CN112233838B - Special cable for intelligent monitoring for rail transit and production process thereof - Google Patents
Special cable for intelligent monitoring for rail transit and production process thereof Download PDFInfo
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- CN112233838B CN112233838B CN202011167262.9A CN202011167262A CN112233838B CN 112233838 B CN112233838 B CN 112233838B CN 202011167262 A CN202011167262 A CN 202011167262A CN 112233838 B CN112233838 B CN 112233838B
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- 238000012544 monitoring process Methods 0.000 title claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 17
- 239000013307 optical fiber Substances 0.000 claims abstract description 79
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 66
- 238000001514 detection method Methods 0.000 claims abstract description 64
- 239000002184 metal Substances 0.000 claims abstract description 63
- 229910052751 metal Inorganic materials 0.000 claims abstract description 63
- 239000010949 copper Substances 0.000 claims abstract description 42
- 229910052802 copper Inorganic materials 0.000 claims abstract description 42
- 239000003063 flame retardant Substances 0.000 claims abstract description 18
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims abstract description 17
- 239000004020 conductor Substances 0.000 claims description 26
- 239000000463 material Substances 0.000 claims description 22
- 238000009413 insulation Methods 0.000 claims description 19
- 238000004804 winding Methods 0.000 claims description 13
- 239000004677 Nylon Substances 0.000 claims description 11
- 229920001778 nylon Polymers 0.000 claims description 11
- 239000004809 Teflon Substances 0.000 claims description 10
- 229920006362 Teflon® Polymers 0.000 claims description 10
- 230000003014 reinforcing effect Effects 0.000 claims description 10
- 239000000779 smoke Substances 0.000 claims description 7
- 229920000098 polyolefin Polymers 0.000 claims description 6
- 229910001220 stainless steel Inorganic materials 0.000 claims description 6
- 239000010935 stainless steel Substances 0.000 claims description 6
- 238000001125 extrusion Methods 0.000 claims description 5
- 239000003365 glass fiber Substances 0.000 claims description 5
- 238000000034 method Methods 0.000 claims description 5
- 229920001169 thermoplastic Polymers 0.000 claims description 5
- 239000004416 thermosoftening plastic Substances 0.000 claims description 5
- 239000011231 conductive filler Substances 0.000 claims description 3
- 239000000945 filler Substances 0.000 claims description 3
- 229920000181 Ethylene propylene rubber Polymers 0.000 description 4
- 229920003020 cross-linked polyethylene Polymers 0.000 description 4
- 239000004703 cross-linked polyethylene Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 230000005684 electric field Effects 0.000 description 4
- 238000005491 wire drawing Methods 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- 238000005265 energy consumption Methods 0.000 description 3
- 230000032683 aging Effects 0.000 description 2
- 229920006231 aramid fiber Polymers 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 239000007943 implant Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 238000007747 plating Methods 0.000 description 1
Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D5/00—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable
- G01D5/26—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light
- G01D5/268—Mechanical means for transferring the output of a sensing member; Means for converting the output of a sensing member to another variable where the form or nature of the sensing member does not constrain the means for converting; Transducers not specially adapted for a specific variable characterised by optical transfer means, i.e. using infrared, visible, or ultraviolet light using optical fibres
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/02—Stranding-up
- H01B13/0207—Details; Auxiliary devices
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
- H01B3/441—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/1875—Multi-layer sheaths
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/1895—Internal space filling-up means
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/22—Metal wires or tapes, e.g. made of steel
- H01B7/226—Helicoidally wound metal wires or tapes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
- H01B7/2806—Protection against damage caused by corrosion
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
- H01B7/292—Protection against damage caused by extremes of temperature or by flame using material resistant to heat
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
- H01B7/295—Protection against damage caused by extremes of temperature or by flame using material resistant to flame
Landscapes
- Physics & Mathematics (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- General Physics & Mathematics (AREA)
- Spectroscopy & Molecular Physics (AREA)
- Insulated Conductors (AREA)
- Communication Cables (AREA)
Abstract
The invention discloses a special cable for intelligent monitoring for track traffic and a production process thereof, wherein the cable structure comprises a cable core, a metal shielding layer, an inner sheath, a flame-retardant belt, a metal armor layer, a belting and an outer sheath which are sequentially arranged from inside to outside; the metal shielding layer comprises two layers of semi-conductive wrapping tape, detection optical fibers, shielding copper wires and semi-conductive filling, wherein the detection optical fibers, the shielding copper wires and the semi-conductive filling are arranged between the semi-conductive wrapping tape and distributed circumferentially; the detection optical fibers and the shielding copper wires are uniformly distributed along the periphery of the cable core respectively; the semi-conductive filling is distributed between the adjacent detection optical fibers and the shielding copper wires and between the adjacent shielding copper wires; the outer diameters of the shielding copper wires and the semiconductive filling are larger than the outer diameter of the detection optical fiber. The invention can effectively avoid the damage of the optical fiber implanted in the cable and reduce the cost of the cable.
Description
Technical Field
The invention relates to the technical field of cables, in particular to a special cable for intelligent monitoring for rail transit and a production process thereof.
Background
The rail transit can effectively relieve traffic pressure and environmental pollution and can drive local economic development, so that the rail transit is an important point of future investment. The security of rail transit line operation is the focus of operation and maintenance company focus always, and manual inspection not only working strength is big, can't real-time supervision moreover, once unexpected, can cause serious personnel and property loss.
The optical fiber has excellent electromagnetic interference resistance and low energy consumption, and can realize the measurement of parameters such as local overheating, disturbance, partial discharge and the like of the cable through the displacement variation of the light wave. However, how to implant the optical fiber into the cable and ensure that the optical fiber is not damaged is always a main technical difficulty in the field due to the small gap of the single-core cable.
Disclosure of Invention
The invention aims to provide a special cable for intelligent monitoring for track traffic and a production process thereof, which can effectively avoid damage to optical fibers implanted into the cable and reduce the cost of the cable.
The technical scheme for realizing the aim of the invention is as follows:
A special cable for intelligent monitoring for track traffic comprises a cable core, a metal shielding layer, an inner sheath, a flame-retardant belt, a metal armor layer, a belting and an outer sheath which are sequentially arranged from inside to outside; the metal shielding layer comprises two layers of semi-conductive wrapping tape, detection optical fibers, shielding copper wires and semi-conductive filling, wherein the detection optical fibers, the shielding copper wires and the semi-conductive filling are arranged between the semi-conductive wrapping tape and distributed circumferentially; the detection optical fibers and the shielding copper wires are uniformly distributed along the periphery of the cable core respectively; the semi-conductive filling is distributed between the adjacent detection optical fibers and the shielding copper wires and between the adjacent shielding copper wires; the outer diameters of the shielding copper wires and the semiconductive filling are larger than the outer diameter of the detection optical fiber.
Further, the cable core comprises a conductor layer, a conductor shielding layer and an insulating and insulating shielding layer which are sequentially arranged from inside to outside.
Further, the conductor layer adopts two kinds of tin-plated or tin-free stranded conductors.
Further, the insulating material is crosslinked polyethylene XLPE or ethylene propylene rubber EPR.
Further, the detection optical fiber adopts a stainless steel armored single-mode or multi-mode optical fiber unit.
Further, the outer diameter of the detection optical fibers is controlled to be 1.8+/-0.1 mm, the number of the detection optical fibers is 1-4, and the number of the optical fibers in each detection optical fiber is 2-24.
Further, the shielding copper wire adopts an annealed soft copper wire.
Further, the outer diameter of the shielding copper wire is controlled to be 2.0+/-0.05 mm, the number of the shielding copper wire is not less than 8, and the specific number of the shielding copper wire is suitable for the short-circuit current of the shielding copper wire. The following table shows:
Further, the semiconductive fill contains a centrally disposed reinforcing core and thermoplastic semiconductive material extruded outside the reinforcing core.
Further, the outer diameter of the semiconductive filling is controlled to be 2.0+/-0.5 mm, and the insulation resistivity of the semiconductive material is less than or equal to 100 OMEGA.m.
Further, the reinforcing core is made of aramid fiber or copper wire.
Further, the semiconductive wrapping belt comprises a semiconductive Teflon belt arranged on the inner layer and a semiconductive nylon belt arranged on the outer layer.
Further, the metal armor layer is made by winding nonmagnetic flat or round metal wires.
Further, the inner sheath is made of PE or low-smoke halogen-free flame-retardant polyolefin material.
Further, the thickness of the inner sheath is 1.0-3.0 mm.
Further, the wrapping tape adopts a glass fiber tape.
The production process of the special cable for intelligent monitoring for the rail transit comprises the following steps:
Step one: manufacturing a cable core; twisting the conductor after wire drawing to prepare a conductor layer, and extruding the conductor shielding layer, the insulation and the insulation shielding layer outside in a three-layer co-extrusion mode;
step two: manufacturing a metal shielding layer; wrapping a layer of semi-conductive wrapping tape outside the cable core, wherein the covering rate is 15-20%, then wrapping the detection optical fiber, the shielding copper wire and the semi-conductive filler on the semi-conductive wrapping tape on a special shielding machine for the cable, wherein the wrapping pitch diameter is 10-16 times, the filler is round and compact, and wrapping a layer of semi-conductive wrapping tape, wherein the covering rate is 15-20%;
step three: extruding an inner sheath outside the metal shielding layer, and wrapping a layer of flame-retardant tape;
step four: winding a flat metal wire outside the flame retardant band to prepare a metal armor layer;
step five: wrapping a layer of wrapping tape outside the metal armor layer, and extruding an outer sheath outside the wrapping tape to prepare the cable.
Further, in the fourth step, the width of the flat wire is L, the thickness of the flat wire is H, and the core diameter of the flat wire is D, so that the number of the flat wires is n=int (pi× (d+h)/(L)). Wherein the thickness of the flat metal wire is about 2.0mm, and the width is 2.5-4.0 mm.
By adopting the technical scheme, the invention has the following beneficial effects:
The metal shielding layer can monitor the use state of the cable in real time by arranging the detection optical fiber; by arranging the shielding copper wire, electromagnetic interference can be effectively prevented, and a shielding effect of safety protection is achieved; the semi-conductive filling is arranged between the detection optical fiber and the shielding copper wire, so that the shielding copper wire can be ensured to be uniformly distributed outside the cable core, an electric field is uniformly distributed when the cable core is electrified for use, and conductivity among the copper wires is improved; the outer diameters of the shielding copper wires and the semiconductive filling are larger than the outer diameter of the detection optical fiber, the detection optical fiber is protected from being damaged during stranding, and the detection optical fiber is not directly contacted with the copper wires with higher hardness, but is contacted with the softer semiconductive filling, so that the buffer of the detection optical fiber is increased, and the detection optical fiber is prevented from being damaged; the shielding section of the existing intelligent monitoring cable for track traffic is generally 16-50 mm 2, when the semi-conductive filling is not available, more copper wires can be added for ensuring electric field balance of the cable, the shielding section is far more than 50mm 2, the shielding cost is high, the semi-conductive filling is used for replacing part of copper wires, and a large amount of cost is saved.
The detection optical fiber adopts stainless steel armoured optical fiber, so that the internal optical fiber unit is further protected from damage; in addition, the detection optical fiber adopts a single-mode or multi-mode optical fiber unit, can meet different use requirements and has wide use range.
The semiconductive filling of the invention improves the overall strength of the semiconductive filling by arranging the reinforcing core at the center, and extrudes the thermoplastic semiconductive material outside the reinforcing core, thereby ensuring the semiconductive performance of the material, being easier to process and mold and having good mechanical property.
The semiconductive wrapping belt comprises the semiconductive Teflon belt arranged on the inner layer and the semiconductive nylon belt arranged on the outer layer, and the semiconductive Teflon belt has the characteristics of high strength, excellent shielding performance and small resistance, and is used under the metal wires of the metal shielding layer to play a good role in cushion and shielding; the semi-conductive nylon belt has smooth surface, can improve the roundness of the metal shielding layer after wrapping, and can prevent the outer inner sheath from being embedded into the metal shielding layer during extrusion.
The metal armor layer is made by winding the nonmagnetic flat metal wires, and compared with the metal armor layer wound by round metal wires, the metal armor layer can reduce the outer diameter of a cable core by 1.0-1.5 mm, and save the material of an outer sheath; in addition, the number of the wire cores with the same outer diameter wound by the flat metal wires is less than that of the round metal wires, so that the energy consumption of a wire drawing process is reduced.
The inner sheath is made of PE or low-smoke halogen-free flame-retardant polyolefin material, has good insulating effect, and improves the flame retardance of the cable.
The glass fiber tape is adopted as the tape, and has the characteristics of high temperature resistance, heat preservation, insulation, fire resistance, corrosion resistance, aging resistance, weather resistance, high strength, smooth appearance and the like, so that the overall performance of the cable is further improved.
The production process of the invention adopts the special shielding machine for the cable, can reduce the rotation angle when the detection optical fiber is twisted, and gives a certain buffer to further protect the detection optical fiber from damage.
The production process of the invention strictly controls the width and thickness ratio of the flat metal wire, can effectively prevent the flat metal wire from turning over during stranding, and improves the winding efficiency.
Drawings
In order that the invention may be more readily understood, a more particular description of the invention will be rendered by reference to specific embodiments that are illustrated in the appended drawings, in which:
Fig. 1 is a schematic view of a cable structure according to the present invention.
Fig. 2 is a schematic structural view of a cable-only shield machine according to the present invention;
fig. 3 is an enlarged view of a portion of a cage machine of the cable-specific shield.
The reference numerals in the drawings are:
The cable core 1, the conductor layer 1-1, the conductor shielding layer 1-2, the insulation 1-3, the insulation shielding layer 1-4, the metal shielding layer 2, the detection optical fiber 2-1, the shielding copper wire 2-2, the semiconductive filling 2-3, the semiconductive Teflon tape 2-4, the semiconductive nylon tape 2-5 inner sheath 3, the flame retardant tape 4, the metal armor layer 5, the tape wrapping 6, the outer sheath 7, the pay-off rack 8, the wire guide 9, the first wrapping machine 10, the strander 11-1, the motor 11-2, the wire guide 11-3, the wire distributor 11-4, the circular arc-shaped wire guide 11-5, the second wrapping machine 12, the meter 13, the tension machine 14 and the wire collecting rack 15.
Detailed Description
In order to better understand the above technical solutions, the following detailed description will refer to the accompanying drawings and specific embodiments.
Example 1
Referring to fig. 1, the special cable for intelligent monitoring for track traffic in this embodiment includes a cable core1, a metal shielding layer 2, an inner sheath 3, a flame retardant belt 4, a metal armor layer 5, a wrapping belt 6 and an outer sheath 7 which are sequentially arranged from inside to outside. The inner sheath 3 adopts PE, has good insulation effect and thickness of 2.0mm, and tightly wraps the metal shielding layer 2. The flame-retardant belt 4 adopts a low-smoke halogen-free high-flame-retardant belt (OI is more than or equal to 70). The wrapping tape 6 is made of glass fiber, and has the characteristics of high temperature resistance, heat preservation, heat insulation, fire resistance, flame retardance, corrosion resistance, aging resistance, weather resistance, high strength, smooth appearance and the like, so that the overall performance of the cable is further improved. . The outer sheath 7 is made of low-smoke halogen-free or low-smoke low-halogen material.
The cable core 1 comprises a conductor layer 1-1, a conductor shielding layer 1-2, an insulation 1-3 and an insulation shielding layer 1-4 which are sequentially arranged from inside to outside. The conductor layer 1-1 adopts two tin plating stranded conductors. The conductor shielding layer 1-2 adopts a semiconductive crosslinked polyolefin inner shielding material. The material of the insulation 1-3 is crosslinked polyethylene XLPE. The insulating shielding layers 1-4 are made of semiconductive crosslinked polyolefin outer shielding materials.
The metal shielding layer 2 comprises two layers of semi-conductive wrapping tape, detection optical fibers 2-1, shielding copper wires 2-2 and semi-conductive filling 2-3, wherein the detection optical fibers 2-1, the shielding copper wires 2-2 and the semi-conductive filling 2-3 are arranged between the semi-conductive wrapping tape and are distributed circumferentially. The semi-conductive wrapping belt comprises a semi-conductive Teflon belt 2-4 arranged on the inner layer and a semi-conductive nylon belt 2-5 arranged on the outer layer, wherein the semi-conductive Teflon belt 2-4 plays a good role in cushion layer and shielding, the surface of the semi-conductive nylon belt 2-5 is smooth, the rounding degree of the metal shielding layer 2 can be improved after wrapping, and meanwhile, the sheath 3 in the outer layer can be prevented from being embedded into the metal shielding layer 2 during extrusion. The detection optical fibers 2-1 are stainless steel armoured single-mode optical fiber units and are uniformly distributed along the periphery of the cable core 1, and the stainless steel armoured single-mode optical fiber units are further protected from damage. The outer diameter of the detection optical fibers 2-1 is controlled to be 1.8+/-0.1 mm, the number of the detection optical fibers is 4, and the number of the optical fibers in each detection optical fiber is 20. The shielding copper wires 2-2 are annealed soft copper wires and are uniformly distributed along the periphery of the cable core, the outer diameter of the shielding copper wires 2-2 is controlled to be 2.0+/-0.05 mm, and the number of the shielding copper wires is 16. The semiconductive fills 2-3 are distributed between the adjacent detection optical fibers 2-1 and the shielding copper wires 2-2 and between the adjacent shielding copper wires 2-2, in this embodiment, one semiconductive fill 2-3 is respectively arranged between the detection optical fibers 2-1 and the adjacent shielding copper wires 2-2, and three semiconductive fills 2-3 are respectively arranged between the rest of the adjacent shielding copper wires 2-2, which are 56 semiconductive fills 2-3 in total. The outer diameters of the shielding copper wires 2-2 and the semiconductive filling 2-3 are slightly larger than the outer diameter of the detection optical fiber 2-1. The outer diameter of the semiconductive filling 2-3 is controlled to be 2.0+/-0.5 mm, and the semiconductive filling comprises a reinforcing core arranged in the center and thermoplastic semiconductive material extruded outside the reinforcing core, so that the semiconductive performance of the material is ensured, and the semiconductive filling is easier to machine and form and has good mechanical property. The reinforcing core adopts aramid fiber, the overall strength of the semiconductive filling is improved by 2-3, the insulation resistivity of the semiconductive material is less than or equal to 100 omega m, and the semiconductive material of the embodiment is thermoplastic semiconductive shielding material.
The metal armor layer 5 is made by winding nonmagnetic flat metal wires, the number of the flat metal wires is N=INT (pi× (D+H)/(L)), wherein L is the width of the flat metal wires, H is the thickness of the flat metal wires, D is the wire core diameter after the flame-retardant tape 4 is wound, the width and thickness ratio of the flat metal wires are strictly controlled, the flat metal wires can be effectively prevented from turning over during twisting, and the winding efficiency is improved. Compared with the metal armor layer 5 wound by round metal wires, the outer diameter of the cable core can be reduced by 1.0-1.5 mm, and the material of the outer sheath 7 is saved; in addition, the number of the wire cores with the same outer diameter wound by the flat metal wires is less than that of the round metal wires, so that the energy consumption of a wire drawing process is reduced. In this embodiment, the wire width L is about 3.0mm, the thickness H is about 2.0mm, the core diameter D is 32.5mm, and 36 flat wires are provided.
The production process of the special cable for intelligent monitoring for rail transit in the embodiment comprises the following steps:
step one: manufacturing a cable core 1; the conductor is twisted to prepare a conductor layer 1-1 after wire drawing, and the outside of the conductor layer is extruded with a conductor shielding layer 1-2, an insulation layer 1-3 and an insulation shielding layer 1-4 in a three-layer co-extrusion mode;
Step two: manufacturing a metal shielding layer 2; wrapping a layer of semi-conductive Teflon tape 2-4 outside a cable core 1, wherein the overlap ratio is 18%, then wrapping the detection optical fiber 2-1, the shielding copper wire 2-2 and the semi-conductive filler 2-3 on the semi-conductive Teflon tape 2-4 according to a designed structure on a special shielding machine for the cable, wherein the winding pitch diameter ratio is 13 times, the filler is round and compact, wrapping a layer of semi-conductive nylon tape 2-5, and the overlap ratio is 18%;
Specifically, the special cable shielding machine shown in fig. 2 to 3 comprises a pay-off rack 8, a wire guide 9, a first wrapping machine 10, a stranding machine 11-1, a motor 11-2, a wire guide 11-3, a deconcentrator 11-4, a circular arc-shaped wire head 11-5, a second wrapping machine 12, a meter 13, a tension machine 14 and a take-up rack 15.
The cable core 1 is mounted on a reel and placed on a pay-off rack 8 of a special cable shielding machine, and the semiconducting te-poly tangential belts 2-4 are wound on the cable core 1 through a first winding machine 10 via a wire guide 9. The first wrapping machine 10 can adjust the wrapping angle in conjunction with the payout speed.
The wrapping speed is adjusted according to the paying-off speed, the reels provided with the detection optical fiber 2-1, the shielding copper wire 2-2 and the semiconductive filling 2-3 are respectively arranged on the stranding machine 11, and the stranding machine 11 can adjust paying-off tension. The tension of the detection optical fiber 2-1 and the semi-conductive filling 2-3 is controlled to be 3-6N, preferably 4N, and the tension of the shielding copper wire 2-2 is controlled to be 8-15N, preferably 12N. Specifically, the tray provided with the detection optical fiber 2-1, the shielding copper wire 2-2 and the semiconductive filling 2-3 is respectively arranged on the stranding cage 11-1 of the stranding cage machine 11, wherein the tray provided with the detection optical fiber 2-1 is arranged at a position close to the motor 11-2, so that the paying-off length is reduced, and the damage to the detection optical fiber 2-1 caused by excessive contact with other positions is prevented. The detection optical fiber 2-1 enters the wire guide 11-3 through a guide wheel and a wire passing nozzle on the motor 11-2, and the wire passing nozzle and a wire guide wheel on the nylon wire guide 11-3 are made of nylon materials, so that the detection optical fiber 2-1 is prevented from being damaged. The detection optical fiber 2-1, the shielding copper wire 2-2 and the semiconductive filling 2-3 respectively pass through the deconcentrator 11-4 according to a set structural sequence, then enter the die through the arc-shaped lead head 11-5, and the arc-shaped lead head 11-5 is arranged to prevent the detection optical fiber 2-1, the shielding copper wire 2-2 and the semiconductive filling 2-3 from being damaged due to overlarge bending angle before entering the die.
The detection optical fiber 2-1, the shielding copper wire 2-2 and the semiconductive filling 2-3 are wound on the wire core after wrapping the semiconductive Teflon tape 2-4 through a die. And wrapping the semiconductive nylon belts 2-5 outside the shielding layer by a second wrapping machine 12. The wire core is drawn by a tension machine 14 through a meter 13, and then is wound on a winding drum through a winding frame 15.
Step three: extruding an inner sheath 3 outside the metal shielding layer 2, and wrapping a layer of flame-retardant tape 4;
step four: winding flat metal wires outside the flame-retardant belt 4 to prepare a metal armor layer 5;
Step five: and wrapping a layer of wrapping tape 6 outside the metal armor layer 5, wherein the wrapping tape 6 is a glass fiber tape, and extruding an outer sheath 7 outside the wrapping tape 6 to prepare the cable.
The metal shielding layer 2 of the embodiment can monitor the use state of the cable in real time by arranging the detection optical fiber 2-1; the shielding copper wire 2-2 is arranged, so that electromagnetic interference can be effectively prevented, and a shielding effect of safety protection is achieved; the semi-conductive filling 2-3 is arranged between the detection optical fiber 2-1 and the shielding copper wires 2-2 and between the adjacent shielding copper wires 2-2, so that the shielding copper wires 2-2 can be ensured to be uniformly distributed outside the cable core 1, an electric field is uniformly distributed when the cable core is electrified for use, and the conductivity between the copper wires is increased; the outer diameters of the shielding copper wires 2-2 and the semiconductive filling wires 2-3 are larger than the outer diameter of the detection optical fiber 2-1, the detection optical fiber 2-1 is protected from damage during stranding, the detection optical fiber 2-1 is not directly contacted with the copper wires with larger hardness, but is contacted with the softer semiconductive filling wires 22, so that the buffer of the detection optical fiber 2-1 is increased, and the damage of the detection optical fiber 2-1 is prevented; the shielding section of the existing intelligent monitoring cable for track traffic is generally 16-50 mm 2, when the semi-conductive filling is not available, more copper wires can be added for ensuring the electric field balance of the cable, the shielding section is far more than 50mm 2, the shielding cost is high, the semi-conductive filling is used for replacing part of copper wires, and a large amount of cost is saved.
In addition, the production process of the embodiment adopts the special shielding machine for the cable, can reduce the rotation angle of the detection optical fiber 2-1 during twisting, and provides a certain buffer to further protect the detection optical fiber from being damaged.
Example 2
The special cable for intelligent monitoring for track traffic of this embodiment is basically the same as embodiment 1, except that: the conductor layer 1-1 adopts two types of tin-free stranded conductors; the material of the insulation 1-3 is ethylene propylene rubber EPR; the detection optical fiber 2-1 adopts a stainless steel armoured multimode optical fiber unit; the inner sheath 3 is made of low-smoke halogen-free flame-retardant polyolefin material, so that the flame retardance of the cable is improved; the reinforced core of the semi-conductive filling 2-3 adopts copper wires, so that different use requirements are met, and the application range is wide.
While the foregoing is directed to embodiments of the present invention, other and further details of the invention may be had by the present invention, it should be understood that the foregoing description is merely illustrative of the present invention and that no limitations are intended to the scope of the invention, except insofar as modifications, equivalents, improvements or modifications are within the spirit and principles of the invention.
Claims (8)
1. The utility model provides a special cable for intelligent monitoring for track traffic which characterized in that: the cable comprises a cable core (1), a metal shielding layer (2), an inner sheath (3), a flame-retardant belt (4), a metal armor layer (5), a belting (6) and an outer sheath (7) which are sequentially arranged from inside to outside; the metal shielding layer (2) comprises two layers of semi-conductive wrapping bands, detection optical fibers (2-1), shielding copper wires (2-2) and semi-conductive filling (2-3), wherein the detection optical fibers (2-1), the shielding copper wires (2-2) and the semi-conductive filling (2-3) are arranged between the semi-conductive wrapping bands and are distributed circumferentially; the detection optical fibers (2-1) and the shielding copper wires (2-2) are uniformly distributed along the periphery of the cable core (1); the semi-conductive filling (2-3) is distributed between the adjacent detection optical fibers (2-1) and the shielding copper wires (2-2) and between the adjacent shielding copper wires (2-2); the outer diameters of the shielding copper wire (2-2) and the semiconductive filling (2-3) are larger than the outer diameter of the detection optical fiber (2-1);
the semiconductive filling (2-3) comprises a centrally located reinforcing core and thermoplastic semiconductive material extruded outside the reinforcing core;
the semiconductive wrapping belt comprises a semiconductive Teflon belt (2-4) arranged on the inner layer and a semiconductive nylon belt (2-5) arranged on the outer layer.
2. The special cable for intelligent monitoring for track traffic according to claim 1, wherein: the cable core (1) comprises a conductor layer (1-1), a conductor shielding layer (1-2), an insulation layer (1-3) and an insulation shielding layer (1-4) which are sequentially arranged from inside to outside.
3. The special cable for intelligent monitoring for track traffic according to claim 1, wherein: the detection optical fiber (2-1) adopts a stainless steel armored single-mode or multi-mode optical fiber unit.
4. The special cable for intelligent monitoring for track traffic according to claim 1, wherein: the metal armor layer (5) is made of nonmagnetic flat or round metal wires in a winding mode.
5. The special cable for intelligent monitoring for track traffic according to claim 1, wherein: the inner sheath (3) is made of PE or low-smoke halogen-free flame-retardant polyolefin material.
6. The special cable for intelligent monitoring for track traffic according to claim 1, wherein: the wrapping belt (6) is made of glass fiber belts.
7. The production process of the special cable for intelligent monitoring for the rail transit is characterized by comprising the following steps of:
Step one: manufacturing a cable core (1); the conductor is twisted after being drawn to prepare a conductor layer (1-1), and the outside of the conductor layer is extruded with a conductor shielding layer (1-2), an insulation layer (1-3) and an insulation shielding layer (1-4) in a three-layer co-extrusion mode;
step two: manufacturing a metal shielding layer (2); wrapping a layer of semi-conductive wrapping tape outside the cable core (1), wherein the covering rate is 15-20%, then wrapping the detection optical fiber (2-1), the shielding copper wire (2-2) and the semi-conductive filler (2-3) on the semi-conductive wrapping tape on a special shielding machine for the cable at the same time, wherein the wrapping pitch diameter is 10-16 times, the filler is round and compact, wrapping a layer of semi-conductive wrapping tape, and the covering rate is 15-20%;
step three: extruding an inner sheath (3) outside the metal shielding layer (2), and wrapping a layer of flame-retardant tape (4);
step four: winding a flat metal wire outside the flame-retardant belt (4) to prepare a metal armor layer (5);
step five: and wrapping a layer of wrapping tape (6) outside the metal armor layer (5), and extruding an outer sheath (7) outside the wrapping tape (6) to prepare the cable.
8. The process for producing the special cable for intelligent monitoring for rail transit according to claim 7, wherein the process comprises the following steps of: in the fourth step, the width of the flat wire is L, the thickness of the flat wire is H, and the core diameter of the flat wire is D, so that the number of the flat wires is n=int (pi× (d+h)/(L)).
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| CN207458628U (en) * | 2017-03-10 | 2018-06-05 | 江苏华能电缆股份有限公司 | A kind of ultradeep well ultra-wideband heavy duty charge bearing detecting cable |
| CN110010292A (en) * | 2019-05-13 | 2019-07-12 | 远东电缆有限公司 | Rail traffic intelligent monitoring looped network cable |
| CN111430064B (en) * | 2020-04-03 | 2023-02-28 | 远东电缆有限公司 | Single-phase alternating current intelligent monitoring cable for railway and production process thereof |
| CN111462956B (en) * | 2020-04-20 | 2021-09-07 | 远东电缆有限公司 | Production process of intelligent monitoring traction cable for high-speed rail and cable |
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