CN-122025227-A - Intelligent monitoring tensile torsion-resistant cable and preparation method thereof

CN122025227ACN 122025227 ACN122025227 ACN 122025227ACN-122025227-A

Abstract

The invention discloses an intelligent monitoring tensile torsion-resistant cable and a preparation method thereof, and belongs to the field of cable manufacturing. The invention improves the embedding compatibility of the sensor and reduces the interface stress concentration by arranging the multi-level conductor and embedding the optical fiber composite wire and the conductive fiber composite wire in the multi-level conductor, and improves the stability and accuracy of signal detection by embedding a stainless steel wire for calibrating the detection positions of the optical fiber composite wire and the conductive fiber composite wire at intervals of preset distances.

Inventors

ZHU YU
WANG YONGCAI
Shi Baiwan
LING GUOZHEN

Assignees

江苏上上电缆集团有限公司
江苏上上电缆集团新材料有限公司

Dates

Publication Date: 20260512
Application Date: 20250902

Claims (14)

1. An intelligent monitoring tensile torsion-resistant cable is characterized by comprising a multi-layer conductor, an insulating layer extruded outside the multi-layer conductor, a composite sheath extruded outside the insulating layer, The multi-layer conductor comprises a central layer, an intermediate layer and an outer layer, wherein the intermediate layer comprises an optical fiber composite wire, the outer layer comprises a conductive fiber composite wire, The composite sheath comprises an inner bonding layer, a reinforcing layer and an outer protective layer, wherein the reinforcing layer comprises a positioning conductor, and the positioning conductor is used for calibrating the detection positions of the optical fiber composite wire and the conductive fiber composite wire.
2. The intelligent monitoring tensile torsion-resistant cable of claim 1, wherein the conductive fiber composite wire comprises aramid fibers and copper foil, the aramid fibers being spaced apart from the hot-pressed composite copper foil by a predetermined distance.
3. The intelligent monitoring tensile torsion-resistant cable of claim 2, wherein the optical fiber composite wire comprises an optical fiber, a coating layer coated on the periphery of the optical fiber, and the coating layer is epoxy resin.
4. The intelligent monitoring tensile torsion-resistant cable according to claim 1, wherein the reinforcing layer comprises an aramid woven mesh, the positioning conductor is a stainless steel wire, and the aramid woven mesh is embedded with one stainless steel wire at intervals of a preset distance.
5. The intelligent monitoring tensile torsion-resistant cable according to claim 4, wherein the reinforcing layer comprises aramid short fibers, and the aramid short fibers and the PA66 are mixed in proportion and then infrared heated and bonded on the surface of the aramid woven mesh.
6. The intelligent monitoring tensile torsion-resistant cable according to claim 1, wherein the insulating layer comprises Ethylene Propylene Rubber (EPR) and ethylene-vinyl acetate copolymer (EVA), and the EVA is added in an amount of 5-10wt% so that the peel strength of the interfacial bonding force between the insulating layer and the composite sheath is not less than 6N/cm.
7. The intelligent monitoring tensile torsion-resistant cable of claim 1, further comprising a monitoring system, the monitoring system comprising a sensing unit, a signal transmission unit, a processing unit, the signal transmission unit being configured to connect the sensing unit and the signal transmission unit, the sensing unit comprising the optical fiber composite wire and the conductive fiber composite wire, the signal transmission unit comprising an optical fiber jumper and an outgoing line of the conductive fiber composite wire, the processing unit comprising a junction box with an FBG demodulator or bridge built in.
8. The method for manufacturing the intelligent monitoring tensile torsion-resistant cable according to any one of claims 1 to 7, comprising the following steps: S1, twisting a multi-layer conductor and embedding a sensor; s2, extruding and wrapping an insulating layer; S3, forming a composite sheath; The S4 sensor is integrated with the monitoring system.
9. The method for manufacturing the intelligent monitoring tensile torsion-resistant cable according to claim 8, wherein the S1 multi-layer conductor stranding and sensor embedding further comprises the following steps: s11, preparing a copper rod of a central layer by adopting continuous extrusion-wire drawing, S12, arranging a plurality of middle layer conductors and a plurality of optical fiber composite wires around a single conductor of a central layer, and twisting the central layer conductors in the S direction according to preset tension by adopting a tubular twisting machine; S13, arranging a plurality of outer conductors and a plurality of conductive fiber composite wires, and twisting the wires in the Z direction according to preset tension by adopting a cage type stranding machine.
10. The method for manufacturing the intelligent monitoring tensile torsion-resistant cable according to claim 9, wherein the S2 insulating layer extrusion further comprises the following steps: s21, mixing Ethylene Propylene Rubber (EPR) and ethylene-vinyl acetate copolymer (EVA) in an internal mixer at 80-90 ℃ for 25min; S22, filtering the mixed material after banburying through a filter screen; Extruding the mixed material filtered in the step S23 through an extruder, wherein the temperature of the extruder body is 165-175 ℃, the temperature of the extruder head is 185-195 ℃, and the rotating speed of a screw is 20-30 rpm; S24, steam vulcanization is carried out on the insulating layer, and the pressure is 0.8+/-0.05 MPa, the temperature is 180+/-2 ℃, and the vulcanization is carried out for 85+/-5 minutes, so that the peeling strength of the insulating layer and the conductor is more than or equal to 6N/cm.
11. The method for manufacturing the intelligent monitoring tensile torsion-resistant cable according to claim 10, wherein the S3 composite sheath forming and sensor integration further comprises the following steps: and (3) preparing an adhesive layer in S31, extruding the modified TPU containing 0.8wt% of epoxy groups through an extruder, wherein the extrusion temperature is 195+/-5 ℃, and the thickness of the adhesive layer is 1.0-2.0 mm.
12. The method for manufacturing the intelligent monitoring tensile torsion-resistant cable according to claim 11, wherein the step of integrating the S3 composite sheath forming with the sensor further comprises the steps of manufacturing an S32 reinforcing layer, wherein the step of manufacturing the S32 reinforcing layer comprises the following steps: S321, preparing an aramid woven net by a braiding machine, wherein the warp density is 12-15 pieces/cm, the weft density is 10-12 pieces/cm, the braiding angle is +/-12 degrees, and 1 stainless steel wire is inserted every 100mm in the braiding process; S322, mixing the aramid short fibers with the length of 3-5mm with PA66 according to the ratio of 8:2, spraying air flow to the surface of an aramid woven mesh, and bonding by infrared heating at 90 ℃; s323, spirally winding the filled aramid woven net outside the inner bonding layer in a mode that the screw pitch is equal to 2 times of the thickness of the strong layer, and performing hot pressing and shaping.
13. The method for manufacturing the intelligent monitoring tensile torsion-resistant cable according to claim 12, wherein the S3 composite sheath forming and sensor integration further comprises the following steps: And (3) preparing an S33 external protection layer, extruding weather-proof TPU containing 2.5wt% of carbon black and 0.8wt% of hindered amine light stabilizer through an extruder, wherein the extrusion temperature is 205+/-5 ℃, the thickness of the external protection layer is 1.5-2.5 mm, the surface of the external protection layer is subjected to corona treatment, the power is 5+/-0.5 kW, the treatment speed is 10+/-1 m/min, and the surface energy after treatment is more than or equal to 50mN/m.
14. The method for manufacturing an intelligent monitoring tensile torsion-resistant cable according to claim 13, wherein the integration of the S4 sensor with the monitoring system further comprises the steps of: S41, stripping an outer protective layer, a reinforcing layer and an inner bonding layer which are 500mm long at the end part of the cable, exposing the insulating layer, and adhering and fixing the outgoing lines of the optical fiber jumper wire and the conductive fiber composite wire with the insulating layer through epoxy adhesive to avoid torsion damage; s42, installing a junction box, namely installing an IP67 waterproof junction box after the sheaths at two ends of the cable are stripped, and connecting outgoing lines of the optical fiber jumper and the conductive fiber composite wire into an FBG demodulator or an electric bridge; S43, calibrating a strain-tension curve of a sensor through a tensile test, setting a broken wire early warning threshold value, and installing a S44 sealing sleeve, namely sleeving a fluororubber sealing sleeve with compression set less than or equal to 15% at the end part of a cable, and testing tightness at-40 ℃ without leakage.

Description

Intelligent monitoring tensile torsion-resistant cable and preparation method thereof Technical Field The invention relates to the field of cable manufacturing, in particular to a cable capable of intelligently monitoring tensile resistance and torsion resistance based on a multi-layer conductor and a composite sheath and a preparation method thereof. Background In complex application scenes such as offshore wind power, plateau wind power and the like, the cable needs to bear high-frequency torsion (+/-1200 degrees/min), instantaneous high tension (more than or equal to 60 kN) and compound stress of extreme environments (-40 ℃ to +120 ℃ and salt mist and greasy dirt) for a long time. Under such working conditions, the conductors (such as copper wires) and the sheath (such as aramid fibers) of the traditional cable are prone to breaking due to fatigue accumulation, and the sheath material may crack due to repeated bending or chemical corrosion. The existing cable operation and maintenance mainly relies on regular manual inspection or passive power failure maintenance, internal damage cannot be monitored in real time, sudden fracture risk is caused, and maintenance cost is extremely high after cable fracture. The prior art has the main drawbacks of the following, The structure has the defects of insufficient reliability, easy dislocation of fibers under high-frequency torsion of the traditional tensile structure (such as a single aramid fiber woven layer), stress concentration, weak bonding force of a sheath-reinforced layer interface, peeling strength of <5N/cm and high layering risk after long-term dynamic load. Sensor embedding technology is not mature: the volume conflict is that the diameter of the existing FBG or resistance strain sensor is larger than 1mm, the twisting compactness is destroyed after the conductor is embedded, and the tensile strength is reduced; Signal interference, namely, the monitoring signal is easy to be subjected to electromagnetic interference (such as a motor and a frequency converter), so that the false alarm rate is high. The monitoring dimension is single, namely, only a single parameter of tension or torsion is monitored, and the multidimensional damage evolution rule of broken wire-strain cannot be associated. Therefore, it is needed to develop a conformal technology for twisting a microsensor and a conductor with strong structural compatibility, and an interface strengthening process under extreme environments, so that the cable can synchronously realize the functions of tension resistance, torsion resistance and wire breakage monitoring, and the monitoring is real-time and reliable. Disclosure of Invention The invention provides an intelligent monitoring tensile torsion-resistant cable, which solves the problems of insufficient reliability of a protective structure, insufficient tensile torsion resistance, low detection and positioning precision of broken wires, weak embedding compatibility of sensors, concentrated interface stress, influence on the whole mechanical performance of the cable, poor environmental adaptability and easiness in electromagnetic interference of monitoring signals. The core technical scheme of the invention is that a multi-level conductor is arranged, an optical fiber composite wire and a conductive fiber composite wire are embedded in the multi-level conductor, a composite sheath is arranged to comprise an inner bonding layer, a reinforcing layer and an outer protective layer for three-layer protection, the reinforcing layer is provided with an aramid woven net, and a stainless steel wire is embedded at intervals of a preset distance for calibrating the detection positions of the optical fiber composite wire and the conductive fiber composite wire, so that the embedding compatibility of a sensor is improved, the concentration of interface stress is reduced, and the stability and the accuracy of signal detection are improved. The specific scheme of the invention is as follows: an intelligent monitoring tensile torsion-resistant cable comprises a multi-layer conductor, an insulating layer extruded outside the multi-layer conductor, a composite sheath extruded outside the insulating layer, The multi-layer conductor comprises a central layer, an intermediate layer and an outer layer, wherein the intermediate layer comprises an optical fiber composite wire, the outer layer comprises a conductive fiber composite wire, The composite sheath comprises an inner bonding layer, a reinforcing layer and an outer protective layer, wherein the reinforcing layer comprises a positioning conductor, and the positioning conductor is used for calibrating the detection positions of the optical fiber composite wire and the conductive fiber composite wire. Further, the conductive fiber composite wire comprises aramid fibers and copper foil, wherein the aramid fibers are used for hot-pressing the composite copper foil at preset intervals. Further, the optical fiber compo