Intelligent quick-plug connector system

Abstract

The invention relates to the technical field of connectors, in particular to an intelligent quick-plug connector system, which comprises an insulating box, a quick-plug connector, a wire hole, a wire pressing nose, a copper bar, a central processing unit and a distributed temperature monitoring mechanism, and is characterized in that the distributed temperature monitoring mechanism and the central processing unit are respectively arranged in the insulating box; the distributed temperature monitoring mechanism comprises a first temperature sensor, a second temperature sensor and a third temperature sensor, the first temperature sensor is arranged at the joint of the copper bar and the quick connector, the second temperature sensor is arranged on the upper surface of the wire pressing nose, the third temperature sensor is arranged on the inner wall of the wire hole, and a wireless communication module is further arranged in the insulation box; and an elastic locking structure is arranged at the joint of the copper bar and the wire pressing nose. According to the invention, under the action of the elastic locking structure, the contact surfaces are maintained to be tightly attached, and the contact conduction performance is kept to be reliable; according to the invention, all electrical connection weak points are covered by the distributed temperature monitoring network, and the probability of electrical fire is significantly reduced by combining real-time alarm.

Description

Technical Field

[0001] The present invention relates to the technical field of connectors, and in particular to an intelligent quick-insert connector system. Background Art

[0002] In the field of power transmission and distribution and electrical connection, the quick-insert terminal connector, as a key electrical connection component, its reliability and safety directly affect the stability of the power supply system. Existing conversion plugs generally adopt a single temperature monitoring or mechanical overload protection design, but there are still the following technical defects in high-temperature, high-load or vibration environments: Blind area of local overheat monitoring: Traditional plugs mostly rely on a single temperature sensor to monitor the overall temperature rise, and it is impossible to accurately locate the abnormal heat generation of key heat sources such as copper bar connection points, terminal nose contact surfaces, and cable bends, resulting in the risk of false alarms or missed alarms. For example, when the contact resistance of the terminal nose increases due to oxidation, the overall temperature may not reach the alarm threshold, but the local temperature rise has caused carbonization of the insulating material. Insufficient contact stability: The connection structure between the terminal nose fixed by bolts and the copper bar is prone to looseness under the action of long-term vibration or thermal expansion and contraction, and it is impossible to achieve pressure self-compensation. There is an easy occurrence of gap looseness between the terminal nose and the copper bar, resulting in a discharge phenomenon, affecting the use reliability. Summary of the Invention

[0003] In view of the problems in the prior art, the present invention provides an intelligent quick-insert connector system, which is ingeniously designed and is connected to the intelligent terminal of the technician through a wireless communication module, facilitating the technician to perform remote monitoring and control, improving the use convenience. The technician can use the intelligent terminal to adjust the safe temperature threshold through the wireless communication module; among them, three temperature sensors are respectively deployed in three key heat source areas inside the plug; the central processor collects sensor data in real time. When the temperature of any temperature sensor exceeds the preset safe temperature threshold, the buzzer is immediately triggered to alarm and the specific fault location is fed back through the display screen to accurately locate the abnormal heat source; in addition, under the action of the elastic locking structure, the contact surface is maintained in close contact, and the contact conduction performance is kept reliable; the present invention covers all weak electrical connection points through a distributed temperature monitoring network, combined with real-time alarm, and can issue an early warning before the risk of fire formation, significantly reducing the probability of electrical fire.

[0004] To solve the above technical problems, the present invention adopts the following technical solutions:

[0005] The present invention provides an intelligent quick-insert connector system, which includes an insulating box, a quick-insert connector, a wire hole, a pressure terminal, a copper busbar, a central processor, and a distributed temperature monitoring mechanism. The distributed temperature monitoring mechanism and the central processor are respectively arranged inside the insulating box. The distributed temperature monitoring mechanism includes a first temperature sensor, a second temperature sensor, and a third temperature sensor. The first temperature sensor is arranged at the connection between the copper busbar and the quick-insert connector. The second temperature sensor is arranged on the upper surface of the pressure terminal. The third temperature sensor is arranged on the inner wall of the wire hole. A wireless communication module is also installed inside the insulating box. A display screen and a buzzer are arranged on the insulating box. The display screen, the buzzer, the wireless communication module, the first temperature sensor, the second temperature sensor, and the third temperature sensor are respectively electrically connected to the central processor;

[0006] An elastic locking structure is provided at the connection between the copper busbar and the pressure terminal. The elastic locking structure includes a V-shaped conductive elastic sheet. The open end of the V-shaped conductive elastic sheet is fixedly connected to the copper busbar. The closed end of the V-shaped conductive elastic sheet is in fitting and abutting connection with the lower surface of the pressure terminal to form a surface contact.

[0007] Among them, a switch button, an up button, and a down button are also arranged on the insulating box. The switch button, the up button, and the down button are respectively electrically connected to the central processor. The up button and the down button are used to adjust the safety temperature threshold.

[0008] Among them, a positioning support is arranged on the bottom wall inside the insulating box. A positioning groove for positioning the copper busbar is arranged on the positioning support.

[0009] Among them, a limiting cross bar is also installed inside the insulating box. The limiting cross bar is located above the copper busbar. The limiting cross bar is used to limit and install the copper busbar on the positioning support.

[0010] Among them, fixing lugs are arranged on both sides of the open end of the V-shaped conductive elastic sheet. Reserved installation grooves are respectively arranged on the upper end face and the lower end face of the copper busbar. The fixing lugs are fixedly connected to the reserved installation grooves of the copper busbar by riveting or welding.

[0011] Among them, the elastic locking structure further includes a shape memory alloy pre-tightening ring. The shape memory alloy pre-tightening ring is an open annular structure. The shape memory alloy pre-tightening ring is sleeved on the outer periphery of the pressure terminal and sleeves the closed end of the V-shaped conductive elastic sheet on the lower end face of the pressure terminal.

[0012] Among them, an anti-misoperation protection cover is arranged at the front end of the quick-insert connector. The anti-misoperation protection cover is connected to the front end of the quick-insert connector through a magnetic locking mechanism. One end of the anti-misoperation protection cover is connected to the insulating box through a flipping mechanism.

[0013] Among them, the unlocking magnetic induction intensity of the magnetic locking mechanism is set to 300 - 500 gauss.

[0014] Among them, the distributed temperature monitoring mechanism further includes an infrared thermal imaging module disposed on the inner wall of the insulating box, and the detection range of the infrared thermal imaging module covers the connection area between the copper bar and the pressure terminal nose.

[0015] Among them, the intelligent quick - plug connector system further includes a dynamic impedance adjustment mechanism. The dynamic impedance adjustment mechanism and the distributed temperature monitoring mechanism are respectively connected to the central processor by signals. The dynamic impedance adjustment mechanism includes a piezoelectric ceramic array disposed at the connection between the copper bar and the pressure terminal nose. The piezoelectric ceramic array is connected to the central processor and dynamically adjusts the contact pressure according to the feedback signal of the distributed temperature monitoring mechanism.

[0016] Advantages of the present invention:

[0017] The present invention is ingeniously designed. It is connected to the technician's intelligent terminal through a wireless communication module, which is convenient for technicians to conduct remote monitoring and control, improving the usage convenience. Technicians can use the intelligent terminal to adjust the safe temperature threshold through the wireless communication module. Among them, three temperature sensors are respectively deployed in three key heat source areas inside the plug. The central processor collects sensor data in real - time. When the temperature of any one temperature sensor exceeds the preset safe temperature threshold, the buzzer is immediately triggered to alarm and the specific fault location is fed back through the display screen, realizing accurate positioning of the abnormal heat source. In addition, under the action of the elastic locking structure, the V - shaped conductive elastic sheet forms dynamic pressure compensation between the copper bar and the pressure terminal nose through its elastic deformation characteristics: during the long - term use of the plug or in a vibration environment, the V - shaped conductive elastic sheet continuously applies a reverse force to offset the deformation caused by thermal expansion and contraction or mechanical stress of the metal connector, maintaining the tight fit of the contact surface and ensuring reliable contact conduction performance. The present invention covers all weak electrical connection points through a distributed temperature monitoring network, combined with real - time alarm, can issue an early warning before the formation of the fire risk, significantly reducing the probability of electrical fire. Description of the Drawings

[0018] Figure 1 It is a schematic structural diagram of an intelligent quick - plug connector system of the present invention.

[0019] Figure 2 It is a schematic structural diagram of the present invention after hiding the magnetic locking mechanism.

[0020] Figure 3 It is a schematic internal structural diagram of an intelligent quick - plug connector system of the present invention.

[0021] Figure 4 is Figure 3 A schematic structural diagram after hiding the pressure terminal nose.

[0022] Figure 5 This is a schematic diagram of the internal structure of the insulating box of the present invention.

[0023] In Figures 1 to 5 the attached drawings, the reference numerals include:

[0024] 1. Insulating box; 2. Quick plug connector; 3. Wire hole; 4. Pressure terminal; 5. Copper busbar; 6. Cable; 7. First temperature sensor; 8. Second temperature sensor; 9. Third temperature sensor; 10. Display screen; 11. Buzzer; 12. V-shaped conductive elastic sheet; 13. Switch button; 14. Up button; 15. Down button; 16. Heat dissipation fin; 17. Positioning support; 18. Positioning groove; 19. Limit cross bar; 20. Shape memory alloy pre-tightening ring; 21. Anti-misoperation protection cover; 22. Piezoelectric ceramic array; 23. First turning shaft; 24. Turning connection piece; 25. Second turning shaft. Detailed implementation manners

[0025] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described 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 efforts belong to the protection scope of the present invention. It can be understood that the accompanying drawings are only for reference and illustration, and are not used to limit the present invention. The connection relationships shown in the drawings are only for clear description and do not limit the connection methods.

[0026] It should be noted that when a component is considered to be "connected" to another component, it can be directly connected to the other component, or there may be an intermediate component at the same time. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field to which the present invention belongs. It also should be noted that unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection, and can be the communication inside two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations. The terms used in the description of the present invention in this specification are only for the purpose of describing specific embodiments and are not intended to limit the present invention.

[0027] It should also be noted that in the description of the present invention, it should be noted that the orientation or positional relationship indicated by terms such as "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, it should not be construed as a limitation to the present invention. In addition, the terms "first", "second", and "third" are only used for descriptive purposes and cannot be construed as indicating or implying relative importance.

[0028] Embodiment 1

[0029] As Figures 1 to 5 shown, Embodiment 1 of the present application provides an intelligent quick-connect connector system, which includes an insulating box 1, a quick-connect joint 2, a wire hole 3, a wire pressing nose 4, a copper busbar 5, a central processor, and a distributed temperature monitoring mechanism. The distributed temperature monitoring mechanism and the central processor are respectively arranged inside the insulating box 1. The distributed temperature monitoring mechanism includes a first temperature sensor 7, a second temperature sensor 8, and a third temperature sensor 9. The first temperature sensor 7 is arranged at the connection between the copper busbar 5 and the quick-connect joint 2. The second temperature sensor 8 is arranged on the upper surface of the wire pressing nose 4. The third temperature sensor 9 is arranged on the inner wall of the wire hole 3. A wireless communication module is also installed inside the insulating box 1. A display screen 10 and a buzzer 11 are arranged on the insulating box 1. The display screen 10, the buzzer 11, the wireless communication module, the first temperature sensor 7, the second temperature sensor 8, and the third temperature sensor 9 are respectively electrically connected to the central processor; of course, the display screen 10 can be used to display the temperature curve corresponding to the temperature sensor over time; an elastic locking structure is provided at the connection between the copper busbar 5 and the wire pressing nose 4. The elastic locking structure includes a V-shaped conductive elastic sheet 12. The open end of the V-shaped conductive elastic sheet 12 is fixedly connected to the copper busbar 5. The closed end of the V-shaped conductive elastic sheet 12 is in surface contact with the lower surface of the wire pressing nose 4 in a fitting and abutting manner.

[0030] Specifically, the embodiment of the present application is ingeniously designed. It is connected to the technician's intelligent terminal through a wireless communication module, which facilitates the technician's remote monitoring and control, improving the usability. The technician can use the intelligent terminal to adjust the safe temperature threshold through the wireless communication module. Among them, the wireless communication module can be a Bluetooth module, a WIFI module, etc. Among them, the three temperature sensors are respectively deployed in three key heat source areas inside the plug: The first temperature sensor 7 monitors the connection point of the copper busbar 5 and the quick-connect joint 2 (which is prone to heat due to plugging and unplugging wear or poor contact); the second temperature sensor 8 monitors the surface of the pressure terminal nose 4 (the connection between the cable 6 and the plug is prone to temperature rise due to overload or oxidation); the third temperature sensor 9 monitors the inner wall of the wire hole 3 (local overheating may be caused by wire bending or extrusion). The central processor collects sensor data in real time. When the temperature at any monitoring point (temperature sensor) exceeds the preset safe temperature threshold, the buzzer 11 is immediately triggered to alarm and the specific fault location is fed back through the display screen 10, realizing precise positioning of the abnormal heat source. In addition, under the action of the elastic locking structure, the V-shaped conductive elastic sheet 12 forms a dynamic pressure compensation between the copper busbar 5 and the pressure terminal nose 4 through its elastic deformation characteristics: During long-term use of the plug or in a vibrating environment, the V-shaped conductive elastic sheet 12 continuously applies a reverse acting force to offset the deformation of the metal connector caused by thermal expansion and contraction or mechanical stress, maintaining the close fit of the contact surface and ensuring reliable contact conduction performance. The present invention covers all weak electrical connection points through a distributed temperature monitoring network, combined with real-time alarm, and can issue an early warning before the fire risk is formed, significantly reducing the probability of electrical fires.

[0031] In the embodiment of the present application, a plurality of heat dissipation fins 16 are respectively arranged on both sides of the insulating box 1. Specifically, with the above arrangement, it is convenient to dissipate heat from the insulating box 1, improving the use safety and reliability.

[0032] In the embodiment of the present application, a switch button 13, an up button 14 and a down button 15 are further arranged on the insulating box 1. The switch button 13, the up button 14 and the down button 15 are respectively electrically connected to the central processor. The up button 14 and the down button 15 are used to adjust the safe temperature threshold. Specifically, with the above arrangement, it is convenient for the technician to adjust the safe temperature threshold. When the first temperature sensor 7, the second temperature sensor 8 and the third temperature sensor 9 detect a temperature higher than the temperature threshold, they send a signal to the central processor, and the central processor drives the buzzer 11 to sound an alarm to remind the technician of abnormal temperature.

[0033] In the embodiment of the present application, the copper bar 5 is arranged in an L shape, facilitating the connection of both ends of the copper bar 5 to the quick-insert connector 2 and the pressure terminal 4 respectively; a positioning support member 17 is provided on the bottom wall inside the insulating box 1, and a positioning groove 18 for positioning the copper bar 5 is provided on the positioning support member 17. Among them, a limiting cross bar 19 is further installed inside the insulating box 1, the limiting cross bar 19 is located above the copper bar 5, and the limiting cross bar 19 is used to limit and install the copper bar 5 on the positioning support member 17. Specifically, under the above settings, the copper bar 5 is supported by the positioning support member 17, so that a gap is formed between the copper bar 5 and the bottom wall of the insulating box 1, facilitating heat dissipation and at the same time facilitating the installation and connection of the V-shaped conductive elastic sheet 12; further, through the setting of the positioning groove 18, the installation position of the copper bar 5 is ensured to be accurate, and in cooperation with the limiting cross bar 19, the copper bar 5 is ensured not to be loose, improving the structural stability.

[0034] In the embodiment of the present application, fixing lugs are provided on both sides of the open end of the V-shaped conductive elastic sheet 12, and reserved installation grooves (not shown in the figure) are respectively provided on the upper and lower end surfaces of the copper bar 5, and the fixing lugs are fixedly connected to the reserved installation grooves of the copper bar 5 by riveting or welding. Specifically, the V-shaped conductive elastic sheet 12 is made of beryllium copper alloy (conductivity ≥ 20% IACS, elastic modulus ≥ 120 GPa), and the V-shaped angle is designed to be 60° - 90°, providing an initial clamping force through elastic deformation.

[0035] Further, the elastic locking structure further includes a shape memory alloy pre-tightening ring 20. The shape memory alloy pre-tightening ring 20 is an open annular structure. The shape memory alloy pre-tightening ring 20 is sleeved on the outer periphery of the pressure terminal 4 and tightly sleeves the closed end of the V-shaped conductive elastic sheet 12 on the lower end surface of the pressure terminal 4. Wherein, the inner diameter of the shape memory alloy pre-tightening ring 20 is slightly smaller than the outer diameter of the pressure terminal 4. The shape memory alloy pre-tightening ring 20 is made of nickel-titanium-based shape memory alloy (phase transition temperature 50 - 80 °C), and has a two-way memory effect after pre-deformation treatment. At high temperature (> phase transition point), the inner diameter shrinkage rate ≥ 8%. Under the cooperation of the shape memory alloy pre-tightening ring 20 and the V-shaped conductive elastic sheet 12, the elastic pre-tightening force of the V-shaped conductive elastic sheet 12 makes the pressure terminal 4 in close contact with the copper busbar 5. The shape memory alloy pre-tightening ring 20 is in the martensite phase state, applying a radial restraint force to the closed end of the elastic sheet to prevent elastic relaxation. When the temperature rises: that is, when the contact surface between the pressure terminal 4 and the copper busbar 5 is heated to the shape memory alloy phase transition temperature (such as 70 °C) due to current overload, the shape memory alloy pre-tightening ring 20 undergoes austenite phase transition, and the inner diameter shrinks (the shrinkage amount is about 0.5 - 1 mm), further compressing the closed end of the V-shaped conductive elastic sheet 12, increasing the clamping force by 20% - 30%, compensating for the decrease in contact pressure caused by thermal expansion of the material. When the temperature drops: the shape memory alloy pre-tightening ring 20 returns to the martensite phase state, the inner diameter expands, allowing the V-shaped conductive elastic sheet 12 to elastically rebound, avoiding plastic deformation caused by over-clamping. Under the above synergistic effect, through the coupling of the temperature-controlled phase transition characteristics of the shape memory alloy and the elastic deformation of the V-shaped conductive elastic sheet 12, the dynamic adjustment of the contact pressure with temperature change is realized. The contact resistance fluctuation range ≤ 5 μΩ, and the temperature rise suppression effect reaches 15% - 20%. The elastic locking structure solves the problem of contact deterioration caused by thermal cycling of traditional connectors through the temperature-controlled phase transition of the shape memory alloy and the elastic energy storage of the V-shaped conductive elastic sheet 12, and the mechanical life is increased to 10,000 times of plugging and unplugging.

[0036] In the embodiment of the present application, the surface of the V-shaped conductive elastic sheet 12 of the elastic locking structure is provided with a gradient composite coating. The gradient composite coating includes a silver-copper composite conductive layer, a diamond-like carbon wear-resistant layer, and a graphene heat dissipation layer arranged in sequence from the inside to the outside. Wherein, the thickness of the silver-copper composite conductive layer is 50 - 80 μm; the thickness of the diamond-like carbon wear-resistant layer is 10 - 15 μm; the thickness of the graphene heat dissipation layer is 5 - 8 μm.

[0037] Specifically, the silver-copper composite conductive layer (50 - 80 μm) serves as the base contact layer, directly contacting the surface of the pressure terminal 4 and undertaking the core conductive function. The high conductivity of silver (conductivity 1.6×10^8 S / m) is combined with the mechanical strength of copper (tensile strength ≥200 MPa) to achieve a balance between low contact resistance (≤5 μΩ) and anti-plastic deformation ability. Silver (Ag) and copper (Cu) are co-deposited in a mass ratio of 70:30 through magnetron sputtering to form a nano-scale alternating layered structure. The silver layer is preferentially distributed on the contact surface to reduce resistance, and the copper layer provides structural support, enabling the contact resistance to be stabilized at ≤10 μΩ (required by IEC 60512 standard); the conductivity attenuation rate < 3% (after 10,000 insertion and extraction cycles).

[0038] The diamond-like carbon wear-resistant layer (10 - 15 μm) prevents surface wear caused by plugging and unplugging friction, arc erosion, etc., protects the integrity of the conductive layer, and extends the service life. The diamond-like carbon wear-resistant layer is formed by plasma-enhanced chemical vapor deposition (PECVD) to generate an amorphous diamond-like carbon (DLC) coating with a hardness of 15 - 20 GPa (Vickers hardness) and a friction coefficient as low as 0.1 - 0.2; the wear-resistant life is increased by 3 - 5 times (ASTM G99 test standard); the surface scratch depth < 2 μm (under a 10 N load, 1,000 friction cycles).

[0039] The graphene heat dissipation coating (5 - 8 μm) forms a vertical array of graphene nanosheets on the surface through electrophoretic deposition. Utilizing its in-plane thermal conductivity (5,300 W / m·K), it establishes an efficient heat conduction path, reducing the temperature rise of the contact surface between the copper busbar 5 and the pressure terminal 4 by 15 - 20 °C (under rated current), and increasing the heat dissipation rate by 40% (compared with the non-coated elastic piece). It can quickly conduct the Joule heat of the contact surface between the copper busbar 5 and the pressure terminal 4, suppress the temperature rise, and avoid excessive shrinkage of the shape memory alloy pre-tightening ring 20 triggered by too high temperature.

[0040] Specifically, the synergistic mechanism of the gradient composite coating in the embodiments of the present application realizes a step-by-step progression of electrical conductivity, wear resistance, and heat dissipation: the silver-copper layer preferentially ensures the electrical contact performance, the diamond-like carbon layer blocks external mechanical damage, and the graphene layer quickly conducts the internal heat, forming a protective chain with complementary functions. Further, the interface stress is optimized: by gradient composition design (such as adding a 50-nm transition Cr layer between the silver-copper layer and the diamond-like carbon layer), the difference in thermal expansion coefficients of different materials is reduced (CTE matching degree > 90%), avoiding coating peeling. At the same time, dynamic adaptability is achieved: the high thermal conductivity of the graphene coating and the temperature-controlled contraction of the shape memory alloy pre-tightening ring 20 form a thermal feedback closed loop: when the temperature rises, the pre-tightening ring pressurizes to enhance contact, and the graphene accelerates heat dissipation to prevent temperature runaway; through material function stratification and interface collaborative optimization, the gradient composite coating solves the three core problems of unstable electrical contact, fast mechanical wear, and low heat dissipation efficiency in traditional quick-connect connectors, directly supporting key performance indicators such as 10,000 insertion and extraction cycles of the elastic locking structure, stability of contact resistance of ±5 μΩ, and suppression of temperature rise of 15 - 20 °C, improving the reliability of the connector.

[0041] Embodiment 2

[0042] In Embodiment 2 of the present application, it is further defined that: a misoperation prevention protection cover 21 is provided at the front end of the quick-connect joint 2, the misoperation prevention protection cover 21 is connected to the front end of the quick-connect joint 2 through a magnetic locking mechanism, and one end of the misoperation prevention protection cover 21 is connected to the insulating box 1 through a flipping mechanism. Specifically, the flipping mechanism includes a first flipping shaft 23, a flipping connecting piece 24, and a second flipping shaft 25. The first flipping shaft 23 is rotatably provided on the insulating box 1. One end of the flipping connecting piece 24 is connected to the first flipping shaft 23, the other end of the flipping connecting piece 24 is connected to the second flipping shaft 25, and one end of the misoperation prevention protection cover 21 is movably connected to the second flipping shaft 25. In this setting, when the misoperation prevention protection cover 21 is opened, it is convenient for the misoperation prevention protection cover 21 to flip backward to facilitate the insertion of the quick-connect joint 2; among them, the misoperation prevention protection cover 21 is embedded with a neodymium iron boron permanent magnet (surface magnetic induction intensity 800 - 1000 Gauss), and a soft magnetic alloy sheet (Permalloy material, permeability ≥ 80,000) is provided at the front end of the quick-connect joint 2. The soft magnetic alloy sheet is correspondingly arranged with the neodymium iron boron permanent magnet, and the soft magnetic alloy sheet and the neodymium iron boron permanent magnet form a closed magnetic circuit; when the misoperation prevention protection cover 21 is closed on the quick-connect joint 2, that is, when the magnetic locking mechanism is locked, the magnetic attraction force makes the misoperation prevention protection cover 21 closely adhere to the surface of the quick-connect joint 2; among them, a silicone rubber sealing strip is provided on the inner side of the misoperation prevention protection cover 21, and the silicone rubber sealing strip is arranged at the contact surface position between the misoperation prevention protection cover 21 and the quick-connect joint 2.

[0043] In the embodiments of the present application, the unlocking magnetic induction intensity of the magnetic locking mechanism is set to 300 - 500 Gauss. Specifically, the lower limit of 300 Gauss ensures that external forces such as daily vibration (≤5 Grms) and wind force (≤Grade 12) cannot accidentally unlock it; the upper limit of 500 Gauss avoids the unlocking tool being too large due to excessive magnetic force (the size of the tool magnet is controlled within φ10×5 mm), meeting the ergonomic operation requirements. Among them, when it is necessary to unlock the magnetic locking mechanism, technicians need to use a special tool (such as a magnetic key with a reverse magnetic pole) to approach the edge of the protective cover. The reverse magnetic field (300 - 500 Gauss) generated by the tool cancels the locking magnetic circuit, reducing the net magnetic suction force to ≤50 Gauss. At this time, the protective cover can be manually lifted; of course, without a tool, a separation force of ≥5 N needs to be applied to manually open it, and the probability of accidental opening is <0.1 times / year.

[0044] Embodiment Three

[0045] In Embodiment Three of the present application, it is further defined that: the distributed temperature monitoring mechanism further includes an infrared thermal imaging module disposed on the inner wall of the insulating box 1, and the detection range of the infrared thermal imaging module covers the connection area between the copper busbar 5 and the pressure terminal nose 4. Specifically, the infrared thermal imaging module covers the connection area between the copper busbar 5 and the pressure terminal nose 4, generating a two-dimensional temperature distribution thermal image in real time, accurately identifying local overheating (such as abnormal contact resistance areas caused by oxidation), making up for the blind spots of point-type temperature sensors (which only monitor fixed points), and can detect hidden temperature rises caused by micro-gap discharges or metal fatigue cracks, improving the comprehensiveness of temperature monitoring.

[0046] Embodiment Four

[0047] In the fourth embodiment of the present application, it is further defined that: a triaxial MEMS stress sensor (not shown in the figure) is embedded at the connection between the inner wall of the pressure terminal nose 4 and the cable 6, and the detection directions of the triaxial MEMS stress sensor are respectively parallel to the axial direction, the radial direction and the tangential direction of the contact surface of the cable 6. Specifically, in the embodiment of the present application, the detection characteristics of the triaxial MEMS stress sensor are utilized. Axial stress (X-axis): Detect the axial displacement of the cable 6 caused by thermal expansion or mechanical tension (accuracy ±0.1 N); Radial stress (Y-axis): Monitor the attenuation of the radial compression force of the pressure terminal nose 4 on the cable 6 (alarm when the contact pressure < 20 N due to, for example, the relaxation of the spring piece); Tangential stress (Z-axis): Identify abnormal shear forces during vibration or plugging and unplugging processes (protection is triggered when the threshold > 50 N); The triaxial MEMS stress sensor adopts a silicon-based MEMS piezoresistive unit (range ±200 N, non-linear error < 0.5%), and converts the mechanical signal into an electrical signal through a Wheatstone bridge; The triaxial MEMS stress sensor is internally provided with a temperature compensation module (drift < 0.02% FS / °C in the range of -40°C to 125°C), eliminating the interference of material thermal expansion on the measurement; When it is detected that the radial compression force drops > 15%, the buzzer 11 is automatically triggered to alarm and the compensation action of the shape memory alloy pre-tightening ring 20 is started to avoid contact failure; In addition, in the embodiment of the present application, the remaining mechanical life of the connector can also be predicted (error < 5%) through a stress-temperature coupling analysis model (recording the stress cycle data of 100,000 plugging and unplugging operations), optimizing the connector life prediction and facilitating the real-time monitoring of the loosening of the connection.

[0048] Specifically, in the embodiment of the present application, by integrating the data fusion of the infrared thermal imaging module (temperature field) and the triaxial MEMS sensor (stress field), a temperature-stress correlation model is constructed to distinguish the root causes of electrical overload and mechanical looseness (accuracy > 95%); When it is detected that the tangential stress exceeds the limit (plugging and unplugging offset), the current is immediately cut off and a shutdown instruction is sent through the wireless communication module to prevent arc damage; Solve the traditional monitoring defects: Traditional connectors only rely on temperature or single mechanical parameter monitoring and cannot cover the thermal-mechanical coupling failure mode (such as the decrease in contact pressure caused by material creep due to temperature rise); It is applicable to fields such as rail transit and data centers where zero tolerance for connector failure is required, and the MTBF (mean time between failures) is increased from 50,000 hours to 100,000 hours.

[0049] Embodiment Five

[0050] In the fifth embodiment of the present application, it is further defined that: a composite heat dissipation structure is provided on the surface of the insulation box 1. The composite heat dissipation structure includes a microchannel cooling system provided on the surface of the graphene heat conduction layer and a phase change heat storage capsule communicated with the microchannel. The flow channel width of the microchannel cooling system is 0.5-1 mm; the capsule is filled with a paraffin-based composite phase change material. Specifically, under the above settings, the graphene heat conduction layer is embedded in the inner wall of the insulation box 1 in a honeycomb hexagonal grid, closely attached to the heat source area of the copper busbar 5 and the pressure terminal 4 (covering an area ≥ 80% of the heat source surface); the graphene heat conduction layer is bonded to the inner wall of the insulation box 1 through an epoxy resin heat conduction adhesive (heat conduction coefficient ≥ 5 W / m·K) and is in direct contact with the microchannel cooling system; the microchannel cooling system adopts a dendritic fractal flow channel, the main channel width is 1 mm, the width of the end branch flow channel is 0.5 mm, the depth is 0.8 mm, and the total length is 12 m. The dendritic fractal flow channel is etched on the surface of an aluminum substrate (thickness 3 mm). The aluminum substrate is connected to the graphene heat conduction layer through hot press welding to form a "graphene-microchannel" composite heat conduction interface. Hydrofluoroether (HFE-7100, boiling point 61°C) is filled in the dendritic fractal flow channel to dissipate heat by natural convection circulation; the phase change heat storage capsule adopts a spherical copper shell capsule with a diameter of 3 mm, filled with a paraffin-based composite phase change material (melting point 60°C, latent heat ≥ 180 kJ / kg), and is embedded in the reserved groove of the microchannel aluminum substrate in an array form (spacing 10 mm), arranged parallel to the flow channel, and fixed by welding; under the above settings, the composite heat dissipation structure realizes two levels of heat dissipation: primary heat dissipation (passive heat conduction): the Joule heat generated by the copper busbar 5 and the pressure terminal 4 is rapidly laterally diffused through the graphene heat conduction layer (in-plane heat conductivity ≥ 1,500 W / m·K), and the heat is evenly distributed to the microchannel area; secondary heat dissipation (microchannel phase change cooling): after the heat is transferred to the microchannel aluminum substrate, the hydrofluoroether in the flow channel is vaporized by heat (vaporization latent heat 110 kJ / kg), absorbing a large amount of heat; the gaseous cooling medium rises along the dendritic flow channel to the condensation area at the top of the insulation box 1 (in contact with the environment), liquefies and then flows back to the bottom of the flow channel to form a natural cycle; the phase change heat storage capsule melts and absorbs heat (the heat storage density is increased by 40%) when the temperature > 60°C, delaying the temperature rise rate.

[0051] Embodiment Six

[0052] In the sixth embodiment of the present application, it is further defined that: the intelligent quick-connect connector system further includes a dynamic impedance adjustment mechanism, and the dynamic impedance adjustment mechanism and the distributed temperature monitoring mechanism are respectively signal-connected to the central processor. The dynamic impedance adjustment mechanism includes a piezoelectric ceramic array provided at the connection between the copper busbar and the pressure terminal nose. The piezoelectric ceramic array is connected to the central processor and dynamically adjusts the contact pressure according to the feedback signal of the distributed temperature monitoring mechanism; the infrared thermal imaging module, the switch button 13, the up button 14, the down button 15, the display screen 10, the buzzer 11, the wireless communication module, the first temperature sensor 7, the second temperature sensor 8, and the third temperature sensor 9 are respectively electrically connected to the central processor; the dynamic impedance adjustment mechanism includes a strain sensor and a piezoelectric ceramic array 22 provided at the connection between the copper busbar 5 and the pressure terminal nose 4. The piezoelectric ceramic array 22 is connected to the central processor and dynamically adjusts the contact pressure according to the feedback signal of the distributed temperature monitoring mechanism; the strain sensor detects the deformation of the contact surface at the connection between the copper busbar 5 and the pressure terminal nose 4, and forms a closed-loop feedback control with the piezoelectric ceramic array 22. The central processor has a built-in fuzzy control algorithm, generates a piezoelectric ceramic drive signal according to temperature, deformation, and current data, and the drive voltage range is ±50V to ±100V. The piezoelectric ceramic array 22 uses PZT-5H material, and the drive voltage is ±80V; the piezoelectric ceramic array 22 is arranged on the surface of the copper busbar 5 in a matrix form, and the single array unit size is 5mm×5mm; the strain sensor detects the contact surface deformation, and the central processor adjusts the piezoelectric ceramic drive voltage according to the deformation amount and temperature data to keep the contact resistance stable within ±5%; the fuzzy control algorithm integrates temperature gradient, current load, and environmental humidity parameters to generate an adaptive control signal (the fuzzy control algorithm is a conventional technology and will not be elaborated here).

[0053] Among them, piezoelectric ceramic materials (such as PZT-5H) have the inverse piezoelectric effect, that is, they will generate mechanical deformation when a voltage is applied; when the central processor adjusts the drive voltage (±50V to ±100V) according to the sensor data, the unit (5mm×5mm) of the piezoelectric ceramic array 22 will expand or contract, thereby applying a dynamic pressure to the contact surface between the copper busbar 5 and the pressure terminal nose 4; in the embodiment of the present application, by adjusting the drive voltage, the tightness of the contact surface is changed in real time, thereby reducing the contact resistance (stable within ±5%), and realizing dynamic adjustment of the contact pressure; the embodiment of the present application reduces the joule heat caused by poor contact, and cooperates with the temperature sensor to achieve thermal-mechanical coupling control, which is beneficial to suppressing temperature rise.

[0054] Among them, a strain sensor (not shown in the figure) is embedded in the surface of the copper busbar 5. By detecting the micro-deformation of the contact surface (such as material expansion or mechanical loosening), the deformation amount is converted into a resistance or capacitance signal and transmitted to the central processing unit; the strain sensor and the piezoelectric ceramic array 22 form a "perception-response" closed loop to ensure the adjustment accuracy; the CPU of this application integrates temperature sensors (thermal state), strain sensors (deformation amount) and current data, and generates an optimized drive signal through a fuzzy control algorithm; specifically: high temperature + excessive deformation → increase the piezoelectric ceramic drive voltage and enhance the contact pressure to reduce the resistance; low temperature + normal deformation → maintain the reference voltage and reduce energy consumption.

[0055] In the embodiment of this application, when the current suddenly increases and the temperature of the contact surface rises to the threshold value, the strain sensor detects the expansion deformation of the copper busbar 5, and the central processing unit immediately adjusts the piezoelectric ceramic drive voltage (such as ±80V) to enhance the contact pressure to reduce the resistance, and at the same time quickly dissipates heat through the graphene heat conduction layer. The embodiment of this application solves the technical problem of traditional connectors relying on fixed structure design by active adjustment instead of passive protection, and the embodiment of this application realizes "adaptive" impedance matching through real-time sensing and dynamic response of piezoelectric ceramics.

[0056] In the embodiment of this application, the adaptive intelligent quick-insert connector system further includes an energy recovery device, which includes an energy management chip, a thermoelectric power generation chip and a super capacitor. The thermoelectric power generation chip is installed in the quick-insert joint 2. The hot end of the thermoelectric power generation chip is in contact with the connection terminal in the quick-insert joint 2, and the cold end of the thermoelectric power generation chip extends to the surface of the insulating box 1. The thermoelectric power generation chip and the super capacitor form an energy storage circuit. Specifically, the thermoelectric power generation chip uses bismuth telluride material, and the output power reaches 8mW / cm at ΔT = 30°C 2 ; the super capacitor stores electric energy to supply the sensor and the display screen 10 to achieve zero external power supply; the energy management chip dynamically adjusts the working point of the power generation chip through the maximum power point tracking (MPPT) algorithm to ensure that the power generation efficiency is ≥92% when the temperature difference fluctuates. The generated electric energy is stored in a super capacitor with a capacity of 10F. Its low internal resistance characteristic supports fast charge and discharge to meet the needs of low-power devices such as sensors and display screens 10; the super capacitor can provide a voltage of ≥5V for the system, completely replacing the external power supply; under full-load conditions, the annual recoverable electric energy is ≥1.2kWh, reducing carbon emissions; reducing the overall temperature rise of the connector through thermoelectric power generation indirectly extends the life of components.

[0057] In the embodiment of the present application, the adaptive intelligent quick-connect connector system further includes a self-healing insulation structure. The self-healing insulation structure includes a microcapsule composite coating coated on the inner wall of the insulation box 1. The microcapsule composite coating contains a heat-responsive insulation repair agent. When the local temperature exceeds the set threshold, the microcapsule composite coating ruptures to release the repair agent. The heat-responsive insulation repair agent in the microcapsule composite coating contains 60% by mass of a silicone rubber matrix and 40% of silicon carbide nanowires. After repair, the insulation resistance recovery rate is ≥95%. When microcracks are generated on the inner wall of the insulation box 1 due to arc, mechanical friction or aging, the heat-responsive repair agent is automatically released and fills the defects to restore the insulation performance. When the local temperature is abnormal (such as 85°C ± 3°C), the repair is triggered to prevent minor damage from expanding into a breakdown fault. After repair, a silicon carbide nanowire-reinforced network is formed on the coating to improve the high-temperature resistance and arc resistance. Among them, the wall material of the microcapsule is a polyurethane-silica composite material, and its glass transition temperature (Tg) matches the set threshold (85°C ± 3°C). When the local temperature exceeds the threshold, the wall material softens and ruptures to release the internal repair agent. The size of the microcapsule is: diameter 50μm, density 2000 pieces / mm 2 , ensuring uniform distribution of the repair agent. The repair process of the self-healing insulation structure is as follows: After the repair agent contacts the air, the silicone rubber matrix cures into a film within 15 minutes, and silicon carbide nanowires (diameter 50 - 100nm) form an interlocked three-dimensional network in the coating to achieve the following functions: Insulation recovery: Fill the cracks to make the insulation resistance recovery rate ≥95%; Mechanical strengthening: The nanowires bridge both sides of the cracks, and the tensile strength of the coating is increased by 50%; Arc resistance: The high thermal conductivity (490W / (m·K)) of silicon carbide disperses the arc energy, and the breakdown voltage strength ≥3kV / mm.

[0058] In the embodiment of the present application, the maintenance cost is reduced by 60% under the above settings: The self-healing function reduces the frequency of manual inspections, and the single repair cost is only 1 / 5 of the traditional replacement; Safety improvement: The breakdown voltage strength after repair reaches 3kV / mm, which is higher than the national standard (2.5kV / mm); Service life extension: It supports ≥5 self-healing cycles, and the overall life of the connector is extended by more than 2 times.

[0059] The above is only a preferred embodiment of the present invention, and it does not impose any form of limitation on the present invention. Although the present invention is disclosed above in a preferred embodiment, it is not intended to limit the present invention. Any person skilled in the art, without departing from the scope of the technical solution of the present invention, when making some changes or modifications using the above-disclosed technical content into equivalent embodiments of equivalent changes, but as long as it does not depart from the content of the technical solution of the present invention, any simple modification, equivalent change and modification made to the above embodiments according to the technical means of the present invention shall fall within the scope of the technical solution of the present invention.

Claims

1. An intelligent quick-insert connector system, characterized in that: It includes an insulating box, a quick-plug connector, a wire hole, a wire crimping nose, a copper busbar, a central processing unit and a distributed temperature monitoring mechanism, wherein the distributed temperature monitoring mechanism and the central processing unit are respectively arranged inside the insulating box, and the distributed temperature monitoring mechanism includes a first temperature sensor, a second temperature sensor and a third temperature sensor, wherein the first temperature sensor is arranged at the connection between the copper busbar and the quick-plug connector, the second temperature sensor is arranged on the upper surface of the wire crimping nose, and the third temperature sensor is arranged on the inner wall of the wire hole, and a wireless communication module is also installed in the insulating box, and a display screen and a buzzer are arranged on the insulating box, and the display screen, the buzzer, the wireless communication module, the first temperature sensor, the second temperature sensor and the third temperature sensor are respectively electrically connected to the central processing unit; An elastic locking structure is provided at the connection between the copper busbar and the wire crimping nose, and the elastic locking structure includes a V-shaped conductive spring sheet, the open end of the V-shaped conductive spring sheet is fixedly connected to the copper busbar, and the closed end of the V-shaped conductive spring sheet is fitted and abutted against the lower surface of the wire crimping nose to form surface contact.

2. The intelligent quick-connect connector system according to claim 1, wherein: The insulating box is also provided with a switch button, an upward adjustment button and a downward adjustment button, and the switch button, the upward adjustment button and the downward adjustment button are electrically connected to the central processing unit respectively, and the upward adjustment button and the downward adjustment button are used to adjust the safety temperature threshold.

3. An intelligent quick-connect connector system according to claim 1, characterized in that: A positioning support is provided on the bottom wall of the insulation box, and a positioning groove for positioning the copper busbar is provided on the positioning support.

4. An intelligent quick-connect connector system according to claim 3, characterized in that: A limiting cross bar is also installed in the insulation box. The limiting cross bar is located above the copper bar and is used to limit the copper bar to be installed on the positioning support.

5. The intelligent quick-connect connector system according to claim 1, wherein: Fixed ears are provided on both sides of the open end of the V-shaped conductive spring sheet, and reserved installation grooves are respectively provided on the upper end surface and the lower end surface of the copper busbar. The fixed ears are fixedly connected to the reserved installation grooves of the copper busbar by riveting or welding.

6. The intelligent quick-connect connector system according to claim 1, wherein: The elastic locking structure also includes a memory alloy pre-tightening ring, which is an open ring structure. The memory alloy pre-tightening ring is sleeved on the outer periphery of the wire crimping nose and tightly sleeves the closed end of the V-shaped conductive spring onto the lower end surface of the wire crimping nose.

7. An intelligent quick-insert connector system according to claim 1, characterized in that: The front end of the quick-plug connector is provided with an anti-accidental touch protection cover, which is connected to the front end of the quick-plug connector through a magnetic locking mechanism, and one end of the anti-accidental touch protection cover is connected to the insulation box through a flip mechanism.

8. An intelligent quick-insert connector system according to claim 7, characterized in that: The unlocking magnetic induction intensity of the magnetic locking mechanism is set to 300-500 Gauss.

9. An intelligent quick-connect connector system according to claim 1, characterized in that: The distributed temperature monitoring mechanism also includes an infrared thermal imaging module arranged on the inner wall of the insulation box, and the detection range of the infrared thermal imaging module covers the connection area between the copper busbar and the wire crimping nose.

10. An intelligent quick-connect connector system according to claim 1, characterized in that: The intelligent quick-plug connector system also includes a dynamic impedance adjustment mechanism, and the dynamic impedance adjustment mechanism and the distributed temperature monitoring mechanism are respectively connected to the central processing unit signal. The dynamic impedance adjustment mechanism includes a piezoelectric ceramic array arranged at the connection between the copper bus and the wire crimping nose, and the piezoelectric ceramic array is connected to the central processing unit to dynamically adjust the contact pressure according to the feedback signal of the distributed temperature monitoring mechanism.

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