CN109065250B - Ceramic insulation separation conductor high-voltage cable and single-wire copper conductor manufacturing method - Google Patents
Ceramic insulation separation conductor high-voltage cable and single-wire copper conductor manufacturing method Download PDFInfo
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- 239000004020 conductor Substances 0.000 title claims abstract description 150
- 239000000919 ceramic Substances 0.000 title claims abstract description 80
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 title claims abstract description 69
- 229910052802 copper Inorganic materials 0.000 title claims abstract description 66
- 239000010949 copper Substances 0.000 title claims abstract description 66
- 238000009413 insulation Methods 0.000 title claims abstract description 42
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 27
- 238000000926 separation method Methods 0.000 title claims description 13
- 239000011224 oxide ceramic Substances 0.000 claims abstract description 34
- 229910044991 metal oxide Inorganic materials 0.000 claims abstract description 33
- 150000004706 metal oxides Chemical class 0.000 claims abstract description 33
- 238000000034 method Methods 0.000 claims abstract description 22
- 239000004065 semiconductor Substances 0.000 claims abstract description 21
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 12
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 12
- 238000006243 chemical reaction Methods 0.000 claims description 40
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 claims description 31
- 239000002002 slurry Substances 0.000 claims description 22
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 claims description 19
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 17
- 239000000395 magnesium oxide Substances 0.000 claims description 14
- 239000000843 powder Substances 0.000 claims description 13
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 12
- 238000000137 annealing Methods 0.000 claims description 10
- 239000011780 sodium chloride Substances 0.000 claims description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 8
- 238000010438 heat treatment Methods 0.000 claims description 7
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 7
- 229910000480 nickel oxide Inorganic materials 0.000 claims description 7
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000002184 metal Substances 0.000 claims description 5
- 238000007493 shaping process Methods 0.000 claims description 5
- 238000007664 blowing Methods 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 4
- 238000000576 coating method Methods 0.000 claims description 4
- 229910052759 nickel Inorganic materials 0.000 claims description 4
- 229910001948 sodium oxide Inorganic materials 0.000 claims description 4
- KKCBUQHMOMHUOY-UHFFFAOYSA-N sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 claims description 3
- 238000007599 discharging Methods 0.000 claims description 2
- 238000005253 cladding Methods 0.000 claims 4
- 239000004411 aluminium Substances 0.000 claims 2
- 230000000903 blocking effect Effects 0.000 claims 2
- 230000003139 buffering effect Effects 0.000 claims 2
- 238000005192 partition Methods 0.000 claims 1
- 230000000149 penetrating effect Effects 0.000 claims 1
- 230000002500 effect on skin Effects 0.000 abstract description 9
- 239000010426 asphalt Substances 0.000 abstract description 8
- 238000005260 corrosion Methods 0.000 abstract description 5
- 230000008569 process Effects 0.000 description 11
- 238000002955 isolation Methods 0.000 description 10
- QPLDLSVMHZLSFG-UHFFFAOYSA-N Copper oxide Chemical compound [Cu]=O QPLDLSVMHZLSFG-UHFFFAOYSA-N 0.000 description 7
- 230000000694 effects Effects 0.000 description 7
- 229960004643 cupric oxide Drugs 0.000 description 6
- 239000005751 Copper oxide Substances 0.000 description 5
- 230000005540 biological transmission Effects 0.000 description 5
- 229910000431 copper oxide Inorganic materials 0.000 description 5
- 238000005516 engineering process Methods 0.000 description 5
- 229910052574 oxide ceramic Inorganic materials 0.000 description 5
- NTGONJLAOZZDJO-UHFFFAOYSA-M disodium;hydroxide Chemical compound [OH-].[Na+].[Na+] NTGONJLAOZZDJO-UHFFFAOYSA-M 0.000 description 4
- 238000004513 sizing Methods 0.000 description 4
- 238000005491 wire drawing Methods 0.000 description 4
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 3
- 239000010440 gypsum Substances 0.000 description 3
- 229910052602 gypsum Inorganic materials 0.000 description 3
- XLYOFNOQVPJJNP-ZSJDYOACSA-N heavy water Substances [2H]O[2H] XLYOFNOQVPJJNP-ZSJDYOACSA-N 0.000 description 3
- 238000005406 washing Methods 0.000 description 3
- 238000004804 winding Methods 0.000 description 3
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 2
- 239000000292 calcium oxide Substances 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 238000004132 cross linking Methods 0.000 description 2
- 238000001125 extrusion Methods 0.000 description 2
- 230000001050 lubricating effect Effects 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 241001391944 Commicarpus scandens Species 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000002468 ceramisation Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005265 energy consumption Methods 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 239000003292 glue Substances 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000000314 lubricant Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 239000002086 nanomaterial Substances 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- UKLNMMHNWFDKNT-UHFFFAOYSA-M sodium chlorite Chemical compound [Na+].[O-]Cl=O UKLNMMHNWFDKNT-UHFFFAOYSA-M 0.000 description 1
- 229960002218 sodium chlorite Drugs 0.000 description 1
- PVGBHEUCHKGFQP-UHFFFAOYSA-N sodium;n-[5-amino-2-(4-aminophenyl)sulfonylphenyl]sulfonylacetamide Chemical compound [Na+].CC(=O)NS(=O)(=O)C1=CC(N)=CC=C1S(=O)(=O)C1=CC=C(N)C=C1 PVGBHEUCHKGFQP-UHFFFAOYSA-N 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 238000010301 surface-oxidation reaction Methods 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- 239000004636 vulcanized rubber Substances 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/30—Insulated conductors or cables characterised by their form with arrangements for reducing conductor losses when carrying alternating current, e.g. due to skin effect
- H01B7/303—Conductors comprising interwire insulation
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B9/00—Power cables
- H01B9/006—Constructional features relating to the conductors
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Insulated Conductors (AREA)
Abstract
The invention discloses a ceramic insulation separated conductor high-voltage cable and a single-wire copper conductor manufacturing method, wherein the ceramic insulation separated conductor high-voltage cable comprises a plurality of strands of fan-shaped section wire harness conductors, a semiconductor tape wrapping layer wrapping the wire harness conductors, a cross-linked insulating layer wrapping the semiconductor tape wrapping layer, a semiconductor buffer water-blocking tape wrapping layer wrapping the cross-linked insulating layer, an aluminum sheath wrapping the semiconductor buffer water-blocking tape wrapping layer, an asphalt anti-corrosion layer wrapping the aluminum sheath, and an outer sheath layer wrapping the asphalt anti-corrosion layer, wherein the wire harness conductors comprise a plurality of single-wire copper conductors, a metal oxide ceramic layer is formed on the surface of the single-wire copper conductors by using a ceramic treatment method, the resistance difference between the ceramic layer and the pure copper conductors is used as an internal eddy current insulating layer of the conductor wire harness, each single-wire copper conductor is insulated, the circulation of eddy current in the conductors is, thereby reducing the skin effect of the alternating current high-voltage cable with larger diameter and section.
Description
Technical Field
The invention relates to the technical field of power transmission and wire and cable industry, in particular to a design and manufacturing technology of a ceramic insulation separation conductor high-voltage cable and a method for reducing eddy current loss in a conductor.
Background
The high-voltage alternating current cable can generate skin effect and proximity effect in use, and the theory of the high-voltage alternating current cable is as follows: for alternating currents, self-induced electromotive forces occur in the conductors against the passage of the current. Taking a conductor with a circular cross section as an example: the closer to the center of the conductor, the larger the self-induced electromotive force is generated; the closer to the surface, the less the self-induced electromotive force is. This results in a greater current density towards the surface of the conductor. Since the self-induced electromotive force increases with increasing frequency, the skin effect is more pronounced with increasing frequency. When power frequency (50Hz) current passes through the conductor, the current only flows in a thin layer on the surface of the conductor, the equivalent cross section of current carrying is reduced, the resistance is increased, and simultaneously eddy current heating is generated in the conductor, so that the energy loss is increased (about 10-15% of the current carrying capacity). The physical phenomenon is always a technical problem which is difficult to solve in the wire and cable industry, and the design concept of general selection is a cable structure with insulated and isolated conductors. The specific measures proposed in the prior published patent application nos. CN200131053240X, CN201410678887X, CN201410678950X, CN201410684864X, CN2014107092413, CN2014107662262, CN2014207249063, etc. can be divided into seven categories: (1) an insulating water-barrier tape; (2) insulating and water-proof paste; (3) insulating crepe paper; (4) a semiconductor shielding nonwoven fabric; (5) vulcanized rubber; (6) insulating adhesive glue; (7) the technical problems that the skin effect is reduced, the current-carrying capacity of the cable can be improved, and the eddy current electric energy loss of the internal conductor of the high-voltage cable is reduced are solved. These methods of isolating conductors inevitably present the following technical problems in the production of high-voltage cables with large cross-sections:
1) The high-voltage cable is easy to break the insulating isolation layer on a production line, so that the yield of the cable is reduced;
2) The insulating isolation layer is too thick, so that the molding size of the cable is too large and does not meet the requirements of the existing related technical standards;
3) The paper and textile isolation layer is easily affected with damp, so that the local breakdown inside the cable is caused;
4) Each bundle of conductors with the fan-shaped cross section is extruded to form a bundle of insulating layers, and the insulating layers cannot be insulated and isolated from each other inside the bundle of conductors, so that the phenomenon of eddy current generation is not treated;
5) The thickness of the copper oxide layer on the surface of the conductor is uneven, and part of the adjacent surface of the conductor is crushed in production, so that the isolation effect is lost.
Technical information is queried, M.Takaoka et al, IEEE Transaction on Power Apparatus and Systems, (Vol.PAS-99, No.3May/June) in 1980 published a "Development of Flexible Joint for Large Capacity sub-location O.F.Cable" paper, and proposed: for 500kV cables, sodium chlorite and alkali (NaCIO) were used as chemicals2NaOH) oxidizes the surface of the formed wire harness, so that the skin effect of alternating current transmission is reduced, and the current-carrying capacity of the cable is improved. This technique is also mentioned in the "practical SEGMENTAL CONDUCTORS WITH CUPRIC OXIDE FILM-INSULATED STRANDS" published in the 1983 article by Wire Journal International Vol.16, Issue 10. The following patent applications, US4325750, US4411710, US4571453 and US5094703, all disclose such techniques. In appearance, the bundle conductors are subjected to surface oxidation treatment to achieve the function of insulation and isolation, but in practice, sufficient insulation and isolation cannot be formed inside each bundle, and therefore, generation of eddy current inevitably consumes electric energy.
The general opinion in the power transmission and transformation technology industry is that the current-carrying capacity of a conductor (cable) is improved, the measure is not only that the skin effect is reduced by insulating the surface conductor of the wire harness, but also that the eddy current loss is reduced by maintaining the insulation of the inner conductor of the wire harness, and the cable structure design which is reasonable and adapts to the production process conditions is also provided. The core problems of the prior art in the wire and cable industry are as follows:
1) The skin effect of the cable cannot be avoided, particularly the eddy current energy consumption in the conductor cannot be avoided due to the fact that the alternating current high-voltage cable with a larger diameter and a larger cross section is generated, and the eddy current loss is reduced.
2) The extrusion process of forming the fan-shaped section for improving the dense filling coefficient of the wire harness exists in the cable production. How to maintain the conductor insulation isolation layer from being damaged.
3) The high temperature heating in the cable production must be maintained at a temperature at which the single-wire conductors are not softened and deformed. How to form conductor insulation isolation layers.
how to solve the technical problems and realize the reduction of the electric energy eddy current loss of the high-voltage alternating-current cable, and finding a proper conductor insulation and isolation measure is the technical problem to be solved by the invention.
Disclosure of Invention
the invention aims to solve the technical problem of providing a ceramic insulation separation conductor high-voltage cable and a single-wire copper conductor manufacturing method, and measures for reducing eddy current loss in conductors are provided.
In order to solve the technical problems, the invention adopts the following technical scheme: a ceramic insulation separation conductor high-voltage cable comprises a multi-strand fan-shaped section wire harness conductor, a semiconductor tape wrapping layer wrapping the wire harness conductor, a cross-linked insulating layer wrapping the semiconductor tape wrapping layer, a semiconductor buffer water-blocking tape wrapping layer wrapping the cross-linked insulating layer, an aluminum sheath wrapping the semiconductor buffer water-blocking tape wrapping layer, an asphalt anticorrosive layer wrapping the aluminum sheath, and an outer sheath layer wrapping the asphalt anticorrosive layer, wherein the wire harness conductor comprises a plurality of single-wire copper conductors, and metal oxide ceramic layers are arranged on the surfaces of the single-wire copper conductors.
Preferably, the metal oxide ceramic layer comprises copper oxide, magnesium oxide, sodium oxide, calcium oxide, and nickel oxide.
Preferably, the metal oxide ceramic layer has a thickness in the range of 0.20mm to 0.65 mm.
preferably, the resistances of the metal oxide ceramic layer and the single wire copper conductor differ in value by 1011。
According to the technical scheme, the metal oxide ceramic layer is formed on the surface of the single-wire copper conductor by using a ceramic treatment method, the resistance difference between the ceramic layer and the pure copper conductor is used as an internal eddy current insulation layer of the conductor wire harness, each single-wire copper conductor is insulated, the circulation of eddy current in the conductor is fully isolated, the eddy current loss is inhibited, and the skin effect of the alternating-current high-voltage cable with larger diameter and section is reduced.
The invention also provides a manufacturing method of the ceramic insulation separation conductor high-voltage cable single-wire copper conductor, the single-wire copper conductor reaches the single-wire diameter required by a high-voltage cable product, then the single-wire copper conductor is heated to the annealing temperature and penetrates into the ceramic reaction tube, a plurality of tube joints are arranged on the side surface of the reaction tube, nano-scale powder and slurry are added into the reaction tube in a pressure blowing mode through the tube joints, the nano-scale powder and the slurry are subjected to chemical reaction in the reaction tube, and a metal oxide ceramic layer is formed on the surface of the heated single-wire copper conductor, wherein the nano-scale powder and the slurry comprise water vapor, sodium oxide, sodium chloride, sodium hydroxide, calcium sulfate, magnesium oxide and nickel oxide on the tube wall.
by adopting the technical scheme, the metal oxide ceramic layer is formed on the surface of the single-wire copper conductor by using a ceramic treatment method, cannot be removed in the water washing process, and can be used as a solid lubricant between the single wires in the wire harness stranding process to achieve the purpose of protecting the ceramic insulation of the inner layer, so that the metal oxide ceramic layer subjected to the ceramic insulation treatment on the surface of the copper conductor can not be damaged, and a foundation is laid for realizing a high-voltage cable structure with the conductor fully isolated.
Preferably, the ceramic reaction tube is a nickel-based metal tube.
Preferably, the ceramic reaction tube is vertically arranged, and a single-line outlet shaping die is arranged at the upper part of the ceramic reaction tube to play a role in rounding the metal oxide ceramic layer.
preferably, a ceramic slurry outlet for discharging unreacted ceramic slurry is provided at a lower portion of the ceramic reaction tube.
Preferably, the single-wire copper conductor penetrates into the ceramic reaction tube through a single-wire guide wheel, the single-wire guide wheel is a conductive contact guide wheel, and a large current of 50V DC and more than 2000A is applied between the conductive contact guide wheels of the single-wire copper conductor.
Preferably, the single copper conductor is heated to an annealing temperature range of 550 ℃ to 600 ℃ by a conductive contact guide wheel.
The following detailed description of the present invention will be provided in conjunction with the accompanying drawings.
Drawings
the invention is further described with reference to the accompanying drawings and the detailed description below:
FIG. 1 is a schematic view of a single-wire copper conductor coated with a metal oxide ceramic layer;
FIG. 2 is a schematic view of a single-wire copper conductor surface ceramization process;
FIG. 3 is a schematic view of the densification of the oxide ceramic layer at the conductor outlet;
FIG. 4 is a schematic view of ceramic slurry outflow from the ceramic slurry outflow port;
FIG. 5 is a schematic view of a fan-shaped wire harness shaped from round strands;
Fig. 6 is a schematic structural diagram of a ceramic insulated divided conductor high voltage cable.
In the figure: 1-a copper conductor; 2-copper oxide (CuO); 3-magnesium oxide (MgO); 4-calcium oxide (CaO); 5-sodium oxide (NaO); 6-nickel oxide (NiO); 7-single line copper conductor movement direction; 8-ceramic reaction tube; 9-conductor heating power supply; 10-conductive contact guide wheel; 11-single line outlet sizing die; 12-Water vapor (Air + H)2O); 13-sodium oxide (NaO); 14-sodium chloride (NaCl); 15-sodium hydroxide (NaOH); 16-calcium sulfate (Gypsum Fibrosum CaSO)4 2H2O); 17-magnesium oxide (MgO); 18-ceramic slurry outflow; 19-a metal oxide ceramic layer; 20-ceramic sizing die; 21-oxide ceramic slip; 22-semiconductor tape winding layer; 23-crosslinking the insulating layer; 24-semiconductor buffer water-blocking tape layer; 25-an aluminum sheath; 26-asphalt anticorrosive coating; 27-outer cross-linked insulating layer.
Detailed Description
In the first embodiment, referring to fig. 1, a single-wire copper conductor 1 is provided with a metal oxide ceramic layer on the surface of the single-wire copper conductor 1.
Wherein the metal oxide ceramic layer comprises copper oxide 2, magnesium oxide 3, calcium oxide 4, sodium oxide 5 and nickel oxide 6. By steam (Air + H)2o), sodium oxide (NaO), sodium chloride (NaCl), sodium hydroxide (NaOH), calcium sulfate (gypsum CaSO)4 2H2The slurry is brought into contact with the surface of a copper conductor in a hot annealed state (550 ℃ to 600 ℃) to form a dense metal oxide ceramic layer, and the slurry is doped with metal oxide ceramic powders such as magnesium oxide (MgO), calcium oxide (CaO), sodium oxide (NaO), and nickel oxide (NiO).
One of ordinary skill in the art would recognize that: the ceramic material is necessarily sintered into a massive structure, but otherwise, the ceramic material may be a powdered mixture, and a portion of the metal oxide may be firmly bonded to the metal to form the insulating layer. The copper oxide can be pasted on the surface of the single-wire copper conductor in a nano-scale structure, other metal oxides are pasted on the outer surface of the single-wire copper conductor, the metal oxides cannot be removed in the water washing process, and the copper oxide can be used as lubricating powder between the single wires in the twisting process of the wire harness to achieve the purpose of protecting ceramic insulation of the inner layer.
the high-voltage alternating-current cable produced by the oxide ceramic insulating copper conductor can realize that: the eddy current power loss of 10% in the using process of the cable is reduced, the skin effect of the cable is reduced, the power transmission efficiency is improved, the insulation layer of a single wire in the cable production is not damaged, and the production cost is reduced.
The metal oxide ceramic layer has a thickness of 0.20mm to 0.65mm, good bonding with the copper conductor, deformation resistance (die extrusion) plasticity along with conductor deformation, and a resistance different from the copper conductor by 10 in value11The resistance of (2). The thickness requirement of single line surface ceramic insulation is the requirement of high voltage cable structural design, and too thick can increase high voltage cable's external diameter, and too thin can influence insulating effect.
A metal oxide ceramic layer is arranged on the surface of the single-wire conductor, and the resistance difference between the ceramic layer and the pure copper conductor is utilized to be 1011As an inner eddy current insulation layer of the conductor wire harness. However, in many single-wire surface insulation layer production technologies in the wire and cable technology industry, it is difficult to determine whether the production technology, design structure requirements, technical requirements constrained by engineering application, and the like of the high-voltage cross-linked cable can be met. The insulating layer is broken in the bundling process of the single wires, the cable structure is influenced by the thickness of the single wires, and the insulating effect is influenced by moisture. Therefore, the method for manufacturing the single-wire copper conductor is very important to prevent the metal oxide ceramic layer from breaking and falling off and to prevent the thickness from being too large.
Second embodiment, referring to fig. 2 to 4, in view of the important effect of the manufacturing method of the single-wire copper conductor on the performance of the surface metal oxide ceramic layer, the present invention provides a method for manufacturing a single-wire copper conductor of a high-voltage cable with a ceramic insulation separation conductor, wherein after the single-wire copper conductor reaches the single-wire diameter required by the high-voltage cable product and is heated, the single-wire copper conductor penetrates into a ceramic reaction tube 8 according to the moving direction 7 of the single-wire copper conductor, a plurality of tube joints are arranged on the side surface of the reaction tube, nano-scale powder and slurry are added into the reaction tube by blowing through the tube joints by pressure, and the materials in the ceramic reaction tube 8 simultaneously undergo chemical reactions of oxidation and reduction when encountering the hot surface of the copper conductor. Some are abrupt technical oxidation processes doped with metal oxide inclusions, and some are reaction rate-moderated to maintain the copper conductor surface from erosion, and finally to form the metal oxide ceramic layer 19.
Wherein the nanoscale powder and slurry comprise water vapor (Air + H)2O)12, sodium oxide (NaO)13, sodium chloride (NaCl)14, sodium hydroxide (NaOH)15, calcium sulfate (gypsum CaSO)4 2H2O)16 and magnesium oxide (MgO) 17.
Wherein the ceramic reaction tube 8 is a nickel-based metal tube. Due to the use of the nickel-based metal tube, the metal oxide ceramic layer may contain a small amount of nickel oxide.
The ceramic reaction tube 8 is vertically arranged, and a single-line outlet shaping die 11 is arranged at the upper part of the ceramic reaction tube. The lower part of the ceramic reaction tube is provided with a ceramic slurry outlet 18. The ceramic sizing die 20 is embedded in the single-wire outlet sizing die 11, so that redundant ceramic powder is removed, and the function of rounding the metal oxide ceramic layer is achieved. The ceramic slurry outlet allows the oxide ceramic slurry 21 to flow out, and the oxide ceramic slurry 21 can be recycled and blown into the ceramic reaction tube 8 again under air pressure to participate in the chemical reaction.
The ceramic reaction device is fused in a continuous annealing device of a copper wire drawing machine, and a single-wire copper conductor penetrates into the ceramic reaction tube through a single-wire guide wheel, so that the ceramic reaction device is suitable for the wire winding speed of about 20 m/s.
in the embodiment, the single wire guide wheels are conductive contact guide wheels 10, the conductive contact guide wheels 10 are connected with a conductor heating power supply 9, 50VDC and large current of about 2000-2500A are applied between the conductive contact guide wheels 10 of the single wires through the conductor heating power supply 9, and the applied current depends on the temperature of the conductor. The heating is carried out at the annealing temperature range of 550-600 ℃. At the annealing temperature, the single-wire copper conductor can be in a soft state, but the basic tensile strength cannot be lost, so that the single-wire copper conductor can be completely adapted to the working condition of copper wire drawing machine equipment by matching with proper take-up tension.
After being washed by water, the copper conductor single wire is dried before being taken up by a wire drawing machine. In fact, the process is rapid cooling after continuous annealing on a copper wire drawing machine, the single wire is cooled by a water tank, the application performance of the ceramic insulating layer cannot be influenced, and redundant alkaline substances are removed.
in the second embodiment, referring to fig. 6, a ceramic insulation separated conductor high-voltage cable includes a plurality of strands of fan-shaped cross-section wire harness conductors, a semiconductor tape wrapping layer 22 wrapping the wire harness conductors, a cross-linked insulation layer 23 wrapping the semiconductor tape wrapping layer, a semiconductor buffer water-blocking tape wrapping layer 24 wrapping the cross-linked insulation layer, an aluminum sheath 25 wrapping the semiconductor buffer water-blocking tape wrapping layer, an asphalt anti-corrosion layer 26 wrapping the aluminum sheath, and an outer sheath layer 27 wrapping the asphalt anti-corrosion layer.
The section of the ceramic insulation separation conductor high-voltage cable is 1000-2500mm2，
As shown in fig. 5, the tension and the pressure of the pressing wheel of the wire twisting machine can be properly controlled during twisting the single-wire copper conductor 1 subjected to ceramic insulation treatment into a round twisted wire, so as to maintain the ceramic insulation layer from being damaged. And then forming the sector-shaped section stranded wire by a plurality of shaping dies (or pressing wheels), wherein the number of the shaping dies is properly increased in the process so as to reduce the damage of deformation pressure on the ceramic insulating layer on the surface of the single-wire copper conductor. And then the cable enters a cabling machine to be stranded to form a conductor structure required by the cross-linked high-voltage cable, and a local large ceramic insulation layer can be broken in the process, but the integral split insulation isolation effect of the cable conductor is not influenced.
According to the production process of a common cross-linked high-voltage cable, a ceramic insulation separation conductor is used without the technical difficulty of restriction, a semiconductor tape is wound on the outer surface of the conductor by winding, and then the production process of a cross-linked layer is carried out to form a cross-linked insulation layer. Then the semi-conductor buffer water-blocking tape is wrapped and directly sent into a Commform aluminum extruder to form a straight pipe aluminum sheath. The straight pipe aluminum sheath has an excellent effect on balancing local capacitance parameters of the cable, and can avoid local discharge damage of the high-voltage cable. Then coating an asphalt anti-corrosion layer, and forming an outer sheath layer on the outer layer, thereby producing the ceramic insulation separation conductor high-voltage cable. The whole production line is continuous and is independently carried out in the production link of the copper conductor.
Except for the ceramic insulation treatment of the surface of the single-wire conductor, the other structures are the technical means which are conventional in the wire and cable technical industry, thereby maintaining the technical foundation of the invention.
Table 1: experimental result of cable with same section of common conductor surface and conductor subjected to surface ceramic treatment
As listed in table 1, the experimental results of the ceramic insulated high-voltage cable with separated conductors disclosed by the present invention and the ordinary high-voltage cable with the same section and specification show that: under the same experimental conditions, the temperature rise is reduced by about 8%, and the converted current-carrying capacity is improved by about 8%. This means that the technical content proposed by the present invention can indeed reduce the electric energy of eddy current loss in the high-voltage cable, which is a measure for saving the electric energy loss economic benefit in the electric energy transmission process in the order of hundreds of millions.
The invention also provides a method for reducing the eddy current loss in the conductor of the ceramic insulation separation conductor high-voltage cable, which comprises the following steps:
Step 1, after a neutral or alkaline lubricating liquid is used to reach the diameter of a single wire required by a high-voltage cable product on a single-wire copper conductor, the single wire is penetrated into a special ceramic equipment reaction tube through a single-wire guide wheel, and a large current of about 50VDC 2000A is applied between tension pulleys at two ends of the single wire to heat the single wire. The magnitude of the current depends on the annealing temperature of the single-wire conductor;
step 2, blowing steam (Air + H) into the reaction tube at a pressure of 1.2bar2O), sodium oxide (NaO), sodium chloride (NaCl), sodium hydroxide (NaOH), calcium sulfate (gypsum CaSO)4 2H2O), magnesium oxide (MgO), and other nanoscale powders and slurries. Grinding the solid material to obtain powder of 1200 mesh or larger;
And 3, performing ceramic insulation treatment on the surfaces of the single wires in the reaction tube, then feeding the single wires into a washing tank through a guide wheel, wherein the surfaces of the washed single wire copper conductors are in a black and lusterless state, and directly feeding the single wire copper conductors into a wire-rewinding machine. At the moment, the take-up tension is properly controlled, the annealed and softened single-wire copper conductor cannot be deformed, and the surface of the single-wire copper conductor is broken to form a ceramic insulating layer;
Step 4, stranding the wire harness by using the single-wire copper conductor subjected to ceramic insulation treatment, and properly adjusting the forming die of the stranding machine to maintain small deformation of the single wire, particularly proper pressure on the wire harness in a transition mode from a circular shape to a fan-shaped shape;
And 5, stranding the fan-shaped wire harness to form a conductor part required by the high-voltage cable structure, and then carrying out a general production process of cross-linking the high-voltage cable to manufacture the ceramic insulation separation conductor cable.
the process has low production cost and is easy to master.
While the invention has been described with reference to specific embodiments, it will be understood by those skilled in the art that the invention is not limited thereto, and may be embodied in other forms without departing from the spirit or essential characteristics thereof. Any modification which does not depart from the functional and structural principles of the present invention is intended to be included within the scope of the claims.
Claims (7)
1. The utility model provides a pottery insulating partition conductor high tension cable, includes that stranded fan-shaped cross section pencil conductor, the semiconductor tape around the package pencil conductor winds the covering, the cross-linked insulation layer of cladding semiconductor tape around the covering, around the semiconductor buffering water blocking tape of cross-linked insulation layer around the covering, the outer jacket layer of cladding semiconductor buffering water blocking tape around the aluminium sheath of covering, the pitch anticorrosive coating of cladding aluminium sheath, cladding pitch anticorrosive coating, pencil conductor includes a plurality of single line copper conductor, its characterized in that: the surface of the single-wire copper conductor is provided with a metal oxide ceramic layer, the thickness of the metal oxide ceramic layer is within the range of 0.20mm to 0.65mm, and the metal oxide ceramic layer is generated through chemical reaction when the single-wire copper conductor is heated to the annealing temperature range of 550 ℃ to 600 ℃; the manufacturing method of the ceramic insulation separation conductor high-voltage cable comprises the following steps: the method comprises the steps of enabling a single-wire copper conductor to reach the single-wire diameter required by a high-voltage cable product, heating to an annealing temperature, penetrating into a ceramic reaction tube, arranging a plurality of tube joints on the side face of the reaction tube, adding nanoscale powder and slurry into the reaction tube in a pressure blowing mode through the tube joints, carrying out chemical reaction on the nanoscale powder and the slurry in the reaction tube, and forming a metal oxide ceramic layer when meeting the surface of the heated single-wire copper conductor, wherein the nanoscale powder and the slurry comprise water vapor, sodium oxide, sodium chloride, sodium hydroxide, calcium sulfate, magnesium oxide and nickel oxide on the tube wall.
2. a ceramic insulated divided conductor high voltage cable according to claim 1, characterized in that: the resistances of the metal oxide ceramic layer and the single-wire copper conductor differ in value by 1011。
3. A ceramic insulated divided conductor high voltage cable according to claim 1, characterized in that: the ceramic reaction tube is a nickel-based metal tube.
4. A ceramic insulated divided conductor high voltage cable according to claim 3, characterized in that: the ceramic reaction tube is vertically arranged, and a single-line outlet shaping die is arranged at the upper part of the ceramic reaction tube, so that the function of rounding the metal oxide ceramic layer is achieved.
5. A ceramic insulated divided conductor high voltage cable according to claim 4, characterized in that: the lower part of the ceramic reaction tube is provided with a ceramic slurry outlet for discharging unreacted ceramic slurry.
6. a ceramic insulated divided conductor high voltage cable according to claim 1, characterized in that: the single-wire copper conductor penetrates into the ceramic reaction tube through the single-wire guide wheel, the single-wire guide wheel is a conductive contact guide wheel, and a large current of 50V DC and more than 2000A is applied between the conductive contact guide wheels of the single-wire copper conductor.
7. A ceramic insulated divided conductor high voltage cable according to claim 6, characterized in that: the single copper conductor is heated to the annealing temperature range of 550-600 ℃ by the conductive contact guide wheel.
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| TWI734313B (en) * | 2019-12-23 | 2021-07-21 | 遠東科技大學 | Manufacturing method of a ceramic insulating layer wire |
| CN112571583A (en) * | 2020-11-27 | 2021-03-30 | 珠海读书郎网络教育有限公司 | Extrusion device and extrusion method for conductive ceramics |
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| US3257245A (en) * | 1960-08-01 | 1966-06-21 | Physical Sciences Corp | Wire coating apparatus |
| JPS59103212A (en) * | 1982-12-06 | 1984-06-14 | 株式会社フジクラ | Method of producing insulated wire |
| JPH03182005A (en) * | 1989-12-11 | 1991-08-08 | Sumitomo Electric Ind Ltd | Ceramic coated insulated wire and its manufacturing method |
| JPH06302227A (en) * | 1993-04-16 | 1994-10-28 | Supply Control:Kk | Preventive method for transmission loss and transmission line used therefor |
| DE19957070A1 (en) * | 1999-11-26 | 2001-06-21 | Markus Bamberger | Coating for a surface of an object such as an electrical conductor comprises a binder based on a resin or a thermoplastic material and a glass and/or ceramic component |
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Denomination of invention: Manufacturing method of high voltage cable and single wire copper conductor with ceramic insulation and separated conductor Effective date of registration: 20201203 Granted publication date: 20191217 Pledgee: Dushangang sub branch of Zhejiang Pinghu Rural Commercial Bank Co., Ltd Pledgor: ZHEJIANG CHENGUANG CABLE Co.,Ltd. Registration number: Y2020330001100 |
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Date of cancellation: 20210617 Granted publication date: 20191217 Pledgee: Dushangang sub branch of Zhejiang Pinghu Rural Commercial Bank Co., Ltd Pledgor: ZHEJIANG CHENGUANG CABLE Co.,Ltd. Registration number: Y2020330001100 |