阅读说明：本技术 一种翻车机用特种电缆的制造方法及电缆 (Manufacturing method of special cable for dumper and cable ) 是由 王嘉豪 何志峰 金国 祝军 凌国桢 于 2021-08-27 设计创作，主要内容包括：一种翻车机用特种电缆的制造方法,包括步骤：1)制造电缆导体；2)挤包导体绝缘层和钢丝绳外护层；3)线芯、抗拉绳和填充绳成缆绕包；4)编织镀锡铜丝屏蔽层；5)挤包氟塑料内护套；6)挤包尼龙外护套。一种所述制造方法制得电缆,是由镀锡导体外挤包绝缘层构成的线芯；由钢丝绳与外挤包钢丝绳护层构成的抗拉绳；多根线芯和一根抗拉绳以及填充绳共同绞合成缆芯,缆芯外依次包裹聚酯带、屏蔽层、内护套和外护套。本电缆制造方法制得电缆可良好的解决户外高强度翻车机设备电缆使用需求,达到径向防水、优良的抗拉、耐磨、耐高低温、防紫外线、屏蔽抗干扰等性能。(A manufacturing method of a special cable for a dumper comprises the following steps: 1) manufacturing a cable conductor; 2) extruding a conductor insulating layer and a steel wire rope outer protective layer; 3) the wire core, the tensile rope and the filling rope are cabled and wrapped; 4) weaving a tinned copper wire shielding layer; 5) extruding and wrapping a fluoroplastic inner sheath; 6) and extruding and wrapping a nylon outer sheath. The cable manufactured by the manufacturing method is a wire core formed by extruding and coating an insulating layer outside a tinned conductor; the tensile rope is formed by a steel wire rope and an outer extruded steel wire rope protective layer; a plurality of wire cores, one tensile rope and the filling rope are jointly twisted into a cable core, and a polyester belt, a shielding layer, an inner sheath and an outer sheath are sequentially wrapped outside the cable core. The cable manufactured by the cable manufacturing method can well meet the use requirement of outdoor high-strength car dumper equipment cables, and achieves the performances of radial water resistance, excellent tensile strength, wear resistance, high and low temperature resistance, ultraviolet resistance, shielding, interference resistance and the like.)

1. A manufacturing method of a special cable for a dumper is characterized by comprising the following steps:

1) manufacturing a cable conductor;

2) extruding a conductor insulating layer and a steel wire rope outer protective layer;

3) the wire core, the tensile rope and the filling rope are cabled and wrapped;

4) weaving a tinned copper wire shielding layer;

5) extruding and wrapping a fluoroplastic inner sheath;

6) a nylon outer sheath is extruded and wrapped,

the step 1) comprises the following steps:

1.1) preformed monofilaments:

drawing: drawing the copper rod into filaments by adopting corresponding wire drawing dies respectively;

the wire drawing process comprises the following steps: sequentially penetrating a copper rod into a plurality of wire drawing dies according to the pass, and enabling the single-wire cambered surface to correspond to the die hole cambered grooves, so that the stable stress of the copper wire is ensured, and the section of the single wire is free from deviation;

1.2) plating a tin layer outside the bare copper monofilament to prepare the tin-plated copper monofilament, wherein the thickness of the tin layer is controlled to be 0.7-0.9 mu m.

1.3) taking the tin-plated copper monofilaments as required to form a conductor in a stranded mode;

the step 2) comprises the following steps: silicon rubber insulating materials are extruded outside the conductor and the steel wire rope, and a wire core and an anti-tensile rope are respectively manufactured;

the temperature zone of the rubber extruding machine for extruding the silicon rubber insulating material is controlled as follows: 140-160 ℃ in the first area, 150-190 ℃ in the second area, 190-200 ℃ in the third area, 200-220 ℃ in the fourth area and 220-230 ℃ in the fifth area; the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections; setting the temperature of the machine head: 250 ℃;

preheating the conductor before the conductor enters an extruding machine, wherein the preheating temperature is 100 +/-10 ℃;

the extrusion mode of the silicon rubber insulating material is an extrusion mode, during the extrusion process, the steam pressure is 14-16 bar, the production speed is 7-9 m/min, and the rotating speed of a screw of an extrusion rubber machine is 20-30 r/min;

water cooling in a cold water tank for 20 min; the water temperature of the cold water tank is controlled to be 8-15 ℃;

the step 3) comprises the following steps:

3.1) performing cabling and stranding on the plurality of wire cores, the 1 anti-stretching rope and the plurality of filling ropes on a cabling machine to prepare a cable core; the tensile cord is at an axial position;

the cabling direction is left, and the cabling pitch-diameter ratio is controlled to be 12-14 times; before cabling, the tension of each coil wire core is uniformly adjusted;

the rotating speed of a stranding cage of the cable former is 66-78 r/min, and the traction speed of the cable former is 20-30 m/min;

3.2) lapping polyester tapes outside the cable core in an overlapping way;

when wrapping, the traction speed is 40-60 m/min, and the wrapping pitch is 30 mm;

the step 4) comprises the following steps: a braiding machine is used, and a tinned copper wire is adopted to braid and shield outside the cable core to manufacture a shielding layer; the weaving density is not less than 80%;

the step 5) comprises the following steps: extruding fluoroplastic outside the shielding layer to prepare an inner sheath, wherein the extrusion mode is a pipe extrusion mode;

the temperature area of the plastic extruding machine for extruding fluoroplastics is controlled as follows: 130-180 ℃ in the first area, 180-200 ℃ in the second area, 200-230 ℃ in the third area, 225-245 ℃ in the fourth area and 240-260 ℃ in the fifth area; the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections; setting the temperature of the machine head: 280 ℃;

the semi-finished product after fluoroplastic extrusion is cooled in sections: the temperature of the first section of water tank is 50-70 ℃, and the temperature of the second section of water tank is room temperature;

when the fluoroplastic is extruded, the cable head is lifted off the water surface;

the step 6) comprises the following steps: extruding nylon sheath material to obtain an outer sheath, wherein the extrusion mode is a tube extrusion mode;

6.1) carrying out preheating treatment on the cable prepared in the step 5);

6.2) drying the nylon sheath material;

6.3) controlling the temperature zone of the extruding machine for extruding and coating the nylon sheath material as follows: the first area is 201 ℃, the second area is 212 ℃, the third area is 232 ℃, the fourth area is 230 ℃, the fifth area is 233 ℃ and the sixth area is 235 ℃; the first zone and the second zone are feeding sections, the third zone and the fourth zone are plasticizing sections, and the fifth zone and the sixth zone are homogenizing sections; the temperature of the machine neck is 241 ℃, the first area of the machine head is 241 ℃, and the second area of the machine head is 244 ℃;

6.4) the nylon sheath is cooled by sectional water, the water temperature of the first section of water tank is 50-70 ℃, and the water of the second section of water tank is normal temperature.

2. The manufacturing method of a special cable for a dumper according to claim 1, characterized in that in step 1.1), the diameter range of the tin-plated copper monofilament is 0.32 mm-0.85 mm; in the step 1.3), the diameter range of the conductor is 1.6 mm-2.5 mm; the stranding direction of the tin-plated copper monofilament is the left direction, and the stranding pitch diameter ratio is 18-25 times.

3. The manufacturing method of the special cable for the dumper as claimed in claim 1, wherein the nominal thickness range of the insulation layer and the steel wire rope sheath is 0.6-0.8 mm, and the thickness of the thinnest point is more than or equal to 90-0.1 mm of the nominal value.

4. The method for manufacturing a special cable for a dumper as claimed in claim 1, wherein in the step 3.1), the number of the wire cores is 3-16, and the cross-sectional area of the conductor of each wire core is 1.5mm²～4mm²；

The filling rope is formed by twisting a high-temperature-resistant polypropylene reticular tearing film;

in the step 3.2), the nominal thickness of the polyester tape is 0.04mm, the lapping overlapping width is not less than 5mm, and the lapping pitch is 30 mm.

5. The method for manufacturing a special cable for the dumper as claimed in claim 1, wherein in the step 3.1), the tensile rope is formed by wrapping a steel wire rope sheath outside the steel wire rope; the steel wire rope is formed by twisting 49 steel wires with the nominal diameter of 0.17mm, and the twist pitch diameter ratio is 20-25 times; the nominal thickness of the steel wire rope protective layer is 0.7mm, the outer diameter of the tensile rope is 3.1mm, the difference between the outer diameter of the tensile rope and the outer diameter of the wire core is not more than 1.0mm, and the tensile strength of the steel wire rope is 14KN/mm²。

6. The manufacturing method of the special cable for the dumper according to claim 1, wherein in the step 4), the nominal diameter range of the tinned copper wire is 0.15-0.20 mm; the weaving pitch was 46 mm.

7. The manufacturing method of the special cable for the dumper as claimed in claim 1, wherein in the step 5), the nominal thickness of the inner sheath is 0.8-1.0 mm, and the thickness of the thinnest point is more than or equal to 80% of the nominal value.

8. The manufacturing method of the special cable for the dumper as claimed in claim 1, wherein in the step 6), the nominal thickness range of the outer sheath is 1.0-1.2 mm, and the thickness of the thinnest point is more than or equal to 85-0.1 mm of the nominal value.

9. A cable manufactured by the manufacturing method of any one of claims 1 to 8, which is characterized in that a core formed by extruding an insulating layer outside a tinned conductor; the tensile rope is formed by a steel wire rope and an outer extruded steel wire rope protective layer; the cable comprises a plurality of wire cores, an anti-tensile rope and a filling rope which are twisted together into a cable core, wherein a polyester tape, a shielding layer, an inner sheath and an outer sheath are sequentially wrapped outside the cable core;

the tinned conductor is formed by stranding tinned copper monofilaments, and the diameter range of the tinned copper monofilaments is 0.32-0.85 mm; the diameter range of the conductor is 1.6 mm-2.5 mm; the stranding direction of the tin-plated copper monofilament is left, and the stranding pitch diameter ratio is 18-25 times;

the insulating layer is made of silicon rubber insulating material, the nominal thickness range of the insulating layer is 0.6-0.8 mm, and the thickness of the thinnest point is more than or equal to 90-0.1 mm of the nominal value;

the filling rope is a high-temperature-resistant polypropylene reticular tearing film;

the polyester tape is provided with a nominal thickness of 0.04mm, and the lapping overlapping width is not less than 5 mm;

the shielding layer is formed by weaving metal weaving wires; the nominal diameter range of the weaving silk is 0.15-0.20 mm, and the weaving density is not less than 80%; the metal braided wire is a tinned copper wire;

the inner sheath is made of fluoroplastic sheath materials, the nominal thickness of the inner sheath is 0.8-1.0 mm, and the thickness of the thinnest point is more than or equal to 80% of the nominal value;

the outer sheath is made of nylon sheath materials, the nominal thickness range of the outer sheath is 1.0-1.2 mm, and the thickness of the thinnest point is larger than or equal to 85-0.1 mm of the nominal value.

Technical Field

The invention relates to a novel special cable for equipment and a cable manufacturing method, in particular to a special cable with excellent tensile property, wear resistance, high and low temperature resistance, ultraviolet resistance, radial water resistance, shielding anti-interference performance and the like for an outdoor high-strength dumper, and belongs to the technical field of cables.

Background

The cable for the equipment has special service environment, and especially the cable for the outdoor high-strength car dumper has higher requirements on the performances of tensile strength, wear resistance, high and low temperature resistance, ultraviolet resistance, radial water resistance, shielding, interference resistance and the like of the cable, the cable for the conventional equipment cannot meet the requirements, and the problem is solved by matching a special cable in order to avoid potential safety hazards generated in the high-strength use process of the equipment.

Disclosure of Invention

In order to solve the technical problems, the invention provides a manufacturing method of a special cable for a dumper, and the manufacturing method can realize the manufacturing of the special cable product through the specific structural design, material use and production process control of the cable.

A manufacturing method of a special cable for a dumper comprises the following steps:

1) manufacturing a cable conductor 2;

2) the conductor insulating layer 3 and the steel wire rope outer protective layer 9 are extruded;

3) the wire core, the tensile rope and the filling rope 4 are cabled and wrapped;

4) weaving a tinned copper wire shielding layer 5;

5) extruding and wrapping a fluoroplastic inner sheath 6;

6) a nylon outer sheath 7 is extruded and wrapped,

the step 1) comprises the following steps:

1.1) preformed monofilaments:

drawing: drawing the copper rod into filaments by adopting corresponding wire drawing dies respectively;

the wire drawing process comprises the following steps: sequentially penetrating a copper rod into a plurality of wire drawing dies according to the pass, and enabling the single-wire cambered surface to correspond to the die hole cambered grooves, so that the stable stress of the copper wire is ensured, and the section of the single wire is free from deviation;

1.2) plating a tin layer outside the bare copper monofilament to prepare the tin-plated copper monofilament, wherein the thickness of the tin layer is controlled to be 0.7-0.9 mu m.

1.3) taking the tin-plated copper monofilaments as required to form a conductor in a stranded mode;

the step 2) comprises the following steps: silicon rubber insulating materials are extruded outside the conductor and the steel wire rope, and a wire core and an anti-tensile rope are respectively manufactured;

the temperature zone of the rubber extruding machine for extruding the silicon rubber insulating material is controlled as follows: 140-160 ℃ in the first area, 150-190 ℃ in the second area, 190-200 ℃ in the third area, 200-220 ℃ in the fourth area and 220-230 ℃ in the fifth area; the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections; setting the temperature of the machine head: 250 ℃;

preheating the conductor before the conductor enters an extruding machine at the preheating temperature of 100 +/-10 ℃;

the extrusion mode of the silicon rubber insulating material is an extrusion mode, during the extrusion process, the steam pressure is 14-16 bar, the production speed is 7-9 m/min, and the rotating speed of a screw of an extrusion rubber machine is 20-30 r/min;

water cooling in a cold water tank for 20 min; the water temperature of the cold water tank is controlled to be 8-15 ℃;

the step 3) comprises the following steps:

3.1) performing cabling and stranding on the plurality of wire cores, the 1 anti-stretching rope and the plurality of filling ropes on a cabling machine to prepare a cable core; the tensile cord is at an axial position;

the tensile rope consists of a steel wire rope and a steel wire rope protective layer, the steel wire rope is formed by twisting 49 steel wires with the nominal diameter of 0.17mm, the twisting pitch diameter ratio is 20-25 times, the nominal thickness of the steel wire rope protective layer is 0.7mm, and the calculated outer diameter of the tensile rope is 3.1 mm; the difference between the outer diameter of the tensile rope and the outer diameter of the wire core is not more than 1.0mm, the tensile strength of the steel wire rope in the tensile rope is obviously superior to that of the copper core in the wire core and reaches 14KN/mm²。

The cabling direction is left, and the cabling pitch-diameter ratio is controlled to be 12-14 times; before cabling, the tension of each coil wire core is uniformly adjusted;

the rotating speed of a stranding cage of the cable former is 66-78 r/min, and the traction speed of the cable former is 20-30 m/min;

the anti-stretching rope is placed at the central axis position instead of the outer layer during cabling, so that the problems of unstable structure and non-round appearance caused by incomplete consistency of the outer diameters of the anti-stretching rope and the wire core can be avoided, the tensile strength of a finished cable product is obviously improved, and the cable is prevented from breaking the wire core under the high-strength operation of the tipper.

3.2) lapping polyester tapes outside the cable core in an overlapping way;

when wrapping, the traction speed is 40-60 m/min, and the wrapping pitch is 30 mm;

the step 4) comprises the following steps: a braiding machine is used, and a tinned copper wire is adopted to braid and shield outside the cable core to manufacture a shielding layer; the weaving density is not less than 80%; the weaving pitch is 46 mm;

the step 5) comprises the following steps: extruding fluoroplastic (preferably polyfluorinated ethylene propylene) outside the shielding layer to prepare an inner sheath, wherein the extrusion mode is a pipe extrusion mode;

the temperature area of the plastic extruding machine for extruding fluoroplastics is controlled as follows: 130-180 ℃ in the first area, 180-200 ℃ in the second area, 200-230 ℃ in the third area, 225-245 ℃ in the fourth area and 240-260 ℃ in the fifth area; the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections; setting the temperature of the machine head: 280 ℃;

the semi-finished product after fluoroplastic extrusion is cooled in sections: the temperature of the first section of water tank is 50-70 ℃, and the temperature of the second section of water tank is room temperature;

when the fluoroplastic is extruded, the cable head is lifted off the water surface;

the step 6) comprises the following steps: extruding nylon sheath material to obtain an outer sheath, wherein the extrusion mode is a tube extrusion mode;

6.1) carrying out preheating treatment on the cable prepared in the step 5);

6.2) drying the nylon sheath material;

6.3) controlling the temperature zone of the extruding machine for extruding and coating the nylon sheath material as follows: the first area is 201 ℃, the second area is 212 ℃, the third area is 232 ℃, the fourth area is 230 ℃, the fifth area is 233 ℃ and the sixth area is 235 ℃; the first zone and the second zone are feeding sections, the third zone and the fourth zone are plasticizing sections, and the fifth zone and the sixth zone are homogenizing sections; the temperature of the machine neck is 241 ℃, the first area of the machine head is 241 ℃, and the second area of the machine head is 244 ℃;

and 6.4) cooling the nylon sheath by adopting sectional water, wherein the water temperature of the first section of water tank is 50-70 ℃, and the water of the second section of water tank is normal temperature.

In the step 1.1), the diameter range of the tin-plated copper monofilament is 0.32 mm-0.85 mm; in the step 1.3), the diameter range of the conductor is 1.6 mm-2.5 mm; the stranding direction of the tin-plated copper monofilament is the left direction, and the stranding pitch diameter ratio is 18-25 times.

The nominal thickness range of the insulating layer and the steel wire rope protective layer is 0.6-0.8 mm, and the thickness of the thinnest point is more than or equal to 90-0.1 mm of the nominal value.

In the step 3.1), the number of the wire cores is 3-16, and the sectional area of the conductor of each wire core is 1.5mm²～4mm²；

The filling rope is formed by twisting a high-temperature-resistant polypropylene reticular tearing film;

in the step 3.2), the nominal thickness of the polyester tape is 0.04mm, and the lapping overlapping width is not less than 5 mm.

In the step 4), the nominal diameter range of the tinned copper wire is 0.15-0.20 mm.

In the step 5), the nominal thickness of the inner sheath is 0.8-1.0 mm, and the thickness of the thinnest point is more than or equal to 80% of the nominal value.

In the step 6), the nominal thickness range of the outer sheath is 1.0-1.2 mm, and the thickness of the thinnest point is more than or equal to 85-0.1 mm of the nominal value.

Advantageous effects

After the technical scheme is adopted, the invention has the following beneficial effects:

in order to meet the special application environment of the cable for the outdoor high-strength dumper, the requirements of the cable on the performances of tensile strength, wear resistance, high and low temperature resistance, ultraviolet resistance, radial water resistance, shielding, interference resistance and the like are met.

(1) The silicon rubber material, the fluoroplastic material and the nylon outer sheath material have good high and low temperature resistance, and are respectively used as an insulating layer, an inner sheath and an outer sheath of a cable, the tinned conductor can prevent a copper wire from being oxidized and blackened in high-temperature and humid conditions, the reliability of the conductor is improved, the silicon rubber also has good electrical performance, and the material combination has excellent electrical performance and can meet the high and low temperature resistance requirements of a use environment.

(2) The tensile rope consists of a steel wire rope and a silicon rubber protective layer, and the tensile property of the cable can be greatly improved.

(3) The tinned copper braided wire has waterproof performance and can play a good role in shielding and resisting interference on the cable.

(4) The nylon outer sheath is extruded by a special process, and the nylon material has good fatigue resistance stability, impact resistance, wear resistance and ultraviolet resistance while playing a role in radial water prevention.

On the basis of newly designed cable shape structure, the cable simultaneously uses specific structural parameters, material combination and processing technology to achieve the effects of tensile resistance, wear resistance, high and low temperature resistance, ultraviolet resistance, radial water resistance, shielding, interference resistance and the like of the cable, and can be well suitable for normal operation of an outdoor high-strength car dumper.

Drawings

FIG. 1 is a schematic view of the radial structure of the cable of the present invention;

in the figure: the cable comprises a tinned conductor 1, an insulating layer 2, a filling rope 3, a polyester belt 4, a shielding layer 5, an inner sheath 6, an outer sheath 7, a steel wire rope 8 and a steel wire rope protective layer 9.

Detailed Description

The technical scheme is further explained by combining the drawings and the specific embodiment as follows:

referring to fig. 1, the cable manufacturing method of this example produces a cable structure: a wire core formed by extruding and wrapping an insulating layer 2 outside a tinned conductor 1; the tensile rope is composed of a steel wire rope 8 and an outer extruded steel wire rope protective layer 9; a plurality of wire cores, a tensile rope and a filling rope 3 are jointly twisted into a cable core, and a polyester tape 4, a shielding layer 5, an inner sheath 6 and an outer sheath 7 are sequentially wrapped outside the cable core.

In the embodiment, the tinned conductor is formed by stranding tinned copper monofilaments, and the diameter range of the tinned copper monofilaments is 0.32-0.85 mm; the diameter range of the conductor is 1.6 mm-2.5 mm; the stranding direction of the tin-plated copper monofilament is the left direction, and the stranding pitch diameter ratio is 18-25 times. The tinned conductor can prevent the copper wire from being oxidized and blackened when being wetted at high temperature, and the reliability of the conductor is improved.

The insulating layer is made of silicon rubber insulating materials, the nominal thickness range of the insulating layer is 0.6-0.8 mm, and the thickness of the thinnest point is larger than or equal to 90-0.1 mm of the nominal value. The filling rope of the cable is a high-temperature-resistant polypropylene reticular tearing film, and is tightly filled in the middle of the cable core in the cabling process, so that the effects of improving the roundness of the cable and enhancing the waterproof performance are achieved.

The polyester tape is provided with a nominal thickness of 0.04mm, and the lapping overlapping width is not less than 5 mm; the shielding layer is formed by weaving metal weaving wires; the nominal diameter range of the weaving silk is 0.15-0.20 mm; the weaving density is not less than 80%; the metal braided wire is a tinned copper wire. The inner sheath is made of fluoroplastic sheath materials, the nominal thickness of the inner sheath is 0.8-1.0 mm, and the thickness of the thinnest point is larger than or equal to 80% of the nominal value. The outer sheath is made of nylon sheath materials, the nominal thickness range of the outer sheath is 1.0-1.2 mm, and the thickness of the thinnest point is larger than or equal to 85-0.1 mm of the nominal value.

The cable can well meet the use requirements of outdoor high-strength car dumper equipment cables, and achieves the performances of radial water resistance, excellent tensile strength, wear resistance, high and low temperature resistance, ultraviolet resistance, shielding, interference resistance and the like.

The insulation material can be silicon rubber insulation material XJ-80A, and the manufacturer is Suzhou Renaude Cable materials Co.

In this example, fluoroplastic _ F46 was used as the inner sheath, and the manufacturer was Olympic plastics, Inc. of Tianchang.

In this example, the outer sheath is made of nylon 12 sheath material _ L25W40X, and the manufacturer is Switzerland EMS (China) trade company Limited.

The cable manufacturing method comprises the following steps: 1) manufacturing a cable conductor; 2) extruding a conductor insulating layer and a steel wire rope outer protective layer; 3) the wire core, the tensile rope and the filling rope are cabled and wrapped; 4) weaving a tinned copper wire shielding layer; 5) extruding and wrapping a fluoroplastic inner sheath; 6) an extruded nylon outer sheath, which is characterized in that

The step 1) comprises the following steps:

1.1) preformed monofilaments:

drawing: drawing the copper rod into filaments by adopting corresponding wire drawing dies respectively;

the wire drawing process comprises the following steps: sequentially penetrating a copper rod into 11 wire drawing dies according to the pass, and enabling the single-wire arc surface to correspond to the die hole arc groove, so that the stress stability of the copper wire is ensured, and the section of the single wire is free from deviation;

1.2) plating a tin layer outside the bare copper monofilament, wherein the thickness of the tin layer is controlled to be 0.7-0.9 μm.

1.3) stranding the tin-plated copper monofilaments prepared in the step 1.2) to form the conductor.

The step 2) comprises the following steps: the conductor and the steel wire rope are externally extruded with silicon rubber materials to form a wire core and an anti-stretching rope, and the temperature zone of an extrusion rubber machine for extruding the silicon rubber is controlled as follows: 140-160 ℃ in the first area, 150-190 ℃ in the second area, 190-200 ℃ in the third area, 200-220 ℃ in the fourth area and 220-230 ℃ in the fifth area; the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections; setting the temperature of the machine head: 250 ℃; because of the adoption of the silicon rubber material, the application temperature range is wider, and the silicon rubber insulating material not only can provide better insulating property, but also has better production adaptability.

The temperature of the machine head part needs to be accurately controlled, and meanwhile, the conductor needs to be subjected to preheating treatment, wherein the preheating temperature is (100 +/-10) DEG C; the measures lead the insulating material to be wrapped more tightly, and the defects of air bubbles and the like are not easy to generate in the process.

The extrusion mode of the silicone rubber is an extrusion mode, during the extrusion process, the steam pressure is 14-16 bar, the production speed is 7-9 m/min, and the rotating speed of a screw of an extrusion rubber machine is 20-30 r/min;

water cooling in a cold water tank for 20 min; the water temperature of the cold water tank is controlled to be 8-15 ℃; after the conductor wrapped with the insulating material is fully cooled at low temperature, the molecular structure of the insulating material is good in stability, and the insulating material is wound on a wire coil to avoid deformation of a wire core and uneven in insulating thickness.

The step 3) comprises the following steps: cabling and stranding the wire core, the tensile rope and the filling rope on cabling machine equipment, wherein the cabling direction is the left direction, and the cabling pitch-diameter ratio is controlled to be (12-14) times; the tension of each coil wire core is uniformly adjusted before cabling. The cabled cable core is round, compact, stable in structure, correct in twisting direction, uniform in pitch, continuous, complete and clear in number. No defects such as creek, oil stain scratch and the like. The outer layer of the cable core is lapped by a layer of polyester tape with nominal thickness of 0.04mm, and the lapping overlapping width is not less than 5 mm; when the tape is wrapped, the tension of the tape is uniformly adjusted, and the wrapping is continuous, complete, flat and compact, and the covering is uniform.

The step 4) comprises the following steps: the cable core is shielded by adopting a tinned copper wire woven fabric, the parallel and pay-off tension of the tinned copper wire is uniformly adjusted, the flat cable is compact, and the phenomena of crossing, line pressing, line stacking and line disorder are avoided;

the braid is not allowed to be integrally connected, and burrs caused by root and strand breakage must be repaired to the root. The replacement of the wire bar is allowed 1 time per 1 meter. When the braided filaments are broken in the braiding process, the insertion type treatment is needed, and the exposed monofilaments are repaired to be flat. Two repairs are not allowed to occur at the same position, and each repair place is at least 1m apart; the weaving density is not less than 80%.

Step 5) comprises extruding a fluoroplastic inner sheath outside the shielding layer, wherein the extrusion mode is a tube extrusion mode, and the temperature zone of an extruding machine extruding fluoroplastic is controlled as follows: 130-180 ℃ in the first area, 180-200 ℃ in the second area, 200-230 ℃ in the third area, 225-245 ℃ in the fourth area and 240-260 ℃ in the fifth area; the first zone is a feeding section, the second zone and the third zone are plasticizing sections, and the fourth zone and the fifth zone are homogenizing sections; setting the temperature of the machine head: 280 ℃; the semi-finished product after fluoroplastic extrusion is cooled in sections: the temperature of the first section of water tank is 50-70 ℃, and the temperature of the second section of water tank is normal temperature. During extrusion molding, the cable head should be lifted away from the water surface, and axial water inflow is not allowed. Preferably, the polyfluorinated ethylene propylene has a wide processing temperature range, and is easy to introduce into production. During cooling, temperature-division and sectional cooling is required to avoid influence of fluoroplastic solidification and shrinkage unevenness on the precision of the subsequent process.

The step 6) comprises extruding a nylon outer sheath on the outermost layer, wherein the extrusion mode is a tube extrusion mode, and the reference temperature and the attention items of nylon extrusion are shown in table 1;

TABLE 1

In order to optimize the cable performance, the nylon sheath material is adopted. The jacket material has high requirements on the precision of processing temperature, and the temperature is controlled accurately. In order to repeatedly combine the inner and outer sheath materials with large property difference, the cable is preheated before the outer sheath is manufactured. Because the inner sheath is heated in the extrusion process, the cooling requirement of the fluoroplastic is brought into consideration in the process of cooling.

Detection by destructive dissection test: the control deviation of the outer diameter of the cable conductor is +/-0.1 mm, the control deviation of the outer diameter of the cable insulation wire core is +/-0.2 mm, and the control deviation of the outer diameter of the finished cable of the same specification is +/-0.5 mm, so that the cable can be perforated and laid in equipment. And (3) controlling the softness: the hardness of the material is controlled, wherein the hardness of the insulating material is less than or equal to 60A. Through detection, the detection requirements of the cable on the electrical property, the mechanical property and the special property are shown in table 2, and in the detection items in table 2, the results are all qualified:

TABLE 2

Serial number	Name of item	Data of
			1	Electrical performance of cable
1.1	Conductor DC resistance test	11.2Ω/km
			1.2	AC voltage test	2.5kV/5min without breakdown
1.3	Insulation resistance test at maximum rated temperature	35MΩ·km
			2	Structural size of cable
2.1	Insulation thickness (average thickness)	0.7mm
			2.2	Nominal diameter of braided copper wire	0.20mm
2.3	Sheath thickness (average thickness)	1.0mm
			2.4	Outer diameter of cable	14.5mm
2.5	Roundness of cable	0.8mm
			3	Insulating mechanical and physical properties
3.1	Test of original mechanical properties of insulation	17.2 Mpa; the elongation at break is 350%
			3.2	Insulation aging mechanical property test (high temperature resistance)	18.5 Mpa; elongation at break of 300%
3.3	Insulation ozone resistance test	No cracking of the sample
			4	Abrasion resistance test of sheath	YJB125/150 round trip 236 times
5	Ultraviolet resistance test of sheath	Satisfy the requirement of
			6	Ozone resistance test of sheath	No cracking of the sample
7	Low temperature tensile test of sheath	Elongation at break 320%
			8	Cable single flame retardant test	Satisfy the requirement of
9	Screening inhibition factor test	Shielding suppression coefficient 0.02

The experimental conditions of the tensile property, the high and low temperature resistance, the shielding property, the ultraviolet resistance and the wear resistance of the cable are shown in the following table 3:

TABLE 3