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CN-122025234-A - Smart cable with built-in state monitoring chip and preparation method

CN122025234ACN 122025234 ACN122025234 ACN 122025234ACN-122025234-A

Abstract

The invention relates to an intelligent cable with a built-in state monitoring chip and a preparation method thereof, belonging to the technical field of power cables, and comprising a conductor, an insulating layer wrapped on the outer layer of the conductor, a monitoring assembly and an energy collecting module; the intelligent cable comprises a cable body, an energy collection module, a monitoring assembly, a packaging layer, a conductor and an insulating layer, wherein the monitoring assembly is arranged in the cable body and is used for monitoring operation state parameters of the cable in real time and transmitting data to the outside, the energy collection module is electrically connected with the monitoring assembly and is used for collecting energy in the cable operation environment and supplying power to the monitoring assembly, the monitoring assembly is integrally packaged by the packaging layer and is axially and fixedly arranged between the conductor and the insulating layer along the cable, the intelligent cable with the built-in state monitoring chip and the preparation method are used for enabling the intelligent cable to be an organic whole with self-sensing and self-power supply capability through the integrated built-in of the monitoring assembly and the energy collection module, and the monitoring assembly is embedded between the conductor and the insulating layer and is structurally and deeply fused without affecting the mechanical and electrical performances of the cable.

Inventors

  • YUE FAN
  • HUANG XUAN

Assignees

  • 武汉市新星电线电缆有限责任公司

Dates

Publication Date
20260512
Application Date
20260310

Claims (10)

  1. 1. The intelligent cable with the built-in state monitoring chip comprises a conductor (1) and an insulating layer (2) wrapped on the outer layer of the conductor (1), and is characterized by further comprising a monitoring assembly (3) and an energy collecting module (4); The monitoring assembly (3) is arranged in the cable body and is used for monitoring the running state parameters of the cable in real time and transmitting data to the outside; The energy collection module (4) is electrically connected with the monitoring assembly (3) and is used for collecting energy in a cable operation environment and supplying power to the monitoring assembly (3); the monitoring assembly (3) is integrally packaged by the packaging layer (5) and is fixedly arranged between the conductor (1) and the insulating layer (2) along the axial direction of the cable; the monitoring assembly (3) comprises a monitoring unit (31) for collecting operation state parameters, a communication module (32) for data communication and a processing chip (33) for processing, storing and primarily diagnosing the monitoring data.
  2. 2. A smart cable incorporating a status monitoring chip according to claim 1, wherein the monitoring unit (31) comprises: The temperature sensor is used for monitoring the real-time temperature of the cable; a stress/strain sensor for monitoring mechanical stress or deformation to which the cable is subjected; and the partial discharge sensor is used for monitoring partial discharge signals in the cable.
  3. 3. The intelligent cable with the built-in state monitoring chip according to claim 1, wherein the communication module (32) is a wireless communication module, and the wireless communication module adopts any one of radio frequency identification, bluetooth low energy, zigbee or narrowband internet of things.
  4. 4. The intelligent cable with the built-in state monitoring chip according to claim 1, wherein the packaging layer (5) is made of a flexible polymer composite material, the thermal expansion coefficient of the packaging layer (5) is matched with that of the insulating layer (2), and the packaging layer (5) is of a streamline structure attached to the surface of the conductor (1) so as to reduce the influence on the electric field distribution of the cable.
  5. 5. The intelligent cable with the built-in state monitoring chip according to claim 1, wherein the energy collecting module (4) is at least one of an induction power taking unit, a thermoelectric conversion unit or a vibration power generation unit.
  6. 6. The intelligent cable with the built-in state monitoring chip according to claim 1, wherein the number of the monitoring components (3) is a plurality of the monitoring components, and the monitoring components are distributed at preset intervals along the axial direction of the cable to form a monitoring array.
  7. 7. A method for manufacturing a smart cable incorporating a status monitoring chip as claimed in any one of claims 1 to 6, comprising the steps of: S1, providing a conductor (1); S2, fixedly arranging the monitoring assembly (3) at a preset position on the surface of the conductor (1); S3, integrally packaging the monitoring assembly (3) by adopting a packaging material to form a packaging layer (5) with a streamline shape; s4, extruding and wrapping the periphery of the packaged conductor (1) to form an insulating layer (2), and embedding the packaging layer (5) between the conductor (1) and the insulating layer (2) to obtain the intelligent cable core wire.
  8. 8. The method for manufacturing a smart cable of a built-in state monitoring chip according to claim 7, wherein in step S3, the encapsulation is performed by a mold casting or three-dimensional printing process, the encapsulation material is unvulcanized silicone rubber, epoxy resin or polyurethane, and the curing treatment is performed after the encapsulation.
  9. 9. The method of claim 7, wherein in step S4, the extrusion temperature, pressure and drawing speed are controlled so that the molten insulating material can tightly wrap the encapsulation layer (5) and fill all the gaps between the encapsulation layer and the conductor (1) without damaging the monitoring component (3) when the insulation layer is extruded.
  10. 10. The method for manufacturing a smart cable into which a status monitor chip is built according to claim 7, further comprising: and S5, performing calibration test on the prepared intelligent cable, namely synchronously reading the data of the monitoring unit (31) and the data of external reference measuring equipment under a standard working condition, establishing a data correction model and writing the data correction model into a processing chip (33) of the monitoring assembly (3).

Description

Smart cable with built-in state monitoring chip and preparation method Technical Field The invention relates to the technical field of power cables, in particular to an intelligent cable with a built-in state monitoring chip and a preparation method thereof. Background The power cable is used as a key carrier for electric energy transmission and is widely applied to the fields of urban power grids, rail transit, new energy power generation, industrial power supply and the like. Along with the development of the power system towards intelligentization and high reliability, higher requirements are put forward on real-time monitoring and fault early warning of the running state of the cable. The traditional cable has no state sensing capability, and the health state of the traditional cable is usually evaluated by external inspection or off-line test, so that the problems of monitoring lag, low coverage rate, high cost and the like exist, and potential faults such as local overheating, abnormal mechanical stress, insulation degradation and the like in the cable are difficult to discover in time. At present, some technical solutions for attaching a sensor or a monitoring device to the outside of a cable are tried, but the external monitoring devices often have the problems of complex installation, easy environmental interference, influence on the structural integrity of the cable body and the like. In addition, the problem of power supply of the monitoring device is also a great challenge, the battery is adopted for supplying power, the battery needs to be replaced periodically, and the complexity of wiring and potential safety hazards are increased when external power is taken. Therefore, how to realize the built-in, self-powered and integrated monitoring device and combine with the cable manufacturing process becomes an important direction of intelligent cable development. Therefore, the intelligent cable with the built-in state monitoring chip and the preparation method thereof are provided, the monitoring assembly and the energy collecting module are integrally built in the cable body, so that the real structural fusion and the state self-perception are realized, and a reliable technical basis is provided for real-time monitoring, intelligent diagnosis and preventive maintenance of the cable. Disclosure of Invention Aiming at the defects of the prior art, the intelligent cable with the built-in state monitoring chip and the preparation method thereof provided by the invention have the advantages of deep integration, self-powered continuous operation, multi-dimensional state real-time sensing and intelligent diagnosis, high reliability, feasible large-scale production and the like, and solve the problems that the traditional cable lacks built-in sensing capability, an external monitoring scheme is difficult to install and maintain, depends on an external power supply and is difficult to realize long-term real-time state monitoring and early fault early warning. In order to achieve the above purpose, the present invention provides the following technical solutions: A smart cable with a built-in state monitoring chip comprises a conductor, an insulating layer wrapping the outer layer of the conductor, a monitoring assembly and an energy collecting module; The monitoring component is arranged in the cable body and is used for monitoring the running state parameters of the cable in real time and transmitting data to the outside; the energy collection module is electrically connected with the monitoring assembly and is used for collecting energy in a cable operation environment and supplying power to the monitoring assembly; The monitoring assembly is integrally packaged by the packaging layer and is fixedly arranged between the conductor and the insulating layer along the axial direction of the cable; the monitoring assembly comprises a monitoring unit for collecting operation state parameters, a communication module for data communication and a processing chip for processing, storing and primarily diagnosing the monitoring data. Further, the monitoring unit includes: The temperature sensor is used for monitoring the real-time temperature of the cable; a stress/strain sensor for monitoring mechanical stress or deformation to which the cable is subjected; and the partial discharge sensor is used for monitoring partial discharge signals in the cable. Further, the communication module is a wireless communication module, and the wireless communication module adopts any one communication protocol of radio frequency identification, low-power consumption Bluetooth, zigbee or narrowband Internet of things. Further, the packaging layer is made of a flexible polymer composite material, the thermal expansion coefficient of the packaging layer is matched with that of the insulating layer, and the packaging layer is of a streamline structure attached to the surface of the conductor, so that the influence on the electric fiel