram of a membrane package production line of the present invention;

[0045] FIG3 is a schematic diagram of a twisted transposition pressure-forming wrapping production line according to the present invention;

[0046] FIG4 is a schematic diagram of the manufacturing process of the stranding transposition pressing process equipment of the present invention;

[0047] FIG5 is a partial enlarged view of the manufacturing process of the stranding transposition pressing process equipment of the present invention;

[0048] FIG6 is a schematic diagram of the position of the stranding transposition profiling process equipment of the present invention;

[0049] FIG7 is a schematic diagram of the cooperation between the flat transposed stranded wire and the die assembly of the present invention;

[0050] FIG8 is a schematic cross-sectional view of L1→L4 of the present invention;

[0051] FIG9 is a schematic diagram of the flat transposed stranded wire structure of the present invention;

[0052] FIG10 is an outline view of the twisted transposition device of the present invention;

[0053] FIG11 is a schematic diagram of the base of the twisted transposition device of the present invention;

[0054] FIG12 is a schematic diagram of the upper and lower displacement adjustment components of the twisted transposition device of the present invention;

[0055] FIG13 is a schematic diagram of a front-to-rear displacement adjustment assembly of a twisting transposition device according to the present invention;

[0056] FIG14 is a schematic diagram of the left and right displacement adjustment components of the twisting transposition device of the present invention;

[0057] FIG15 is a second schematic diagram of the left-right displacement adjustment assembly of the twisted transposition device of the present invention;

[0058] FIG16 is a schematic diagram of a mold box assembly of a twisting transposition device according to the present invention;

[0059] FIG17 is a schematic diagram of a die assembly of a twisting transposition device according to the present invention;

[0060] FIG18 is a schematic diagram of a die sleeve of a twisting transposition device according to the present invention;

[0061] FIG19 is a schematic diagram of a core of a twisting transposition device according to the present invention;

[0062] FIG20 is a schematic diagram of the cooperation between the mold core and the mold sleeve of the twisting transposition device mold assembly of the present invention;

[0063] FIG21 is an outline view of a four-roller profiling device according to the present invention;

[0064] FIG22 is an outline view of the roll-forming assembly of the present invention;

[0065] FIG23 is a structural diagram of the housing assembly of the roll-forming assembly according to the present invention from a first perspective;

[0066] FIG24 is a second perspective view of the internal structure of the roll-forming assembly of the present invention;

[0067] FIG25 is a front view of a roll-forming assembly housing assembly of the present invention;

[0068] FIG26 is a structural diagram of the roll forming assembly of the present invention;

[0069] FIG27 is a front view of a roll forming assembly of the present invention;

[0070] FIG28 is an exploded view of a roll forming assembly of the present invention;

[0071] FIG29 is an exploded view of a control assembly of a roll forming assembly according to the present invention;

[0072] FIG30 is an outline view of the base of the present invention;

[0073] FIG31 is a projection and cross-sectional view of the cam preloading device of the present invention;

[0074] FIG32 is a schematic diagram of the cam preloading device bracket of the present invention.

[0075] Reference numerals: L0, metal round single wire; L1, film-wrapped round single wire; L4, flat transposed stranded wire; 12, film covering layer; 13, wrapped insulation layer; 14, film fiber composite cloth wrapping layer; 21, shifting disc centering pay-off device; 22, surface cleaning device; 23, half-cut taping head; 24, traction wheel; 25, negative pressure dust removal device; 26, spark machine; 27, shifting disc centering take-up device; 31, stranding cage; 32, transposition and profiling process equipment; 33, No. 1 taping machine; 34, No. 2 taping machine; 35, crawler traction machine; 36, spark machine; 37, gantry rail take-up and arrangement machine; A, stranding transposition device; A1, first base; A11, connection threaded hole; A2, upper and lower displacement assembly; A21, platform; A22, first bolt fastener; A23, second bolt fastener; A24, first threaded hole; A25, second threaded hole; A26, third threaded hole; A3, front-back displacement assembly; A31, slider; A32, optical axis guide; A33, second base; A34, lead screw; A35, trapezoidal nut; A36, third base; A37, First handwheel; A4, left-right displacement assembly; A41, square tray; A42, optical axis; A43, first lead screw; A44, second handwheel; A45, fourth threaded hole; A46, fifth threaded hole; A5, mold box assembly; A51, mold box body; A52, sixth threaded hole; A53, first through hole; A54, end cover; A55, tightening bolt; A56, locking assembly; A57, cavity; A6, mold assembly; A61, mold sleeve; A62, mold core; A63, first shaft; A64, elastic coupling; A65, second shaft; A66, straight slot gradually tapered through hole; A67, straight slot gradually tapered tongue; A68, straight slot gradually tapered ring body transposition channel; B. Cam preload device; B1. Curved roller shaft; B2. Bracket; B3. Connecting bearing; B4. Third shaft; B5. Fastening bolt; B6. Slotted through hole; B7. Fastening screw; B8. Second through hole; C. Four-roll forming device; C1. Roll forming device; C11. Housing assembly; C111. Housing bottom plate; C112. Housing side plate; C113. Housing face plate; C1110. Seventh threaded hole; C12. Roll forming assembly; C121. Roller; C122. Bearing assembly; C1221. First bearing; C1222. Second bearing; C123. Connecting shaft; C124. Third bushing; C125. Roller clamping displacement member; C126. Upper displacement workpiece; C12711. Linear guide rail number 1; C12712 , Linear Guide Rail No. 2; C12713, Track Fastening Screw No. 1; C12714, Slider Fastening Screw No. 1; C12721, Guide Rail Slider No. 2; C12722, Sliding Guide Rail No. 2; C12723, Track Fastening Screw No. 2; C12724, Slider Fastening Screw No. 2; C128, Bushing Fastening Screw; C1291, First Bearing Retaining Ring; C13, Control Assembly; C131, Third Handwheel;C132, bearing sleeve; C133, fourth bearing; C134, second lead screw; C135, second bearing retaining ring; C136, key block; C137, bearing sleeve fastening screw; C14, third through hole; C15, first threaded guide hole; C16, second threaded guide hole; C17, fourth through hole. DETAILED DESCRIPTION

[0076] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0077] The components of the embodiments of the present invention generally described and shown in the drawings herein may be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of the invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the invention.

[0078] Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative work shall fall within the scope of protection of the present invention.

[0079] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0080] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0081] 1 to 32 , an embodiment of the present invention provides a low-deviation flat transposed conductor for a UHV supporting reactor, comprising a flat transposed stranded conductor L4 and a wrapped insulating layer;

[0082] The flat transposed stranded wire L4 comprises n (n is an even number and n ≥ 6) membrane-wrapped round single wires L1, each having an outer diameter of d, and is twisted and transposed and pressed into a double-layer arrangement structure according to a certain pitch, a certain lay direction, and a certain angle θ. The membrane-wrapped round single wire L1 comprises a metal round single wire L0 and a membrane coating 12. The material of the metal round single wire L0 can be copper, aluminum, copper alloy, aluminum alloy, or copper-aluminum alloy. The wrapping direction of the membrane coating 12 is the same as the lay direction of the flat transposed stranded wire L4.

[0083] The wrapped insulation layer includes two layers of film wrapping layers 13 and one layer of film fiber composite cloth wrapping layer 14. The wrapping direction of the film wrapping layer is the same as the twisting direction of the flat transposed stranded wire L4, and the wrapping direction of the film fiber composite cloth wrapping layer 14 is opposite to the wrapping direction of the film wrapping layer 13.

[0084] The manufacturing process of the low-deviation flat transposed conductor for the UHV supporting reactor comprises the following specific steps:

[0085] Step 1, round single wire drawing: First, select the base material for making round single wire, that is, metal rod. Then, use a wire drawing machine to draw the metal rod into metal round single wire L0. The wire drawing machine should be equipped with an eddy current flaw detection online inspection point. The metal round single wire passes the defect screening before closing. Defects include cracks, invisible fractures, hidden seams, inclusions, pores, etc.

[0086] Step 2, round single wire film wrapping: take the metal round single wire L0 in step 1, complete it through the film wrapping production line and obtain the film wrapped round single wire L1, the film wrapping production line includes a disc moving and centering pay-off device 21, a surface cleaning device 22, a half-cut taping head 23, a traction wheel 24, a negative pressure dust removal device 25, a spark machine 26, and a disc moving and centering take-up device 27;

[0087] Step 3, twisting, transposition and press-forming wrapping: Take the film-wrapped single wire L1 in step 2, and complete it through the twisting, transposition and press-forming wrapping production line to obtain a low-deviation flat transposed conductor for ultra-high voltage supporting reactors. The twisting, transposition and press-forming wrapping production line includes a twisting cage 31, twisting, transposition and press-forming process equipment 32, a No. 1 wrapping machine 33, a No. 2 wrapping machine 34, a crawler traction machine 35, a spark machine 36, and a gantry ground rail wire take-up and arrangement machine 37.

[0088] The twisted transposition and profiling process equipment 32 of the twisted transposition and profiling wrapping production line is shown below in conjunction with Figures 1 to 11. An embodiment of the present invention provides a twisted transposition and profiling process equipment for flat transposed conductors for ultra-high voltage supporting reactors, including a twisted transposition device A, a cam pre-pressing device B, and a four-roller profiling device C;

[0089] The stranding transposition device A includes a first base A1, an up-down displacement assembly A2, a front-back displacement assembly A3, a left-right displacement assembly A4, a mold box assembly A5, a mold assembly A6 and a stranding cage J. Four threaded holes are provided on the plane of the first base A1;

[0090] The vertical displacement assembly A2 of the twisted transposition device A includes a platform A21 and four sets of fasteners, each set of fasteners including a first bolt fastener A22 and a second bolt fastener A23. The platform A21 is provided with a set of first threaded holes A24, a set of second threaded holes A25, and a set of threaded holes. The first bolt fasteners A22 connect the platform A21 to the connecting threaded holes A11 on the base plane through the threaded holes of the platform A21. The bolt fasteners A23 are supported on the upper surface of the platform A21 through the threaded holes of the platform A21.

[0091] The front-rear displacement assembly A3 of the twisted transposition device A includes two sets of linear guide rails and a set of screw rod assemblies, each set of the linear guide rails includes two sliders A31 and an optical axis guide rail A32, the screw rod assembly includes a second base A33, a screw rod A34, a trapezoidal nut A35, a third base A36 and a first handwheel A37, the linear guide rails are arranged on both sides of the screw rod assembly, the optical axis guide rail A32 is connected to the second threaded hole A25 in the platform A21 through a threaded fastener, the second base A33 is connected to the third threaded hole A26 in the platform A21 through a threaded fastener, the third base A36 is connected to the first threaded hole A24 in the platform A21 through a threaded fastener, one end of the screw rod A34 is fixed to the second base A33, and the other end of the screw rod A34 passes through the third base A36 to connect to the first handwheel A37;

[0092] The left-right displacement assembly A4 of the twisted transposition device A includes a square tray A41, an optical axis A42, a first lead screw A43, and a second handwheel A44. Four sets of fifth threaded holes A46 and fourth threaded holes A45 are provided at the bottom of the square tray A41. The fifth threaded holes A46 are connected to the slider A31 of the linear guide of the front-to-back displacement assembly A3 via threaded fasteners. The fourth threaded holes A45 are connected to the trapezoidal nut A35 of the lead screw assembly of the front-to-back displacement assembly A3 via threaded fasteners.

[0093] The mold box assembly A5 of the twisting transposition device A includes a mold box body A51, an end cover A54, a tightening bolt A55, and a locking assembly A56. The upper portion of the mold box body A51 and the end cover A54 form a cavity A57. First through holes A53 are provided on both sides of the bottom of the mold box body A51, and a sixth threaded hole A52 is provided in the middle of the bottom of the mold box body A51. The first through hole A53 cooperates with the optical axis A42 of the left-right displacement assembly A4, and the sixth threaded hole A52 cooperates with the first lead screw A43 of the left-right displacement assembly A4.

[0094] The mold assembly A6 of the twisting transposition device A includes a mold sleeve A61, a mold core A62, a first shaft A63, an elastic coupling A64 and a second shaft A65. A straight slot gradually tapered through hole A66 is provided in the mold sleeve A61. One end of the mold core A62 is a straight slot gradually tapered tongue A67, and the other end of the mold core A62 is connected to the first shaft A63, the flexible coupling and the second shaft A65 in sequence. The mold sleeve A61 is fixed in the cavity A57 of the mold box assembly A5 by a locking assembly A56 and a tightening bolt A55. A straight slot gradually tapered ring body transposition channel A68 is formed between the straight slot gradually tapered through hole A66 of the mold sleeve A61 and the straight slot gradually tapered tongue A67 of the mold core A62.

[0095] The cam preload device B includes an arc-shaped roller shaft B1, a bracket B2, a connecting bearing B3, a third shaft B4, a fastening bolt B5, and a fastening screw B7. Bearing holes are provided on both sides of the arc-shaped roller shaft B1. Second through holes B8 are provided on both sides of the lower end of the bracket B2, and slotted through holes B6 are provided on both sides of the upper end of the bracket B2. The outer ring of the connecting bearing B3 is assembled into the bearing hole of the arc-shaped roller shaft B1, and the third shaft B4 is assembled into the inner ring of the connecting bearing B3. Both ends of the third shaft B4 are fixed to the slotted through holes B6 by fastening bolts B5. The two sets of arc-shaped roller shafts B1 form a minimum spacing T3 between the outer arc surfaces.

[0096] The four-roll forming device C includes a roll forming device C1 and a base. The roll forming device C1 includes a housing assembly C11, a roll forming assembly C12, and a control assembly C13. The housing assembly C11 includes a housing bottom plate C111, a housing side plate C112, and a housing panel C113. The surfaces of the housing panel C113 and the housing bottom plate C111 are both provided with a cross-shaped opening. The housing bottom plate C111 is provided with four rows of seventh threaded holes C1110. The upper, lower, right, and left end surfaces of the housing side plate C112 are each provided with a third through hole C14. The upper left, lower right, upper right, and lower left end surfaces of the housing side plate C112 are each provided with a notch.

[0097] The rolling assembly C12 includes a roller C121, a bearing group C122, a connecting shaft C123, a third sleeve C124, a roller clamping displacement member C125, an upper displacement workpiece C126, a linear guide rail No. 1 C12711 and a linear guide rail No. 2 C12712. There are four sets of the rolling assembly C12. The linear guide rail No. 1 C12711 includes a guide rail slider No. 1, a sliding guide rail No. 1, a track fastening screw No. 1 C12713 and a slider fastening screw No. 1 C12714. The sliding guide rail No. 1 is fixed to the seventh threaded hole C1110 of the shell bottom plate C111 by the track fastening screw No. 1 C12713. One side of the sliding guide rail No. 1 is slidably connected to the guide rail slider No. 1, and the guide rail slider No. 1 is fixed by the slider fastening screw No. 1 C12714 On the upper character displacement workpiece C126, a fourth through hole C17 is provided on the bottom surface of the upper character displacement workpiece C126, and a second threaded guide hole C16 is provided on the side surface of the upper character displacement workpiece C126. The linear guide rail No. 2 C12712 includes a guide rail slider No. 2 C12721, a sliding guide rail No. 2 C12722, a track fastening screw No. 2 C12723, and a slider fastening screw No. 2 C12724. The sliding guide rail No. 2 C12722 is connected to the upper character displacement workpiece C126 through the track fastening screw No. 2 C12723, and the outer wall of the sliding guide rail No. 2 C12722 is slidably connected to the guide rail slider No. 2 C12721, and the guide rail slider No. 2 C12721 is connected to the roller clamping displacement member C125 through the slider fastening screw No. 2 C12724;

[0098] Bearing holes are provided on both sides of the roller C121. The bearing assembly C122 includes a first bearing C1221 and a second bearing C1222. The outer rings of the first and second bearings C1221 and C1222 are tightly fitted in the bearing holes. The connecting shaft C123 is tightly fitted to the inner rings of the first and second bearings C1221 and C1222. Two first bearing retaining rings C1291 are respectively provided on the outer sides of the first and second bearings C1221 and C1222. The roller clamping displacement member C125 is connected to a third sleeve C124 on both sides via sleeve fastening screws C128.

[0099] The control component C13 includes a third hand wheel C131, a bearing sleeve C132, a fourth bearing C133, a second screw C134, a second bearing retaining ring C135, a key block C136 and a bearing sleeve fastening screw C137. The control component C13 is provided with eight sets in total, and every two sets of control components C13 correspond to the rolling components C12. The second screw C134 on one set of control components C13 passes through the third through hole C14 and engages with the second threaded guide hole C16. The bearing sleeve C132 on one set of control components C13 is fixed to the outer wall of the shell side plate C112 by the bearing sleeve fastening screw C137, and the bearing sleeve C132 corresponds to the position of the third through hole C14. The other set of control components The bearing sleeve C132 on the control component C13 is fixed to the bottom of the upper displacement workpiece C126 by the bearing sleeve fastening screw C137, and the bearing sleeve C132 corresponds to the position of the fourth through hole C17. The second screw C134 on another group of the control component C13 is engaged with the first threaded guide hole C15, and the second screw C134 is rotatably connected with the bearing sleeve C132 through the fourth bearing C133. The outer wall of the second screw C134 is provided with a key block C136 by opening a key groove, and the key block C136 is connected to the third handwheel C131 on one side. The second bearing retaining ring C135 is sleeved on the outside of the second screw C134 and fixed to the bottom of the fourth bearing C133 by bolts.

[0100] Specifically, the twisting transposition device A, the cam preloading device B and the four-roller profiling device C are arranged in series in sequence, the distance d1 between the twisting transposition device A and the cam preloading device B is controlled within a range of 50 mm to 500 mm, and the distance d2 between the cam preloading device B and the four-roller profiling device C is controlled within a range of 100 mm to 3000 mm.

[0101] Specifically, the shaft of the mold assembly A6 in the twisting transposition device A is connected to the central tube of the twisting cage J, the mold sleeve A61 and the mold core A62 cannot rotate, and the relative position between the mold sleeve A61 and the mold core A62 is fixed after forming the straight slot gradually tapered ring body transposition channel A68.

[0102] Specifically, the outer circumferential width of the roller C121 of the roll-forming device C1 is T1, the distance between the outer circumferential surface of the roller C121 and the end of the shaft hole side of the clamping displacement member is T2, and the width of T1 ≤ the width of T2.

[0103] Specifically, the outer circumferential surfaces of the four rollers C121 of the roll-forming device C1 together form a rectangular roll-forming die, and the four rollers C121 correspond to the cross-shaped opening.

[0104] Specifically, the elastic coupling A64 of the mold assembly A6 should be a spring coupling, a slit coupling or a parallel groove coupling.

[0105] Specifically, the quantitative relationship between the sizing zone length L, the sizing zone height h, and the sizing zone width w of the straight slot gradually tapered through hole A66 of the die sleeve A61 should be: 2h≤L and 0.5w≤L≤1.5w, and the quantitative relationship between the sizing zone height h of the straight slot gradually tapered through hole A66 of the die sleeve A61 and the number n of the membrane-wrapped round single wire L1, the outer diameter d of the membrane-wrapped round single wire L1, and the twisting angle θ of the flat transposed stranded wire L4 is: h=d (1+1 / cos(θ))+x, x is an adjustment parameter with a value range of 0∽0.5d. The quantitative relationship between the sizing zone width w of the straight slot gradually tapered through hole A66 of the mold sleeve A61 and the number n of membrane-wrapped round single wires L1, the outer diameter d of the membrane-wrapped round single wires L1, and the twisting angle θ of the flat transposed stranded wire L4 is: w=0.5nd / cos(θ)+(0.5n-1)y, y is an adjustment parameter with a value range of 0∽0.2.

[0106] Specifically, the angles after the membrane-wrapped single line L1 and the straight-notch gradually tapered ring body transposition channel A68 are matched are α and β, the angles of the straight-notch gradually tapered through hole A66 of the mold sleeve A61 are α1 and β1, and the angles of the straight-notch gradually tapered tongue A67 of the mold core A62 are α2 and β2. The quantitative relationship between α, β, α1, β1, α2 and β2 is: α≥α1, β≥β1, α1=α2+(1°∽10°), β1=β2+(1°∽10°).

[0107] The key performance indicators of the low-deviation flat transposed conductor product for UHV reactors of the present invention lie in its low-deviation characteristics, including the DC resistance deviation rate of each film-wrapped round wire in the stranded conductor and the core-to-core insulation resistance index. The DC resistance deviation rate is primarily determined by the final state of the flat transposed conductor, including the material state, dimensional state, and length state. Specifically, in the manufacturing process, the material state of the metal wire is primarily related to manufacturing defects and can be inspected through online testing methods such as eddy current testing and ultrasonic testing. However, the most difficult key characteristics to control are dimensional state and length state. Due to the unique characteristics of the flat transposed conductor structure—twisting, transposition, high aspect ratio, and roller forming—the accuracy of transposition, consistency of pitch, and uniformity of deformation all lead to dimensional and length variations in the film-wrapped round aluminum wire. For example, when transposition jumpers occur, at least two film-wrapped round aluminum wires will inevitably cross and overlap. Abnormal deformation of the film-wrapped round aluminum wires at the crossover point not only causes large deviations in the DC resistance of the metal wires, but can also directly damage the film-wrapped insulation and even cause abnormal distortion of the stranded conductor structure. Therefore, the key points of the present invention lie in the scientific nature of the stranding transposition pressing process equipment mechanism and the rationality of the process parameter design, mainly as follows:

[0108] 1. The flat transposed conductor includes a flat transposed stranded wire L4 (hereinafter referred to as a stranded wire) and a wrapped insulating layer 13. The manufacturing process includes the following steps: round single wire drawing → round single wire film wrapping → stranded transposition press wrapping. The forming process of the flat transposed stranded wire L4 is completed on the stranded transposition press wrapping process equipment and is the core of the entire manufacturing process. The complete process nodes are: film wrapping round single wire L1 → passing through the stranding cage distribution plate → stranded transposition through the transposition channel of the stranding transposition device A → initially formed flat transposed stranded wire L2 → passing through the cam preloading device (B) → pre-formed flat transposed stranded wire L3 → passing through the four-roller press wrapping device C → finally formed flat transposed stranded wire L4. The cross-sectional state of the semi-finished product L1 → L2 → L3 → L4 is shown in Figure 8;

[0109] 2. At the process node of membrane-wrapped single wire L1 → initially formed flat transposed stranded wire L2, the circumferential distribution state of the membrane-wrapped single wire L1 is gradually changed to the initially formed state of the flat transposed stranded wire L2 through the transposition channel of the twisted transposition device (A), and the transposition channel is designed as a straight-notch gradually tapered ring transposition channel A68, which solves the process science problem of the membrane-wrapped single wire L1 changing from a circumferential distribution state to a twisted transposition initially formed state of the flat transposed conductor. Combined with the above-mentioned precise control of the displacement of the mold sleeve in the up and down, front and back, and left and right directions, the uniformity of the transposition channel of the transposition device in the static state is ensured from the perspective of mechanical coordination, meeting the uniformity and accuracy requirements of the transposition forming of the transposed conductor.

[0110] The straight-slot gradually tapered ring body transposition channel A68 is formed by the straight-slot gradually tapered through hole A66 of the mold sleeve A61 and the straight-slot gradually tapered tongue A67 of the mold core A62. The mold core A62 is fixed to the central tube of the stranding cage 31, and the mold sleeve A61 is fixed to the mold box of the stranding transposition device A. The two are separated from each other. The stranding cage 31 is large in size and heavy in weight. It is easy to generate vibration during rotation and transmit it to the mold core A62, causing the uniformity of the transposition channel to decrease. To solve this problem, the core A62 of the stranding transposition device is connected to the center tube of the stranding equipment using an elastic coupling A64. In addition to the ability to transmit axial torque, the elastic coupling A64 also has a 360° radial angular displacement deviation characteristic, realizing a flexible shaft transmission effect. From the perspective of design principles, it eliminates the defect of limited uniformity of the transposition channel due to static fit concentricity deviation of the die sleeve A61 and the die core A62, and especially solves the problem of decreased dynamic uniformity of the transposition channel - that is, the uniformity problem of the transposition channel under the medium and high frequency vibration state generated when the stranding equipment rotates under high load. Furthermore, the elastic coupling A64's telescopic properties provide adaptive characteristics to the transposition channel. By adjusting the die sleeve A61 to compress the elastic coupling A64 more, the gap between the transposition channel and the membrane-wrapped single wire L1 decreases, leading to higher transposition accuracy and suitability for membrane-wrapped single wires L1 with smaller elastic moduli. Conversely, the greater the range of dynamic transposition channel size variations, the more suitable it is for membrane-wrapped single wires L1 with larger elastic moduli, preventing excessive stress from causing wear on the membrane layer 12. During speed changes in the stranding equipment, changes in the tension of the membrane-wrapped single wire L1 can also affect transposition accuracy. The adaptive characteristics of the elastic coupling A64 effectively mitigate tension fluctuations, ensuring a smooth transposition process during high- and low-speed switching.

[0111] For transposed conductors with a width-to-thickness ratio exceeding 3, when the gap size of the transposition channel exceeds 1.05 times the diameter of the membrane-wrapped single wire L1, the surface quality of the membrane-wrapped single wire L1 is controllable, and the flat transposed stranded wire L2 is in an initial shaping state after exiting the mold sleeve A6. The membrane-wrapped single wire L1 is deformed to a large extent on both sides of the stranded wire, basically in a folded state, with a thickness exceeding 2.1 times the diameter of the membrane-wrapped single wire L1. The flat transposed stranded wire L2 is in a hollow state (see Figure 8 for details), and the net height of the hollow part exceeds 0.1 times the diameter of the membrane-wrapped single wire. The membrane-wrapped single wire in this state has not been yielded and shaped, and may slip at any time. The arc-shaped roller C121 of the cam preloading device B pre-presses and solidifies the middle area of ​​the transposed conductor, causing the middle area of ​​the outer surface on both sides of the stranded wire to be concave, and the stranded wire changes from an initial shaping state to a pre-solidified state, thereby improving the stability of the transposition pitch and preventing the pitch from loosening or slipping and jumping.

[0112] 2. Regarding the rationality of process parameter design, the membrane-wrapped round wire L1 is twisted and transposed through the transposition channel to form the initially formed flat transposed strand L2. The rationality of the design of the width w and height h of the die sleeve sizing zone directly affects the strand quality. According to the forming mechanism of flat transposed strands, each membrane-wrapped round wire in the strand has an equal twist pitch. A certain angle (θ) exists between the membrane-wrapped round wire L1 and the strand's central axis. The cross-section of the membrane-wrapped round wire L1 perpendicular to the strand's central axis is not circular, but rather approximately elliptical. The major axis of the ellipse is approximately d / cos(θ), as shown in Figure 9. Because the membrane-wrapped round wires L1 are not fully yielded, the gaps between the membrane-wrapped round wires L1 are significant, especially in terms of thickness. The membrane-wrapped round wires are almost in a kinked state (the bending radius is not negligible). The gap size is related to factors such as twist pitch, wire size, and elastic modulus, and is usually obtained through experimental verification. Therefore, the calculation formulas for the width w and height h of the sizing zone of the die sleeve A61 can be summarized as follows:

[0113] w=0.5nd / cos(θ)+(0.5n-1)y, where n is the number of single lines wrapped in the membrane (the same below),

[0114] y is the gap adjustment parameter, and its value range is 0∽0.2;

[0115] h=d(1+1 / cos(θ))+x, where x is an adjustment parameter with a value range of 0∽0.5d.

[0116] 3. In order to reduce the forming resistance of the flat transposed stranded wire L2, the quantitative relationship between the angles (α1, β1) of the straight slot gradually tapered through hole A66 of the die sleeve A61 and the angles (α2, β2) of the straight slot gradually tapered tongue A66 of the die core A62 is optimized, so that α1 = α2 + (1°∽10°), β1 = β2 + (1°∽10°), so that the size of the straight slot tapered ring transposition channel A68 formed between the die sleeve A61 and the die core A62 shows a gradual trend from large to small, which just conforms to the progressiveness of the yielding process of the membrane-wrapped single wire L1, thereby ensuring the forming accuracy and reducing the forming resistance. By adjusting the various displacement components of the twisting and transposition device A, the angles α and β of the membrane-wrapped single wire L1 when entering the straight-notch gradually tapered ring transposition channel A68 satisfy α≥α1 and β≥β1. By reducing the stress on the conical tongue of the mold core A62 during the twisting and transposition process of the membrane-wrapped single wire L1, the friction resistance between the membrane-wrapped single wire L1 and the transposition channel is reduced, thereby preventing the membrane layer 12 from being damaged by friction in the transposition channel.

[0117] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A low-deviation flat transposed conductor for an ultra-high voltage supporting reactor, characterized in that; It includes a flat transposed stranded wire (L4) and a wrapped insulating layer; The flat transposed stranded wire (L4) comprises n film-wrapped round single wires (L1), wherein n is an even number and n≥6, and each of the film-wrapped round single wires (L1) forms a double-layer arrangement structure, wherein the film-wrapped round single wire is provided with a metal round single wire (L0) and a film coating (12), and the wrapping direction of the film coating (12) is the same as the twisting direction of the flat transposed stranded wire (L4); The wrapped insulating layer comprises two layers of film wrapping layers (13) and one layer of film fiber composite cloth wrapping layer (14); the wrapping direction of the film wrapping layer (13) is the same as the twisting direction of the flat transposed stranded wire (L4), and the wrapping direction of the film fiber composite cloth wrapping layer (14) is opposite to the wrapping direction of the film wrapping layer (13).

2. The manufacturing process of a low-deviation flat transposed conductor for a UHV supporting reactor according to claim 1, characterized in that; The specific steps are as follows: Step 1, round single wire drawing: firstly, a metal rod for making a round single wire is selected, and then the metal rod is drawn into a metal round single wire (L0) by a wire drawing machine; Step 2, round single wire film wrapping: taking the metal round single wire (L0) in step 1, completing the film wrapping production line and obtaining a film wrapped round single wire (L1), wherein the film wrapping production line comprises a disc shifting and centering pay-off device (21), a surface decontamination and cleaning device (22), a half-cut wrapping head (23), a traction wheel (24), a negative pressure dust removal device (25), a spark machine (26), and a disc shifting and centering take-up device (27); Step 3, twisting, transposing and pressing: taking the film-wrapped round single wire (L1) in step 2, completing it through a twisting, transposing and pressing production line to obtain a low-deviation flat transposed conductor for an ultra-high voltage supporting reactor, wherein the twisting, transposing and pressing production line comprises a twisting cage (31), a twisting, transposing and pressing process equipment (32), a first wrapping machine (33), a second wrapping machine (34), a crawler traction machine (35), a spark machine (36), and a gantry ground rail wire taking-up and arranging machine (37).

3. The manufacturing process of a low-deviation flat transposed conductor for a UHV supporting reactor according to claim 2, characterized in that: The twisting transposition profiling process equipment (32) contained in the twisting transposition profiling wrapping production line in step 3 includes a twisting transposition device (A), a cam pre-pressing device (B), and a four-roller profiling device (C); The twisting transposition device (A) comprises a first base (A1), an up-and-down displacement assembly (A2), a front-and-back displacement assembly (A3), a left-and-right displacement assembly (A4), a mold box assembly (A5), a mold assembly (A6) and a twisting cage (J), wherein four threaded holes (A11) are arranged on a plane of the first base (A1); The up-down displacement assembly (A2) of the twisted transposition device (A) comprises a platform (A21) and four groups of fasteners, each group of the fasteners comprises a first bolt fastener (A22) and a second bolt fastener (A23), a group of first threaded holes (A24), a group of second threaded holes (A25) and a group of threaded holes (A26) are arranged in the platform (A21), the first bolt fastener (A22) connects the platform (A21) to the connecting threaded holes (A11) of the base plane through the threaded holes of the platform (A21), and the bolt fastener (A23) is supported on the upper surface of the platform (A21) through the threaded holes of the platform (A21); The front-rear displacement assembly (A3) of the twisted transposition device (A) comprises two sets of linear guide rails and one set of screw rod assembly, each set of the linear guide rails comprises two sliders (A31) and an optical axis guide rail (A32), the screw rod assembly comprises a second base (A33), a screw rod (A34), a trapezoidal nut (A35), a third base (A36) and a first hand wheel (A37), the linear guide rails are arranged on both sides of the screw rod assembly, and the optical axis guide rail (A32) is connected by a threaded fastener. In the second threaded hole (A25) of the platform (A21), the second base (A33) is connected to the third threaded hole (A26) of the platform (A21) through a threaded fastener, the third base (A36) is connected to the first threaded hole (A24) of the platform (A21) through a threaded fastener, one end of the screw rod (A34) is fixed to the second base (A33), and the other end of the screw rod (A34) passes through the third base (A36) to connect to the first hand wheel (A37); The left-right displacement assembly (A4) of the twisted transposition device (A) comprises a square tray (A41), an optical axis (A42), a first lead screw (A43) and a second hand wheel (A44); the bottom of the square tray (A41) is provided with four groups of fifth threaded holes (A46) and fourth threaded holes (A45); the fifth threaded holes (A46) are connected to the slider (A31) of the linear guide rail of the front-back displacement assembly (A3) through threaded fasteners; the fourth threaded holes (A45) are connected to the trapezoidal nut (A35) of the lead screw assembly of the front-back displacement assembly (A3) through threaded fasteners; The mold box assembly (A5) of the twisting displacement device (A) comprises a mold box body (A51), an end cover (A54), a tightening bolt (A55) and a locking assembly (A56); the upper part of the mold box body (A51) and the end cover (A54) form a cavity (A57); first through holes (A53) are arranged on both sides of the bottom of the mold box body (A51); a sixth threaded hole (A52) is arranged in the middle of the bottom of the mold box body (A51); the first through hole (A53) cooperates with the optical axis (A42) of the left and right displacement assembly (A4); and the sixth threaded hole (A52) cooperates with the first lead screw (A43) of the left and right displacement assembly (A4); The mold assembly (A6) of the twisting transposition device (A) comprises a mold sleeve (A61), a mold core (A62), a first shaft rod (A63), an elastic coupling (A64) and a second shaft rod (A65), wherein the mold sleeve (A61) is provided with a straight slot gradually tapered through hole (A66), one end of the mold core (A62) is a straight slot gradually tapered tongue (A67), and the other end of the mold core (A62) is connected in sequence to the first shaft rod (A63), an elastic coupling (A64) and a second shaft rod (A65). 3) A flexible coupling (A64) and a second shaft (A65), wherein the mold sleeve (A61) is fixed in the cavity (A57) of the mold box assembly (A5) through a locking assembly (A56) and a tightening bolt (A55), and a straight-slotted gradually tapered through hole (A66) of the mold sleeve (A61) and a straight-slotted gradually tapered tongue (A67) of the mold core (A62) form a straight-slotted gradually tapered ring body transposition channel (A68); The cam preloading device (B) comprises an arc roller shaft (B1), a bracket (B2), a connecting bearing (B3), a third shaft (B4), a fastening bolt (B5) and a fastening screw (B7), wherein bearing holes are arranged on both sides of the arc roller shaft (B1), second through holes (B8) are arranged on both sides of the lower end of the bracket (B2), and the bracket (B2) Grooved through holes (B6) are respectively provided on both sides of the upper end, the outer ring of the connecting bearing (B3) is assembled in the bearing hole of the arc roller shaft (B1), and the third shaft rod (B4) is assembled in the inner ring of the connecting bearing (B3), and both ends of the third shaft rod (B4) are fixed to the grooved through holes (B6) by fastening bolts (B5), and the two sets of arc roller shafts (B1) form a minimum spacing T3 between the outer arc surfaces; The four-roll forming device (C) comprises a roll forming device (C1) and a base (C2), wherein the roll forming device (C1) comprises a housing component (C11), a roll forming component (C12) and a control component (C13), wherein the housing component (C11) comprises a housing bottom plate (C111), a housing side plate (C112) and a housing panel (C113), wherein the surfaces of the housing panel (C113) and the housing bottom plate (C111) are both provided with a cross-shaped opening (C110), wherein the housing bottom plate (C111) is provided with four rows of seventh threaded holes (C1100), wherein the upper, lower, right and left end surfaces of the housing side plate (C112) are each provided with a third through hole (C14), and the upper left, lower right, upper right and lower left end surfaces of the housing side plate (C112) are each provided with a notch (C18); The rolling assembly (C12) includes a roller (C121), a bearing group (C122), a connecting shaft (C123), a third sleeve (C124), a roller clamping displacement member (C125), an upper character displacement workpiece (C126), a linear guide rail No. 1 (C1271) and a linear guide rail No. 2 (C1272). The rolling assembly (C12) has four sets in total. The linear guide rail No. 1 (C1271) includes a guide rail slider No. 1 (C12711), a sliding guide rail No. 1 (C12712), a track fastening screw No. 1 (C12713) and a slider fastening screw No. 1 (C12714). The sliding guide rail No. 1 (C12712) is fastened by a track fastening screw No. 1 ( C12713) is fixed on the seventh threaded hole (C1100) of the shell bottom plate (C111), one side of the sliding guide rail No. 1 (C12712) is slidably connected with a guide slider No. 1 (C12711), and the guide slider No. 1 (C12711) is fixed on the upper character displacement workpiece (C126) through a slider fastening screw No. 1 (C12714), and a fourth through hole (C17) is opened on the bottom surface of the upper character displacement workpiece (C126), and a second threaded guide hole (C16) is opened on the side surface of the upper character displacement workpiece (C126), and the linear guide rail No. 2 (C1272) includes a guide slider No. 2 (C12721), a sliding guide rail No. 2 (C12722), Track fastening screw No. 2 (C12723), slider fastening screw No. 2 (C12724), the sliding guide rail No. 2 (C12722) is connected to the upper displacement workpiece (C126) through the track fastening screw No. 2 (C12723), and the outer wall of the sliding guide rail No. 2 (C12722) is slidably connected with the guide rail slider No. 2 (C12721), and the guide rail slider No. 2 (C12721) is connected to the roller clamping displacement member (C125) through the slider fastening screw No. 2 (C12724); Bearing holes are arranged on both sides of the roller (C121); the bearing group (C122) comprises a first bearing (C1221) and a second bearing (C1222); the outer rings of the first bearing (C1221) and the second bearing (C1222) are assembled in the bearing holes by tight fitting; the connecting shaft (C123) is assembled on the inner rings of the first bearing (C1221) and the second bearing (C1222) by tight fitting; two first bearing retaining rings (C1291) are respectively arranged on the outer sides of the first bearing (C1221) and the second bearing (C1222); and the third sleeves (C124) are connected to both sides of the roller clamping displacement member (C125) by sleeve fastening screws (C128); The control assembly (C13) includes a third hand wheel (C131), a bearing sleeve (C132), a fourth bearing (C133), a second lead screw (C134), a second bearing retaining ring (C135), a key block (C136) and a bearing sleeve fastening screw (C137). The control assembly (C13) is provided with eight sets in total, and every two sets of control assemblies (C13) correspond to the rolling assembly (C12). The second lead screw (C134) on one set of the control assemblies (C13) passes through the third through hole (C14) and engages with the second threaded guide hole (C16). The bearing sleeve (C132) on one set of the control assemblies (C13) is fixed by the bearing sleeve fastening screw (C137). On the outer wall of the housing side plate (C112), the bearing sleeve (C132) corresponds to the position of the third through hole (C14), the bearing sleeve (C132) on another group of the control components (C13) is fixed to the bottom of the upper displacement workpiece (C126) by a bearing sleeve fastening screw (C137), and the bearing sleeve (C132) corresponds to the position of the fourth through hole (C17), the second lead screw (C134) on another group of the control components (C13) is engaged with the first threaded guide hole (C15), the second lead screw (C134) is rotatably connected to the bearing sleeve (C132) through the fourth bearing (C133), and the outer wall of the second lead screw (C134) is through A key block (C136) is placed through the key slot, one side of the key block (C136) is connected to a third hand wheel (C131), and the second bearing retaining ring (C135) is sleeved on the outside of the second lead screw (C134) and fixed to the bottom of the fourth bearing (C133) by bolts.

4. The manufacturing process of a low-deviation flat transposed conductor for a UHV supporting reactor according to claim 3, characterized in that: The twisting transposition device (A), the cam pre-pressing device (B) and the four-roller profiling device (C) are arranged in series in sequence, and the distance d1 between the twisting transposition device (A) and the cam pre-pressing device (B) is controlled within a range of 50 mm to 500 mm, and the distance d2 between the cam pre-pressing device (B) and the four-roller profiling device (C) is controlled within a range of 100 mm to 3000 mm.

5. The manufacturing process of a low-deviation flat transposed conductor for a UHV supporting reactor according to claim 3, characterized in that: The shaft rod (65) of the mold assembly (6) in the stranding transposition device (A) is connected to the central tube of the stranding cage (J).

6. The manufacturing process of a low-deviation flat transposed conductor for a UHV supporting reactor according to claim 3, characterized in that: The width of the outer circumference of the roller (C121) of the roll-forming device (C1) is T1, the distance between the outer circumference of the roller (C121) and the end of the shaft hole side of the clamping displacement member (C125) is T2, and the width of T1 is ≤ the width of T2.

7. The manufacturing process of a low-deviation flat transposed conductor for a UHV supporting reactor according to claim 3, characterized in that: The outer circumferential surfaces of the four rollers (C121) of the roller forming device (C1) together form a rectangular roller forming die opening (C19), and the four rollers (C121) correspond to the cross-shaped opening (C110).

8. The manufacturing process of a low-deviation flat transposed conductor for a UHV supporting reactor according to claim 3, characterized in that: The elastic coupling (A64) of the mold assembly (A6) in the twisting transposition device (A) is selected from a spring coupling, a slit coupling or a parallel groove coupling. The quantitative relationship between the sizing zone length L, the sizing zone height h and the sizing zone width w of the straight slot gradually tapered through hole (A66) of the mold sleeve (A61) should be: 2h≤L and 0.5w≤L≤1.5w. The quantitative relationship between the sizing zone height h of the straight slot gradually tapered through hole (A66) of the mold sleeve (A61) and the number n of the membrane-wrapped round single wires (L1), the outer diameter d of the membrane-wrapped round single wires (L1) and the twisting angle θ of the flat transposition stranded wire (L4) is: h=d(1+1 / cos(θ))+x, where x is an adjustment parameter with a value range of The quantitative relationship between the width w of the sizing zone of the straight slotted tapered through hole (A66) of the mold sleeve (A61), the number n of the membrane-wrapped round single wires (L1), the outer diameter d of the membrane-wrapped round single wires (L1), and the twisting angle θ of the flat transposed stranded wire (L4) is: w=0.5nd / cos(θ)+(0.5n-1)y, y is an adjustment parameter with a value range of 0∽0.

2.

9. The manufacturing process of a low-deviation flat transposed conductor for a UHV supporting reactor according to claim 3, characterized in that: The angles of the film-wrapped circular single line (L1) and the straight-notch gradually tapered ring body transposition channel (A68) after matching are α and β, the angles of the straight-notch gradually tapered through hole (A66) of the mold sleeve (A61) are α1 and β1, and the angles of the straight-notch gradually tapered tongue (A67) of the mold core (A62) are α2 and β2. The quantitative relationship between α, β, α1, β1, α2 and β2 is: α≥α1, β≥β1, 10. The low-deviation flat transposed conductor for UHV supporting reactor according to claim 1, characterized in that; The material of the metal round single wire is copper, aluminum, copper alloy, aluminum alloy or copper-aluminum alloy.

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