Mechanical separation control device and separation method for an electrical connector

Abstract

The application discloses a mechanical separation control device and method of an electric connector, relates to the field of electric system testing, and comprises a separation device, wherein the separation device comprises a separation and insertion fixing base, a separation and insertion separation base, a force sensor, a pulling hook fixing device, a pulling hook, a stepping motor and a position sensor, the separation and insertion separation base is horizontally and slidingly connected to the separation and insertion fixing base, the stepping motor is used for driving the separation and insertion separation base to move relative to the separation and insertion fixing base, the separation and insertion separation base is connected to the pulling hook through the force sensor, and the force sensor is used for detecting pulling force information of the pulling hook; a plurality of position sensors are arranged along the moving direction of the separation and insertion separation base to detect position information of the separation and insertion separation base; the socket end of the electric connector is detachably connected to the separation and insertion fixing base, and the plug end of the electric connector is connected to the pulling hook. Controllable synchronous separation of the electric connector in the comprehensive matching test process of the electric system can be realized.

Description

Technical Field

[0001] This application belongs to the field of electrical system testing and is used to test the separation characteristics of electrical systems during the comprehensive matching test of electrical systems. Background Technology

[0002] Electrical connectors are typical electromechanical components widely used in the aerospace industry. They are fundamental components for achieving electrical connections and signal transmission between stages of a launch vehicle. Electrical connectors play a crucial role in electrical systems, and their performance directly affects the normal operation of the entire equipment system. If the electrical connectors between rocket stages fail to separate, it will interfere with the rocket's condition, affect satellite safety, or directly lead to launch failure. Statistics show that failures caused by components such as electrical connectors account for 30% of all spacecraft system failures, resulting in incalculable losses.

[0003] Research on aerospace electrical connectors in China started relatively late, and most studies focus on the reliability of individual connector connections, with less attention paid to electrical system-level testing. During integrated electrical system matching tests, multiple electrical connectors need to be separated according to the flight sequence and test procedures. Currently, this is mainly done manually with one person directing and multiple people cooperating. However, because the entire process is done manually, it causes delays in separation time, making it impossible to guarantee operation according to the flight sequence instructions, and further compromising the synchronization of system separation. This affects the quality and coverage of integrated electrical system matching tests. Summary of the Invention

[0004] The technical problem solved by this application is to overcome the shortcomings of the prior art and provide a mechanical separation control device for electrical connectors, which can realize the controllable synchronous separation of electrical connectors during the comprehensive matching test of electrical system.

[0005] This project addresses the limitation of uncontrollable start and end times in manual mechanical separation during integrated electrical system matching tests by developing a mechanical separation control device. This device can receive electrical system test commands and achieve controllable synchronous separation of multiple plugs, thus resolving the problem of poor separation synchronization.

[0006] The technical solution provided in this application is as follows:

[0007] A mechanical separation control device for an electrical connector includes a separation device, which comprises a plug fixing base, a plug separation base, a force sensor, a hook fixing device, a hook, a stepper motor, and a position sensor. The plug separation base is horizontally slidably connected to the plug fixing base. The stepper motor drives the plug separation base to move relative to the plug fixing base. The plug separation base is connected to the hook via the force sensor, which detects the pulling force information of the hook. Multiple position sensors are arranged along the moving direction of the plug separation base to detect the position information of the plug separation base. The socket end of the electrical connector is detachably connected to the plug fixing base, and the plug end of the electrical connector is connected to the hook.

[0008] The end of the connector mounting base is provided with a connector plate, and the top of the connector plate is provided with a U-shaped mounting groove. The plug end of the electrical connector is provided with a flange, which is inserted downward into the mounting groove to connect the plug end of the electrical connector to the connector plate.

[0009] It also includes a separate controller, which comprises a host computer, a switch, a motor controller, and an analog signal acquisition module;

[0010] The host computer is used to send control signals to the motor controller and the analog signal acquisition module.

[0011] A switch is used for signal exchange between a host computer, a motor controller, an analog signal acquisition module, and an electrical system.

[0012] The analog signal acquisition module receives control signals from the host computer, acquires position information from the position sensor and tension information from the tension sensor based on the control signals, and feeds back the position information from the position sensor and the tension information from the tension sensor to the host computer.

[0013] The motor controller receives control signals from the host computer, controls the driver according to the control signals, and then controls the stepper motor to move through the driver.

[0014] Three position sensors are arranged sequentially along the sliding direction of the insertion / separation base, and are, from near to far from the insertion / separation plate, the left extreme position sensor, the middle position sensor, and the right extreme position sensor.

[0015] The plug end of the electrical connector is fixedly connected to a release cable, which is used to attach a hook.

[0016] A method for separating an electrical connector, using any of the aforementioned electrical connector mechanical separation control devices, includes:

[0017] Move the connector / disconnect base to the position that triggers the left limit position sensor to reset it;

[0018] After resetting, connect the plug end of the electrical connector to the pull hook and the socket end of the electrical connector to the plug plate of the plug holder;

[0019] Move the connector separation base away from the connector plate to pre-tighten it;

[0020] After pre-tensioning is completed, the electrical connectors are separated.

[0021] The process of moving the connector release base towards the position that triggers the left limit position sensor for reset includes: the host computer sending a reset signal, which is then transmitted to the motor controller and analog signal acquisition module via a switch; the analog signal acquisition module acquiring the position information of the position sensor and sending the position signal back to the host computer; the host computer determining whether the connector release base is at the left limit position and controlling the connector release base to move towards the left limit position via the motor controller; and controlling the connector release base to move towards the right limit position via the motor controller if the position of the connector release base reaches the left limit position. Throughout the process, if the connector release base reaches a relative zero position with the left limit position, the movement stops, completing the reset.

[0022] The process of moving the connector separation base away from the connector plate for pre-tensioning includes: the host computer sending a pre-tensioning signal, which is then transmitted to the motor controller and analog signal acquisition module via a switch; the analog signal acquisition module acquiring the tension information from the tension sensor and transmitting it to the host computer via the switch; the host computer judging based on the tension information; if the tension information is <3N, the host computer controls the motor controller via the switch; the motor controller starts the stepper motor, thereby controlling the connector separation base to move until the tension information is ≥3N, at which point the pre-tensioning state is complete, and the host computer controls the stepper motor to shut down.

[0023] After the pre-tensioning is completed, the electrical connector is separated, including:

[0024] The host computer issues the separation command through the host control software, or the host computer receives the separation command input from the launch vehicle's electrical system and then issues the separation command.

[0025] The separation command is transmitted via Ethernet through the switch to the motor controller and analog signal acquisition module. The analog signal acquisition module collects the position information from the position sensor and the tension information from the force sensor, and sends the position signal to the host computer. The motor controller controls the stepper motor through the driver. The movement of the stepper motor drives the plug-in separation base to move closer to the right limit position sensor until the tension information is 0 or the position information is that the plug-in separation base has reached the right limit position sensor, causing the plug-in separation base to stop moving.

[0026] In summary, this application includes at least the following beneficial technical effects:

[0027] The designed mechanical separation control device for electrical connectors can realize the controllable separation of multiple electrical connectors on each separation surface according to the flight sequence during the integrated matching test of the electrical system. The separation consistency of each group of electrical connectors driven by the separation device is no more than 200ms, which improves the test coverage of the integrated matching test of the launch vehicle electrical system. Attached Figure Description

[0028] Figure 1 This is a block diagram of the principle.

[0029] Figure 2 For the separation process flowchart;

[0030] Figure 3 This is a schematic diagram of the external shape of the separation device;

[0031] Figure 4 This is a schematic diagram of the general three-dimensional structure of the separation device.

[0032] The following are the symbols and their meanings: 1. Insertion fixing base; 2. Insertion separation base; 3. Force sensor; 4. Hook fixing device; 5. Hook; 6. Stepper motor; 7. Insertion card plate. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments disclosed in the present invention will be described in further detail below with reference to the accompanying drawings.

[0034] This application discloses a mechanical separation control device for an electrical connector, and a schematic diagram of the electrical connector mechanical separation control device is attached. Figure 1 As shown, the mechanical separation control device for electrical connectors mainly consists of a separation controller and separation devices. The separation controller controls the movement of the separation devices, triggering sensor feedback signals to the computer to achieve closed-loop control. The entire system adopts an Ethernet architecture; the separation controller controls each level of the separation devices via Ethernet and simultaneously receives feedback signals from the sensors installed on the separation devices.

[0035] The separation device is used to separate the plug end and the socket end of the electrical connector, and the plug end and the socket end of the electrical connector are connected to each other. The plug end of the electrical connector is connected to a separation hook 5.

[0036] A schematic diagram of the separation device is attached. Figure 3 and Figure 4As shown, the separation device includes a connector fixing base 1, a connector separation base 2, a force sensor 3, a hook fixing device 4, a hook 5, a stepper motor 6, a connector clamping plate 7, and a position sensor. A separation cable is fixedly connected to the plug end of the electrical connector. The end of the hook 5 can be separated to hook the separation cable of the electrical connector. After hooking the hook 5 to the separation cable, pushing the hook fixing device 4 towards the plug end locks the hook 5, thus fixing the separation cable to the hook 5. The connector fixing base 1 is equipped with a connector clamping plate 7. A flange is provided on the outside of the plug end of the electrical connector, and the flange can be fixed inside the connector clamping plate, so that the socket end of the electrical connector is installed in the connector fixing base 1. The height of the connector clamping plate 7 can be adjusted according to the requirements of the electrical connector (0-20mm). The motor driver of the separation controller is connected to the stepper motor of the separation device via a cable, thereby controlling the stepper motor to drive the connector separation base 2 to pull the hook 5. The separation device is equipped with position sensors, and three position sensors are arranged sequentially along the sliding direction of the insertion / separation base 2. These sensors, arranged from closest to furthest from the insertion / separation plate 7, are the left extreme position sensor, the middle position sensor, and the right extreme position sensor. A tension sensor is installed between the hook 5 and the insertion / separation base 2 to collect changes in tension during the separation process.

[0037] The hook 5 is a V-shaped structure formed by bending a metal part. The tip of the V-shaped structure is connected to the split-and-connect base 2 via a steel wire rope. The force sensor 3 is connected to the steel wire rope. The open end of the V-shaped structure (i.e., the split end) is used to connect the separation cable. The hook fixing device 4 has a fixing hole, and the V-shaped structure extends into the fixing hole. Specifically, after the end of the separation cable is located inside the V-shaped structure, the hook fixing device 4 is moved towards the open end of the V-shaped structure. The hook fixing device 4 compresses the opening of the V-shaped structure until the opening clamps the separation cable. At this point, the separation cable is connected to the V-shaped structure.

[0038] When the connector release base 2 triggers the left limit position sensor, and the electrical connector is fixed on the connector mounting base 1, the hook 5 can be directly hooked onto the release cable. At this time, the tension value sensed by the force sensor 3 is 0 or close to 0. When the connector release base 2 triggers the right limit position sensor, the plug end and socket end of the electrical connector have been separated.

[0039] The modular design of the separation device described above ensures that the plug can be slidably separated without damaging the electrical connector and cable.

[0040] The separation controller comprises a host computer, a switch, a motor controller, and an analog signal acquisition module. The host computer, as the system control center, runs the control software and has functions such as local control, automatic control, reset, pre-tensioning, separation status indication, and separation force display. The switch is used for signal exchange between the host computer, the motor controller, the analog signal acquisition module, and the electrical system. The analog signal acquisition module is used to acquire position information from the position sensor and tension information from the force sensor; the motor controller controls the driver, which in turn controls the stepper motor's movement.

[0041] The separation flowchart is attached. Figure 2 As shown, during the experiment, the host computer first sends a reset signal, which is then sent to the motor controller and analog signal acquisition module via the switch. The motor controller performs a reset operation based on the signal from the analog signal acquisition module, causing the connector separation base to move to the position that triggers the left limit position sensor. Then, the flange outside the connector plug is fixed to the connector plate 7, and the separation cable is connected to the hook 5. After that, the host computer sends a pre-tensioning signal to perform pre-tensioning. The pre-tensioning signal is sent to the motor controller and analog signal acquisition module via the switch. The analog signal acquisition module collects the tension information from the tension sensor and sends it to the host computer via the switch. The host computer judges based on the tension information. If the tension information is <3N, the host computer controls the motor controller through the switch. The motor controller controls the stepper motor to start, and then controls the connector separation base 2 to move until the tension information is ≥3N, the pre-tensioning state is completed, and the host computer controls the stepper motor to turn off. The separation of the electrical connector can be performed in local control mode or automatic mode.

[0042] The electrical connector can be separated using either a local control mode or a remote control mode. In local control mode, a separation command is issued via host computer software. This command is then transmitted via Ethernet to the motor controller through a switch. The motor controller controls the stepper motor through a driver, causing the stepper motor to move and triggering the position sensor and tension sensor. The analog signal acquisition module receives the position sensor and tension sensor signals and sends them to the host computer through the switch. In remote control mode, the host computer receives the separation command signal from the launch vehicle's electrical system and performs the separation control action accordingly.

[0043] The reset operation specifically includes: the host computer first sends a reset signal, which is then sent to the motor controller and analog signal acquisition module via the switch. The analog signal acquisition module acquires the position information from the position sensor and sends the position signal to the host computer. The host computer determines whether the position of the plug-in / separation base is at the left limit position. If so, it controls the plug-in / separation base to move to the left limit position via the motor controller. If the position of the plug-in / separation base reaches the left limit position, it controls the plug-in / separation base to move to the right limit position via the motor controller. During the entire process, if the relative position with the left limit position is zero, the movement stops, and the reset is completed.

[0044] The contents not described in detail in this application specification are common knowledge to those skilled in the art.

[0045] The present application has been described in detail above with reference to specific embodiments and exemplary examples; however, these descriptions should not be construed as limiting the present application. Those skilled in the art will understand that various equivalent substitutions, modifications, or improvements can be made to the technical solutions and implementation methods of the present application without departing from the spirit and scope of the present application, and all such modifications and improvements fall within the scope of the present application. The scope of protection of the present application is determined by the appended claims.

Claims

1. A method for separating an electrical connector, characterized in that, Separation is performed using a mechanical separation control device for an electrical connector. The mechanical separation control device for an electrical connector includes: a separation device, which includes a plug fixing seat (1), a plug separation base (2), a force sensor (3), a hook fixing device (4), a hook (5), a stepper motor (6), and a position sensor. The plug separation base (2) is horizontally slidably connected to the plug fixing seat (1). The stepper motor (6) is used to drive the plug separation base (2) to move relative to the plug fixing seat (1). The plug separation base (2) is connected to the hook (5) through the force sensor (3). The position sensors include: a left extreme position sensor, a middle position sensor, and a right extreme position sensor; depending on the distance to the insertion card plate (7) of the insertion fixing seat (1), from near to far, they are the left extreme position sensor, the middle position sensor, and the right extreme position sensor; Separation methods include: Move the insert / separate base (2) to the position that triggers the left limit position sensor to reset it; After resetting, connect the plug end of the electrical connector to the hook (5) and connect the socket end of the electrical connector to the plug plate (7) of the plug fixing base (1); Move the insertion / separation base (2) away from the insertion / separation plate (7) to pre-tighten it; After pre-tensioning, the electrical connectors are disconnected; The process of moving the plug-in separation base (2) to the position that triggers the left limit position sensor to perform a reset includes: the host computer sends a reset signal, the reset signal is sent to the motor controller and analog signal acquisition module through the switch, the analog signal acquisition module acquires the position information of the position sensor and sends the position signal to the host computer, the host computer determines that if the position of the plug-in separation base is not at the left limit position, then the motor controller controls the plug-in separation base (2) to move to the left limit direction, if the position of the plug-in separation base (2) reaches the left limit position, then the motor controller controls the plug-in separation base (2) to move to the right limit position, and if the relative position with the left limit position reaches zero during the whole process, the movement stops and the reset is completed; The process of moving the insertion / separation base (2) away from the insertion / separation plate (7) for pre-tensioning includes: the host computer sending a pre-tensioning signal, which is then sent to the motor controller and analog signal acquisition module via a switch. The analog signal acquisition module collects the tension information from the tension sensor and sends it to the host computer via a switch. The host computer makes a judgment based on the tension information. If the tension information is <3N, the host computer controls the motor controller via the switch. The motor controller controls the stepper motor to start, thereby controlling the insertion / separation base (2) to move until the tension information is ≥3N, at which point the pre-tensioning state is completed, and the host computer controls the stepper motor to shut down. After the pre-tensioning is completed, the electrical connector is separated, including: The host computer issues the separation command through the host control software, or the host computer receives the separation command input from the launch vehicle's electrical system and then issues the separation command. The separation command is transmitted via Ethernet to the motor controller and analog signal acquisition module through the switch. The analog signal acquisition module collects the position information of the position sensor and the tension information of the force sensor (3), and sends the position signal to the host computer. The motor controller controls the stepper motor through the driver. The movement of the stepper motor drives the insertion and separation base (2) to move closer to the right limit position sensor until the tension information is 0 or the position information is that the insertion and separation base (2) reaches the right limit position sensor, so that the insertion and separation base (2) stops moving.

2. The method for separating an electrical connector according to claim 1, characterized in that: The mechanical separation control device for electrical connectors also includes a separation controller, which comprises a host computer, a switch, a motor controller, and an analog signal acquisition module.

3. The method for separating an electrical connector according to claim 2, characterized in that: The end of the plug fixing base (1) is provided with a plug clamp plate (7), and the top of the plug clamp plate (7) is provided with a U-shaped mounting groove. The plug end of the electrical connector is provided with a flange, which is inserted downward into the mounting groove to connect the plug end of the electrical connector to the plug clamp plate.

4. The method for separating an electrical connector according to claim 2, characterized in that: The plug end of the electrical connector is fixedly connected to a separation steel cable, which is used to hook the pull hook (5).

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