CN112216441A - Energy-saving composite conductor and high-performance long-life wire and cable based on same - Google Patents
Energy-saving composite conductor and high-performance long-life wire and cable based on same Download PDFInfo
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- CN112216441A CN112216441A CN202011055862.6A CN202011055862A CN112216441A CN 112216441 A CN112216441 A CN 112216441A CN 202011055862 A CN202011055862 A CN 202011055862A CN 112216441 A CN112216441 A CN 112216441A
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- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
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- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
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- H—ELECTRICITY
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- 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
- H01B13/0006—Apparatus or processes specially adapted for manufacturing conductors or cables for reducing the size of conductors or cables
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- H01B13/0016—Apparatus or processes specially adapted for manufacturing conductors or cables for heat treatment
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- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/30—Insulated conductors or cables characterised by their form with arrangements for reducing conductor losses when carrying alternating current, e.g. due to skin effect
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Abstract
The invention belongs to the technical field of wires and cables, and particularly relates to an energy-saving composite conductor and a high-performance long-life wire and cable based on the conductor. The high-performance long-life wire and cable is composed of a conductor, an insulating layer, a filling layer, a wrapping layer and a sheath, wherein the insulating layer is wrapped outside the conductor, the wrapping layer and the sheath are sequentially arranged outside the insulating layer, the filling layer is arranged between the adjacent insulating layers and between the insulating layer and the wrapping layer, and the conductor is the energy-saving composite conductor. Compared with the prior art, the energy-saving composite conductor can effectively reduce the temperature of the lead, save copper materials and reduce line loss. Because the temperature rise of the electric wire and the electric cable is reduced, the insulation material is not carbonized, and the insulation service life of the copper-clad aluminum core electric wire and the electric cable can meet the maintenance-free requirement of more than 30 years.
Description
Technical Field
The invention belongs to the technical field of wires and cables, and particularly relates to an energy-saving composite conductor and a high-performance long-life wire and cable based on the conductor.
Background
The cable is an important conductive device of a power system, plays a role in transmitting electric energy, and is mainly used for electric energy transmission of a generator, a transformer, a motor and the like. At present, the connection between electrical equipment such as high-low voltage power distribution of a substation, a motor device and the like and corresponding power distribution devices is mostly made of pure copper cables. Because "skin effect", lead to pure copper cable at transmission electric energy in-process electric current mainly concentrate on the cable surface, this can lead to the cable to produce more heat, the year electric quantity of restriction cable leads to the inside copper product utilization efficiency of cable to reduce simultaneously, and the copper product is extravagant serious.
In order to cope with the rising copper price, some enterprises begin to adopt aluminum with lower price to replace copper or adopt a copper-clad aluminum cable structure.
For example, chinese patent CN108063000B discloses a copper-clad aluminum core with high conductivity for use in cables, alloy elements with different contents are added into molten aluminum melted by high-purity aluminum, under the condition of copper cladding, the conductivity, tensile strength and section elongation of a processed aluminum alloy conductor are obviously improved, the tensile strength reaches 150MPa, the yield strength reaches 85MPa, and the conductivity is improved by 24-28%, the aluminum alloy conductor undergoes recovery and recrystallization processes in the process of intermediate annealing, fine isometric crystals gradually replace uneven crystal grains, the structure tends to be stable, the tensile strength, bending resistance, corrosion resistance and creep resistance of the aluminum alloy conductor can be enhanced, and the conductivity of the aluminum alloy conductor can also be improved. However, the copper-clad aluminum core material in the above patent is relatively complex in preparation method, needs to be prepared by alloy liquid casting, and has high energy requirement, and on the other hand, the copper-clad aluminum core material in the patent mainly emphasizes conductivity, and does not use the product in related tests of cable manufacturing and the like.
Chinese patent CN109754925A discloses a hollow cable, which comprises a plurality of strands of wires and an insulating outer sheath (1) covering all the wires, wherein the wires (2) are arranged in a hollow manner, the wires are closely arranged, and a hollow layer formed after the wires are arranged is filled with a light elastic filler (3) or supported by a spiral spring (17). The wires of the cable adopt a hollow arrangement mode to utilize the skin effect of alternating current, the cross section of the conductor is effectively utilized, the alternating current resistance is small, and the power loss is small. Meanwhile, the hollow arrangement enables the external contact surface of the cable to be large, the heat dissipation condition to be good, the temperature rise of the cable to be low, and the heat dissipation of conductor materials is facilitated, so that the normal service life of the cable is ensured. However, the cable structure in the above patent is too complex, and the preparation difficulty is large.
Chinese patent CN108511116B discloses a hydrate temperature-control heat-dissipation low-voltage cable, which comprises a conductor, a first nano-graphite coating, a rubber insulating layer, an inner shielding layer, a glass fiber protective layer, a hydrate material layer, a second nano-graphite coating, a belting layer, an outer shielding layer, an inner sheath layer, an armor layer and an outer sheath layer. According to the cable, the hydrate material is filled in the twisted gap of the shielding insulating wire by utilizing the high heat storage density of the hydrate and the excellent heat transfer characteristic of the nano particles, and the nano graphite coating is added on the outer layer of the conductor and the inner wall of the wrapping tape layer, so that the temperature rise of the cable can be effectively controlled, the current-carrying capacity is improved, and the heat dissipation performance is improved. This patent technique has solved traditional low tension cable and has made self temperature rising because of self generates heat when heavy current load work, leads to cable insulation level to descend, and the life-span shortens, equipment fault rate increases, defects such as conflagration risk increase, and the great buried cable of calorific capacity that the instantaneous peak current of specially adapted, intermittent type nature load arouse. However, the cable structure in the patent is too complex, and the preparation difficulty is large.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide an energy-saving composite conductor and a high-performance long-life wire cable based on the conductor.
The purpose of the invention can be realized by the following technical scheme:
the invention utilizes the principle of skin effect, integrates the production and manufacturing process, the composite material heat treatment technology, the copper-aluminum cladding drawing atom metallurgy technology, the novel material stranding technology and other process links, uniformly coats the copper layer on the aluminum core, realizes the metallurgical bonding of atoms on the interface of copper and aluminum, and stretches and twists to form the novel conductive material with the characteristics of high strength, light weight, flexibility, environmental protection and the like.
The invention firstly provides a preparation method of an energy-saving composite conductor, which comprises the following steps:
(1) the surface of the aluminum rod is coated with a copper strip, and then the longitudinal seam of the copper strip is welded under the protection of inert gas,
(2) the combined aluminum rod and copper strip are subjected to heat treatment and drawing to produce a copper-clad aluminum wire with good cladding,
(3) annealing treatment: annealing the obtained copper-clad aluminum wire,
(4) rewinding: the copper-clad aluminum wire after annealing treatment is subjected to compound winding,
(5) stranding: and twisting the wound conducting wire to obtain the energy-saving composite conductor.
Further, before the step (1), the aluminum rod is pretreated, and the pretreatment procedure comprises the following steps: paying off an aluminum rod, removing oil, cleaning, brightening, passivating, cleaning and drying.
The aluminum rod is drawn in a sizing mode after being paid off, so that the roundness of the aluminum rod is guaranteed during production, the drawn aluminum rod directly enters the deoiling cleaning mechanism, the deoiled aluminum rod is washed with clear water, the washed aluminum rod enters the neutralizing treatment mechanism, the aluminum rod is subjected to acid neutralizing treatment, the treated aluminum rod is cleaned with clear water, the cleaned aluminum rod is subjected to passivation treatment, the passivation treatment has the effect that the aluminum rod is required to be free of an aluminum oxide film during copper cladding, so that the bonding strength of aluminum and copper is guaranteed, the passivated aluminum rod is washed with clear water, the cleaned aluminum rod is dried, and the dried aluminum rod can completely meet the requirements of the production process.
Further, before the step (1), the copper strip is pretreated, and the pretreatment procedure comprises the following steps: the method comprises the steps of strip placing for coiling the copper strip, width fixing and edge cutting, oil removing, cleaning, brightening treatment, passivation, cleaning and drying.
The copper strips directly get into deoiling wiper mechanism after opening a book, the copper strips after the deoiling washes by the clear water again, the copper strips after the washing reentries neutralization treatment mechanism, carry out acid neutralization treatment to the copper strips, the copper strips after will handling again carries out the clear water washing, the copper strips after the washing still needs passivation treatment, passivation treatment's effect requires the copper strips to guarantee not have the copper oxide film when coating with the aluminium pole, in order to guarantee the bonding strength of copper and aluminium, the copper strips after the passivation again washs by the clear water, the copper strips after will wasing at last dries, the copper strips after the drying just can satisfy production technology's needs completely.
After the copper strip passes through the previous working procedures, the copper-clad aluminum wire with good cladding is produced through edge pressing, arc pressing, forming process, shaping process, argon arc welding, traction and twice drawing, and the copper-clad aluminum wire is orderly and equidistantly wound on a standard working disc of 1200 mm by a hydraulic winding and unwinding machine. The whole coating production of copper-clad aluminum is completed. The yield of the production line is about 95%. Compared with the production process in the prior art, the yield of the product is improved by about 5 percent. And the production line can completely produce 2000 m long copper-clad aluminum wires.
Preferably, the thickness of the copper strip in the step (1) is 0.38mm, and the width of the copper strip in the step (1) is 31.4 mm; the diameter of the aluminum rod is 8.6mm, the copper accounts for 15%, the aluminum accounts for 85%, and the linear diameter of the finished product is less than 3.00 mm.
Preferably, the process conditions need to be controlled during welding in the step (1), and the invention provides a feasible welding method, which comprises the following steps:
firstly, pure argon is sent into each tube and then reaches each required position, the flow rate is 8-10 kgf/cme/nin20 ℃ of a welding gun, the flow rate in a cladding machine is 30-40 kgf/cme/nin20 ℃, the gas is inflated for 5 minutes before welding, the height of a welding electrode is 1-1.8 mm, a phi 2.4mm tungsten electrode is adopted, and the tungsten electrode is adjusted after each welding disc is ensured so as to ensure the welding quality of the tungsten electrode. The welding current is 120-180A; the welding speed is about 20 m/min, the welding seam is about 1.5mm, whether the tungsten electrode is aligned with the welding seam or not needs to be checked after the welding is started, and the brushing condition, the change of welding current and the change of welding speed need to be checked at any time in the welding process so as to ensure the welding quality. Cutting off the non-brushed parts of the copper strip and the aluminum rod when the wire take-up cylinder is wound for about 20 circles, and sealing the ends in time; when the welding is carried out at 3/4, the sealed end head is taken down to facilitate gas discharge, and the welding process is immediately switched to a stretching process (about 5-10 minutes).
The welding quality requirements are as follows: the welding seam is full, and both sides are linear and bright. The phenomena of open welding and hole punching do not occur in the welding process.
Wherein, the heat treatment of the combined aluminum rod and copper strip in the step (2) can adopt the conventional method in the field, and the invention provides an optional method as follows:
21) before a product (an aluminum rod and a copper strip which are combined together) is loaded into a vacuum tank, various instruments, safety valves, pressure vacuum meters, circulating cooling water pipes, thermocouples, a working power supply, a vacuum pump, a ventilator and sealing rings of a control box of the tank are carefully checked whether the instruments, the safety valves, the pressure vacuum meters, the circulating cooling water pipes, the thermocouples and the working power supply, the vacuum pump, the ventilator and the sealing rings are normal or not, whether different changes exist;
22) whether the inner surface of the tank is clean or not is checked, no water accumulation or no oil stain exists, and the tank is required to be cleaned and wiped clean before being filled with the tank each time;
23) canning: the hanging bracket which is well placed with the wire to be withdrawn is stably and accurately hung in the tank, and the surface of the wire cannot be contacted with the tank body, so that the wire is prevented from being damaged and scratched; the fastening bolts are aligned up and down and are symmetrically fastened, so that the air leakage caused by uneven stress is prevented;
24) after the bolts are fastened, connecting a vacuum pipe, opening a cooling water valve before vacuumizing, inserting a rubber pipe into an exhaust port in the tank, paying attention to the fact that air cannot leak, starting a vacuum pump, fastening the fastening bolts if no abnormity exists, pumping gas for 15 minutes when a vacuum pressure gauge indicates-0.1 Mpa, ensuring that no residual gas exists in the tank, closing an air outlet valve, cutting off a power supply of the vacuum pump, and avoiding air from flowing back into the tank,
25) opening an argon valve before filling argon into the tank, removing air in the pipe, inserting the pipe into an air inlet, filling nitrogen to 0.02Mpa, closing the valve of the air inlet, closing the nitrogen valve,
26) the annealing of heating will treat that the vacuum tank of annealing steadily puts into the stove, connects condenser tube, opens the water valve, checks whether cooling water, circulation are normal back everywhere, starts the fan, inserts the thermocouple, then starts the heater, adjusts temperature control instrument, because the annealing line footpath is different, and the annealing temperature is different, specifically sees appendix table 1.
TABLE 1 Heat treatment temperature and Cooling time
And (3) after heat treatment in the step (2), drawing by adopting a conventional technical means in the field.
The annealing treatment of the copper-clad aluminum wire obtained in the step (3) can adopt a conventional method in the field, and the invention provides a selectable method which is as follows:
31) preparation before annealing: adjusting and controlling the temperature according to the product requirements, heating the copper-clad aluminum wire within the range of 260-295 ℃, putting the obtained copper-clad aluminum wire into an annealing hanger in order, then putting the copper-clad aluminum wire into an annealing tank, sealing the annealing tank, vacuumizing the annealing tank, injecting argon gas, and then putting the tank into a furnace;
32) heating, heat preservation and cooling: heating the first furnace for 2.5 hours, preserving heat for 2.5 hours, taking out the tank and cooling; continuously heating for 2 hours in a second furnace, keeping the temperature for 2.5 hours, taking out and cooling, naturally cooling for 12 hours until the surface temperature of the tank reaches below 60 ℃, then opening the cover and taking out the annealed copper-clad aluminum wire,
33) the temperature of the annealing furnace of the wire core is generally controlled below 300 ℃, and the wiring speed is determined according to the size of the cross section of the conductor. Because the annealing temperature of the copper wire is low, the steam quantity generated during the cooling of the water inlet tank is small, the oxidation phenomenon occurs occasionally, and in order to increase the steam quantity and improve the steam density, the temperature of the water tank is not too low and is generally controlled to be about 70 ℃; meanwhile, the conductor sleeve at the wire inlet end is required to be sleeved on the wire running pipe to reduce the cross section of a water vapor outlet and relieve the passivity of steam at the inlet, so that the conductor is in a stable preheating state, and the softening effect is improved.
The rewinding in the step (4) can adopt a conventional method in the field, and the invention provides an alternative method as follows:
41) rewinding the annealed copper-clad aluminum wire monofilament onto a cable reel, inspecting the quality of the cable reel during rewinding, and indicating the number, the weight and the like;
42) when the copper-clad aluminum wire is rewound, the conditions of surface finish degree, size and the like of the wire are checked, the wire is required to be arranged neatly and uniformly, and the phenomena of loose loops and wire pressing are avoided;
43) phi 775 cable drum: the weight is not less than 330kg (except for special requirements of users), and the upper limit is not more than 2.5cm away from the outer edge of the cable drum according to the actual weight of materials and the requirements of customers; phi 1020 cable drum: 1000kg-1200kg, and the distance from the outer edge of the cable reel is not more than 2.5 cm.
44) When the wire is rewound, the winding speed needs to be controlled, and the machine is not too fast, so that the machine can be stopped for processing if a problem is found.
The stranding in the step (5) can adopt a conventional method in the field, and the stranded wire is composed of a plurality of single wires. Generally, the single wires constituting the stranded wire are many and thin, so that the flexibility of the electric wire cable is increased, and the reliability of the line connection is improved. Some wire and cable conductors do not require a large cross section, but are twisted for better flexibility or high reliability, resulting in an energy-efficient composite conductor.
The production line has reasonable process, perfect preparation and strong operability, and is the most advanced production line of the domestic production process at present.
The energy-saving copper-clad aluminum composite conductor provided by the invention is prepared by a copper-aluminum composite molding process, an aluminum core wire is adopted to replace copper to form a cable main body, and a copper layer with a certain proportion is coated outside the aluminum core wire to obtain the energy-saving composite conductor. The energy-saving composite conductor combines the functional advantages of copper and aluminum, and the use amount of copper is reduced to a certain extent by adopting the measure of a copper-clad aluminum composite conductor. In terms of cable manufacturing cost, the cost of the raw material of the metal conductor of the aluminum conductor cable is much lower than that of the copper conductor cable, about one fourth of the cost, under the condition of the same current-carrying capacity.
The energy-saving composite conductor disclosed by the invention utilizes the principle of skin effect, production elements and innovative technologies such as a comprehensive production manufacturing process, a novel composite material heat treatment technology, a copper-aluminum cladding drawing atom metallurgy technology, a novel material stranding technology and the like to uniformly coat a copper layer on an aluminum core, so that atoms on a copper-aluminum interface are metallurgically combined and are drawn and stranded to form a novel conductive material with the characteristics of high strength, light weight, flexibility, environmental friendliness and the like. Compared with the traditional copper core cable, the temperature of the lead can be effectively reduced, copper materials are saved, and the line loss is reduced.
The invention also provides a high-performance long-life wire cable based on the energy-saving composite conductor. The high-performance long-life wire and cable based on the energy-saving composite conductor is composed of a conductor, an insulating layer, a filling layer, a wrapping layer and a sheath, wherein the insulating layer is wrapped outside the conductor, the wrapping layer and the sheath are sequentially arranged outside the insulating layer, the filling layer is arranged between the adjacent insulating layers and between the insulating layer and the wrapping layer, and the conductor is an energy-saving composite conductor, namely a copper-clad aluminum conductor.
Furthermore, the insulating layer is formed by adopting a three-layer co-extrusion technology and comprises an inner insulating layer and an outer insulating layer, wherein the inner insulating layer is an irradiation cross-linked polyethylene insulating layer, the outer insulating layer is an irradiation halogen-free polyolefin insulating layer, and a plurality of phase-splitting color strips protruding out of the outer insulating layer are formed on the outer surface of the outer insulating layer in an extrusion wrapping mode.
Furthermore, the section of the phase separation color bar is semicircular, and the color of the phase separation color bar on the outer insulating layer is different.
Further, the filling layer is formed by: is formed by directly extruding aluminum hydroxide and magnesium hydroxide in a gel state, and the aluminum hydroxide and the magnesium hydroxide in the gel state are densely filled in gaps of the insulating layer. The thermal conductivity coefficient of the filling layer is more than 100 times higher than that of air, and the filling layer can be immediately decomposed once being fired, so that aluminum hydroxide and magnesium hydroxide are changed into aluminum oxide and magnesium oxide, and simultaneously a large amount of crystal water is discharged, the temperature of a heated body (cable) is reduced by the generation of water vapor, and the heat radiation and the heat conduction inside an external flame are seriously blocked by the porous air pocket formed by the water vapor; the high thermal conductivity in normal state makes the rated current-carrying capacity of the cable not decrease or increase reversely (about 15% -20%), and when the flame is in fire, the cable is reversely inverted into a high thermal resistance material to prevent the invasion of high temperature inside.
Further, the wrapping layer is made of a halogen-free flame-retardant tape or a non-woven fabric material.
Further, the sheath is made of radiation cross-linked polyolefin sheath material.
The service life detection of the high-performance long-life wire and cable and the sheath is carried out according to a method specified in GB/T11026.1, and the service life of the cable at the average working temperature of 70 ℃ of a conductor is deduced through an Arrhenius curve.
The energy-saving copper-clad aluminum composite conductor and the high-performance long-life electric wire and cable based on the conductor provided by the invention are used as a composite conductor material, so that a large amount of copper materials can be saved, and compared with a pure copper cable, the energy-saving copper-clad aluminum composite conductor has the advantages of larger current-carrying capacity, smaller line loss and lower temperature rise. According to the actual operation case, the copper-clad aluminum core electric wire and cable can reduce the electric loss by 5-10% compared with a pure copper cable. Meanwhile, the copper-clad aluminum core wire and cable is more flexible, easier to form, light in weight and convenient to transport and construct.
The high-performance long-life wire and cable based on the energy-saving copper-clad aluminum composite conductor mainly has the characteristics of energy conservation, high performance and long service life, and particularly comprises the following components in percentage by weight:
1) the special design of copper-aluminum proportioning. The special design of the copper-aluminum ratio ensures that the copper-clad aluminum core wire meets the requirement of the power carrying capacity, and simultaneously greatly reduces the using amount of copper, reduces the cost of the wire, improves the performance of the wire and reduces the temperature rise of the wire.
2) And (3) using a copper-aluminum cladding welding technology. The technology is the basis and the premise of copper-clad aluminum core wire and cable manufacturing, and the uniformity of welding seams is the guarantee of the subsequent drawing process.
3) Copper-aluminum drawing annealing metallurgy fusion technology. The technology can realize uniform metallurgical bonding based on the principle of copper-aluminum interface, and ensure the conductivity and conductivity stability of the composite material.
Compared with the traditional copper core cable, the energy-saving composite conductor can effectively reduce the temperature of the lead, save copper materials and reduce the line loss. Because the temperature rise of the electric wire and the electric cable is reduced, the insulation material is not carbonized, and the insulation service life of the copper-clad aluminum core electric wire and the electric cable can meet the maintenance-free requirement of more than 30 years.
Drawings
FIG. 1: the structural schematic diagram of the high-performance long-life wire and cable based on the energy-saving composite conductor.
FIG. 2: the life end point value of each test temperature is determined based on the insulation life detection data of the high-performance long-life wire and cable of the energy-saving composite conductor in example 2, wherein K2 represents the elongation at break retention rate (%), and tau represents the thermal aging time (h).
FIG. 3: in example 2, the temperature index curve of the insulation life detection data of the high-performance long-life wire and cable based on the energy-saving composite conductor is shown.
FIG. 4: the specific detection data of the insulation life detection data of the high-performance long-life wire and cable based on the energy-saving composite conductor in the embodiment 2.
FIG. 5: the life end point value of each test temperature is determined based on the insulation life detection data of the high-performance long-life wire and cable sheath of the energy-saving composite conductor in example 2, wherein K2 represents the elongation at break retention rate (%), and tau represents the thermal aging time (h).
FIG. 6: in example 2, the temperature index curve of the insulation life detection data of the high-performance long-life wire and cable sheath based on the energy-saving composite conductor is shown.
FIG. 7: the specific detection data of the insulation life detection data of the high-performance long-life wire and cable sheath based on the energy-saving composite conductor in the embodiment 2.
Detailed Description
The invention is described in detail below with reference to the figures and specific embodiments.
Example 1
The preparation method of the energy-saving composite conductor comprises the following steps:
(1) the surface of the aluminum rod is coated with a copper strip, and then the longitudinal seam of the copper strip is welded under the protection of inert gas,
(2) the combined aluminum rod and copper strip are subjected to heat treatment and drawing to produce a copper-clad aluminum wire with good cladding,
(3) annealing treatment: annealing the obtained copper-clad aluminum wire,
(4) rewinding: the copper-clad aluminum wire after annealing treatment is subjected to compound winding,
(5) stranding: and twisting the wound conducting wire to obtain the energy-saving composite conductor.
Before the step (1), the aluminum rod is pretreated, and the pretreatment procedure comprises the following steps: paying off an aluminum rod, removing oil, cleaning, brightening, passivating, cleaning and drying. Pretreating the copper strip, wherein the pretreatment procedure comprises the following steps: the method comprises the steps of strip placing for coiling the copper strip, width fixing and edge cutting, oil removing, cleaning, brightening treatment, passivation, cleaning and drying.
The aluminum rod is drawn in a sizing mode after being paid off, so that the roundness of the aluminum rod is guaranteed during production, the drawn aluminum rod directly enters the deoiling cleaning mechanism, the deoiled aluminum rod is washed with clear water, the washed aluminum rod enters the neutralizing treatment mechanism, the aluminum rod is subjected to acid neutralizing treatment, the treated aluminum rod is cleaned with clear water, the cleaned aluminum rod is subjected to passivation treatment, the passivation treatment has the effect that the aluminum rod is required to be free of an aluminum oxide film during copper cladding, so that the bonding strength of aluminum and copper is guaranteed, the passivated aluminum rod is washed with clear water, the cleaned aluminum rod is dried, and the dried aluminum rod can completely meet the requirements of the production process.
Further, before the step (1), the copper strip is pretreated, and the pretreatment procedure comprises the following steps: the method comprises the steps of strip placing for coiling the copper strip, width fixing and edge cutting, oil removing, cleaning, brightening treatment, passivation, cleaning and drying.
The copper strips directly get into deoiling wiper mechanism after opening a book, the copper strips after the deoiling washes by the clear water again, the copper strips after the washing reentries neutralization treatment mechanism, carry out acid neutralization treatment to the copper strips, the copper strips after will handling again carries out the clear water washing, the copper strips after the washing still needs passivation treatment, passivation treatment's effect requires the copper strips to guarantee not have the copper oxide film when coating with the aluminium pole, in order to guarantee the bonding strength of copper and aluminium, the copper strips after the passivation again washs by the clear water, the copper strips after will wasing at last dries, the copper strips after the drying just can satisfy production technology's needs completely.
After the copper strip passes through the previous working procedures, the copper-clad aluminum wire with good cladding is produced through edge pressing, arc pressing, forming process, shaping process, argon arc welding, traction and twice drawing, and the copper-clad aluminum wire is orderly and equidistantly wound on a standard working disc of 1200 mm by a hydraulic winding and unwinding machine. The whole coating production of copper-clad aluminum is completed. The yield of the production line is about 95%. Compared with the production process in the prior art, the yield of the product is improved by about 5 percent. And the production line can completely produce 2000 m long copper-clad aluminum wires.
In the step (1), the thickness of the copper strip is 0.38mm, and the width of the copper strip is 31.4 mm; the diameter of the aluminum rod is 8.6mm, the copper accounts for 15%, the aluminum accounts for 85%, and the linear diameter of the finished product is less than 3.00 mm.
Technological conditions need to be controlled during welding in the step (1), and the invention provides a feasible welding method which comprises the following specific steps:
firstly, pure argon is sent into each tube and then reaches each required position, the flow rate is 8-10 kgf/cme/nin20 ℃ of a welding gun, the flow rate in a cladding machine is 30-40 kgf/cme/nin20 ℃, the gas is inflated for 5 minutes before welding, the height of a welding electrode is 1-1.8 mm, a phi 2.4mm tungsten electrode is adopted, and the tungsten electrode is adjusted after each welding disc is ensured so as to ensure the welding quality of the tungsten electrode. The welding current is 120-180A; the welding speed is about 20 m/min, the welding seam is about 1.5mm, whether the tungsten electrode is aligned with the welding seam or not needs to be checked after the welding is started, and the brushing condition, the change of welding current and the change of welding speed need to be checked at any time in the welding process so as to ensure the welding quality. Cutting off the non-brushed parts of the copper strip and the aluminum rod when the wire take-up cylinder is wound for about 20 circles, and sealing the ends in time; when the welding is carried out at 3/4, the sealed end head is taken down to facilitate gas discharge, and the welding process is immediately switched to a stretching process (about 5-10 minutes).
The welding quality requirements are as follows: the welding seam is full, and both sides are linear and bright. The phenomena of open welding and hole punching do not occur in the welding process.
The heat treatment of the combined aluminum rod and copper strip in step (2) may be carried out by the following method:
21) before a product (an aluminum rod and a copper strip which are combined together) is loaded into a vacuum tank, various instruments, safety valves, pressure vacuum meters, circulating cooling water pipes, thermocouples, a working power supply, a vacuum pump, a ventilator and sealing rings of a control box of the tank are carefully checked whether the instruments, the safety valves, the pressure vacuum meters, the circulating cooling water pipes, the thermocouples and the working power supply, the vacuum pump, the ventilator and the sealing rings are normal or not, whether different changes exist;
22) whether the inner surface of the tank is clean or not is checked, no water accumulation or no oil stain exists, and the tank is required to be cleaned and wiped clean before being filled with the tank each time;
23) canning: the hanging bracket which is well placed with the wire to be withdrawn is stably and accurately hung in the tank, and the surface of the wire cannot be contacted with the tank body, so that the wire is prevented from being damaged and scratched; the fastening bolts are aligned up and down and are symmetrically fastened, so that the air leakage caused by uneven stress is prevented;
24) after the bolts are fastened, connecting a vacuum pipe, opening a cooling water valve before vacuumizing, inserting a rubber pipe into an exhaust port in the tank, paying attention to the fact that air cannot leak, starting a vacuum pump, fastening the fastening bolts if no abnormity exists, pumping gas for 15 minutes when a vacuum pressure gauge indicates-0.1 Mpa, ensuring that no residual gas exists in the tank, closing an air outlet valve, cutting off a power supply of the vacuum pump, and avoiding air from flowing back into the tank,
25) opening an argon valve before filling argon into the tank, removing air in the pipe, inserting the pipe into an air inlet, filling nitrogen to 0.02Mpa, closing the valve of the air inlet, closing the nitrogen valve,
26) the annealing of heating will treat that the vacuum tank of annealing steadily puts into the stove, connects condenser tube, opens the water valve, checks whether cooling water, circulation are normal back everywhere, starts the fan, inserts the thermocouple, then starts the heater, adjusts temperature control instrument, because the annealing line footpath is different, and the annealing temperature is different, specifically sees appendix table 1.
TABLE 1 Heat treatment temperature and Cooling time
And (3) after heat treatment in the step (2), drawing by adopting a conventional technical means in the field.
The annealing treatment of the copper-clad aluminum wire obtained in the step (3) can adopt a conventional method in the field, and the invention provides a selectable method which is as follows:
31) preparation before annealing: adjusting and controlling the temperature according to the product requirements, heating the copper-clad aluminum wire within the range of 260-295 ℃, putting the obtained copper-clad aluminum wire into an annealing hanger in order, then putting the copper-clad aluminum wire into an annealing tank, sealing the annealing tank, vacuumizing the annealing tank, injecting argon gas, and then putting the tank into a furnace;
32) heating, heat preservation and cooling: heating the first furnace for 2.5 hours, preserving heat for 2.5 hours, taking out the tank and cooling; continuously heating for 2 hours in a second furnace, keeping the temperature for 2.5 hours, taking out and cooling, naturally cooling for 12 hours until the surface temperature of the tank reaches below 60 ℃, then opening the cover and taking out the annealed copper-clad aluminum wire,
33) the temperature of the annealing furnace of the wire core is generally controlled below 300 ℃, and the wiring speed is determined according to the size of the cross section of the conductor. Because the annealing temperature of the copper wire is low, the steam quantity generated during the cooling of the water inlet tank is small, the oxidation phenomenon occurs occasionally, and in order to increase the steam quantity and improve the steam density, the temperature of the water tank is not too low and is generally controlled to be about 70 ℃; meanwhile, the conductor sleeve at the wire inlet end is required to be sleeved on the wire running pipe to reduce the cross section of a water vapor outlet and relieve the passivity of steam at the inlet, so that the conductor is in a stable preheating state, and the softening effect is improved.
The rewinding in the step (4) can adopt a conventional method in the field, and the invention provides an alternative method as follows:
41) rewinding the annealed copper-clad aluminum wire monofilament onto a cable reel, inspecting the quality of the cable reel during rewinding, and indicating the number, the weight and the like;
42) when the copper-clad aluminum wire is rewound, the conditions of surface finish degree, size and the like of the wire are checked, the wire is required to be arranged neatly and uniformly, and the phenomena of loose loops and wire pressing are avoided;
43) phi 775 cable drum: the weight is not less than 330kg (except for special requirements of users), and the upper limit is not more than 2.5cm away from the outer edge of the cable drum according to the actual weight of materials and the requirements of customers; phi 1020 cable drum: 1000kg-1200kg, and the distance from the outer edge of the cable reel is not more than 2.5 cm.
44) When the wire is rewound, the winding speed needs to be controlled, and the machine is not too fast, so that the machine can be stopped for processing if a problem is found.
The stranding in the step (5) can adopt a conventional method in the field, and the stranded wire is composed of a plurality of single wires. Generally, the single wires constituting the stranded wire are many and thin, so that the flexibility of the electric wire cable is increased, and the reliability of the line connection is improved. Some wire and cable conductors do not require a large cross section, but are twisted for better flexibility or high reliability, resulting in an energy-efficient composite conductor.
In the embodiment, a copper-aluminum drawing annealing metallurgy fusion technology is adopted, the technology can realize uniform metallurgical bonding of a copper-aluminum interface principle, and the conductivity stability of the composite material are guaranteed. Specifically, in this embodiment, the key control points of the process include:
1) when feeding, whether the surface of the aluminum rod is abraded or not is checked at first, and the aluminum rod influencing the sizing roundness is cut off.
2) And (4) blanking according to the length of the copper strip blanking list and the length and weight of the aluminum rod.
3) Inspecting the ring forging machine and selecting a ring forging block.
4) Lubricating oils use a mixture of metal-drawing agents and engine oils, typically in a ratio of 1: 1, fine adjustment is carried out on the ratio of the metal drawing agent to the engine oil according to the surface viscosity of the stretched aluminum rod and the humidity degree of the aluminum rod, the metal drawing agent is slightly reduced due to the overlarge viscosity of the stretched aluminum rod, and the humidity metal drawing agent of the aluminum rod is relatively increased. When the amount of stretching reached 20 tons and the surface of the stretched aluminum rod was observed to be dirty, the lubricating oil was replaced.
5) Before stretching, whether the operation of the stretcher is normal or not is checked, and the speed of the stretcher is set to be 140 m/min. The specification of the die is selected according to the drawing wire diameter of the aluminum rod, the die is placed in the die groove in parallel and cannot be placed reversely or misplaced, the used die is replaced periodically, cleaning and polishing treatment are carried out for later use, and the out-of-tolerance die cannot be used.
6) An aluminum rod die: phi 10 welder specification: phi 9.2, phi 8.9 and phi 8.6mm, and the specification and tolerance of the tensile wire diameter (based on the aluminum rod after being cleaned)
7) Phi 10 welding machine aluminum rod wire diameter: Φ 8.6mm, tolerance ± 0.05mm, tensile mass: and observing whether the surface of the wire is scratched or not at any time during stretching.
8) Preparation before annealing: adjusting and controlling the temperature according to the product requirements, heating the materials to a temperature of between 260 and 295 ℃, putting the materials into an annealing hanger in order, then putting the materials into an annealing tank, sealing the annealing tank, vacuumizing the annealing tank, injecting argon gas, and then putting the tank into a furnace.
9) Heating, heat preservation and cooling: heating the first furnace for 2.5 hours, preserving heat for 2.5 hours, taking out the tank and cooling; continuously heating for 2 hours in a second furnace, keeping the temperature for 2.5 hours, taking out and cooling, naturally cooling for 12 hours until the surface temperature of the tank reaches below 60 ℃, opening the cover and taking out the annealing line.
10) The temperature of the annealing furnace of the wire core is generally controlled below 300 ℃, and the wiring speed is determined according to the size of the cross section of the conductor. Because the annealing temperature of the copper wire is low, the steam quantity generated during the cooling of the water inlet tank is small, the oxidation phenomenon occurs occasionally, and in order to increase the steam quantity and improve the steam density, the temperature of the water tank is not too low and is generally controlled to be about 70 ℃; meanwhile, the conductor sleeve at the wire inlet end is required to be sleeved on the wire running pipe to reduce the cross section of a water vapor outlet and relieve the passivity of steam at the inlet, so that the conductor is in a stable preheating state, and the softening effect is improved.
The cross section and resistivity of the energy-saving composite conductor obtained in the embodiment are compared with those of the conventional copper core conductor, and the results are shown in tables 1 and 2.
TABLE 1
According to the test data in table 1, the resistivity of the energy-saving composite conductor of the embodiment is basically consistent with that of the copper conductor, and the difference of the weight of the cable is 5% -10%.
TABLE 2
According to the test data in table 2, the resistivity of the energy-saving composite conductor of the embodiment is basically consistent with that of the copper conductor, and the weight difference of the cable is within the range of 3% -8%.
Example 2
The high-performance long-life wire and cable based on the energy-saving composite conductor is provided. The high-performance long-life wire and cable structure based on the energy-saving composite conductor is shown in figure 1 and comprises a conductor 1, an insulating layer 2, a filling layer 3, a wrapping layer 4 and a sheath 5, wherein the insulating layer is coated on the outer side of the conductor, the wrapping layer and the sheath are sequentially arranged on the outer side of the insulating layer, the filling layers are arranged between adjacent insulating layers and between the insulating layer and the wrapping layer, and the conductor is an energy-saving composite conductor, namely a copper-clad aluminum conductor.
In this embodiment, the insulating layer is formed by a three-layer co-extrusion technique, and includes an inner insulating layer and an outer insulating layer, where the inner insulating layer is an irradiation cross-linked polyethylene insulating layer, the outer insulating layer is an irradiation halogen-free polyolefin insulating layer, and a plurality of phase-splitting color bars protruding from the outer insulating layer are formed on the outer surface of the outer insulating layer by extrusion.
In this embodiment, the cross section of the phase splitting color bar is semicircular, and the color of the phase splitting color bar on the outer insulating layer is different.
In this embodiment, the filling layer is formed by: is formed by directly extruding aluminum hydroxide and magnesium hydroxide in a gel state, and the aluminum hydroxide and the magnesium hydroxide in the gel state are densely filled in gaps of the insulating layer. The thermal conductivity coefficient of the filling layer is more than 100 times higher than that of air, and the filling layer can be immediately decomposed once being fired, so that aluminum hydroxide and magnesium hydroxide are changed into aluminum oxide and magnesium oxide, and simultaneously a large amount of crystal water is discharged, the temperature of a heated body (cable) is reduced by the generation of water vapor, and the heat radiation and the heat conduction inside an external flame are seriously blocked by the porous air pocket formed by the water vapor; the high thermal conductivity in normal state makes the rated current-carrying capacity of the cable not decrease or increase reversely (about 15% -20%), and when the flame is in fire, the cable is reversely inverted into a high thermal resistance material to prevent the invasion of high temperature inside.
In this embodiment, the wrapping layer is made of a halogen-free flame retardant tape or a non-woven fabric material.
In this embodiment, the sheath is made of radiation cross-linked polyolefin sheath material.
The service life of the high-performance long-life wire and cable is detected according to a method specified in GB/T11026.1, and the service life of the cable at the average working temperature of 70 ℃ of a conductor is deduced through an Arrheius curve.
The life end point value of each test temperature is determined based on the insulation life detection data of the high-performance long-life wire and cable of the energy-saving composite conductor in the embodiment, and reference is made to fig. 2, wherein K2 represents the elongation at break retention rate (%), and tau represents the thermal aging time (h).
In this embodiment, the temperature index curve of the insulation life detection data of the high-performance long-life wire and cable based on the energy-saving composite conductor refers to fig. 3.
Specific detection data of the insulation life detection data of the high-performance long-life wire and cable based on the energy-saving composite conductor in the embodiment refer to fig. 4.
Referring to fig. 5, the life end point values at each test temperature of the insulation life test data of the high-performance long-life electric wire and cable sheath based on the energy-saving composite conductor in example 2 are determined, wherein K2 represents elongation at break retention (%), and τ represents the thermal aging time (h).
In this embodiment, the temperature index curve of the insulation life detection data of the high-performance long-life electric wire and cable sheath based on the energy-saving composite conductor refers to fig. 6.
Specific detection data of the insulation life detection data of the sheath of the high-performance long-life electric wire and cable based on the energy-saving composite conductor in the embodiment refer to fig. 7.
The embodiments described above are described to facilitate an understanding and use of the invention by those skilled in the art. It will be readily apparent to those skilled in the art that various modifications to these embodiments may be made, and the generic principles described herein may be applied to other embodiments without the use of the inventive faculty. Therefore, the present invention is not limited to the above embodiments, and those skilled in the art should make improvements and modifications within the scope of the present invention based on the disclosure of the present invention.
Claims (10)
1. The preparation method of the energy-saving composite conductor is characterized by comprising the following steps of:
(1) the surface of the aluminum rod is coated with a copper strip, and then the longitudinal seam of the copper strip is welded under the protection of inert gas,
(2) the combined aluminum rod and copper strip are subjected to heat treatment and drawing to produce the copper-clad aluminum wire,
(3) annealing treatment: annealing the obtained copper-clad aluminum wire,
(4) rewinding: the copper-clad aluminum wire after annealing treatment is subjected to compound winding,
(5) stranding: and twisting the wound conducting wire to obtain the energy-saving composite conductor.
2. The method for preparing the energy-saving composite conductor according to claim 1, wherein the aluminum rod is pretreated before the step (1), and the pretreatment procedure comprises the following steps: paying off an aluminum rod, removing oil, cleaning, brightening, passivating, cleaning and drying.
3. The method for preparing the energy-saving composite conductor according to claim 1, wherein the copper strip is pretreated before the step (1), and the pretreatment procedure comprises the following steps: the method comprises the steps of strip placing for coiling the copper strip, width fixing and edge cutting, oil removing, cleaning, brightening treatment, passivation, cleaning and drying.
4. The energy-saving composite conductor-based high-performance long-life wire and cable according to claim 1, wherein the high-performance long-life wire and cable comprises a conductor, an insulating layer, a filling layer, a wrapping layer and a sheath, the insulating layer is coated outside the conductor, the wrapping layer and the sheath are sequentially arranged outside the insulating layer, the filling layer is arranged between the adjacent insulating layers and between the insulating layer and the wrapping layer, and the conductor is the energy-saving composite conductor according to claim 1.
5. The high-performance long-life wire and cable according to claim 4, wherein the insulation layer is formed by a three-layer co-extrusion technique and comprises an inner insulation layer and an outer insulation layer, the inner insulation layer is an irradiation cross-linked polyethylene insulation layer, the outer insulation layer is an irradiation halogen-free polyolefin insulation layer, and a plurality of phase-splitting color strips protruding from the outer insulation layer are formed on the outer surface of the outer insulation layer in an extrusion manner.
6. The high-performance long-life wire and cable according to claim 5, wherein the cross section of the phase separation color strip is semicircular, and the color of the phase separation color strip on the outer insulation layer is different.
7. The high performance long life electrical wire cable of claim 4 wherein said filler layer is formed by: is formed by directly extruding aluminum hydroxide and magnesium hydroxide in a gel state, and the aluminum hydroxide and the magnesium hydroxide in the gel state are densely filled in gaps of the insulating layer.
8. The high-performance long-life wire and cable according to claim 4, wherein the wrapping layer is made of halogen-free flame retardant tape or non-woven fabric material.
9. The high-performance long-life electric wire and cable according to claim 4, wherein the sheath is made of radiation cross-linked polyolefin sheath material.
10. The high performance long life wire and cable of claim 4 wherein said high performance long life wire and cable is a four core structure.
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| US3800405A (en) * | 1971-10-26 | 1974-04-02 | Kabel Metallwerke Ghh | Method for producing copper-clad aluminum wire |
| JPS6360017A (en) * | 1986-08-29 | 1988-03-16 | Showa Electric Wire & Cable Co Ltd | Manufacture of copper covered aluminum wire |
| CN1851833A (en) * | 2006-05-23 | 2006-10-25 | 金亚东 | Aluminium in copper alloy line, and its preparing method and production apparatus |
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