Weapon interface cable applying coupler to match multi-channel signals and preparation method of weapon interface cable

Abstract

The invention discloses a weapon interface cable applying a coupler to be matched with multichannel signals and a preparation method of the weapon interface cable. The weapon interface cable comprises a coupler circuit and four coaxial contact body circuits. The method is suitable for the technical field of multi-channel signal transmission and protection matched with a coupler in a weapon interface cable. According to the cable, the possibility that the cable is matched with multi-channel signals by applying the coupler is realized through a plurality of modes such as model selection design of four coaxial contact body differential lines, differential design of signals in the coupler, crimping lap joint structure design, shielding lap joint structure design and the like. The coupler is matched with multi-channel signals, and the overall shielding is kept continuous.

Description

Technical Field

[0001] The invention belongs to the technical field of cable structures, and in particular relates to a weapon interface cable for matching multi-channel signals using a coupler and a preparation method thereof. Background Art

[0002] Weapon interface cables are special cables used in aircraft missile-borne systems. Affected by the use requirements, they face strict space control. Therefore, the design of the cables used inside must pay great attention to space saving and integration. The cable must not only have a compact size so that it can be efficiently laid out in the effective space, but also maximize its functionality through precise integrated design. There is strong electromagnetic interference in the missile-borne system during operation, and the multi-channel signals of input and output have high requirements on the real-time nature, transmission certainty, and fault tolerance of the data. The application coupler can match or adapt the impedance or characteristics between different circuits and systems, transmit signals between different circuits or systems, isolate the ground or potential difference between the input and output circuits or systems, reduce noise and interference, and improve the safety and stability of the circuit or system.

[0003] Therefore, in view of this situation, there is an urgent need for a weapon interface cable that can effectively match multi-channel signals. Summary of the invention

[0004] The object of the present invention is to provide a weapon interface cable using a coupler to match multi-channel signals, so as to solve the problems in the prior art.

[0005] The present invention is realized by the following technical scheme: a weapon interface cable using a coupler to match multi-channel signals, characterized in that it comprises a cable body, an input end and a plurality of output ends located on the body, each output end is connected to the input end through a wire and a signal line respectively; The signal line includes four coaxial contacts connected in sequence, a high-speed differential network line connected to the four coaxial contacts, and a 1553B data bus connected to the coupler; the high-speed differential network line and the 1553B data bus are connected via a crimping terminal.

[0006] Furthermore: the cable body includes a sheath layer, an insulating layer and a shielding layer arranged from the outside to the inside, as well as conductive wires and signal wires located inside.

[0007] Furthermore: a conductive cloth is provided outside the position where the high-speed differential network cable and the 1553B data bus are connected through the crimping terminal, and the two ends of the conductive cloth are electrically connected to the shielding layers on both sides of the connection position respectively.

[0008] Further: the 1553B data bus is connected to each output terminal through a coupler.

[0009] The present invention also discloses a method for preparing a weapon interface cable using a coupler to match multi-channel signals, which is characterized by comprising the steps of connecting a quad-coaxial contact body with a high-speed differential network cable, crimping the high-speed differential network cable with a 1553B data bus, and connecting the 1553B data bus with a coupler; wherein: 1) Steps for connecting the quad-coaxial contact body and the high-speed differential network cable: insert the stripped wire core into the crimping barrel of the contact body, position it, use the crimping pliers to insert the wire into the hole of the pliers, make the end of the contact contact the bottom of the crimping barrel, hold the crimping handle, and complete the crimping; 2) Crimping steps for high-speed differential network cables and 1553B data buses: insert the wire cores of the high-speed differential network cables and 1553B data buses into the corresponding crimping terminal ports in a predetermined order, and crimp the crimping terminals using crimping pliers; 3) Steps for connecting the 1553B data bus to the coupler: insert the wire cores of the 1553B data bus into the corresponding coupler terminal ports in a predetermined order and connect them by welding; the other end of the 1553B data bus connected to the output end is connected to the terminal of the connector; Finally, the wiring harness consisting of the connected signal wires and conductors is covered with a shielding sleeve and a sheath, and the parts where the shielding sleeve and the sheath are connected to the input end and the output end are shrunk and sealed with a heat shrink tube.

[0010] Further: it also includes the steps of cutting and bonding the conductive cloth in the crimping treatment area, wherein, use scissors to cut off the excess shielding layer at both ends, ensure neat cutting, clean the bonding surface, and do a good job of polishing. When pasting, the overlapping and pressurized paste should be applied, and the overlapping width should not be less than 5mm. Wrap the wire harness with 1 / 2 of the width of the winding tape to ensure uniform thickness after bonding, and keep it flat and wrinkle-free during winding.

[0011] The advantages of the present invention are as follows: This solution, through a highly integrated structure, saves space and weight while maintaining high performance. The high-speed differential network cable is fully shielded on the four coaxial contacts to form a fully enclosed shielding network for the transmission channel, thereby ensuring safe and reliable transmission performance in harsh environments. The electromagnetic coupling of the coupler and the independent transmission channel of the 1553B data bus are utilized to ensure that multi-channel signals are transmitted in different circuits and systems over short distances while maintaining continuity and integrity. The stable connection between the data bus and the high-speed differential network cable ensures smooth and unimpeded transmission of signals between the two, meeting the stringent requirements of multi-channel composite signal transmission applications for high speed, stability and reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a schematic diagram of the overall structure of the present invention; Figure 2 A schematic diagram of the connection structure of multi-channel signal lines for coupler matching; Figure 3 It is a schematic diagram of the connection structure between the high-speed differential network cable and the total number of data; Figure 4 A schematic diagram of the receiving and output signals of the coupler using the 1553B data bus; Figure 5 This is a schematic diagram of the signal line connection structure; Figure 6 It is a schematic cross-sectional view of part of the structure.

[0013] The serial numbers in the figure are as follows: 1 is the main body, 2 is the input end, 3 is the output end, 4 is the quad-coaxial contact body, 5 is the high-speed differential network cable, 6 is the coupler, 7 is the 1553B data bus, 8 is the crimping terminal, 10 is a sheath layer, 11 is an insulating layer, 12 is a shielding layer, and 13 is a conductive fabric. DETAILED DESCRIPTION

[0014] Reference Figure 1-6 The present invention discloses a weapon interface cable for matching multi-channel signals using a coupler, comprising a cable body 1, an input end 2 and a plurality of output ends 3 located on the body, each output end being connected to the input end through a wire and a signal line; The signal line includes four coaxial contacts 4 connected in sequence, a high-speed differential network line 5 connected to the four coaxial contacts, and a 1553B data bus 7 connected to a coupler 6; the high-speed differential network line and the 1553B data bus are connected via a crimping terminal 8.

[0015] Preferably, the cable body includes a sheath layer 10, an insulating layer 11 and a shielding layer 12 arranged from outside to inside, and conductive wires and signal wires located inside.

[0016] Preferably: a conductive cloth 13 is coated or wrapped outside the position where the high-speed differential network cable and the 1553B data bus are connected through the crimping terminal, and the two ends of the conductive cloth are electrically connected to the shielding layers on both sides of the connection position respectively.

[0017] Preferably: the 1553B data bus is connected to each output terminal through a coupler.

[0018] The present invention also discloses a method for preparing a weapon interface cable using a coupler to match multi-channel signals, including the steps of connecting a quad-coaxial contact body with a high-speed differential network cable, crimping the high-speed differential network cable with a 1553B data bus, and connecting the 1553B data bus with a coupler; wherein: 1) Steps for connecting the quad-coaxial contact body and the high-speed differential network cable: insert the stripped wire core into the crimping barrel of the contact body, position it, use the crimping pliers to insert the wire into the hole of the pliers, make the end of the contact contact the bottom of the crimping barrel, hold the crimping handle, and complete the crimping; 2) Crimping steps for high-speed differential network cables and 1553B data buses: insert the wire cores of the high-speed differential network cables and 1553B data buses into the corresponding crimping terminal ports in a predetermined order, and crimp the crimping terminals using crimping pliers; 3) Steps for connecting the 1553B data bus to the coupler: insert the wire cores of the 1553B data bus into the corresponding coupler terminal ports in a predetermined order and connect them by welding; the other end of the 1553B data bus connected to the output end is connected to the terminal of the connector; Finally, the wiring harness consisting of the connected signal wires and conductors is covered with a shielding sleeve and a sheath, and the parts where the shielding sleeve and the sheath are connected to the input end and the output end are shrunk and sealed with a heat shrink tube.

[0019] Among them, there is no shielding sleeve in the area corresponding to the crimping terminal, and a shielding layer is formed by wrapping with conductive cloth and electrically connected to the shielding sleeves on both sides; the end is crimped and then shrunk and sealed.

[0020] Preferably: it also includes the step of cutting and bonding the conductive cloth in the crimping treatment area. Specifically, use scissors to cut off the excess shielding layer at both ends to ensure neat cutting, clean the bonding surface, and do a good job of polishing. When pasting, the overlapped paste should be pasted and pressed firmly. The overlap width should not be less than 5mm. Wrap it on the wire harness at 1 / 2 of the width of the winding tape to ensure uniform thickness after bonding, and keep it flat and wrinkle-free during winding.

[0021] Embodiment: This embodiment discloses a weapon interface cable that uses a coupler to match multi-channel signals, including a cable body, an input end and four output ends located on the body, each output end is connected to the input end through a wire and a signal line; the input end is connected to the control system through a connector (model J599 / 26TJ20SQAPN30803G), and the output end is connected to the port of the weapon system.

[0022] The signal line refers to the path for transmitting signals, which includes four coaxial contacts connected in sequence, high-speed differential network cables connected to the four coaxial contacts, and 1553B data buses connected to the couplers; the high-speed differential network cables and the 1553B data buses are connected through crimping terminals. In this structure, the complete connection path of multi-channel signals is input signal point → four coaxial contacts → high-speed differential network cables → crimping overlap structure (crimping terminals) → coupler line → output signal point.

[0023] Among them, Figure 3 As shown in the figure, the four output high-speed differential network cables of the quad-coaxial contact body are the receiving end, which are Mux A (BM+), Mux A (BM-), Mux B (BM+), and Mux B (BM-) from top to bottom. They are connected to the coupler after being transferred through the crimping terminal. Figure 4As shown, there are two groups of couplers, each group has two receiving ends and four output ends. One of the receiving ends is connected to Mux A (BM+) and Mux A (BM-), and the other is connected to Mux A (BC); the output ends are Mux A (BM), 1# Mux A (RT), 2# MuxA (RT) and 3# Mux A (RT) (coupler B is the same, the corresponding A is B).

[0024] In this embodiment, the multi-channel signals, shielded signals and other radio frequency signals received by the weapon interface input end adopt a highly integrated design, which saves space and weight while maintaining high performance. According to the input signal characteristics, in order to improve the anti-interference and signal transmission quality of the system, a four-core aviation special high-speed differential network cable is selected and terminated with a four-coaxial contact body, and the wiring is centralized without mutual interference, simplifying the wiring process. At the same time, the high-speed differential network cable is fully shielded 360 degrees on the four-coaxial contact body to form a fully enclosed shielding network for the transmission channel, ensuring safe and reliable transmission performance in harsh environments.

[0025] Furthermore, to ensure that the high-frequency circuit signal input at the four-coaxial contact end is not distorted or attenuated during transmission, the weapon interface cable uses a coupler to maintain signal integrity. Combined with the characteristics of the weapon interface cable, the number of signals at the cable output end is greater than the number of signals at the input end. Multiple 1553B data buses are selected at the output end of the coupler to output data to the target device. The electromagnetic coupling of the coupler and the independent transmission channel of the 1553B data bus are utilized to ensure that multi-channel signals are transmitted in different circuits and systems over short distances while maintaining continuity and integrity.

[0026] Furthermore, a stable connection between the data bus and the high-speed differential network cable is achieved. The crimping terminal is accurately installed at the end of the data bus, and the core of the high-speed differential network cable is inserted into the corresponding crimping terminal slot according to the established color sequence and arrangement rules. The crimping terminal tightly wraps the core of the network cable through the pressure applied by the professional crimping tool to form a strong and reliable electrical connection, ensuring a stable physical connection between the data bus and the high-speed differential network cable, ensuring smooth and unimpeded transmission of signals between the two, and meeting the stringent requirements of multi-channel composite signal transmission applications for high speed, stability and reliability.

[0027] Furthermore, high-quality conductive cloth materials are used, through precision cutting and laminating processes, to be applied to the transfer area that requires shielding protection. The excellent conductivity and good flexibility of the conductive cloth material are used to effectively form a continuous electromagnetic shielding layer to block the intrusion of external electromagnetic interference signals and prevent the leakage of internal electromagnetic energy. The electromagnetic compatibility of the cable is improved in the data bus and high-speed differential network cable crimping area, ensuring the accuracy and stability of multi-channel composite signal transmission, and providing a reliable protective barrier for weapon interface cables.

[0028] The preparation method of this embodiment is as follows: The cable preparation method includes the following steps: cable cutting, laser marking, short-circuiting and switching, bundled sleeve insertion, wire processing, crimping coaxial contact assembly, tail attachment processing and shrinking. Among them: Automatic unloading steps: The unloading machine can automatically strip the insulation of the wire ends and mark the wires with wire numbers or models according to the connection needs. The assemblers can directly crimp or weld the wires to the corresponding holes, reducing the use of identification sleeves and speeding up the wiring harness processing progress.

[0029] Logo printing steps: Laser engraving machine and thermal transfer printer can meet various logo printing needs Automatic wire processing steps: Using a laser wire stripping machine can ensure zero damage to the wire core. For shielding processing, the insulation and lead-out processing of the shielding layer can be achieved through the combination of a shielding scrambler, a shielding cutter, and a shielding twister.

[0030] High-reliability crimping steps for wires: The company's crimping pliers can meet the crimping needs of all American standard contacts. Among them, the pneumatic crimping pliers can greatly reduce labor and improve production efficiency.

[0031] Assembly steps of coaxial contact body: determine the crimping pliers and locator, use a hexagonal wrench to install the locator on the crimping pliers, install the locating core of different contact body specifications on the locator knob, and rotate the knob to make the locating core of the required contact body specification in the center position, adjust the crimping gear, insert the stripped wire core into the crimping barrel of the contact body, insert the crimping piece into the hole of the pliers, make the end of the contact piece contact the bottom of the locating hole, hold the crimping handle to complete the crimping.

[0032] Short-circuit processing steps: The crimping method in the wire short-circuiting method is to use the adapter sleeve, crimping sleeve and other cable accessories to crimp the required short-circuit wire to achieve short-circuit conduction between the wires. Before selecting the crimping method for short-circuiting, you must select the appropriate specifications of crimping sleeves, crimping pliers and other components and tools, and select the correct crimping jaws to crimp the crimping parts.

[0033] Shielding treatment steps: clean the bonding surface and polish it. When pasting, it should be overlapped and pressed firmly. The overlap width is generally not less than 5mm. Wrap 1 / 2 of the width of the wrapping tape on the wire harness for protection. After bonding, the thickness is uniform, neat and beautiful. Keep it flat and wrinkle-free when winding.

[0034] Automatic shrinking steps: Use an automatic heat shrink machine to shrink heat shrink materials such as heat shrink tubes. The touch screen controls the heating temperature of the electric heater in the form of human-computer dialogue. The heating length and travel speed of the cable can be randomly modified. The required control parameters such as the air gun outlet temperature and feed speed can be set on the control panel.

[0035] Among them, the conductive cloth is cut and fitted in the crimping area to ensure shielding continuity. Use scissors to cut off the excess shielding layer at both ends to ensure neat cutting, clean the bonding surface, and do a good job of polishing. When pasting, the overlap should be pasted and pressed firmly. The overlap width is generally not less than 5mm. Wrap the wire harness with 1 / 2 of the width of the wrapping tape for protection. After bonding, the thickness is uniform, neat and beautiful, and it should be kept flat and wrinkle-free when winding.

[0036] In this embodiment, a four-coaxial contact body termination network cable structure is innovatively introduced to achieve highly integrated wiring. This four-coaxial line design not only greatly saves space resources and accommodates more complex signal transmission lines in a limited space, but also effectively enhances the signal's anti-interference ability and transmission stability through the unique structure of the four-coaxial.

[0037] The technology of terminating the 1553B data bus with a coupler is introduced, and the characteristics of the coupler and the 1553B data bus are cleverly used to solve the problem of transmitting the signal feedback from one input end to multiple output ends, thus realizing the accurate distribution and transmission of the signal. The coupler can not only effectively isolate the interference between the output ends, but also ensure that the signal strength and quality can remain consistent when receiving the signal.

[0038] The crimping terminal is accurately installed at the end of the data bus, and at the same time, the core of the high-speed differential network cable is inserted into the corresponding crimping terminal slot according to the established color sequence and arrangement rules. Pressure is applied through professional crimping tools, and the crimping terminal tightly wraps the core of the network cable to form a strong and reliable electrical connection, ensuring a stable physical connection between the data bus and the high-speed differential network cable, ensuring smooth and unimpeded transmission of signals between the two, and meeting the stringent requirements of multi-channel composite signal transmission applications for high speed, stability and reliability.

[0039] High-quality conductive cloth material is used, through precision cutting and laminating process, to be applied to the transfer area that needs shielding protection. The excellent conductivity and good flexibility of the conductive cloth material are used to effectively form a continuous electromagnetic shielding layer to block the intrusion of external electromagnetic interference signals and prevent the leakage of internal electromagnetic energy. The electromagnetic compatibility of the cable is improved in the data bus and high-speed differential network cable crimping area, ensuring the accuracy and stability of multi-channel composite signal transmission, and providing a reliable protective barrier for weapon interface cables.

Claims

1. A weapon interface cable using a coupler to match multi-channel signals, characterized in that: It includes a cable body, an input end and a plurality of output ends located on the body, and each output end is connected to the input end through a wire and a signal line respectively; The signal line includes four coaxial contacts connected in sequence, a high-speed differential network line connected to the four coaxial contacts, and a 1553B data bus connected to the coupler; The high-speed differential network cable and the 1553B data bus are connected via crimp terminals.

2. A weapon interface cable for matching multi-channel signals using a coupler according to claim 1, characterized in that: The cable body comprises a sheath layer, an insulating layer and a shielding layer arranged from the outside to the inside, as well as a conductor and a signal line located inside.

3. A weapon interface cable for matching multi-channel signals using a coupler according to claim 1, characterized in that: Conductive cloth is arranged outside the position where the high-speed differential network cable and the 1553B data bus are connected through the crimping terminal, and the two ends of the conductive cloth are electrically connected to the shielding layers on both sides of the connection position respectively.

4. A weapon interface cable for matching multi-channel signals using a coupler according to claim 1, characterized in that: The 1553B data bus is connected to each output terminal after passing through a coupler.

5. A method for preparing a weapon interface cable using a coupler to match multi-channel signals, characterized in that: The method includes the steps of connecting a quad-coaxial contact body with a high-speed differential network cable, crimping the high-speed differential network cable with a 1553B data bus, and connecting the 1553B data bus with a coupler; wherein: 1) Steps for connecting the quad-coaxial contact body and the high-speed differential network cable: insert the stripped wire core into the crimping barrel of the contact body, position it, use the crimping pliers to insert the wire into the hole of the pliers, make the end of the contact contact the bottom of the crimping barrel, hold the crimping handle, and complete the crimping; 2) Crimping steps for high-speed differential network cables and 1553B data buses: insert the wire cores of the high-speed differential network cables and 1553B data buses into the corresponding crimping terminal ports in a predetermined order, and crimp the crimping terminals using crimping pliers; 3) Steps for connecting the 1553B data bus to the coupler: insert the wire cores of the 1553B data bus into the corresponding coupler terminal ports in a predetermined order and connect them by welding; the other end of the 1553B data bus connected to the output end is connected to the terminal of the connector; Finally, the wiring harness consisting of the connected signal wires and conductors is covered with a shielding sleeve and a sheath, and the parts where the shielding sleeve and the sheath are connected to the input end and the output end are shrunk and sealed with a heat shrink tube.

6. The method for preparing a weapon interface cable using a coupler to match multi-channel signals according to claim 5, characterized in that: It also includes the steps of cutting and pasting the conductive cloth in the crimping treatment area, wherein scissors are used to cut off the excess shielding layer at both ends to ensure neat cutting, clean the bonding surface, and do a good job of polishing. When pasting, the overlapped paste should be pasted and pressed firmly, with an overlap width of not less than 5mm. The wrapping tape is wrapped around the wire harness at 1 / 2 of the width to ensure uniform thickness after bonding, and to keep it flat and wrinkle-free during winding.

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