Portable power overhead line fitting intelligent digital crimping detection device

Abstract

The application discloses a portable power overhead line fitting intelligent digital crimping detection device, which comprises a base, a crimping mechanism and a detection mechanism are arranged on the base in parallel, and a fixing mechanism for fixing a cable is arranged at both ends of the base; a controller for controlling the crimping mechanism and the detection mechanism is arranged in the base; the crimping mechanism comprises a crimping body fixedly connected with the base; a hydraulic crimping device is arranged between the crimping body and the base; and a crimping head for crimping a fitting on the cable is arranged on the hydraulic crimping device. The crimping head with axial and radial alternating arrangement can solve the problem of insufficient tensile resistance of the existing "mouth closing" crimping mode, and can also avoid the problem of fitting cracking caused by overpressure, so that the connection firmness of the cable fitting is improved.

Description

Technical Field

[0001] This invention relates to the field of cable crimping device technology, and more particularly to a high-altitude power transmission line and fitting crimping device, specifically a portable intelligent digital crimping and testing device for overhead power line fittings. Background Technology

[0002] Cable fittings are commonly used cable termination / fixing structures in high-voltage transmission lines. Since fittings are integrally formed metal structures, while cables are composed of multiple strands of wound steel wire, they are typically crimped together to form a single, secure connection. The fundamental principle of fitting crimping is to deform the fitting using external stress, creating compression between it and the cable's steel strands. This compression relies on the inherent shape-maintaining properties of metal to prevent the cable from loosening after crimping, thus achieving a firm connection.

[0003] The quality of the crimping directly determines the connection strength between the cable and the fitting. Since different metals have different crimping limits, crimping the fitting too tightly is not always better. Excessive crimping can easily lead to cracking of the fitting, while insufficient crimping can create a crimping blind spot, forming a gap between the cable and the fitting. This results in insufficient connection strength and a tendency for the cable to loosen. The commonly used crimping method is the tapered crimping, which reduces the space in the fitting to accommodate the cable, squeezing out excess fitting material so that the cable is tightly wrapped around the fitting, achieving a tight connection. The advantage of this method is that the fitting is less prone to cracking, and the cable wires are subjected to uniform stress. However, it also has significant drawbacks. Because the stress is evenly distributed throughout the cable, the contact surface between the fitting's inner wall and the cable is relatively smooth, resulting in lower load-bearing capacity and weaker tensile strength.

[0004] On the other hand, the quality of crimping needs to be inspected. Common inspection methods include external dimensional inspection and internal defect inspection. Current methods for internal defect inspection typically require sending the crimped cable to a testing room for X-ray inspection to eliminate under-crimped or over-crimped products. However, since single cables can range from tens to hundreds of meters in length and are extremely heavy, they are difficult to transport, making the inspection of crimped fittings very costly and inconvenient. Therefore, given the above-mentioned limitations of existing technology, there is an urgent need for a device that can be used for crimping and inspection at the work site or around the project site to eliminate the problem of repeated transportation of cables and fittings, saving significant time, labor, and material costs. Summary of the Invention

[0005] To address the issues mentioned in the background art, such as insufficient tensile strength of cable fittings during crimping, which easily leads to loosening of the crimped fittings, and the high costs in manpower, materials, and time due to the need for round-trip transportation of cables and fittings for defect detection after crimping, this application provides a portable intelligent digital crimping and testing device for overhead power line fittings. This device enables cable fitting crimping and testing at the installation site of transmission and transformation lines or at the project site, eliminating the need for cable handling and allowing crimping and testing to be completed in one go, thus greatly improving the efficiency of crimping and testing.

[0006] To achieve the above objectives, the technical solution adopted in this application is as follows:

[0007] The portable intelligent digital crimping and testing device for overhead power line fittings provided in this application includes a base, on which a crimping mechanism and a testing mechanism are arranged side by side, and a fixing mechanism is provided at both ends of the base for fixing cables; a controller for controlling the crimping mechanism and the testing mechanism is installed inside the base; the crimping mechanism includes a crimping body fixedly connected to the base, and a hydraulic crimper is provided between the crimping body and the base; the hydraulic crimper is equipped with a crimping connector for crimping fittings sleeved on the cable; the testing mechanism includes a first testing unit for detecting the external dimensions of the fitting and a second testing unit for detecting the crimping state of the cable inside the fitting.

[0008] Preferably, the crimping connector includes an upper crimping connector and a lower crimping connector installed symmetrically. The crimping connector is provided with a protrusion for crimping the fitting. The protrusion includes an axial protrusion that is consistent with the length direction of the fitting and a radial protrusion that is arranged along the outer circumference of the fitting. The axial protrusion and the radial protrusion are both arranged in a discrete alternating manner.

[0009] Preferably, the fixing mechanism has two parts, which are respectively installed at both ends of the base and located on the same axis. The fixing mechanism includes a support and a clamping ring for clamping the cable is fixedly installed on the support. The outer circumference of the clamping ring is provided with a clamp for adjusting the tightness of the clamping ring.

[0010] Preferably, the fixing mechanism further includes a wire stripping mechanism, which includes a rotating housing rotatably disposed at either end of the clamping ring, an eccentric wheel rotatably mounted on the rotating housing, a disc blade for cutting the cable protective layer rotatably mounted on the eccentric wheel, and a handle for controlling the rotation of the disc blade around the cable fixedly connected to the eccentric wheel.

[0011] Preferably, the first detection unit adopts a lifting vernier caliper or micrometer structure.

[0012] Preferably, the testing mechanism includes a testing body, and a binocular camera is mounted on the testing body and aligned with the base for capturing the external dimensions of the pressed fitting via video. The binocular camera is electrically connected to an intelligent touch screen mounted on the testing body through an image processing integration unit to form the first testing unit.

[0013] Preferably, the second detection unit includes an X-ray source disposed on the detection body and a detector disposed on the upper surface of the base at a position corresponding to the X-ray source for receiving X-rays for imaging.

[0014] Preferably, the detection mechanism is driven to connect with a moving mechanism disposed within the base. The moving mechanism includes a drive motor disposed at the end of the base, a lead screw coaxially connected to the output shaft of the drive motor, and a slide block driven to connect with the lead screw. The detector is fixedly mounted on the slide block, and the slide block is mounted on at least two parallel slide rails arranged along the length of the base. The free end of the lead screw is rotatably connected to a bearing seat.

[0015] Beneficial effects:

[0016] The present invention uses a pressure head with alternating axial and radial settings to solve the problem of insufficient tensile strength in the existing "contraction" type crimping method, and at the same time avoids the problem of hardware cracking caused by overpressure, thereby improving the connection firmness of cable hardware.

[0017] Axial and radial protrusions enable uniform localized pressure distribution on the fittings, causing localized deformation of the cable at the pressure point. This squeezes the cable to a location on the inner wall of the fitting where the pressure is less, thereby changing the original shape and arrangement of the cable and forming a dispersed ring pressure state. At this point, the tensile strength of the cable and the fitting is generated by the friction between the cable and the fitting and the jamming caused by deformation, resulting in higher tensile strength compared to the existing compression and friction forces.

[0018] This invention enables external dimension inspection and internal defect inspection after crimping is completed, achieving uninterrupted crimping and inspection without the need for additional transportation of crimped cables to a testing room for on-site inspection, thus saving more time and effort. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a three-dimensional isometric view of the present invention.

[0021] Figure 2 yes Figure 1 Another visual axonometric drawing.

[0022] Figure 3 yes Figure 1 The main view.

[0023] Figure 4 It is an isometric drawing of a fixed mechanism structure.

[0024] Figure 5 yes Figure 4 The main view.

[0025] Figure 6 yes Figure 5 A sectional view with the section symbol AA along the center line.

[0026] Figure 7 yes Figure 5 A sectional view of the section symbol BB.

[0027] Figure 8 This is an isometric view of the press-fit connector.

[0028] Figure 9 This is a cross-sectional view of the crimped hardware and cables of this application.

[0029] Figure 10 It is a cross-sectional view of existing technology for crimping hardware and cables.

[0030] In the diagram: 1-Base; 2-Moving mechanism; 3-Fixing mechanism; 31-Handle; 32-Eccentric wheel; 33-Disc blade; 34-Rotating housing; 35-Clamping ring; 36-Support; 37-Clamp; 4-Crimping mechanism; 41-Hydraulic crimper; 42-Crimping connector; 421-Axial convex rib; 422-Radial convex rib; 43-Crimping machine body; 5-Detection mechanism; 51-Detection machine body; 52-Intelligent touch screen; 53-Dual-lens camera; 54-X-ray source; 55-Detector; 6-Cable; 7-Fit. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0032] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0033] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0034] In the description of this application, it should be noted that the use of terms such as "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer" to indicate orientation or positional relationships is based on the orientation or positional relationships shown in the accompanying drawings, or the orientation or positional relationships commonly used when the product is in use. These terms are used solely for the convenience of describing this application and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the use of terms such as "first" and "second" in the description of this application is only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0035] Furthermore, the use of terms such as "horizontal" and "vertical" in the description of this application does not imply that the component is required to be absolutely horizontal or suspended, but rather that it may be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but rather that it may be slightly tilted.

[0036] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0037] Example 1:

[0038] Refer to the instruction manual. Figures 1-3As shown, the portable intelligent digital crimping and testing device for overhead power line fittings provided in this embodiment includes a base 1. A crimping mechanism 4 and a testing mechanism 5 are arranged side by side on the base 1, and a fixing mechanism 3 is provided at both ends of the base 1 for fixing cables 6. A controller for controlling the crimping mechanism 4 and the testing mechanism 5 is installed inside the base 1. The crimping mechanism 4 includes a crimping body 43 fixedly connected to the base 1. A hydraulic crimper 41 is provided between the crimping body 43 and the base 1. A crimping connector 42 for crimping fittings 7 sleeved on the cable 6 is installed on the hydraulic crimper 41. The testing mechanism 5 includes a first testing unit for detecting the external dimensions of the fitting 7 and a second testing unit for detecting the crimping state of the cable 6 inside the fitting 7.

[0039] Working principle:

[0040] Refer to the instruction manual Figures 1-3 The diagram illustrates the crimping process. Select the crimping connector 42 corresponding to the fitting 7 to be crimped. It should be noted that different models and specifications of fittings 7 require crimping connectors 42 that match their external dimensions. Since cables 6 come in various diameters, each cable 6 has a corresponding crimping connector 42. During crimping, first open the fixing mechanism 3, fix the cable 6 to be crimped, and ensure that the end of the cable 6 is fully inserted into the bottom of the fitting 7, aligning the fitting with the crimping connector 42. Use the controller to activate the hydraulic crimper 41, pressing downwards until the crimping force reaches a preset value, then retracting to complete one crimping operation. The controller can be an existing electrical controller, an electrical controller with closed-loop control, or a controller based on a microcontroller. The control technology can be any existing technology and is not considered a technical improvement in this embodiment. For example, in the most common way, a pressure sensor can be installed in the hydraulic line of the hydraulic crimper 41 to collect the oil pressure in real time, thereby accurately controlling the effective crimping force of the hydraulic crimper 41. This force can be displayed on a digital tube or other display device to monitor the crimping force in real time. Once the hydraulic crimper 41 reaches the preset pressure value, it can maintain this pressure for a certain period, such as 10 seconds, to overcome the elastic deformation of the metal and keep it in the crimped state. Then, it is released, and the crimped fitting 7 is subjected to external dimensional inspection by a coaxially set detection mechanism 5. If the external dimensional inspection reveals that the external dimensions of the crimped fitting are not within the specified range, then an internal defect inspection is required to check for internal leakage or overpressure leading to cracking.

[0041] Example 2:

[0042] To further increase the reliability of the crimping, based on Example 1, and in conjunction with the appendix to the instruction manual... Figure 2 and Figure 8As shown, in this embodiment, the crimp connector 42 is further refined. The crimp connector 42 includes an upper crimp connector and a lower crimp connector that are symmetrically installed. The crimp connector 42 is provided with a protrusion for crimping the fitting 7. The protrusion includes an axial protrusion that is consistent with the length direction of the fitting 7 and a radial protrusion that is provided along the outer circumference of the fitting 7. The axial protrusion 421 and the radial protrusion 422 are both discretely alternately arranged. The dispersed axial protrusions 421 and radial protrusions 422 form uniformly dispersed pressure points on the surface of the fitting 7, resulting in greater pressure on both the fitting 7 and the cable 6 at these pressure points. Since the cable 6 is composed of multiple strands of wound steel wire, under external pressure, the wires are forced to be squeezed between adjacent pressure points. Simultaneously, the wires at these pressure points experience a significant radial force, causing them to deform. Thus, when facing axial tension, the deformation of the steel wires and the locking action between the fittings overcome the immense tension. Furthermore, since the steel wires are not arranged in a straight line along the axial direction but are wound, the clamping strength between the cable 6 and the fitting 7 is further increased. (See appendix for details.) Figure 9 and Figure 10 The differences are shown.

[0043] Example 3:

[0044] To better secure cable 6, and considering that the outer insulation layer needs to be removed before crimping cables with insulation, this issue is addressed by referring to the attached... Figures 1-3 As shown, in this embodiment, there are two fixing mechanisms 3, which are respectively installed at both ends of the base 1 and located on the same axis, as follows. Figures 4-7 As shown, the fixing mechanism 3 includes a support 36 and a clamping ring 35 fixedly installed on the support 36 for clamping the cable 6. The outer circumference of the clamping ring 35 is provided with a clamp 37 for adjusting the tightness of the clamping ring 35.

[0045] In this embodiment, the fixing mechanism 3 further includes a wire stripping mechanism. The wire stripping mechanism includes a rotating housing 34 rotatably disposed at either end of the clamping ring 35, an eccentric wheel 32 rotatably mounted on the rotating housing 34, and a disc blade 33 rotatably mounted on the eccentric wheel 32 for cutting the protective layer of the cable 6. The eccentric wheel 32 is also fixedly connected to a handle 31 for controlling the rotation of the disc blade 33 around the cable 6. When the cable 6 to be crimped is a protective steel cable with an insulating layer, firstly, the cable 6 is fixed to the fixing mechanism 3, such as... Figure 1The state is shown. Then, hold the handle 31 and press it appropriately until the disc blade 33 cuts into the insulation layer or reaches the steel core inside the cable 6. While maintaining a positive stress on the handle 31, rotate the handle 31 so that the disc blade 33 performs a 360° cut on the insulation layer on the surface of the cable 6. After the ring cut, since the length of the cable 6 to be crimped is generally no more than 10 cm from the end, the cut insulation layer can be removed by hand before performing the crimping operation described in Example 1.

[0046] Example 4:

[0047] Based on any of the above embodiments, this embodiment further refines the structure for detection. The first detection unit adopts a lifting vernier caliper or micrometer structure. This purely mechanical structure is the simplest, most intuitive, and most durable method, but its accuracy is relatively lower. This embodiment also provides a method with higher dimensional detection accuracy. Specifically, the detection mechanism 5 includes a detection body 51, and a binocular camera 53 is mounted on the detection body 51 and aligned with the base 1 for capturing the external dimensions of the pressed hardware 7 via video. The binocular camera 53 is electrically connected to an intelligent touchscreen 52 mounted on the detection body 51 through an image processing integration unit to form the first detection unit. Image measurement based on binocular cameras has already achieved very high accuracy in existing technologies. For example, the research on high-precision image measurement systems by Niu Penglei, Fan Hua, etc., illustrates the current feasible solutions for image-based ranging and image measurement. Furthermore, existing technologies also have cost modules that can achieve measurement functions through system integration. In this embodiment, as long as it can meet the requirements of close-range image acquisition and measurement, it is not limited to any particular module.

[0048] To further verify the crimping fittings 7 that fail the external dimensional inspection, in this embodiment, the second inspection unit includes an X-ray source 54 mounted on the inspection body 51 and a detector 55 mounted on the upper surface of the base 1 at a position corresponding to the X-ray source 54 for receiving X-rays for imaging. The inspection mechanism 5 is driven by a moving mechanism 2 located within the base 1. The moving mechanism 2 includes a drive motor located at the end of the base 1, a lead screw coaxially connected to the output shaft of the drive motor, and a slide block driven by the lead screw. The detector 55 is fixedly mounted on the slide block, which is mounted on at least two parallel slide rails along the length of the base 1. The free end of the lead screw is rotatably connected to a bearing seat. The function of the moving mechanism 2 is to adjust the position of the inspection mechanism 5 to create more space for the crimping mechanism 4, thereby accommodating the crimping of fittings 7 of different sizes and shapes and avoiding structural interference.

[0049] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A portable intelligent digital crimping test device for overhead power line fittings, comprising a base (1), characterized in that: The base (1) is provided with a crimping mechanism (4) and a detection mechanism (5) arranged in parallel, and a fixing mechanism (3) is provided at both ends of the base (1) for fixing the cable (6); the base (1) is provided with a controller for controlling the crimping mechanism (4) and the detection mechanism (5); the crimping mechanism (4) includes a crimping body (43) fixedly connected to the base (1); a hydraulic crimper (41) is provided between the crimping body (43) and the base (1); the hydraulic crimper (41) is provided with a crimping connector (42) for crimping the fitting (7) sleeved on the cable (6); the detection mechanism (5) includes a first detection unit for detecting the external dimensions of the fitting (7) and a second detection unit for detecting the crimping state of the cable (6) inside the fitting (7); The crimping connector (42) includes an upper crimping connector and a lower crimping connector that are symmetrically installed. The crimping connector (42) is provided with a protrusion for crimping the fitting (7). The protrusion includes an axial protrusion that is consistent with the length direction of the fitting (7) and a radial protrusion that is provided along the outer circumference of the fitting (7). The axial protrusion (421) and the radial protrusion (422) are both arranged in a discrete alternating manner.

2. The portable intelligent digital crimping testing device for overhead power line fittings according to claim 1, characterized in that: The fixing mechanism (3) has two parts, which are respectively installed at both ends of the base (1) and located on the same axis. The fixing mechanism (3) includes a support (36) and a clamping ring (35) fixedly installed on the support (36) for clamping the cable (6). The outer circumference of the clamping ring (35) is provided with a clamp (37) for adjusting the tightness of the clamping ring (35).

3. The portable intelligent digital crimping testing device for overhead power line fittings according to claim 2, characterized in that: The fixing mechanism (3) further includes a wire stripping mechanism, which includes a rotating housing (34) rotatably disposed at either end of the clamping ring (35), an eccentric wheel (32) rotatably mounted on the rotating housing (34), a disc blade (33) for cutting the protective layer of the cable (6) rotatably mounted on the eccentric wheel (32), and a handle (31) fixedly connected to the eccentric wheel (32) for controlling the disc blade (33) to rotate around the cable (6).

4. The portable intelligent digital crimping testing device for overhead power line fittings according to claim 3, characterized in that: The first detection unit adopts a lifting vernier caliper or micrometer structure.

5. The portable intelligent digital crimping testing device for overhead power line fittings according to claim 3, characterized in that: The testing mechanism (5) includes a testing body (51), and a binocular camera (53) is installed on the testing body (51) and aligned with the base (1) for capturing the external dimensions of the pressed fitting (7) via video. The binocular camera (53) is electrically connected to an intelligent touch screen (52) on the testing body (51) through an image processing integration unit to form the first testing unit.

6. The portable intelligent digital crimping testing device for overhead power line fittings according to claim 5, characterized in that: The second detection unit includes an X-ray source (54) disposed on the detection body (51) and a detector (55) disposed on the upper surface of the base (1) at a position corresponding to the X-ray source (54) for receiving X-rays for imaging.

7. The portable intelligent digital crimping testing device for overhead power line fittings according to claim 6, characterized in that: The detection mechanism (5) is driven to connect with the moving mechanism (2) located inside the base (1). The moving mechanism (2) includes a drive motor located at the end of the base (1), a lead screw coaxially connected to the output shaft of the drive motor, and a slide connected to the lead screw. The detector (55) is fixedly mounted on the slide. The slide is mounted on at least two parallel slide rails along the length of the base (1). The free end of the lead screw is rotatably connected to the bearing seat.

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