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WO2021098003A1 - 一种高压直流海缆z型密封电缆导体及其设计方法 - Google Patents

一种高压直流海缆z型密封电缆导体及其设计方法 Download PDF

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Publication number
WO2021098003A1
WO2021098003A1 PCT/CN2019/127799 CN2019127799W WO2021098003A1 WO 2021098003 A1 WO2021098003 A1 WO 2021098003A1 CN 2019127799 W CN2019127799 W CN 2019127799W WO 2021098003 A1 WO2021098003 A1 WO 2021098003A1
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shaped single
shaped
conductor
angle
line
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French (fr)
Inventor
梅文杰
朱建风
潘文林
王皓煜
百梦弟
潘文
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Hengtong Submarine Power Cable Co Ltd
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Hengtong Submarine Power Cable Co Ltd
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
    • H01B5/08—Several wires or the like stranded in the form of a rope
    • 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
    • H01B7/0009—Details relating to the conductive cores
    • 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
    • H01B7/14—Submarine cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00—Power 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

Definitions

  • the invention belongs to the field of power cables, and specifically relates to a high-voltage direct current submarine cable Z-type sealed cable conductor and a design method thereof.
  • HVDC submarine cables In the context of the depletion of offshore wind power resources, the rapid development of offshore wind power, and the global energy interconnection, HVDC submarine cables have large transmission power, low loss, long transmission distance and no need to consider the skin existing on the conductor during the AC transmission process.
  • the advantages such as the effect and the proximity effect have caused extensive research by large-scale submarine cable manufacturers at home and abroad.
  • the conductor design of high-voltage direct current submarine cable usually adopts a circular monofilament circular compaction structure, but if the designed conductor cross-section is too large, due to the limitation of the frame stranding machine equipment, the diameter of each round monofilament will be too large, resulting in the frame stranding machine. The conductor compaction effect is poor or the traction is difficult.
  • the largest cross-section of the round monofilament circular compacted submarine cable conductor with engineering performance is 1800mm 2. If the designed conductor cross-section is larger, the use of the circular monofilament circular compacted structure will not meet the design requirements depending on the current equipment. And this structure is also difficult to meet the requirements of the conductor's water blocking performance in the deeper sea area.
  • the technical problem mainly solved by the present invention is to provide a high-voltage direct current submarine cable Z-type sealed cable conductor and a design method thereof, which can effectively solve the problem of the frame stranding machine being difficult to compress.
  • a technical solution adopted by the present invention is: a high-voltage direct current submarine cable Z-type sealed cable conductor, including a center line and a plurality of single wires, and the plurality of single wires are twisted in the center in a layer-by-layer manner. On the outer wall of the line;
  • the single wire is a Z-shaped single wire, and two adjacent Z-shaped single wires are stacked end to end with each other, and a plurality of the Z-shaped single wires are tightly wound together in a spiral shape through a stranding process;
  • All corners of the Z-shaped single wire are provided with chamfers.
  • the types of the centerline include a circular compact structure and a solid copper rod.
  • a method for designing a Z-type sealed cable conductor of a high-voltage direct current submarine cable includes:
  • the conductor outer diameter D A is calculated by formula (1),
  • S is the cross-sectional area of the conductor
  • ⁇ is the conductor filling factor. According to the previous manufacturing experience, the value of ⁇ is designed.
  • the correction angle ⁇ is calculated by formula (2),
  • Dn is the outer diameter of each corresponding layer
  • L is the pitch of the layer
  • the corrected angle ⁇ calculated in the step 2) is substituted into the formula (3) to calculate the center angle ⁇ corresponding to the extended line on both sides of the Z-shaped single line after correction. 0 ,
  • n is the actual number of the Z-shaped single wires in each corresponding layer
  • ⁇ 1 is the edge angle on one side of the Z-shaped single wires
  • the edge angle is the angle corresponding to the overlapping part of the adjacent Z-shaped single wires.
  • the center of the arc R 1 outside the lower half of the Z-shaped single wire is rotated to the left by ⁇ 1 , so that the Z-shaped single wire forms a sector ,
  • R 1 is the outer arc radius of the Z-shaped single wire
  • R 2 is the inner arc radius of the Z-shaped single wire
  • r is the chamfering radius
  • ⁇ is the left side of the lower end of the Z-shaped single wire and the lower left end.
  • the angle between the center of the chamfer r and the center of the outer arc R 1 , ⁇ is the center of the chamfer r to the outer arc R 2
  • the angle between the center of the circle, ⁇ and ⁇ are approximate values.
  • the radians ⁇ and ⁇ are substituted into the formula (8) to calculate the actual filling factor t of the Z-shaped single wire,
  • the Z-type sealed cable conductor designed by this method meets the conductor's water-blocking performance requirements.
  • the Z-type sealed cable conductor designed by this method does not meet the conductor's water-blocking performance requirements.
  • the round rod for the Z-shaped single wire drawing is designed, and the main characteristic dimensions of the Z-shaped single wire are the angle value ⁇ 0 corresponding to the Z-shaped single wire, and The linear length W corresponding to the smallest fan-shaped outer arc of the Z-shaped single line, the length V of the diagonal of the Z-shaped single line section, the difference between the radii of the inner and outer circles R 1 and R 2 where the Z-shaped single line cross-section ring is located H.
  • the cross-sectional area S of the Z-shaped single wire, the edge value d of the adjacent Z-shaped single wire, and the chamfer r of the Z-shaped single wire where the value of ⁇ 0 is determined by the number of frame twisters per layer, and the angle ⁇ 1 is equal to the value of the angle ⁇ 2 , and the value range of ⁇ 1 is 1/4 ⁇ 0 ⁇ 1/6 ⁇ 0 , the edge value d is the arc length of the angle ⁇ 1 on the center circle R 3 , and R 3 is the Z
  • the central arc radius of the Z-shaped single wire, R 3 R 1 +H/2
  • the diameter of the copper rod used for drawing is D
  • D is the diameter of the smallest circular single wire that accommodates the Z-shaped copper single wire section
  • the value of D is based on W and
  • the Z-shaped sealed cable conductor of the high-voltage direct current submarine cable of the present invention adopts a Z-shaped single-wire circular compaction structure, which effectively solves the problem of difficult compaction of the frame stranding machine, and the conductor compaction
  • the coefficient is higher than that of the circular monofilament circular compacted structure, which can meet the conductor water-blocking performance requirements of the high-voltage direct current submarine cable when laying in the open sea.
  • Figure 1 is a cross-sectional structure diagram of a Z-shaped sealed cable conductor for high-voltage direct current submarine cable and its design method. The centerline of the 6-layer Z-shaped copper conductor with a circular compact structure is produced.
  • Figure 2 is a cross-sectional structure diagram of a Z-shaped sealed cable conductor for a high-voltage direct current submarine cable and its design method.
  • the center line adopts a circular copper rod structure and a cross-sectional structure of a 7-layer Z-shaped copper conductor.
  • Fig. 3 is a schematic structural diagram of the cross-sectional structure of a Z-shaped sealed cable conductor of a high-voltage direct current submarine cable and a Z-shaped copper single wire made by a design method thereof.
  • Fig. 4 is a schematic diagram of the position of the Z-shaped copper single wire angle ⁇ and the angle ⁇ made by a Z-shaped sealed cable conductor of a high-voltage direct current submarine cable and its design method.
  • Figure 5 is a schematic diagram of the influence of the inclination angle ⁇ on the cross-section of the Z-shaped single line in a Z-shaped sealed cable conductor of a high-voltage direct current submarine cable and its design method.
  • Fig. 6 is a cross-sectional structure diagram of a Z-shaped sealed cable conductor of a high-voltage direct current submarine cable and its design method after an optimized 7-layer Z-shaped single-wire circular copper rod structure.
  • Fig. 7 is a schematic cross-sectional structure diagram of a Z-shaped sealed cable conductor of a high-voltage direct current submarine cable and an optimized Z-shaped copper single wire made by its design method.
  • a high-voltage direct current submarine cable Z-type sealed cable conductor including a center line and a number of single wires, a number of the single wires are twisted on the outer wall of the center line in a layered manner, the single wires It is a Z-shaped single wire, and the two adjacent Z-shaped single wires are stacked and matched end to end. A number of the Z-shaped single wires are tightly wound together in a spiral shape through a stranding process, and the Z-shaped single wire circular pressing structure is adopted.
  • wire drawing machine equipment wire drawing and annealing can not meet the requirements, wire drawing equipment can not make such a large conductor, such a thick solid copper rod is not easy to bend, and the cable inevitably needs to be bent in the process of production, transportation and laying, and multiple strands
  • the conductor made of copper single wire (copper wire) is more flexible, the cable bending radius is small, and it is easy to produce, transport and lay.
  • the corners of the Z-shaped single wires are all provided with chamfers, and the chamfer makes the two connected Z-shaped single wires more closely connected.
  • a method for designing a Z-type sealed cable conductor of a high-voltage direct current submarine cable includes:
  • S is the conductor cross-sectional area, which is 3000mm 2
  • Dn is the outer diameter of each corresponding layer
  • L is the pitch of the layer
  • n is the actual number of the Z-shaped single wires in each corresponding layer
  • ⁇ 1 is the edge angle on one side of the Z-shaped single wires
  • the edge angle is the angle corresponding to the overlapping part of the adjacent Z-shaped single wires.
  • R 1 is the outer arc radius of the Z-shaped single wire
  • R 2 is the inner arc radius of the Z-shaped single wire
  • r is the chamfering radius
  • ⁇ is the left side of the lower end of the Z-shaped single wire and the lower left end.
  • the angle between the center of the chamfer r and the center of the outer arc R 1 , ⁇ is the center of the chamfer r to the outer arc R 2
  • the angle between the center of the circle, ⁇ and ⁇ are approximate.
  • the Z-type sealed cable conductor designed by this method meets the conductor's water-blocking performance requirements.
  • the Z-type sealed cable conductor designed by this method does not meet the conductor's water-blocking performance requirements.
  • the main characteristic dimensions of the Z-shaped single wire are the angle value ⁇ 0 corresponding to the Z-shaped single wire, the linear length W corresponding to the smallest fan-shaped outer arc that accommodates the Z-shaped single wire, and the Z The length V of the diagonal of the Z-shaped single-line cross-section , the difference H between the radii of the inner and outer circles R 1 and R 2 where the Z-shaped single-line cross-section ring is located, the cross-sectional area S of the Z-shaped single-line, and the overlap of the adjacent Z-shaped single-line.
  • the boundary value d and the chamfering angle r of the Z-shaped single wire where the value of ⁇ 0 is determined by the number of frame twisters per layer, the value of angle ⁇ 1 is equal to the value of angle ⁇ 2 , and the value range of ⁇ 1 is 1/4 ⁇ 0 ⁇ 1/6 ⁇ 0 , the edge value d is the arc length of the angle ⁇ 1 on the central circle R 3
  • the types of the center line include a circular compacted structure and a solid copper rod.
  • a 6-layer molded circular compacted conductor structure is designed.
  • the Z-shaped copper single-wire conductor with a circular compacted structure is formed by twisting a layer of circular compacted structure and 5 layers of Z-shaped single wires.
  • the Z-shaped copper single-wire conductor with a solid copper rod as the center line consists of 1 layer of solid copper. Copper rod and 5-layer Z-shaped single wire are twisted together.
  • the actual number of frames used is 1, 6 , 12, 18, 24, 30 boxes.
  • the center line uses a solid copper rod with a small size, and the Z-shaped single line area distribution of each layer is more even , Reasonable, the diameter D value of the smallest round single wire accommodating the Z-shaped single wire cross-section is smaller, which is more convenient for the production of the Z-shaped single wire described in the 6 frame.
  • the center line adopts a diameter of The Z-shaped copper conductor design scheme of the solid copper rod is the best, and the stranded wire can be produced at one time, and the production efficiency is higher.
  • Table 1 The design scheme of the circular compacted conductor structure of the 6-layer profiled wire of the 91-frame stranding machine
  • the maximum number of frames that can be set for each layer of the 127 frame twister is 1, 6, 12, 18, 24, 30, and 36 frames.
  • the actual number of frames used is 1, 12, 18, 24, 30, 36 frames.
  • the number of frames that can be used for the 127 frame twister can be set more than that of the 91 frame twister.
  • C, d, e can be seen that the value of ⁇ corresponding to Table 2 decreases, and the cross-sectional area, D value, width W value, diagonal length S value of the Z-type single line are correspondingly reduced, and the Z-type single line width-to-height ratio is The range from 1.3 to 1.7 is more reasonable, indicating that the production scheme of the 127 frame twister is better.
  • the center line adopts a solid copper rod and the center line adopts a circular compacted structure conductor, and the Z-type single line area distribution is not much different. Regardless of whether the center line uses a solid copper rod and the center line uses a Z-shaped copper conductor with a circular compression structure, the corresponding D value is less than 8mm, but the center line uses a solid copper rod with high production efficiency and is produced in the factory It is more applicable.
  • the cross-sectional area of the Z-shaped single wire in box 6 gradually increases, and the value of D gradually increases.
  • the cross-sectional area of the Z-shaped single wire in other boxes is not much different, but the largest The value of D also gradually increases, resulting in increased difficulty in the production of the Z-type single line.
  • the maximum diameter of the copper rod of the Z-shaped single wire produced by the continuous drawing and continuous withdrawal process is 8mm, and the maximum diameter of the copper rod of the Z-shaped single wire produced by the extrusion process method can be 12.9mm or even larger, but the extrusion process
  • the production efficiency of the method is low, and it is difficult to meet the production of large-length conductors.
  • the continuous pulling and unwinding process has high production efficiency and is suitable for the production of large-length conductors.
  • the center line adopts The solid copper rod is conducive to the stranding of one-time conductors, so the diameter of the center line is
  • the Z-shaped copper conductor design with solid copper rod and 7-layer structure design is the best.
  • Table 4 is designed to take a different edge angles [theta] 1 of the embodiment, [theta] 1 can be seen that the smaller the value, the smaller the D value, the more beneficial
  • the Z-shaped single wire is produced by the continuous pulling and unwinding process.
  • the width-to-height ratio of the Z-shaped single wire at the 6 frame is closer to the reasonable range, but the d value of the overlapping side length is also smaller. contain.
  • ⁇ 1 The greater the value of ⁇ 1 is, the greater the value of D, the farther away the aspect ratio of the Z-shaped single line at frame 6 is from the reasonable range, and the larger the value of the side length d, which is beneficial for the adjacent Z-shaped single lines to contain each other, but d If the value is too large, it will obviously increase the difficulty of production, so the edge angle ⁇ 1 ranges from 1/4 ⁇ 0 to 1/6 ⁇ 0 , and the intermediate value 1/5 ⁇ 0 can be selected for this design scheme.
  • Table 4 The center line is the diameter Solid copper rod conductor structure design scheme table
  • the Z-shaped single wire needs to be chamfered in the actual drawing and stranding process to meet the actual production needs, but the existence of the chamfer will make the Z-shaped single wire structure design
  • the solution has gaps to reduce the longitudinal water blocking performance of the conductor. Therefore, it is necessary to select a suitable chamfer, which can not only meet the water blocking performance requirements of the conductor, but also meet the needs of mold processing and actual production.
  • the Z-type single-wire chamfering radius is selected to be 0.3mm, which meets the mold processing capacity and actual production requirements, and the t calculated by step 4)
  • the value is greater than 0.96, which satisfies the conductor's water-blocking performance requirements.
  • the Z-shaped single wire structure can be further optimized.
  • the main characteristic value of the Z-shaped single wire is the angle ⁇ 3 corresponding to the outer arc and the radius is H/2 chamfer R and chamfer r, this structure can not only reduce the cross-sectional area of the Z-shaped single wire, but also improve the production efficiency of the circular compacted conductor.
  • the solid copper rod adopts the 127 frame stranding machine and the 7-layer Z-type single-line structure design scheme.
  • the structure size is optimized as shown in Table 6.
  • Table 6 Optimized 127 frame stranding machine 7-layer Z-type single-line design structure size table
  • each Z-shaped single wire In order to reduce the cross-sectional area of each Z-shaped single wire, it is necessary to keep the cross-sectional area of each Z-shaped single wire basically the same, so the height of each layer is not much different, and the number of Z-shaped single wires arranged in the inner layer Less, so the corresponding circle angle is larger, so it looks more deformed from the outside.
  • the Z-shaped sealed cable conductor of the high-voltage direct current submarine cable of the present invention adopts a Z-shaped single-wire circular compaction structure, which effectively solves the problem of difficulty in compaction by the frame stranding machine, and the conductor is compacted.
  • the coefficient is higher than that of the circular monofilament circular compacted structure, which can meet the conductor water-blocking performance requirements of the high-voltage direct current submarine cable when laying in the open sea.

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Abstract

一种高压直流海缆Z型密封电缆导体及其设计方法，该电缆导体包括中心线和若干单线，若干单线以层层叠加的方式绞合在中心线外壁上；单线为Z型单线，相邻的两个Z型单线之间首尾相互堆叠配合，若干Z型单线通过绞线工艺呈螺旋状紧密缠绕在一起；Z型单线上的转角处均设有倒角。该高压直流海缆Z型密封电缆导体采用Z型单线圆形紧压结构，有效地解决了框绞机紧压难度大的问题，并且导体紧压系数相对于圆形单丝圆形紧压结构高，可以满足高压直流海缆在远海敷设时导体阻水性能要求。

Description

一种高压直流海缆Z型密封电缆导体及其设计方法 技术领域
本发明属于电力电缆领域，具体涉及一种高压直流海缆Z型密封电缆导体及其设计方法。
背景技术
在近海风电资源日益枯竭、远海风电快速发展以及全球能源互联互通背景下，高压直流海缆以其传输功率大、损耗小、输电距离远及不需要考虑交流输电过程中存在于导体上的集肤效应及邻位效应等优点引起国内外大型海底电缆生产厂家广泛的研究。
高压直流海缆导体设计通常采用圆形单丝圆形紧压结构，但如果设计导体截面太大，由于框绞机设备的限制，每根圆形单丝直径就会太大，导致框绞机导体紧压效果差或牵引难度大。
目前圆形单丝圆形紧压海缆导体有工程业绩的最大截面为1800mm 2，如果设计导体截面更大，采用圆形单丝圆形紧压结构依靠目前的设备就会达不到设计要求，且此结构也很难满足更深敷设海域对导体阻水性能的要求。
发明内容
本发明主要解决的技术问题是提供一种高压直流海缆Z型密封电缆导体及其设计方法，能够有效地解决框绞机紧压难度大的问题。
为解决上述技术问题，本发明采用的一个技术方案是：一种高压直流海缆Z型密封电缆导体，包括中心线和若干单线，若干所述单线以层层叠加的方式绞合在所述中心线外壁上；
所述单线为Z型单线，相邻的两所述Z型单线之间首尾相互堆叠配合，若干所述Z型单线通过绞线工艺呈螺旋状紧密缠绕在一起；
所述Z型单线上的转角处均设有倒角。
在本发明一个较佳实施例中，所述中心线的种类包括圆形紧压结构和实心铜棒。
一种高压直流海缆Z型密封电缆导体的设计方法，具体步骤包括：
1)计算导体的外径D A；
2)计算修正角度δ；
3)计算Z型单线两边延长线对应的圆心角θ 0；
4)计算Z型单线的填充系数t；
5)Z型单线拉丝设计；
6)优化Z型单线结构。
在本发明一个较佳实施例中，所述步骤1)中通过公式(1)计算导体外径D A,
Figure PCTCN2019127799-appb-000001
其中S为导体截面面积，η为导体填充系数，根据以往生产制造经验，设计η取值。
在本发明一个较佳实施例中，所述步骤2)中通过公式(2)计算修正角度δ，
Figure PCTCN2019127799-appb-000002
其中Dn为对应的各层的外径，L为此层的节距。
在本发明一个较佳实施例中，所述步骤3)中将步骤2)计算得到的修正角 度δ代入公式(3)中计算出修正后的所述Z型单线两边延长线对应的圆心角θ 0，
Figure PCTCN2019127799-appb-000003
其中n为对应的各层实际所述Z型单线的根数，θ 1为所述Z型单线一侧的搭边角，搭边角为相邻所述Z型单线重叠部分所对应的角度。
在本发明一个较佳实施例中，所述步骤4)中将所述Z型单线的下半部分以外圆弧R 1的圆心为圆心向左旋转θ 1，使得所述Z型单线组成一个扇形，通过公式(4)、(5)计算出角度λ和角度μ，然后通过公式(6)和(7)再将λ和μ转化成弧度α和β，
Figure PCTCN2019127799-appb-000004
Figure PCTCN2019127799-appb-000005
α＝λ/180°*π       (6)
β＝μ/180°*π      (7)
其中R 1为所述Z型单线的外圆弧半径，R 2为所述Z型单线的内圆弧半径，r为倒角半径，λ为所述Z型单线下端左侧边与左下端所述倒角r的圆心到所述外圆弧R 1圆心连线的夹角，μ为所述Z型单线上端左侧边与左上端所述倒角r的圆心到所述外圆弧R 2圆心连线的夹角,λ和μ均为近似值。
在本发明一个较佳实施例中，所述步骤4)中将弧度α和β代入公式(8)中计算出Z型单线的实际填充系数t，
Figure PCTCN2019127799-appb-000006
当t≥η时，该方法设计的Z型密封电缆导体满足导体阻水性能要求，当t＜ η时，该方法设计的Z型密封电缆导体不满足导体阻水性能要求。
在本发明一个较佳实施例中，所述步骤5)中对Z型单线拉丝用的圆杆进行设计，所述Z型单线的主要特征尺寸为所述Z型单线对应角度值θ 0、容纳所述Z型单线的最小扇形外圆弧对应的直线长度W、所述Z型单线截面对角线的长度V、所述Z型单线截面圆环所在的内外圆R 1、R 2半径之差H、所述Z型单线截面面积S、相邻所述Z型单线的搭边值d和所述Z型单线的倒角r，其中θ 0值由每层框绞机框数决定，角度θ 1与角度θ 2的值相等，θ 1取值范围为1/4θ 0～1/6θ 0，搭边值d为在中心圆R 3上角度θ 1的圆弧长度，R 3为所述Z型单线的中心圆弧半径，R 3＝R 1+H/2，用于拉丝的铜杆直径为D，D为容纳所述Z型铜单线截面的最小圆单线的直径，D值根据W和V值选取，当W/V>1时，D＝W，当W/V<1时，D＝V。
在本发明一个较佳实施例中，所述步骤6)中对设计好的所述Z型单线进行优化，将与R 3圆弧相连接的四个所述倒角r的尺寸调整为R，R＝H/2，所述Z型单线外圆弧对应的角度θ 3。
本发明的有益效果是：本发明高压直流海缆Z型密封电缆导体，该电缆导体采用Z型单线圆形紧压结构，有效地解决了框绞机紧压难度大的问题，并且导体紧压系数相对于圆形单丝圆形紧压结构高，可以满足高压直流海缆在远海敷设时导体阻水性能要求。
附图说明
图1为一种高压直流海缆Z型密封电缆导体及其设计方法制作的中心线采用圆形紧压结构的6层Z型铜导体截面结构示意图。
图2为一种高压直流海缆Z型密封电缆导体及其设计方法制作的中心线采用圆形铜棒结构的7层Z型铜导体截面结构示意图。
图3为一种高压直流海缆Z型密封电缆导体及其设计方法制作的Z型铜单线的截面结构示意结构示意图。
图4为一种高压直流海缆Z型密封电缆导体及其设计方法制作的Z型铜单线角度λ和角度μ的位置示意图。
图5为一种高压直流海缆Z型密封电缆导体及其设计方法中倾斜角δ对Z型单线截面影响的示意图。
图6为一种高压直流海缆Z型密封电缆导体及其设计方法制作的优化后7层Z型单线圆形铜棒结构的导体截面结构示意图。
图7为一种高压直流海缆Z型密封电缆导体及其设计方法制作的优化后Z型铜单线的截面结构示意图。
具体实施方式
下面结合附图对本发明的较佳实施例进行详细阐述，以使本发明的优点和特征能更易于被本领域技术人员理解，从而对本发明的保护范围做出更为清楚明确的界定。
请参阅图1至图7，一种高压直流海缆Z型密封电缆导体，包括中心线和若干单线，若干所述单线以层层叠加的方式绞合在所述中心线外壁上，所述单线为Z型单线，相邻的两所述Z型单线之间首尾相互堆叠配合，若干所述Z型单线通过绞线工艺呈螺旋状紧密缠绕在一起，采用所述Z型单线圆形紧压结构，有效地解决了框绞机紧压难度大的问题，并且导体紧压系数相对于圆形单线圆形紧压结构高，可以有效满足高压直流海缆在远海敷设时导体纵向阻水性能要求。
若采用大截面实心铜棒
Figure PCTCN2019127799-appb-000007
拉丝机设备拉丝、退火都打不到要求，拉丝设备没有办法做这么大的导体，这么粗的实心铜棒不易弯曲，而电缆在生产、运输和敷设过程中不可避免的需要弯曲，而多股铜单线(铜丝)绞合而成的导体更易弯曲，电缆弯曲半径小，易于生产、运输和敷设。
所述Z型单线上的转角处均设有倒角，所述倒角使得相连的两所述Z型单线连接更加紧密。
一种高压直流海缆Z型密封电缆导体的设计方法，具体步骤包括：
1)计算导体的外径D A，通过公式(1)计算导体外径D A,
Figure PCTCN2019127799-appb-000008
其中S为导体截面面积，取值3000mm 2，η为导体填充系数，根据以往生产制造经验，设计η取值，取值0.96，通过计算得到D A＝63.08，修正为63.5mm。
2)计算修正角度δ，通过公式(2)计算修正角度δ，
Figure PCTCN2019127799-appb-000009
其中Dn为对应的各层的外径，L为此层的节距。
3)计算Z型单线两边延长线对应的圆心角θ 0，将步骤2)计算得到的修正角度δ代入公式(3)中计算出修正后的所述Z型单线两边延长线对应的圆心角θ 0，
Figure PCTCN2019127799-appb-000010
其中n为对应的各层实际所述Z型单线的根数，θ 1为所述Z型单线一侧的搭边角，搭边角为相邻所述Z型单线重叠部分所对应的角度。
4)计算Z型单线的填充系数t，将所述Z型单线的下半部分以外圆弧R 1的圆心为圆心向左旋转θ 1，使得所述Z型单线组成一个扇形，通过公式(4)、 (5)计算出角度λ和角度μ，然后通过公式(6)和(7)再将λ和μ转化成弧度α和β，
Figure PCTCN2019127799-appb-000011
Figure PCTCN2019127799-appb-000012
α＝λ/180°*π      (6)
β＝μ/180°*π      (7)
其中R 1为所述Z型单线的外圆弧半径，R 2为所述Z型单线的内圆弧半径，r为倒角半径，λ为所述Z型单线下端左侧边与左下端所述倒角r的圆心到所述外圆弧R 1圆心连线的夹角，μ为所述Z型单线上端左侧边与左上端所述倒角r的圆心到所述外圆弧R 2圆心连线的夹角,λ和μ均为近似值。
将弧度α和β代入公式(8)中计算出Z型单线的实际填充系数t，
Figure PCTCN2019127799-appb-000013
当t≥η时，该方法设计的Z型密封电缆导体满足导体阻水性能要求，当t＜η时，该方法设计的Z型密封电缆导体不满足导体阻水性能要求。
5)Z型单线拉丝设计，所述Z型单线的主要特征尺寸为所述Z型单线对应角度值θ 0、容纳所述Z型单线的最小扇形外圆弧对应的直线长度W、所述Z型单线截面对角线的长度V、所述Z型单线截面圆环所在的内外圆R 1、R 2半径之差H、所述Z型单线截面面积S、相邻所述Z型单线的搭边值d和所述Z型单线的倒角r，其中θ 0值由每层框绞机框数决定，角度θ 1与角度θ 2的值相等，θ 1取值范围为1/4θ 0～1/6θ 0，搭边值d为在中心圆R 3上角度θ 1的圆弧长度，R 3为所 述Z型单线的中心圆弧半径，R 3＝R 1+H/2，用于拉丝的铜杆直径为D，D为容纳所述Z型铜单线截面的最小圆单线的直径，D值根据W和V值选取，当W/V>1时，D＝W，当W/V<1时，D＝V。
6)优化Z型单线结构，将与R 3圆弧相连接的四个所述倒角r的尺寸调整为R，R＝H/2，所述Z型单线外圆弧对应的角度θ 3。
所述中心线的种类包括圆形紧压结构和实心铜棒，根据中所述心线采用圆形紧压结构和实心铜棒分别设计了6层型线圆形紧压导体结构，所述中心线为圆形紧压结构的Z型铜单线导体由1层圆形紧压结构和5层Z型单线绞合而成，所述中心线为实心铜棒的Z型铜单线导体由1层实心铜棒和5层Z型单线绞合而成。
6层型线圆形紧压导体结构
采用91框绞机Z型铜导体设计方案
根据所述中心线采用实心铜棒直径不同，分别设计了a、b两种方案，所述中心线采用圆形紧压结构尺寸不同，分别设计了c、d、e等3种方案。
由于91框绞机每层可以设置的最大框数为1、6、12、18、24、30框，为了尽量减小每根所述Z型单线的截面积，实际使用框数为1、6、12、18、24、30框。
由表1可以看出，所述Z型单线角度固定，通过每层所述Z型单线高度调节，控制每层所述每根Z型单线截面积相近，从而达到各层D值最小化。
从方案a到方案e，随着中心线直径增大，24框处及30框处D值基本不变，但6框及12框处所述Z型单线外径增加，所述Z型单线截面积虽然相差不大，但所需铜杆直径D值增大，对应Z型单线连拉连退设备生产难度增大，并且由于所述Z型单线宽高比W/H增大，对应所述Z型单线绞线难度增大。
对比所述中心线采用实心铜棒和所述中心线采用圆形紧压结构的Z型铜导体设计方案，所述中心线采用实心铜棒尺寸小，各层所述Z型单线面积分布更加均匀、合理，容纳Z型单线截面的最小圆单线的直径D值更小，更方便6框所述Z型单线的生产，所述中心线采用直径为
Figure PCTCN2019127799-appb-000014
实心铜棒的Z型铜导体设计方案最优，绞线一次生产，生产效率更高。
Figure PCTCN2019127799-appb-000015
表1 91框绞机6层型线圆形紧压导体结构设计方案表
采用127框绞机Z型铜导体设计方案
127框绞机每层可以设置的最大框数为1、6、12、18、24、30、36框，为了与91框绞机相对比，实际使用框数为1、12、18、24、30、36框。
在设计每层高度相同的情况下，采用127框绞机比91框绞机可使用框数可 以设置更多，分别对比表1方案a、b、c、d、e和表2方案a、b、c、d、e可以看出，表2对应的θ值减小，Z型单线截面面积、D值、宽度W值、对角线长度S值都相应减小，Z型单线宽高比在1.3～1.7范围内，更加合理，说明127框绞机生产方案更优。
对比表2中a、b、c、d、e等5种方案，所述中心线采用实心铜棒和所述中心线采用圆形紧压结构的导体所述Z型单线面积分布差异不大，无论所述中心线采用实心铜棒和所述中心线采用圆形紧压结构的Z型铜导体所对应的D值都小于8mm，但所述中心线采用实心铜棒生产效率高，在工厂生产中更加适用。
Figure PCTCN2019127799-appb-000016
表2 127框绞机6层型线圆形紧压导体结构设计方案表7层型线圆形紧压导体结构
在127框绞机7层型线圆形紧压导体结构中，实际使用框数为1、6、12、18、24、30、36框，导体结构尺寸如表3所示。
对比表3中a、b、c、d、e五个方案，6框处所述Z型单线截面积逐渐增加，D值逐渐增加，其他框处所述Z型单线截面相差不大，但最大D值也逐渐增大，导致所述Z型单线生产难度也增大。
将表3与表2对比可以发现，表3中方案b、c、d、e，每个方案最大D值均高于表2，只有表3方案a最大D值小于表2方案a，因此表3方案a相较于方案b、c、d、e及表2，表3方案a更优。
目前采用连拉连退工艺方法生产所述Z型单线的铜杆最大直径为8mm，采用挤出工艺方法生产所述Z型单线的铜杆最大直径为12.9mm甚至可以更大，但挤出工艺方法生产效率低，难以满足导体大长度生产。连拉连退工艺方法生产效率高，适合导体大长度生产，此外所述中心线采用
Figure PCTCN2019127799-appb-000017
实心铜棒利于一次性导体绞合，因此所述中心线采用直径为
Figure PCTCN2019127799-appb-000018
实心铜棒、7层结构设计的Z型铜导体设计方案最优。
Figure PCTCN2019127799-appb-000019
表3 127框绞机7层型线圆形紧压导体结构设计方案表
以所述中心线为
Figure PCTCN2019127799-appb-000020
实心铜棒，采用127框绞机7层Z型单线结构设计方案为例，表4设计了不同搭边角度θ 1的方案，可以看出θ 1值越小，D值越小，越有利于连拉连退工艺生产Z型单线，6框处所述Z型单线宽高比越接近合理范围，但搭边长度d值也越小，d值太小不利于相邻所述Z型单线互相牵制。
θ 1值越大，D值越大，6框处所述Z型单线宽高比越远离合理范围，搭边长 度d值也越大，有利于相邻所述Z型单线互相牵制，但d值太大会明显增加生产难度，因此搭边角度θ 1取值范围在1/4θ 0～1/6θ 0，此设计方案可选中间值1/5θ 0。
Figure PCTCN2019127799-appb-000021
表4中心线为直径
Figure PCTCN2019127799-appb-000022
实心铜棒导体结构设计方案表
考虑工艺节距对Z型单线尺寸的影响，以中心线为
Figure PCTCN2019127799-appb-000023
实心铜棒，采用127框绞机7层Z型单线结构设计方案为例，节距对单线倾斜角度δ的影响见表5。
Figure PCTCN2019127799-appb-000024
表5节距对单线倾斜角度δ的影响表
所述Z型单线在实际拉丝、绞线生产过程中都需要将所述Z型单线进行所述倒角处理，满足实际生产需要，但所述倒角的存在会使得所述Z型单线结构设计方案有缝隙，降低导体的纵向阻水性能，因此需要选择合适的所述倒角，既能满足导体阻水性能要求，又满足模具加工、实际生产的需要。
以所述中心线为
Figure PCTCN2019127799-appb-000025
铜棒，采用127框绞机7层所述Z型单线结构设计方案为例，所述Z型单线倒角半径选择0.3mm，满足模具加工能力及实际生产要求，通过步骤4)计算得到的t值大于0.96，满足导体阻水性能要求。
考虑到所述中心线内侧所述倒角具有一定的加工难度，可以将所述Z型单线结构进一步优化，优化后所述Z型单线主要特征值为外圆弧对应的角度θ 3、半径为H/2的倒角R和倒角r，此种结构不仅可以减小Z型单线截面面积，还提高了圆形紧压导体生产效率。
因此以中心线为
Figure PCTCN2019127799-appb-000026
实心铜杆，采用127框绞机7层Z型单线结构设计方案结构尺寸优化后如表6所示。
Figure PCTCN2019127799-appb-000027
表6优化后127框绞机7层Z型单线设计方案结构尺寸表
为了减小每根所述Z型单线的截面积需要保持每根所述Z型单线截面积基本保持一致，所以每层高度相差不大，而越往内层所述Z型单线排列的个数少，所以对应的圆周角度大，所以从外观看，显得越变形。
与现有技术相比，本发明高压直流海缆Z型密封电缆导体，该电缆导体采用Z型单线圆形紧压结构，有效地解决了框绞机紧压难度大的问题，并且导体紧压系数相对于圆形单丝圆形紧压结构高，可以满足高压直流海缆在远海敷设时导体阻水性能要求。
在本发明的描述中，需要说明的是，术语“上”、“下”、“左”、“右”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，或者是该 发明产品使用时惯常摆放的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。
以上所述仅为本发明的实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (10)

  1. 一种高压直流海缆Z型密封电缆导体，其特征在于，包括中心线和若干单线，若干所述单线以层层叠加的方式绞合在所述中心线外壁上；
    所述单线为Z型单线，相邻的两所述Z型单线之间首尾相互堆叠配合，若干所述Z型单线通过绞线工艺呈螺旋状紧密缠绕在一起；
    所述Z型单线上的转角处均设有倒角。
  2. 根据权利要求1所述的一种高压直流海缆Z型密封电缆导体，其特征在于：所述中心线的种类包括圆形紧压结构和实心铜棒。
  3. 一种高压直流海缆Z型密封电缆导体的设计方法，其特征在于：具体步骤包括：
    1)计算导体的外径D A；
    2)计算修正角度δ；
    3)计算Z型单线两边延长线对应的圆心角θ 0；
    4)计算Z型单线的填充系数t；
    5)Z型单线拉丝设计；
    6)优化Z型单线结构。
  4. 根据权利要求3所述的一种高压直流海缆Z型密封电缆导体的设计方法，其特征在于：所述步骤1)中通过公式(1)计算导体外径D A,
    Figure PCTCN2019127799-appb-100001
    其中S为导体截面面积，η为导体填充系数，根据以往生产制造经验，设计η取值。
  5. 根据权利要求3所述的一种高压直流海缆Z型密封电缆导体的设计方法，其特征在于：所述步骤2)中通过公式(2)计算修正角度δ，
    Figure PCTCN2019127799-appb-100002
    其中Dn为对应的各层的外径，L为此层的节距。
  6. 根据权利要求5所述的一种高压直流海缆Z型密封电缆导体的设计方法，其特征在于：所述步骤3)中将步骤2)计算得到的修正角度δ代入公式(3)中计算出修正后的所述Z型单线两边延长线对应的圆心角θ 0，
    Figure PCTCN2019127799-appb-100003
    其中n为对应的各层实际所述Z型单线的根数，θ 1为所述Z型单线一侧的搭边角，搭边角为相邻所述Z型单线重叠部分所对应的角度。
  7. 根据权利要求3所述的一种高压直流海缆Z型密封电缆导体的设计方法，其特征在于：所述步骤4)中将所述Z型单线的下半部分以外圆弧R 1的圆心为圆心向左旋转θ 1，使得所述Z型单线组成一个扇形，通过公式(4)、(5)计算出角度λ和角度μ，然后通过公式(6)和(7)再将λ和μ转化成弧度α和β，
    Figure PCTCN2019127799-appb-100004
    Figure PCTCN2019127799-appb-100005
    α＝λ/180°*π      (6)
    β＝μ/180°*π       (7)
    其中R 1为所述Z型单线的外圆弧半径，R 2为所述Z型单线的内圆弧半径，r为倒角半径，λ为所述Z型单线下端左侧边与左下端所述倒角r的圆心到所述外圆弧R 1圆心连线的夹角，μ为所述Z型单线上端左侧边与左上端所述倒角r的圆心到所述外圆弧R 2圆心连线的夹角,λ和μ均为近似值。
  8. 根据权利要求7所述的一种高压直流海缆Z型密封电缆导体的设计方法，其特征在于：所述步骤4)中将弧度α和β代入公式(8)中计算出Z型单线的实际填充系数t，
    Figure PCTCN2019127799-appb-100006
    当t≥η时，该方法设计的Z型密封电缆导体满足导体阻水性能要求，当t＜η时，该方法设计的Z型密封电缆导体不满足导体阻水性能要求。
  9. 根据权利要求3所述的一种高压直流海缆Z型密封电缆导体的设计方法，其特征在于：所述步骤5)中对Z型单线拉丝用的圆杆进行设计，所述Z型单线的主要特征尺寸为所述Z型单线对应角度值θ 0、容纳所述Z型单线的最小扇形外圆弧对应的直线长度W、所述Z型单线截面对角线的长度V、所述Z型单线截面圆环所在的内外圆R 1、R 2半径之差H、所述Z型单线截面面积S、相邻所述Z型单线的搭边值d和所述Z型单线的倒角r，其中θ 0值由每层框绞机框数决定，角度θ 1与角度θ 2的值相等，θ 1取值范围为1/4θ 0～1/6θ 0，搭边值d为在中心圆R 3上角度θ 1的圆弧长度，R 3为所述Z型单线的中心圆弧半径，R 3＝R 1+H/2，用于拉丝的铜杆直径为D，D为容纳所述Z型铜单线截面的最小圆单线的直径，D值根据W和V值选取，当W/V>1时，D＝W，当W/V<1时，D＝V。
  10. 根据权利要求3所述的一种高压直流海缆Z型密封电缆导体的设计方法，其特征在于：所述步骤6)中对设计好的所述Z型单线进行优化，将与R 3圆弧相连接的四个所述倒角r的尺寸调整为R，R＝H/2，所述Z型单线外圆弧对应的角度θ 3。
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