High-current-carrying direct-current shore power flat cable and manufacturing method therefor

Abstract

Provided in the present invention are a high-current-carrying direct-current shore power flat cable and a manufacturing method therefor. The high-current-carrying direct-current shore power flat cable comprises two power wire cores arranged adjacent to each other, and two control wires arranged adjacent to the power wire cores, wherein the two power wire cores are arranged adjacent to each other such that the high-current-carrying direct-current shore power flat cable is flat; and the cross section of each power wire core is circular, and each power wire core comprises a circular segmented unit which is arranged in the middle and has a circular cross section, and a plurality of fan-shaped segmented units which are arranged around the circular segmented unit and have fan-shaped cross sections, a segmented unit isolation layer being arranged around each of the circular segmented unit and the fan-shaped segmented units. By means of using the design of a structure with two power wire cores and by using the design of a flat-cable structure, the high-current-carrying direct-current shore power flat cable in the present invention is conducive to reducing the overall outer diameter of the high-current-carrying direct-current shore power flat cable, and improving the overall bending performance of the high-current-carrying direct-current shore power flat cable.

Description

High-current direct-current shore power flat cable and manufacturing method thereof TECHNICAL FIELD

[0001] The present application relates to a high-current direct-current shore power flat cable and a manufacturing method thereof. BACKGROUND

[0002] As a key element of a shore power system, a shore power cable needs to be provided with a shore power cable storage reel device in the shore power system to meet the application of different distances between a power supply end and a power receiving end. The outer diameter size and bending performance of the shore power cable are one of the key factors affecting the size of the storage device and even the overall size of the shore power device.

[0003] The existing common shore power cable is generally a cylindrical structure composed of a multi-stranded conductor and its insulation and sheath. The bending performance of the cable is closely related to the outer diameter of the cable. When the cable is stored in the storage reel in a disc shape, there is a large gap between adjacent layers of the cable, resulting in a large size of the storage reel and a large overall size of the shore power equipment.

[0004] Therefore, it is necessary to improve the existing shore power cable to solve the above problems. SUMMARY

[0005] The purpose of the present application is to provide a high-current direct-current shore power flat cable to solve the problem of poor bending performance of the existing circular shore power cable.

[0006] To achieve the above purpose, the present application provides a high-current direct-current shore power flat cable, which comprises two adjacent power line cores and two control lines arranged adjacent to the power line cores. The power line cores are adjacent to each other, and the cross section of the power line core is circular. The power line core comprises a circular division unit arranged in the middle section and a plurality of fan-shaped division units arranged around the circular division unit, and the circular division unit and the fan-shaped division unit are both surrounded by a division unit isolation layer.

[0007] As a further improvement of the present application, each power line core comprises four fan-shaped division units.

[0008] As a further improvement of the present application, each power line core is surrounded by a line core insulation layer, and the adjacent two line core insulation layers abut.

[0009] As a further improvement of the present application, each control line abuts with two line core insulation layers.

[0010] As a further improvement of the present application, the line core insulation layer is made of high-insulation high-modulus elastomer flame-retardant ethylene-propylene insulation rubber material.

[0011] As a further improvement of the present application, the control line comprises four control unit lines with circular cross section, a control insulation layer coated outside each of the control unit lines, and a control shielding coating layer coated outside the control insulation layers.

[0012] As a further improvement of the present application, the control unit line is formed by twisting oxygen-free copper wires, the control insulation layer is made of high-insulation high-modulus elastomer flame-retardant ethylene-propylene insulation rubber material, and the control shielding coating layer is made of metal composite carbon fiber wires.

[0013] As a further improvement of the present application, the high-current DC shore power flat cable further comprises an inner protective layer coated outside the control line and the power line core, a braided reinforcing layer coated outside the inner protective layer, and an outer sheath layer coated outside the braided reinforcing layer.

[0014] As a further improvement of the present application, the inner protective layer is made of polyether polyurethane sheath material, the braided reinforcing layer is made of metal composite carbon fiber wires, and the outer sheath layer is made of polyether polyurethane sheath material.

[0015] The present application also provides a manufacturing method of the high-current DC shore power flat cable as described above, which comprises the following steps:

[0016] S1: preparing a power line core;

[0017] S2: forming a line core insulation layer outside the power line core;

[0018] S3: preparing a control line;

[0019] S4: unit parallel, synchronously extruding an inner protective layer;

[0020] S5: fiber braiding to form a braided reinforcing layer;

[0021] S6: outer sheath extrusion to form an outer sheath layer.

[0022] As a further improvement of the present application, step S1 specifically comprises the following steps:

[0023] S11: copper wire drawing and annealing: according to the number of single wires of the split conductor strand, the number of drawing heads is set, a multi-strand single wire continuous drawing and annealing process is adopted, the multi-strand single wire is synchronously drawn and formed at one time to ensure the consistency of the length and tension of the conductor single wire, high-temperature annealing softening is performed through an oven at 500-600°C, and after cooling and drying, the wire is wound on a reel;

[0024] S12: split conductor strand twisting and compression molding: the split conductor strand filaments are twisted into 5 round split conductor strands according to the size of the split conductor strand cross section, and then 4 of the round split conductor strands are compressed into sector-shaped split conductor strands by sector-shaped conductor half compression roller mold group;

[0025] S13: split conductor strand wrapping: the isolation wrapping tape is spirally and overlapped wrapped outside the split conductor strand to form a split unit isolation layer.

[0026] S14: split conductor strand re-twisting: 4 sector-shaped split conductor strands are twisted outside 1 round split conductor strand to form a power line core.

[0027] As a further improvement of the present application, step S2 specifically comprises the following steps:

[0028] S21: rubber mixing: using a banbury mixer, at a temperature of 100-130°C, the raw EPDM rubber and zinc oxide, stearic acid, magnesium silicate powder, sulfur, paraffin oil, antioxidant, DCP are put in and mixed uniformly, then the compounding agents are added according to the respective formula, and mixed uniformly again, extruded into a sheet, then high-temperature extruded and cut into particles, cooled by a vibrating screen, and packaged for use;

[0029] S22: insulation rubber extrusion: using a cold feed rubber extruder, the mixed high-insulation high-modulus elastomer flame-retardant EP insulation rubber is extruded and melted, and uniformly coated outside the power line core through a mold.

[0030] As a further improvement of the present application, step S3 specifically comprises the following steps:

[0031] S31: copper wire drawing and annealing: according to the number of control unit wire conductor filaments, the number of drawing heads is set, using the multi-filament continuous drawing and annealing process, the multi-filament is drawn and formed synchronously at one time, ensuring the consistency of the length and tension of the conductor filaments, and then high-temperature annealing softening is carried out at 500-600°C, and after cooling and drying, it is wound on a wire reel;

[0032] S32: conductor twisting: using a high-speed double-twisted wire machine, the multi-filament drawn wire is twisted into a bundle by rotating the twisting bow, the twisting pitch ratio is 8-10 times, the twisting direction is left, and a control unit wire with a cross-sectional area of 0.5mm 2 -2.5mm 2 is formed.

[0033] S33: rubber mixing: using a banbury mixer, at a temperature of 100-130°C, the raw EPDM rubber and zinc oxide, stearic acid, magnesium silicate powder, sulfur, paraffin oil, antioxidant, DCP are put in and mixed uniformly, then the compounding agents are added according to the respective formula, and mixed uniformly again, extruded into a sheet, then high-temperature extruded and cut into particles, cooled by a vibrating screen, and packaged for use;

[0034] S34: Insulating glue extrusion: using a cold feeding rubber extruder to extrude and melt the mixed high insulation high modulus elastomer flame-retardant ethylene-propylene insulating rubber, and uniformly coat the outside of the control unit wire through a die;

[0035] S35: wire core stranding and shielding wrapping: using a high-speed reverse stranding machine, through the release of reverse reverse, and then through the stranding arch rotation stranding, the stranding pitch ratio is 8-10 times, the stranding direction is right, forming two groups of 4-core control unit cable cores, and using three groups of high-speed concentric wrapping machines to spiral overlap and wrap three layers of tape outside the control unit cable core, from inside to outside, respectively, non-metallic isolation film tape, metal composite shielding film tape, non-metallic isolation film tape, and the wrapping lap rate is ≥25%.

[0036] As a further improvement of the present application, step S4 specifically comprises the following steps:

[0037] S41: unit parallel line: using multiple cable core tension control pay-off devices, the pay-off tension is uniformly set to the same size, using the inner protection parallel line die core die mouth for bundling, the inner protection parallel line die core die mouth is composed of a power line core parallel line die mouth and a control unit line core parallel line die mouth, the power line core and the control line are bundled into the inner protection parallel line die core die mouth, the power line core passes through the power line core parallel line die mouth, and the control line passes through the control unit line core parallel line die mouth, and each unit parallel line forms a fixed and stable arrangement structure;

[0038] S42: inner protection extrusion: using an extruder to extrude and melt high tear-resistant and high wear-resistant elastomer polyether type polyurethane sheath material, and immediately uniformly coat the outside of the cable core after the unit parallel line is completed by the inner protection parallel line die core die mouth.

[0039] As a further improvement of the present application, step S5 specifically comprises the following steps: using a high-speed non-metallic fiber braiding machine to spiral braid the metal composite carbon fiber wire outside the inner protection layer, forming a mesh-shaped braided reinforcing layer; step S6 specifically comprises the following steps: using an extruder to extrude and melt high tear-resistant and high wear-resistant elastomer polyether type polyurethane sheath material, and immediately uniformly coat the outside of the braided reinforcing layer after shaping by the extrusion die, forming an outer sheath layer. Advantages

[0040] The beneficial effects of the present application are that the high-current direct-current shore power flat cable of the present application meets the basic power transmission function of the shore power cable, and has anti-tensile wear resistance, which is beneficial to repeated dragging use of the high-current direct-current shore power flat cable. By adopting the double power line core structure design and the flat cable structure design, it is beneficial to reduce the overall outer diameter of the high-current direct-current shore power flat cable, beneficial to improve the bending performance of the high-current direct-current shore power flat cable, beneficial to eliminate the skin effect, beneficial to reduce power loss, corona loss and interference, beneficial to improve the power transmission efficiency of the shore power system, further beneficial to reduce the manufacturing and operation cost of the shore power transmission system, beneficial to realize energy saving and environmental protection effect. BRIEF DESCRIPTION OF DRAWINGS

[0041] Fig. 1 is a cross-sectional view of the high-current direct-current shore power flat cable of the present application;

[0042] Fig. 2 is a schematic view of a sector-shaped conductor half tight rolling wheel mold for preparing the high-current direct-current shore power flat cable of the present application;

[0043] Fig. 3 is a schematic view of an inner protective parallel line mold core die of the present application for preparing the high-current direct-current shore power flat cable of the present application;

[0044] Fig. 4 is a flowchart of the manufacturing method of the high-current direct-current shore power flat cable of the present application. DETAILED DESCRIPTION

[0045] The technical solutions of the present application will be described in detail below with reference to the accompanying drawings. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0046] In the description of the present application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, therefore cannot be understood as a limitation on the present application. In addition, the terms "first", "second", "third" are only for descriptive purposes, and cannot be understood as indicating or implying relative importance.

[0047] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connecting" should be understood in a broad sense, for example, it can be fixed connection, or detachable connection, or integrally connected; it can be mechanical connection, or electrical connection; it can be direct connection, or indirect connection through intermediate medium, or internal communication of two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances. In addition, the technical features involved in the different embodiments of the present application described below can be combined with each other as long as they do not conflict with each other.

[0048] As shown in FIG. 1, the high-current DC shore power flat cable 100 of the present application comprises two adjacent power line cores 1, two control lines 6 arranged adjacent to the power line cores 1, an inner protective layer 3 covering the control lines 6 and the power line cores 1, a woven reinforcing layer 4 covering the inner protective layer 3, and an outer sheath layer 5 covering the woven reinforcing layer 4.

[0049] The two power line cores 1 are arranged adjacent to each other so that the high-current DC shore power flat cable 100 is flat, the cross section of the power line core 1 is circular, and the power line core 1 comprises a circular segmented unit 12 arranged in the middle part with a circular cross section and a plurality of fan-shaped segmented units 11 arranged around the circular segmented unit 12 with a fan-shaped cross section.

[0050] In this embodiment, each power line core 1 comprises four fan-shaped segmented units 11. In other embodiments, the number of fan-shaped segmented units 11 can also be three or five or more.

[0051] The circular power line core 1 is composed of four fan-shaped segmented units 11 and one circular segmented unit 12 through a twisting process. Compared with a single circular conductor with the same cross section, it has the functions of reducing skin effect and reducing impedance, which is beneficial to increasing the overall current carrying capacity by more than 10%. When applying intermediate frequency (300Hz-30kHz) power transmission technology, or applying DC power transmission technology, compared with a single circular conductor with the same cross section, its functions of reducing skin effect and reducing impedance are more beneficial to improving the transmission efficiency of the cable, reducing power loss, and effectively reducing energy waste.

[0052] The circular segmented unit 12 and the fan-shaped segmented unit 11 are surrounded by a segmented unit isolation layer 13 to avoid direct contact and conduction.

[0053] Each power line core 1 is surrounded by a core insulation layer 2, and the two adjacent core insulation layers 2 abut each other. The core insulation layer 2 is made of high-insulation high-modulus elastomer flame-retardant ethylene-propylene insulation rubber material. Under the premise of ensuring electrical safety and mechanical strength, it is beneficial to the overall bending performance of the high-current DC shore power flat cable 100.

[0054] Each of the control lines 6 abuts against two of the core insulation layers 2. The control line 6 includes four control unit lines 61 with circular cross-sections, a control insulation layer 62 covering the outside of each control unit line 61, and a control shielding covering layer 63 covering the outside of the plurality of control insulation layers 62.

[0055] The control unit line 61 in the control line 6 is made of oxygen-free copper wire with a diameter of φ0.2mm or less twisted together to realize the function of control electrical signal transmission.

[0056] The control insulation layer 62 in the control line 6 is made of high-insulation, high-modulus elastomer flame-retardant ethylene propylene insulating rubber material, which is beneficial to the bending performance of the control line 6 while ensuring electrical safety.

[0057] The control shielding layer 63 in the control line 6 is made of metal composite carbon fiber filament, which has a tensile strength of up to 5880MPa, about 20 times that of copper. Moreover, under the same outer diameter, its braided shielding layer is 86% lighter than that of copper braided shielding layer. This enables it to resist the high-energy electric field generated by the power core 1 during the operation of the high current-carrying DC shore power flat cable 100, and also helps to improve the tensile strength of the control unit.

[0058] Optical fiber units can also be added to the control line 6 to realize optical signal transmission, so that the high current-carrying DC shore power flat cable 100 has a comprehensive transmission function of optoelectronic composite.

[0059] In this embodiment, the diameter of the control line 6 is smaller than the diameter of the power core 1, so the space between the two power cores 1 can accommodate the two control lines 6, thus making the high current-carrying DC shore power flat cable 100 flat and easy to curl.

[0060] The inner protective layer 3 uses a 1.2 g / cm³ material. 3 It is made of polyether-type polyurethane sheath material with high tear resistance and high abrasion resistance elastomer. Its tensile strength is ≥25MPa, elongation at break is ≥300%, and tear resistance is ≥40N. It is beneficial to improve the overall flexibility, tensile strength and abrasion resistance of the high current carrying DC shore power flat cable 100, and meet the needs of repeated dragging use of the high current carrying DC shore power flat cable 100.

[0061] The braided reinforcing layer 4 is made of metal composite carbon fiber filament, which has a tensile strength of 5880MPa, about 20 times that of copper. Under the same outer diameter, the weight of its braided armor layer is reduced by up to 86% compared with the weight of copper braided armor layer. This is beneficial to ensure the high tensile strength of the braided reinforcing layer 4, while also having an electric field shielding effect. This effectively improves the overall anti-interference performance of the high current-carrying DC shore power flat cable 100 and the impact of the electric radiation generated by the high current-carrying DC shore power flat cable 100 during operation on the external environment.

[0062] The outer sheath layer 5 is made of a high- tear-resistant and high- wear-resistant polyether polyurethane sheath material with a thickness of 1.2 g / cm 3 The tensile strength is ≥25 MPa, the elongation at break is ≥300%, and the tear resistance is ≥40 N, which is beneficial to improve the flexibility, tensile resistance and wear resistance of the high-current DC shore power flat cable 100 as a whole, and meets the requirements of repeated dragging use of the high-current DC shore power flat cable 100.

[0063] The high-current DC shore power flat cable 100 can also be used as a single-phase parallel application in an AC shore power system, which can further improve the overall current-carrying capacity and is beneficial to reduce the size of the shore power system cable reel.

[0064] The manufacturing method of the high-current DC shore power flat cable 100 includes the following steps:

[0065] S1: preparing a power line core 1;

[0066] S2: forming a line core insulation layer 2 outside the power line core 1;

[0067] S3: preparing a control line 6;

[0068] S4: unit parallel, synchronously extruding an inner protective layer 3;

[0069] S5: fiber weaving to form a woven reinforcing layer 4;

[0070] S6: outer protection extrusion to form an outer sheath layer 5.

[0071] The step S1 specifically includes the following steps:

[0072] S11: copper wire drawing and annealing: according to the number of single wires of the split conductor strand, the number of drawing heads is set, a multi-strand single wire continuous drawing and continuous annealing process is adopted, the multi-strand single wire is synchronously drawn and formed at one time to ensure the consistency of the length and tension of each single wire, the diameter of each single wire is not more than φ0.5 mm, and high-temperature annealing softening is performed through a 500℃-600℃ oven, and after cooling and drying, the wire is wound on a reel.

[0073] S12: split conductor strand stranding and compacting: the single wires of the split conductor strand are first stranded into 5 round split conductor strands according to the size of the split conductor strand cross section, and then 4 of the round split conductor strands are compacted into a 90° fan-shaped split conductor strand through a fan-shaped conductor half compacting roller die 7 group as shown in FIG. 2; the fan-shaped conductor half compacting roller die 7 group is composed of an upper compacting roller 71 and a lower compacting roller 74, the upper compacting surface 72 of the upper compacting roller 71 is a fan-shaped top arc surface, the lower compacting surface 73 of the lower compacting roller 74 is a fan-shaped bottom arc surface and fan-shaped double side surface, and the remaining 1 round split conductor strand is a round dividing unit 12, and the 4 fan-shaped split conductor strands form a fan-shaped dividing unit 11.

[0074] S13: Split conductor strand wrapping: The split conductor strand is wrapped with a spiral overlap of an isolation wrapping tape on the outside of the split conductor strand, with a wrapping overlap of 10% to 15%, to form a split unit isolation layer 13 outside the fan-shaped split unit 11 and the circular split unit 12.

[0075] S14: Split conductor strand re-twisting: The four wrapped fan-shaped split conductor strands are re-twisted outside the one circular split conductor strand to form the power cable core 1, wherein the re-twisting directions of the positive and negative phase split conductor strands of the finished direct current cable are opposite, i.e. if the positive phase is clockwise, the negative phase is counterclockwise, to ensure that the positive and negative phase conductor internal stresses cancel each other out, avoiding distortion of the finished cable.

[0076] Step S2 specifically includes the following steps:

[0077] S21: Rubber mixing: A rubber mixer is used to mix the raw EPDM rubber and zinc oxide, stearic acid, magnesium silicate powder, sulfur, paraffin oil, antioxidant, DCP (dicumyl peroxide) at a temperature of 100°C to 130°C. After uniform mixing, the compounding agents are added according to the respective formulations, and uniform mixing is performed again. The rubber is then extruded into a sheet, and then high-temperature extrusion and granulation are performed. After cooling by a vibrating screen, the rubber is packaged for use.

[0078] S22: Insulating rubber extrusion: A cold-feeding rubber extruder is used to extrude and melt the mixed high-insulation high-modulus elastomer flame-retardant EPDM insulating rubber, and the rubber is uniformly extruded through a die to form the core insulating layer 2 outside the power cable core 1. The die temperature is 70°C to 90°C, the screw temperature is 55°C to 65°C, and the machine body temperature is 60°C to 70°C.

[0079] Step S3 specifically includes the following steps:

[0080] S31: Copper wire drawing and annealing: The number of drawing heads is set according to the number of conductor filaments of the control unit wire 61. A multi-filament continuous drawing and annealing process is used to synchronously draw and form multiple filaments at one time, ensuring that the lengths and tensions of the filaments are consistent. Each filament has a diameter of no more than φ0.2mm, and is annealed and softened in a 500°C to 600°C oven. After cooling and drying, the filaments are wound onto a spool.

[0081] S32: Conductor twisting: The multiple filaments drawn in step S31 are twisted into a bundle by a high-speed double-twist stranding machine through the rotation of a stranding bow. The stranding pitch ratio is 8 to 10 times, and the stranding direction is leftward, to form the control unit wire 61 with a cross-sectional area of 0.5mm 2 to 2.5mm 2 .

[0082] S33: rubber mixing: using a mixer, at 100-130 °C temperature, into the three EPDM rubber and zinc oxide, stearic acid, magnesium silicate powder, sulfur, paraffin oil, antioxidant, DCP (dicumyl peroxide), mixing uniformly, then add the respective formulation, mixing again, extrusion into a sheet, and then high temperature extrusion granulation, vibration screen cooling after packaging for use.

[0083] S34: insulation glue extrusion: using a cold feed rubber extruder on the mixing of high insulation high modulus elastomer flame retardant EPDM insulation rubber extrusion melting, extrusion evenly coated in the control unit line 61 outside the mold.

[0084] S35: wire core stranded and shielded wrapping: using a high-speed reverse torsion stranded machine, through the line, and then through the twisted arch rotation stranded into a shape, the stranded diameter ratio is 8-10 times, twisted right, forming two groups of 4 core control unit cable core, and using three groups of high-speed concentric wrapping machine in the control unit cable core outside the spiral overlapping three layers of tape, from inside to outside, respectively, non-metallic isolation film, metal composite shielding film, non-metallic isolation film, wrapping cover rate ≥ 25%, this step is used to form a shielding layer 63, shielding layer 63 is obtained after the control line 6.

[0085] Step S4 specifically includes the following steps:

[0086] S41: unit parallel line: using multiple cable core tension control pay-off device, pay-off tension is uniformly set to the same size, using the inner protection parallel line die core die 8 as shown in Figure 3 for bundling, the inner protection parallel line die core die 8 is composed of power line core parallel line die 81 and control unit line core parallel line die 82, power line core 1 and control line 6 are bundled into the inner protection parallel line die core die 8, power line core 1 is threaded through the power line core parallel line die 81, control line 6 is threaded through the control unit line core parallel line die 82, each unit parallel line forms a fixed stable arrangement structure.

[0087] S42: inner protection extrusion: using an extruder to extrude melt the high tear resistance and high wear resistance elastomer polyether type polyurethane sheath material, which is immediately uniformly coated on the outside of the cable core after the unit parallel line is completed by the inner protection parallel line die core die 8, forming an inner protection layer 3.

[0088] Step S5 specifically includes the following steps: using a high-speed non-metallic fiber braiding machine to spiral braid the metal composite carbon fiber wire outside the inner protection layer 3, forming a mesh-like braided reinforcement layer 4; step S6 specifically includes the following steps: using an extruder to extrude melt the high tear resistance and high wear resistance elastomer polyether type polyurethane sheath material, which is immediately uniformly coated on the outside of the braided reinforcement layer 4 after the extrusion die is shaped, forming an outer sheath layer 5.

[0089] The manufacturing method of the high-current direct-current shore power flat cable of the present application can realize the high-current direct-current shore power flat cable 100.

[0090] The high-current direct-current shore power flat cable 100 of the present application meets the basic power transmission function of the shore power cable and the tensile wear resistance, which is beneficial to the repeated dragging use of the high-current direct-current shore power flat cable 100. By adopting the double power line core 1 structure design and the flat cable structure design, it is beneficial to reduce the overall outer diameter of the high-current direct-current shore power flat cable 100, improve the bending performance of the high-current direct-current shore power flat cable 100 as a whole, eliminate the skin effect, reduce the power loss, corona loss and interference, improve the power transmission efficiency of the shore power system, further reduce the manufacturing and operation cost of the shore power transmission system, achieve energy saving and emission reduction and green environmental protection effect.

[0091] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description simple, all possible combinations of the technical features in the above-mentioned embodiments are not described, but as long as the combinations of the technical features do not exist contradictory, they should be considered as the scope of the present application.

[0092] The above-mentioned embodiments only express several embodiments of the present application, and the description is more specific and detailed, but it should not be understood as a limitation on the scope of the patent. It should be pointed out that for ordinary skilled in the art, without departing from the concept of the present application, a number of modifications and improvements can be made, which are all within the scope of the present application. Therefore, the scope of the patent protection of the present application should be subject to the appended claims.

Claims

1. A high current DC shore power flat cable, characterized by: The high-current DC shore power flat cable comprises two adjacent power line cores, two control lines arranged adjacent to the power line cores, and the two power line cores are arranged adjacent to each other so that the high-current DC shore power flat cable is flat, the cross section of the power line core is circular, the power line core comprises a circular division unit arranged in the middle part and a plurality of sector-shaped division units arranged around the circular division unit, and the circular division unit and the sector-shaped division units are both surrounded by a division unit isolation layer.

2. The high current DC shore power flat cable of claim 1, wherein: Each power line core comprises four sector-shaped division units.

3. The high current DC shore power flat cable of claim 1, wherein: Each power line core is surrounded by a line core insulation layer, and the two adjacent line core insulation layers are in abutment.

4. The high current DC shore power flat cable of claim 3, wherein: Each control line is in abutment with the two line core insulation layers.

5. The high current DC shore power flat cable of claim 3, wherein: The line core insulation layer is made of high-insulation high-modulus elastomer fire-retardant ethylene-propylene insulation rubber material.

6. The high current DC shore power flat cable of claim 1, wherein: The control line comprises four control unit lines with circular cross sections, a control insulation layer wrapped outside each control unit line, and a control shielding layer wrapped outside the control insulation layers.

7. The high current DC shore power flat cable of claim 6, wherein: The control unit line is made of oxygen-free copper wire, the control insulation layer is made of high-insulation high-modulus elastomer fire-retardant ethylene-propylene insulation rubber material, and the control shielding layer is made of metal composite carbon fiber wire.

8. The high current DC shore power flat cable of any of claims 1-7, wherein: The high-current DC shore power flat cable further comprises an inner protective layer wrapped around the control line and the power line core, a braided reinforcing layer wrapped outside the inner protective layer, and an outer protective jacket layer wrapped outside the braided reinforcing layer.

9. The high current DC shore power flat cable of claim 8, wherein: The inner protective layer is made of polyether polyurethane sheath material, the braided reinforcing layer is made of metal composite carbon fiber wire, and the outer protective jacket layer is made of polyether polyurethane sheath material.

10. A method of manufacturing a high current DC shore power flat cable according to any one of claims 1-9, characterized in that: The manufacturing method of the high-current DC shore power flat cable comprises the following steps: S1: preparing a power line core; S2: forming a line core insulation layer outside the power line core; S3: preparing a control line; S4: unit parallel, synchronously extruding an inner protective layer; S5: fiber braiding to form a braided reinforcing layer; S6: outer protective extrusion to form an outer protective jacket layer.

11. The method of manufacturing a high current DC shore power flat cable according to claim 10, characterized in that: Step S1 specifically comprises the following steps: S11: copper wire drawing and annealing: according to the number of single wires of the split conductor strand, the number of drawing heads is set, a multi-strand single wire continuous drawing and annealing process is adopted, the multi-strand single wire is formed by one-time synchronous drawing, the length and tension of the conductor single wire are ensured to be consistent, high-temperature annealing softening is performed through a 500-600°C oven, and after cooling and drying, the wire is wound on a reel; S12: split conductor strand twisting and compacting: the single wires of the split conductor strand are twisted into 5 round split conductor strands according to the size of the split conductor strand cross section, and then 4 round split conductor strands are compacted into sector-shaped split conductor strands by a sector-shaped conductor half compacting roller die set; S13: split conductor strand wrapping: an isolation wrapping tape is spirally and overlapped wrapped outside the split conductor strand to form a division unit isolation layer; S14: split conductor strand re-twisting: 4 sector-shaped split conductor strands are twisted outside 1 round split conductor strand to form a power line core.

12. The method of manufacturing a high current DC shore power flat cable of claim 10, wherein: Step S2 specifically comprises the following steps: S21: rubber mixing: using a mixer, at 100-130 DEG C, into the original rubber and zinc oxide, stearic acid, magnesium silicate powder, sulfur, paraffin oil, antioxidant, DCP, mixing evenly, then add the respective formulation, mixing again, extruded into a sheet, and then high temperature extrusion pellet, vibration screen cooling after packaging for use; S22: insulation rubber extrusion: using a cold feed rubber extruder on the mixing of high insulation high modulus elastomer flame retardant ethylene propylene insulation rubber extrusion melting, extrusion evenly coated outside the power line core.

13. The method of manufacturing a high current DC shore power flat cable of claim 10, wherein: Step S3 specifically includes the following steps: S31: copper wire drawing annealing: according to the control unit wire conductor monofilament number setting drawing head number, using multi strand monofilament continuous drawing and continuous annealing process, multi strand monofilament once synchronous drawing forming, ensure the conductor monofilament length and tension consistent, and through the 500-600 DEG C oven high temperature annealing softening, cooling drying after winding to the reel; S32: conductor stranding: the multiple single filaments formed by wire drawing are twisted into a bundle by high-speed double-twist stranding machine through the rotation of stranding bow, the stranding pitch ratio is 8-10 times, the stranding direction is left, and a control unit wire with a cross-sectional area of 0.5mm 2 ~2.5mm 2 ​ S33: rubber mixing: using a mixer, at 100-130 DEG C, into the original rubber and zinc oxide, stearic acid, magnesium silicate powder, sulfur, paraffin oil, antioxidant, DCP, mixing evenly, then add the respective formulation, mixing again, extruded into a sheet, and then high temperature extrusion pellet, vibration screen cooling after packaging for use; S34: insulation rubber extrusion: using a cold feed rubber extruder on the mixing of high insulation high modulus elastomer flame retardant ethylene propylene insulation rubber extrusion melting, extrusion evenly coated outside the control unit wire; S35: core stranding and shielding wrapping: using high speed reverse stranding machine, through the line release reverse, and then stranding bow rotation stranding, stranding pitch ratio is 8-10 times, stranding right, forming two groups of 4 core control unit cable core, and using three groups of high speed concentric wrapping machine in the control unit cable core outside spiral overlapping winding three layers of tape, from inside to outside are non metallic isolation film, metal composite shielding film, non metallic isolation film, wrapping cover rate ≥ 25%.

14. The method of manufacturing a high current DC shore power flat cable of claim 10, wherein: Step S4 specifically includes the following steps: S41: unit stranding: using multiple cable core tension control pay-off device, pay-off tension is uniformly set to the same size, using the inner protection stranding die core die to bundle, the inner protection stranding die core die is composed of power line core stranding die and control unit wire core stranding die, power line core and control line bundle to the inner protection stranding die core die, power line core threading through the power line core stranding die, control line threading through the control unit wire core stranding die, each unit stranding forms a fixed stable arrangement structure; S42: inner protection extrusion: using an extruder on the high tear resistance high wear resistance elastomer polyether type polyurethane sheath material extrusion melting, after shaping by extrusion die immediately evenly coated outside the cable core after unit stranding by the inner protection stranding die core die.

15. The method of manufacturing a high current DC shore power flat cable of claim 10, wherein: The step S5 specifically comprises the following steps: using a high-speed non-metal fiber braiding machine to spiral weave metal composite carbon fiber yarns in the inner protective layer, to form a mesh-shaped braided reinforcing layer; and the step S6 specifically comprises the following steps: using an extruding machine to extrude and melt high-tear-resistance and high-wear-resistance elastomer polyether type polyurethane sheath material, and then uniformly coating the braided reinforcing layer on the outside to form an outer sheath layer.

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