Polaris Wire and Cable Network News: According to the Ministry of Railways' "Medium- and Long-term Railway Network Plan", by 2020, the Ministry of Railways will invest two trillion yuan in railway construction, with an average annual investment of over 100 billion yuan. Since 2004, railway investment in fixed assets has started to increase. According to the medium and long-term plans, from 2006 to 2010, it is estimated that there will be an investment of 160 billion yuan in railway fixed assets each year. By 2020, the country’s railway operating mileage will reach 100,000 kilometers from 72,000 kilometers in 2004, adding 28,000 kilometers, and 35,000 kilometers of existing railways will be transformed by electrification.
Therefore, for a long period of time in the future, the vigorous development of rail transit and other rail transit industries will drive the rapid development of the industrial chain of the industry, bringing unprecedented development opportunities and a new round of investment to the industry. For railway digital signal cables and their series products used in rail transportation, while welcoming unprecedented development opportunities, the original manufacturer’s expansion capabilities and the investment involvement of many powerful cable manufacturers have resulted in The signal cable industry with a relatively small output value triggers fierce competition and, with the difficulty of market access for products, it will face new challenges and certain investment risks.
Functions and Applications 1. Product Functions The railway digital signal cable has the functions of transmitting analog signals (1MHz), digital signals (2Mbit/s), rated voltage AC 750V or DC 1100V and below system control information and power transmission functions. It is suitable for transmission of control information, monitoring information and electric energy between signal equipment and control devices such as railway signal automatic blocking system, axle counting, station codec, computer chain, microcomputer monitoring, dispatcher centralized, dispatch supervision, high power electric switch machines, etc. .
2. Field of application of products The automatic blocking systems currently in operation in China's railways include: AC counting automatic blocking system, 4 information frequency shifting automatic blocking system, 18 information frequency shifting automatic blocking system, France UM71 automatic blocking system, ZPW-2000 series (ZPW-2000, ZPW-2000A) There are no more than 8 types of self-closing systems such as an insulation shift frequency automatic blocking system.
Newly-built railways are being used, and ZPW-2000A automatic blocking systems are used for electrification transformation lines. The supporting cables are internally shielded railway digital signal cables (TB/T3100.5-2004), which are currently high-tech products and the largest amount of market-leading products. The annual output value of the industry is 1500-200 million; the signal cables of other signal systems are used in small quantities and are gradually phased out. They are mainly used for maintenance of existing lines, partial transformation or self-preparation lines, branch lines, and other signal devices that are relatively backward. According to incomplete statistics, the industry's annual output value is less than 1 billion.
ZPW-2000A non-insulated frequency shifting automatic blocking system is based on the introduction of French UM71 non-insulated track circuit technology domestically, combined with China's national conditions to improve system safety, system transmission performance and system reliability technology redevelopment, is a rail transport Heavy-duty, safe, high-speed, ground-based equipment that develops into the direction of locomotive signalization. Its main features are: to achieve a full track of track circuit inspection, greatly reducing the length of the dead zone of the tuning section, to check and protect the tuner unit break fault and beat frequency signal interference, improve the system's anti-jamming level, A major breakthrough in technology has been achieved, with a qualitative improvement in transmission security. And effectively improve the electrical insulation section track transmission length, the track circuit transmission length from 900 meters to 1500 meters.
This system passed the technology signing organized by the Ministry of Railways in May 2002 and was recognized as the only system of railway signal systems. The system uses domestically shielded railway digital signal cable (SPTP type) to replace the original French ZCO3 type cable, breaking the signal transmission "same frequency different cable" limit, to achieve the same frequency of simultaneous transmission in a different cable shield group Frequency information, and when the wire core ground fault condition, the crosstalk interference between shielded groups is equivalent to the two digital signal cables (SPT type) of the sub-cables, that is, the same transmission performance is achieved for the same frequency co-cable and the same frequency sub-cable. And safety and reliability. The copper conductor diameter is reduced, the spare wire group is reduced, the transmission distance is increased, the cost-effectiveness of the system is greatly improved, the construction cost is significantly reduced, and the construction and subsequent maintenance are facilitated.
Main features Inner shielded railway digital signal cable improves the overall electrical performance of the cable on the basis of meeting the original railway signal cable index: the AC rated voltage is increased by 1.5 times, the capacitance index is reduced by 40%, and the insulation resistance index is increased by 2.3 times. At the same time improve the impedance, attenuation, crosstalk and other properties.
The cable improves the anti-jamming capability between the wire groups and realizes the transmission of the same frequency with the same cable. Moreover, when the wire core is in the ground fault state, the crosstalk between the shielding groups is equivalent to the two signal cables of the sub-cable, effectively improving the system's safety.
The cable has high mechanical strength, good anti-corrosion, cold-resistant performance and high shielding performance. It can meet the requirements of electrified railways for strong electric field interference, humidity, and severe cold, as well as the latest standard of the existing signal system and the latest equipment. Requirements; while the cable is compatible with other standard signal system equipment. In addition, the cable can have additional functions of flame retardant and termite resistance according to the use environment.
Structural features 1. Insulating single-wire insulated single-line insulating layer is skin-foam-leather structure, totaling four chromatograms of red, green, white and blue, using the current international advanced three-layer co-extruded tandem line manufacturing, that is, conductor drawing and The extrusion of the insulation layer of the skin-foam-leather structure is completed at one time, and the precise manufacture of the on-line detection and control of the product structure size and performance index is achieved. The main advantages are:
a. The endothelium insulating layer can be well bonded with the conductor to ensure the moisture resistance and the adhesiveness of the insulating layer; the foaming insulating layer is the physical foaming of nitrogen, and the foam is small and dense compared with the traditional chemical foaming. They are not interconnected and therefore have a very high degree of foaming (about 60%). Foaming of the insulating layer means that the working capacity of the four-wire group decreases, and the transmission attenuation constant of the line decreases.
b. The outer skin layer uses high-density insulating material, which has good abrasion resistance and mechanical strength. The resistance to environmental aging is more than 10 times that of ordinary polyethylene materials. It fundamentally solves the problem of the aging of the insulating layer existing in ordinary railway signal cables. Cracking problem.
c. Since the single-line color masterbatch only exists in the skin layer, the insulation resistance and withstand voltage breakdown strength are obviously improved, which is more than 3 times that of ordinary railway signal cables. As the single-line production process realizes the online detection and control of the computer, the uniformity of the single-wire structure is good, and the DC resistance difference of the working line pair is reduced by 50%.
d. The insulated single wire has high manufacturing precision and effectively improves the electrical performance index of the product.
2. The four-wire twisted four-wire group is produced by advanced high-speed star-spinning machines. Each single-line is an active constant tension pay-off line, and the unique twisted twisting device and wire opener are uniquely designed for product performance indicators. The pre-twist device can effectively reduce the capacitive coupling coefficient caused by the insulation eccentricity and make the capacitive coupling coefficient reach a minimum value; the precise tension of the yarn guarantees the symmetry stability of the four-wire set structure and does not enable the skin-bubble-skin structure. Insulation layer deformation and damage; four-wire group twist pitch accuracy, line sequence, and outer diameter control are all key steps in this process, but also a key factor affecting product performance indicators.
3. The purpose of the electromagnetic shielding of the four-wire unit in the four-wire unit shielded inner shielded cable is to use a copper strip longitudinal package, and a copper wire is added along the surface of the copper strip as the draining line to ensure that the shielding layer is laid in the cable. It has stable and reliable shielding performance during construction and long-term use.
4. Cable formation In order to improve the cable's crosstalk index, the twisting pitch is properly designed and matched in the cabling process, and complete twist-twist stranding is achieved, which reduces the direct systematic coupling between lines and reduces crosstalk. .
As many as four kinds of different structures, different sizes of cable units, how to ensure the cable core round, stable and compact in the winding process is the key to the cable process, and must ensure the cable core sequence and sequence Completely correct.
5. Aluminium cable sheathed cable Aluminium sheathed aluminum sheathing is formed by aluminum strips using argon arc welding technology. In order to prevent the electrochemical reaction of the aluminum sheath during use, the surface of the aluminum sheath is coated during the production process.
Aluminium-sheathed cables use the largest amount of cable for the trunk line, so the capacity and quality of the aluminum sheathing process are also critical to the manufacturing process of the product. The aluminum sheath of the cable produced by the argon arc welding technology has stable and reliable welding quality, and can completely withstand the bending test, flaring test and air tightness test according to the relevant standards.
Performance index Compared with ordinary railway signal cables, the railway digital signal cable reduces the working capacitance from 50nF/km to 29nF/km through the structural design and technological measures, and the average value of the capacitive coupling K1 decreases from 141pF/km to 81pF/km. Increased secondary transmission performance indicators such as impedance, attenuation, and crosstalk. Although product quality has great advantages and breakthroughs in technology, according to the actual detection and field use, the product needs further improvement in terms of the following performance indicators. First of all, the mixed conductors, disconnections and oxidations that occur during the use of the product; secondly, the tensile strength, elongation at break, and compression resistance of the insulating layer are improved; finally, the scope of some secondary parameters in the current standard is set. It is not ideal, and it is difficult to match the associated secondary parameters and each frequency point index to the ideal median value.
In particular, the insulation strength is a problem that is currently disagreeable between users (engineering units of the Ministry of Railways), product quality supervision and inspection centers, and manufacturers. This is not only a new technical problem faced by cable manufacturers. Due to the improvement of the insulation strength, there will be a large deviation between the product structure size and performance indicators and the current standards.
Therefore, for a long period of time in the future, the vigorous development of rail transit and other rail transit industries will drive the rapid development of the industrial chain of the industry, bringing unprecedented development opportunities and a new round of investment to the industry. For railway digital signal cables and their series products used in rail transportation, while welcoming unprecedented development opportunities, the original manufacturer’s expansion capabilities and the investment involvement of many powerful cable manufacturers have resulted in The signal cable industry with a relatively small output value triggers fierce competition and, with the difficulty of market access for products, it will face new challenges and certain investment risks.
Functions and Applications 1. Product Functions The railway digital signal cable has the functions of transmitting analog signals (1MHz), digital signals (2Mbit/s), rated voltage AC 750V or DC 1100V and below system control information and power transmission functions. It is suitable for transmission of control information, monitoring information and electric energy between signal equipment and control devices such as railway signal automatic blocking system, axle counting, station codec, computer chain, microcomputer monitoring, dispatcher centralized, dispatch supervision, high power electric switch machines, etc. .
2. Field of application of products The automatic blocking systems currently in operation in China's railways include: AC counting automatic blocking system, 4 information frequency shifting automatic blocking system, 18 information frequency shifting automatic blocking system, France UM71 automatic blocking system, ZPW-2000 series (ZPW-2000, ZPW-2000A) There are no more than 8 types of self-closing systems such as an insulation shift frequency automatic blocking system.
Newly-built railways are being used, and ZPW-2000A automatic blocking systems are used for electrification transformation lines. The supporting cables are internally shielded railway digital signal cables (TB/T3100.5-2004), which are currently high-tech products and the largest amount of market-leading products. The annual output value of the industry is 1500-200 million; the signal cables of other signal systems are used in small quantities and are gradually phased out. They are mainly used for maintenance of existing lines, partial transformation or self-preparation lines, branch lines, and other signal devices that are relatively backward. According to incomplete statistics, the industry's annual output value is less than 1 billion.
ZPW-2000A non-insulated frequency shifting automatic blocking system is based on the introduction of French UM71 non-insulated track circuit technology domestically, combined with China's national conditions to improve system safety, system transmission performance and system reliability technology redevelopment, is a rail transport Heavy-duty, safe, high-speed, ground-based equipment that develops into the direction of locomotive signalization. Its main features are: to achieve a full track of track circuit inspection, greatly reducing the length of the dead zone of the tuning section, to check and protect the tuner unit break fault and beat frequency signal interference, improve the system's anti-jamming level, A major breakthrough in technology has been achieved, with a qualitative improvement in transmission security. And effectively improve the electrical insulation section track transmission length, the track circuit transmission length from 900 meters to 1500 meters.
This system passed the technology signing organized by the Ministry of Railways in May 2002 and was recognized as the only system of railway signal systems. The system uses domestically shielded railway digital signal cable (SPTP type) to replace the original French ZCO3 type cable, breaking the signal transmission "same frequency different cable" limit, to achieve the same frequency of simultaneous transmission in a different cable shield group Frequency information, and when the wire core ground fault condition, the crosstalk interference between shielded groups is equivalent to the two digital signal cables (SPT type) of the sub-cables, that is, the same transmission performance is achieved for the same frequency co-cable and the same frequency sub-cable. And safety and reliability. The copper conductor diameter is reduced, the spare wire group is reduced, the transmission distance is increased, the cost-effectiveness of the system is greatly improved, the construction cost is significantly reduced, and the construction and subsequent maintenance are facilitated.
Main features Inner shielded railway digital signal cable improves the overall electrical performance of the cable on the basis of meeting the original railway signal cable index: the AC rated voltage is increased by 1.5 times, the capacitance index is reduced by 40%, and the insulation resistance index is increased by 2.3 times. At the same time improve the impedance, attenuation, crosstalk and other properties.
The cable improves the anti-jamming capability between the wire groups and realizes the transmission of the same frequency with the same cable. Moreover, when the wire core is in the ground fault state, the crosstalk between the shielding groups is equivalent to the two signal cables of the sub-cable, effectively improving the system's safety.
The cable has high mechanical strength, good anti-corrosion, cold-resistant performance and high shielding performance. It can meet the requirements of electrified railways for strong electric field interference, humidity, and severe cold, as well as the latest standard of the existing signal system and the latest equipment. Requirements; while the cable is compatible with other standard signal system equipment. In addition, the cable can have additional functions of flame retardant and termite resistance according to the use environment.
Structural features 1. Insulating single-wire insulated single-line insulating layer is skin-foam-leather structure, totaling four chromatograms of red, green, white and blue, using the current international advanced three-layer co-extruded tandem line manufacturing, that is, conductor drawing and The extrusion of the insulation layer of the skin-foam-leather structure is completed at one time, and the precise manufacture of the on-line detection and control of the product structure size and performance index is achieved. The main advantages are:
a. The endothelium insulating layer can be well bonded with the conductor to ensure the moisture resistance and the adhesiveness of the insulating layer; the foaming insulating layer is the physical foaming of nitrogen, and the foam is small and dense compared with the traditional chemical foaming. They are not interconnected and therefore have a very high degree of foaming (about 60%). Foaming of the insulating layer means that the working capacity of the four-wire group decreases, and the transmission attenuation constant of the line decreases.
b. The outer skin layer uses high-density insulating material, which has good abrasion resistance and mechanical strength. The resistance to environmental aging is more than 10 times that of ordinary polyethylene materials. It fundamentally solves the problem of the aging of the insulating layer existing in ordinary railway signal cables. Cracking problem.
c. Since the single-line color masterbatch only exists in the skin layer, the insulation resistance and withstand voltage breakdown strength are obviously improved, which is more than 3 times that of ordinary railway signal cables. As the single-line production process realizes the online detection and control of the computer, the uniformity of the single-wire structure is good, and the DC resistance difference of the working line pair is reduced by 50%.
d. The insulated single wire has high manufacturing precision and effectively improves the electrical performance index of the product.
2. The four-wire twisted four-wire group is produced by advanced high-speed star-spinning machines. Each single-line is an active constant tension pay-off line, and the unique twisted twisting device and wire opener are uniquely designed for product performance indicators. The pre-twist device can effectively reduce the capacitive coupling coefficient caused by the insulation eccentricity and make the capacitive coupling coefficient reach a minimum value; the precise tension of the yarn guarantees the symmetry stability of the four-wire set structure and does not enable the skin-bubble-skin structure. Insulation layer deformation and damage; four-wire group twist pitch accuracy, line sequence, and outer diameter control are all key steps in this process, but also a key factor affecting product performance indicators.
3. The purpose of the electromagnetic shielding of the four-wire unit in the four-wire unit shielded inner shielded cable is to use a copper strip longitudinal package, and a copper wire is added along the surface of the copper strip as the draining line to ensure that the shielding layer is laid in the cable. It has stable and reliable shielding performance during construction and long-term use.
4. Cable formation In order to improve the cable's crosstalk index, the twisting pitch is properly designed and matched in the cabling process, and complete twist-twist stranding is achieved, which reduces the direct systematic coupling between lines and reduces crosstalk. .
As many as four kinds of different structures, different sizes of cable units, how to ensure the cable core round, stable and compact in the winding process is the key to the cable process, and must ensure the cable core sequence and sequence Completely correct.
5. Aluminium cable sheathed cable Aluminium sheathed aluminum sheathing is formed by aluminum strips using argon arc welding technology. In order to prevent the electrochemical reaction of the aluminum sheath during use, the surface of the aluminum sheath is coated during the production process.
Aluminium-sheathed cables use the largest amount of cable for the trunk line, so the capacity and quality of the aluminum sheathing process are also critical to the manufacturing process of the product. The aluminum sheath of the cable produced by the argon arc welding technology has stable and reliable welding quality, and can completely withstand the bending test, flaring test and air tightness test according to the relevant standards.
Performance index Compared with ordinary railway signal cables, the railway digital signal cable reduces the working capacitance from 50nF/km to 29nF/km through the structural design and technological measures, and the average value of the capacitive coupling K1 decreases from 141pF/km to 81pF/km. Increased secondary transmission performance indicators such as impedance, attenuation, and crosstalk. Although product quality has great advantages and breakthroughs in technology, according to the actual detection and field use, the product needs further improvement in terms of the following performance indicators. First of all, the mixed conductors, disconnections and oxidations that occur during the use of the product; secondly, the tensile strength, elongation at break, and compression resistance of the insulating layer are improved; finally, the scope of some secondary parameters in the current standard is set. It is not ideal, and it is difficult to match the associated secondary parameters and each frequency point index to the ideal median value.
In particular, the insulation strength is a problem that is currently disagreeable between users (engineering units of the Ministry of Railways), product quality supervision and inspection centers, and manufacturers. This is not only a new technical problem faced by cable manufacturers. Due to the improvement of the insulation strength, there will be a large deviation between the product structure size and performance indicators and the current standards.
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