A method of manufacturing a server shield cable

Abstract

The application relates to a manufacturing method of a server shielding cable in the field of information technology, which comprises the following steps: after the cable structure is determined, precise extrusion and braiding processes are adopted to manufacture the cable, temperature control in the production process is strictly controlled to be in the range of 150 DEG C to 200 DEG C, pressure parameter control is in the range of 0.5 to 1.5 MPa, the size precision and consistency of the cable are ensured, online detection and quality control technologies are used to timely find and eliminate manufacturing defects, and the qualified rate and reliability of the cable are improved; after the manufacturing is completed, the cable is subjected to wiring design, three-dimensional wiring simulation technology is adopted to optimize the wiring path and bending radius of the cable in a narrow space, an adjustable tension pulley guide device and an elastic fixing clamp are designed, stress concentration of the cable in the wiring process is reduced, the service life of the cable is prolonged, and the overall structure of the cable is further optimized according to the wiring design result to adapt to the requirements of the 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 more particularly to a method for manufacturing a server shielded cable. Background Art

[0002] When routing shielded server cables within confined spaces, they are often subjected to external forces, compression and stretching, as well as frequent bending and twisting. This places high demands on the cables' mechanical load-bearing capacity, anti-interference capabilities, and flexibility. In this situation, optimizing cable thickness to accommodate the tight space while maintaining performance has become a pressing technical challenge.

[0003] On the one hand, to improve the mechanical load-bearing capacity and anti-interference capabilities of cables, it is usually necessary to increase cable thickness and strengthen the design of shielding and insulation layers. However, excessively thick cables can make routing difficult, especially in confined spaces, where they take up more space and increase wiring complexity. Furthermore, thick cables are more susceptible to external compression and stretching, leading to cable damage.

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

[0005] Therefore, the challenge of optimizing cable thickness while maintaining the mechanical load-bearing and anti-interference capabilities of server shielded cables, while also balancing flexibility and ease of routing, presents a complex technical challenge. This requires in-depth research and innovation in cable material selection, structural design, and manufacturing processes to find an optimal solution that balances all performance requirements and meets the demands of server shielded cable routing within confined spaces. 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. Based on 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. A multi-layer shielding structure design is adopted, and the braiding angle and winding density are optimized to ensure that the shielding layer coverage reaches 85% to 95%, thereby increasing the cable's shielding effectiveness to more than 60 decibels compared to the baseline value of unshielded cables.

[0008] S2, according to the above material selection, the cable insulation layer is designed, and high flame-retardant and high pressure-resistant strength insulation materials such as cross-linked polyethylene and polyvinyl chloride are selected, the pressure-resistant strength of the cable is improved to more than 1,000 volts, the radial size of the cable is reduced by optimizing the thickness and uniformity of the insulation layer, wiring in a narrow space is facilitated, and meanwhile, high-strength shielding layer materials and outer sheath materials are selected, and a flexible cable support device is designed, so that the mechanical strength and flexibility of the cable are further enhanced;

[0009] S3, after determining the cable structure, precise extrusion and braiding process are used for manufacturing, temperature and pressure parameters in the production process are strictly controlled, the temperature is controlled in the range of 150 DEG C to 200 DEG C, the pressure is controlled in the range of 0.5 to 1.5 MPa, the size accuracy and consistency of the cable are ensured, online detection and quality control technology are used to find and eliminate manufacturing defects in time, and the qualified rate and reliability of the cable are improved;

[0010] S4, after manufacturing, the cable is designed, three-dimensional wiring simulation technology is used to optimize the wiring path and bending radius of the cable in a narrow space, an adjustable tension pulley guide device and an elastic fixing clamp are designed, stress concentration of the cable in the wiring process is reduced, the service life of the cable is improved, and the overall structure of the cable is further optimized according to the wiring design result to adapt to the requirements of the actual wiring environment;

[0011] S5, by comprehensively considering the material characteristics and geometric parameters of the conductor, the insulation layer, the shielding layer and the outer sheath, three-dimensional modeling and performance simulation are carried out by using computer-aided design software, the overall structure of the cable is optimized, and the cable meets the following specific performance index requirements: the mechanical bearing capacity is not less than 1,000 Newton, the anti-interference ability is not less than 60 decibels, the flexibility is equal to 7.5 times of the outer diameter of the cable, through the series of steps, high-performance design and manufacturing of the server shielding cable are realized.

[0012] The technical scheme provided by the embodiment of the application can include the following beneficial effects:

[0013] This invention discloses a method for manufacturing a shielded server cable. This method utilizes high-strength conductor materials and highly elastic, flame-retardant, and compressive-strength insulating materials. It employs a multi-layer insulation and shielding structure, combined with shielding materials featuring high conductivity and high magnetic permeability. The braiding angle and winding density are optimized to achieve a shielding layer coverage of 85% to 95%. Through precision extrusion and braiding processes, strict control of temperature and pressure parameters, and optimized wiring paths using three-dimensional wiring simulation technology, along with the design of tension-adjustable pulley guides and elastic fixing fixtures, the method achieves cable tensile strength of no less than 1,000 Newtons, shielding effectiveness of no less than 60 decibels, and a minimum bend radius equal to 7.5 times the cable's outer diameter. This method effectively addresses the challenges of server cabling in complex environments and improves the reliability and service life of the cable. DETAILED DESCRIPTION

[0014] The following will be described in detail with reference to 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 according to this embodiment includes the following steps:

[0016] S1. To meet the design requirements for server shielded cables, high-strength conductor materials and highly elastic insulation materials are selected, with a multi-layer insulation structure design 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. A multi-layer shielding structure design is adopted, with optimized braiding angles and winding density to achieve a shield coverage of 85% to 95%, raising the cable's shielding effectiveness to over 60 decibels compared to the baseline value of unshielded cables.

[0017] The physical parameters of high-strength conductor material and high-elasticity insulation material are acquired, 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 reaches the design index. For high-conductivity and high-permeability shielding materials, the genetic algorithm is used to optimize the braid angle and winding density parameters of the multi-layer shielding structure, and the electromagnetic field simulation software is used to analyze the shielding effectiveness and determine whether it meets the shielding layer coverage requirement. If not, return to the genetic algorithm for re-optimization. According to the optimized multi-layer insulation structure and multi-layer shielding structure parameters, a three-dimensional model of the server shielding cable is established, and the finite element analysis method is used to apply tensile and bending load conditions on the cable model to determine whether the stress and strain distribution of the cable under load meets the strength and stiffness requirements. For the electromagnetic compatibility performance of the three-dimensional model, the electromagnetic field simulation software is used to analyze the electromagnetic interference of the cable model, 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 structure parameters of the three-dimensional model. According to the detailed design drawings, the conductor, insulation and shielding materials are selected, and the cable samples are produced according to the design requirements of the specifications, sizes and processing technology. The physical performance test and electromagnetic compatibility performance test are carried out on the cable samples to verify whether they meet the design requirements. The cable samples that pass the test are produced in small batches, and the physical performance and electromagnetic compatibility performance of the cable are tested for long-term stability in the actual application environment. According to the test results, the cable design and production process are optimized to form a standardized server shielding cable product.

[0018] Specifically, based on the design requirements of the server shielded cable, a high-strength copper alloy conductor material was selected, with a tensile strength exceeding 300 MPa and a conductivity of 58 MS / m. A highly elastic polyolefin insulation material was selected, with a tensile strength of 30 MPa and an elongation of 500%. Using ANSYS finite element analysis software, a three-dimensional model of the insulation structure was constructed, with the number of insulation layers set to 3 to 6, with a single layer thickness of 1-5 mm. Using orthogonal experimental design, the insulation structure parameters were optimized, resulting in a value of 4 layers and a single layer thickness of 2 mm for optimal overall performance. For shielding, oxygen-free copper foil with a purity of 99.5% and a thickness of 5 to 20 mm was selected. A genetic algorithm was implemented using MATLAB software to optimize the braid angle and winding density parameters of the multi-layer shielding structure. Shielding effectiveness was analyzed using HFSS electromagnetic field simulation software, and the optimized shielding coverage reached over 90%. A 3D solid model of a shielded server cable was constructed in CATIA software. Using ANSYS finite element analysis software, tensile loads ranging from 100 to 500N and bend radii ranging from 10 to 50mm were applied to the cable model to analyze the stress and strain distribution. The stress concentration factor was less than 5, the strain distribution was uniform, and the strength and stiffness requirements were met. Electromagnetic interference analysis of the cable model was performed using CST electromagnetic compatibility software. Within the 30MHz to 1GHz frequency band, the cable's transmission attenuation reached 80 to 120dB, meeting the shielding effectiveness requirement of at least 60dB. Based on the optimized cable structural parameters, detailed design drawings were generated, including a 20mm diameter oxygen-free copper wire conductor, a 20mm diameter polyolefin insulation, and a 10mm thick copper foil shield. Cable samples were fabricated according to the drawings and tested using a physical performance testing system and an electromagnetic compatibility testing system. The physical performance test results matched the simulation results within 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 intact, 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. Select insulation materials with high flame retardancy and high compressive strength, such as cross-linked polyethylene and polyvinyl chloride, to increase the cable's compressive strength to over 1,000 volts. Optimize the thickness and uniformity of the insulation layer to reduce the cable's radial dimensions, facilitating routing in confined spaces. Furthermore, select high-strength shielding and outer sheath materials, and design a flexible cable support device to further enhance the cable's mechanical strength and flexibility.

[0020] Obtain a cable insulation material formula dataset and an electrical performance dataset, wherein the cable insulation material formula dataset includes a preset number of types of insulation material formulas, and the electrical performance dataset includes electrical performance parameters corresponding to each insulation material formula; input the cable insulation material formula dataset and the electrical performance dataset into a machine learning model, and 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 establishes a cable performance prediction model based on a data mining algorithm to predict 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 establishes a correlation between the cable failure mode and the fault cause based on a machine learning algorithm to diagnose the cause of the cable fault and provide maintenance recommendations.

[0021] Specifically, in cable design, cross-linked polyethylene (XLPE) can be used as the insulation material, boasting a breakdown voltage of up to 50 kV / mm. Finite element analysis was used to optimize the insulation layer thickness, keeping it around 3 mm. This ensures excellent insulation performance while keeping the cable outer diameter within 20 mm. The shielding layer can be braided with copper alloy wire. Taking into account both conductivity and mechanical strength, a wire diameter of 2 mm and a braid density exceeding 80% were selected. TPU is used for the outer sheath, boasting a wear resistance over 10 times that of PVC and excellent acid, alkali, and oil resistance. Through 3D modeling and simulation analysis, the geometry and layout of the support clips were optimized, allowing for ±30° bending while maintaining cable fixing spacing within 500 mm. A performance prediction model was developed using a support vector machine algorithm, taking insulation material formulation parameters as input and breakdown voltage and volume resistivity as output. Formula optimization using a genetic algorithm resulted in experimental validation, resulting in a 20% increase in breakdown voltage and an order of magnitude increase in volume resistivity. Using ANSYS software, a three-dimensional finite element model of the cable was constructed to analyze stress distribution under 100N tension and ±90° bending conditions. Using a topology optimization algorithm, the cable structural parameters were optimized, reducing maximum stress by 30% and increasing fatigue life by over 50%. By collecting data from the cable production and usage processes, a Gaussian process regression model for performance parameters was established, enabling online prediction of cable performance with prediction errors within 5%. A decision tree-based fault diagnosis model was also established, achieving a diagnostic accuracy of over 95% for common fault types, enabling intelligent management of the cable's entire lifecycle.

[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 detect and eliminate manufacturing defects, thereby improving the cable's qualification 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 optimal 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 threshold value. If the threshold value range is exceeded, the process parameters are adjusted in time; in the cable production process, the online detection technology is used to obtain the key quality data of the cable's appearance, size, and electrical performance, and the defects of the cable surface are identified by machine vision and image processing algorithms, and the quality status of the cable is comprehensively judged in combination with the electrical performance data; the decision tree algorithm is used to classify and locate the detected cable defects, and the quality of the cable is judged based on the detected defects. According to the defect type and severity, the corresponding quality control strategy and process adjustment plan are automatically generated, and the rapid elimination of defects and quality improvement are achieved 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 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 dimension 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. 2, the electric field strength and heat dissipation performance of the cable are optimal. During the extrusion process, online infrared thermometers and pressure sensors are used to collect extrusion temperature and pressure data in real time. Through the PID control algorithm, the actual values ​​are compared with the preset thresholds (temperature error ±2°C, pressure error ±5MPa), and the temperature and speed parameters of the extruder are automatically adjusted. At the same time, a machine vision algorithm based on convolutional neural networks (CNN) is used to identify defects such as scratches and bubbles 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, and scrapping 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 closed-loop control of defects. Using the association rule mining algorithm April, we analyzed the correlation between various parameters in the cable production process and quality. We found that the correlation coefficient between conductor tensile force and wire breakage rate was 85, and the correlation coefficient between extrusion temperature and insulation thickness deviation was 92, thus forming a knowledge base for quality optimization. We also used the support vector machine (SVM) algorithm to predict cable quality. The similarity between cable parameters and historical data was calculated. When the similarity fell below 7, an early warning was triggered and process parameters were automatically adjusted. Finally, using the Hadoop big data platform, we conducted batch statistical analysis of cable production data, generated quality reports and process optimization recommendations, and continuously improved cable quality.

[0025] After S4 manufacturing is complete, cable routing is designed. 3D routing simulation technology is used to optimize the routing path and bend radius of the cable within confined spaces. Adjustable tension pulley guides and elastic fixtures are designed to reduce stress concentration during routing and increase cable life. Based on the routing design results, the overall cable structure is further optimized to meet the requirements of the actual routing environment.

[0026] The three-dimensional model of the cable and the wiring space model are acquired, assembled by a three-dimensional modeling software, and an initial wiring path is obtained; a three-dimensional wiring simulation algorithm is used to optimize the initial wiring path, the three-dimensional wiring simulation algorithm includes a genetic algorithm and a particle swarm optimization algorithm, under the premise of meeting the cable bending radius constraint, the wiring path is optimized to make the cable length shortest and the wiring space utilization rate highest; according to the optimized wiring path, a pulley guide device is set at the cable turning point and the fixed point, the pulley guide device includes a pulley and an elastic pressure regulating device, the elastic pressure regulating device is a spring or an air bag, the pulley pressure is adjusted through the elastic pressure regulating device to realize the dynamic balance of the cable tension and reduce the stress concentration; an elastic clamp is designed at the cable fixed point, the elastic clamp is made of rubber or elastomer material, cable vibration and displacement are absorbed through deformation to reduce cable fatigue damage; according to the cable material characteristics and the current-carrying capacity demand, a finite element analysis method is used to optimize the cable insulation layer thickness and the shielding layer material, the electrical performance is met while the total weight of the cable is reduced, and the wiring flexibility is improved; for the harsh wiring environment, an environmental resistant material is selected, and a protective layer is coated on the surface of the cable to improve the adaptability and reliability of the cable; through virtual assembly and simulation test, 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 were first modeled using the 3D modeling software SolidWorks. The resulting model was a rectangular parallelepiped with a cable diameter of 10 mm and a wiring space measuring 1 m × 1 m × 2 m. The cable model was then assembled into the wiring space, and interference checking and other functions were used to determine an initial wiring path length of 5 m. Next, a particle swarm optimization algorithm was used with a population size of 50, an evolutionary number of 100, an inertia weight of 8, and a learning factor of 2. The wiring path was optimized, while also considering the constraint that the cable bend radius must be no less than 50 mm. The resulting optimized wiring path length was 8 m, improving wiring space utilization by 20%. Based on the optimized wiring path, a pulley guide with a diameter of 30 mm was installed at the cable bend. A spring applied a 20 N pressure to achieve dynamic balance of cable tension. A 5 mm thick rubber clamp was designed at the cable fixing point. Finite element analysis was used to optimize the clamp structure to allow for 10% deformation during cable vibration and displacement, thereby absorbing cable fatigue damage. Based on a 50A current carrying capacity, multi-physics simulation analysis of the cable insulation and shielding layers using ANSYS software resulted in an optimized insulation thickness of 1mm. Aluminum foil was selected as the shielding material. This optimized insulation thickness reduced the cable weight by 15% while meeting electrical performance requirements, improving routing flexibility. To address the harsh environments the cable may encounter, including temperatures of 60°C, salt spray corrosion, and power-frequency electromagnetic interference, a high-temperature-resistant insulation material was selected, and a 2mm-thick epoxy resin protective layer was applied to the cable surface. Accelerated life testing demonstrated that the cable can operate stably for over 10,000 hours in these harsh environments. Finally, virtual assembly and simulation testing using Creo software validated the optimized cable routing scheme, demonstrating uniform stress distribution with a maximum stress of 10MPa, meeting strength requirements. Heat dissipation simulations showed that the cable's maximum temperature did not exceed 70°C, meeting current carrying capacity requirements. Electromagnetic compatibility analysis demonstrated that the cable's shielding effectiveness reached 60dB, effectively suppressing electromagnetic interference. The resulting complete cable routing design report and installation guide provide 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 requirements: 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] Based on the application scenario and technical requirements of the server shielded cable, the materials for the cable's conductor, insulation layer, shielding layer, and outer sheath are determined. Taking into account the electrical, mechanical, and environmental performance of these materials, computer-aided design software is used to optimize the geometric parameters of the cable's conductor cross-sectional area, insulation layer thickness, shielding layer structure, and outer sheath thickness, yielding geometric parameters that balance the cable's electrical, mechanical, and cost performance. Using finite element analysis, a three-dimensional model of the cable structure is constructed based on the geometric parameters obtained from the optimized design. The stress distribution and deformation of the cable under different operating conditions are simulated to determine whether the cable's tensile strength and bending performance meet the preset requirements. If these requirements are met, the three-dimensional model of the cable structure is determined. Electromagnetic field simulation is used to analyze the shielding effectiveness of the cable shielding layer, optimizing the material selection and structural design of the shielding layer to obtain a cable shielding design with excellent electromagnetic interference resistance. Based on the cable's flexibility requirements, the material formulation and process parameters of the insulation layer and outer sheath are adjusted to improve the cable's bending performance. Based on the simulation analysis results, the cable structure was iteratively optimized over multiple rounds, balancing various performance indicators to arrive at an optimal cable design that met comprehensive performance requirements. Based on this optimal cable design, a manufacturing process and quality control standards were developed 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. 2The cable's geometric parameters include an insulation layer thickness of 8mm, a double-layer aluminum foil shielding structure, and an outer jacket thickness of 2mm. Finite element analysis evaluated the stress distribution and deformation of the cable under a tensile force of 100N and 10,000 bending cycles, ensuring a tensile strength greater than 500N and a bending radius less than 60mm. Electromagnetic compatibility performance simulations demonstrated that the double-layer aluminum foil shielding layer provides shielding effectiveness exceeding 85dB, meeting the requirements of EN55022C 1 assB. To address flexibility requirements, the material formulations of the insulation layer and outer jacket were adjusted, and 10% elastomer was added to improve the cable's bending performance, achieving a minimum bending radius of 8 times the cable's outer diameter. After five rounds of iterative optimization, the optimal design was obtained, meeting the comprehensive performance requirements. A detailed manufacturing process flow encompassing 10 steps, including extrusion, shielding, cabling, and testing, was developed. Twenty key quality control indicators and testing methods, including conductor resistance, insulation resistance, and shielding performance, were established to ensure the consistency and reliability of the cable product. 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 embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, who makes equivalent replacements or changes based on the technical solution and inventive concept of the present invention, should be covered by the scope of protection of the present invention.

Claims

1. A method for manufacturing a server shielded cable, characterized in that: The method comprises the following steps: S1. Based on 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 ensure that the shielding layer coverage reaches 85% to 95%, and the shielding effectiveness of the cable is increased to more than 60 decibels compared to the baseline value of unshielded cable. The S1 includes: Obtain the physical parameters of high-strength conductor materials and high-elasticity insulation materials, and use finite element analysis to determine the optimal number and thickness of multi-layer insulation structures to ensure that the cable's tensile and bending resistance meet the design specifications; For shielding materials with high conductivity and high magnetic permeability, a genetic algorithm is used to optimize the braiding angle and winding density parameters of the multi-layer shielding structure. The shielding effectiveness is analyzed using 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 and shielding structure parameters, a three-dimensional model of the server shielded cable was established. Using finite element analysis, tensile and bending loads were applied to the cable model to determine whether the stress and strain distribution of the cable under the loads met the strength and stiffness requirements. Based on the electromagnetic compatibility performance of the three-dimensional model, electromagnetic interference analysis is performed on the cable model using electromagnetic field simulation software to obtain the transmission attenuation curve of the cable in different frequency bands 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 based on the structural parameters of the 3D model; According to the detailed design drawings, select conductors, insulation and shielding materials, produce 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; We will conduct small batch production of qualified cable samples, conduct long-term stability tests on the cables' physical properties and electromagnetic compatibility in actual application environments, and optimize cable design and production processes based on the test results to form standardized server shielded cable products. S2. Based on the above material selection, the cable insulation layer is designed. Insulation materials with high flame retardancy and high compressive strength are selected to increase the cable's compressive strength to over one thousand volts. By optimizing the thickness and uniformity of the insulation layer, the radial dimension of the cable is reduced to facilitate wiring in confined spaces. At the same time, high-strength shielding layer materials and outer sheath materials are selected, and a flexible cable support device is designed to further enhance the cable's mechanical strength and flexibility. S3. After the cable structure is determined, precision extrusion and braiding processes are used for manufacturing. The temperature and pressure parameters during 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 testing and quality control technology are used to promptly detect and eliminate manufacturing defects, thereby improving the cable's qualification rate and reliability. S4. After manufacturing is completed, the cable wiring design is carried out. 3D wiring simulation technology is used to optimize the cable wiring path and bending radius in a narrow space. A tension-adjustable pulley guide device and elastic fixing fixture are designed to reduce stress concentration during the wiring process and increase the cable's service life. Based on the wiring design results, the overall cable structure 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 requirements: 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, wherein: 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 dataset and the electrical performance dataset 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; Optimizing the insulation material formula according to the mapping relationship 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; Inputting the training data set into a big data analysis model, the big data analysis model establishes a cable performance prediction model based on a data mining algorithm, and is used to predict the performance parameters of the cable under different working conditions; The training data set is input into a fault diagnosis model. 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 recommendations.

3. The method for manufacturing a server shielded cable according to claim 1, wherein: The S3 includes: Obtaining the material composition and geometric dimension data of the cable based on the predetermined cable structural parameters; Finite element analysis and numerical simulation technology are used to obtain the cable structure design parameters after optimizing the insulation layer thickness and conductor cross-sectional area; Based on 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. During the cable production process, online inspection technology is used to obtain key quality data on the cable's appearance, dimensions, and electrical performance. Machine vision and image processing algorithms are used to identify defects on the cable surface, and the quality of the cable is comprehensively judged based on the electrical performance data. A decision tree algorithm is used to classify and locate detected cable defects. Based on the defect type and severity, corresponding quality control strategies and process adjustment plans are automatically generated, enabling rapid defect elimination and quality improvement through closed-loop control. Obtain various parameters and quality data during the cable production process, establish a data mining model, and use association rule analysis and cluster analysis to identify key factors affecting cable quality; 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. Upload the quality data and manufacturing parameters of the cable production process to the cloud platform. Through big data analysis and visualization technology, achieve cross-workshop and cross-batch quality traceability and statistical analysis, generate quality reports and improvement suggestions, and continuously optimize the cable manufacturing process and quality management system.

4. A method for manufacturing a server shielded cable according to any one of claims 1 to 3, characterized in that: The S4 includes: Obtain the cable 3D model and wiring space model, assemble them using 3D modeling software, and obtain the initial wiring path; The initial wiring path is optimized using a 3D wiring simulation algorithm, which includes a genetic algorithm and a particle swarm optimization algorithm. The algorithm optimizes the wiring path to minimize cable length and maximize wiring space utilization while satisfying cable bending radius constraints. According to the optimized wiring path, pulley guide devices are set at the cable turning points and fixed points. The pulley guide devices include pulleys and elastic pressure regulating devices. The elastic pressure regulating devices are used to adjust the pulley pressure to achieve dynamic balance of cable tension and reduce stress concentration. Design an elastic clamp 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. Based on 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, reducing the total cable weight 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 generated.

5. A method for manufacturing a server shielded cable according to any one of claims 1 to 3, characterized in that: The S5 includes: Determine the materials for the conductor, insulation layer, shielding layer, and outer sheath of the server shielded cable based on its application scenarios and technical requirements; Combining the electrical, mechanical and environmental adaptability properties of the material, computer-aided design software is used to optimize the geometric parameters of the conductor cross-sectional area, insulation layer thickness, shielding layer structure and outer sheath thickness 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, based on the geometric parameters obtained from the optimized design, a three-dimensional model 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 a 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 outer sheath; Based on the simulation analysis results, the cable structure is optimized through 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 solution, a manufacturing process flow and quality control standards are formulated to achieve high-performance design and large-scale manufacturing of the server shielded cable.