高导电铜合金绞合导体制造工艺对耐弯折性能的影响

Effect of High-Conductivity Copper Alloy and Stranded Conductor Manufacturing Process on the Flex-life of Robot Communication Data Cables

通过真空水平连铸等技术制备了3种单线导电率在97%IACS以上的镀锡铜合金绞合导体,进而制备了高性能Type-R机器人数据缆,该线缆在弯折半径7D,挂重300 g的条件下耐弯折性能最高可达365万次以上。本工作结合拉力、电阻、反复弯折、电缆传输性能等试验,研究了高导电率铜合金及绞合导体的制造工艺对数据缆耐弯折性能的影响。结果表明,数据缆反复弯折失效总是从部分单线断裂开始,失效行为符合高周期反复弯曲疲劳断裂行为;高导电率的镀锡铜合金绞合导体在单线体积电阻率仅下降2%IACS~3%IACS的情况下,耐弯折性能是传统镀锡铜绞合导体的5~6倍;相同成分的镀锡高导电率铜合金最终单线性能与绞合导体制造工艺相关,在单线性能相近的情况下因束绞结构的不同,耐弯折性能也不同。

Through vacuum horizontal continuous casting and other process,three kinds of tinned copper alloy stranded conductors with conductivity above 97%IACS were prepared,and then high-performance Profinet TYPE-R cable was prepared.The Flex-Life of the cable can reach more than 3.65 million times under the condition of bending radius of 7D and hanging weight of 300 g.The influence of high-conductivity copper alloy and the manufacturing process of stranded conductor on the flex-life of communication cables was studied by tensile force,resistance,repeated bending and cable transmission performance.The results showed that the repeat bending failure of communication cables always started from partial single strands fracture,and the failure behavior conformed to the fatigue fracture under high cycle times.The Flex-Life of the tinned high-conductivity copper alloy stranded conductor was 5-6 times that of the tinned copper stranded conductor while the single strands electrical conductivity only decreased by 2%IACS-3%IACS.The final single strands performance of tinned high-conductivity copper alloy with the same composition was related to the stranded conductor manufacturing process.In the case of similar single strands performance,the Flex-Life fluctuated different with the different bunch-stranded structure on the cables with same single strand property.