High-adaptation integrated cable testing device and testing method

Abstract

The invention discloses a high-adaptation integrated cable testing device and method, and the device comprises an upper cover plate assembly, the upper cover plate assembly is fixedly connected with connectors which are different in specification and model and are combined with key position grooves, the upper cover plate assembly is connected with a lower cover plate assembly through a side plate assembly, a socket PCB is embedded in the lower cover plate assembly, and the lower cover plate assembly is connected with a power supply through a power supply. A PCB insulating plate is arranged on one side of the socket PCB, a socket is arranged on the socket PCB, and the connector is connected with the socket through a wire. The universal upper cover plate assembly is designed, and the connectors with different specifications and models and combined key position grooves are installed on the upper cover plate assembly, so that the problem that the connectors with the same specifications and models cannot be mutually inserted due to different key positions is solved, the cable has higher adaptability with the upper cover plate assembly in the testing process, and the cost is reduced. The cable testing device designed by the invention can test a plurality of cables at the same time, and synchronous testing of the plurality of cables is realized.

Description

Technical Field

[0001] The present invention belongs to the field of cable testing, and relates to a highly adaptable integrated cable testing device and a testing method. Background Art

[0002] In modern industrial production and the manufacturing process of various electronic devices, the correctness of various cable connections is crucial. Once there are problems such as incorrect connection, missing connection, abnormal resistance, or abnormal insulation, it may affect the normal operation of the equipment to a small extent, and may even cause serious safety accidents in severe cases. Therefore, after the cable is welded, rigorous correctness detection must be carried out. Currently, the industry mainly uses two methods: manual detection and dedicated equipment detection, but both methods have certain defects.

[0003] Manual detection mainly relies on workers' rich experience and professional knowledge to judge parameters such as the connection state, resistance value, and insulation performance of the cable one by one through visual inspection and simple tool measurement. However, this method has a significant problem of low efficiency. When faced with the detection task of a large number of cables, manual detection requires a lot of time and effort, and it is difficult to meet the high-efficiency requirements of modern large-scale production. Moreover, manual detection also has some insurmountable limitations. For example, it is often impossible for manual workers to accurately identify relatively hidden welding faults such as virtual soldering and cold soldering. Virtual soldering means that only a small amount of metal is connected at the solder joint, seemingly welded, but actually the connection is not firm; cold soldering is caused by insufficient temperature or insufficient welding time during the welding process, resulting in incomplete fusion of the metal. These problems may gradually appear after the equipment has been running for a period of time, posing a huge hidden danger to the stable operation of the equipment.

[0004] Dedicated equipment detection makes up for the deficiencies of manual detection to a certain extent. Dedicated equipment usually uses advanced electronic detection technology to quickly and accurately conduct a comprehensive detection of the cable. It not only has high test efficiency but also good correctness. Through an automated detection process, a large amount of human and material resources can be saved, and the production efficiency can be greatly improved. However, dedicated equipment is not perfect either. In actual applications, due to the lack of a professional test adapter, it cannot adapt to cables with various different plugs. Cables produced by different manufacturers have a wide variety of plug specifications and models, and the key position designs are also different. This results in that when dedicated equipment faces diversified cables, it often cannot carry out detection work because it cannot achieve precise docking with the cable plug, resulting in a low utilization rate of the dedicated equipment. Moreover, in order to adapt to as many cables as possible, operators may frequently plug and unplug the equipment interface, and this frequent plugging and unplugging operation is extremely likely to cause physical damage to the equipment interface, thereby affecting the overall performance and service life of the equipment, increasing the equipment maintenance cost and downtime.

[0005] Therefore, there is an urgent need for a highly adaptable integrated cable testing device and testing method. Summary of the Invention

[0006] The purpose of the present invention is to provide a highly adaptable integrated cable testing device and testing method, which can accommodate various types of aviation plug connector heads, and then match different types of cables. It can cover 100% of the testing of circular connector cable products, so as to overcome the low efficiency of manual detection in the prior art, which is difficult to meet the needs of large-scale production, and cannot detect hidden welding faults such as virtual soldering and cold soldering. Although the special equipment has high testing efficiency and accuracy, due to the lack of professional testing adapters, it cannot adapt to cables with various plug specifications and different keyway designs, resulting in low equipment utilization rate. Frequent plugging and unplugging also damage the equipment, increasing the maintenance cost and downtime.

[0007] In order to achieve the above purpose, the present invention provides the following technical solutions to be realized:

[0008] In the first aspect, the present invention provides a highly adaptable integrated cable testing device, including an upper cover plate assembly. Different specifications and models of connectors with combined keyway slots are fixedly connected to the upper cover plate assembly. The upper cover plate assembly is connected to a lower cover plate assembly through a side plate assembly. A socket PCB board is embedded in the lower cover plate assembly. A PCB insulating plate is arranged on one side of the socket PCB board. A socket is arranged on the socket PCB board. The connector is connected to the socket through a wire. It effectively solves the problem that connectors of the same specification and model cannot be inserted into each other due to different keyways, making the cable have higher adaptability to the upper cover plate assembly during the testing process.

[0009] Furthermore, the connector is grooved with a main keyway, a first variable keyway, and a second variable keyway. The main keyway is arranged on the left side of the connector. The first variable keyway is arranged in the lower right corner of the connector. The second variable keyway is arranged in the upper right corner of the connector. The angle of the first variable keyway is 89° - 146°, and the angle of the second variable keyway is 207° - 271°. It further improves the adaptability of the connector to cable plugs with different keyway designs.

[0010] Furthermore, the lower cover plate assembly includes solder pad holes. The points of the connector are welded to the points on the solder pad holes on the socket PCB board one by one through wires. The precise point-to-point welding ensures the accuracy of the test signal transmission, and then ensures that parameters such as virtual soldering and cold soldering that cannot be detected manually can be accurately measured during the testing process. It effectively solves the bottleneck problem of undetectable errors in manual testing, greatly improves the cable testing quality, and ensures the operation stability and safety of the equipment.

[0011] Furthermore, a plurality of positioning pins are provided on both sides of the socket PCB board. The positioning pins penetrate through the lower cover assembly. The arrangement of the positioning pins enhances the stability of the installation of the socket PCB board, ensures the stability of signal transmission during the test, and avoids affecting the test results due to component loosening.

[0012] Furthermore, the side plate assembly includes a first side plate, a support frame, and a second side plate. The two first side plates are arranged on the left and right sides of the lower cover assembly, and the second side plate is arranged on the front and back sides of the lower cover assembly. The first side plate and the second side plate are connected by the support frame.

[0013] Furthermore, a number of silicone rubbers for strengthening the wire are arranged at intervals on the wire. The arrangement of the silicone rubbers strengthens the wire, prevents the wire from being damaged due to shaking, pulling, etc. during the test, ensures the stable transmission of the test signal, and improves the accuracy and stability of the test.

[0014] Furthermore, handles are provided on both sides of the upper cover assembly.

[0015] Furthermore, the socket adopts a 96ZK socket, and the socket PCB board adopts a 96ZK socket PCB board.

[0016] Furthermore, the connector is an XCF type circular connector.

[0017] In a second aspect, the present invention provides a method for using a highly adaptable integrated cable testing device. The specific steps are as follows:

[0018] Correspondingly insert the two ends of the cable to be tested onto the upper cover assembly, and then insert the socket on the lower cover assembly into the dedicated cable tester substrate to test the connection correctness of the cable.

[0019] Compared with the prior art, the present invention has the following beneficial technical effects:

[0020] The present invention provides a highly adaptable integrated cable testing device, designs a universal upper cover assembly, and installs connectors with different specifications and combined keyway slots on the upper cover assembly to solve the problem that connectors of the same specification cannot be inserted into each other due to different keyways, making the cable have higher adaptability to the upper cover assembly during the test, broadening the application range of the testing device, and matching different types of cables to reduce costs.

[0021] The cable testing device designed by the present invention can test multiple cables simultaneously, achieving synchronous testing of multiple cables, significantly improving the testing efficiency, meeting the requirements for rapid cable detection in modern large-scale production, and solving the problem of low efficiency of manual detection. At the same time, it can ensure the functionality of the dedicated testing equipment, accurately test parameter information such as virtual soldering and cold soldering that cannot be detected manually, effectively solve the bottleneck problem of undetectable errors in manual testing, greatly improve the quality of cable testing, and ensure the stability and safety of equipment operation. By designing a testing device that adapts to multiple cables, the frequent plugging and unplugging operations of the dedicated equipment due to adapting different cables are reduced, the number of insertions of the plug board for the machine interface is decreased, thereby effectively reducing the physical damage to the dedicated equipment, extending the service life of the dedicated equipment, and reducing the maintenance cost and downtime of the equipment. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 It is a schematic diagram of the cable testing device in the embodiment of the present invention.

[0023] Figure 2 It is a front view schematic diagram of the XCF type circular connector without merged key slots in the embodiment of the present invention.

[0024] Figure 3 It is a schematic diagram of the key position angle distribution of the socket of the XCF type circular connector without merged key slots in the embodiment of the present invention.

[0025] Figure 4 It is a schematic diagram of the key position angle distribution of the plug of the XCF type circular connector without merged key slots in the embodiment of the present invention.

[0026] Figure 5 It is a front view schematic diagram of the XCF type circular connector with merged key slots in the embodiment of the present invention.

[0027] Figure 6 It is a schematic diagram of the upper cover assembly of the cable testing device in the embodiment of the present invention.

[0028] Figure 7 It is a schematic diagram of the lower cover assembly of the cable testing device in the embodiment of the present invention.

[0029] Figure 8 It is a schematic diagram of the internal wiring of the cable testing device in the embodiment of the present invention.

[0030] In the figure, 1 is a connector; 1-1 is the No. 3 variable key position; 1-2 is the No. 4 variable key position; 1-3 is the main key position; 1-4 is the No. 1 variable key position; 1-5 is the No. 2 variable key position; 1-6 is the first variable key position; 1-7 is the second variable key position; 2 is the upper cover plate assembly; 2-1 is the handle; 3 is the lower cover plate assembly; 3-1 is the socket; 3-2 is the positioning pin; 3-3 is the PCB insulating board; 3-4 is the socket PCB board; 3-5 is the pad hole; 4-1 is the first side plate; 4-2 is the support frame; 4-3 is the second side plate; 5 is the silicone rubber; 6 is the wire. Detailed implementation mode

[0031] In order to enable those skilled in the art to better understand the solution of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative work shall fall within the protection scope of the present invention.

[0032] It should be noted that the terms "first", "second", etc. in the description and claims of the present invention and the above drawings are used to distinguish similar objects, and do not necessarily need to be used to describe a specific order or sequence. It should be understood that such data can be interchanged under appropriate circumstances so that the embodiments of the present invention described here can be implemented in an order other than those illustrated or described here. In addition, the terms "including" and "having" and any variations thereof are intended to cover non-exclusive inclusion. For example, a process, method, system, product or device including a series of steps or units does not necessarily have to be limited to those clearly listed steps or units, but may include other steps or units not clearly listed or inherent to these processes, methods, products or devices.

[0033] As Figure 1 As shown, a highly adaptable integrated cable testing device includes an upper cover plate assembly 2. A connector 1 with different specifications and combined key slots is fixedly connected to the upper cover plate assembly 2. The upper cover plate assembly 2 is connected to a lower cover plate assembly 3 through a side plate assembly. A socket PCB board 3-4 is embedded in the lower cover plate assembly 3. A PCB insulating board 3-3 is arranged on one side of the socket PCB board 3-4. A socket 3-1 is arranged on the socket PCB board 3-4. The connector 1 is connected to the socket 3-1 through a wire 6.

[0034] As Figures 5 to 8As shown in the figure, the connector 1 with different specifications and combined key slots is slotted with a main key slot 1-3, a first variable key slot 1-6, and a second variable key slot 1-7. The main key slot 1-3 is arranged on the left side of the connector 1, the first variable key slot 1-6 is arranged at the lower right corner of the connector 1, and the second variable key slot 1-7 is arranged at the upper right corner of the connector 1. The angle of the first variable key slot 1-6 is 89° to 146°, and the angle of the second variable key slot 1-7 is 207° to 271°. The lower cover assembly 3 includes a pad hole 3-5, and the points of the connector 1 are welded one by one with the points on the pad hole 3-5 on the socket PCB board 3-4 through a wire 6. A plurality of positioning pins 3-2 are arranged on both sides of the socket PCB board 3-4, and the positioning pins 3-2 penetrate through the lower cover assembly 3. The side plate assembly includes a first side plate 4-1, a support frame 4-2, and a second side plate 4-3. Two first side plates 4-1 are arranged on the left and right sides of the lower cover assembly 3, and the second side plate 4-3 is arranged on the front and rear sides of the lower cover assembly 3. The first side plate 4-1 and the second side plate 4-3 are connected by the support frame 4-2. A plurality of silicone rubbers 5 for strengthening the wire 6 are arranged at intervals on the wire 6. Handles 2-1 are arranged on both sides of the upper cover assembly 2. The socket 3-1 uses a 96ZK socket, and the socket PCB board 3-4 uses a 96ZK socket PCB board.

[0035] Taking the XCF type circular connector as an example, as Figure 2 、 Figure 3 and Figure 4As shown in the figure, the XCF type circular connector is divided into: main key positions 1-3, variant key position 1-4 of No. 1, variant key position 1-5 of No. 2, variant key position 1-1 of No. 3, and variant key position 1-2 of No. 4. In the figure, A, B, C, and D are the key position angles corresponding to variant key position 1-4 of No. 1, variant key position 1-5 of No. 2, variant key position 1-1 of No. 3, and variant key position 1-2 of No. 4 respectively; there are 5 different key position angles for the 4 variant key positions, which are: N key position (normal key position), X key position, Y key position, Z key position, and W key position. By calculating the angle union of the 4 variant key positions under 5 different key position angles, the angle union of variant key position 1-4 under 5 different key position angles is (105°, 100°, 110°, 95°, 90°); the angle union of variant key position 1-5 of No. 2 under 5 different key position angles is (140°, 142°, 145°, 135°, 130°); the angle union of variant key position 1-1 of No. 3 under 5 different key position angles is (215°, 220°, 208°, 210°, 224°); the angle union of variant key position 1-2 of No. 4 under 5 different key position angles is (265°, 260°, 250°, 255°, 270°); Selecting two variant key positions as a group in turn, variant key position 1-4 of No. 1 and variant key position 1-5 of No. 2 are combined into a group, and the result is (105°, 100°, 110°, 95°, 90°, 140°, 142°, 145°, 135°, 130°). Selecting the minimum angle and the maximum angle as the grooving angle area, the grooving angle is 90° to 145°; variant key position 1-1 of No. 3 and variant key position 1-2 of No. 4 are combined into a group, and the result is (215°, 220°, 208°, 210°, 224°, 265°, 260°, 250°, 255°, 270°). Selecting the minimum angle and the maximum angle as the grooving angle area, the grooving angle is 208° to 270°; Then expand the grooving angle by 2° - 3° (to prevent difficult mating due to machining errors). After expansion, as Figure 4 shown, variant key position 1-4 of No. 1 and variant key position 1-5 of No. 2 are combined into the first variant key position 1-6 with an angle of 89° to 146°; variant key position 1-1 of No. 3 and variant key position 1-2 of No. 4 are combined into the second variant key position 1-7 with an angle of 207° to 271°. The grooved XCF type circular connector can be mated compatibly with any 5 different variant key position XCF type circular connectors of the same specification under the normal limit of the main key position. During mating, it is limited by the unprocessed main key position and the metal shell. The specific key position angle union is shown in Table 1.

[0036] Table 1 Key Position Angle Parameters of XCF Type Connector

[0037]

[0038]

[0039] Design the corresponding 96ZK socket PCB board, assemble the 96ZK socket, positioning pins, PCB insulating board and 96ZK socket PCB board on the lower cover assembly, design the corresponding upper cover assembly of the integrated combined key position XCF type circular connector, and install the XCF type circular connector with the combined key position on the upper cover assembly. Then assemble the upper cover assembly with the support frame, two first side plates and two second side plates to form a semi-assembled cable testing device. The positions of the XCF type circular connector are welded one by one with the positions on the pad holes of the 96ZK socket PCB board through wires to form a conduction loop, and silicone rubber is used to reinforce the wire harness to ensure reliability. Taking the upper cover assembly integrating three different specifications of XCF type circular connectors as an example, the internal wiring relationship of the testing device is shown in Table 2. Among them, the "XCF14F10Z1P1", "XCF18F21Z1P1" and "XCF22F37Z1P1" connectors have 10, 21 and 37 contact positions respectively, with a total of 68 contact positions, which can be connected to the same 96ZK socket (a total of 96 contact points). Connect the positions on the 96ZK socket PCB board in sequence according to the position order to realize the internal wiring of the testing device. Finally, perform the final assembly of the lower cover assembly and the semi-assembled cable testing device to form a complete integrated cable testing device.

[0040] Table 2 Internal Wiring Relationship Table of Cable

[0041]

[0042]

[0043] In a second aspect, the present invention further provides a method for using a highly adaptable integrated cable testing device. When performing cable correctness testing, hold the handle 2-2 tightly, so that the integrated cable testing device is positioned through the positioning pin 3-2 with the base guide sleeve of the dedicated cable tester. Insert the socket on the lower cover plate assembly into the dedicated cable tester substrate in an opposing manner, and then insert the connectors at both ends of the cable to be tested into the corresponding sockets of the integrated cable testing device. Since the connectors of the integrated cable testing device have different specifications and models and the design of the combined keyway slots, it can be adapted to various types of cable connectors, greatly improving the universality of testing. After connecting to the dedicated cable testing equipment, the dedicated equipment software can be used to test the correctness of the cable connection. With its unique design, the integrated cable testing device can achieve simultaneous and rapid testing of multiple cables by the dedicated equipment. When faced with a large number of testing tasks for different types of cables, it can significantly improve the utilization rate of the equipment and avoid the situation of equipment idleness caused by poor equipment adaptability in the past. At the same time, since the device realizes efficient docking with the cable, the number of operations of frequently plugging and unplugging the dedicated equipment is reduced. Frequent plugging and unplugging are likely to cause physical damage to the interfaces of the dedicated equipment. Reducing such operations not only ensures the efficiency and accuracy of cable testing, but also effectively extends the service life of the dedicated equipment, reduces the maintenance cost and downtime of the equipment, and brings higher economic benefits to the enterprise. Taking the correctness detection of XCF series circular connector cables with 5 different specifications as an example, the comparison of the manual testing efficiency and the testing efficiency of the testing device is shown in Table 3.

[0044] Table 3 Comparison Table of Manual Testing and Testing Device Testing

[0045] Cable testing method Number of cables to be tested (pcs) Testing time (min) Accuracy rate Manual testing 25 125 96％ Testing by testing device 25 10 100％

[0046] In the process of traditional manual measurement of cable correctness, at least two people need to cooperate closely to carry out the work. This is because in manual measurement, one person is responsible for operating the measurement tool, such as a multimeter, to detect various parameters of the cable, and the other person needs to assist in recording the measurement data and adjust or change the test position of the cable when necessary. Moreover, manual measurement can only adopt the method of testing one by one in sequence and cannot detect multiple cables simultaneously. It takes at least 125 minutes to measure 25 cables. This method not only consumes manpower but also has extremely low efficiency. Using this integrated cable testing device, only 1 person can easily complete all testing tasks. In actual operation,

[0047] At least two people are required to cooperate to manually measure the correctness of cables, and only one cable can be tested at a time. Measuring 25 cables requires at least 125 minutes. When using the test device for measurement, one person can complete all the tests. First, insert 25 cables simultaneously into the corresponding connector 1 socket of the test device, and then connect the test device to the cable testing equipment. It only takes 10 minutes to complete the correctness test of the cables, and the test efficiency is increased by 12.5 times. Compared with manual testing, the correctness of the equipment test using this test device can reach 100%. It can comprehensively and accurately detect the cables, effectively avoiding the possible human errors and oversights in manual measurement, making the test results more reliable.

[0048] After verification, applying a highly adaptable integrated cable test device designed by the present invention can achieve simultaneous testing of multiple cables, solve the bottleneck problem of undetected errors in manual testing, and greatly improve the quality and efficiency of cable testing. At the same time, by designing different integrated upper cover assemblies, the testing of circular connector cables can be 100% covered, saving a large amount of human and material resources, improving the utilization rate of special equipment, reducing the number of plug-ins of the machine, and extending the service life of special equipment.

[0049] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An integrated cable testing device with high adaptability, characterized in that, It includes an upper cover plate assembly (2), on which a connector (1) with different specifications and combined key slots is fixedly connected. The upper cover plate assembly (2) is connected to a lower cover plate assembly (3) through a side plate assembly. An outlet PCB board (3-4) is embedded in the lower cover plate assembly (3). A PCB insulating board (3-3) is arranged on one side of the outlet PCB board (3-4). An outlet (3-1) is arranged on the outlet PCB board (3-4). The connector (1) is connected to the outlet (3-1) through a wire (6).

2. The highly adaptable integrated cable testing device according to claim 1, characterized in that The connector (1) is grooved with a main key position (1-3), a first variable key position (1-6) and a second variable key position (1-7). The main key position (1-3) is arranged on the left side of the connector (1). The first variable key position (1-6) is arranged at the lower right corner of the connector (1). The second variable key position (1-7) is arranged at the upper right corner of the connector (1). The angle of the first variable key position (1-6) is 89°-146°. The angle of the second variable key position (1-7) is 207°-271°.

3. An integrated cable testing device with high adaptability according to claim 1, characterized in that, The lower cover plate assembly (3) includes pad holes (3-5). The points of the connector (1) are welded to the points on the pad holes (3-5) on the outlet PCB board (3-4) one by one through the wire (6).

4. An integrated cable testing device with high adaptability according to claim 1, characterized in that, A plurality of positioning pins (3-2) are arranged on both sides of the outlet PCB board (3-4). The positioning pins (3-2) penetrate through the lower cover plate assembly (3).

5. An integrated cable testing device with high adaptability according to claim 1, characterized in that, The side plate assembly includes a first side plate (4-1), a support frame (4-2) and a second side plate (4-3). The two first side plates (4-1) are arranged on the left and right sides of the lower cover plate assembly (3). The second side plate (4-3) is arranged on the front and back sides of the lower cover plate assembly (3). The first side plate (4-1) and the second side plate (4-3) are connected through the support frame (4-2).

6. A highly adaptable integrated cable testing device according to claim 1, characterized in that A number of silicone rubbers (5) for strengthening the wire (6) are arranged at intervals on the wire (6).

7. An integrated cable testing device with high adaptability according to claim 1, characterized in that, Handles (2-1) are arranged on both sides of the upper cover plate assembly (2).

8. An integrated cable testing device with high adaptability according to claim 1, characterized in that, The outlet (3-1) adopts a 96ZK outlet, and the outlet PCB board (3-4) adopts a 96ZK outlet PCB board.

9. The highly adaptable integrated cable testing device according to claim 1, wherein, The connector (1) is an XCF type circular connector.

10. A method for using a highly adaptable integrated cable testing device, characterized in that, Applying a highly adaptable integrated cable testing device as described in any one of claims 1-9, the specific steps are as follows: Correspondingly insert the two ends of the cable to be tested into the upper cover plate assembly (2), and then insert the outlet (3-1) on the lower cover plate assembly (3) into the special cable tester substrate, and the connection correctness of the cable can be tested.

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