Wiring method of electric connector

Abstract

The invention provides an electric connector wiring method. The method comprises the following steps: manufacturing a cable identifier; blanking the cable and inspecting the blanking quality of the cable; splitting the end part of the cable to expose a cable core, and pasting a cable identifier to the end part of the cable; tinning is carried out on a wire core in the cable, and tinning quality is checked; and crimping the end part of the wire core subjected to tin coating with an electric connector, and checking the crimping quality. According to the method, the wiring quality of the electric connector can be ensured, and the operation reliability of the electric connector is ensured.

Description

Technical Field

[0001] The invention relates to the field of wire connection, and in particular to a method for connecting an electric connector. Background Art

[0002] When installing electronic cabinets on board ships, it is often necessary to install electrical connectors. Common electrical connectors include two-stage electrical connectors with tail clips and two-stage electrical connectors with stuffing boxes.

[0003] As a basic component in marine equipment, electrical connectors are mainly used to transmit electrical signals and electrical energy. As the nerve center of information transmission, when wiring the electrical connector, any poor contact or breakage at any connection point on the electrical connector will have a great impact on the marine equipment system, making wrong instructions and even causing major accidents.

[0004] In order to ensure high reliability of the operation of the electrical connector, it is necessary to adopt a suitable process method for wiring the electrical connector to meet the wiring quality of the electrical connector. Summary of the invention

[0005] In view of the above-mentioned shortcomings of the related art, an object of the present invention is to provide an electrical connector wiring method for meeting the wiring quality of the electrical connector and ensuring high reliability of the operation of the electrical connector.

[0006] To achieve the above-mentioned purpose and other related purposes, the present invention provides an electrical connector wiring method, the method comprising: making a cable marker; cutting the cable and inspecting the cable cutting quality; opening the cable end to expose the wire core, and attaching the cable marker to the cable end; tinning the wire core in the cable and inspecting the tinning quality; crimping the tinned wire core end to the electrical connector and inspecting the crimping quality.

[0007] Optionally, the step of making a cable marker includes: first making a cable information table, the cable information table including the cable number and the wiring information corresponding to each cable, then cutting the cable information table to cut out the wiring information of each cable, and then sticking tape on each wiring information for later use.

[0008] Optionally, the step of cutting the cable and inspecting the quality of the cable cutting includes: according to the length and quantity of the cable to be cut, choosing to operate on a special cutting table or cut manually, and inspecting the cable after cutting. The outer insulation layer of the cable should be smooth, straight, free of bubbles, bumps, depressions, scars and aging, the wire core should be bright and free of signs of oxidation, and the cable should not have joints, broken wires, or scratches.

[0009] Optionally, the step of tinning the wire cores in the cable includes: selecting a tinning method according to the cable size and cleaning the tinned cable with absorbent cotton dipped in a small amount of anhydrous ethanol.

[0010] Optionally, if the diameter of a single cable is greater than or equal to 8 mm or the sum of the diameters of multiple wires is greater than or equal to 8 mm, dip the stripped cable in an appropriate amount of flux and vertically place it into a tin pot. The solder temperature in the tin pot is not higher than 290° C. and the tinning time is 1-2s.

[0011] Optionally, if the diameter of a single cable is less than 8 mm, evenly apply flux on the core of the cable, dip the soldering iron tip into the molten solder, slide the soldering iron tip downward to make the solder flow downward, and rotate the cable at the same time so that each side of the core is tinned.

[0012] Optionally, a non-tin-plated length of 0.5mm-1mm is left at the root of the wire core.

[0013] Optionally, the tinning quality inspection items include: cable insulation layer damage, wire core damage, wire core twisting and wire core tinning

[0014] Optionally, the step of crimping the tinned wire core end with the electrical connector includes: stripping the end insulation layer of the cable on the electrical connector to expose the wire core, and placing the wire core and the previously tinned cable into a crimping barrel for crimping, and at the same time putting a heat shrink tubing on the cable, the heat shrink tubing wrapping the junction between the crimping barrel and the cable.

[0015] Optionally, if the cross-sectional areas of the cable on the electrical connector and the previously tinned cable are different, the cross-sectional area of ​​the cable with the smaller cross-sectional area is not less than 60% of the cable with the larger cross-sectional area.

[0016] As described above, the wiring method of the electrical connector of the present invention has the following beneficial effects: since many devices need to be wired on a ship, by making cable labels, the labels can be attached to the corresponding cables for marking before wiring, thereby avoiding wiring errors during the wiring process and improving the wiring quality. In addition, by tinning the cables, oxidation can be prevented and the conductivity can be increased, thereby improving the wiring quality and ensuring the reliability of the operation of the electrical connector. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 Shown is a schematic diagram of a wiring method for an electrical connector according to an embodiment of the present invention.

[0018] Figure 2 Shown is a schematic diagram of a crimping head of an electrical connector according to an embodiment of the present invention. DETAILED DESCRIPTION

[0019] The following describes the embodiments of the present invention through specific examples, and those skilled in the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and the details in this specification can also be modified or changed in various ways based on different viewpoints and applications without departing from the spirit of the present invention.

[0020] For example, when describing the embodiments of the present invention in detail, for the sake of convenience, the cross-sectional view showing the device structure will not be partially enlarged according to the general scale, and the schematic view is only an example, which should not limit the scope of protection of the present invention. In addition, in actual production, the three-dimensional space dimensions of length, width and depth should be included.

[0021] For ease of description, spatial relational terms such as "under", "below", "below", "below", "above", "on", etc. may be used herein to describe the relationship of one element or feature shown in the drawings to other elements or features. It will be understood that these spatial relational terms are intended to include other directions of the device in use or operation in addition to the directions depicted in the drawings. In addition, when a layer is referred to as being "between" two layers, it can be the only layer between the two layers, or there can be one or more intervening layers. As used herein, "between..." means including the end point values.

[0022] In the context of the present application, a structure in which a first feature is described as being "above" a second feature may include embodiments in which the first and second features are formed in direct contact, and may also include embodiments in which additional features are formed between the first and second features, such that the first and second features may not be in direct contact.

[0023] It should be noted that the illustrations provided in this embodiment are only used to illustrate the basic concept of the present invention in a schematic manner, and therefore the illustrations only show components related to the present invention rather than being drawn according to the number, shape and size of components in actual implementation. In actual implementation, the type, quantity and proportion of each component may be changed arbitrarily, and the component layout may also be more complicated.

[0024] like Figure 1 As shown, this embodiment provides a wiring method for a two-stage electric connector with a tail clip, the method comprising the steps of:

[0025] S1. Make cable labels.

[0026] First, make a cable information table, fill in the cable information and the corresponding wiring information of each cable, as shown in Table 1.

[0027] Table 1

[0028]

[0029] The cable number indicates the number of the cable. Usually, a cable contains multiple wires. During the wiring process, each cable can be numbered for easy identification.

[0030] When wiring, the two ends of each cable will be connected to different devices or equipment respectively. In order to facilitate wiring, the two ends of the cable can be named and distinguished. Taking the cable with cable number 1 as an example, the project codes XS1 and XB1 are the names of the two ends of the cable. It can be understood that XS1 is the name of the head end of the cable, and XB1 is the name of the tail end of the cable.

[0031] The terminal number represents the specific wiring location at the beginning or end of the cable. Taking the cable with cable number 1 as an example, the project code XS1 corresponds to the terminal number 1, which means that the XS1 end of the cable needs to be wired to the terminal with terminal number 1.

[0032] When the cable information table is completed, first cut off the header information horizontally. The cut table is as follows.

[0033] Table 2

[0034] 1 XS1 1 XB1 2 2 XS2 1 K1 2 3 XS3 1 K2 2

[0035] Then cut off the cable number vertically along the table line. The cut table is as follows.

[0036] Table 3

[0037] XS1 1 XB1 2 XS2 1 K1 2 XS3 1 K2 2

[0038] Then cut off the two columns of terminal numbers in the table, keep the two columns of project codes and write the corresponding terminal numbers in the blanks of each project code, as shown in the following table. The terminal numbers initially filled in the cable information table can also be changed according to the actual working conditions. For example, in the initial preparation work, the cable end XS1 is connected to terminal number 1. If the connection object needs to be changed during the actual connection, the new terminal number can be filled in after XS1, which means that the cable end XS1 is connected to the new terminal; if the connection object does not need to be changed, the original terminal number is still filled in after XS1.

[0039] Table 4

[0040]

[0041] Then cut it in the horizontal direction, and the result after cutting is as shown in Table 5.

[0042] Table 5

[0043]

[0044] Then start cutting from the middle of the project code and the terminal number to divide it into two parts, and finally stick tape on the project code and the terminal number respectively.

[0045] Table 6

[0046]

[0047] S2. Cut the cables.

[0048] When cutting, according to the length and number of cables to be cut, the operator can choose to use a dedicated unloading table or choose manual unloading at the work station. Usually, if the unloading length is greater than 2m and the number of cables to be cut is greater than 10, it is necessary to unload on a dedicated unloading table. When operating on a dedicated unloading table, place the cable on the roller, and the operator pulls the starting end of the cable by hand to unload according to the length marked on the unloading table. When the unloading length is between 0m-3m, you can choose to cut the cable at a length of 2-3 cables, and then use scissors or side cutting pliers to divide a long cable into multiple short cables of corresponding lengths. It should be noted that during the unloading process, appropriate margins should be left for each cable, and the cable cutting should be neat without damaging the cable.

[0049] During the cutting process, the cable should be naturally straight, not twisted, and not pulled too tight. When there is no length tolerance requirement for the cable, the cable length should be a positive error, and the error should not exceed 5mm.

[0050] After the cable is cut, it is opened and marked, that is, the project code and terminal number are pasted on the end of the cable. The mark should be 5 cm away from the cable end. Single-end or double-end marking can be selected according to the structure and assembly characteristics of the chassis.

[0051] After the cutting is completed, the cable needs to be inspected to ensure that the cable meets the requirements. The inspection includes: the outer insulation layer of the cable should be smooth, straight, free of bubbles, nodules, depressions, scars and aging, and the wire core should be bright and free of oxidation marks. The cable should not have defects such as joints, broken wires, scratches, etc. The cable specifications, colors, brands, etc. meet the requirements of relevant technical documents. The cable opening length meets the requirements of relevant technical documents. When there is no tolerance requirement, the processing error is 0 to +5mm. The shielding sleeve should not be loose, and only one broken strand of the metal wire is allowed within 1m length.

[0052] S3. Tin the wires in the cable.

[0053] If the diameter of a single cable is greater than or equal to 8mm or the sum of the diameters of multiple wires is greater than or equal to 8mm, tinning with a temperature-controlled tin pot can ensure the cleanliness of the welding surface and avoid the formation of tin bridges, thereby reducing welding defects. For cables with a diameter less than 8mm, manual tinning can be used, that is, manual tinning with tin bars and pliers or using solder wire, solder paste, etc.

[0054] During the tinning process, first remove the insulation layer on each wire in the cable to expose the wire core. If manual tinning is used, gently clamp the wire insulation layer with tweezers, dip a small amount of flux with a small brush, and evenly apply it to the wire core. The flux cannot be applied to the root of the wire core. Among them, select the soldering iron tip of the protective temperature-controlled soldering iron according to the diameter of the wire core, and the temperature is controlled at 300℃±10℃, and the tinning time is not more than 3s. When tinning, dip the soldering iron tip in an appropriate amount of molten solder, place the soldering iron tip at a distance of 1mm from the root of the wire, slide the soldering iron tip downward with your hand to make the solder flow downward, and at the same time, the other hand can rotate the cable so that each side of the wire is tinned. After tinning, wipe the wire end clean with a small amount of anhydrous ethanol dipped in absorbent cotton.

[0055] If a temperature-controlled tin pot is used for tinning, dip the stripped wire into an appropriate amount of flux and place it vertically into the tin pot. The solder temperature in the tin pot should not be higher than 290°C and the tinning time should be 1-2s. After tinning, wipe the wire ends clean with absorbent cotton dipped in a small amount of anhydrous ethanol.

[0056] In this embodiment, a length of 0.5 mm to 1 mm without tinning is left at the root of the wire core.

[0057] After tinning, inspection is required to check whether the tinning steps are performed correctly. The inspection steps include: the surface of the wire core after tinning should be bright and smooth, without sharp burrs and other phenomena, and the solder should be perfectly wetted and evenly distributed. The thickness of the tin layer of the wire core after tinning should be uniform, without residue and flux adhesion. There is no solder or flux residue adsorbed on the wire insulation layer. If the solder flows into the inside of the wire insulation layer, the head should be re-stripped, twisted, and tinned immediately. It is understandable that in the process of inspecting the wire, the inspection methods include but are not limited to visual inspection, using a magnifying glass, or anatomical analysis.

[0058] After the tinning step is completed, the quality of the cable itself needs to be inspected to ensure that the cable can meet the use requirements. The inspection items of the cable include but are not limited to the damage of the insulation layer, the damage of the wire core, the twisting of the wire core, and the tinning of the wire core.

[0059] The defects of insulation layer damage are specifically manifested in: cracking, crushing, abrasions, etc. causing the insulation layer thickness to decrease, the fiber insulation layer of the cable becomes black, and the blackening section exceeds 2mm, and the plastic insulation layer of the cable changes color, and the length of the color change exceeds 2mm.

[0060] The defects of wire core damage are specifically manifested in: scratches, curling, notches, cuts, broken strands, etc., which cause the cross-sectional area of ​​the conductive wire core to decrease.

[0061] The defects of wire core twisting are specifically manifested in: wrong twisting direction of the conductive wire core, wire core damage, broken strands or single strands protruding, improper twisting tightness, etc.

[0062] The defects of tinning the wire core are: poor solder wetting, sharp edges, failure to penetrate into the multiple strands, and flux and solder adhering to the insulation layer.

[0063] S4. Crimp the tinned core ends of the cable to the electrical connector.

[0064] For example, the tinned cable is crimped with the crimping head of the electrical connector. The crimping head includes a crimping barrel. Preparation work needs to be done before crimping. The hardness of the wire core should be close to the hardness of the crimping barrel material to prevent the crimping tool from crushing the wire due to the hardness of the wire core being too soft. Among them, the material of the crimping barrel is copper or copper alloy. The crimping barrel should be clean and free of debris, and there should be no oil film, discoloration, rust, scratches, peeling of the lock layer and deformation. When the surface of the crimping barrel is silver-locked, the surface should be smooth and should not be black. When crimping, it should be preferred to crimp one cable in one crimping barrel; as long as it can meet the use requirements, two cables are allowed to be crimped in one crimping barrel, but no more than two cables; when one crimping barrel crimps two cables of different cross-sections, if the cross-sectional area of ​​the cable on the electrical connector and the previously tinned cable is different, the cross-sectional area of ​​the cable with the smaller cross-sectional area should not be less than 60% of the cable with the larger cross-sectional area; when one crimping barrel crimps cables, the lock type of the cable core should be the same.

[0065] Use a thermal stripper to strip the outermost insulation layer of the cable at the electrical connector end. The stripping length can be 3.5mm to 6.8mm. The fiber wrap insulation layer of the internal conductor of the cable is also stripped with a thermal stripper. If the fiber PVC wire is stripped, the PVC insulation layer is moved back before thermal stripping. After stripping the fiber wrap insulation layer of the internal conductor of the installation line, the PVC insulation layer is moved forward to shrink the fiber wrap insulation layer 1 to 2mm inside the PVC insulation layer. When stripping the wire, the core is not allowed to be damaged and there must be no residual insulation layer on the core.

[0066] Put the stripped cable core and the previously tinned cable into the crimping barrel. If the stripped core layers are messed up, gently twist them in the original direction to restore them to their original state, and then put the core into the corresponding crimping tool for crimping. At the same time, put a heat shrink sleeve on the cable, and the heat shrink sleeve wraps the intersection of the crimping barrel and the cable (such as Figure 2As shown, the dotted line indicates the location of the heat shrink sleeve, and a is the size of the heat shrink sleeve protruding from the crimping barrel, which is 20 mm here). When the crimping joints of the cable and the electrical connector are connected, the crimping joints of the electrical connector are inserted into the corresponding sealing body of the electrical connector for assembly.

[0067] If the crimping head needs to be removed from the sealing body, use a removal tool to insert it into the sealing body hole of the electrical connector along the cable, and try to keep the removal tool perpendicular to the end face of the sealing body, push the removal tool into place, and then take out the crimping head to be removed together with the removal tool.

[0068] After the cable and the crimping head are crimped, an inspection operation is required. The inspection steps include:

[0069] 1. Appearance inspection

[0070] After crimping, visually inspect the crimp barrel using a 5x or higher magnifying glass.

[0071] The crimping barrel should not have any damage such as rust.

[0072] The wire barrel after crimping should not have unexpected sharp edges, metal peeling, burrs, lock layer damage or cuts, etc.

[0073] The cable insulation layer should not be damaged, damaged or burnt (slight fading of the insulation layer caused by heat stripping is allowed).

[0074] The cable core should not be broken, scored or have base metal exposed.

[0075] When there is an inspection hole, the cable core should be visible through the inspection hole.

[0076] 2. The crimping parts cannot be loose, or there can be no breakage or deformity caused by crimping.

[0077] 3. The color ring is allowed to fall off partially, but it cannot affect the identification of the color of the color ring when checking the crimping barrel.

[0078] 4. The deformation of the crimping barrel is only allowed to be the indentation caused by the crimping tool. The pressing points should be uniform and the crimping parts are not allowed to bend; there should be no cracks or penetration caused by crimping.

[0079] The above embodiments are merely illustrative of the principles and effects of the present invention, and are not intended to limit the present invention. Anyone familiar with the art may modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by a person of ordinary skill in the art without departing from the spirit and technical concept disclosed by the present invention shall still be covered by the claims of the present invention.

Claims

1. A method for wiring an electrical connector, characterized in that: The method comprises: Make cable markings; Cut the cables and inspect the quality of the cables; Open the cable end to expose the core, and attach the cable marker to the cable end; Tin the wire cores in the cable and inspect the quality of the tinning; Crimp the tinned wire core ends to the electrical connector and inspect the crimping quality.

2. The electrical connector wiring method according to claim 1, characterized in that: The steps of making the cable marker include: first making a cable information table, the cable information table includes the cable number and the wiring information corresponding to each cable, then cutting the cable information table to cut out the wiring information of each cable, and then sticking adhesive tape on each wiring information for standby use.

3. The electrical connector wiring method according to claim 1, characterized in that: The steps of cutting the cables and inspecting the quality of the cables include: according to the length and quantity of the cables to be cut, selecting a special cutting table or manual cutting, inspecting the cables after cutting, the outer insulation layer of the cables should be smooth, straight, free of bubbles, bumps, depressions, scars and aging, the wire core should be bright and free of oxidation marks, and the cables should not have joints, broken wires or scratches.

4. The electrical connector wiring method according to claim 1, characterized in that: The step of tinning the wire core in the cable comprises: selecting the tinning method according to the cable size and cleaning the tinned cable with absorbent cotton dipped in a small amount of anhydrous ethanol.

5. The electrical connector wiring method according to claim 4, characterized in that: If the diameter of a single cable is greater than or equal to 8mm or the sum of the diameters of multiple wires is greater than or equal to 8mm, dip the stripped cable in an appropriate amount of flux and vertically place it into the tin pot. The solder temperature in the tin pot should not be higher than 290℃, and the tinning time should be 1-2s.

6. The electrical connector wiring method according to claim 4, characterized in that: If the diameter of a single cable is less than 8mm, apply flux evenly on the core of the cable, dip the soldering iron tip into the molten solder, slide the soldering iron tip downward to make the solder flow downward, and rotate the cable at the same time so that each surface of the core is tinned.

7. The electrical connector wiring method according to claim 4, characterized in that: Leave 0.5mm-1mm of untinned length at the root of the wire core.

8. The electrical connector wiring method according to claim 1, characterized in that: The items for inspecting the quality of tinning include: damage to the cable insulation layer, damage to the wire core, twisting of the wire core and tinning of the wire core.

9. The electrical connector wiring method according to claim 1, characterized in that: The step of crimping the tinned wire core end with the electrical connector includes: stripping the end insulation layer of the cable on the electrical connector to expose the wire core, placing the wire core and the previously tinned cable into a crimping barrel for crimping, and at the same time putting a heat shrink tubing on the cable, the heat shrink tubing wrapping the junction between the crimping barrel and the cable.

10. The electrical connector wiring method according to claim 9, characterized in that: If the cross-sectional areas of the cable on the electrical connector and the previously tinned cable are different, the cross-sectional area of ​​the cable with the smaller cross-sectional area shall not be less than 60% of the cable with the larger cross-sectional area.

Images