Connection structure and system of a travel switch and a cable

Abstract

The utility model discloses a kind of connection structure and system of travel switch and cable, belong to travel switch technical field, including plug male head and with the detachable connection of plug male head plug female head, plug male head includes with travel switch being connected male head shell, the male needle group of being placed in male head shell and with male head shell being connected male head connecting piece, the male needle of male needle group is electrically connected with the terminal in travel switch, at least some male head connecting piece stretches to the outside of travel switch;Plug female head includes with cable being connected female head shell, the female needle group of being placed in female head shell and with female head shell being connected female head connecting piece, cable is electrically connected with female needle group in being placed in female head shell, the inside of female head connecting piece is equipped with jack, when female head connecting piece is connected with male head connecting piece, male needle is inserted into jack and is electrically connected with female needle;To solve the problem that travel switch work reliability is reduced due to frequent disassembly, maintenance and the problem of low efficiency of routine maintenance.

Description

Technical Field

[0001] This utility model relates to the field of limit switch technology, and in particular to a connection structure and system for a limit switch and a cable. Background Technology

[0002] Traditional limit switches are directly wired to cables, with the signal line fixedly connected to the switch body via terminals. Taking the crank-arm type limit switch of a thermal power plant steam trap as an example, the steam trap requires multiple major and minor overhauls and routine maintenance each year. Each overhaul and routine maintenance requires disassembling the limit switch. Frequent disassembly of the limit switch can easily lead to stripping or damage to the limit switch terminals, causing poor cable contact and abnormal switch status. Frequent disconnection and reconnection of the cable can also cause the cable to break, making the limit switch unable to work properly. Moreover, this disassembly and assembly method is time-consuming and labor-intensive, resulting in low efficiency in overhaul and routine maintenance.

[0003] Therefore, how to provide a connection structure and system for limit switches and cables to solve the problems of reduced reliability of limit switches and low efficiency of inspection and daily maintenance caused by frequent disassembly is a technical problem that urgently needs to be solved by those skilled in the art. Utility Model Content

[0004] The purpose of this utility model is to address the defects and deficiencies in the existing technology by providing a connection structure and system for limit switches and cables, thereby solving the problems of reduced reliability of limit switches and low efficiency in inspection and daily maintenance caused by frequent disassembly.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0006] This utility model provides a connection structure between a limit switch and a cable, comprising: a male connector, the male connector including a male connector housing, a male pin assembly, and a male connector fitting, the male connector housing being detachably connected to the limit switch, the male pin assembly being disposed inside the male connector housing, the male pin assembly including at least two male pins, one end of each male pin being electrically connected to a terminal block inside the limit switch, the male connector fitting being connected to the end of the male connector housing away from the limit switch, and at least a portion of its structure extending outside the limit switch, the other end of each male pin extending to the end face of the male connector fitting; plug-in The female connector includes a female connector housing, a female pin assembly, and a female connector connector. The female pin assembly is located inside the female connector housing and includes the same number of female pins as the male pins. A cable located inside the female connector housing is electrically connected to one end of the female pins. The female connector connector is located at the end of the female connector housing away from the cable. The female connector connector has a number of sockets inside that are the same as the number of female pins. One female pin is provided in each socket. The female connector connector and the male connector connector are detachably connected. The male pin is inserted into the socket and electrically connected to the female pin.

[0007] In one embodiment, the male connector includes a male nut and a male rubber core installed inside the male nut, and the female connector includes a female nut and a female rubber core installed inside the female nut. The male nut has external threads, and the female nut has internal threads. The male nut and the female nut are threadedly connected. The female rubber core has a columnar structure, and the male rubber core has a first through hole inside. The female rubber core is inserted into the first through hole.

[0008] In one embodiment, the female connector core has a columnar female connector core body, and the male connector core has a male connector core body. The male connector core body has a first through hole inside. The female connector core body has an anti-misalignment groove, and the male connector core body has an anti-misalignment protrusion that cooperates with the anti-misalignment groove. The anti-misalignment protrusion is placed in the anti-misalignment groove so that the male pin can be inserted into the corresponding insertion hole.

[0009] In one embodiment, a first sealing connector is provided at the insertion surfaces of the female rubber core and the male rubber core.

[0010] In one embodiment, the female connector core further includes a female connector core base, the female connector core base being installed inside the female connector housing, the female connector core column being installed inside the female connector nut, and the female connector core column having the insertion hole inside.

[0011] In one embodiment, the male connector core further includes a male connector core base, which is installed inside the male connector housing. The male connector core column is installed inside the male connector nut, and the inserts of all the male pins constituting the male pin group are placed in the first through hole.

[0012] In one embodiment, the limit switch has a threaded connection hole inside, and the outer surface of the male connector housing has an external thread that matches the threaded connection hole. The male connector housing is threadedly connected to the threaded connection hole.

[0013] In one embodiment, the male pin is electrically connected to a terminal block inside the limit switch via a wire, and the wire is crimped to the terminal block.

[0014] In one embodiment, the female pin is electrically connected to the cable via a wire, and the wire and the cable are welded together via corrosion-resistant galvanized terminals.

[0015] This utility model also provides a connection system for a limit switch and a cable, including a connection structure, a limit switch and a cable, wherein the limit switch and the cable are connected through the connection structure.

[0016] The present invention achieves the following technical advantages over the prior art:

[0017] The limit switch and male connector are detachably connected, while the cable is connected to the female connector. The male connector has a set of male pins inside, with one end of the male pins electrically connected to the terminal block inside the limit switch. The female connector has a set of female pins inside, with one end of the female pins electrically connected to the cable. When the male and female connectors are connected, the male pins contact the corresponding female pins to achieve electrical connection, allowing the electrical signal to be transmitted to the limit switch via the cable, female connector, and male connector. The detachable connection between the male and female connectors facilitates disconnection of the limit switch from the cable during maintenance. Compared to the direct wiring connection between the limit switch and the cable, this eliminates the need for frequent cable disassembly and assembly, reducing the risk of poor cable contact and cable breakage. It also improves the reliability of the connection between the limit switch and the cable, reduces maintenance costs, and offers convenient and safe maintenance. Furthermore, it improves disassembly and maintenance efficiency, reducing maintenance time from 5 minutes per operation to 10 seconds per operation, saving significant labor time costs. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the structure of the male connector disclosed in a specific embodiment of the present utility model;

[0020] Figure 2 This is an exploded structural diagram of a male connector disclosed in a specific embodiment of the present utility model;

[0021] Figure 3 This is a schematic diagram of the structure of the female connector disclosed in a specific embodiment of the present utility model;

[0022] Figure 4 This is an exploded structural diagram of a female connector disclosed in a specific embodiment of the present utility model;

[0023] Figure 5 This is a schematic diagram of the assembly structure of the male and female connectors disclosed in a specific embodiment of the present invention.

[0024] Figure 6 This is a schematic diagram of an end-to-end error-proof structure disclosed in a specific embodiment of the present utility model, wherein 6-a is the end with an error-proof protrusion and 6-b is the end with an error-proof groove;

[0025] Figure 7 This is a schematic diagram of the installation structure of the limit switch and the male connector disclosed in a specific embodiment of this utility model;

[0026] Figure 8 This is a wiring diagram of a limit switch disclosed in a specific embodiment of this utility model.

[0027] Among them, 100 is the male connector; 101 is the male nut; 1011 is the stud; 1012 is the base; 102 is the male mating nut; 103 is the male core; 1031 is the male core post; 10311 is the anti-misalignment boss; 1032 is the male core base; 104 is the second sealing connector; 105 is the male pin assembly; 1051 is the male pin; 106 is the male outer shell; 107 is the third sealing connector; 108 is the male locking claw; and 109 is the male locking nut.

[0028] 200. Plug-in female connector; 201. Female connector nut; 202. Female connector mating nut; 203. First sealing connector; 204. Female connector core; 2041. Female connector core column; 20411. Anti-misalignment groove; 2042. Female connector core base; 205. Fourth sealing connector; 206. Female pin assembly; 2061. Female pin; 207. Female connector housing; 208. Fifth sealing connector; 209. Female connector locking claw; 210. Female connector locking nut;

[0029] 300. Limit switch; 301. Built-in switch; 302. Outer cover; 303. Head; 304. Rocker arm; 305. Ball bearing; 306. Threaded connection hole. Detailed Implementation

[0030] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0031] To make the above-mentioned objectives, features and advantages of this utility model more apparent and understandable, the utility model will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0032] like Figures 1 to 8 As shown, this utility model provides a connection structure between a limit switch and a cable, including a male connector 100 and a female connector 200. The male connector 100 includes a male connector housing 106, a male pin assembly 105, and a male connector connector. The male connector housing 106 is detachably connected to the limit switch 300. The male pin assembly 105 is located inside the male connector housing 106 and includes at least two male pins 1051. One end of each male pin 1051 is electrically connected to a terminal block inside the limit switch 300, and one male pin 1051 is connected to one terminal block. The male connector connector is connected to the end of the male connector housing 106 away from the limit switch 300, and at least a portion of its structure extends outside the limit switch 300. The other end of each male pin 1051 extends to the end face of the male connector connector.

[0033] The female connector 200 includes a female connector housing 207, a female pin assembly 206, and a female connector. The female pin assembly 206 is located inside the female connector housing 207 and includes female pins 2061 in the same number as male pins 1051. A cable located inside the female connector housing 207 is electrically connected to one end of the female pins 2061. The female connector is located at the end of the female connector housing 207 away from the cable. The female connector has a number of sockets in the same number as the female pins 2061. One female pin 2061 is provided in one socket. The female connector and the male connector are detachably connected. The male pins 1051 are inserted into the sockets and electrically connected to the female pins 2061.

[0034] It is understandable that: part of the male connector 100 is located inside the limit switch 300, and the other part extends to the outside of the limit switch 300. One end of the male pin group 105 inside the male connector 100 is electrically connected to the terminal block inside the limit switch 300, and the other end extends to the end of the male connector 100 located outside the limit switch 300; one end of the female connector 200 is connected to the cable, and the other end is detachably connected to the male connector 100. One end of the female pin group 206 inside the female connector 200 is electrically connected to the cable. When the male connector 100 and the female connector 200 are plugged in, the other end of the female pin group 206 is electrically connected to the male pin group 105. The electrical signal flows sequentially through the cable → female connector 200 → male connector 100 → limit switch 300, realizing the connection between the cable and the limit switch.

[0035] The connection between the male connector housing 106 and the limit switch 300 can be as follows: the limit switch 300 has a threaded connection hole 306 inside, which penetrates one end face of the limit switch 300. The outer surface of the male connector housing 106 has an external thread that matches the threaded connection hole 306. During use, the external thread of the male connector housing 106 is aligned with the threaded connection hole 306, and then tightened to secure it. In one embodiment, the threaded connection hole 306 has an M20×1.5 internal thread, and the external thread of the male connector housing 106 is of the same specification, secured with a torque of 25 N·m. The connection between the male connector housing 106 and the limit switch 300 can also be a snap-fit ​​connection, a connection via a threaded connector, etc. The connection methods between the male connector housing 106 and the limit switch 300 are not limited to those listed; other feasible connection methods are also possible.

[0036] The male pin group 105 includes at least two male pins 1051, and the female pin group 206 includes at least two female pins 2061. The number of male pins 1051 constituting the male pin group 105 and the number of female pins 2061 constituting the female pin group 206 are the same. Alternatively, the number of male pins 1051 constituting the male pin group 105 / the number of female pins 2061 constituting the female pin group 206 should match the plug specifications (the plug consists of a male connector 100 and a female connector 200; plug specifications include two-pin, three-pin, four-pin, five-pin, six-pin, and seven-pin plugs, etc.). The plug specification selected here should match the number of terminals within the limit switch 300. In one embodiment, the plug is a four-pin aviation plug. The wiring method within the limit switch 300 is as follows: Figure 8As shown, the tail of the male pin 1051 is electrically connected to the internal terminal of the limit switch 300 via a wire (this end is the input terminal of the limit switch 300). In one embodiment, the internal terminal of the limit switch 300 is a corrosion-resistant galvanized terminal. The wire is crimped to the corrosion-resistant galvanized terminal. The output terminal of the limit switch 300 is ensured to have a reliable connection between the wire and the contact in a high-temperature environment by using high-temperature resistant Sn96Ag4 solder (melting point ≥300℃). The tail of the female pin 2061 is electrically connected to the cable (or the status output signal cable of the limit switch 300) via a wire. Specifically, the wire inside the female connector 200 is soldered to the cable via a corrosion-resistant galvanized terminal. The female connector 200 and the cable are wired according to color codes, with the red wire connected to the +24V wire, the black wire connected to the GND wire (i.e., ground or 0 wire), the yellow wire connected to the normally open contact, and the blue wire connected to the normally closed contact.

[0037] The male connector includes a male nut 101 and a male rubber core 103 installed inside the male nut 101; the female connector includes a female nut 201 and a female rubber core 204 installed inside the female nut 201. The male nut 101 has external threads, and the female nut 201 has internal threads. When the male connector and the female connector are connected, the male nut 101 and the female nut 201 are threadedly connected. The female rubber core 204 has a columnar structure. The male rubber core 103 has a first through hole inside. When the male connector and the female connector are connected, the female rubber core 204 is inserted into the first through hole.

[0038] refer to Figure 2 The male nut 101 includes a stud 1011 and a base 1012. The stud 1011 has external threads, and the female nut 201 is a cylindrical structure with internal threads. When the male connector and the female connector are connected, the stud 1011 and the female nut 201 are threadedly connected. In one embodiment, the tightening torque of the stud 1011 and the female nut 201 is 0.6 to 1.2 Nm to prevent the plug from accidentally falling off. The base 1012 of the male nut 101 has internal threads, and the front end of the male connector housing 106 (i.e., the end connected to the male nut 101) has external threads. The base 1012 is threadedly connected to the front end of the male connector housing 106. The front end of the female connector housing 207 (i.e., the end connected to the female nut 201) also has external threads, and the female nut 201 is threadedly connected to the female connector housing 207.

[0039] Continue to refer to Figure 2The female head core 204 includes a female head core base 2042 and a female head core column 2041. The female head core base 2042 is installed inside the female head housing 207, and the female head core column 2041 is installed inside the female head nut 201. The female needle assembly 206 is sequentially inserted into the female head core base 2042 and the female head core column 2041. The female head core column 2041 has insertion holes inside, and the number of insertion holes is the same as the number of female needles 2061 that make up the female needle assembly 206. Each insertion hole accommodates one female needle 2061. The male connector core 103 includes a male connector core base 1032 and a male connector core column 1031. The male connector core base 1032 is installed inside the male connector housing 106, and the male connector core column 1031 is installed inside the male connector nut 101. The male pin assembly 105 is sequentially inserted into the male connector core base 1032 and the male connector core column 1031. The male connector core column 1031 has a first through hole inside, which is used to accommodate the insertion pins of all the male pins 1051 that make up the male pin assembly 105. When the male connector and the female connector are connected, the female connector core column 2041 is inserted into the first through hole in the male connector core column 1031, and the male pins 1051 are inserted into their corresponding insertion holes, so that the male pins 1051 and their corresponding female pins 2061 are electrically connected.

[0040] Please refer to Figure 6 The female connector core 2041 is provided with a mis-proof groove 20411, and the male connector core 1031 is provided with a mis-proof protrusion 10311. When inserting, the mis-proof protrusion 10311 is placed in the mis-proof groove 20411 so that the male pin 1051 can be inserted into the corresponding female pin 2061's socket, thus avoiding the male pin 1051 and female pin 2061 being mis-inserted and affecting signal transmission.

[0041] A first sealing connector 203 is provided at the insertion surfaces of the female connector core 2041 and the male connector core 1031. In one embodiment, the first sealing connector 203 is a silicone sealing ring (Shore hardness 70A, temperature resistance ≥150℃, thickness 2mm), with a protection rating of IP67, which can also isolate heat conduction between the male connector core 1031 and the female connector core 2041.

[0042] Please refer to Figure 2 and Figure 4In one embodiment, a second sealing connector 104 is provided at the connection between the male connector core base 1032 and the male connector housing 106. A male locking claw 108 and a male locking nut 109 are installed at the end of the male connector housing 106 away from the male connector nut 101. A third sealing connector 107 is provided at the connection between the male locking claw 108 and the male connector housing 106. The male locking claw 108 has multiple snap-fit ​​pieces, which engage with the inner wall of the male connector housing 106 to achieve locking. By tightening the male locking nut 109, it engages with the male locking claw, ensuring that the plug cannot be accidentally disengaged after connection. A male connector mating nut 102 is also provided between the male connector nut 101 and the male connector housing 106.

[0043] A fourth sealing connector 205 is provided at the connection between the female connector core base 2042 and the female connector housing 207. A female connector locking claw 209 and a female connector locking nut 210 are installed at the end of the female connector housing 207 away from the female connector nut 201. A fifth sealing connector 208 is provided at the connection between the female connector locking claw 209 and the female connector housing 207. The female connector locking claw 209 has multiple snap-fit ​​pieces, which engage with the inner wall of the female connector housing 207 to achieve locking. By tightening the female connector locking nut 210, it engages with the female connector locking claw, ensuring that the plug cannot be accidentally dislodged after connection. A female connector mating nut 202 is also provided between the female connector nut 201 and the female connector housing 207.

[0044] In one embodiment, the plug consisting of male connector 100 and female connector 200 is a four-pin aviation plug, wherein the model of male connector 100 is YH4M-4010 and the model of female connector 200 is YH4F-4010. Under normal temperature and pressure and in the waterproof connector male and female mating state, the contact resistance of the pin surface plating of male pin 1051 and female pin 2061 is ≤10mΩ; according to method 1005 in GJB1217-1991, under normal temperature and pressure, between the conductor and the insulator (female connector core 204, male connector core 103), the insulation resistance is greater than 10MΩ at a test voltage (RMS) of DC 500V.

[0045] The only improvement of the limit switch 300 in this utility model is the addition of a threaded connection hole 306. The rest of the structure of the limit switch 300, such as the built-in switch 301, outer cover 302, head 303, rocker arm 304, ball bearing 305, etc., all adopt existing technologies.

[0046] This utility model also provides a connection system for a limit switch and a cable, including the above-mentioned connection structure, a limit switch 300 and a cable, wherein the limit switch 300 and the cable are connected through the connection structure.

[0047] The innovative design of the limit switch 300 and its cable connection structure achieves breakthroughs through three core technologies: ① The male pin 1051 and female pin 2061 adopt MIL-DTL-26482 standard military-grade gold-plated pins, achieving a 10,000-cycle mating life (traditional terminals <500 cycles); ② The built-in IP67-rated silicone sealing ring and anti-misinsertion guide groove design maintain a contact resistance ≤1mΩ even under 2.5MPa high-pressure water flushing conditions; ③ Integrated dual-channel redundant contacts, with a contact failure rate ≤0.05% after 1,000 hot-plug tests (traditional methods >12%). Practical applications show that maintenance time is reduced from 300 seconds / cycle to 8-10 seconds / cycle, annual maintenance hours per unit are reduced by 420 hours, and signal anomaly events are reduced by 96.7%. The device simultaneously passed the IEC 60068-2 vibration test (10-500Hz / 3.5Grms) and salt spray test (480h / 5%NaCl), achieving tool-free maintenance and live plug-and-play functionality. The overall operation and maintenance cost is reduced by more than 57%, while also saving a significant amount of manual maintenance time, reducing the number of people required from 4-5 to just 1.

[0048] It should be noted that, for those skilled in the art, it is obvious that this utility model is not limited to the details of the above exemplary embodiments, and that it can be implemented in other specific forms without departing from the spirit or essential characteristics of this utility model. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of this utility model is defined by the appended claims rather than the foregoing description. Therefore, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this utility model, and no reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A connection structure between a limit switch and a cable, characterized in that, include: A male connector includes a male connector housing, a male pin assembly, and a male connector fitting. The male connector housing is detachably connected to a limit switch. The male pin assembly is located inside the male connector housing and includes at least two male pins. One end of each male pin is electrically connected to a terminal block inside the limit switch. The male connector fitting is connected to the end of the male connector housing away from the limit switch, and at least a portion of its structure extends outside the limit switch. The other end of each male pin extends to the end face of the male connector fitting. A female connector includes a female connector housing, a female pin assembly, and a female connector member. The female pin assembly is located inside the female connector housing and includes the same number of female pins as the male pins. A cable located inside the female connector housing is electrically connected to one end of the female pins. The female connector member is located at the end of the female connector housing away from the cable. The female connector member has a number of sockets inside that are the same as the number of female pins. One female pin is provided in each socket. The female connector member and the male connector member are detachably connected. The male pin is inserted into the socket and electrically connected to the female pin.

2. The connection structure between the limit switch and the cable according to claim 1, characterized in that, The male connector includes a male nut and a male rubber core installed inside the male nut. The female connector includes a female nut and a female rubber core installed inside the female nut. The male nut has external threads, and the female nut has internal threads. The male nut and the female nut are threadedly connected. The female rubber core has a columnar structure, and the male rubber core has a first through hole inside. The female rubber core is inserted into the first through hole.

3. The connection structure between the limit switch and the cable according to claim 2, characterized in that, The female connector core has a columnar structure, and the male connector core has a male connector core. The male connector core has a first through hole inside. The female connector core has an anti-misalignment groove, and the male connector core has an anti-misalignment protrusion that cooperates with the anti-misalignment groove. The anti-misalignment protrusion is placed in the anti-misalignment groove so that the male pin can be inserted into the corresponding insertion hole.

4. The connection structure between the limit switch and the cable according to claim 3, characterized in that, The female rubber core column and the male rubber core column are provided with a first sealing connector at their insertion surfaces.

5. The connection structure between the limit switch and the cable according to claim 3, characterized in that, The female connector core also includes a female connector core base, which is installed inside the female connector housing. The female connector core column is installed inside the female connector nut, and the female connector core column has the insertion hole inside.

6. The connection structure between the limit switch and the cable according to claim 5, characterized in that, The male connector core also includes a male connector core base, which is installed inside the male connector housing. The male connector core column is installed inside the male connector nut, and the insertion pins of all the male pins that make up the male pin group are placed in the first through hole.

7. The connection structure between the limit switch and the cable according to claim 1, characterized in that, The limit switch has a threaded connection hole inside, and the outer surface of the male connector housing has an external thread that matches the threaded connection hole. The male connector housing is threadedly connected to the threaded connection hole.

8. The connection structure between the limit switch and the cable according to claim 1, characterized in that, The male pin is electrically connected to the internal terminal of the limit switch via a wire, and the wire is crimped to the terminal.

9. The connection structure between the limit switch and the cable according to claim 1, characterized in that, The female pin is electrically connected to the cable via a wire, and the wire and the cable are welded together via corrosion-resistant galvanized terminals.

10. A connection system for a limit switch and a cable, characterized in that, The invention includes the connection structure, limit switch, and cable as described in any one of claims 1 to 9, wherein the limit switch and the cable are connected through the connection structure.

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