Special vehicle electromagnetic shielding cable assembly, installation tooling and installation method

Abstract

The present invention belongs to the technical field of electromagnetic shielding cables, especially electromagnetic shielding cable assemblies, installation tools and installation methods for special vehicles. Aiming at the problems in the prior art that there is a lack of shielding measures outside the wire itself, it is difficult to weld the cable to the contact of the connector, and the groove of the female plug is easy to accumulate dust, the following solution is proposed. It includes: a female connector, a male connector and a plurality of wire cores. The plurality of wire cores form a cable splicing assembly, and a first connection assembly is arranged at one end of the female connector for connecting one end of the cable splicing assembly to the female connector. In the present invention, the first light tin-plated copper shielding sleeve and the second light tin-plated copper shielding sleeve can be used to wrap the wire and the wire harness respectively, so as to improve the electromagnetic shielding performance of the cable assembly. In addition, the plurality of first contacts are arranged in a V-shaped row, and the plurality of second contacts are arranged in an inverted V-shaped row, which is not only convenient for later welding with the wire cores, but also can expose the first contacts and the second contacts, facilitating the removal of dust at any time.

Description

Technical Field

[0001] The present invention relates to the technical field of electromagnetic shielding cables, and particularly to an electromagnetic shielding cable assembly for special vehicles, an installation tooling, and an installation method. Background Art

[0002] With the development and progress of the vehicle industry and the electronics industry, vehicles are evolving from simple mechanical products towards advanced mechatronics. In special vehicles, intelligent power supply and distribution technologies are increasingly used for internal power supply and distribution, and the components used inside the control box are becoming more and more precise, with more intelligent and integrated designs. This has made the electrical signals transmitted and used inside the vehicle increasingly complex. As is well known, various products inside the vehicle are constantly in a vibration and impact environment, which will generate many noise sources, such as electric motors, fuel pumps, air conditioner starters, satellite navigation systems, etc. The complex use environment and more precise control circuits have also imposed higher requirements on the electromagnetic compatibility of the cable assemblies for transmitting signals inside the vehicle.

[0003] Currently, the cable assemblies used inside special vehicles usually consist of electrical connectors welded to shielded three-strand wires, shielded twisted-pair wires, or high-temperature insulated silver-plated copper wires, with a heat shrinkable tube as the outer sheath.

[0004] However, there are still the following deficiencies in the installation of cable assemblies in the prior art:

[0005] 1. For the complex electrical signal transmission inside the vehicle currently, this manufacturing method does not fully consider the requirements of electromagnetic shielding. For example, there is no shielded connection between the electrical connector and the wire, and there is a lack of shielding measures outside the wire itself. These defects make the cable assembly vulnerable to electromagnetic radiation interference from other devices or circuits inside the vehicle during signal transmission, resulting in the transmitted signal having clutter or surges. This not only fails to ensure the smooth transmission of the signal but also easily causes damage to the in-vehicle devices.

[0006] 2. The cable and the connector are often connected by welding. However, due to the large number of wire cores in the cable and their annular arrangement, it will cause obstacles between the wire cores during subsequent welding, hindering the welding of the wire cores to the contacts in the connector.

[0007] 3. When the cable and the plug are welded, when the male plug and the female plug are docked, it is often necessary to insert the contacts in the male plug into the grooves in the female plug. However, the grooves in the female plug are prone to accumulating dust, and over time, the dust will block the female plug, resulting in poor contact between the male plug and the female plug.

[0008] In view of the above problems, the present invention document proposes an electromagnetic shielding cable assembly for special vehicles, an installation tooling, and an installation method. Summary of the Invention

[0009] The present invention provides a special vehicle electromagnetic shielding cable assembly, an installation tooling and an installation method, which solve the disadvantages in the prior art that there is a lack of shielding measures outside the wire itself, it is difficult to weld the cable and the connector contact, and the groove of the female plug is prone to accumulate dust.

[0010] The present invention provides the following technical solutions:

[0011] A special vehicle electromagnetic shielding cable assembly, comprising: a female connector, a male connector and a plurality of wire cores, and the plurality of wire cores form a cable splicing assembly;

[0012] A first connection assembly, arranged at one end of the female connector, for connecting one end of the cable splicing assembly with the female connector;

[0013] A second connection assembly, arranged inside the male connector, for connecting the other end of the cable splicing assembly with the male connector.

[0014] In a possible design, the cable splicing assembly includes an insulating layer sleeved on the outer wall of the wire core, the wire core and the insulating layer form a wire, a first light tin-plated copper shielding sleeve is sleeved on the outer wall of the wire, a plurality of wires are twisted to form a wire harness, a plurality of insulating tape layers for ensuring the stability of the wire harness are sleeved on the outer wall of the wire harness, a second light tin-plated copper shielding sleeve is sleeved on the outer wall of the wire harness, and the second light tin-plated copper shielding sleeve wraps the insulating tape layer, and a plurality of heat shrinkable tubes are sleeved on the outer wall of the second light tin-plated copper shielding sleeve.

[0015] In a possible design, the first connection assembly includes a fixed head fixedly connected to one end of the female connector, a plurality of first contacts are fixedly penetrated through the top of the female connector, and the plurality of first contacts are arranged in a V-shaped arrangement. One end of the first contact penetrates through the fixed head and is provided with a first welding groove, and the wire core is welded to the first welding groove. A semi-circular groove is arranged on the side of the fixed head away from the first welding groove, a trapezoidal arc is fixedly connected to the inner wall of the top of the semi-circular groove, and a second threaded ring is threadedly sleeved on the outer wall of the fixed head. The second threaded ring and the fixed head cooperate to form a circular groove, which is convenient for pouring glue after the wire core and the first contact are welded. A plurality of sealing strips are fixedly connected to the top of the female connector, and two adjacent sealing strips are distributed on both sides of the first contact. When the female connector and the male connector are spliced, the bottom of the male connector fits with the top of the female connector. Through the sealing strips, the sealing performance between the female connector and the male connector can be increased, and the first contact and the second contact can be sealed.

[0016] In a possible design, the second connection component includes a plurality of rectangular grooves provided in the male connector, and the plurality of rectangular grooves are arranged in an inverted V shape. The inner wall of the top of the rectangular groove is fixedly connected with a second contact. One end of the second contact fixedly penetrates through the male connector and is provided with a second welding groove, and the second welding groove is welded to the wire core. The bottom of the second contact is fixedly connected with a plurality of resilient arc-shaped contact pieces located in the rectangular groove, and the resilient arc-shaped contact pieces cooperate with the first contact. Thread grooves are provided on the outer walls of both the female connector and the male connector, and a first thread ring is threadedly sleeved on the outer walls of the two thread grooves. The female connector and the male connector can be further connected through the first thread ring, and the first thread ring and the female connector and the male connector cooperate to form a circular groove, which is convenient for potting after the wire core and the second contact are welded later.

[0017] In a possible design, another possibility of the second contact. The bottom of the second contact is fixedly connected with a plurality of W-shaped contact pieces. Both ends of the W-shaped contact pieces touch the bottom of the second contact. When the male connector is inserted into the semi-circular groove, the male connector is tightly attached to the female connector under the action of the trapezoidal arc. Both bottom ends of the W-shaped contact pieces can touch the first contact. The connection stability between the first contact and the second contact can be increased by the fact that both bottom ends of the W-shaped contact pieces can touch the first contact.

[0018] In a possible design, another possibility of the second contact. The bottom of the second contact is fixedly connected with a plurality of V-shaped contact pieces. One end of the V-shaped contact piece touches the bottom of the second contact. When the male connector is inserted into the semi-circular groove, the male connector is tightly attached to the female connector under the action of the trapezoidal arc. The bottom end of the W-shaped contact piece can touch the first contact. The connection stability between the first contact and the second contact can be increased by the fact that the bottom of the W-shaped contact piece can touch the first contact.

[0019] The electromagnetic shielding cable installation tooling for special vehicles is used to weld the first contact and the second contact in the above-mentioned special vehicle electromagnetic shielding cable assembly to the wire core respectively, and includes a bottom plate. The top of the bottom plate is fixedly connected with an L-shaped bracket;

[0020] An alignment component is arranged on the top of the bottom plate and is used to make a plurality of first contacts in the female connector and a plurality of second contacts in the male connector be in the same horizontal plane respectively;

[0021] A welding component is arranged in the L-shaped bracket and is used to weld the first contact and the second contact to the wire core respectively.

[0022] In one possible design, the alignment assembly includes a sliding platform slidably connected to the top of the base plate, the sliding platform is fixedly connected to a fixed seat on the side close to the L-shaped bracket, the fixed seat is rotatably connected to a rotating shaft on the side away from the L-shaped bracket, one end of the rotating shaft is fixedly connected to a semicircular frame, and the semicircular frame is slidably connected to the sliding platform, a yield groove is provided in the sliding platform, sliding grooves are provided on both sides of the top of the semicircular frame, a pressure plate is slidably connected to the sliding groove, a protrusion is fixedly connected to the top of the pressure plate, a first spring is fixedly connected to one side of the pressure plate, and one end of the first spring is fixedly connected to an inner wall of one side of the sliding groove.

[0023] In one possible design, the welding assembly includes an electric push rod fixedly connected to the top of the L-shaped bracket, the output shaft of the electric push rod passes through the L-shaped bracket and is fixedly connected to a movable plate, a plurality of welding guns are fixedly connected to the bottom of the movable plate, a sliding rod slides through the movable plate, the outer wall fixed sleeve of the sliding rod is provided with a sliding plate, the outer wall sleeve of the sliding rod is provided with a second spring fixedly connected to the top of the sliding plate, and the top of the second spring is fixedly connected to the bottom of the movable plate, a push plate is provided under the movable plate, the top of the push plate is provided with a sliding groove, and the bottom end of the sliding rod extends into the sliding groove and slides with the sliding groove.

[0024] The method for installing the special vehicle electromagnetic shielding cable assembly comprises the following steps:

[0025] S1. Cut the heat shrink tubing and make wire markers: Cut the heat shrink tubing that meets the requirements to the specified length and use white self-adhesive paper to make cable markers;

[0026] S2. Wire cutting: Cut the wires that meet the requirements to the specified length;

[0027] S3. Thread the wire through the heat shrink tube: Select a heat shrink tube that matches the wire diameter and thread it through the wire.

[0028] S4. Wire stripping: Select appropriate wire strippers according to the thickness of the insulation layer and strip the insulation layer of the outer wall of the wire core;

[0029] S5. Wire tinning: Wires should be tinned immediately after stripping;

[0030] S6. Paste the wire number mark: Paste the wire number mark within 30 to 70 cm from the bare wire end;

[0031] S7, twisted wire harness: twist the wires with the same destination into a bundle;

[0032] S8. Thread a light tinned copper shielding sleeve over the wire harness: Thread a second light tinned copper shielding sleeve over the twisted wire harness, and then cover the outer layer of the second light tinned copper shielding sleeve with a heat shrink tubing.

[0033] S9. Place the female connector in the semi-circular frame. By activating the electric push rod, the bottom of the pushing plate touches the right-angle part of the inner wall of the female connector, enabling multiple right-angle parts of the inner wall of the female connector to be on the same horizontal line.

[0034] S10. Then move the sliding table. The first welding groove is located below the welding torch. The moving plate drives the welding torch to move down further. The welding torch welds the wire core to the first contact. By analogy, the wire core can be welded to the second contact on the male connector.

[0035] S11. Push one end of the male connector into the semi-circular groove. The bottom of the male connector fits tightly with the top of the female connector, and the resilient arc-shaped contact can touch the top of the first contact tightly, ensuring the stability of the connection between the second contact and the first contact.

[0036] S12. After the female connector and the male connector are spliced, put the first threaded ring on the threaded grooves of the female connector and the male connector, thread the second threaded ring on the outer wall of the fixed head, and pour glue into the second threaded ring and the first threaded ring respectively.

[0037] It should be understood that the above general description and the following detailed description are only exemplary and do not limit the present invention.

[0038] In the present invention, a first light tin-plated copper shielding sleeve is sleeved on the outer wall of the wire of the electromagnetic shielding cable assembly for special vehicles. Multiple wires are twisted to form a wire harness. The outer wall of the wire harness is sleeved with a plurality of insulating tape layers for ensuring the stability of the wire harness. The outer wall of the wire harness is sleeved with a second light tin-plated copper shielding sleeve, and the second light tin-plated copper shielding sleeve wraps the insulating tape layer. The outer wall of the second light tin-plated copper shielding sleeve is sleeved with a plurality of heat shrinkable tubes. The electromagnetic shielding performance of the cable assembly can be increased by the first light tin-plated copper shielding sleeve and the second light tin-plated copper shielding sleeve.

[0039] In the present invention, a plurality of first contacts are fixedly penetrated through the top of the female connector of the electromagnetic shielding cable assembly for special vehicles. The top inner wall of the rectangular groove is fixedly connected with a second contact. The bottom of the second contact is fixedly connected with a plurality of resilient arc-shaped contacts located in the rectangular groove, and the resilient arc-shaped contacts cooperate with the first contacts. By exposing the first contacts and the resilient arc-shaped contacts to the outside, the dust on the surfaces of the first contacts and the resilient arc-shaped contacts can be removed at any time, preventing excessive dust accumulation from affecting the stability of the connection between the second contact and the first contact.

[0040] In the present invention, a plurality of first contacts penetrate through and are fixed at the top of the female connector of the electromagnetic shielding cable assembly for special vehicles, and the plurality of first contacts are arranged in a V shape. A plurality of rectangular grooves are provided in the male connector, and the plurality of rectangular grooves are arranged in an inverted V shape. A second contact is fixedly connected to the inner wall of the top of the rectangular groove. Through the arrangement of the first contact and the second contact, the welding of the first contact, the second contact and the wire core can be easily completed, improving the welding efficiency;

[0041] In the present invention, a fixing seat is fixedly connected to one side of the sliding table close to the L-shaped bracket. A rotating shaft is rotatably connected to one side of the fixing seat. One end of the rotating shaft is fixedly connected to a semi-circular frame, and the semi-circular frame is slidably connected in the sliding table. The female connector is placed in the semi-circular frame. The output shaft of the electric push rod pushes the moving plate downward. The bottom of the pushing plate touches the right-angle part of the inner wall of the female connector. As the moving plate and the pushing plate continue to move downward, the pushing plate drives the female connector and the semi-circular frame to rotate around the rotating shaft, so that the plurality of right-angle parts on the inner wall of the female connector are on the same horizontal line, which is convenient for multiple welding torches to perform welding simultaneously in the later stage, improving the welding efficiency.

[0042] In the present invention, the first light tin-plated copper shielding sleeve and the second light tin-plated copper shielding sleeve can respectively wrap the wire and the wire harness, thereby increasing the electromagnetic shielding performance of the cable assembly. In addition, the plurality of first contacts are arranged in a V shape, and the plurality of second contacts are arranged in an inverted V shape. This not only facilitates the later welding with the wire core but also exposes the first contact and the second contact, making it convenient to remove dust at any time, ensuring the stability of the connection between the first contact and the second contact. In addition, through the cooperation of the pushing plate and the semi-circular frame, the plurality of first contacts can be on the same horizontal line, which is convenient for unified welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 is the front view structural schematic diagram of the electromagnetic shielding cable assembly for special vehicles provided by the embodiment of the present invention;

[0044] Figure 2 is the sectional structural schematic diagram in the A-A direction of the electromagnetic shielding cable assembly for special vehicles provided by the embodiment of the present invention;

[0045] Figure 3 is the three-dimensional structural schematic diagram of the cooperation between the female connector and the male connector of the electromagnetic shielding cable assembly for special vehicles provided by the embodiment of the present invention;

[0046] Figure 4 is the three-dimensional structural schematic diagram of the fixing head and the female connector of the electromagnetic shielding cable assembly for special vehicles provided by the embodiment of the present invention;

[0047] Figure 5 is the three-dimensional sectional structural schematic diagram of the fixing head and the first contact of the material taking assembly of the electromagnetic shielding cable assembly for special vehicles provided by the embodiment of the present invention;

[0048] Figure 6 It is a three - dimensional sectional view structure diagram of the male connector of the electromagnetic shielding cable assembly for special vehicles provided by the embodiment of the present invention;

[0049] Figure 7 It is a three - dimensional sectional view structure diagram of the second contact of the electromagnetic shielding cable assembly for special vehicles provided by the embodiment of the present invention;

[0050] Figure 8 It is a three - dimensional structure diagram of the installation tooling for the electromagnetic shielding cable of special vehicles provided by the embodiment of the present invention;

[0051] Figure 9 It is a three - dimensional structure diagram of the sliding table and the semi - circular frame of the installation tooling for the electromagnetic shielding cable of special vehicles provided by the embodiment of the present invention;

[0052] Figure 10 It is an enlarged structure diagram at position B of the installation tooling for the electromagnetic shielding cable of special vehicles provided by the embodiment of the present invention;

[0053] Figure 11 It is a three - dimensional sectional view structure diagram of the moving plate of the installation tooling for the electromagnetic shielding cable of special vehicles provided by the embodiment of the present invention;

[0054] Figure 12 It is a three - dimensional structure diagram of the second contact and the W - shaped contact piece of the electromagnetic shielding cable assembly for special vehicles provided by Embodiment 2 of the present invention;

[0055] Figure 13 It is a three - dimensional structure diagram of the second contact and the V - shaped contact piece of the electromagnetic shielding cable assembly for special vehicles provided by Embodiment 3 of the present invention.

[0056] Reference numerals:

[0057] 1. Core; 2. Insulation layer; 3. First light tin-plated copper shielding sleeve; 4. Insulating tape layer; 5. Second light tin-plated copper shielding sleeve; 6. Heat shrinkable tube; 7. Fixed head; 8. Female connector; 9. First contact; 10. Semi-circular groove; 11. Trapezoidal arc; 12. Male connector; 13. Second contact; 14. Second welding groove; 15. First welding groove; 16. Rectangular groove; 17. Tough arc-shaped contact piece; 18. Threaded groove; 19. First threaded ring; 20. Second threaded ring; 21. Sealing strip; 22. Base plate; 23. L-shaped bracket; 24. Sliding table; 25. Fixed seat; 26. Rotating shaft; 27. Semi-circular frame; 28. Sliding groove; 29. Pressing plate; 30. Protrusion; 31. First spring; 32. Electric push rod; 33. Moving plate; 34. Welding torch; 35. Slide bar; 36. Slide plate; 37. Second spring; 38. Pushing plate; 39. Chute; 40. W-shaped contact piece; 41. V-shaped contact piece; 42. Relief groove. Detailed implementation manner

[0058] The embodiments of the present invention will be described below with reference to the accompanying drawings in the embodiments of the present invention.

[0059] In the description of the embodiments of the present invention, it should be noted that unless otherwise clearly specified and limited, the terms "connection" and "installation" should be understood in a broad sense. For example, "connection" can be a detachable connection or a non-detachable connection; it can be a direct connection or an indirect connection through an intermediate medium. In addition, "communication" can be a direct communication or an indirect communication through an intermediate medium. Among them, "fixing" means that they are connected to each other and the relative positional relationship after connection remains unchanged. The orientation terms mentioned in the embodiments of the present invention, such as "inside", "outside", "top", "bottom", etc., are only references to the direction of the accompanying drawings. Therefore, the orientation terms used are for better and clearer description and understanding of the embodiments of the present invention, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation to the embodiments of the present invention.

[0060] In the embodiments of the present invention, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first" and "second" may explicitly or implicitly include one or more of such features.

[0061] In the embodiments of the present invention, "and / or" is only a description of the association relationship of associated objects, indicating that three relationships may exist. For example, A and / or B may represent: A exists alone, A and B exist simultaneously, and B exists alone. In addition, the character " / " in this article generally represents an "or" relationship between the front and rear associated objects.

[0062] References to "one embodiment" or "some embodiments" or the like in this specification mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in one or more embodiments of the present invention. Thus, statements such as "in one embodiment", "in some embodiments", "in other some embodiments", "in still other embodiments", etc. that appear in different places in this specification do not necessarily all refer to the same embodiment, but mean "one or more but not all embodiments", unless otherwise specifically emphasized. The terms "comprising", "including", "having" and their variants all mean "including but not limited to", unless otherwise specifically emphasized.

[0063] Embodiment 1

[0064] Referring to Figure 1 、 Figure 2 and Figure 3 For the electromagnetic shielding cable assembly of the special vehicle in this embodiment, it includes: a female connector 8, a male connector 12, and a plurality of wire cores 1. The plurality of wire cores 1 form a cable splicing assembly, a first connection assembly is arranged at one end of the female connector 8 and is used to connect one end of the cable splicing assembly to the female connector 8, and a second connection assembly is arranged inside the male connector 12 and is used to connect the other end of the cable splicing assembly to the male connector 12.

[0065] Referring to Figure 1 and Figure 2 For the cable splicing assembly, it includes an insulating layer 2 sleeved on the outer wall of the wire core 1. The wire core 1 and the insulating layer 2 form a wire. A first light tin-plated copper shielding sleeve 3 is sleeved on the outer wall of the wire. A plurality of wires are twisted to form a wire harness. A plurality of insulating tape layers 4 for ensuring the stability of the wire harness are sleeved on the outer wall of the wire harness. A second light tin-plated copper shielding sleeve 5 is sleeved on the outer wall of the wire harness, and the second light tin-plated copper shielding sleeve 5 wraps the insulating tape layer 4. A plurality of heat shrinkable tubes 6 are sleeved on the outer wall of the second light tin-plated copper shielding sleeve 5. The electromagnetic shielding performance of the cable assembly can be enhanced by the first light tin-plated copper shielding sleeve 3 and the second light tin-plated copper shielding sleeve 5.

[0066] Referring to Figure 4 and Figure 5, the first connection component includes a fixed head 7 fixedly connected to one end of the female connector 8. A plurality of first contact heads 9 are fixedly penetrated through the top of the female connector 8, and the plurality of first contact heads 9 are arranged in a V shape. One end of the first contact head 9 penetrates through the fixed head 7 and is provided with a first welding groove 15, and the wire core 1 is welded to the first welding groove 15. A semi-circular groove 10 is provided on the side of the fixed head 7 away from the first welding groove 15. A trapezoidal arc 11 is fixedly connected to the inner wall of the top of the semi-circular groove 10. A second thread ring 20 is threadedly sleeved on the outer wall of the fixed head 7. The second thread ring 20 and the fixed head 7 cooperate to form a circular groove, which is convenient for potting after the wire core 1 and the first contact head 9 are welded. A plurality of sealing strips 21 are fixedly connected to the top of the female connector 8, and two adjacent sealing strips 21 are distributed on both sides of the first contact head 9. When the female connector 8 and the male connector 12 are spliced, the bottom of the male connector 12 fits against the top of the female connector 8. The sealing strips 21 can increase the sealing performance between the female connector 8 and the male connector 12 and seal the first contact head 9 and the second contact head 13.

[0067] Refer to Figure 6 and Figure 7 , the second connection component includes a plurality of rectangular grooves 16 provided in the male connector 12, and the plurality of rectangular grooves 16 are arranged in an inverted V shape. A second contact head 13 is fixedly connected to the inner wall of the top of the rectangular groove 16. One end of the second contact head 13 fixedly penetrates through the male connector 12 and is provided with a second welding groove 14, and the second welding groove 14 is welded to the wire core 1. A plurality of resilient arc-shaped contact pieces 17 located in the rectangular groove 16 are fixedly connected to the bottom of the second contact head 13, and the resilient arc-shaped contact pieces 17 cooperate with the first contact head 9. Thread grooves 18 are provided on the outer walls of both the female connector 8 and the male connector 12. A first thread ring 19 is threadedly sleeved on the outer walls of the two thread grooves 18. The first thread ring 19 can further connect the female connector 8 and the male connector 12, and the first thread ring 19 and the female connector 8 and the male connector 12 cooperate to form a circular groove, which is convenient for potting after the wire core 1 and the second contact head 13 are welded. By exposing the first contact head 9 and the resilient arc-shaped contact pieces 17 to the outside, the dust on the surfaces of the first contact head 9 and the resilient arc-shaped contact pieces 17 can be removed at any time, preventing excessive dust accumulation from affecting the connection stability between the second contact head 13 and the first contact head 9. Through the arrangement of the first contact head 9 and the second contact head 13, the welding of the first contact head 9, the second contact head 13 and the wire core 1 can be easily completed, improving the welding efficiency.

[0068] Refer to Figure 8The special vehicle electromagnetic shielding cable installation tool of this embodiment is used to weld the first contact 9 and the second contact 13 in the above-mentioned special vehicle electromagnetic shielding cable assembly to the wire core 1 respectively, and includes a base plate 22, and an L-shaped bracket 23 is fixedly connected to the top of the base plate 22. An alignment component is arranged on the top of the base plate 22, and is used to respectively make the multiple first contacts 9 in the female connector 8 and the multiple second contacts 13 in the male connector 12 in the same horizontal plane; a welding component is arranged in the L-shaped bracket 23, and is used to weld the first contact 9 and the second contact 13 to the wire core 1 respectively.

[0069] Reference Figure 9 and Figure 10 The alignment component includes a sliding table 24 slidably connected to the top of the bottom plate 22, a fixed seat 25 is fixedly connected to the side of the sliding table 24 close to the L-shaped bracket 23, and a rotating shaft 26 is rotatably connected to the side of the fixed seat 25 away from the L-shaped bracket 23. One end of the rotating shaft 26 is fixedly connected to a semicircular frame 27, and the semicircular frame 27 is slidably connected to the sliding table 24. A clearance groove 42 is provided in the sliding table 24, and sliding grooves 28 are provided on both sides of the top of the semicircular frame 27. A pressure plate 29 is slidably connected in the sliding groove 28, and a protrusion 30 is fixedly connected to the top of the pressure plate 29. One side of the pressure plate 29 is fixed A first spring 31 is fixedly connected, and one end of the first spring 31 is fixedly connected to the inner wall of one side of the sliding groove 28. The female connector 8 is placed in the semicircular frame 27. The output shaft of the electric push rod 32 pushes the movable plate 33 to move downward, and the bottom of the pushing plate 38 touches the right-angled part of the inner wall of the female connector 8. As the movable plate 33 and the pushing plate 38 continue to move downward, the pushing plate 38 drives the female connector 8 and the semicircular frame 27 to rotate with the rotating shaft 26 as the center, so that the multiple right-angled parts of the inner wall of the female connector 8 are on the same horizontal line, which is convenient for multiple welding guns 34 to weld at the same time in the later stage, thereby improving welding efficiency.

[0070] Reference Figure 11 The welding assembly includes an electric push rod 32 fixedly connected to the top of the L-shaped bracket 23. The output shaft of the electric push rod 32 passes through the L-shaped bracket 23 and is fixedly connected to a movable plate 33. A plurality of welding guns 34 are fixedly connected to the bottom of the movable plate 33. A sliding rod 35 slides through the movable plate 33. The outer wall of the sliding rod 35 is fixedly sleeved with a slide plate 36. The outer wall of the sliding rod 35 is sleeved with a second spring 37 fixedly connected to the top of the slide plate 36, and the top of the second spring 37 is fixedly connected to the bottom of the movable plate 33. A pushing plate 38 is provided under the movable plate 33. A sliding groove 39 is provided on the top of the pushing plate 38, and the bottom end of the sliding rod 35 extends into the sliding groove 39 and slides with the sliding groove 39.

[0071] Example 2

[0072] Reference Figure 12, Another possibility for the second contact 13 is that a plurality of W-shaped contact pieces 40 are fixedly connected to the bottom of the second contact 13. Both ends of the W-shaped contact piece 40 touch the bottom of the second contact 13. When the male connector 12 is inserted into the semi-circular groove 10, the male connector 12 fits tightly with the female connector 8 under the action of the trapezoidal arc 11. Both bottom ends of the W-shaped contact piece 40 can touch the first contact 9. The ability of both bottom ends of the W-shaped contact piece 40 to touch the first contact 9 can increase the connection stability between the first contact 9 and the second contact 13.

[0073] Embodiment 3

[0074] Refer to Figure 13 , Another possibility for the second contact 13 is that a plurality of V-shaped contact pieces 41 are fixedly connected to the bottom of the second contact 13. One end of the V-shaped contact piece 41 touches the bottom of the second contact 13. When the male connector 12 is inserted into the semi-circular groove 10, the male connector 12 fits tightly with the female connector 8 under the action of the trapezoidal arc 11. The bottom end of the W-shaped contact piece 40 can touch the first contact 9. The ability of the bottom of the W-shaped contact piece 40 to touch the first contact 9 can increase the connection stability between the first contact 9 and the second contact 13.

[0075] Installation method of the electromagnetic shielding cable assembly for special vehicles, including the following steps:

[0076] S1. Cut the heat shrinkable tube 6 and make wire markings: Cut the heat shrinkable tube 6 that meets the requirements to the specified length. The cut is neat, without skew or damage. Use white self-adhesive paper to make cable markings. The marking characters are accurate, clear and easy to distinguish. There is no color difference allowed in the marking color code for the same batch. Use white self-adhesive paper to print the wire numbers on the self-adhesive white paper. The wire numbers should be accurate, clear and easy to distinguish. The various markings made of white self-adhesive paper not only have clear handwriting, but also can prevent oil stains and water. Compared with the markings made of ordinary A4 white printing paper, the service life of the markings is extended to a great extent;

[0077] S2. Wire cutting: Cut the wire that meets the requirements to the specified length. During cutting, the wire should not be flattened or damaged, and the conductor layer and insulation layer 2 of the uncut part should not be damaged;

[0078] S3. Pass the wire through the heat shrinkable tube 6: Select the heat shrinkable tube 6 that matches the wire diameter, cut the heat shrinkable tube 6 according to the wire length, and pass it through the wire. The cut heat shrinkable tube 6 is required to have a neat cut, and the shielding layer should not be loose;

[0079] S4. Wire stripping: Wire stripping is carried out during termination to prevent the wire core 1 from oxidizing. Select a suitable wire stripping pliers according to the thickness of the insulation layer 2. During wire stripping, the insulation layer 2 of the un-stripped part should not be damaged. The damaged wire core 1 should not exceed the regulations in the following table. The end of the stripped insulation layer 2 should be flush, without burrs, and should not be flattened or pinched to damage the insulation layer 2 of the non-stripped part;

[0080] S5. Tinning of the wire: Tinning should be carried out immediately after wire stripping (the exposure time of the wire core 1 should not exceed 2 hours to prevent wire oxidation). Dip the wire core 1 of the wire into an appropriate amount of neutral soldering flux and vertically immerse it into the tin melting furnace. When tinning, the trimmed part of the wire insulation layer 2 should be 0.5 - 1 mm away from the solder surface, and the tinning time is about 1 - 2 s. After tinning the wire, immediately put the tinned end into cold water (for heat dissipation) and dry it to prevent the insulation layer 2 from shrinking or cracking. After completion, visually inspect the appearance of the tinned part, which should be smooth, bright, without sharp tips or burrs, the tin layer should be of uniform thickness, and there should be no residue or soldering flux adhesion.

[0081] S6. Pasting wire number label: Paste the wire number label within the range of 30 - 70 from the bare wire end of the wire. It should be pasted firmly and the wire number text should be clearly distinguishable.

[0082] S7. Twisting the wire harness: Twist the wires with the same destination (the number of wires is greater than 1) into a bundle, and tie it with black insulating tape layer 4 for 3 - 5 turns every 300 - 500. The tying should be firm, and the twisted wire harness should not rebound. The tightness of the twisted wire harness should be consistent, the wire harness should be straight, and there should be no knotting or individual wires protruding. After twisting, the first light tin-plated copper shielding sleeves 3 outside each wire in the wire harness can better contact each other, tightly wind around, improving the anti-electromagnetic interference ability. At the same time, the twisted wire harness has a neater and more beautiful appearance, and it also avoids the phenomenon that individual wires have slight differences in length due to the uncontrolled middle direction and winding of each wire. After aligning and soldering, it may cause the wires between individual solder joints to be tight due to the difference in wire length, thus reducing the reliability of the solder joints.

[0083] S8. Threading a light tin-plated copper shielding sleeve outside the wire harness: Thread a second light tin-plated copper shielding sleeve 5 with appropriate specifications and length outside the twisted wire harness to improve the overall anti-electromagnetic interference ability and wear resistance of the cable, and put a heat shrinkable tube 6 on the outer layer of the second light tin-plated copper shielding sleeve 5.

[0084] S9. Place the female connector 8 in the semi-circular frame 27. One end of the female connector 8 fits against the inner wall of one side of the semi-circular frame 27. Through the elastic force of the first spring 31 on the pressing plate 29, push the pressing plate 29 towards the middle. At this time, the pressing plate 29 just touches the top of the female connector 8, thus playing a clamping role on the female connector 8. Start the electric push rod 32, and the output shaft of the electric push rod 32 pushes the moving plate 33 downward. The bottom of the pushing plate 38 touches the right-angled part of the inner wall of the female connector 8. As the moving plate 33 moves downward, the pushing plate 38 squeezes the second spring 37 upward, and the pushing plate 38 can also drive the female connector 8 and the semi-circular frame 27 to rotate around the rotating shaft 26 during the downward movement. At this time, the pushing plate 38 can make multiple right-angled parts on the inner wall of the female connector 8 be on the same horizontal line.

[0085] S10. Next, move the sliding table 24 so that the sliding table 24 drives the female connector 8 to move, and the first welding groove 15 is just located below the welding torch 34. Slip the solder joint heat shrink tube over the outer wall of the wire core 1 in the wire harness, and place the wire core 1 in the first welding groove 15. The moving plate 33 drives the welding torch 34 to continue moving downwards. The welding torch 34 welds the wire core 1 and the first contact 9. Multiple wire cores 1 and first contacts 9 can be welded at one time, improving the welding efficiency. Then, the moving plate 33 moves upwards to release the pressing of the push plate 38 on the female connector 8. Push the push plate 38 to the right. Then, the moving plate 33 continues to move downwards, and the push plate 38 touches the right-angled part on the inner wall of the female connector 8 again. The female connector 8 and the semi-circular frame 27 rotate in the opposite direction. Then, weld the first contact 9 on the other half of the female connector 8 and the wire core 1. After welding, heat the solder joint heat shrink tube to further connect the wire core 1 and the first contact 9 together. By analogy, the wire core 1 can be welded to the second contact 13 on the male connector 12;

[0086] S11. When the male connector 12 and the female connector 8 are respectively welded to the wire core 1, fit the bottom of the male connector 12 to the top of the female connector 8. Then, push one end of the male connector 12 into the semi-circular groove 10. As the male connector 12 is inserted, the male connector 12 can make the bottom of the male connector 12 fit tightly to the top of the female connector 8 under the action of the trapezoidal arc 11. The resilient arc-shaped contact piece 17 can tightly touch the top of the first contact 9, ensuring the stability of the connection between the second contact 13 and the first contact 9. At the same time, the first contact 9 can be exposed, facilitating the cleaning of the first contact 9 and preventing dust from accumulating on the first contact 9 and affecting the connectivity between the first contact 9 and the second contact 13;

[0087] S12. After the female connector 8 and the male connector 12 are spliced, the first threaded ring 19 is sleeved on the threaded groove 18 on the female connector 8 and the male connector 12. The threaded groove 18 is threadedly connected to the first threaded ring 19. Tightening the first threaded ring 19 can further fix the female connector 8 and the male connector 12. At the same time, a circular groove is formed on one side of the first threaded ring 19, the female connector 8 and the male connector 12. At this time, the insulating layer 2 of the wire harness can be flush with one side of the first threaded ring 19. Then, the second threaded ring 20 is threadedly sleeved on the outer wall of the fixed head 7. Glue is poured into the second threaded ring 20 and the first threaded ring 19 respectively, and the glue pouring is carried out in 2 times. The height of each glue pouring is half of the length of the solder joint heat shrinkable tube. Then, the shielding tape is used to connect the fixed head 7 and the end of the male connector 12 away from each other and the second light tin-plated copper shielding sleeve 5 in a half-lap manner at 360°. The shielding tape should closely fit the fixed head 7, the male connector 12 and the second light tin-plated copper shielding sleeve 5 to avoid suspension and gaps between the shielding tape and the housing. The overlap amount of the shielding tape with the second light tin-plated copper shielding sleeve 5 and the end of the fixed head 7 and the male connector 12 away from each other is not less than 10. Finally, the upper and lower ends of the shielding tape are fixed with round copper wires, which should be arranged neatly and bundled firmly, with a winding width of 4 - 6. After the round copper wires are bundled, 3 points are evenly brazed along the circumference. The joints of the round copper wires shall not form sharp corners and must be brazed to prevent the heat shrinkable tube 6 from being punctured during heat shrinkage.

[0088] However, as is well known to those skilled in the art, the working principles and wiring methods of the electric push rod 32 and the welding torch 34 are common knowledge, and they both belong to conventional means or well-known common sense, so they will not be elaborated here. Those skilled in the art can make arbitrary selections according to their needs or convenience.

[0089] The above is only the specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art can easily think of changes or substitutions within the technical scope disclosed by the present invention, and all of them should be covered by the protection scope of the present invention; without conflict, the embodiments of the present invention and the features in the embodiments can be combined with each other. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.

Claims

1. Special vehicle electromagnetic shielding cable assembly, characterized in that, Comprising: A female connector (8), a male connector (12) and a plurality of wire cores (1), and the plurality of wire cores (1) form a cable splicing assembly; A first connection assembly, arranged at one end of the female connector (8), for connecting one end of the cable splicing assembly to the female connector (8); A second connection assembly, arranged inside the male connector (12), for connecting the other end of the cable splicing assembly to the male connector (12). The cable splicing assembly includes an insulating layer (2) sleeved on the outer wall of the wire core (1), and the wire core (1) and the insulating layer (2) form a wire. The first connection assembly includes a fixed head (7) fixedly connected to one end of the female connector (8). A plurality of first contact heads (9) are fixedly penetrated through the top of the female connector (8), and the plurality of first contact heads (9) are arranged in a V shape. One end of the first contact head (9) penetrates through the fixed head (7) and is provided with a first welding groove (15), and the wire core (1) is welded to the first welding groove (15). A semi-circular groove (10) is arranged on one side of the fixed head (7) away from the first welding groove (15). A trapezoidal arc (11) is fixedly connected to the inner wall of the top of the semi-circular groove (10). The second connection assembly includes a plurality of rectangular grooves (16) arranged inside the male connector (12), and the plurality of rectangular grooves (16) are arranged in an inverted V shape. A second contact head (13) is fixedly connected to the inner wall of the top of the rectangular groove (16). One end of the second contact head (13) fixedly penetrates through the male connector (12) and is provided with a second welding groove (14), and the second welding groove (14) is welded to the wire core (1). A plurality of resilient arc-shaped contact pieces (17) located inside the rectangular groove (16) are fixedly connected to the bottom of the second contact head (13), and the resilient arc-shaped contact pieces (17) cooperate with the first contact heads (9).

2. The electromagnetic shielding cable assembly for special vehicles according to claim 1, characterized in that A first lightweight tin-plated copper shielding sleeve (3) is sleeved on the outer wall of the wire. A plurality of wires are twisted to form a wire harness. A plurality of insulating tape layers (4) for ensuring the stability of the wire harness are sleeved on the outer wall of the wire harness. A second lightweight tin-plated copper shielding sleeve (5) is sleeved on the outer wall of the wire harness, and the second lightweight tin-plated copper shielding sleeve (5) wraps the insulating tape layer (4). A plurality of heat shrinkable tubes (6) are sleeved on the outer wall of the second lightweight tin-plated copper shielding sleeve (5).

3. The electromagnetic shielding cable assembly for special vehicles according to claim 1, characterized in that A second threaded ring (20) is threadedly sleeved on the outer wall of the fixed head (7). A plurality of sealing strips (21) are fixedly connected to the top of the female connector (8), and two adjacent sealing strips (21) are distributed on both sides of the first contact head (9).

4. The electromagnetic shielding cable assembly for special vehicles according to claim 1, characterized in that, Threaded grooves (18) are arranged on the outer walls of the female connector (8) and the male connector (12), and a first threaded ring (19) is threadedly sleeved on the outer walls of the two threaded grooves (18).

5. For the special vehicle electromagnetic shielding cable assembly according to claim 4, another possibility of the second contact (13), characterized in that, A plurality of W-shaped contact pieces (40) are fixedly connected to the bottom of the second contact head (13), and both ends of the W-shaped contact pieces (40) are in contact with the bottom of the second contact head (13).

6. Another possibility of the second contact (13) of the electromagnetic shielding cable assembly for special vehicles according to claim 4, characterized in that A plurality of V-shaped contact pieces (41) are fixedly connected to the bottom of the second contact head (13), and one end of the V-shaped contact pieces (41) is in contact with the bottom of the second contact head (13).

7. Special vehicle electromagnetic shielding cable installation tooling, which is used for welding the first contact (9) and the second contact (13) in the special vehicle electromagnetic shielding cable assembly described in any one of the above claims 1-6 to the wire core (1) respectively, and is characterized in that, It comprises a bottom plate (22), the top of which is fixedly connected to an L-shaped bracket (23); An alignment component is provided on the top of the base plate (22) and is used to respectively make the plurality of first contacts (9) in the female connector (8) and the plurality of second contacts (13) in the male connector (12) be in the same horizontal plane; the alignment component comprises a sliding table (24) slidably connected to the top of the base plate (22), a fixed seat (25) is fixedly connected to the side of the sliding table (24) close to the L-shaped bracket (23), and a rotating shaft (26) is rotatably connected to the side of the fixing seat (25) away from the L-shaped bracket (23), and one end of the rotating shaft (26) is fixed to the side of the fixing seat (25) away from the L-shaped bracket (23). A semicircular frame (27) is fixedly connected, and the semicircular frame (27) is slidably connected in the sliding platform (24), a yielding groove (42) is provided in the sliding platform (24), sliding grooves (28) are provided on both sides of the top of the semicircular frame (27), a pressure plate (29) is slidably connected in the sliding groove (28), a protrusion (30) is fixedly connected to the top of the pressure plate (29), a first spring (31) is fixedly connected to one side of the pressure plate (29), and one end of the first spring (31) is fixedly connected to the inner wall of one side of the sliding groove (28); A welding assembly is provided in an L-shaped bracket (23) and is used to weld the first contact (9) and the second contact (13) to the wire core (1) respectively; the welding assembly comprises an electric push rod (32) fixedly connected to the top of the L-shaped bracket (23), the output shaft of the electric push rod (32) passes through the L-shaped bracket (23) and is fixedly connected to a movable plate (33), the bottom of the movable plate (33) is fixedly connected to a plurality of welding guns (34), and a sliding rod (34) is slidably passed through the movable plate (33) 5), the outer wall fixed sleeve of the slide rod (35) is provided with a slide plate (36), the outer wall sleeve of the slide rod (35) is provided with a second spring (37) fixedly connected to the top of the slide plate (36), and the top of the second spring (37) is fixedly connected to the bottom of the movable plate (33), a push plate (38) is provided below the movable plate (33), a slide groove (39) is provided on the top of the push plate (38), and the bottom end of the slide rod (35) extends into the slide groove (39) and slides with the slide groove (39).

8. The installation method of the electromagnetic shielding cable installation tooling for special vehicles according to claim 7, characterized in that, The following steps are involved: S1. Cut the heat shrink tube (6) and make a wire mark: Cut the heat shrink tube (6) that meets the requirements to the specified length and use white self-adhesive paper to make a cable mark; S2. Wire cutting: Cut the wires that meet the requirements to the specified length; S3. Threading the wire through the heat shrink tube (6): Select a heat shrink tube (6) that matches the wire diameter and thread it through the wire; S4. Wire stripping: Select appropriate wire strippers according to the thickness of the insulation layer (2) to strip the insulation layer (2) from the outer wall of the wire core (1); S5. Wire tinning: Wires should be tinned immediately after stripping; S6. Paste the wire number mark: Paste the wire number mark within 30~70cm from the bare wire end; S7, twisted wire harness: twist the wires with the same destination into a bundle; S8. Light tin-plated copper shielding sleeve for external threading of wire harness: Thread a second light tin-plated copper shielding sleeve (5) over the twisted wire harness, and then slip a heat shrinkable tube (6) over the outer layer of the second light tin-plated copper shielding sleeve (5); S9. Place the female connector (8) in the semi-circular frame (27). By activating the electric push rod (32), the bottom of the push plate (38) touches the right-angle part of the inner wall of the female connector (8), enabling multiple right-angle parts on the inner wall of the female connector (8) to be on the same horizontal line; S10. Then move the sliding table (24) so that the first welding groove (15) is located below the welding torch (34). The moving plate (33) drives the welding torch (34) to move down further, and the welding torch (34) welds the wire core (1) to the first contact (9). By analogy, the wire core (1) can be welded to the second contact (13) on the male connector (12); S11. Push one end of the male connector (12) into the semi-circular groove (10). The bottom of the male connector (12) fits tightly against the top of the female connector (8), and the resilient arc-shaped contact piece (17) can tightly touch the top of the first contact (9), ensuring the stability of the connection between the second contact (13) and the first contact (9); S12. After the female connector (8) and the male connector (12) are spliced, slip the first threaded ring (19) over the threaded groove (18) on the female connector (8) and the male connector (12). Thread the second threaded ring (20) onto the outer wall of the fixed head (7), and pour glue into the second threaded ring (20) and the first threaded ring (19) respectively.

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