High-power metal connecting terminal and manufacturing method thereof

Abstract

The invention discloses a high-power metal connecting terminal and a manufacturing method thereof. The high-power metal connecting terminal comprises a round jack assembly and a round head assembly inserted into the round jack assembly. A step part is arranged at the first end of the round head assembly, a square inserting block is formed on the step part, and a hollow hole penetrating into the round head assembly is formed in one end face of the square inserting block; an annular groove is formed in one end of the round head assembly, a copper elastic piece assembly is arranged in the annular groove, the width of the copper elastic piece assembly in the natural state is smaller than the thickness of the annular groove, and the width of the copper elastic piece assembly in the completely-flattened state is larger than the thickness of the annular groove. The round head assembly is inserted into the round jack assembly, rapid disassembly and replacement of the connector are realized, the hollow hole is arranged, so that the weight and material consumption of the whole round head assembly are reduced, the cost is reduced, and the elastic sheet assembly and the annular groove can play a role in plugging and unplugging limiting of the round head assembly and play a role in electric conduction at the same time.

Description

Technical Field

[0001] The present invention relates to the technical field of connectors, and in particular to a high-power metal connecting terminal and a manufacturing method thereof. Background Art

[0002] In modern power transmission and distribution systems, high-power metal connectors are widely used in many key areas such as high-voltage transmission lines, industrial power equipment, renewable energy systems, and electric vehicles. As the core components of power transmission, the reliability and performance of these connectors directly affect the stability and efficiency of the entire system. With the continuous growth of power demand and the increasing complexity of the application environment, traditional connectors not only need to withstand higher current loads, but also must maintain excellent thermal management and mechanical stability under various complex working conditions. Therefore, efficient and accurate performance testing methods for high-power metal connectors are particularly important to ensure their safety and durability in practical applications.

[0003] In the prior art, the performance testing of high-power metal connection terminals mainly relies on single-dimensional data collection and analysis methods, such as monitoring the thermal distribution of the connection terminals through temperature sensors, or using current sensors to detect current changes. However, these methods often lack comprehensive evaluation of the connection terminals under a variety of complex working conditions and cannot fully reflect their dynamic performance in actual use. These deficiencies limit the comprehensiveness and accuracy of the performance testing of the connection terminals, and cannot provide sufficient scientific basis for their design optimization and maintenance strategies.

[0004] In view of this, it is necessary to improve the performance detection technology of high-power metal connection terminals in the prior art to solve the technical problem that its detection lacks comprehensiveness. Summary of the invention

[0005] The object of the present invention is to provide a high-power metal connecting terminal and a manufacturing method thereof to solve the above technical problems.

[0006] To achieve this object, the present invention adopts the following technical solutions: A high-power metal connection terminal comprises a round socket component and a round head component plugged into the round socket component; The first end of the round head component is provided with a stepped portion, the stepped portion forms a square plug block, the side wall of the square plug block is provided with a positioning hole for connecting a power line, and one end surface of the square plug block is provided with a hollow hole penetrating to the inside of the round head component; An annular groove is provided at one end of the round head component, and a copper spring component is provided in the annular groove. The width of the copper spring component in a natural state is smaller than the thickness of the annular groove, and the width in a completely flattened state is larger than the thickness of the annular groove.

[0007] Optionally, the copper shrapnel assembly is in a circular ring shape, and the copper shrapnel assembly is provided with a plurality of small shrapnels connected in sequence along its circumferential direction; The small spring piece is gradually arched outward from both ends to the middle, and an arc-shaped transition surface is arranged on the arched portion in the middle.

[0008] Optionally, the small spring sheet includes two symmetrically arranged spring sheet feet, two sides of the spring sheet feet are respectively provided with flat surfaces, and groove portions are provided adjacent to the flat surfaces.

[0009] The present invention also provides a performance detection method for a high-power metal connection terminal, which is used to detect the high-power metal connection terminal as described above. The performance detection method includes: A flexible temperature sensing film is arranged in close contact with the length direction of the round head component and the round socket component, and the flexible temperature sensing film is used to collect temperature gradient data of the connection terminal in real time at multiple positions; Place the connection terminal in the environmental simulation device and connect the connection terminal to the test circuit, and at the same time, arrange the current sensor and the vibration sensor; Use controllable power supply and environmental simulation device to simulate current fluctuation, temperature change, vibration impact in actual application. By setting environmental conditions under different load modes, real-time monitoring is performed to obtain temperature gradient data, current change data, and vibration data during the working process of the connection terminal. A multi-source data fusion algorithm is used to synchronously process temperature gradient data, current change data, and vibration data. Specifically, time synchronization and signal correction are used to eliminate time delays and interference between data to form a fused multidimensional data set, and filtering technology is used to remove noise. Based on the fused multidimensional data set, a deep learning model is applied to perform in-depth analysis. Through feature extraction and pattern recognition, the correlation factors between temperature distribution, current change and vibration characteristics are identified. Based on the correlation factors, the thermal response and electrical performance of the connection terminals under different working conditions are analyzed to find potential hot spots and fault points and obtain key performance parameters. The key performance parameters obtained from the in-depth analysis are input into the performance simulation model of the connection terminal, and the simulation software is used to simulate the thermoelectric response of the connection terminal under complex working conditions; Dynamic performance evaluation is carried out by combining simulated thermoelectric response and actual response data, and the performance index of the connector in a complex usage environment is quantified through comprehensive scoring of multi-dimensional indicators.

[0010] Optionally, the multi-source data fusion algorithm is used to synchronously process the temperature gradient data, the current change data and the vibration data, specifically by time synchronization and signal correction, to eliminate the time delay and interference between the data, to form a fused multidimensional data set, and to remove noise using filtering technology, specifically including: By integrating a synchronous clock module on the flexible temperature sensing film, the current sensor and the vibration sensor, the collection time of each data source has a unified time reference, and the collection time of each data point is marked with a timestamp; Apply interpolation algorithms to perform time alignment on multi-source data after time synchronization. According to the sampling frequency differences of different sensors, linear interpolation or spline interpolation methods are used to fill in the missing data points in the time series. Performing signal correction on the synchronized and aligned source data, and using the pre-calibrated sensor response curve, performing linear and nonlinear correction on the output signals of the flexible temperature sensing film, the current sensor and the vibration sensor to eliminate the system error and environmental drift of the sensor; Determine the time offset of each data source through cross-correlation analysis, and apply the corresponding time shift algorithm to align the temperature gradient data, current change data and vibration data in the time domain to eliminate the time delay between the data; Adaptive filters and frequency domain filtering techniques are used to suppress noise and external interference signals in multi-source data for data preprocessing.

[0011] Optionally, the method uses an adaptive filter and a frequency domain filtering technology to suppress noise and external interference signals in the multi-source data to perform data preprocessing, and then further includes: According to the signal strength of each data source, the pre-processed temperature gradient data, current change data and vibration data are weightedly fused through the weighted average algorithm to form a fused multi-dimensional data set, and the key features of the preset range are extracted through the feature extraction method of principal component analysis to construct a feature vector; Through linear normalization or Z-score standardization method, the dimensional differences between different data sources are eliminated so that each feature vector is within the same scale range, so as to perform data standardization on the fused multidimensional data set.

[0012] Optionally, the deep learning model is applied to perform in-depth analysis based on the fused multidimensional data set, and the correlation factors between temperature distribution, current change and vibration characteristics are identified through feature extraction and pattern recognition. The thermal response and electrical performance of the connection terminals under different working conditions are analyzed based on the correlation factors, potential hot spots and fault points are found, and key performance parameters are obtained, including: Extracting characteristic information of the multidimensional data set by using Fourier transform-based signal processing technology, wherein the characteristic information includes peak value, mean value, standard deviation, spectrum characteristics and vibration mode based on time domain and frequency domain; Establish a multi-level deep learning model and use the extracted feature information as input information for training. In the deep learning model design, CNN is used to process frequency domain feature data, LSTM is used to process time domain feature data, and the multi-layer structure of the neural network is combined to perform multi-dimensional feature association learning. Through the trained deep learning model, pattern recognition and correlation analysis are carried out to identify the potential correlation factors between temperature distribution, current changes and vibration characteristics; the specific process includes automatically extracting the correlation factors through the activation function and weight adjustment of the middle layer of the neural network, using visualization technology to reduce the dimensionality of the extracted high-dimensional features to help identify key correlation factors, and displaying the correlation patterns of temperature, current and vibration in the form of images and heat maps.

[0013] Optionally, the method further includes performing pattern recognition and correlation analysis through a trained deep learning model to identify potential correlation factors among temperature distribution, current change and vibration characteristics, and then: Through the correlation factors output by the deep learning model, a thermodynamic model of the connection terminal under different temperature, current and vibration conditions is constructed to identify its thermal diffusion characteristics, current conduction characteristics and the impact of vibration on the terminal material, and a thermal-electrical-vibration multi-physics field coupling analysis is performed to analyze the thermal response and electrical performance of the connection terminal under different working conditions; During the analysis process, the key correlation factors output by the deep learning model are combined with physical models and thermodynamic principles. The high-temperature areas are located through thermal response data, and the current change and vibration data are used to identify current-intensive areas and areas affected by shocks. In this way, the areas where failures may occur are located, and the potential hot spots and failure points of the connection terminals are explored to obtain key performance parameters.

[0014] Optionally, the key performance parameters obtained by the in-depth analysis are input into a performance simulation model of the connection terminal, and the thermoelectric response of the connection terminal under complex working conditions is simulated by simulation software, specifically including: The key performance parameters obtained are standardized and passed to the performance simulation model as input data. Specifically, a structured data format is used and each key performance parameter is input into the simulation software through an interface. According to the working environment and working conditions of the connection terminals, a suitable multi-physics field coupling simulation model is constructed. The boundary conditions, material properties and load modes of the performance simulation model are set through the simulation software to simulate the thermoelectric response of the connection terminals under complex working conditions, and a comprehensive analysis is performed combining multiple factors of heat, electricity and vibration. The simulation software is used to simulate the thermoelectric response under multiple working conditions. By simulating the performance of the connection terminals under different loads and environmental conditions, the temperature distribution, current conduction characteristics and vibration effects are analyzed. Based on the simulation results, potential hot spots and fault points are identified, and the results are compared and verified.

[0015] Compared with the prior art, the present invention has the following beneficial effects: when working, the round head component is plugged into the round jack component to realize the rapid disassembly and replacement of the connector, and the step portion is provided to fix the power cord and the round head component, wherein the round head component is integrally formed and is provided with a hollow hole, thereby reducing the weight and material of the entire round head component and reducing the cost, while the rounded side wall meets the demand for high-power power transmission; the copper spring sheet component and the annular groove can play the role of limiting the insertion and removal of the round head component, and when plugged in, the copper spring sheet component is compressed and offset against the annular groove, playing the role of providing an elastic supporting force for the round jack component, and at the same time, the copper spring sheet component plays a conductive role on the contact surface, avoiding wear of the round jack component, resulting in a situation where no contact affects conductivity. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0017] The structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with this technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantive technical significance. Any structural modification, change in proportion or adjustment of size, without affecting the effects and purposes that can be achieved by the present invention, should still fall within the scope of the technical contents disclosed by the present invention.

[0018] Figure 1 This is a schematic diagram of the overall structure of the high-power metal connection terminal of the first embodiment; Figure 2 This is a schematic structural diagram of a round head assembly of a high-power metal connection terminal of the first embodiment of the present invention; Figure 3 It is a schematic diagram of a half-section structure of a round head component of a high-power metal connection terminal of the first embodiment of the present invention; Figure 4 It is a schematic structural diagram of the copper spring assembly of the high-power metal connecting terminal of the first embodiment of the present invention.

[0019] Illustrations: round jack assembly 10 , round head assembly 20 , stepped portion 21 , square plug block 22 , positioning hole 23 , hollow hole 24 , annular groove 25 , copper shrapnel assembly 30 , small shrapnel 31 , shrapnel foot 311 , groove portion 312 . DETAILED DESCRIPTION

[0020] In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] In the description of the present invention, it should be understood that the terms "upper", "lower", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, 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 of the present invention. It should be noted that when a component is considered to be "connected" to another component, it may be directly connected to the other component or there may be a centrally arranged component at the same time.

[0022] The technical solution of the present invention is further described below with reference to the accompanying drawings and through specific implementation methods.

[0023] Embodiment 1: Combination Figures 1 to 4 As shown, an embodiment of the present invention provides a high-power metal connection terminal, including a round jack component 10, and a round head component 20 plugged into the round jack component 10; a first end portion of the round head component 20 is provided with a stepped portion 21, and the stepped portion 21 forms a square plug block 22, and a side wall surface of the square plug block 22 is provided with a positioning hole 23 for connecting a power cord, and one end surface of the square plug block 22 is provided with a hollow hole 24 that passes through the inside of the round head component 20; an annular groove 25 is provided at one end portion of the round head component 20, and a copper spring component 30 is provided in the annular groove 25, and the width of the copper spring component 30 in a natural state is less than the thickness of the annular groove 25, and the width in a completely flattened state is greater than the thickness of the annular groove 25.

[0024] The working principle of the present invention is as follows: when working, the round head component 20 is plugged into the round jack component 10 to achieve rapid disassembly and replacement of the connector. The step portion 21 is provided to fix the power cord and the round head component 20, wherein the round head component 20 is integrally formed and is provided with a hollow hole 24, thereby reducing the weight and material of the entire round head component 20 and reducing the cost. At the same time, the rounded side wall meets the needs of high-power power transmission; the copper spring component 30 and the annular groove 25 can play a role in limiting the insertion and removal of the round head component 20. When plugged in, the copper spring component 30 is compressed and offset against the annular groove 25, which plays a role in providing an elastic supporting force for the round jack component 10. At the same time, the copper spring component 30 plays a conductive role on the contact surface, thereby avoiding wear of the round jack component 10, resulting in a situation where no contact affects conductivity.

[0025] In this embodiment, the copper spring assembly 30 is in the shape of a ring, and is provided with a plurality of small springs 31 connected in sequence along the circumferential direction of the copper spring assembly 30; the small springs 31 are gradually arched outward from both ends to the middle, and the arched portion in the middle is provided with an arc-shaped transition surface. The use of this design is that the overall elastic support is achieved by welding together (or integrally casting and bending) a plurality of small springs 31 arranged in a ring shape.

[0026] In this embodiment, the small spring piece 31 includes two symmetrically arranged spring piece feet 311, and both sides of the spring piece feet 311 are respectively provided with flat surfaces, and adjacent to the flat surfaces are provided with groove parts 312. It should be noted that the flat surfaces play a role in connecting adjacent small spring pieces 31, and the groove parts 312 play a role in reducing the strength of the position, so that the small spring piece 31 has the role of providing deformation space during the elastic deformation process.

[0027] Embodiment 2: The present invention further provides a performance detection method for a high-power metal connection terminal, which is used to detect the high-power metal connection terminal as in the first embodiment. The performance detection method includes: S1. A flexible temperature sensing film is fittedly arranged along the length direction of the round head component 20 and the round socket component 10. The flexible temperature sensing film is used to collect temperature gradient data of the connection terminal at multiple positions in real time; wherein the temperature gradient data tests the temperature information of different points along the length direction of the connection terminal, thereby integrating into a temperature gradient data with position-temperature information.

[0028] S2, place the connection terminal in the environmental simulation device, and connect the connection terminal to the test circuit. At the same time, arrange the current sensor and vibration sensor. Through this process, the performance of the connection terminal can be comprehensively evaluated to simulate the electrical characteristics and vibration characteristics under real working conditions.

[0029] S3, using controllable power supply and environmental simulation device to simulate current fluctuation, temperature change, vibration shock in actual application, by setting environmental conditions under different load modes, during the working process of the connection terminal, real-time monitoring to obtain temperature gradient data, current change data and vibration data; Through the controllable power supply and environmental simulation device, this step simulates the current fluctuations, temperature changes, vibration shocks and other working conditions that may occur in actual applications, and adjusts the environmental conditions by setting different load modes. In this process, temperature gradient data, current change data and vibration data are monitored and collected in real time. This step helps to further understand the performance and coping ability of the connection terminals under complex working conditions, and provides a large amount of data for analysis.

[0030] S4 uses a multi-source data fusion algorithm to synchronously process temperature gradient data, current change data, and vibration data. Specifically, through time synchronization and signal correction, the time delay and interference between the data are eliminated to form a fused multidimensional data set, and filtering technology is used to remove noise to ensure the purity and accuracy of the data.

[0031] S5, based on the fused multidimensional data set, applies a deep learning model for in-depth analysis. Through feature extraction and pattern recognition, it identifies the correlation factors between temperature distribution, current change and vibration characteristics. Based on the correlation factors, it analyzes the thermal response and electrical performance of the connection terminals under different working conditions, finds potential hot spots and fault points, and obtains key performance parameters.

[0032] S6, inputting the key performance parameters obtained from the in-depth analysis into the performance simulation model of the connection terminal, and using simulation software to simulate the thermoelectric response of the connection terminal under complex working conditions.

[0033] S7 combines simulated thermoelectric response and actual response data to conduct dynamic performance evaluation, and quantifies the performance index of the connector in complex usage environments through comprehensive scoring of multi-dimensional indicators.

[0034] The working principle of the present invention is as follows: during detection, a flexible temperature sensing film is used to arrange multiple monitoring points in the length direction of the connecting terminal to realize real-time acquisition of the temperature gradient, the connecting terminal is placed in an environmental simulation device, and the test circuit is turned on, and a current sensor and a vibration sensor are configured at the same time to obtain current fluctuation and mechanical vibration data; then, a controllable power supply and an environmental simulation device are used to simulate the variable loads and environmental conditions in actual use, and the temperature, current and vibration data are monitored and recorded in real time. The multi-source data fusion algorithm is used to synchronously process the collected multi-dimensional data, and the delay and interference between the data are eliminated through time synchronization and signal correction. The filtering technology is used to purify the data, and based on the fused data set, a deep learning model is used for in-depth analysis. Extract features and identify the correlation factors between temperature, current and vibration, so as to find potential hot spots and fault points, obtain key performance parameters, input the key performance parameters into the performance simulation model, simulate the thermoelectric response of the connection terminals under complex working conditions through simulation software, combine the simulation results with the actual monitoring data, conduct dynamic performance evaluation, and quantify the performance index of the connector under complex use environment through comprehensive scoring of multi-dimensional indicators; this method systematically evaluates the performance of the connection terminals under complex working conditions in the links of data collection, processing, analysis, simulation and evaluation, significantly improves the comprehensiveness of performance detection, realizes a comprehensive and accurate evaluation of high-power metal connection terminals, and provides a basis for the design optimization and maintenance strategy of the connection terminals.

[0035] In this embodiment, step S4 specifically includes: S41, by integrating a synchronous clock module on the flexible temperature sensing film, the current sensor and the vibration sensor, the collection time of each data source has a unified time reference, and the collection time of each data point is marked with a timestamp; By integrating a synchronous clock module on the flexible temperature sensor film, current sensor and vibration sensor, the acquisition time of each data source has a unified time reference. This innovative approach solves the problem of time asynchrony of multi-sensor data. The acquisition time of each data point is marked with a timestamp to ensure the time consistency of the data source during subsequent data fusion and alignment.

[0036] S42, applying an interpolation algorithm to perform time alignment processing on the time-synchronized multi-source data, and using a linear interpolation or spline interpolation method to fill in the missing data points in the time series according to the sampling frequency differences of different sensors; Interpolation algorithms are applied to time align the synchronized multi-source data. When the sampling frequencies of multiple sensors are usually different, linear interpolation or spline interpolation methods are used to fill in the missing data points in the time series to ensure the consistency of the data of each sensor on the time axis. This step can solve the time misalignment problem caused by inconsistent sampling frequencies and improve the accuracy and completeness of data fusion.

[0037] S43, performing signal correction on each source data after synchronization and alignment, using a pre-calibrated sensor response curve, performing linear and nonlinear correction on output signals of the flexible temperature sensing film, the current sensor, and the vibration sensor, to eliminate system errors and environmental drifts of the sensors; Using the pre-calibrated sensor response curve, the output signals of the flexible temperature sensing film, current sensor and vibration sensor are corrected to eliminate the sensor's systematic error and environmental drift. By performing linear and nonlinear corrections, the measurement deviation that may be caused by sensor errors is resolved. The innovation of this step is that the reliability of the sensor data can be significantly improved through a precise calibration process.

[0038] S44, determining the time offset of each data source through cross-correlation analysis, and applying a corresponding time shift algorithm to align the temperature gradient data, the current change data, and the vibration data in the time domain to eliminate the time delay between the data; Through cross-correlation analysis, the time offset between each data source is determined, and the time shift algorithm is applied to correct it so that the temperature gradient data, current change data and vibration data are aligned in the time domain. This step solves the time delay problem caused by equipment accuracy or other factors, thereby achieving high-precision data alignment. This method can effectively eliminate time delay in a multi-sensor environment and ensure the time synchronization of each data source.

[0039] S45, using adaptive filters and frequency domain filtering technology to suppress noise and external interference signals in multi-source data to perform data preprocessing.

[0040] Specifically, it includes the application of Kalman filtering, Wiener filtering or wavelet transform filtering methods to effectively remove environmental noise, electromagnetic interference and other random noises, and improve the signal-to-noise ratio of the data.

[0041] S46, performing weighted fusion on the preprocessed temperature gradient data, current change data and vibration data by a weighted average algorithm according to the signal strength of each data source to form a fused multidimensional data set, and extracting key features of a preset range by a feature extraction method of principal component analysis to construct a feature vector; According to the signal strength of each data source, a weighted average algorithm is used to perform weighted fusion of the pre-processed temperature gradient data, current change data, and vibration data to form a multidimensional data set. On this basis, the principal component analysis (PCA) method is used to extract key features within a preset range and construct feature vectors. This innovative method fuses multiple data sources and uses PCA to effectively extract the most representative features, thereby reducing the data dimension while retaining key information.

[0042] S47, through linear normalization or Z-score standardization method, the dimensional differences between different data sources are eliminated so that each feature vector is within the same scale range, so as to perform data standardization on the fused multidimensional data set.

[0043] In this embodiment, it is specifically described that step S5 specifically includes: S51, extracting feature information of the multidimensional data set using a Fourier transform-based signal processing technique, wherein the feature information includes a peak value, a mean value, a standard deviation, a spectrum characteristic, and a vibration mode based on a time domain and a frequency domain; Feature information is extracted from multidimensional data sets through Fourier transform-based signal processing technology. Fourier transform can convert time domain signals into frequency domain signals, thereby effectively revealing the spectral characteristics of the signal. These features include peak value, mean value, standard deviation, spectral characteristics, and vibration mode, which can fully reflect the changing laws of temperature, vibration, and current signals. Through this method, data can be deeply analyzed in the frequency domain and time domain, and potential important features can be extracted to provide high-quality input information for subsequent deep learning models.

[0044] S52, establish a multi-level deep learning model, and use the extracted feature information as input information for training. In the deep learning model design, CNN is used to process frequency domain feature data, LSTM is used to process time domain feature data, and the multi-layer structure of the neural network is combined to perform association learning of multi-dimensional features; In this step, a multi-level deep learning model is first established. This model uses a convolutional neural network (CNN) to process frequency domain feature data and a long short-term memory network (LSTM) to process time domain feature data, and performs multi-dimensional feature association learning through the multi-layer structure of the neural network. CNN can efficiently extract local features from frequency domain data, while LSTM is good at processing time series data and capturing temporal dependencies. In this way, the deep learning model can learn the complex relationships between different features and provide support for further pattern recognition and analysis.

[0045] S53, through the trained deep learning model, performs pattern recognition and correlation analysis to identify the potential correlation factors between temperature distribution, current change and vibration characteristics; the specific process includes automatically extracting the correlation factors through the activation function and weight adjustment of the middle layer of the neural network, using visualization technology to reduce the dimensionality of the extracted high-dimensional features to help identify key correlation factors, and displaying the correlation pattern of temperature, current and vibration in the form of images and heat maps.

[0046] Based on the trained deep learning model, pattern recognition and association analysis are performed. This process automatically extracts the potential correlation factors between temperature, current, and vibration characteristics through the activation function and weight adjustment of the middle layer of the neural network. Through visualization technology, the extracted high-dimensional features are reduced in dimension to help identify key correlation factors. The correlation patterns between temperature, current, and vibration are displayed in the form of images and heat maps to intuitively present their mutual relationships. This analysis can help further understand the performance characteristics of the connection terminals and identify potential problems in their working process.

[0047] S54, through the correlation factors output by the deep learning model, a thermodynamic model of the connection terminal under different temperature, current and vibration conditions is constructed to identify its thermal diffusion characteristics, current conduction characteristics and the influence of vibration on the terminal material, and a thermal-electrical-vibration multi-physics field coupling analysis is performed to analyze the thermal response and electrical performance of the connection terminal under different working conditions; In this stage, based on the correlation factors output by the deep learning model, a thermodynamic model of the connection terminal under different temperature, current and vibration conditions is constructed. The thermal-electric-vibration multi-physics coupling analysis is performed by identifying the thermal diffusion characteristics of the connection terminal, the current conduction characteristics, and the influence of vibration on the terminal material. Through the multi-physics coupling analysis, we can gain a deep understanding of the thermal response and electrical performance of the connection terminal under complex working conditions, so as to evaluate its working performance in practical applications.

[0048] S55, during the analysis process, the key correlation factors output by the deep learning model are combined with physical models and thermodynamic principles. The high-temperature areas are located through thermal response data, and the current change and vibration data are used to identify the current-intensive areas and areas affected by shocks. The areas where faults may occur are located to explore the potential hot spots and fault points of the connection terminals and obtain key performance parameters.

[0049] This process can effectively explore potential hot spots and fault points that may occur in the connection terminals under different working conditions, providing data support for subsequent performance evaluation and fault prediction. At the same time, the key performance parameters obtained through analysis can provide a basis for the design improvement and optimization of the connection terminals.

[0050] In this embodiment, it is specifically described that step S6 specifically includes: S61, the key performance parameters obtained are standardized and passed to the performance simulation model as input data, specifically using a structured data format and inputting each key performance parameter into the simulation software through an interface.

[0051] S62, according to the working environment and working conditions of the connection terminals, build a suitable multi-physics field coupling simulation model, set the boundary conditions, material properties and load mode of the performance simulation model through the simulation software, simulate the thermoelectric response of the connection terminals under complex working conditions, and conduct a comprehensive analysis combining multiple factors of heat, electricity and vibration.

[0052] S63 uses simulation software to simulate the thermoelectric response under multiple working conditions. By simulating the performance of the connection terminals under different loads and environmental conditions, the temperature distribution, current conduction characteristics and vibration effects are analyzed. Based on the simulation results, potential hot spots and fault points are identified, and the results are compared and verified.

[0053] Embodiment three: The present invention also provides a method for manufacturing a high-power metal connection terminal, which is used to manufacture the high-power metal connection terminal as in the first embodiment. Specifically, the manufacturing method includes: Step 1, providing metal materials and designing molds, and using CNC machine tools to process the preliminary shapes of the round socket component and the round head component; According to the technical requirements, suitable metal materials are selected for the production of terminal components, especially round head components and copper spring components. Round head components can be made of high-strength alloy materials to enhance tensile strength and electrical conductivity, while copper spring components need to be made of high-conductivity copper alloy materials.

[0054] Design the molds for the round head assembly and the square plug-in block, and at the same time design the circular ring of the copper spring assembly to ensure that the springs are arranged along the circumference and reserve appropriate elastic deformation space. Especially in the design of the small spring foot, the processing of the groove part must ensure its accuracy.

[0055] Step 2: using injection molding or precision casting technology to make a round head component, and forming a stepped portion and a hollow hole at one end thereof; Round socket component processing: According to the design drawings, the round socket components are cut and formed by precision CNC lathes. Through CNC machine processing, the dimensional accuracy of the round socket components is ensured to meet the design requirements.

[0056] Surface treatment: Surface treatment is performed on the round jack assembly to ensure that the connection part is smooth and free of burrs, reducing the friction resistance during plugging and unplugging.

[0057] Hollow holes are processed on the round head components by laser cutting technology or micro drilling machine to reduce material usage and reduce weight.

[0058] Step 3, processing the copper spring assembly through a stamping die to ensure the shape of the spring foot and the elastic deformation space; Forming of copper shrapnel components: Use stamping dies to stamp copper materials into annular shrapnel according to design requirements. According to the design of the shrapnel foot, the stamping process ensures the accuracy of each small shrapnel and the perfect forming of the groove.

[0059] Ring structure assembly: Arrange multiple small springs in a circular direction and weld or bend them into a complete copper spring assembly. Ensure the elasticity and deformation space of the small springs to ensure connection stability.

[0060] Step 4: Assemble the copper spring assembly into the annular groove of the round head assembly according to the design requirements, ensuring that the spring fits the groove; Assembly installation: Install the copper spring assembly into the annular groove of the round head assembly. Use the automated assembly line to achieve precise docking to ensure that the natural state of the spring fits the annular groove.

[0061] Shrapnel assembly compression test: Under simulated working conditions, the compression test is performed to ensure that the copper shrapnel assembly can provide appropriate elastic support force when the round head assembly is inserted into the round socket assembly and prevent excessive wear.

[0062] Step 5: Conduct conductivity and durability tests to ensure that the round head assembly and the copper spring assembly are stably connected and have good current conduction performance; Conductivity test: Use a conductivity tester to test the conductivity between the round head assembly and the copper spring assembly to ensure good current conduction capability.

[0063] Step six: conduct appearance inspection and packing to ensure product quality meets standards and is ready for shipment.

[0064] As described above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features thereof may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A high-power metal connection terminal, characterized in that: It includes a round socket component and a round head component plugged into the round socket component; The first end of the round head component is provided with a stepped portion, the stepped portion forms a square plug block, the side wall of the square plug block is provided with a positioning hole for connecting a power line, and one end surface of the square plug block is provided with a hollow hole penetrating to the inside of the round head component; An annular groove is provided at one end of the round head component, and a copper spring component is provided in the annular groove. The width of the copper spring component in a natural state is smaller than the thickness of the annular groove, and the width in a completely flattened state is larger than the thickness of the annular groove.

2. The high-power metal connection terminal according to claim 1, characterized in that: The copper spring assembly is in a circular shape, and is provided with a plurality of small springs connected in sequence along its circumferential direction; The small spring piece is gradually arched outward from both ends to the middle, and an arc-shaped transition surface is arranged on the arched portion in the middle.

3. The high-power metal connection terminal according to claim 2, characterized in that: The small spring sheet comprises two symmetrically arranged spring sheet feet, and both sides of the spring sheet feet are respectively provided with flat surfaces, and groove parts are arranged adjacent to the flat surfaces.

4. A performance detection method for a high-power metal connection terminal, characterized in that: Used to detect the high-power metal connection terminal according to any one of claims 1 to 3, the performance detection method comprises: A flexible temperature sensing film is arranged in close contact with the length direction of the round head component and the round socket component, and the flexible temperature sensing film is used to collect temperature gradient data of the connection terminal in real time at multiple positions; Place the connection terminal in the environmental simulation device and connect the connection terminal to the test circuit, and at the same time, arrange the current sensor and the vibration sensor; Use controllable power supply and environmental simulation device to simulate current fluctuation, temperature change, vibration impact in actual application. By setting environmental conditions under different load modes, real-time monitoring is performed to obtain temperature gradient data, current change data, and vibration data during the working process of the connection terminal. A multi-source data fusion algorithm is used to synchronously process temperature gradient data, current change data, and vibration data. Specifically, time synchronization and signal correction are used to eliminate time delays and interference between data to form a fused multidimensional data set, and filtering technology is used to remove noise. Based on the fused multidimensional data set, a deep learning model is applied to perform in-depth analysis. Through feature extraction and pattern recognition, the correlation factors between temperature distribution, current change and vibration characteristics are identified. Based on the correlation factors, the thermal response and electrical performance of the connection terminals under different working conditions are analyzed to find potential hot spots and fault points and obtain key performance parameters. The key performance parameters obtained from the in-depth analysis are input into the performance simulation model of the connection terminal, and the simulation software is used to simulate the thermoelectric response of the connection terminal under complex working conditions; Dynamic performance evaluation is carried out by combining simulated thermoelectric response and actual response data, and the performance index of the connector in a complex usage environment is quantified through comprehensive scoring of multi-dimensional indicators.

5. The performance detection method of a high-power metal connection terminal according to claim 4, characterized in that: The multi-source data fusion algorithm is used to synchronously process the temperature gradient data, current change data and vibration data, specifically through time synchronization and signal correction, to eliminate the time delay and interference between the data, to form a fused multi-dimensional data set, and to remove noise using filtering technology, specifically including: By integrating a synchronous clock module on the flexible temperature sensing film, the current sensor and the vibration sensor, the collection time of each data source has a unified time reference, and the collection time of each data point is marked with a timestamp; Apply interpolation algorithms to perform time alignment on multi-source data after time synchronization. According to the sampling frequency differences of different sensors, linear interpolation or spline interpolation methods are used to fill in the missing data points in the time series. Performing signal correction on the synchronized and aligned source data, and using the pre-calibrated sensor response curve, performing linear and nonlinear correction on the output signals of the flexible temperature sensing film, the current sensor and the vibration sensor to eliminate the system error and environmental drift of the sensor; Determine the time offset of each data source through cross-correlation analysis, and apply the corresponding time shift algorithm to align the temperature gradient data, current change data and vibration data in the time domain to eliminate the time delay between the data; Adaptive filters and frequency domain filtering techniques are used to suppress noise and external interference signals in multi-source data for data preprocessing.

6. The performance detection method of a high-power metal connection terminal according to claim 5, characterized in that: The method uses adaptive filters and frequency domain filtering technology to suppress noise and external interference signals in multi-source data to perform data preprocessing, and then further includes: According to the signal strength of each data source, the pre-processed temperature gradient data, current change data and vibration data are weightedly fused through the weighted average algorithm to form a fused multi-dimensional data set, and the key features of the preset range are extracted through the feature extraction method of principal component analysis to construct a feature vector; Through linear normalization or Z-score standardization method, the dimensional differences between different data sources are eliminated so that each feature vector is within the same scale range, so as to perform data standardization on the fused multidimensional data set.

7. The performance detection method of a high-power metal connection terminal according to claim 4, characterized in that: Based on the fused multidimensional data set, the deep learning model is applied to perform in-depth analysis, and the correlation factors between temperature distribution, current change and vibration characteristics are identified through feature extraction and pattern recognition. Based on the correlation factors, the thermal response and electrical performance of the connection terminals under different working conditions are analyzed, potential hot spots and fault points are found, and key performance parameters are obtained, including: Extracting characteristic information of the multidimensional data set by using Fourier transform-based signal processing technology, wherein the characteristic information includes peak value, mean value, standard deviation, spectrum characteristics and vibration mode based on time domain and frequency domain; Establish a multi-level deep learning model and use the extracted feature information as input information for training. In the deep learning model design, CNN is used to process frequency domain feature data, LSTM is used to process time domain feature data, and the multi-layer structure of the neural network is combined to perform multi-dimensional feature association learning. Through the trained deep learning model, pattern recognition and correlation analysis are carried out to identify the potential correlation factors between temperature distribution, current changes and vibration characteristics; the specific process includes automatically extracting the correlation factors through the activation function and weight adjustment of the middle layer of the neural network, using visualization technology to reduce the dimensionality of the extracted high-dimensional features to help identify key correlation factors, and displaying the correlation patterns of temperature, current and vibration in the form of images and heat maps.

8. The performance detection method of a high-power metal connection terminal according to claim 7, characterized in that: The method uses the trained deep learning model to perform pattern recognition and correlation analysis to identify potential correlation factors between temperature distribution, current change and vibration characteristics, and then includes: Through the correlation factors output by the deep learning model, a thermodynamic model of the connection terminal under different temperature, current and vibration conditions is constructed to identify its thermal diffusion characteristics, current conduction characteristics and the impact of vibration on the terminal material, and a thermal-electrical-vibration multi-physics field coupling analysis is performed to analyze the thermal response and electrical performance of the connection terminal under different working conditions; During the analysis process, the key correlation factors output by the deep learning model are combined with physical models and thermodynamic principles. The high-temperature areas are located through thermal response data, and the current change and vibration data are used to identify current-intensive areas and areas affected by shocks. In this way, the areas where failures may occur are located, and the potential hot spots and failure points of the connection terminals are explored to obtain key performance parameters.

9. The performance detection method of a high-power metal connection terminal according to claim 4, characterized in that: The key performance parameters obtained by the in-depth analysis are input into the performance simulation model of the connection terminal, and the thermoelectric response of the connection terminal under complex working conditions is simulated by simulation software, specifically including: The key performance parameters obtained are standardized and passed to the performance simulation model as input data. Specifically, a structured data format is used and each key performance parameter is input into the simulation software through an interface. According to the working environment and working conditions of the connection terminals, a suitable multi-physics field coupling simulation model is constructed. The boundary conditions, material properties and load modes of the performance simulation model are set through the simulation software to simulate the thermoelectric response of the connection terminals under complex working conditions, and a comprehensive analysis is performed combining multiple factors of heat, electricity and vibration. The simulation software is used to simulate the thermoelectric response under multiple working conditions. By simulating the performance of the connection terminals under different loads and environmental conditions, the temperature distribution, current conduction characteristics and vibration effects are analyzed. Based on the simulation results, potential hot spots and fault points are identified, and the results are compared and verified.

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