Manufacturing method of server shielding cable

Abstract

The invention relates to a method for manufacturing a server shielding cable in the technical field of information, which comprises the following steps of: after a cable structure is determined, manufacturing by adopting a precise extrusion and weaving process, strictly controlling the temperature in a range of 1150-2100 DEG C and the pressure parameter in a range of 0.5-1.5 MPa in the production process, and manufacturing the server shielding cable by adopting the precise extrusion and weaving process. The size precision and consistency of the cable are ensured, the manufacturing defects are found and eliminated in time by using the on-line detection and quality control technology, and the qualified rate and reliability of the cable are improved; after manufacturing is completed, cable wiring design is carried out, a three-dimensional wiring simulation technology is adopted, the wiring path and the bending radius of the cable in a narrow space are optimized, a pulley guide device and an elastic fixing clamp which can adjust tension are designed, stress concentration of the cable in the wiring process is reduced, the service life of the cable is prolonged, and according to the wiring design result, the cable is manufactured. And the overall structure of the cable is further optimized so as to meet the requirements of an actual wiring environment.

Description

Technical Field

[0001] The present invention relates to the field of information technology, in particular to a cable manufacturing technology, and in particular to a method for manufacturing a server shielded cable. Background Art

[0002] When server shielded cables are routed in a narrow space, they are often squeezed and stretched by external forces, and also need to withstand frequent bending and twisting, which places high demands on the mechanical bearing capacity, anti-interference ability, and flexibility of the cables. In this case, how to optimize the thickness design of the cables while ensuring the performance of the cables to meet the wiring requirements of a narrow space has become a technical problem that needs to be solved urgently.

[0003] On the one hand, in order to improve the mechanical bearing capacity and anti-interference ability of the cable, it is usually necessary to increase the thickness of the cable and strengthen the design of the shielding layer and the insulation layer. However, too thick a cable will make wiring difficult, especially in a small space, where thick cables will take up more space and increase the difficulty of wiring. In addition, thick cables are also more susceptible to external force compression and stretching, resulting in cable damage.

[0004] On the other hand, in order to improve the flexibility of the cable and adapt to frequent bending and twisting, it is usually necessary to reduce the thickness of the cable and use a softer material. However, a cable that is too thin cannot meet the requirements of mechanical bearing capacity and anti-interference ability, and is prone to breakage, short circuit and other problems during use, affecting the reliability and stability of the servo system.

[0005] Therefore, how to meet the mechanical load-bearing capacity and anti-interference ability of the server shielded cable, take into account the flexibility and wiring convenience of the cable, and optimize the thickness design of the cable has become a complex technical contradiction. This requires in-depth research and innovation in cable material selection, structural design, process manufacturing, etc., to find an optimal solution that takes into account various performance requirements to meet the needs of server shielded cable wiring in a small space. Summary of the invention

[0006] The present invention provides a method for manufacturing a server shielded cable, the method comprising the following steps:

[0007] S1. According to the design requirements of server shielded cables, high-strength conductor materials and high-elasticity insulation materials are selected, and a multi-layer insulation structure design is adopted to improve the cable's tensile and bending resistance. Shielding materials with high conductivity and high magnetic permeability, such as copper foil and aluminum foil, are selected, and a multi-layer shielding structure design is adopted. The braiding angle and winding density are optimized to make the coverage of the shielding layer reach 85% to 95%, and the shielding effectiveness of the cable is increased to more than 60 decibels relative to the baseline value of the unshielded cable;

[0008] S2. Design the cable insulation layer according to the above material selection, select insulating materials with high flame retardancy and high compressive strength, such as cross-linked polyethylene and polyvinyl chloride, to increase the compressive strength of the cable to more than one thousand volts, and optimize the thickness and uniformity of the insulating layer to reduce the radial size of the cable, so as to facilitate wiring in a small space. At the same time, select high-strength shielding layer materials and outer sheath materials, design flexible cable support devices, and further enhance the mechanical strength and flexibility of the cable;

[0009] S3. After the cable structure is determined, precision extrusion and braiding processes are used for manufacturing. The temperature and pressure parameters in the production process are strictly controlled. The temperature is controlled within the range of 150 to 200 degrees Celsius, and the pressure is controlled within the range of 0.5 to 1.5 MPa to ensure the dimensional accuracy and consistency of the cable. Online detection and quality control technology is used to timely discover and eliminate manufacturing defects and improve the qualification rate and reliability of the cable.

[0010] S4. After manufacturing, the cable wiring design is carried out. The 3D wiring simulation technology is used to optimize the cable wiring path and bending radius in a narrow space. The pulley guide device and elastic fixing clamp with adjustable tension are designed to reduce the stress concentration of the cable during the wiring process and increase the service life of the cable. According to the wiring design results, the overall structure of the cable is further optimized to meet the requirements of the actual wiring environment;

[0011] S5. By comprehensively considering the material properties and geometric parameters of the conductor, insulation layer, shielding layer and outer sheath, using computer-aided design software for three-dimensional modeling and performance simulation, the overall structure of the cable is optimized to ensure that the cable meets the following specific performance indicators: the tensile strength in mechanical bearing capacity is not less than one thousand Newtons, the shielding effectiveness in anti-interference ability is not less than sixty decibels, and the minimum bending radius in flexibility is equal to 7.5 times the outer diameter of the cable. Through this series of steps, high-performance design and manufacturing of server shielded cables can be achieved.

[0012] The technical solution provided by the embodiment of the present invention may have the following beneficial effects:

[0013] The present invention discloses a method for manufacturing a server shielded cable, which selects high-strength conductor materials and insulating materials with high elasticity, high flame retardancy and high compressive strength, and adopts a multi-layer insulation and shielding structure, combined with shielding materials with high conductivity and high magnetic permeability, and optimizes the braiding angle and winding density, so that the coverage rate of the shielding layer reaches 85% to 95%. Through precision extrusion and braiding processes, strictly controlling temperature and pressure parameters, and optimizing the wiring path using three-dimensional wiring simulation technology, designing a pulley guide device and an elastic fixing fixture with adjustable tension, the performance indicators of the cable tensile strength not less than one thousand Newtons, the shielding effectiveness not less than sixty decibels, and the minimum bending radius equal to 7.5 times the outer diameter of the cable are finally achieved, effectively solving the problem of server wiring in complex environments and improving the reliability and service life of the wiring. DETAILED DESCRIPTION

[0014] The following will be described clearly and in detail in conjunction with the technical solutions in the embodiments of the present invention. The described embodiments are only a part of the embodiments of the present invention.

[0015] A method for manufacturing a server shielded cable in this embodiment includes the following steps:

[0016] S1. According to the design requirements of server shielded cables, high-strength conductor materials and high-elasticity insulation materials are selected, and multi-layer insulation structure design is adopted to improve the cable's tensile and bending resistance. Shielding materials with high conductivity and high magnetic permeability, such as copper foil and aluminum foil, are selected, and multi-layer shielding structure design is adopted. The braiding angle and winding density are optimized to make the coverage of the shielding layer reach 85% to 95%, and the shielding effectiveness of the cable is increased to more than 60 decibels relative to the baseline value of the unshielded cable.

[0017] The physical parameters of high-strength conductor materials and high-elasticity insulation materials are obtained, and the finite element analysis method is used to determine the optimal number of layers and thickness of the multi-layer insulation structure, so that the tensile and bending resistance of the cable can meet the design indicators. For shielding materials with high conductivity and high magnetic permeability, the genetic algorithm is used to optimize the braiding angle and winding density parameters of the multi-layer shielding structure. The shielding effectiveness is analyzed by electromagnetic field simulation software to determine whether the shielding layer coverage requirements are met. If not, the genetic algorithm is returned to re-optimize. According to the optimized multi-layer insulation structure and multi-layer shielding structure parameters, a three-dimensional model of the server shielded cable is established. The finite element analysis method is used to apply tensile and bending load conditions to the cable model to determine whether the stress and strain distribution of the cable under the load meets the strength and stiffness requirements. For the electromagnetic compatibility performance of the three-dimensional model, the electromagnetic interference analysis of the cable model is performed through the electromagnetic field simulation software, and the transmission attenuation curve of the cable in different frequency bands is obtained to determine whether the shielding effectiveness of the cable meets the design requirements. If the strength, stiffness and electromagnetic compatibility performance of the cable model meet the design requirements, the detailed design drawings of the cable are generated according to the structural parameters of the three-dimensional model. According to the detailed design drawings, we select conductors, insulation and shielding materials, make cable samples according to the specifications and processing technology required by the design, and conduct physical performance and electromagnetic compatibility tests on the cable samples to verify whether they meet the design requirements. We produce small batches of qualified cable samples, conduct long-term stability tests on the physical properties and electromagnetic compatibility of the cables in the actual application environment, and optimize the cable design and production process based on the test results to form standardized server shielded cable products.

[0018] Specifically, according to the design requirements of the server shielded cable, high-strength copper alloy conductor materials are selected, whose tensile strength can reach more than 300MPa and conductivity can reach 58MS / m; high-elastic polyolefin insulation materials are selected, whose tensile strength can reach 30MPa and elongation can reach 500%. Through ANSYS finite element analysis software, a three-dimensional model of the insulation structure is established, and the number of insulation layers is set to 3 to 6, and the thickness of a single layer is 1-5mm. Through the orthogonal experimental design method, the insulation structure parameters are optimized, and the number of insulation layers with the best comprehensive performance is 4 layers and the thickness of a single layer is 2mm. For shielding materials, oxygen-free copper foil with a purity of 99.5% and a thickness of 5 to 20mm is selected; MATLAB software programming is used to implement genetic algorithms to optimize the braiding angle and winding density parameters of the multi-layer shielding structure, and the shielding effectiveness is analyzed through HFSS electromagnetic field simulation software. The optimized shielding layer coverage can reach more than 90%. A three-dimensional solid model of the server shielded cable was established in CATIA software. Through ANSYS finite element analysis software, a tensile load of 100 to 500N and a bending radius of 10 to 50mm were applied to the cable model to analyze the stress and strain distribution of the cable. The stress concentration factor was less than 5, and the strain was evenly distributed, meeting the strength and stiffness requirements. CST electromagnetic compatibility software was used to analyze the electromagnetic interference of the cable model. In the frequency band of 30MHz to 1GHz, the transmission attenuation of the cable can reach 80 to 120dB, meeting the shielding effectiveness requirement of more than 60dB. According to the optimized cable structure parameters, the detailed design drawings of the cable were generated, including the conductor using oxygen-free copper wire with a diameter of 20mm, the insulation using polyolefin material with a diameter of 20mm, and the shielding using 10mm thick copper foil. The cable samples were made according to the drawings, and the cable samples were tested through the physical performance test system and the electromagnetic compatibility test system. The error between the physical performance test results and the simulation results was less than 5%, and the electromagnetic compatibility test results met the design requirements. The cable samples that pass the test are mass-produced in 100-meter batches and work continuously for 1,000 hours in the server system. The cable appearance is not damaged, and there is no obvious change in physical properties and electromagnetic compatibility performance indicators. The optimized server shielded cable products can be put into mass production.

[0019] S2. Design the cable insulation layer based on the above material selection. Use highly flame-retardant and high-voltage-resistant insulation materials, such as cross-linked polyethylene and polyvinyl chloride, to increase the cable's voltage-resistant strength to more than one thousand volts. Optimize the thickness and uniformity of the insulation layer, reduce the radial size of the cable, and facilitate wiring in a small space. At the same time, select high-strength shielding layer materials and outer sheath materials, and design flexible cable support devices to further enhance the mechanical strength and flexibility of the cable.

[0020] Obtain a cable insulation material formula data set and an electrical performance data set, wherein the cable insulation material formula data set includes a preset number of types of insulation material formulas, and the electrical performance data set includes electrical performance parameters corresponding to each insulation material formula; input the cable insulation material formula data set and the electrical performance data set into a machine learning model, wherein the machine learning model establishes a mapping relationship between the insulation material formula and the electrical performance based on a support vector machine algorithm or a neural network algorithm; optimize the insulation material formula according to the mapping relationship to obtain an optimized insulation material formula; adjust the insulation material production process parameters according to the optimized insulation material formula to obtain improved insulation material production process parameters; obtain cable production data, test data and usage data, The production data includes raw material parameters, equipment parameters and process parameters, the test data includes electrical performance parameters and mechanical performance parameters, and the usage data includes environmental parameters, load parameters and fault information; the cable production data, test data and usage data are cleaned, feature extracted and labeled to obtain a training data set; the training data set is input into a big data analysis model, and the big data analysis model is based on a data mining algorithm to establish a cable performance prediction model for predicting the performance parameters of the cable under different working conditions; the training data set is input into a fault diagnosis model, and the fault diagnosis model is based on a machine learning algorithm to establish a correlation between cable failure modes and failure causes, so as to diagnose the causes of cable failures and provide maintenance suggestions.

[0021] Specifically, in cable design, cross-linked polyethylene can be used as the insulating material, and its breakdown voltage can reach 50kV / mm. The thickness of the insulating layer can be optimized by finite element analysis and controlled to about 3mm, which can ensure the insulation performance while controlling the outer diameter of the cable within 20mm. The shielding layer can be woven with copper alloy wire. Considering the conductivity and mechanical strength, the wire diameter is selected as 2mm, and the braiding density reaches more than 80%. The outer sheath is made of TPU material, which has a wear resistance of more than 10 times that of PVC and excellent acid, alkali and oil resistance. Through three-dimensional modeling and simulation analysis, the geometry and layout of the support buckle are optimized, and the cable fixing spacing is controlled within 500mm while allowing ±30° bending. Using the support vector machine algorithm, the insulation material formula parameters are used as input, and the breakdown voltage and volume resistivity are used as output. A performance prediction model is established, and the formula is optimized by genetic algorithm. In experimental verification, the breakdown voltage is increased by 20% and the volume resistivity is increased by 1 order of magnitude. Based on ANSYS software, a three-dimensional finite element model of the cable was established to analyze the stress distribution under 100N tension and ±90° bending conditions. The cable structural parameters were optimized through the topology optimization algorithm, reducing the maximum stress by 30% and increasing the fatigue life by more than 50%. Through the data collection of cable production and use process, a Gaussian process regression model of performance parameters was established to achieve online prediction of cable performance, with the prediction error controlled within 5%. At the same time, a fault diagnosis model based on a decision tree was established, with a diagnostic accuracy of more than 95% for common fault types, realizing intelligent management of the entire life cycle of the cable.

[0022] S3. After the cable structure is determined, precision extrusion and braiding processes are used for manufacturing. The temperature and pressure parameters in the production process are strictly controlled. The temperature is controlled within the range of 150 to 200 degrees Celsius, and the pressure is controlled within the range of 0.5 to 1.5 MPa to ensure the dimensional accuracy and consistency of the cable. Online detection and quality control technology is used to promptly discover and eliminate manufacturing defects and improve the cable's pass rate and reliability.

[0023] According to the predetermined cable structure parameters, the material composition and geometric dimension data of the cable are obtained; the finite element analysis and numerical simulation technology are used to obtain the cable structure design parameters after the best insulation layer thickness and conductor cross-sectional area are optimized; according to the optimized cable structure design parameters, the cable is manufactured by precision extrusion and braiding process, and the extrusion temperature and pressure parameters are monitored in real time and compared with the preset thresholds. If the threshold range is exceeded, the process parameters are adjusted in time; in the cable production process, online detection technology is used to obtain the key quality data of the cable's appearance, size, and electrical performance, and the defects on the cable surface are identified through machine vision and image processing algorithms, and the quality status of the cable is comprehensively judged in combination with the electrical performance data; for the detected cable defects, a decision tree algorithm is used for classification and positioning, and the quality of the cable is determined based on the actual situation. According to the defect type and severity, the corresponding quality control strategy and process adjustment plan are automatically generated, and the defects are quickly eliminated and the quality is improved through closed-loop control; various parameters and quality data in the cable production process are obtained, and a data mining model is established. Through association rule analysis and cluster analysis, the key factors affecting the cable quality are mined; for abnormal working conditions and quality fluctuations in the production process, the support vector machine algorithm is used for prediction and early warning, and the quality risk is judged by real-time comparison of cable parameters and historical data, and the corresponding control measures are automatically triggered; the quality data and manufacturing parameters of the cable production process are uploaded to the cloud platform, and through big data analysis and visualization technology, cross-workshop and cross-batch quality traceability and statistical analysis are achieved, and quality reports and improvement suggestions are generated to continuously optimize the cable manufacturing process and quality management system.

[0024] Specifically, according to the material composition and geometric size data of the cable, the finite element analysis software ANSYS Maxwell was used to model and simulate the cable structure. Through parametric scanning and optimization algorithms such as genetic algorithm and particle swarm algorithm, the insulation layer thickness of 5mm and the conductor cross-sectional area of ​​50mm were obtained. 2When the cable is cut off, the electric field strength and heat dissipation performance are optimal. During the extrusion process, an online infrared thermometer and pressure sensor are used to collect extrusion temperature and pressure data in real time. The actual value is compared with the preset threshold (temperature error ±2°C, pressure error ±5MPa) through the PID control algorithm to automatically adjust the temperature and speed parameters of the extruder. At the same time, a machine vision algorithm based on a convolutional neural network (CNN) is used to identify scratches, bubbles and other defects on the cable surface, with an identification accuracy of more than 98%. Combined with electrical test data, such as insulation resistance greater than 100GΩ·m, the cable quality is comprehensively judged. For the detected defects, a decision tree model based on the C5 algorithm is used to automatically generate corresponding quality control strategies such as isolation, rework, scrapping, etc. according to the type of defect (such as conductor damage, insulation layer shedding, etc.) and severity (defect area ratio). The process parameter adjustment is triggered by the MES system to achieve defect closed-loop control. The association rule mining algorithm April was used to analyze the correlation between various parameters and quality in the cable production process. It was found that the correlation coefficient between conductor tensile force and broken wire rate was 85, and the correlation coefficient between extrusion temperature and insulation thickness deviation was 92, forming a quality optimization knowledge base. The support vector machine (SVM) algorithm was used to predict the cable quality. The similarity between cable parameters and historical data was calculated. When the similarity was less than 7, an early warning was triggered and the process parameters were automatically adjusted. Finally, the Hadoop big data platform was used to perform batch statistical analysis on cable production data, generate quality reports and process optimization suggestions, and continuously improve cable quality.

[0025] S4. After manufacturing is completed, the cable wiring design is carried out. The three-dimensional wiring simulation technology is used to optimize the wiring path and bending radius of the cable in a narrow space. The pulley guide device and elastic fixing clamp with adjustable tension are designed to reduce the stress concentration of the cable during the wiring process and increase the service life of the cable. According to the wiring design results, the overall structure of the cable is further optimized to meet the requirements of the actual wiring environment.

[0026] The three-dimensional model of the cable and the wiring space model are obtained, and assembled through the three-dimensional modeling software to obtain the initial wiring path; the initial wiring path is optimized by using a three-dimensional wiring simulation algorithm, and the three-dimensional wiring simulation algorithm includes a genetic algorithm and a particle swarm optimization algorithm. Under the premise of satisfying the cable bending radius constraint, the wiring path is optimized to minimize the cable length and maximize the wiring space utilization rate; according to the optimized wiring path, a pulley guide device is set at the cable turning point and the fixed point, and the pulley guide device includes a pulley and an elastic pressure regulating device, and the elastic pressure regulating device is a spring or an air bag. The pulley pressure is adjusted by the elastic pressure regulating device to achieve dynamic balance of cable tension and reduce stress concentration; An elastic clamp is designed for the cable fixing point. The elastic clamp is made of rubber or elastomeric material and absorbs cable vibration and displacement through deformation to reduce cable fatigue damage. The finite element analysis method is used to optimize the thickness of the cable insulation layer and the shielding layer material according to the cable material characteristics and current-carrying capacity requirements, thereby reducing the total weight of the cable while meeting the electrical performance and improving wiring flexibility. For harsh wiring environments, environmentally resistant materials are selected and a protective layer is coated on the cable surface to improve the adaptability and reliability of the cable. Through virtual assembly and simulation testing, the optimized cable wiring scheme is verified, the cable stress distribution, heat dissipation performance and electromagnetic compatibility are evaluated, and a cable wiring design report and installation guidance document are formed.

[0027] Specifically, the cable and wiring space are first modeled using the 3D modeling software SolidWorks, and a rectangular parallelepiped with a cable diameter of 10mm and a wiring space of 1m×1m×2m is obtained. Then the cable model is assembled into the wiring space, and the total length of the initial wiring path is 5m through interference checking and other functions. Then the particle swarm optimization algorithm is used, and the population size is set to 50, the evolutionary generation is 100, the inertia weight is 8, and the learning factor is 2. At the same time, the constraint that the cable bending radius is not less than 50mm is considered to optimize the wiring path. Finally, the optimized wiring path length is 8m, and the wiring space utilization rate is increased by 20%. According to the optimized wiring path, a pulley guide device with a pulley diameter of 30mm is set at the cable turning point. The spring applies a pressure of 20N to achieve dynamic balance of cable tension. A rubber clamp is designed at the cable fixing point, and the clamp thickness is 5mm. Through finite element analysis, the clamp structure is optimized so that it can produce 10% deformation when the cable vibrates and displaces, thereby absorbing cable fatigue damage. Based on the current carrying capacity of the cable of 50A, the multi-physics field simulation analysis of the cable insulation layer and the shielding layer was carried out using ANSYS software, and the thickness of the insulation layer was optimized to 1mm. Aluminum foil was selected as the shielding layer material. While meeting the electrical performance, the total weight of the cable was reduced by 15%, and the wiring flexibility was improved. In view of the harsh environment that the cable may encounter, such as 60℃ high temperature, salt spray corrosion, and power frequency electromagnetic interference, high temperature resistant insulation materials were selected, and a 2mm thick epoxy resin protective layer was coated on the cable surface. After accelerated life test, the cable can work stably for more than 10,000 hours in harsh environment. Finally, virtual assembly and simulation tests were performed by Creo software to verify the optimized cable wiring scheme. The stress distribution was uniform, and the maximum stress was 10MPa, which met the strength requirements; the heat dissipation simulation showed that the maximum temperature of the cable did not exceed 70℃, which met the current carrying capacity requirements; the electromagnetic compatibility analysis showed that the cable shielding effectiveness reached 60dB, which could effectively suppress electromagnetic interference. Finally, a complete cable wiring design report and installation guidance document were formed, providing reliable guidance for practical engineering applications.

[0028] S5. By comprehensively considering the material properties and geometric parameters of the conductor, insulation layer, shielding layer and outer sheath, using computer-aided design software for three-dimensional modeling and performance simulation, the overall structure of the cable is optimized to ensure that the cable meets the following specific performance indicators: the tensile strength in mechanical bearing capacity is not less than one thousand Newtons, the shielding effectiveness in anti-interference ability is not less than sixty decibels, and the minimum bending radius in flexibility is equal to 7.5 times the outer diameter of the cable. Through this series of steps, high-performance design and manufacturing of server shielded cables can be achieved.

[0029] According to the application scenarios and technical requirements of the server shielded cable, the materials of the conductor, insulation layer, shielding layer and outer sheath of the cable are determined. In combination with the electrical, mechanical and environmental adaptability of the materials, computer-aided design software is used to optimize the design of the conductor cross-sectional area, insulation layer thickness, shielding layer structure and outer sheath thickness geometric parameters of the cable to obtain geometric parameters that balance the electrical performance, mechanical performance and cost of the cable. Using the finite element analysis method, the cable structure is three-dimensionally modeled according to the geometric parameters obtained by the optimized design, and the stress distribution and deformation of the cable under different working conditions are simulated to determine whether the tensile strength and bending performance of the cable meet the preset requirements. If the preset requirements are met, the three-dimensional model of the cable structure is determined. Through electromagnetic field simulation, the shielding effectiveness of the cable shielding layer is analyzed, the material selection and structural design of the shielding layer are optimized, and a cable shielding layer design scheme with good anti-electromagnetic interference capability is obtained. In combination with the flexibility requirements of the cable, the bending performance of the cable is improved by adjusting the material formula and process parameters of the insulation layer and the outer sheath. According to the simulation analysis results, the cable structure is optimized for multiple rounds of iterations to balance various performance indicators and obtain the optimal cable design that meets the comprehensive performance requirements. Based on the optimal cable design, the manufacturing process and quality control standards are formulated to achieve high-performance design and large-scale manufacturing of the server shielded cable.

[0030] Specifically, in the design of the server shielded cable, electrical performance, mechanical performance and environmental adaptability were comprehensively considered, and materials such as copper conductor, cross-linked polyethylene insulation, aluminum foil shielding and PVC outer sheath were selected. Using ANSYS Maxwell software, the cable structure was 3D modeled and electromagnetic field simulated, and the conductor cross-sectional area was optimized to 5mm 2, the thickness of the insulation layer is 8mm, the shielding layer adopts a double-layer aluminum foil structure, and the thickness of the outer sheath is 2mm. Through finite element analysis, the stress distribution and deformation of the cable under 100N tension and 10,000 bending cycles were evaluated to ensure that the tensile strength of the cable is greater than 500N and the bending radius is less than 60mm. The electromagnetic compatibility performance simulation shows that the double-layer aluminum foil shielding layer can provide a shielding effectiveness of more than 85dB, meeting the requirements of the EN55022C l assB standard. In view of the flexibility requirements, the material formula of the insulation layer and the outer sheath was adjusted, and 10% of the elastomer was added to improve the bending performance of the cable. The minimum bending radius can reach 8 times the outer diameter of the cable. After 5 rounds of iterative optimization, the optimal design scheme that meets the comprehensive performance requirements was obtained. A detailed manufacturing process flow including 10 processes such as extrusion, shielding, cabling, and testing was formulated, and 20 key quality control indicators and testing methods such as conductor resistance, insulation resistance, and shielding performance were established to ensure the consistency and reliability of cable products. Through high-performance design and large-scale manufacturing, technological innovation and industrial application of server shielded cables have been achieved.

[0031] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A method for manufacturing a server shielded cable, characterized in that: The method comprises the following steps: S1. According to the design requirements of server shielded cables, high-strength conductor materials and high-elasticity insulation materials are selected, and a multi-layer insulation structure design is adopted to improve the cable's tensile and bending resistance. Shielding materials with high conductivity and high magnetic permeability are selected, and a multi-layer shielding structure design is adopted. The braiding angle and winding density are optimized to make the coverage of the shielding layer reach 85% to 95%, and the shielding effectiveness of the cable is increased to more than 60 decibels relative to the baseline value of the unshielded cable; S2. Based on the above material selection, the cable insulation layer is designed, and insulating materials with high flame retardancy and high compressive strength are selected to increase the compressive strength of the cable to more than one thousand volts. By optimizing the thickness and uniformity of the insulating layer, the radial size of the cable is reduced to facilitate wiring in a small space. At the same time, high-strength shielding layer materials and outer sheath materials are selected, and flexible cable support devices are designed to further enhance the mechanical strength and flexibility of the cable; S3. After the cable structure is determined, precision extrusion and braiding processes are used for manufacturing. The temperature and pressure parameters in the production process are strictly controlled. The temperature is controlled within the range of 150 to 200 degrees Celsius, and the pressure is controlled within the range of 0.5 to 1.5 MPa to ensure the dimensional accuracy and consistency of the cable. Online detection and quality control technology is used to timely discover and eliminate manufacturing defects and improve the qualification rate and reliability of the cable. S4. After manufacturing, the cable wiring design is carried out. The 3D wiring simulation technology is used to optimize the cable wiring path and bending radius in a narrow space. The pulley guide device and elastic fixing clamp with adjustable tension are designed to reduce the stress concentration of the cable during the wiring process and increase the service life of the cable. According to the wiring design results, the overall structure of the cable is further optimized to meet the requirements of the actual wiring environment; S5. By comprehensively considering the material properties and geometric parameters of the conductor, insulation layer, shielding layer and outer sheath, using computer-aided design software for three-dimensional modeling and performance simulation, the overall structure of the cable is optimized to ensure that the cable meets the following specific performance indicators: the tensile strength in mechanical bearing capacity is not less than one thousand Newtons, the shielding effectiveness in anti-interference ability is not less than sixty decibels, and the minimum bending radius in flexibility is equal to 7.5 times the outer diameter of the cable. Through this series of steps, high-performance design and manufacturing of server shielded cables can be achieved.

2. The method for manufacturing a server shielded cable according to claim 1, characterized in that: The S1 includes: Obtain the physical parameters of high-strength conductor materials and high-elasticity insulation materials, and use finite element analysis methods to determine the optimal number and thickness of multi-layer insulation structures, so that the tensile and bending resistance of the cable can meet the design indicators; For shielding materials with high conductivity and high magnetic permeability, genetic algorithms are used to optimize the braiding angle and winding density parameters of the multi-layer shielding structure. The shielding effectiveness is analyzed through electromagnetic field simulation software to determine whether the shielding layer coverage requirements are met. If not, the genetic algorithm is returned for re-optimization. Based on the optimized multi-layer insulation structure and multi-layer shielding structure parameters, a three-dimensional model of the server shielded cable is established. The finite element analysis method is used to apply tensile and bending load conditions to the cable model to determine whether the stress and strain distribution of the cable under the load meets the strength and stiffness requirements. According to the electromagnetic compatibility performance of the three-dimensional model, the electromagnetic interference analysis of the cable model is carried out through electromagnetic field simulation software to obtain the transmission attenuation curve of the cable in different frequency bands and determine whether the shielding effectiveness of the cable meets the design requirements; If the strength, stiffness and electromagnetic compatibility performance of the cable model meet the design requirements, the detailed design drawings of the cable are generated according to the structural parameters of the 3D model; According to the detailed design drawings, select conductors, insulation and shielding materials, make cable samples according to the specifications and processing technology required by the design, and conduct physical performance tests and electromagnetic compatibility performance tests on the cable samples to verify whether they meet the design requirements; Small batch production is carried out on cable samples that pass the test. Long-term stability tests are carried out on the physical properties and electromagnetic compatibility performance of the cables in actual application environments. The cable design and production process are optimized based on the test results to form standardized server shielded cable products.

3. The method for manufacturing a server shielded cable according to claim 1, characterized in that: The S2 includes: Acquire a cable insulation material formula data set and an electrical performance data set, wherein the cable insulation material formula data set includes a preset number of insulation material formulas, and the electrical performance data set includes electrical performance parameters corresponding to each insulation material formula; Inputting the cable insulation material formula data set and the electrical performance data set into a machine learning model, wherein the machine learning model establishes a mapping relationship between the insulation material formula and the electrical performance based on a support vector machine algorithm or a neural network algorithm; According to the mapping relationship, the insulation material formula is optimized to obtain an optimized insulation material formula; According to the optimized insulation material formula, the insulation material production process parameters are adjusted to obtain improved insulation material production process parameters; Acquire cable production data, test data and usage data, wherein the production data includes raw material parameters, equipment parameters and process parameters, the test data includes electrical performance parameters and mechanical performance parameters, and the usage data includes environmental parameters, load parameters and fault information; Performing data cleaning, feature extraction and data labeling on the cable production data, test data and usage data to obtain a training data set; The training data set is input into a big data analysis model, and the big data analysis model is based on a data mining algorithm to establish a cable performance prediction model for predicting the performance parameters of the cable under different working conditions; The training data set is input into a fault diagnosis model, which establishes a correlation between cable failure modes and failure causes based on a machine learning algorithm, so as to diagnose the causes of cable failures and provide maintenance recommendations.

4. The method for manufacturing a server shielded cable according to claim 1, characterized in that: The S3 includes: According to the predetermined cable structural parameters, the material composition and geometric dimension data of the cable are obtained; Finite element analysis and numerical simulation techniques are used to obtain the optimal cable structure design parameters after the insulation layer thickness and conductor cross-sectional area are optimized; According to the optimized cable structure design parameters, the cable is manufactured using precision extrusion and braiding processes. The extrusion temperature and pressure parameters are monitored in real time and compared with the preset thresholds. If they exceed the threshold range, the process parameters are adjusted in time. In the cable production process, online detection technology is used to obtain key quality data of the cable's appearance, size and electrical performance, and defects on the cable surface are identified through machine vision and image processing algorithms. Combined with the electrical performance data, the quality status of the cable is comprehensively judged; The decision tree algorithm is used to classify and locate the detected cable defects. According to the defect type and severity, the corresponding quality control strategy and process adjustment plan are automatically generated, and the defects are quickly eliminated and the quality is improved through closed-loop control. Obtain various parameters and quality data in the cable production process, establish a data mining model, and mine the key factors affecting cable quality through association rule analysis and cluster analysis; For abnormal working conditions and quality fluctuations in the production process, the support vector machine algorithm is used for prediction and early warning. By comparing cable parameters with historical data in real time, quality risks are determined and corresponding control measures are automatically triggered. The quality data and manufacturing parameters of the cable production process are uploaded to the cloud platform. Through big data analysis and visualization technology, quality traceability and statistical analysis across workshops and batches can be achieved, and quality reports and improvement suggestions can be generated to continuously optimize the cable manufacturing process and quality management system.

5. A method for manufacturing a server shielded cable according to any one of claims 1 to 4, characterized in that: The S4 includes: Obtain the cable 3D model and wiring space model, assemble them through 3D modeling software, and obtain the initial wiring path; The initial wiring path is optimized by using a three-dimensional wiring simulation algorithm, wherein the three-dimensional wiring simulation algorithm includes a genetic algorithm and a particle swarm optimization algorithm, and the wiring path is optimized to minimize the cable length and maximize the wiring space utilization rate under the premise of satisfying the cable bending radius constraint; According to the optimized wiring path, a pulley guide device is set at the cable turning point and the fixed point, and the pulley guide device includes a pulley and an elastic pressure regulating device. The pulley pressure is adjusted by the elastic pressure regulating device to achieve dynamic balance of cable tension and reduce stress concentration; An elastic clamp is designed at the cable fixing point. The elastic clamp is made of rubber or elastomer material and absorbs cable vibration and displacement through deformation to reduce cable fatigue damage; According to the cable material characteristics and current carrying capacity requirements, the finite element analysis method is used to optimize the cable insulation layer thickness and shielding layer material, thereby reducing the total weight of the cable while meeting the electrical performance requirements and improving wiring flexibility; In view of the harsh wiring environment, environmentally resistant materials are selected and a protective layer is applied on the cable surface to improve the adaptability and reliability of the cable; Through virtual assembly and simulation testing, the optimized cable wiring scheme is verified, the cable stress distribution, heat dissipation performance and electromagnetic compatibility are evaluated, and a cable wiring design report and installation guidance document are formed.

6. A method for manufacturing a server shielded cable according to any one of claims 1 to 4, characterized in that: The S5 includes: Determine the materials of the conductor, insulation layer, shielding layer and outer sheath of the cable according to the application scenarios and technical requirements of the server shielded cable; In combination with the electrical, mechanical and environmental adaptability properties of the material, computer-aided design software is used to optimize the conductor cross-sectional area, insulation layer thickness, shielding layer structure and outer sheath thickness geometric parameters of the cable to obtain geometric parameters that balance the electrical performance, mechanical performance and cost of the cable; Using the finite element analysis method, according to the geometric parameters obtained by the optimized design, three-dimensional modeling of the cable structure is performed to simulate the stress distribution and deformation of the cable under different working conditions, and determine whether the tensile strength and bending performance of the cable meet the preset requirements; If the preset requirements are met, determining the three-dimensional model of the cable structure; Through electromagnetic field simulation, the shielding effectiveness of the cable shielding layer is analyzed, the material selection and structural design of the shielding layer are optimized, and a cable shielding layer design scheme with good anti-electromagnetic interference capability is obtained; In combination with the flexibility requirements of the cable, the bending performance of the cable is improved by adjusting the material formula and process parameters of the insulation layer and the outer sheath; According to the simulation analysis results, the cable structure is optimized for multiple rounds of iterations to balance various performance indicators and obtain the optimal cable design that meets the comprehensive performance requirements; According to the optimal cable design scheme, a manufacturing process flow and quality control standards are formulated to achieve high-performance design and large-scale manufacturing of the server shielded cable.