Non-equal length end shear method for preventing aircraft cable breakage

Abstract

The application discloses a non-equal-length end shearing method for preventing airplane cable breakage, which comprises the following steps: 1) according to a three-dimensional numerical model of the airplane cable, the radius and angle simulation of the airplane cable bending is carried out, the shearing allowance is set according to the simulation situation of the airplane cable, and the preliminary shearing of the airplane cable is completed; 2) a shearing line mold matched with the airplane cable is manufactured according to the electric connector data of the airplane cable; 3) each electric wire is led out at the connecting end of the airplane cable and the electric connector, and then a mark tube facilitating identification and processing is sleeved on each led-out electric wire; 4) according to the mark tube sleeved on each electric wire in the airplane cable, each electric wire is installed and fixed in the shearing standardized mold, and then the cable is sheared at the rear part of the mold, and the non-equal-length end shearing method for preventing airplane cable breakage is obtained. The application solves the long-term problem of airplane cable design and processing in the industry, guarantees the safety of the power supply system and the signal transmission of each system of the airplane, and avoids the system inoperable or fault caused by the line fault.

Description

Technical Field

[0001] This invention relates to the field of aviation equipment technology, specifically to a method for cutting non-equal length ends of aircraft cables to prevent breakage. Background Technology

[0002] With the continuous development of aircraft technology, aircraft cables have been designed, used, and maintained as electrical interconnection systems, requiring stable and reliable performance to meet the operational requirements of aircraft in different environments.

[0003] However, traditional aircraft cables only consider the branch length, neglecting to incorporate bending and twisting factors into the manufacturing process. For example, without considering bending and twisting, wire cutting only considers cable length, resulting in neatly cut cables where the outer wires experience greater stress during installation, making them prone to breakage at the termination point. Furthermore, some cable connectors have numerous wires, sometimes hundreds. Cutting the middle wires to the same neatness as the outer ones results in the outer wires experiencing greater tensile stress after connection, while the middle wires are squeezed and bent. This can cause the outer wires to break during installation and is even more prone to twisting and breaking during flight. This can easily lead to numerous cable termination breakages, causing aircraft malfunctions and even catastrophic accidents. Therefore, solving the problem of cable termination breakage is crucial. Controlling the wiring process based on cable bending direction and installation stress is essential to avoid excessive stress at the connection points. This requires starting with wire cutting. Finding a way to reduce or eliminate stress at cable termination points and ensure cable safety is an urgent problem to be solved. Summary of the Invention

[0004] The purpose of this invention is to provide a method for cutting non-equal length ends of aircraft cables to prevent system malfunctions or failures caused by line faults, thereby ensuring flight safety, completing safe flight and scheduled tasks, reducing maintenance frequency, improving aircraft availability and utilization efficiency, saving time, and reducing operating costs.

[0005] This invention is achieved through the following technical solution: a method for preventing breakage of non-equal length ends of aircraft cables during cutting, characterized by comprising the following steps:

[0006] (1) Based on the three-dimensional digital model of the aircraft cable, simulate the bending radius and angle of the aircraft cable, set the shearing allowance according to the simulation of the aircraft cable, and complete the initial shearing of the aircraft cable.

[0007] (2) Manufacture a matching shearing die based on the electrical connector data of the aircraft cable;

[0008] (3) Lead out each wire from the connection end of the aircraft cable and electrical connector, and then put a marking tube on each wire for easy identification and processing.

[0009] (4) Based on the marking tubes on each wire in the aircraft cable, install and fix each wire in the standardized cutting mold, and then cut the cable at the back of the mold.

[0010] The working principle of this technical solution is as follows: if the traditional method of aligning and neatly cutting the wires is used, the wires in the cable will inevitably be stressed after processing or installation, leading to wire breakage during actual operation and causing aircraft malfunctions or accidents. Electrical connectors that connect to aircraft cables are mainly divided into two types in terms of shape: round and rectangular. Each shape of electrical connector has a series of models according to specific standards. Based on existing standard electrical connectors, a standardized series of cutting dies are designed to achieve non-uniform length cutting processing, ensuring that the individual wires inside the processed cable are not stressed and avoiding breakage.

[0011] To better implement the method of the present invention, further, in step (1), the specific process of simulating the radius and angle of the aircraft cable bend is to project the two-dimensional diagram of the aircraft cable model onto a flat platform to determine that the cable layout is consistent with the actual laying.

[0012] To better implement the method of the present invention, in step (1), the shearing allowance is set to 300 mm.

[0013] To better implement the method of the present invention, in step (2), the electrical connector data of the aircraft cable includes the size of the electrical connector and the actual layout position of the pinholes.

[0014] To better implement the method of the present invention, the shearing die manufactured in step (2) further includes a rectangular electrical connector shearing die and a circular electrical connector shearing die.

[0015] To better implement the method of the present invention, the shearing die is further provided with a plurality of wire holes arranged according to the electrical connector connected to the aircraft cable, and each wire is fixed in the corresponding wire hole according to the marking tube.

[0016] To better implement the method of the present invention, the thickness of the shearing die is further 100-200 mm.

[0017] To better implement the method of the present invention, the marking tube surface in step (3) is further recorded with the function of each wire and the specific processing details required.

[0018] Compared with the prior art, the present invention has the following advantages and beneficial effects:

[0019] (1) This invention solves the long-standing problem of aircraft cable design and processing in the industry. Starting from the source of cable end-connection breakage, it finds the reasons and solutions for the easy breakage of aircraft cables due to installation bending, high-density wiring or thick wire wiring, and fundamentally solves the problem.

[0020] (2) This invention ensures the safety and reliability of the aircraft system power supply system and the signal transmission of each system, so that the aircraft can avoid system failure or malfunction caused by line faults, ensure flight safety, and complete safe flight and the tasks to be performed as required.

[0021] (3) The present invention can reduce the frequency of maintenance, improve the aircraft's uptime and utilization efficiency, save time, and reduce the cost of use. Attached Figure Description

[0022] Other features, objects, and advantages of the invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0023] Figure 1 This is a three-dimensional structural diagram of the aircraft cable cutting using a rectangular electrical connector cutting die in this invention.

[0024] Figure 2 This is a schematic diagram of the planar structure of the rectangular electrical connector cutting die used for cutting aircraft cables in this invention.

[0025] Figure 3 This is a three-dimensional structural diagram of the circular electrical connector cutting die used in the invention for cutting aircraft cables.

[0026] Among them: 1—aircraft cable, 2—electric wire, 3—marking tube, 4—rectangular electrical connector cutting die, 5—circular electrical connector cutting die. Detailed Implementation

[0027] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0028] In the description of this invention, it should be understood that the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and 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 invention.

[0029] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" 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 of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0030] Example 1:

[0031] This embodiment provides a method for preventing the cutting of non-equal length ends of aircraft cables from breaking, including the following steps:

[0032] (1) Based on the three-dimensional digital model of the aircraft cable, simulate the radius and angle of the aircraft cable bending. Project the two-dimensional model of the aircraft cable onto the flat platform to ensure that the cable layout is consistent with the laying pre-object. Set a cutting allowance of 300mm according to the simulation of the aircraft cable to complete the initial cutting of the aircraft cable. The cutting allowance is left so that the wire of the aircraft cable can be adjusted when passing through the cutting line mold.

[0033] (2) Based on the size of the electrical connector of the aircraft cable and the actual layout of the pinhole, manufacture a shearing die with a thickness of 100-200mm to match it.

[0034] (3) Each wire is led out from the connection end of the aircraft cable and the electrical connector, and then a marking tube for easy identification and processing is put on each wire. The surface of the marking tube records the function of each wire and the specific processing requirements.

[0035] (4) Based on the marking tubes on each wire in the aircraft cable, install and fix each wire in the standardized cutting mold, and then cut the cable at the back of the mold.

[0036] The resulting non-uniformly cut aircraft cables can have their lengths adjusted according to the installation bends, high-density wiring, or thick wire wiring terminations of the aircraft cables.

[0037] It enables aircraft to avoid system malfunctions or failures caused by circuit faults, ensuring flight safety and completing safe flight and prescribed tasks; it can reduce maintenance frequency, improve aircraft uptime and utilization efficiency, save time, and reduce operating costs.

[0038] Example 2:

[0039] This embodiment, based on the above embodiments, provides a method for cutting the non-equal length ends of aircraft cables using a rectangular electrical connector cutting die, such as... Figure 1 , Figure 2 As shown:

[0040] Based on the three-dimensional digital model of aircraft cable 1, the bending radius and angle of aircraft cable 1 are simulated. The two-dimensional drawing of the aircraft cable model is projected onto a flat platform to ensure that the layout of the aircraft cable is consistent with the pre-layout. A cutting allowance of 300mm is set according to the simulation of aircraft cable 1 to complete the initial cutting of the aircraft cable. A rectangular electrical connector cutting die 4 with a thickness of 100mm is manufactured for the size of the rectangular dot connector and the actual layout of the pinholes. Each wire 2 is led out from the connection end of the aircraft cable 1 and the electrical connector. Then, a marking tube 3 for easy identification and processing is fitted on each wire 2. The surface of the marking tube records the function of each wire and the specific processing details. The rectangular electrical connector cutting die 4 has several wire holes arranged according to the electrical connector connected to the aircraft cable. Each wire 2 is installed and fixed in the corresponding wire hole according to the marking tube 3. Finally, the wires are cut on the back of the die to obtain the non-equal length end of the aircraft cable 1 connected to the rectangular electrical connector.

[0041] Example 3:

[0042] This embodiment, based on the above embodiments, provides a method for cutting the non-equal length ends of aircraft cables using a rectangular electrical connector cutting die, such as... Figure 3 As shown:

[0043] Based on the three-dimensional digital model of aircraft cable 1, the bending radius and angle of aircraft cable 1 are simulated. The two-dimensional drawing of the aircraft cable model is projected onto a flat platform to ensure that the layout of the aircraft cable is consistent with the pre-layout. A cutting allowance of 300mm is set according to the simulation of aircraft cable 1 to complete the initial cutting of the aircraft cable. A rectangular electrical connector cutting die 5 with a thickness of 150mm is manufactured for the size of the rectangular dot connector and the actual layout of the pinholes. Each wire 2 is led out from the connection end of aircraft cable 1 and electrical connector. Then, a marking tube 3 for easy identification and processing is fitted on each wire 2. The surface of the marking tube records the function of each wire and the specific processing details. The rectangular electrical connector cutting die 4 has several wire holes arranged according to the electrical connector connected to the aircraft cable. Each wire 2 is installed and fixed in the corresponding wire hole according to the marking tube 3. Finally, the wires are cut on the back of the die to obtain the non-equal length end of aircraft cable 1 connected to the rectangular electrical connector.

[0044] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A method for preventing breakage of non-equal-length ends of aircraft cables during cutting, characterized in that, Includes the following steps: (1) Based on the three-dimensional digital model of the aircraft cable, simulate the radius and angle of the aircraft cable bending, set the shearing allowance according to the simulation of the aircraft cable, and complete the initial shearing of the aircraft cable. (2) A cutting die is manufactured to match the electrical connector data of the aircraft cable. The cutting die has several wire holes arranged according to the electrical connector connected to the aircraft cable. (3) Lead out each wire from the connection end of the aircraft cable and the electrical connector, and then put a marking tube on each wire for easy identification and processing; (4) Based on the marking tubes on each wire in the aircraft cable, install and fix each wire in the corresponding wire hole in the standardized cutting mold according to the marking tubes, and then cut the cable at the back of the mold.

2. The method for preventing breakage of non-equal length ends of aircraft cables according to claim 1, characterized in that, In step (1), the specific process of simulating the radius and angle of the aircraft cable bend is to project the two-dimensional model of the aircraft cable onto a flat platform to determine that the cable layout is consistent with the actual laying.

3. A method for preventing breakage of non-equal-length ends of aircraft cables according to claim 1 or 2, characterized in that, In step (1), the shearing allowance is set to 300mm.

4. A method for preventing breakage of non-equal-length ends of aircraft cables according to claim 1 or 2, characterized in that, In step (2), the electrical connector data of the aircraft cable includes the size of the electrical connector and the actual layout position of the pinholes.

5. A method for preventing breakage of non-equal-length ends of aircraft cables according to claim 4, characterized in that, The wire cutting mold manufactured in step (2) includes a rectangular electrical connector wire cutting mold and a circular electrical connector wire cutting mold.

6. The method for preventing breakage of non-equal length ends of aircraft cables according to claim 5, characterized in that, The thickness of the shearing die is 100~200mm.

7. A method for preventing breakage of non-equal length ends of aircraft cables according to claim 1 or 2, characterized in that, The marking tube surface in step (3) records the function of each wire and the specific processing requirements.

Images