高压直流海底电缆异形单线圆形紧压导体的设计

Design of Special-Shaped Single Wire Circular Compact Conductor for High-Voltage DC Undersea Cable

介绍了500kV直流海底电缆铜导体的设计过程。通过理论计算、CAD画图模拟设计,提出了5种异形单线圆形紧压导体设计方案。在比较异形单线宽高比和截面积后,发现采用127盘框绞机生产6层结构异形单线圆形紧压导体优于采用91盘框绞机生产5层结构异形单线圆形紧压导体;在比较生产效率和阻水效果后,发现中心线采用直径6.0mm实心铜棒结构优于中心线采用圆形紧压导体结构。最终选择了生产难度较低、生产效率较高的中心线采用直径6.0mm实心铜棒6层异形单线圆形紧压非正规绞合结构的导体设计方案。对于该方案,后期还需要通过设备参数调整,在生产试制过程中继续优化。当异形单线模具倒角半径为0.30mm,完全能满足填充系数要求,考虑到实际生产过程中的一些不确定因素,导体结构和倒角半径可做进一步调整。

The designing process of 500 kV DC undersea cable copper conductor is introduced.Five designs of special-shaped single wire circular compact conductor are put forward through theoretical calculation and CAD drawing simulation.After comparing the aspect ratio and sectional area of special-shaped single wire,it is found that the 6-layer structure special-shaped single wire circular compact produced by 127-drum frame-type strander is better than that of 5-layer structure produced by 91-drum frame-type strander.After comparing productivity and waterblocking effect,it is found that usingΦ6.0mm solid copper bar as the center conductor is better than using circular compact conductor structure.Finally a scheme using the 6-layer special-shaped single wire circular compact informal stranded structure with the center conductor ofΦ6.0mm solid copper bar is selected because of the lower production difficulty and the higher production efficiency.For this design,it still needs continual optimization during the trialproduction through adjusting the parameters of the equipment in the latter stage.The filling factor can be fully met when the chamfer radius of the special-shaped single wire mold is 0.30 mm.But considering some uncertainties during the actual production process,the conductor structure and the chamfer radius can be further adjusted.