Design and Application of Seamless Smooth Aluminum-Sheathed Cable

Aiming at the problem of frequent electrochemical corrosion and even breakdown during operation of high-voltage corrugated aluminum-sheathed cables, this paper deeply studies the design and application of a new type of seamless smooth aluminum-sheathed cable. It focuses on discussing its core manufacturing processes: adopting continuous extrusion technology to achieve precision manufacturing of the seamless smooth aluminum sheath, including aluminum rod processing, mold optimization, precise temperature control, and conductor anti-scorching and moisture-proof design; innovatively applying roller-type diameter reduction process to solve the gap control between aluminum sheath and conductor and surface flatness problem; implementing triple-layer co-extrusion for the protective jacket to ensure tight bonding of hot-melt adhesive, conductive layer and outer sheath, forming a unified integral structure. Verification through systematic performance tests: mechanical strength tests show that after diameter reduction, the transverse plasticity of the aluminum sheath is enhanced, and the overall anti-side pressure and impact resistance are improved; bending tests confirm that the cable meets the strict 20 times bending requirement with excellent bending performance; installation application tests show that the cable performs well during actual installation, with undamaged and wrinkle-free surface, smoothly passing DC withstand voltage tests. The results show that this seamless smooth aluminum-sheathed cable has smooth inner and outer surfaces without weld seams, effectively eliminating discharge risks caused by poor contact. It possesses excellent mechanical properties, reliable bending performance and installation adaptability, providing an effective technical solution for enhancing the safe and stable operation of power grids.