A high-power metal connection terminal and its manufacturing method

Abstract

The present invention discloses a high-power metal connection terminal and a manufacturing method thereof, which includes a round jack component and a round head component inserted into the round jack component; a stepped portion is provided at the first end of the round head component, and a square insertion block is formed on the stepped portion. A hollow hole penetrating into the interior of the round head component is provided on one end face of the square insertion block; an annular groove is provided at one end of the round head component, and a copper elastic sheet component is arranged in the annular groove. The width of the copper elastic sheet component in the natural state is smaller than the thickness of the annular groove, and the width in the fully flattened state is larger than the thickness of the annular groove; inserting the round head component into the round jack component realizes the quick disassembly and replacement of the connector. A hollow hole is provided, thereby reducing the weight and material consumption of the entire round head component, reducing costs. The elastic sheet component and the annular groove can play a role in limiting the insertion and extraction of the round head component, and at the same time play a role in conducting electricity.

Description

Technical Field

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

[0002] In modern power transmission and distribution systems, high-power metal connection terminals are widely used in multiple key fields such as high-voltage transmission lines, industrial power equipment, renewable energy systems, and electric vehicles. As the core components for power transmission, the reliability and performance of these connection terminals 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 connection terminals not only need to withstand higher current loads but also must maintain excellent thermal management and mechanical stability under various complex working conditions. Therefore, an efficient and accurate performance detection method for high-power metal connection terminals is particularly important to ensure their safety and durability in practical applications.

[0003] In the prior art, the performance detection of high-power metal connection terminals mainly relies on single-dimensional data acquisition and analysis methods. For example, the thermal distribution of the connection terminals is monitored through temperature sensors, or the current change is detected using current sensors. However, these methods often lack a comprehensive evaluation of the connection terminals under various complex working conditions and cannot fully reflect their dynamic performance in actual use. These deficiencies limit the comprehensiveness and accuracy of the connection terminal performance detection 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 of lack of comprehensive evaluation in their detection. Summary of the Invention

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

[0006] To achieve this purpose, the present invention adopts the following technical solutions:

[0007] A high-power metal connection terminal includes a round socket component and a round head component inserted into the round socket component;

[0008] A stepped portion is provided at the first end of the round head component. The stepped portion forms a square plug-in block. A positioning hole for connecting a power line is provided on the side wall surface of the square plug-in block. A hollow hole penetrating through the inside of the round head component is provided on one end surface of the square plug-in block;

[0009] One end of the round head component is provided with an annular groove, and a copper elastic sheet component is arranged in the annular groove. The width of the copper elastic sheet component in its natural state is smaller than the thickness of the annular groove, and the width in its fully flattened state is larger than the thickness of the annular groove.

[0010] Optionally, the copper elastic sheet component is in a circular ring shape, and a plurality of sequentially connected small elastic sheets are arranged along its circumferential direction;

[0011] The small elastic sheet is gradually arched outward from its two ends to the middle, and an arc transition surface is arranged at the arched part in the middle.

[0012] Optionally, the small elastic sheet includes two symmetrically arranged elastic sheet feet, and flat surfaces are respectively arranged on both sides of the elastic sheet feet, and groove parts are arranged adjacent to the flat surfaces.

[0013] 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:

[0014] A flexible temperature sensing film is adhesively arranged in the length direction of the round head component and the round jack component. The flexible temperature sensing film is used to collect temperature gradient data of the connection terminal in real time at multiple positions;

[0015] The connection terminal is placed in an environment simulation device, and the connection terminal is conducted with a test circuit. At the same time, a current sensor and a vibration sensor are arranged;

[0016] Using a controllable power supply and an environment simulation device, simulate the current fluctuation, temperature change, and vibration impact in actual applications. By setting the environmental conditions under different load modes, during the operation of the connection terminal, obtain temperature gradient data, current change data, and vibration data in real time;

[0017] Adopt a multi-source data fusion algorithm to synchronously process the temperature gradient data, current change data, and vibration data. Specifically, through time synchronization and signal correction, eliminate the time delay and interference between the data, form a fused multi-dimensional data set, and use filtering technology to remove noise;

[0018] Based on the fused multi-dimensional data set, apply a deep learning model for in-depth analysis. Through feature extraction and pattern recognition, identify the correlation factors between the temperature distribution, current change, and vibration characteristics. Based on the correlation factors, analyze the thermal response and electrical performance of the connection terminal under different working conditions, discover potential hot spots and fault points, and obtain key performance parameters;

[0019] Input the key performance parameters obtained from the in-depth analysis into the performance simulation model of the connection terminal, and use simulation software to simulate the thermoelectric response of the connection terminal under complex working conditions;

[0020] Combining the simulated thermoelectric response and actual response data, dynamic performance evaluation is carried out, and through the comprehensive scoring of multi-dimensional indicators, the performance index of the connector in a complex usage environment is quantified.

[0021] Optionally, 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, the time delay and interference between the data are eliminated to form a fused multi-dimensional data set, and filtering technology is used to remove noise, specifically including:

[0022] By integrating a synchronous clock module on the flexible temperature sensing film, current sensor, and vibration sensor, the acquisition moments of each data source have a unified time reference, and the acquisition time of each data point is marked with a time stamp;

[0023] Apply the interpolation algorithm to perform time alignment processing on the multi-source data after time synchronization. For 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;

[0024] Perform signal correction on the synchronized and aligned data from each source. Using the pre-calibrated sensor response curve, linear and non-linear corrections are performed on the output signals of the flexible temperature sensing film, current sensor, and vibration sensor to eliminate the systematic errors and environmental drifts of the sensors;

[0025] 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;

[0026] Use an adaptive filter and frequency domain filtering technology to suppress the noise and external interference signals in the multi-source data for data preprocessing.

[0027] Optionally, after using the adaptive filter and frequency domain filtering technology to suppress the noise and external interference signals in the multi-source data for data preprocessing, the following steps are also included:

[0028] According to the signal strength of each data source, the preprocessed temperature gradient data, current change data, and vibration data are weighted and fused through a weighted average algorithm to form a fused multi-dimensional data set, and key features within a preset range are extracted through the feature extraction method of principal component analysis to construct a feature vector;

[0029] Through linear normalization or Z-score standardization methods, the dimension differences between different data sources are eliminated, so that each feature vector is within the same scale range to perform data standardization processing on the fused multi-dimensional data set.

[0030] Optionally, based on the fused multi-dimensional dataset, a deep learning model is applied for in-depth analysis. Through feature extraction and pattern recognition, the correlation factors among the 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 discover potential hot spots and fault points, and key performance parameters are obtained, specifically including:

[0031] The signal processing technology based on Fourier transform is used to extract the feature information of the multi-dimensional dataset. The feature information includes peaks, means, standard deviations, spectral characteristics, and vibration modes based on the time domain and frequency domain;

[0032] A multi-level deep learning model is established, and the extracted feature information is used as input information for training. In the design of the deep learning model, CNN is used to process the frequency domain feature data, LSTM is used to process the time domain feature data, and combined with the multi-layer structure of the neural network, the correlation learning of multi-dimensional features is carried out;

[0033] Through the trained deep learning model, pattern recognition and correlation analysis are carried out to identify the potential correlation factors among the 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 dimension of the extracted high-dimensional features to help identify the key correlation factors, and displaying the correlation patterns of temperature, current, and vibration in the form of images and heat maps.

[0034] Optionally, after identifying the potential correlation factors among the temperature distribution, current change, and vibration characteristics through the trained deep learning model, the following steps are further included:

[0035] Based on the correlation factors output by the deep learning model, a thermodynamic model of the connection terminals under different temperature, current, and vibration conditions is constructed to identify their heat diffusion characteristics, current conduction characteristics, and the influence of vibration on the terminal materials, and thermo-electro-vibration multi-physical field coupling analysis is carried out to analyze the thermal response and electrical performance of the connection terminals under different working conditions;

[0036] During the analysis process, through the key correlation factors output by the deep learning model, combined with the physical model and thermodynamic principles, the high-temperature region is located through the thermal response data, the current-intensive region and the region affected by the impact are identified using the current change and vibration data, and the possible fault regions are located to discover the potential hot spots and fault points existing in the connection terminals, and key performance parameters are obtained.

[0037] Optionally, input the key performance parameters obtained from the in-depth analysis into the performance simulation model of the connection terminal, and use simulation software to simulate the thermoelectric response of the connection terminal under complex working conditions, specifically including:

[0038] After standardizing the obtained key performance parameters, transfer them as input data to the performance simulation model. Specifically, use a structured data format and input each key performance parameter into the simulation software through an interface.

[0039] According to the working environment and conditions of the connection terminal, construct a suitable multi-physics field coupling simulation model. Set the boundary conditions, material properties, and load modes of the performance simulation model through the simulation software to simulate the thermoelectric response of the connection terminal under complex working conditions, and conduct comprehensive analysis by combining multiple factors of heat, electricity, and vibration.

[0040] Use the simulation software to perform thermoelectric response simulations under multiple working conditions. By simulating the performance of the connection terminal under different loads and environmental conditions, analyze its temperature distribution, current conduction characteristics, and vibration effects. According to the simulation results, identify potential hot spots and fault points, and conduct result comparison and verification.

[0041] Compared with the prior art, the present invention has the following beneficial effects: During operation, insert the round head component into the round socket component to achieve quick disassembly and replacement of the connector. The stepped portion can fix the power cord and the round head component. The round head component is integrally formed and provided with hollow holes, thereby reducing the weight and material consumption of the entire round head component, reducing costs, and at the same time, the rounded side wall meets the requirements of high-power power transmission; the copper elastic sheet component and the annular groove can play a role in limiting the insertion and extraction of the round head component. When inserted, the copper elastic sheet component is compressed and abuts against the annular groove, providing an elastic support force for the round socket component. At the same time, the copper elastic sheet component conducts electricity at the contact surface, avoiding wear of the round socket component and preventing non-contact and affecting electricity conduction. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0043] The structures, proportions, sizes, etc. depicted in the accompanying drawings of this specification are only used to match the content disclosed in the specification for those familiar with this technology to understand and read, and are not used to limit the conditions for the implementation of the present invention. Therefore, they do not have any substantial technical significance. Any modification of the structure, change in the proportional relationship, or adjustment of the size, without affecting the effects that the present invention can produce and the purposes that can be achieved, should still fall within the scope covered by the technical content disclosed in the present invention.

[0044] Figure 1 is a schematic diagram of the overall structure of the high-power metal connection terminal of the first embodiment;

[0045] Figure 2 is a schematic diagram of the structure of the round head component of the high-power metal connection terminal of the first embodiment;

[0046] Figure 3 is a schematic diagram of the half-sectional structure of the round head component of the high-power metal connection terminal of the first embodiment;

[0047] Figure 4 is a schematic diagram of the structure of the copper elastic sheet component of the high-power metal connection terminal of the first embodiment.

[0048] Illustration: Round socket component 10, round head component 20, stepped portion 21, square insertion block 22, positioning hole 23, hollow hole 24, annular groove 25, copper elastic sheet component 30, small elastic sheet 31, elastic sheet foot 311, groove portion 312. Detailed implementation manners

[0049] In order to make the invention objectives, features, and advantages of the present invention more obvious and understandable, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the embodiments described below are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts shall fall within the scope of protection of the present invention.

[0050] In the description of the present invention, it should be understood that the orientation or positional relationship indicated by the terms "upper", "lower", "top", "bottom", "inner", "outer", etc. is based on the orientation or positional relationship shown in the accompanying drawings, and is 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 intermediate components present at the same time.

[0051] The technical solution of the present invention will be further described below in conjunction with the accompanying drawings and through specific embodiments.

[0052] Embodiment 1:

[0053] Combined with Figures 1 to 4 As shown, the embodiment of the present invention provides a high-power metal connection terminal, including a round jack assembly 10 and a round head assembly 20 inserted into the round jack assembly 10; a stepped portion 21 is provided at the first end of the round head assembly 20, a square plug-in block 22 is formed on the stepped portion 21, a positioning hole 23 for connecting a power line is provided on the side wall surface of the square plug-in block 22, and a hollow hole 24 penetrating into the inside of the round head assembly 20 is provided on one end surface of the square plug-in block 22; an annular groove 25 is provided at one end of the round head assembly 20, and a copper elastic sheet assembly 30 is arranged in the annular groove 25. The width of the copper elastic sheet assembly 30 in the natural state is less than the thickness of the annular groove 25, and the width in the fully flattened state is greater than the thickness of the annular groove 25.

[0054] The working principle of the present invention is as follows: During operation, the round head assembly 20 is inserted into the round jack assembly 10 to achieve quick disassembly and replacement of the connector. The stepped portion 21 can play a role in fixing the power line and the round head assembly 20. The round head assembly 20 is integrally formed and provided with a hollow hole 24, thereby reducing the weight and material consumption of the entire round head assembly 20, reducing costs, and at the same time, the round side wall meets the requirements of high-power power transmission; the copper elastic sheet assembly 30 and the annular groove 25 can play a role in limiting the insertion and extraction of the round head assembly 20. When inserted, the copper elastic sheet assembly 30 is compressed and abuts against the annular groove 25, providing an elastic support force for the round jack assembly 10. At the same time, the copper elastic sheet assembly 30 conducts electricity at the contact surface, avoiding wear of the round jack assembly 10 and preventing non-contact and affecting electricity conduction.

[0055] In this embodiment, the copper elastic sheet assembly 30 is circular, and a plurality of small elastic sheets 31 connected in sequence are arranged along the circumferential direction of the copper elastic sheet assembly 30; the small elastic sheets 31 are gradually arched outward from both ends to the middle, and an arc transition surface is provided at the arched portion in the middle. The purpose of this design is to achieve overall elastic support through a plurality of small elastic sheets 31 arranged in a ring (or integrally cast and bent).

[0056] In this embodiment, the small elastic sheet 31 includes two symmetrically arranged elastic sheet feet 311, and flat surfaces are respectively provided on both sides of the elastic sheet feet 311, and a groove portion 312 is provided adjacent to the flat surface. It should be noted that the flat surface plays a role in connecting adjacent small elastic sheets 31, and the groove portion 312 plays a role in reducing the strength at this position, so that the small elastic sheet 31 gives a deformation space during the elastic deformation process.

[0057] Embodiment 2:

[0058] The present invention also provides a performance detection method for high-power metal connection terminals, which is used to detect the high-power metal connection terminals as in Embodiment 1. The performance detection method includes:

[0059] S1, a flexible temperature sensing film is disposed in a fitting manner in the length direction of the round head component 20 and the round jack component 10. The flexible temperature sensing film is used to collect temperature gradient data of the connection terminal in real time at multiple positions; wherein, the temperature gradient data tests the temperature information of different points along the length direction of the connection terminal, so as to integrate into a temperature gradient data with position-temperature information.

[0060] S2, the connection terminal is placed in an environment simulation device, and the connection terminal is conducted with a test circuit. At the same time, a current sensor and a vibration sensor are arranged; through this process, the performance of the connection terminal can be comprehensively evaluated, and the electrical characteristics and vibration characteristics under real working conditions can be simulated.

[0061] S3, using a controllable power supply and an environment simulation device, simulating current fluctuations, temperature changes, and vibration impacts in actual applications. By setting the environmental conditions under different load modes, during the working process of the connection terminal, temperature gradient data, current change data, and vibration data are obtained in real-time monitoring;

[0062] Through the controllable power supply and the environment simulation device, this step simulates the working conditions such as current fluctuations, temperature changes, and vibration impacts that may occur in actual applications, and adjusts the environmental conditions by setting different load modes. During 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 response ability of the connection terminal under complex working conditions, and provides a large amount of data for analysis.

[0063] S4, a 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, the time delay and interference between the data are eliminated, a fused multi-dimensional data set is formed, and filtering technology is used to remove noise to ensure the purity and accuracy of the data.

[0064] S5, based on the fused multi-dimensional data set, a deep learning model is applied for in-depth analysis. Through feature extraction and pattern recognition, the correlation factors between the temperature distribution, current change, and vibration characteristics are identified. Based on the correlation factors, the thermal response and electrical performance of the connection terminal under different working conditions are analyzed, potential hot spots and fault points are found, and key performance parameters are obtained.

[0065] S6, the key performance parameters obtained from the in-depth analysis are input into the performance simulation model of the connection terminal, and simulation software is used to simulate the thermoelectric response of the connection terminal under complex working conditions.

[0066] S7. Combine the simulated thermoelectric response and actual response data to conduct dynamic performance evaluation, and quantify the performance index of the connector in complex usage environments through comprehensive scoring of multi-dimensional indicators.

[0067] The working principle of the present invention is as follows: During detection, a flexible temperature sensing film is used to arrange multiple monitoring points along the length direction of the connection terminal to achieve real-time acquisition of the temperature gradient. The connection terminal is placed in an environmental simulation device, and the test circuit is conducted. At the same time, a current sensor and a vibration sensor are configured 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. The delay and interference between the data are eliminated through time synchronization and signal correction, and filtering technology is used to purify the data. Based on the fused data set, a deep learning model is applied for in-depth analysis to extract features and identify the correlation factors between temperature, current, and vibration, so as to discover potential hot spots and fault points, obtain key performance parameters. The key performance parameters are input into the performance simulation model, and the thermoelectric response of the connection terminal under complex working conditions is simulated through simulation software. Combining the simulation results with the actual monitoring data, dynamic performance evaluation is carried out, and the performance index of the connector in complex usage environments is quantified through comprehensive scoring of multi-dimensional indicators. This method systematically evaluates the performance of the connection terminal under complex working conditions in all aspects of data acquisition, processing, analysis, simulation, and evaluation, significantly improves the comprehensiveness of performance detection, and realizes the comprehensive and accurate evaluation of high-power metal connection terminals, providing a basis for the design optimization and maintenance strategy of the connection terminal.

[0068] In this embodiment, step S4 specifically includes:

[0069] S41. Integrate a synchronous clock module on the flexible temperature sensing film, current sensor, and vibration sensor to make the acquisition moments of each data source have a unified time reference, and use time stamps to mark the acquisition time of each data point.

[0070] By integrating a synchronous clock module on the flexible temperature sensing film, current sensor, and vibration sensor, the acquisition moments of each data source have a unified time reference. This innovative approach solves the problem of asynchronous time of multi-sensor data. The acquisition time of each data point is marked by a time stamp to ensure the time consistency of the data sources when subsequent data fusion and alignment are performed.

[0071] S42. Apply an interpolation algorithm to perform time alignment processing on the multi-source data after time synchronization. For 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.

[0072] Apply interpolation algorithms to perform time alignment processing on the synchronized multi-source data. In the case where the sampling frequencies of multiple sensors usually vary, linear interpolation or spline interpolation methods are used to fill in the missing data points in the time series, ensuring the consistency of the data from each sensor on the time axis. This step can solve the time misalignment problem caused by inconsistent sampling frequencies and improve the accuracy and integrity of data fusion.

[0073] S43. Perform signal correction on each source data after synchronization and alignment. Using the pre-calibrated sensor response curves, perform linear and non-linear corrections on the output signals of the flexible temperature sensing film, current sensor, and vibration sensor to eliminate the systematic errors and environmental drifts of the sensors.

[0074] Using the pre-calibrated sensor response curves, correct the output signals of the flexible temperature sensing film, current sensor, and vibration sensor to eliminate the systematic errors and environmental drifts of the sensors. By performing linear and non-linear corrections, the measurement deviations that may be caused by sensor errors are solved. The innovation of this step lies in that through an accurate calibration process, the reliability of sensor data can be significantly improved.

[0075] S44. Determine the time offsets 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 delays between the data.

[0076] Through cross-correlation analysis, determine the time offsets between each data source and apply the time shift algorithm for correction to align the temperature gradient data, current change data, and vibration data 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 delays in a multi-sensor environment and ensure the time synchronization of each data source.

[0077] S45. Use adaptive filters and frequency domain filtering techniques to suppress the noise and external interference signals in the multi-source data for data preprocessing.

[0078] Specifically, methods such as Kalman filtering, Wiener filtering, or wavelet transform filtering are applied to effectively remove environmental noise, electromagnetic interference, and other random noises, and improve the signal-to-noise ratio of the data.

[0079] S46. According to the signal intensities of each data source, perform weighted fusion on the preprocessed temperature gradient data, current change data, and vibration data through a weighted average algorithm to form a fused multi-dimensional data set, and extract the key features within a preset range through the feature extraction method of principal component analysis to construct a feature vector.

[0080] According to the signal strengths of each data source, the weighted average algorithm is used to perform weighted fusion on the preprocessed temperature gradient data, current change data, and vibration data to form a multi-dimensional 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 effectively extracts the most representative features using PCA, thereby reducing the data dimension while retaining key information.

[0081] S47, Through linear normalization or Z-score normalization methods, eliminate the dimensional differences between different data sources so that each feature vector is within the same scale range to perform data standardization processing on the fused multi-dimensional data set.

[0082] In this embodiment, specifically, step S5 specifically includes:

[0083] S51, Use signal processing technology based on Fourier transform to extract the feature information of the multi-dimensional data set. The feature information includes peaks, means, standard deviations, spectral characteristics, and vibration modes based on the time domain and frequency domain;

[0084] Through signal processing technology based on Fourier transform, extract the feature information from the multi-dimensional data set. Fourier transform can convert the time-domain signal into a frequency-domain signal, thereby effectively revealing the spectral characteristics of the signal. These features include peaks, means, standard deviations, spectral characteristics, and vibration modes, etc., which can comprehensively reflect the change laws of temperature, vibration, and current signals. Through this method, it is possible to deeply analyze the data in the frequency domain and time domain, extract potential important features, and provide high-quality input information for subsequent deep learning models.

[0085] S52, Establish a multi-level deep learning model and use the extracted feature information as input information for training. In the design of the deep learning model, use CNN to process frequency-domain feature data, use LSTM to process time-domain feature data, and combine the multi-layer structure of the neural network to perform associated learning of multi-dimensional features;

[0086] In this step, first establish a multi-level deep learning model. This model uses a convolutional neural network (CNN) to process frequency-domain feature data, uses a long short-term memory network (LSTM) to process time-domain feature data, and performs associated learning of multi-dimensional features through the multi-layer structure of the neural network. CNN can efficiently extract local features in 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.

[0087] S53. Through the trained deep learning model, perform pattern recognition and correlation analysis to identify the potential correlation factors among the 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 perform dimensionality reduction processing on the extracted high-dimensional features to help identify the key correlation factors, and presenting the correlation patterns of temperature, current, and vibration in the form of images and heat maps.

[0088] Based on the trained deep learning model, perform pattern recognition and correlation analysis. In this process, the potential correlation factors among temperature, current, and vibration characteristics are automatically extracted through the activation function and weight adjustment of the middle layer of the neural network. Through visualization technology, dimensionality reduction processing is performed on the extracted high-dimensional features to help identify the key correlation factors. The correlation patterns among temperature, current, and vibration are presented in the form of images and heat maps to intuitively show their mutual relationships. This analysis can help further understand the performance characteristics of the connection terminal and identify potential problems during its operation.

[0089] S54. Through the correlation factors output by the deep learning model, construct a thermodynamic model of the connection terminal under different temperature, current, and vibration conditions, identify its heat diffusion characteristics, current conduction characteristics, and the impact of vibration on the terminal material, and perform thermo-electric-vibration multi-physics field coupling analysis to analyze the thermal response and electrical performance of the connection terminal under different working conditions.

[0090] In this stage, based on the correlation factors output by the deep learning model, construct a thermodynamic model of the connection terminal under different temperature, current, and vibration conditions. By identifying the heat diffusion characteristics, current conduction characteristics of the connection terminal, and the impact of vibration on the terminal material, perform thermo-electric-vibration multi-physics field coupling analysis. Through multi-physics field coupling analysis, the thermal response and electrical performance of the connection terminal under complex working conditions can be deeply understood, so as to evaluate its working performance in actual applications.

[0091] S55. During the analysis process, through the key correlation factors output by the deep learning model, combined with the physical model and thermodynamic principles, locate the high-temperature area through the thermal response data, use the current change and vibration data to identify the current-intensive area and the area affected by shock, and locate the areas where faults may occur to excavate the potential hot spots and fault points existing in the connection terminal and obtain the key performance parameters.

[0092] This process can effectively excavate the potential hot spots and fault points that may occur in the connection terminal 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 terminal.

[0093] In this embodiment, specifically, step S6 specifically includes:

[0094] S61. After the obtained key performance parameters are processed by standardization, they are passed as input data to the performance simulation model. Specifically, a structured data format is adopted, and each key performance parameter is input into the simulation software through an interface.

[0095] S62. According to the working environment and conditions of the connection terminal, 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 terminal under complex conditions, and a comprehensive analysis is carried out by combining multiple factors of heat, electricity, and vibration.

[0096] S63. Use the simulation software to perform thermoelectric response simulations under multiple conditions. By simulating the performance of the connection terminal under different loads and environmental conditions, analyze its temperature distribution, current conduction characteristics, and vibration effects. According to the simulation results, identify potential hot spots and fault points, and conduct result comparison and verification.

[0097] Embodiment Three:

[0098] The present invention also provides a manufacturing method for a high-power metal connection terminal, which is used to manufacture the high-power metal connection terminal as in Embodiment One. Specifically, the manufacturing method includes:

[0099] Step One: Provide metal materials and design molds, and use a numerical control machine tool to machine the preliminary shapes of the round socket component and the round head component.

[0100] According to technical requirements, select suitable metal materials for producing the connection terminal components, especially the round head component and the copper spring piece component. The round head component can select a high-strength alloy material to enhance the tensile strength and electrical conductivity, while the copper spring piece component needs to select a copper alloy material with high electrical conductivity.

[0101] Design the molds for the round head component and the square plug-in block. At the same time, for the circular ring design of the copper spring piece component, ensure that the spring pieces are arranged along the circumferential direction and leave appropriate elastic deformation space. Especially in the design of the small spring piece feet, the processing of the groove part should ensure its accuracy.

[0102] Step Two: Use injection molding or precision casting technology to manufacture the round head component, and form a stepped part and a hollow hole at one end of it.

[0103] Processing of the round socket component: According to the design drawings, cut and form the round socket component through a precision numerical control lathe. Through numerical control machine tool processing, ensure that the dimensional accuracy of the round socket component meets the design requirements.

[0104] Surface treatment: Perform surface treatment on the round socket component to ensure that the connection part is smooth and free of burrs, and reduce the frictional resistance during plugging and unplugging.

[0105] The round head component is processed with hollow holes by laser cutting technology or a micro drill press to reduce material usage and lighten the weight.

[0106] Step 3: Process the copper shrapnel component through a stamping die to ensure the shape and elastic deformation space of the shrapnel feet;

[0107] Forming of the copper shrapnel component: Using a stamping die, the copper material is stamped into a ring-shaped shrapnel according to the design requirements. According to the design of the shrapnel feet, ensure the precision of each small shrapnel and the perfect forming of the groove part during the stamping process.

[0108] Assembly of the ring structure: Arrange multiple small shrapnels in a circumferential direction and weld or bend them into a complete copper shrapnel component. Ensure the elasticity and deformation space of the small shrapnels to guarantee the connection stability.

[0109] Step 4: Assemble the copper shrapnel component into the annular groove of the round head component according to the design requirements to ensure the shrapnel fits the groove;

[0110] Combined installation: Install the copper shrapnel component into the annular groove of the round head component. Achieve precise docking through an automated assembly line to ensure the natural state of the shrapnel fits the annular groove.

[0111] Compression test of the shrapnel component: Simulate the working state. Through the compression test, ensure that the copper shrapnel component can provide appropriate elastic support force when the round head component is inserted into the round jack component and prevent excessive wear.

[0112] Step 5: Conduct conductivity and durability tests to ensure the stable connection between the round head component and the copper shrapnel component and good current conduction performance;

[0113] Conductivity test: Use a conductivity tester to detect the conductivity between the round head component and the copper shrapnel component to ensure its good current conduction ability.

[0114] Step 6: Conduct an appearance inspection and perform packaging to ensure the product quality meets the standards and prepare for shipment.

[0115] As described above, the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: they can still modify the technical solutions recorded in the foregoing embodiments, or perform equivalent replacements for some of the technical features; and these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate 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 the square plug block is provided with a hollow hole penetrating to the inside of the round head component; The second end of the round head component is provided with an annular groove, 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 width of the annular groove, and the width in a completely flattened state is larger than the width of the annular groove; The copper shrapnel assembly is in a circular shape, and 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 the arched portion in the middle is set as an arc-shaped transition surface; The small spring piece includes two symmetrically arranged spring piece feet, and both sides of the spring piece feet are respectively provided with flat surfaces, and groove parts are arranged adjacent to the flat surfaces, so that the small spring piece has deformation space.

2. 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 claim 1, 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.

3. The performance detection method of a high-power metal connection terminal according to claim 2, 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.

4. The performance detection method of a high-power metal connection terminal according to claim 3, 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.

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