CN115206601A - Manufacturing method of communication cable special for cruise ship - Google Patents
Manufacturing method of communication cable special for cruise ship Download PDFInfo
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- CN115206601A CN115206601A CN202210737046.6A CN202210737046A CN115206601A CN 115206601 A CN115206601 A CN 115206601A CN 202210737046 A CN202210737046 A CN 202210737046A CN 115206601 A CN115206601 A CN 115206601A
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- 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
- H01B13/02—Stranding-up
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- 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
- H01B13/06—Insulating conductors or cables
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- 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
- H01B13/06—Insulating conductors or cables
- H01B13/14—Insulating conductors or cables by extrusion
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- 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
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
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- 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
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/26—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping
- H01B13/2613—Sheathing; Armouring; Screening; Applying other protective layers by winding, braiding or longitudinal lapping by longitudinal lapping
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
- Y02A30/00—Adapting or protecting infrastructure or their operation
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Abstract
一种邮轮专用通信电缆的制造方法，步骤包括：1)制造线芯导体，2)制造线芯耐火层，3)制造线芯绝缘层，4)制造线对绞组，5)制造缆芯，6)制造编织铠装层；7)制造外护套。本方法通过各个步骤中工艺参数的设计和优化，使制得产品可达到设计要求，并具有很高的优品率以及提供了生产效率。
A method for manufacturing a special communication cable for cruise ships, comprising the steps of: 1) manufacturing a core conductor, 2) manufacturing a refractory layer of the core, 3) manufacturing an insulating layer of the core, 4) manufacturing a pair of twisted pairs, and 5) manufacturing a cable core, 6) Manufacture the braided armor layer; 7) Manufacture the outer sheath. Through the design and optimization of process parameters in each step, the method enables the obtained product to meet the design requirements, has a high quality rate and provides production efficiency.
Description
Technical Field
The technical scheme belongs to the technical field of cables, and particularly relates to a manufacturing method of a communication cable special for a mail steamer.
Background
The SOLAS code of the international maritime safety committee stipulates that passenger ships such as cruise ships can drive to safe ports by virtue of own power under the condition of fire or water inflow, wherein the fire or water inflow condition does not exceed a ship damage threshold value. During "safe return to port", all on-board ship personnel will reside centrally in a safe area and provide basic services for their safety and health. If the vessel damage exceeds the "threshold", SOLAS now requires that the critical system must be able to operate for 3 hours while taking into account the total damage to an entire main fire zone. The communication cable is used for conveying the signals of the whole mail steamer, has higher requirements than the common communication cable for the ship, and is required to keep normal work so as to ensure the safe return port of the ship.
Accordingly, a communication cable for a cruise ship has been proposed in the prior art to solve the above problems. Taking the cable shown in fig. 1 as an example, a core conductor 1 is wrapped by a core fire-resistant layer 2 and a core insulating layer 3 to form a core, and two cores are twisted in pairs to form a twisted-pair group; the 3 pairs of twisted wire groups and the glass fiber filling ropes are twisted into a cable core, and the cable core is externally coated with a water-blocking protective layer 5, a braided armor layer 6 and an outer sheath 7.
The cable has the main problems in the production process that the cable which can not reach the theoretical performance can not be produced by adopting the traditional production process or correcting the traditional production process according to experience and the like, and even the cable which meets the conventional requirements can not be produced.
Disclosure of Invention
Research and trial experiments show that the reasons for the above problems are mainly as follows:
1. tin powder and tin slag are easy to exist in the production process of the tin-plated copper monofilament adopted by the conductor, and the disconnection and the like are easy to cause in the extrusion process.
The tin coating mainly improves the corrosion resistance and oxidation resistance of the conductor, and is convenient for welding in use. The main reason is that tin is attached to copper in a plating way, and the ductility of the tin and the copper is different in the production process, so that if the thickness of the tin layer is insufficient, the tin layer is broken and falls off.
2. The outer diameter of the wire core is not uniform.
The fire-resistant layer wraps the mica tape outside the conductor, and has the function of bundling the conductor besides fire resistance. In the course of working, the mica tape around package tension, around package overlap degree all have an influence to the thickness behind the parcel flame retardant coating, moreover, around package tension too big still can stretch out the mica tape, around the package overlap degree not enough then influence fire resistance. After the insulating material of the insulating layer is selected, the melting degree, the fluidity, the mold matching parameters and the like of the insulating material all influence the uniformity and the thickness of the insulating layer, and the formulation of the process parameters directly determines the insulating property and the outer diameter of a wire core.
3. The effect of the braided armor process on shielding effectiveness, braiding efficiency, and flexibility.
In the national standard, the shielding performance is considered only by the weaving density and not by the shielding effectiveness. Therefore, in the processing of the braided shielding layer of most cables at present, only the fitting point is searched from the aspects of production efficiency and braided density/flexibility, and no parameter of shielding efficiency is added. After the shielding effectiveness parameters are introduced, the formulation difficulty of the processing technology is increased by multiple orders of magnitude.
4. The consistency of the mechanical protection performance of the cable is insufficient.
After the sheath material of the outer sheath is selected, the melting degree, the fluidity, the mold matching parameters and the like of the sheath material all influence the uniformity and the thickness of the outer sheath, and the formulation of the process parameters directly determines the protective performance and the outer diameter of the cable.
Through the analysis of the technical problems, the invention provides a novel manufacturing method of the cable, which is manufactured through the processes of all links, so that the functions and the performance of the manufactured cable meet the design requirements, and the manufactured cable has high yield.
A manufacturing method of a communication cable special for a cruise ship comprises the following steps:
1) Manufacturing a wire core conductor:
conductor of the core: is formed by twisting tinned copper monofilaments; the diameter range of the tin-plated copper monofilament is 0.365 mm-0.375 mm; the stranded lay length of the tinned copper monofilament is 12-20 times of the outer diameter of the stranded conductor; tin platingThe copper monofilament is annealed tin-plated copper monofilament, the thickness of tin layer is not less than 0.6 μm, the oxygen content of copper in the tin-plated copper monofilament is not more than 0.001%, and the volume resistivity at 20 deg.C is not more than 0.01760 Ω.mm 2 /m；
2) Manufacturing a core fire-resistant layer:
taking a wire core conductor, and tightly and snugly wrapping two layers of mica tapes outside the wire core conductor by adopting a mica tape wrapping machine, wherein the overlapping rate of the two layers of mica tapes in overlapping wrapping is not less than 50%;
when the mica tape on the inner layer is wrapped, the traction speed is 5-6 m/min, the wrapping pitch is 6 +/-0.5 mm, and the tension on the mica tape is 40-45N; the wrapping direction is right, and the thickness of the wrapping tape is 0.15mm;
when the outer mica tape is wrapped, the traction speed is 5-6 m/min, the wrapping pitch is 6 +/-0.5 mm, and the tension on the mica tape is 40-45N; the wrapping direction is left, and the thickness of the wrapping tape is 0.15mm;
3) Manufacturing a wire core insulating layer:
taking the cable prepared in the step 2), and extruding an insulating material outside the cable to prepare a wire core insulating layer;
a mould core and a mould sleeve are arranged on a machine head of the plastic extruding machine, and the aperture of the mould core is = the diameter of the conductor after the fire-resistant layer is lapped plus 0.2mm;
from the feeding direction to the discharging direction, the body temperature regions of the plastic extruding machine are respectively as follows: the first zone is 135 +/-5 ℃, the second zone is 140 +/-5 ℃ and the third zone is 145 +/-5 ℃; machine neck temperature: 155. + -. 5 ℃ and head temperature: 165 +/-5 ℃; the machine body and the machine head are heated by adopting a thermocouple;
wherein: the first zone is a feeding section, the second zone is a plasticizing section, and the third zone is a homogenizing section;
the silane crosslinking material insulating material has the characteristics of high volume resistivity, small dielectric loss, good thermal aging resistance, good stress cracking resistance and the like, and the temperature in the interval can enable the material performance to reach the optimal level, and the appearance of a wire core and the production rate to reach the optimal level. The processing quality of the insulating layer is greatly improved by adopting a specific extrusion process.
4) Manufacturing a wire pair twisting group:
carrying out wire pair twisting on the wire core prepared in the step 3), wherein the twisting pitch is not more than 150mm;
the twisting equipment is a star twister, the traction speed is 20-30 m/min, and the rotating speed of the wrapping head is 250-300 r/min; the stranding and doubling die of the star twister adopts a tungsten steel die, the inner aperture is equal to the strand outer diameter of the wire core, and the strand direction is the left direction;
not more than 150mm pair twist pitch can reduce electromagnetic radiation and outside electromagnetic interference's influence, and suitable traction speed can carry out close cooperation with wrapping head rotational speed, combines into one with two processes, and effectual production efficiency that has improved.
5) Manufacturing a cable core:
stranding the plurality of wire pair-twisted sets prepared in the step 4) and the glass fiber filling rope together into a cable core, and then winding and wrapping a water-blocking protective layer, wherein the range of stranding pitch is not more than 25 times;
the twisting equipment of the cable core is a back-twist type cable former, the rotating speed of a twisting cage of the cable former is 70-80 r/min, the traction speed is 9-12 m/min, and the rotating speed of a wrapping head is 450-460 r/min; the cabling doubling die of the cabling machine adopts a tungsten steel die, the inner aperture is equal to the outer diameter of the twisted wire pair group, and the cabling direction is the right direction;
adopt glass fiber filling rope can effectual protection cable structure's stability when burning, prevent the rapid upwards propagation of flame, and suitable traction speed can carry out close cooperation with around the package head rotational speed, merges into one with twice process, the effectual production efficiency that has improved.
The water-blocking protective layer is formed by lapping a ceramic silicon rubber belt, and the lapping rate of the overlapping lapping of the ceramic silicon rubber belt is not less than 25%; when wrapping, the traction speed is 480-500 m/min, the wrapping pitch is 35 +/-5 mm, and the tension on the ceramic silicon rubber belt is 40-45N; the wrapping direction is left, and the thickness of the ceramic silicon rubber belt is 0.4mm;
6) Manufacturing a woven armor layer;
the braided armor layer is formed by braiding tinned copper wires, the diameter of each single wire of each tinned copper wire is 0.3mm, the braiding angle is 35-60 degrees (preferably 45 degrees), and the braiding coverage rate is not less than 90 percent;
the braided armor layer can effectively carry out electromagnetic shielding, ensures the transmission of internal signals, can enhance the tensile strength of the cable, and has the advantages of improving the electromagnetic shielding performance, saving the cost and improving the production efficiency due to proper braiding angles and braiding density.
7) Manufacturing an outer sheath:
extruding sheath materials outside the braided armor layer to form an outer sheath;
from feeding to ejection of compact direction, fuselage warm area is: the first zone is 138 +/-5 ℃, the second zone is 145 +/-5 ℃, the third zone is 155 +/-5 ℃, the fourth zone is 158 +/-5 ℃ and the fifth zone is 158 +/-5 ℃; machine neck temperature: zone one 158 ± 5 ℃, head temperature: 155 +/-5 ℃; the machine body is heated by a thermocouple; the cooling of the machine body is carried out by adopting a blower.
Wherein: 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.
Thermoplastic low-smoke halogen-free material type sheath material can effectively prevent the rapid spread of the cable fire condition when the cable is on fire, has small smoke quantity, can satisfy that the smoke density and light transmittance of the cable exceeds 60 percent when the cable is burnt, ensures the safety and health of personnel, adopts the process to extrude, can make the material performance reach the optimal level, and simultaneously the sheath appearance and the production rate reach the best.
Drawings
FIG. 1 is a schematic radial cross-sectional view of the cable of the present embodiment;
in the figure: the cable core comprises a cable core conductor 1, a cable core fire-resistant layer 2, a cable core insulating layer 3, a glass fiber filling rope 4, a water-blocking protective layer 5, a woven armor layer 6 and an outer sheath 7.
Detailed Description
The technical solution is further described below with reference to specific examples as follows:
the cable is made by the method of this example as shown in figure 1. The cable is formed by sequentially wrapping a water-blocking protective layer 5, a braided armor layer 6 and an outer sheath 7 outside a cable core; the cable core is a round-section cable formed by twisting 3 pairs of twisted wire sets and a glass fiber filling rope 4; the range of the stranding pitch is no greater than 25 times the outer diameter of the pair of strands; on any radial section of the cable, 3 groups of twisted wires form an equilateral triangle which is symmetrical; the outer diameter of the twisted pair group ranges from 6.6mm to 7.0mm; the pair-twisted line group is formed by twisting 2 wire coresA cable having a circular cross section; the twist pitch is not more than 150mm; the wire core is formed by sequentially wrapping a wire core fire-resistant layer 2 and a wire core insulating layer 3 outside a wire core conductor 1; the conductor of the wire core is formed by a tin-plated copper monofilament; the outer diameter range of the core conductor is 1.05mm to 1.15mm; the outer diameter range of the core conductor is 2.2mm to 2.4mm after the fireproof layer is wrapped, and the thickness range of the core insulating layer is 0.5mm to 0.7mm; the outer diameter of the glass fiber filling rope is 2mm; the core conductor is formed by twisting tin-plated copper monofilaments; the diameter range of the tin-plated copper monofilament is 0.365 mm-0.375 mm; the twisting pitch of the tinned copper monofilament is 12-20 times of the outer diameter of the twisted conductor; the tin-plated copper monofilament is annealed tin-plated copper monofilament, the thickness of tin layer is not less than 0.6 μm, the oxygen content of copper in tin-plated copper monofilament is not more than 0.001%, and the volume resistivity at 20 deg.C is not more than 0.01760 Ω 2 M; the thickness of the outer sheath is 1.0mm to 1.4mm.
To this end, the invention provides a method for manufacturing a communication cable special for a cruise ship, which comprises the following steps:
1) Manufacturing a wire core conductor:
conductor of the core: is formed by twisting tinned copper monofilaments; the diameter range of the tin-plated copper monofilament is 0.365 mm-0.375 mm; the twisting pitch of the tinned copper monofilament is 12-20 times of the outer diameter of the twisted conductor; the tin-plated copper monofilament is annealed tin-plated copper monofilament, the thickness of the tin layer is not less than 0.6 μm, the oxygen content of copper in the tin-plated copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01760 omega mm 2 /m；
2) Manufacturing a core fire-resistant layer:
taking a wire core conductor, and tightly and snugly wrapping two layers of mica tapes outside the wire core conductor by adopting a mica tape wrapping machine, wherein the overlapping rate of the two layers of mica tapes overlapped and wrapped is not less than 50%;
when the mica tape on the inner layer is wrapped, the traction speed is 5-6 m/min, the wrapping pitch is 6 +/-0.5 mm, and the tension on the mica tape is 40-45N; the wrapping direction is right, and the thickness of the wrapping tape is 0.15mm;
when the outer layer of mica tape is lapped, the traction speed is 5-6 m/min, the lapping pitch is 6 +/-0.5 mm, and the tension on the mica tape is 40-45N; the wrapping direction is left, and the thickness of the wrapping tape is 0.15mm;
3) Manufacturing a wire core insulating layer:
taking the cable prepared in the step 2), and extruding and wrapping a two-step silane cross-linked insulating material outside the cable to prepare a cable core insulating layer;
a mould core and a mould sleeve are arranged on a machine head of the plastic extruding machine, and the diameter of the mould core is = 0.2mm plus the diameter of the conductor after the refractory layer is wrapped;
4) Manufacturing a wire pair twisting group:
taking the wire core prepared in the step 3) to perform wire pair twisting, wherein the wire pair twisting pitch is not more than 150mm;
the twisting equipment is a star twister, the traction speed is 20-30 m/min, and the rotating speed of the wrapping head is 250-300 r/min; the stranding and doubling die of the star strander adopts a tungsten steel die, the inner aperture is equal to the pair stranding outer diameter of the wire cores, and the pair stranding direction is the left direction;
5) Manufacturing a cable core:
stranding the plurality of wire pair-twisted sets prepared in the step 4) and the glass fiber filling rope together into a cable core, and then winding and wrapping a water-blocking protective layer, wherein the range of stranding pitch is not more than 25 times;
the twisting equipment of the cable core is a back-twist type cable former, the rotating speed of a twisting cage of the cable former is 70-80 r/min, the traction speed is 9-12 m/min, and the rotating speed of a wrapping head is 450-460 r/min; the cabling doubling die of the cabling machine adopts a tungsten steel die, the inner aperture is equal to the outer diameter of the twisted wire pair group, and the cabling direction is the right direction;
the water-blocking protective layer is formed by lapping a ceramic silicon rubber belt, and the lapping rate of the overlapping lapping of the ceramic silicon rubber belt is not less than 25%; when wrapping, the traction speed is 480-500 m/min, the wrapping pitch is 35 +/-5 mm, and the tension on the ceramic silicon rubber belt is 40-45N; the wrapping direction is left, and the thickness of the ceramic silicon rubber belt is 0.4mm;
6) Manufacturing a braided armor layer;
the braided armor layer is formed by braiding tinned copper wires, the diameter of each single wire of each tinned copper wire is 0.3mm, the braiding angle is 35-60 degrees, and the braiding coverage rate is not less than 90%;
7) Manufacturing an outer sheath:
and a thermoplastic low-smoke halogen-free sheath material is extruded outside the braided armor layer to form the outer sheath.
In this example: in the step 3), the preparation method of the insulating material comprises the following steps:
3.1 ) the following mixture in parts by mass
Ethylene-vinyl acetate: ethylene octene copolymer: linear low density polyethylene: the mass ratio of the polyethylene grafted maleic anhydride is 60:15:15:10, 100 parts of a mixture;
polyethylene wax: the mass ratio of the silicone master batch is 1:5, 3 parts of a mixture;
magnesium hydroxide: the mass ratio of the aluminum hydroxide is 2:1, 150 parts of the mixture;
antioxidant 1010: 1 part of a mixture of 1 part by mass of the antioxidant 168 and 1 part by mass of the antioxidant;
mixing for 15 minutes at the temperature of 145 ℃, and then extruding and granulating at the temperature of 130-150 ℃ to prepare master batch;
3.2.1 100 parts of master batch by mass are taken, and are stirred and adsorbed for 4 hours at 55 ℃ together with 1 part of vinyl silane, 0.2 part of amino silane and 0.04 part of dicumyl peroxide; and then extruding at the temperature of 140-160 ℃, and carrying out water-cooling bracing granulation to obtain the silane grafted polyolefin A material.
3.2.2 154 parts of master batch by mass and 2 parts of dibutyltin dilaurate are mixed for 15 minutes at 145 ℃; then extruding and granulating at the temperature of 130-150 ℃ to obtain a catalyst master batch B material.
In the step 3), taking a silane grafted polyolefin material A and a catalyst master batch material B according to a mass ratio of 95:5, uniformly compounding, extruding the mixture on the surface of the conductor by an extruding machine, and placing the conductor in a water bath at 70 ℃ for 2 hours;
from feeding to ejection of compact direction, extruding machine fuselage temperature zone is respectively: the first zone is 135 +/-5 ℃, the second zone is 140 +/-5 ℃ and the third zone is 145 +/-5 ℃; machine neck temperature: 155. + -. 5 ℃ C., head temperature: 165 +/-5 ℃; the machine body and the machine head are heated by adopting a thermocouple;
wherein: the first zone is a feeding section, the second zone is a plasticizing section, and the third zone is a homogenizing section.
In this example, in step 6), the braiding angle of the braided armor layer is 45 °.
In the step 7), the sheath material comprises the following components in parts by mass:
wherein: the mass content of the vinyl acetate in the ethylene-vinyl acetate copolymer is 20-50%, and the melt index is 2-10 g/10min (the test condition is 190 ℃/2.16 kg);
in order to further improve the heat resistance of the product and avoid cracking, the mass content of butyl acrylate in the ethylene-butyl acrylate copolymer is 15-30%, and the melt index is 2-10 g/10min (the test condition is 190 ℃/2.16 kg);
the melt index of the ultra-low density polyethylene is 0.5-20 g/10min (the test condition is 190 ℃/2.16 kg); the compatilizer is POE-g-MAH, and the melt index of the POE is 2-10 g/10min (the test condition is 190 ℃/2.16 kg);
the antioxidant is tetra [ beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionic acid ] pentaerythritol ester and tri [2, 4-di-tert-butylphenyl ] phosphite ester with the mass ratio of (1-1.5): (1-0.5).
The particle size of the aluminum hydroxide is 0.5-5 mu m, and the surface of the aluminum hydroxide is treated by stearic acid, vinyl silane or titanate;
the particle size of the magnesium hydroxide is 0.5-5 mu m, and the surface of the magnesium hydroxide is treated by stearic acid, vinyl silane or titanate;
the particle size of the sepiolite is 1-100 nm.
The sheath material adopts the extruding machine to extrude, from feeding to ejection of compact direction, extruding machine fuselage warm area is: the first zone is 138 +/-5 ℃, the second zone is 145 +/-5 ℃, the third zone is 155 +/-5 ℃, the fourth zone is 158 +/-5 ℃ and the fifth zone is 158 +/-5 ℃; machine neck temperature: first zone 158 ± 5 ℃, head temperature: 155 +/-5 ℃; the machine body is heated by a thermocouple; the cooling of the machine body is carried out by adopting a blower;
wherein: 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.
In this example, the line equipment of the star strander comprises 4 pay-off reels and 1 rear pay-off frame wheel type pay-off frame; the pay-off reels are respectively set to A1, A2, A3, A4 and A5;
a sinle silk is placed to A1, and a sinle silk is placed to A2.
In this example, the untwisted type cable former is 1+6 cable former, and the cable equipment of the cable former has 6 pay-off reels and 1 rear pay-off rack wheel type pay-off frame; the pay-off reels are respectively set to A1, A2, A3, A4, A5, A6 and A7;
a1 is provided with a pair of twisted sets, A2 is provided with a pair of twisted sets, and A3 is provided with a pair of twisted sets.
The insulating layer prepared by the method has an insulation resistance constant of not less than 3670 MOmega.km at 20 ℃, an insulation resistance constant of not less than 3.67 MOmega.km at 90 ℃, and an insulation cumulative resistivity of not less than 1.0 x 10 at 20 DEG C 15 Omega cm, and insulator resistivity of not less than 1.0 x 10 at 90 deg.C 12 Omega cm; the insulation tensile strength is not less than 12.5MPa, and the elongation at break is not less than 200%; under the conditions of 135 ℃ and 168 hours later, the change rate of the tensile strength is not more than +/-25 percent, and the change rate of the elongation at break is not more than +/-25 percent; pH value is not less than 4.3, conductivity is not more than 10 μ S/mm, HCl and HBr content is not more than 0.5%, and HF content is not more than 0.1%.
Irradiating the insulating layer, sampling the insulating layer, and keeping the elongation at break not more than 175% and the permanent deformation not more than 15% at 250 deg.C for 15min
The main base material of the glass fiber filling rope is alkali-free glass fiber material; filling ropes with different sizes are placed aiming at different gaps in the cable core; in addition, the filling material can not deform, age, decompose, crack and the like under the condition of insulation at 100 ℃ for 168 hours, and still keeps the original good shape.
The outer sheath prepared by the method has good flexibility, low smoke, zero halogen, no toxicity, flame retardance, anti-aging performance and the like, and can pass A-type bundled combustion test, and the elongation at break of the sheath material is not less than 30% at the temperature of-15 ℃ for 4 hours.
The cable ensures that the cable can still continuously work for 3 hours or more when a fire disaster happens to a ship through the specific design of materials and structures, so that the normal work is kept, and the safe port return of the ship is ensured. The application of the technology can ensure the safety and health of personnel, respect the International maritime personal Life safety convention, and is beneficial to better service for people by ship equipment.
The cable selects tin-plated copper as a conductor material; stranding a plurality of annealed metal filaments to form a conductor, wherein the resistivity of the metal filaments is not more than 0.01760 omega mm 2 M: a plurality of metal filaments are twisted into a conductor, and the plurality of metal filaments are divided into a plurality of layers from inside to outside; two adjacent metal monofilaments in each layer of metal monofilaments are tightly attached to each other; in the two adjacent layers of metal monofilaments, the inner layer metal monofilament and the outer layer metal monofilament are tightly attached; the twisting direction of the metal monofilaments at the outermost layer is the left direction, and the twisting directions of the adjacent two layers of metal monofilaments are opposite; the twisting pitch of the metal monofilament at the outermost layer is 12-20 times of the outer diameter after twisting; the fire-resistant layer is wrapped outside the corresponding conductor in a wrapping mode, the fire-resistant layer is composed of two layers of mica tapes, and the insulating layer is wrapped outside the fire-resistant layer in an extruding mode. And a water-blocking protective layer is wound outside the cable core, is a ceramic silicon rubber belt, and has a winding lapping rate of not less than 25%. And weaving metal wires outside the water-blocking protective layer, wherein the metal wires are tinned copper wires, and the weaving coverage rate is not less than 90%. And tightly wrapping the sheath material outside the braided armor by adopting an extrusion production mode to form a sheath layer, and cooling to form the cable.
The manufacturing method of the cable is explained as follows:
in the selection of the process parameters, when the intermediate value and the preferred value are selected, the one-time excellent rate of the product reaches 99.4 percent, and when the intermediate value and the preferred value are relaxed within a range value, although the product meeting the quality requirement can be obtained, the one-time excellent rate is more between 98 percent and 99 percent.
As a result, the cable is characterized by comprising:
1) Good fire resistance: pass the harsh 3 hour strike + water spray fire test;
2) Excellent bundled flame retardant properties: meeting IEC 60332-3-22 bundled A-type combustion.
3) Good low toxicity: meets the requirement of item 6.5 in GB/T19666-2019
4) Is safe to human body and environment
Substantially free of harmful substances of 13, including: asbestos, polychlorinated biphenyl, chromium, lead, mercury, perfluorooctane, sulfuric acid and the like, and the safety of personnel and environment is guaranteed.
5) High electrical property
The inspected product is detected by a third-party type, and the actually measured insulation resistance constant of the actually measured insulation is 81100 Momega.km which is far higher than the required 3670 Momega.km.
Claims (6)
1. A manufacturing method of a communication cable special for a cruise ship is characterized by comprising the following steps:
1) Manufacturing a wire core conductor:
conductor of the core: is formed by twisting tinned copper monofilaments; the diameter range of the tin-plated copper monofilament is 0.365 mm-0.375 mm; the twisting pitch of the tinned copper monofilament is 12-20 times of the outer diameter of the twisted conductor; the tin-plated copper monofilament is annealed tin-plated copper monofilament, the thickness of the tin layer is not less than 0.6 μm, the oxygen content of copper in the tin-plated copper monofilament is not more than 0.001%, and the volume resistivity at 20 ℃ is not more than 0.01760 omega mm 2 /m；
2) Manufacturing a core fire-resistant layer:
taking a wire core conductor, and tightly and snugly wrapping two layers of mica tapes outside the wire core conductor by adopting a mica tape wrapping machine, wherein the overlapping rate of the two layers of mica tapes overlapped and wrapped is not less than 50%;
when the mica tape on the inner layer is wrapped, the traction speed is 5-6 m/min, the wrapping pitch is 6 +/-0.5 mm, and the tension on the mica tape is 40-45N; the wrapping direction is right, and the thickness of the wrapping tape is 0.15mm;
when the outer mica tape is wrapped, the traction speed is 5-6 m/min, the wrapping pitch is 6 +/-0.5 mm, and the tension on the mica tape is 40-45N; the wrapping direction is left, and the thickness of the wrapping tape is 0.15mm;
3) Manufacturing a wire core insulating layer:
taking the cable prepared in the step 2), and extruding and wrapping a two-step silane crosslinking insulating material outside the cable to prepare a wire core insulating layer;
a mould core and a mould sleeve are arranged on a machine head of the plastic extruding machine, and the aperture of the mould core is = the diameter of the conductor after the fire-resistant layer is lapped plus 0.2mm;
4) Manufacturing a wire pair twisting group:
carrying out wire pair twisting on the wire core prepared in the step 3), wherein the twisting pitch is not more than 150mm;
the twisting equipment is a star twister, the traction speed is 20-30 m/min, and the rotating speed of the wrapping head is 250-300 r/min; the stranding and doubling die of the star twister adopts a tungsten steel die, the inner aperture is equal to the strand outer diameter of the wire core, and the strand direction is the left direction;
5) Manufacturing a cable core:
stranding the plurality of wire pair-twisted sets prepared in the step 4) and the glass fiber filling rope together into a cable core, and then winding and wrapping a water-blocking protective layer, wherein the range of stranding pitch is not more than 25 times;
the twisting equipment of the cable core is a back-twist type cable former, the rotating speed of a twisting cage of the cable former is 70-80 r/min, the traction speed is 9-12 m/min, and the rotating speed of a wrapping head is 450-460 r/min; the cabling doubling die of the cabling machine adopts a tungsten steel die, the inner aperture is equal to the outer diameter of the twisted wire pair group, and the cabling direction is the right direction;
the water-blocking protective layer is formed by lapping a ceramic silicon rubber belt, and the lapping rate of the overlapping lapping of the ceramic silicon rubber belt is not less than 25%; when wrapping, the traction speed is 480-500 m/min, the wrapping pitch is 35 +/-5 mm, and the tension on the ceramic silicon rubber belt is 40-45N; the wrapping direction is left, and the thickness of the ceramic silicon rubber belt is 0.4mm;
6) Manufacturing a woven armor layer;
the braided armor layer is formed by braiding tinned copper wires, the diameter of each single wire of each tinned copper wire is 0.3mm, the braiding angle is 35-60 degrees, and the braiding coverage rate is not less than 90%;
7) Manufacturing an outer sheath:
and a thermoplastic low-smoke halogen-free sheath material is extruded outside the braided armor layer to form the outer sheath.
2. The method for manufacturing a communication cable for a cruise ship according to claim 1, wherein the insulating material is prepared by the following steps in step 3):
3.1 ) the following mixture in parts by mass
Ethylene-vinyl acetate: ethylene octene copolymer: linear low density polyethylene: the mass ratio of the polyethylene grafted maleic anhydride is 60:15:15:10, 100 parts of a mixture;
polyethylene wax: the mass ratio of the silicone master batch is 1:5, 3 parts of a mixture;
magnesium hydroxide: the mass ratio of the aluminum hydroxide is 2:1, 150 parts of the mixture;
antioxidant 1010: 1 part of a mixture of 1 part of antioxidant 168 and 1 part of a mixture of;
mixing for 15 minutes at the temperature of 145 ℃, and then extruding and granulating at the temperature of 130-150 ℃ to prepare master batch;
3.2.1 100 parts of master batch by mass are taken, and stirred and adsorbed for 4 hours at 55 ℃ together with 1 part of vinyl silane, 0.2 part of amino silane and 0.04 part of dicumyl peroxide; then extruding at the temperature of 140-160 ℃, and then carrying out water-cooling bracing granulation to obtain a silane grafted polyolefin A material;
3.2.2 154 parts of master batch by mass and 2 parts of dibutyltin dilaurate are mixed for 15 minutes at the temperature of 145 ℃; then extruding and granulating at the temperature of 130-150 ℃ to obtain a catalyst master batch B material.
3. The manufacturing method of a communication cable special for a cruise ship according to claim 1, wherein in the step 3), the silane-grafted polyolefin material A and the catalyst master batch material B are mixed according to a mass ratio of 95:5, uniformly compounding, extruding the mixture on the surface of the conductor by an extruding machine, and placing the conductor in a water bath at 70 ℃ for 2 hours;
from feeding to ejection of compact direction, extruding machine fuselage warm area is respectively: the first zone is 135 +/-5 ℃, the second zone is 140 +/-5 ℃ and the third zone is 145 +/-5 ℃; machine neck temperature: 155. + -. 5 ℃ and head temperature: 165 +/-5 ℃; the machine body and the machine head are heated by a thermocouple;
wherein: the first zone is a feeding section, the second zone is a plasticizing section, and the third zone is a homogenizing section.
4. A method for manufacturing a communication cable for a cruise ship according to claim 1, wherein in said step 6), the braided armor layer is braided at a braiding angle of 45 °.
5. The manufacturing method of a communication cable special for a mail steamer as claimed in claim 1, wherein in the step 7), the sheathing material comprises the following components in parts by weight:
formulation components
Wherein: the mass content of vinyl acetate in the ethylene-vinyl acetate copolymer is 20-50%, the melt index is 2-10 g/10min, and the test condition is 190 ℃/2.16kg;
in order to further improve the heat resistance of the product and avoid cracking, the mass content of butyl acrylate in the ethylene-butyl acrylate copolymer is 15-30%, the melt index is 2-10 g/10min, and the test condition is 190 ℃/2.16kg;
the melt index of the ultra-low density polyethylene is 0.5-20 g/10min, and the test condition is 190 ℃/2.16kg;
the compatilizer is POE-g-MAH, the melt index of the POE is 2-10 g/10min, and the test condition is 190 ℃/2.16kg;
the antioxidant is tetra [ beta- (3, 5-di-tert-butyl-4-hydroxyphenyl) propionic acid ] pentaerythritol ester and tris [2, 4-di-tert-butylphenyl ] phosphite ester with the mass ratio of (1-1.5): (1-0.5);
the particle size of the aluminum hydroxide is 0.5-5 mu m, and the surface of the aluminum hydroxide is treated by stearic acid, vinyl silane or titanate;
the particle size of the magnesium hydroxide is 0.5-5 mu m, and the surface of the magnesium hydroxide is treated by stearic acid, vinyl silane or titanate;
the particle size of the sepiolite is 1-100 nm.
6. A method for manufacturing a communication cable dedicated to a cruise ship according to claim 1, wherein said sheath material is extruded by an extruder, and a temperature zone of a body of the extruder is as follows: the first zone is 138 +/-5 ℃, the second zone is 145 +/-5 ℃, the third zone is 155 +/-5 ℃, the fourth zone is 158 +/-5 ℃ and the fifth zone is 158 +/-5 ℃; machine neck temperature: first zone 158 ± 5 ℃, head temperature: 155 +/-5 ℃; the machine body is heated by a thermocouple; the cooling of the machine body is carried out by adopting a blower;
wherein: 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.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN119864202A (en) * | 2025-01-08 | 2025-04-22 | 浙江高远电缆有限公司 | Flexible ceramic mineral insulation high-flame-retardance fireproof cable and processing technology thereof |
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| CN113380467A (en) * | 2021-05-28 | 2021-09-10 | 江苏上上电缆集团有限公司 | Manufacturing method of reinforced fire-resistant marine power cable |
| CN113930006A (en) * | 2021-08-20 | 2022-01-14 | 江苏上上电缆集团新材料有限公司 | Rapid-crosslinking two-step silane-crosslinked low-smoke halogen-free insulating material, and preparation method and application thereof |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN201655350U (en) * | 2010-04-08 | 2010-11-24 | 安徽华菱电缆集团有限公司 | Transponder data transmission cable |
| CN110938252A (en) * | 2019-11-28 | 2020-03-31 | 江苏上上电缆集团新材料有限公司 | B1-grade stress cracking resistant thermoplastic low-smoke halogen-free cable material and preparation method thereof |
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Application publication date: 20221018 |