Elastic wall cables for electrical connection of long-range guided rocket compartments in complex environments

Abstract

The present invention discloses a bullet-proof cable for electrical connection of long-range guided rocket compartments in complex environments, and the bullet-proof cable is mainly composed of a flat braided cable, a high-temperature resistant shielding sleeve, etc. The flat braided cable is the main body of the bullet-proof cable, which is woven with aviation wires and has a rectangular cross-sectional configuration. It is mainly used for electrical signal transmission such as power supply, serial communication, ignition pulse, and status query between guidance and control compartments of long-range guided rockets. The flat braided cable is coated with a high-temperature resistant shielding sleeve on the outside to achieve external heat protection and anti-interference of the cable. The bullet-proof cable is laid on the outer surface of the engine casing and is tied and fixed with a cable mounting seat to prevent movement during flight vibration. The cable is covered with a non-metallic cable cover on the outside to increase the smoothness of the aerodynamic shape of the guided rocket and prevent the direct effect of airflow on the bullet-proof cable during flight. The bullet-proof cable of the present invention has a simple structure, compact size, is easy to fix and install, and has the ability to resist high temperatures and electromagnetic interference.

Description

Technical Field

[0001] The invention belongs to the field of rocket technology, and in particular relates to a wall-mounted cable for electrical connection of long-range guided rocket compartments in complex environments. Background Art

[0002] Long-range guided rocket wall cables are a crucial component of the electrical connections within the guidance and control cabin of the rocket. Lay along the missile's axis, the wall cables are installed on the upper surface of the engine casing. The rear end of the cable typically connects to the rocket's flight control actuators, while the front end connects to the rocket's guidance system. They serve as the central nervous system for the transmission of electrical energy and communication signals to the rocket.

[0003] Conventional ammunition flies at relatively low speeds and altitudes, with short flight times, resulting in less severe aerodynamic heating. Metal cable covers protect the cables, and high-temperature resistance and electromagnetic interference resistance are generally not required for the wall cables themselves. However, long-range guided rockets flying at hypersonic speeds spend extended periods in flight, where cables must withstand sustained high temperatures generated by multiple heat sources, including aerodynamic heating and engine combustion. Excessive temperatures can cause the non-metallic sheathing between conductors in the wall cables to soften and break, leading to short circuits between cable strands and disrupted rocket communications, potentially causing loss of control or airburst. Furthermore, wall cables installed on the exterior of the missile body are subject to various electromagnetic interference signals from the rocket's own radio frequency signals and external devices, compromising the quality of electrical signal transmission. During hypersonic flight, the large amount of static electricity generated by the missile body also poses a significant challenge to reliable electrical signal transmission. Therefore, wall cables with high-temperature resistance and electromagnetic interference resistance are crucial for maintaining reliable electrical connections between the modules of long-range guided rockets at hypersonic speeds. Summary of the Invention

[0004] In order to overcome the deficiencies of the prior art, the present invention provides a kind of elastic wall cable for electrical connection of long-range guided rocket compartment in complex environment, the elastic wall cable mainly consists of flat braided cable, high temperature resistant shielding sleeve and the like. The flat braided cable is the main body of the elastic wall cable, which is woven with aviation wire and has a rectangular cross-sectional configuration. It is mainly used for electrical signal transmission such as power supply, serial communication, ignition pulse and status query between the guidance and control compartments of long-range guided rockets. The flat braided cable is coated with a high temperature resistant shielding sleeve on the outside to achieve external heat protection and anti-interference of the cable. The elastic wall cable is laid on the outer surface of the engine casing and is tied and fixed with a cable mounting seat to prevent movement during flight vibration. The cable is covered with a non-metallic cable cover on the outside to increase the smoothness of the aerodynamic shape of the guided rocket and prevent the direct effect of airflow on the elastic wall cable during flight. The elastic wall cable of the present invention has a simple structure, compact size, is easy to fix and install, and has the ability to resist high temperature and electromagnetic interference.

[0005] The technical solutions adopted by the present invention to solve the technical problems are as follows:

[0006] A bullet-proof cable for electrical connection of long-range guided rocket compartments in complex environments, comprising a flat braided cable, a high-temperature resistant shielding sleeve, and an electrical connector;

[0007] The flat braided cable includes twisted pair wires, single strand extruded wires and twisted pair shielded wires; the twisted pair wires, single strand extruded wires and twisted pair shielded wires are braided in layers; single strand extruded wires are used for low frequency signal transmission, twisted pair wires are used for pulse signal transmission, and twisted pair shielded wires are used for high frequency signal transmission;

[0008] The high temperature resistant shielding sleeve comprises Teflon high temperature resistant cloth and nickel copper conductive cloth;

[0009] The outer periphery of the flat braided cable is provided with a high temperature resistant shielding sleeve; from the inside to the outside, Teflon high temperature resistant cloth and nickel copper conductive cloth are arranged in sequence;

[0010] The electrical connector includes a tail accessory and a locking screw; the two ends of the elastic wall cable are crimped with the electrical connector, and the tail accessory of the electrical connector presses and fixes the high-temperature resistant shielding sleeve and the flat braided cable, and locks it with a locking screw to prevent movement.

[0011] Preferably, the flat braided cable is braided with multiple layers and multiple types of aviation high-temperature resistant wires.

[0012] Preferably, the aviation high-temperature resistant wire is aramid fiber.

[0013] Preferably, the tail fitting is made of stainless steel.

[0014] Preferably, the nickel-copper conductive cloth has a radiation protection effect of 70-80 dB and a surface resistance of 0.03-0.05 Ω.

[0015] Preferably, the Teflon high temperature resistant cloth has a temperature resistance of -140°C to 360°C and a tensile strength of 130 / 120 N / cm.

[0016] Preferably, the high temperature resistant shielding sleeve and the flat braided cable are bundled and fixed by aramid yarn.

[0017] The beneficial effects of the present invention are as follows:

[0018] (1) The flat braided cable of the present invention is braided using aviation high-temperature resistant extruded wire. The conductors are layered, classified, selected, and braided according to the type of transmitted signal. It has a compact structure, high space utilization, strong anti-interference ability, high technological maturity, a wide range of material sources, and is suitable for mass production.

[0019] (2) The nickel-copper conductive fabric used in this invention is a widely available woven material that is heat-resistant, radiation-proof, has good adhesion, and excellent electrical conductivity. Nickel-copper conductive fabric is used as the outer shielding material for elastic-wall cables. Designers can also enhance its heat resistance by coating it with heat-resistant materials, depending on the specific product requirements.

[0020] (3) The Teflon high-temperature resistant cloth used in the present invention is ultra-thin, high-temperature resistant, high-tensile strength, and smooth in surface. While improving the high-temperature resistance of the elastic wall cable, it also reduces the installation space occupied by the coating material. At the same time, it provides a certain mechanical strength for the elastic wall cable, forming a protective layer to reduce damage to the cable harness during transportation and installation.

[0021] (4) The present invention fully utilizes the shielding performance of nickel-copper conductive cloth and the high-temperature resistance of Teflon cloth. The elastic wall cable combined with the flat braided cable can achieve the shielding function in a limited installation space. It does not need to use a metal cable cover to provide shielding, which reduces the weight of the cable cover and reduces the limitations of material selection.

[0022] (5) All hypersonic long-range guided rocket models using this invention have successfully flown. Telemetry data from flight tests indicates that the electrical signals from the guidance and control cabin maintained excellent quality throughout the entire process, unaffected by external or internal electromagnetic interference or the high-temperature environment. Disassembly of the flight prototype wreckage revealed that the cladding and cables remained consistent with their pre-flight appearance, with no signs of surface blackening or scorching caused by high temperatures. This demonstrates the reliability of the thermal protection, meeting rocket flight requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the installation cross section of the present invention.

[0024] Figure 2 It is a cross-sectional diagram of elastic wall cable.

[0025] Figure 3 It is a schematic diagram of the appearance of the elastic wall cable of the present invention.

[0026] Figure markings: 1. Flat braided cable; 2. High-temperature resistant shielding sleeve; 3. Electrical connector; 4. Cable cover; 5. Mounting base; 6. Fastening screw; 7. Engine compartment; 1-1. Twisted pair wire; 1-2. Single-strand extruded wire; 1-3. Twisted-pair shielded wire; 2-1. Nickel-copper conductive cloth; 2-2. Teflon high-temperature resistant cloth; 3-1. Tail accessory; 3-2. Locking screw. DETAILED DESCRIPTION

[0027] The present invention will be further described below with reference to the accompanying drawings and examples.

[0028] The technical problem to be solved by the present invention is to provide a reliable elastic-wall cable for the electrical connection of the guidance and control cabin of a hypersonic long-range guided rocket, so as to prevent abnormal transmission of electrical signals in the guidance and control cabin caused by aerodynamic heating and interference from the external electromagnetic environment, thereby ensuring reliable transmission of electrical signals and rocket flight safety.

[0029] Based on the practical needs of electrical signal transmission between the modules of hypersonic long-range guided rockets, this invention proposes a new type of elastic-wall cable. This invention effectively reduces electromagnetic interference caused by laying the elastic-wall cable outside the missile body, as well as electrical signal transmission interference and safety issues caused by aerodynamic heating in flight. It has been successfully used in model flight tests. The invention features a simple structure, low cost, a short construction period, and excellent protection, making it easy to promote and apply.

[0030] To achieve the aforementioned benefits, the present invention provides a low-cost, quick-install, and highly reliable elastic-wall cable. This elastic-wall cable primarily consists of a flat braided cable, a high-temperature-resistant shielding sleeve, and an electrical connector. Together with a cable cover, mounting bracket, fastening screws, and engine compartment, it forms the electrical connection and mounting structure for the guidance and control compartment of a long-range guided rocket. This ensures that electrical signal transmission is unaffected by aerodynamic heating and electromagnetic interference during the flight of a hypersonic long-range guided rocket.

[0031] Flat braided cables are the main component of elastic-wall cables, woven from multiple layers of various types of aviation-grade, high-temperature-resistant conductors. The design is divided into zones based on the electrical signal types of the guidance and control cabin, with transmission lines for low-frequency, pulse, and high-frequency signals braided in layers. Single-strand extruded wire is used for low-frequency signals, twisted-pair wire for pulse signals, and shielded twisted-pair wire for high-frequency signals. To ensure insulation performance and structural strength, all of these wiring harnesses utilize aviation-grade, high-temperature-resistant extruded wire.

[0032] The high-temperature shielding sleeve is constructed from an outer layer of nickel-copper conductive fabric and an inner layer of Teflon heat-resistant fabric. The flat braided cable is threaded through the sleeve and crimped onto the electrical connector. The connector tailpiece secures the sleeve and the flat braided cable to prevent movement. The stainless steel tailpiece ensures reliable contact with the sleeve, ensuring a secure and continuous outer shield for the flexible-wall cable.

[0033] The outer layer of nickel-copper conductive cloth has excellent conductivity, radiation protection, and good adhesion. The radiation protection effect is: 70~80 dB, and the surface resistance is: 0.03~0.05Ω;

[0034] The inner layer of Teflon high temperature resistant cloth is ultra-thin, high temperature resistant, and has high tensile strength. It can withstand temperatures from -140°C to 360°C and has a tensile strength of 130 / 120N / cm.

[0035] Aramid yarn is used to secure the high-temperature shielding sleeve and flat braided cable. The overall thickness of the elastic-wall cable is 2mm to 3mm lower than the restraint height between the cable cover and the engine compartment. Steel wire is used to secure the elastic-wall cable to the cable mounting brackets, with pairs of mounting brackets located every 200mm to 300mm to ensure secure cable retention.

[0036] Example:

[0037] like Figure 1 As shown, the hypersonic long-range guided rocket wall cable of the present invention is mainly composed of a flat braided cable, a high-temperature resistant shielding sleeve, and an electrical connector. Together with a cable cover, a mounting base, fastening screws, and an engine compartment section, they constitute the electrical connection and installation structure between the guidance and control compartments of the long-range guided rocket, ensuring that the transmission of electrical signals is not affected by aerodynamic heating and electromagnetic interference during the flight of the hypersonic long-range guided rocket.

[0038] like Figure 1 、 Figure 2 As shown, the elastic-wall cable is a flat braided cable made of multiple layers of multi-type aviation conductors, braided with aramid fiber. The outer layers of the flat braided cable are composed of flexible materials, including high-temperature-resistant Teflon fabric and nickel-copper conductive fabric, ensuring a 360° fit. The elastic-wall cable is securely attached to the engine compartment using mounting brackets and fastening screws. Finally, the cable cover is closed, leaving a 2mm to 3mm gap between the top and the cover, while the bottom fits snugly against the rocket engine compartment.

[0039] like Figure 3 As shown, electrical connector tail accessories are used at both ends of the elastic wall cable to achieve reliable contact and fixation between the flat braided cable and the high-temperature resistant shielding sleeve. The electrical connector tail accessories are made of stainless steel. After the elastic wall cable is tightened and fixed, its shielding continuity can be ensured.

[0040] Hypersonic long-range guided rocket models using this invention have all successfully flown. Telemetry data transmitted during flight demonstrates excellent electrical signal quality in the guidance and control cabin throughout the flight, unaffected by external or internal electromagnetic interference or high-temperature environments. Disassembly of the flight prototype wreckage revealed that the cladding and cables remained consistent with their pre-flight appearance, with no signs of surface blackening or scorching caused by high temperatures. This demonstrates the reliability of the thermal protection, meeting rocket flight requirements.

Claims

1. A wall-mounted cable for electrical connection of long-range guided rocket compartments in complex environments, characterized in that: Includes flat braided cables, high temperature resistant shielding sleeves, and electrical connectors; The flat braided cable includes twisted pair wires, single strand extruded wires and twisted pair shielded wires; the twisted pair wires, single strand extruded wires and twisted pair shielded wires are braided in layers; single strand extruded wires are used for low frequency signal transmission, twisted pair wires are used for pulse signal transmission, and twisted pair shielded wires are used for high frequency signal transmission; The high temperature resistant shielding sleeve comprises Teflon high temperature resistant cloth and nickel copper conductive cloth; The outer periphery of the flat braided cable is provided with a high temperature resistant shielding sleeve; from the inside to the outside, Teflon high temperature resistant cloth and nickel copper conductive cloth are arranged in sequence; The electrical connector includes a tail fitting and a locking screw; both ends of the elastic wall cable are crimped with the electrical connector, and the tail fitting of the electrical connector presses and fixes the high-temperature resistant shielding sleeve and the flat braided cable, and is locked with a locking screw to prevent movement; The cross-sectional width of the elastic wall cable is 50-60 mm, and the cross-sectional thickness is 6-10 mm, which can be used for reliable transmission of no less than 100 electrical signals in a small space. The elastic wall cable can adapt to the temperature environment of -40℃ to 290℃ and the external electromagnetic environment of frequency of 10KHz to 40GHz and electric field strength not more than 200V / m; The flat braided cable is woven with multiple layers of multi-type aviation-resistant high-temperature wires. The flat braided cable consists of a first harness layer of twisted-pair wires, a second harness layer of single-strand extruded wires, and a third harness layer of twisted-pair shielded wires. Aramid yarn is used to weave between the layers. By designing the harness arrangement, the gap between each layer is uniform, and the harness width and height are kept consistent, making the cable space compact. The sizes and quantities of the flat braided cable, twisted pair cables, single strand extruded cables, and twisted shielded pair cables are as follows: 18 pairs of twisted pair cables with a wire diameter of 0.15 mm2, 18 pairs of twisted shielded pair cables with a wire diameter of 0.15 mm2, and 38 single strand extruded cables with a wire diameter of 0.15 mm2; The high temperature resistant shielding sleeve is an integrated high temperature resistant shielding sleeve, and the outer layer of nickel-copper conductive cloth and the inner layer of Teflon high temperature resistant cloth are tightly combined to form an integrated sheath; The high temperature resistant shielding sleeve has a thickness of 0.16 mm to 0.20 mm and a weight of 30 to 40 g / m.

2. The elastic wall cable for electrical connection of long-range guided rocket compartment in complex environment according to claim 1 is characterized in that: The elastic wall cable is designed based on the cable size and cross-section, and uses a flat rectangular connector with a stainless steel shell. The elastic wall cable is fastened with tail accessories, wire clamps and copper mesh pads to ensure the overall shielding continuity of the elastic wall cable.

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