Method of making universal cable
It is used for manufacturing universal electric cables for oil production used as feed, heating at downhole equipment, etc. and load-carrying cables. Solves the problem of increasing the resistance of the cable to tension, crushing and impact loads in the manufacturing process, jump, lifting operations and maintenance. Reduces labor and material costs. Is holding tripping operation at low temperatures. The insulating coating on the conductors (TJ) impose by extrusion simultaneously on two parallel and at a fixed distance from one another TJ to form between them a rigid jumpers of insulating material in one pass, and the formation of multi-core universal cable is carried out in the process of applying for isolated TJ pillows under armour and belt armor by placing between two isolated simultaneously TJ isolated individually TJ. When this jumper is placed TJ isolated from a material with different specific resistances, and different sections. Profile jumpers of insulating material may be flat, wipmania. 4 C.p. f-crystals, 2 Il. The invention relates to technology universal (multipurpose) electric cables for oil production that are used in conjunction with the equipment of oil and water wells to supply electric motors of submersible pumps, the limit of heating up of high-viscosity oil and gas mixture in the well, to prevent and eliminate parfenovitch tubes in the well, to the limit of heating up of pipelines, as well as the load-bearing cable.A known method of manufacturing a universal cable, including the manufacture of the conductors, overlaying the conductive core by extrusion sequentially first, then the second heat-resistant insulation membranes, testing of semi-finished product and the subsequent formation of the insulated conductive wires of the multiwire cable by imposing on isolated veins protective winding pillows under armor - with a simultaneous imposition on her belt profiled reservation, or by imposing on the insulated cores total hose shell pillows under armor - with the subsequent imposition on her belt profiled, and Lastochkin to the claimed technical nature.The disadvantages of this method are: - poor performance, because of the imposition of a two-layer shell (to provide the required insulating properties) requires each mine twice to pass through the extruder; - requires considerable labor and material costs in the process of isolating conductive wires and the formation of these cables, and when booking, because for each of the conductors must be individual drum and respectively terminating device.In addition, the cable is manufactured in a known manner, is not a high electrical and mechanical characteristics, namely: - insufficient high resistance isolation medium veins crush lateral veins, which is expressed at elevated temperatures during operation of the cable when the average veins can be crushed lateral veins; - lack of firmness construction of the cable to tensile and impact loads in the process of winding and operation of the cable in the borehole conditions: during operation of the cable occurs hood cable on 7-15%, which leads to the violation (escape) insulating membrane with veins, as well as the divergence of orbits armor and, as a consequence of the violation of this temperature and below, in the process of rewinding and tripping operation occurs cracking of the insulation shells.These drawbacks made known method of cable reduce its operational reliability, resulting in the cable goes down and to the further exploitation unsuitable.The technical task to be solved by the invention is to improve the operational reliability of the manufactured universal cable, in particular, improved resistance to stretching, squashing and shock loads in the manufacturing process, jump, lifting operations and maintenance.Also solves the problem of reducing labor and material costs in the manufacture of the universal cable.Additionally solved the technical problem - providing for a tripping operation at low temperatures by providing samoprogreva cable.The goal of the project is achieved in that in the known method of manufacturing a universal cable which includes applying to the conductive core by extrusion of at least one insulating sheath, the formation of the insulated conductive wires stranded to the her armor or overlay on the insulated conductive wires total protective hose sheath with the subsequent imposition on her armor, what's new is that the insulating sheath is applied extrusion simultaneously on two parallel and at a fixed distance from each other, the conductors to form between them a rigid jumpers of insulating material, and insulating sheaths for the two conductive wires with a rigid bridge between them impose by extrusion in a single pass, the formation of multi-core universal cable in the overlay process on isolated veins or protective winding or overlay hose winding and booking on the bridge between the two insulated conductors are placed insulated conductive wires individually insulated, and the shape of the cable is attached in the booking process.On the bridge between two isolated at the same time the electric conductors accommodated isolated strands of conductive material with different resistivity and different cross-sections.Profile jumpers of insulating material between two conductors when the extrusion perform flat, convex, concave.The jumper between the cores in the process of isolating perform the specified width, height and shape.The shape of the cable in procession shell impose extrusion simultaneously on two parallel and at a fixed distance from each other, the conductors to form between them a rigid jumpers from the same insulating material, moreover, the imposition of isolation on two cores are produced in a single pass, is provided by: - improving the performance of cable manufacturing; - reducing the number of reels and pay offs devices during manufacturing and rewinding of the material; - creating rigid structures of the semi-finished product (finished product) due to the formed rigid bridges between isolated veins.The operation of isolating conductive wires offered by way allows you to tuck the average cable conductor individually insulated in a fixed interval on a rigid jumper, thus eliminating the negative effects of stretching, squashing and shock loads on the cable core. Such rigid lateral insulated conductors will help protect against crushing and mechanical damage secondary veins that are located in more severe conditions as in the manufacturing process of the cable, and in the process of exploitation.The implementation of hard jumpers of different profiles - flat, convex, or concave, and the specified width, height, and shape - allows you to use universal cable for heating various surfaces and therefore extend the functionality of such a cable.Blogvideo material with different resistivity and different cross-section, have the opportunity to place between the main veins auxiliary leads with high resistivity and a smaller cross-section, which can function as an additional source of heat capacity and use the extra cores for samoprogreva cable directly in the field, which allows runs of cable at low temperatures (below 18oC) without insulation.In Fig.1 and 2 variants of multi-conductor cable manufactured according to the proposed method.The process of manufacture of stranded universal cable includes the following operations: manufacture of conductive wires; overlaying the insulation on the wires; the test material; forming a multi-conductor cable by placing between the side isolated veins medium insulated conductors conducting simultaneous operations overlay on the conductor insulation of the winding (pillows under armor) with a simultaneous imposition of the reservation, or overlay total hose casings (pillows under armor) with a subsequent booking.The manufacture of the conductors 1, for example copper, carried out by the conventional methods.Insulating shell 2 on meneralnye in parallel and spaced at a fixed distance from each other of copper wires 1. The design of the extrusion head allows you to get the desired profile of the blend polymer material, in which between the two insulated conductors are immediately formed a rigid crosspiece 3 of the same insulating material. Moreover, the imposition of insulation on the two wires carry out in a single pass. Profile jumper 3 of insulating material between two conductors 1 at extrusion may be flat (Fig.1), convex, or concave (Fig. 2) depending on the surface profile of the heating and destination of the cable. The jumper between the cores 3 in the process of isolating perform the specified width, height and form that is provided by the corresponding profile of the holes in the matrix of the extrusion head. The width of the jumper 3 between the lateral veins 1 is sufficient to accommodate up to it the required number of secondary conductive insulated conductors 1. As thermoplastic insulation can be used the following materials: polyethylene, block copolymers of propylene, polytetrafluoroethylene or other material whose parameters match the operating temperature of the cable.When forming, for example, a three-core cable overlaying the insulating sheath can be accomplished according to scheme 2+1 od the individual insulating sheath on the middle vein.Then of insulated conductive wires 1 stranded form, such as three-core cable. For this purpose, the armored vehicle with leptobrachium make the semi-finished product of two simultaneously insulated copper conductors 1. Simultaneously with the process of applying copper insulated wires 1 protective winding 4 (pillows under armor) and simultaneous with this armour plating 5 of the profiled galvanized strip for jumper 3 between isolated side copper conductors 1 start with giving the device and placed her middle individually isolated copper core 1. The bridge 3 can be stacked with additional conductive individually isolated veins 6 of conductive material with high resistivity and a smaller cross-section, for example, steel. Additional conductive steel wires 6 are placed between the main (copper) conductors 1, filling the void between them.In the process of booking a cable is passed through the forming the profile of the rollers, causing the cable to give the desired shape.Thus, the proposed method of manufacture of the cable allows you to produce a universal cable, power electrical (copper core), and the e cores allows then to ensure operational reliability - to increase the resistance of the cable, for use in corrosive environments and harsh downhole conditions to stretching, crushing, shock loads. And laying in the gaps between the main veins additional steel lived further enhances the mechanical strength of the cable, eliminating distortion both in the transverse and in longitudinal section. In addition, manufactured declared by way of the cable can be rewound and carry out lifting operations, use, and at low temperatures (below 18oC).The proposed method allows to reduce material and labor costs - fewer drums and radiating devices in the manufacture of the cable. Added the possibility to reduce the intensity and weight of the cable is not less than 1.7 times as overlapping turns of tape armor for the working conditions in the borehole due to the rigid structures of isolated lateral veins is reduced to 20-25% (instead of 45-50% for cables manufactured according to THE 16505 129-82). Besides increasing the productivity in the manufacture of the cable, because the imposition of isolation is at the same time on two cores.
Claims1. A method of manufacturing a universal cable that includes nalog polirovannyj conductive wires of the multiwire cable by imposing on isolated conductive protective conductor winding with a simultaneous imposition on her armor or overlay on the insulated conductive wires total protective hose sheath with the subsequent imposition on her armor, wherein the insulating sheath is applied extrusion simultaneously on two parallel and at a fixed distance from one another conductive wires to form between them a rigid jumpers of insulating material, and insulating sheaths for the two conductive wires with a rigid bridge between them impose by extrusion in a single pass, the formation of multi-core universal cable in the overlay process on isolated veins or protective winding or overlay total hose sheath and booking on the bridge between the two insulated conductors simultaneously place the insulated conductive wires with individual isolation and the shape of the cable is attached in the booking process.2. Method of making universal cable under item 1, characterized in that the jumper between the two isolated at the same time the electric conductors accommodated isolated strands of conductive material with different specific resistances, and different sections.3. Method of making universal cable under item 1, characterized in that the profile of the jumpers of insulating material between two conductors when extrud the tives such as those that the jumper between the cores in the process of isolating perform the specified width, height and shape.5. Method of making universal cable under item 1, characterized in that the shape of the cable in the booking process attached by passing it through a forming profile rollers.
FIELD: cable engineering; plastic-covered sector cables.
SUBSTANCE: proposed extrusion head that provides for regulating insulation thickness over perimeter of sector cable cores has body, mandrel holder, mandrel with cylindrical part, die, mandrel evacuation device, and device for positioning conducting core in mandrel; two cuts symmetrical relative to vertical axis of mandrel are made on external surface of its cylindrical part; these cuts are disposed so that fixed radiant position of sector in mandrel is ensured and its rays originate from geometric center of mandrel and cross points limiting left- and right-hand rounding of sector; angle between symmetry axes of cuts is not over 180 deg.; angle of cuts to generating lines of cylinder is minimum 1 deg.
EFFECT: reduced material input of cable.
1 cl, 3 dwg, 1 tbl
FIELD: controlling electric cable sheath capacitive reactance.
SUBSTANCE: proposed method for controlling capacitive reactance of tubular sheath formed by means of extrusion of insulating compound on electric cable in extrusion head includes introduction of foaming agent in insulating compound so as to enhance capacitive reactance of tubular insulating sheath; prior to do so, definite amount of foaming agent is used so as to obtain predetermined capacitive reactance for tubular insulating sheath and in order to ensure precision control of capacitive reactance of tubular insulating sheath, gas pressure is applied to at least external surface area of insulating compound extruded by extrusion head, gas pressure being varied so as to control capacitive reactance value of tubular insulating sheath.
EFFECT: enhanced precision of controlling capacitive reactance of electric-cable sheath.
9 cl, 3 dwg
FIELD: electric cable manufacture.
SUBSTANCE: proposed method includes following steps: (a) feeding conductor at predetermined feed rate; (b) extruding thermoplastic insulating layer in radial direction on external side of conductor; (c) cooling down insulating layer obtained by extrusion to temperature not over 70 °C; (d) forming metal screen closed on circumference around mentioned insulating layer obtained by extrusion. Procedures are run continuously, that is, period between cooling-down step and initiation of screen formation is inversely proportional to conductor feed rate.
EFFECT: facilitated procedure.
19 cl, 10 dwg
FIELD: electrical engineering.
SUBSTANCE: invention relates to the method of producing the cable composed of a conductor, an inner semi-conducting layer with thickness smaller than or equal to 0.4 mm, an insulating layer enveloping the said inner semi-conducting layer. The proposed method includes the stage of co-extrusion of the inner semi-conducting and insulating layers. The aforesaid stage comprises making the first circular flux of the inner semi-conducting layer and the second circular flux of the insulating layer, bringing the said first circular flux outer surface in contact with the said circular flux inner surface at a certain axial distance from the contact point of the aforesaid surfaces. The method comprises also the combination of the preset feed rate and the said contact point in the function of semi-conducting and insulating material dynamic viscosity (η) allowing the interrelation between the tangential strain of the inner semi-conducting layer nearby the radial inner wall of the extrusion die and the tangential strain of the insulating layer nearby the extrusion die radial outer wall makes from 0.5 to 4. The method includes also the pressure extrusion of the insulating and outer semi-conducting layers onto the conductor.
EFFECT: miniature cable conductor retaining good general mechanical and electrical properties.
22 cl, 5 dwg, 5 tbl, 5 ex
FIELD: power engineering.
SUBSTANCE: device for induction heating of electric conductor downstream extrusion head in process of making electric cables (8), which comprise insulating layer on electric conductor, which includes induction facility (5) for creation of magnetic field, at the same time device contains the first separate part, which includes induction facility (5), and the second separate part, which includes guide facilities (4) and is installed in junction box (3), for direction of magnetic field developed with induction facility (5), and overheat protection of junction box.
EFFECT: expansion of technological needs of devices.
17 cl, 5 dwg
SUBSTANCE: methods are disclosed to manufacture an insulated electric wire, in which the primary layer of the coating, comprising at least a dried layer of enamel, is formed on a metal conductor to create an electric wire with a primary coating, and the second layer of the coating is formed by extrusion of the electric wire coating with the primary coating on the primary layer. The methods includes a process of pre-heating of an electric wire, in which the surface of the primary layer of the coating is pre-heated using a pre-heating facility, and a process of resin extrusion, in which the secondary layer of the coating is formed by extrusion on the pre-heated primary layer of the coating using the resin extrusion facility. Also devices are disclosed to manufacture an insulated electric wire.
EFFECT: invention provides for production of a wire that is more reliable in operation, making it possible to prevent a corona-forming discharge.
39 cl, 4 dwg
FIELD: electrical engineering.
SUBSTANCE: method of production of power cable including conductor and ply of polymer coat. This method comprises the steps whereat polypropylene matrix is mixed with dielectric fluid to obtain polymer mix. Hydrodynamic pressure of said mix is increased. Polymer mix is filtered. Said polymer mix is forced through extrusion head to get coat ply on conductor and cable is cooled.
EFFECT: decreased amount of contaminants, process with sufficient rate.
13 cl, 3 dwg
SUBSTANCE: invention relates to production of power cable for transmission and distribution of middle-voltage or high-voltage electric energy. Method of power cable manufacturing containing at least one electrically conductive core and at least one thermoplastic electric insulating layer, includes steps in which thermoplastic material in solid form, having enthalpy of fusion, equal or less than 70 J/g is impregnated with dielectric fluid medium to produce impregnated thermoplastic material; said impregnated thermoplastic material in crushed solid form is fed into single-worm extruder and extruded impregnated thermoplastic material onto said at least one conducting core to form said at least one thermoplastic electric insulating layer, according to which said impregnated thermoplastic material is not subjected to any treatment at any stage of mechanical homogenization in molten state.
EFFECT: invention provides improved dielectric strength.
14 cl, 2 dwg
FIELD: technological processes.
SUBSTANCE: conductive element is covered with a stitched synthetic material at extrusion step (4) and the stitching reaction is carried out after the extrusion step (4). The conductive element is preheated at the preheating step (3) before the extrusion step by generating within the conductive element of inductive eddy currents that heat up the conductive element. The preheating step (3) is carried out with gradual raising of the conductive element temperature so that the difference (DT) in temperatures between the outermost region (a) of the conductive element and the inner layer (b) of the conductive element remains below a predetermined level at the end of the preheating step.
EFFECT: invention ensures against loss of contact between its layers via temperature difference reduction in the cross section of the conductive element.
10 cl, 5 dwg
SUBSTANCE: method contains the following stages: extrusion (4) stage, where a conductor (12) is covered with a layer of banded material, stage at which perform binding reaction is performed by treating the coated conductor in the vulcanization tube (6) after the extrusion stage, and cooling stage (7), at which the coated conductor is cooled. The assembly further comprises of an induction heating device (10), located after the vulcanization tube (6) for heating the coated conductor.
EFFECT: invention makes it possible to speed up the binding process and increase the linear speed of the process.
4 cl, 9 dwg
FIELD: power supply cables.
SUBSTANCE: proposed cable that can be used to supply with power electrical loads and at the same time to transmit telephone, television, computer, and radio communication signals has one or more similar sections incorporating central flat current-carrying conductor disposed between two flat insulating tapes, the latter being disposed, in their turn, between two flat neutral conductors whose width is greater than that of current-carrying conductor by double thickness of insulating tape.
EFFECT: enhanced conductivity and enlarged functional capabilities of cable.
1 cl, 2 dwg
FIELD: electronic engineering; gas panel manufacture.
SUBSTANCE: protective coating that can be used for manufacturing contact members of gas-panel strip conductors is formed on both sides of polyamide and applied by stenciling method using for the purpose dielectric composition resistant to 20-30% alkali solutions at temperature of 65 - 85oC that incorporates in its composition ethyl cellulose in the amount of maximum 9 parts by weight and organic solvent in the amount of minimum 91 parts by weight with boiling temperature of ≥ 190oC, minimal amount of ethyl cellulose and maximal amount of organic solvent being, respectively, 7.5 and 92.5 parts by weight.
EFFECT: improved rheological and protective properties of coating using proposed composition.
1 cl, 1 ex
FIELD: printed-circuit boards, multilayer conductors, and ribbon cables.
SUBSTANCE: proposed method involves spatial disposition of conducting communication lines which makes it possible to compensate for electromagnetic pickups in three-phase power circuits caused by self-induction and is based on compensating effect attained by superimposing electromagnetic inductances shifted in phase due to phase shift of currents carried by three adjacent conductors; novelty is that only positive (forward) currents carried by three adjacent layers and shifted in phase through 120 deg. are used in three-phase circuits. Passing three-phase current of same amplitude through three adjacent conducting tracks disposed strictly in parallel one on top of other in these three adjacent layers where columns built of conducting tracks occurring in three layers are formed we shall obtain equal-amplitude vectors in each layer using cyclic phase transfer; these vectors correspond to harmonic oscillations on vector diagram from all three phases (A, B, C).
EFFECT: maximized compensation of noise caused by self-induction.
4 cl, 3 dwg
FIELD: electrochemical industry; power cables for feeding submersible motors of oil pumps.
SUBSTANCE: proposed cable has current-conductors covered with first and second insulating layers, as well as protective pad and armor common for all conductors. Insulation is made of fluorine-containing copolymers which enhances cable thermal stability to 230 °C.
EFFECT: reduced mass and size, enhanced thermal stability of cable.
9 cl, 1 dwg, 1 tbl
FIELD: electrical engineering; cables for feeding underground equipment of oil wells such as submersible oil pump motors and other pieces of equipment.
SUBSTANCE: novelty is that proposed electric cable has at least two parallel polymeric material insulated current-carrying conductors, each conductor being also covered with metal band sheath coated on two sides with crosswise corrugated polymeric material longitudinally placed on insulation with its edges overlapping; conductors covered with mentioned sheath have common external armor of spirally arranged metal bands. Mentioned sheath provided with longitudinally disposed corrugated metal band having integral polymeric weld provides for desired tightness of insulation and for its reliable protection. Compared with prior art, proposed cable is characterized in its suitability for use in oil wells in direct contact with well liquids.
EFFECT: enhanced resistance to environmental impacts, enlarged service life of cable.
1 cl, 4 dwg