Catenary dropper crimping structure and crimping method

Abstract

The invention discloses a catenary dropper crimping structure and a crimping method, and relates to the technical field of catenary dropper crimping, the catenary dropper crimping structure comprises a crimping pipe, the crimping pipe comprises a pair of crimping channels arranged symmetrically, one end of a stranded wire penetrates through the two crimping channels in sequence and forms a hanging ring, and the other end of the stranded wire penetrates through the other crimping channel to form a connecting rod; each crimping channel comprises an arc segment and two straight line segments, the arc segment is a fillet at the joint of the two straight line segments, the two straight line segments form an obtuse angle, the adjacent crimping channels are not contacted and communicated, two ports at the same side are not communicated, and the stranded wires are fixed in the crimping channels. According to the dropper main line, through the cooperation of the crimping pipe and the heart-shaped ring, it can be guaranteed that the dropper main line is not bent at the crimping pipe, and the bending stress and the fatigue fracture risk of a stranded wire at the position are reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of catenary suspension clamp crimping, and particularly to a catenary suspension clamp crimping structure and a crimping method. Background Art

[0002] The catenary suspension is connected between the contact wire and the carrier cable. When static, it plays a role in maintaining the spatial geometric posture of the catenary. When a train passes at high speed, the vibration of the contact wire is transmitted to the carrier cable through the suspension, playing a role in load transmission and stabilizing the catenary. At the same time, the suspension also has a certain electrical current-carrying capacity. Generally speaking, the suspensions are divided into integral adjustable suspensions, integral non-adjustable suspensions, and rigid suspensions. Among them, both the integral adjustable suspension and the integral non-adjustable suspension use flexible stranded wires to play the role of length adjustment. After the length of the suspension is determined, the stranded wire needs to be locked with the components. Usually, a crimping tube is used. The stranded wire is passed through the crimping tube, and after installing the heart-shaped ring, it is passed back through the crimping tube and then connected to the terminal. The two stranded wires contained in the crimping tube are pressed tightly by a special tool in cooperation with a special mold, so that the stranded wire is locked and does not slide therein. This process is called the suspension crimping process, and the shape of the crimping tube and the state after crimping are collectively referred to as the suspension crimping method.

[0003] After the conventional crimping tube crimps the suspension, the two suspension wires are arranged in parallel in the crimping tube. However, since only one stranded wire leads to the stress direction, when the suspension is stressed, the crimping tube will be in an inclined state, resulting in a bend with a small bending radius at the outlet position of the crimping tube for the stranded wire, commonly known as a "hard bend". After multiple cyclic vibrations, the stranded wire at this part is prone to fatigue fracture, as Figure 9 shown. At the same time, since the two stranded wires in the crimping tube of the traditional crimping method are parallel, at this time, as long as the suspension is stressed and straightened, a hard bend will inevitably form at the outlet part of the main wire in the crimping tube; at the same time, the heart-shaped ring is just at the outlet of the crimping tube, and the heart-shaped ring needs to divide the stranded wire into two directions, resulting in a bend with a small bending radius at the heart-shaped ring part at the other end outlet of the crimping tube for the two groups of stranded wires. Tests show that this part is also a part where the suspension is prone to fatigue fracture. In addition, for the stranded wire going to the terminal, due to the insufficient distance between the stranded wire at the outlet position of the crimping tube and the stressed stranded wire, wear and fracture often occur inside or outside the crimping tube during vibration. Summary of the Invention

[0004] The purpose of the present invention is to provide a catenary suspension clamp crimping structure and a crimping method to solve the problems existing in the above-mentioned prior art, so that the main wire of the suspension has no bend at the port of the crimping tube, reducing the radial shear force and fatigue fracture risk of the stranded wire at this part.

[0005] To achieve the above purpose, the present invention provides the following solutions: The present invention provides a crimping structure for a catenary dropper, including a crimping tube. The crimping tube includes a pair of symmetrically arranged crimping channels. One end of the stranded wire sequentially passes through the two crimping channels to form a hanging loop. Each crimping channel includes an arc segment and two straight segments. The arc segment is a fillet at the connection of the two straight segments. The two straight segments form an obtuse angle. The adjacent crimping channels do not contact and communicate, and the two ports on the same side do not communicate. The stranded wire is fixed within the crimping channel.

[0006] Preferably, the included angle between the two straight segments of the same crimping channel is 145° - 180°, and the included angle between the two ports of the straight segments on the same opening side of the crimping tube is 0° - 45°.

[0007] Preferably, the two straight segments are symmetrically arranged with respect to the center line of the arc segment, and the length of the straight segment is 2 mm - 14 mm.

[0008] Preferably, the arc radius of the arc segment is at least 3 mm.

[0009] Preferably, the arc length of the arc segment is at least 2 mm.

[0010] Preferably, the wall thickness of the crimping channel is at least 1 mm, and the inner diameter of the crimping channel matches the outer diameter of the stranded wire and is 4 mm - 15 mm.

[0011] Preferably, the length of the crimping channel along the length direction of the stranded wire is 10 mm - 60 mm, and the width perpendicular to the length direction of the stranded wire is 8 mm - 50 mm.

[0012] Preferably, the material of the crimping channel includes metal or metal alloy.

[0013] Preferably, the crimping channel is an integrally formed part made of copper or copper alloy, and the stranded wire is fixed within the crimping channel by crimping.

[0014] The present invention also relates to a catenary dropper crimping method. Based on the above catenary dropper crimping structure, the method specifically includes the following steps: S1, cutting the material. Cut a cylindrical tube with an inner diameter of 8 - 16 mm into pipe segments of a set length for standby. S2. The pipe is deformed. The circular cross-section of the pipe segment is evenly pressed into a waist-shaped cross-section to form a flat pipe. The length of the waist-shaped cross-section is 15 mm and the width is 5 mm. The two ends of the flat pipe are flared with the same width, so that the opening lengths at both ends of the flat pipe are greater than the internal opening length. As a result, two side walls with straight segments smoothly connected by arc segments appear on the left and right sides of the flat pipe, and the included angle between the axes of the two straight-segment side walls on the same side is 145°-180°, or the included angle between the axes of the two straight-segment side walls on the same opening side is 0°-45°, forming a flared flat pipe. S3. The two ends of the stranded wire after passing around the heart-shaped ring are respectively passed through the flared flat pipe, and the opening of the flared flat pipe is made to abut against the edge of the heart-shaped ring, and this position state is maintained. S4. A mold is used to apply pressure to the upper and lower surfaces of the flared flat pipe to press the flared flat pipe and the stranded wire tightly, and the middle part of the flared flat pipe is made to fit with the stranded wire, so that two symmetrical and closed crimping multi-segments are formed in the middle part of the flared flat pipe, and a pair of crimping channels are formed. Each of the crimping multi-segments includes an arc segment and two straight segments. The arc segment is a fillet at the connection of the two straight segments, and the openings of the two arc segments both face the outside of the flared flat pipe, and the sliding load of the stranded wire in the crimping channel is at least greater than 2 kN.

[0015] The present invention has achieved the following technical effects compared with the prior art: Through the cooperation of the suspension string main wire, the pressure pipe and the heart-shaped ring, it can be ensured that there is no bending of the suspension string main wire at the pressure pipe, reducing the bending stress and fatigue fracture risk of the stranded wire at this part. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required to be used in the embodiments. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0017] Figure 1 It is a schematic structural diagram of the catenary suspension string crimping structure in the embodiment of the present invention Figure 1 ; Figure 2 It is a schematic structural diagram of the catenary suspension string crimping structure in the embodiment of the present invention Figure 2 ; Figure 3 It is a schematic structural diagram of the catenary suspension string crimping structure in the embodiment of the present invention Figure 3 ; Figure 4 It is a schematic structural diagram of the catenary suspension string crimping structure in the embodiment of the present invention Figure 4 ; Figure 5 Schematic structure of the catenary suspension crimping structure in the embodiment of the present invention Figure 5 ; Figure 6 Schematic diagram of the use and assembly of the catenary suspension crimping structure in the embodiment of the present invention Figure 1 ; Figure 7 Schematic diagram of the use and assembly of the catenary suspension crimping structure in the embodiment of the present invention Figure 2 ; Figure 8 In [diagram], a, b, c, d, and e are the process flow charts of the catenary suspension crimping method in the second embodiment of the present invention; Figure 9 Schematic diagram of the use and assembly of the catenary suspension crimping structure in the prior art; In the figure: 1 - stranded wire, 2 - crimping tube, 3 - crimping channel, 4 - straight section, 5 - arc section, 6 - heart-shaped loop, 7 - main suspension wire, 8 - suspension loop. Specific embodiments

[0018] 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 shall fall within the protection scope of the present invention.

[0019] The purpose of the present invention is to provide a catenary suspension crimping structure and a crimping method to solve the problems existing in the prior art, so that the main suspension wire has no bending at the port of the crimping tube, reducing the radial shear force and the risk of fatigue fracture of the stranded wire at this part.

[0020] To make the above objects, features, and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below in conjunction with the accompanying drawings and specific embodiments.

[0021] Embodiment 1 As Figures 1 to 7 shown, a catenary suspension crimping structure is provided in this embodiment, including a crimping tube 2. The crimping tube 2 includes a pair of symmetrically arranged crimping channels 3. One end of the stranded wire 1 sequentially passes through the two crimping channels 3 and forms a hanging loop shape. Each crimping channel 3 includes an arc section 5 and two straight sections 4. The arc section 5 is a fillet at the connection of the two straight sections 4. The two straight sections 4 form an obtuse angle. The adjacent crimping channels 3 do not contact and communicate, and the two ports on the same side do not communicate. The stranded wire 1 is fixed in the crimping channel 3.

[0022] As an alternative, in this embodiment, the included angle between the two straight segments 4 of the same crimping channel 3 is 145° to 180°, preferably 164°. The included angle between the two ports of the straight segments 4 on the same opening side of the crimping tube 2 is 0° to 45°, preferably 16°, which is similar to a hyperbolic shape. In this embodiment, a non-parallel wire arrangement scheme in the crimping tube is proposed, and then a wire arrangement scheme based on a hyperbola-like suspension string is proposed, verifying the stress state of the suspension string, so that the main wire always coincides with the loading direction when the suspension string is loaded, and there is no hard bend in the wire 1. The crimping method in this embodiment optimizes the shape of the matching heart-shaped ring 6, specifically modifying the included angle and length of the two straight segments of the heart-shaped ring 6, making it alignable with the crimping tube, facilitating the crimping operation, and protecting the wire 1 at the same time.

[0023] As an alternative, in this embodiment, the two straight segments 4 are symmetrically arranged about the center line of the arc segment 5, and the length of the straight segment 4 is 2 mm to 14 mm.

[0024] As an alternative, in this embodiment, the arc radius of the arc segment 5 is at least 3 mm.

[0025] As an alternative, in this embodiment, the arc length of the arc segment 5 is at least 2 mm.

[0026] As an alternative, in this embodiment, the wall thickness of the crimping channel 3 is at least 1 mm to ensure the connection strength. The inner diameter of the crimping channel 3 matches the outer diameter of the wire 1 after crimping and is 4 mm to 15 mm.

[0027] As an alternative, in this embodiment, the length of the crimping channel 3 along the length direction of the wire 1 is 10 mm to 60 mm, preferably 30 mm, and the width perpendicular to the length direction of the wire 1 is 8 mm to 50 mm, preferably 20 mm.

[0028] As an alternative, in this embodiment, the material of the crimping channel 3 includes metal or metal alloy, which is convenient for crimping and ensures a certain connection strength.

[0029] As an alternative, in this embodiment, the crimping channel 3 is preferably an integrally formed part made of copper or copper alloy. The wire 1 is fixed in the crimping channel 3 by crimping, and the sliding load of the wire 1 in the crimping channel 3 is at least greater than 2 kN, meeting the stress requirements when the wire 1 is used as the main wire 7 of the suspension string.

[0030] The crimping structure of the crimping channel 3 of the present embodiment eliminates the hard bending of the stranded wire 1 at the outlet of the traditional suspension string under stress; and the two groups of stranded wires 1 are in a separated state, avoiding wear between the stranded wires 1; at the same time, the distance between the stranded wire leading to the terminal block and the main line of the suspension string is relatively large, and at the same time, the width of the bayonet of the matching heart-shaped ring 6 is enlarged to match it with the opening of the crimping channel 3, which can avoid mutual wear of the stranded wire 1 outside the crimping tube 2; in addition, the overall dimensions of the crimping tube 2 and the heart-shaped ring 6 match the traditional crimping method, and can be directly adapted to the suspension ring 8, wire clamps, terminal blocks, suspension string main line 7, bolts and nuts, etc. used in the current suspension string, which is convenient for engineering application.

[0031] The main wire 7 of the suspension string in this embodiment has no bends at the end of the crimping tube 2, which reduces the bending stress of the stranded wire 1 at this position and reduces the risk of fatigue fracture of the stranded wire 1 at this position; the stranded wire 1 at the transition position between the heart-shaped ring of the suspension string and the crimping tube is aligned and has no bends, which reduces the bending stress of the stranded wire 1 at this position and reduces the risk of fatigue fracture of the stranded wire 1 at this position; the stranded wire of the current-carrying ring of the suspension string maintains a distance from the stranded wire of the main wire of the suspension string at the crimping tube position, which reduces the risk of wear between the strands.

[0032] Embodiment 2 like Figure 8 As shown, this embodiment provides a contact network dropper string crimping method, based on the contact network dropper string crimping structure of the above embodiment 1, specifically comprising the following steps: S1, cutting the cylindrical tube with an inner diameter of 12 mm into tube sections of set length for later use; S2, pressing and deforming the tube, uniformly pressing the circular cross section of the tube section into a waist-shaped cross section, forming a flat tube, the length of the waist-shaped cross section is 15 mm, and the width is 5 mm; expanding the two ends of the flat tube with the same width, so that the opening lengths of the two ends of the flat tube are greater than the internal opening length, so that two straight line segments 4 appear on the left and right sides of the flat tube. The side walls are smoothly connected by arc segments, and the axis angle of the side walls of the two straight line segments 4 on the same side is 145°~170°, or the axis angle of the side walls of the two straight line segments 4 on the same opening side is 10°~30°, forming an expanded flat tube; S3, passing the two ends of the stranded wire 1 around the heart-shaped ring 6 through the expanded flat tube respectively, and making the opening of the expanded flat tube collide with the edge of the heart-shaped ring 6, and maintaining this position; S4, use a mold to apply pressure to the upper and lower surfaces of the expanded flat tube, press the expanded flat tube and the stranded wire 1, and make the middle part of the expanded flat tube fit with the stranded wire 1, so that two symmetrical and closed crimping multi-segment lines are formed in the middle of the expanded flat tube, and a pair of crimping channels 3 are formed, and the crimping multi-segment lines each include an arc segment 5 and two straight line segments 4, the arc segment 5 is a chamfered corner at the connection of the two straight line segments 4, and the openings of the two arc segments 5 are both facing the outside of the expanded flat tube, and the sliding load of the stranded wire 1 in the crimping channel 3 is at least greater than 2KN, which meets the force requirement of the stranded wire 1 when used as the main line 7 of the suspension string.

[0033] In use, both ends of the main string of the suspension string 7 respectively form a hanging loop through a compression tube 2 and a heart-shaped loop 6. Then, the two heart-shaped loops 6 are respectively hung on the suspension loops 8 at the upper and lower ends. The suspension loop 8 is connected to the contact wire and the catenary (or elastic suspension wire) through a contact wire suspension string clamp. The stranded wire bent out from the compression tube 2 is connected to the contact wire suspension string clamp and the catenary (elastic suspension wire) suspension string clamp through a terminal, forming a complete set of suspension strings.

[0034] Embodiment III As Figure 9 shown, in this embodiment, a method for crimping a catenary suspension string is provided. Based on the catenary suspension string crimping structure of the above Embodiment I, the method specifically includes the following steps: S1. Cut the copper tube with an outer diameter of 14 mm and an inner diameter of 12 mm into tube segments with a length of 30 mm.

[0035] S2. Press the tube segment with a circular cross-section into a waist-shaped hole cross-section structure with a diameter of 5 mm and a length of 15 mm.

[0036] S3. Use a special mold to expand the mouth inside and outside, so that the waist-shaped hole is deformed into a flared mouth structure with symmetrical front and rear ports, and the opening angle of the flared mouth is 16°, forming a double-V-shaped flat tube structure.

[0037] S4. Pass the heart-shaped loop 6 and the stranded wire 1 through the double-V-shaped flat tube structure according to the assembly position requirements.

[0038] S5. Use a special crimping mold to press the copper tube and the stranded wire 1 tightly from the upper and lower directions respectively until the middle part of the compression tube 2 is crimped and closed, and the sliding load of the stranded wire 1 inside the compression tube 2 is at least greater than 2 kN, meeting the design standard.

[0039] In the description of this specification, the description with reference to terms such as "an implementation manner", "certain implementation manners", "illustrative implementation manners", "this embodiment", "specific examples" or "some examples" etc. means that the specific features, structures, materials or characteristics described in connection with the implementation manner or example are included in at least one implementation manner or example of the present invention. In this specification, the schematic expressions of the above terms do not necessarily refer to the same implementation manner or example. Moreover, the specific features, structures, materials or characteristics described can be combined in a suitable manner in any one or more implementation manners or examples.

[0040] In the present invention, specific examples are used to illustrate the principle and implementation manner of the present invention. The description of the above embodiments is only used to help understand the method and its core idea of the present invention; at the same time, for those of ordinary skill in the art, according to the idea of the present invention, there will be changes in the specific implementation manner and application scope. In summary, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. An overhead catenary dropper crimping structure, characterized in that: It comprises a crimping tube, which comprises a pair of crimping channels symmetrically arranged, one end of the stranded wire passes through the two crimping channels in sequence to form a hanging loop, each of the crimping channels comprises an arc segment and two straight segments, the arc segment is a chamfer at the connection of the two straight segments, the two straight segments form an obtuse angle, adjacent crimping channels are not in contact and connected, and the two ports on the same side are not connected, and the stranded wire is fixed in the crimping channel.

2. The catenary suspension clamp crimping structure according to claim 1, wherein: The included angle between the two straight segments of the same crimping channel is 145° to 180°, and the included angle between the two ports of the straight segment located on the same opening side of the crimping tube is 0° to 45°.

3. The catenary suspension clamp crimping structure according to claim 1, wherein: The two straight line segments are symmetrically arranged about the center line of the arc segment, and the length of the straight line segment is 2 mm to 14 mm.

4. The catenary suspension clamp crimping structure according to claim 1, characterized in that: The arc radius of the arc segment is at least 3 mm.

5. The contact wire dropper crimping structure according to claim 1, characterized in that: The arc length of the arc segment is at least 2 mm.

6. The catenary suspension clamp crimping structure according to claim 1, wherein: The wall thickness of the crimping channel is at least 1 mm, and the inner diameter of the crimping channel matches the outer diameter of the stranded wire and is 4 mm to 15 mm.

7. The contact wire dropper crimping structure according to claim 1, characterized in that: The length of the crimping channel along the length direction of the stranded wire is 10 mm to 60 mm, and the width perpendicular to the length direction of the stranded wire is 8 mm to 50 mm.

8. The catenary suspension clamp crimping structure according to claim 1, characterized in that: The material of the crimping channel includes metal or metal alloy.

9. The catenary suspension clamp crimping structure according to claim 1, characterized in that: The crimping channel is an integrally formed part made of copper or copper alloy, and the stranded wire is fixed in the crimping channel by crimping.

10. A method for crimping a catenary dropper, based on the catenary dropper crimping structure described in any one of claims 1 to 9, characterized in that, The steps include: S1, cutting the cylindrical tube with an inner diameter of 8-16 mm into tube sections of set length for standby use; S2, pressing and deforming the tube, uniformly pressing the circular cross section of the tube section into a waist-shaped cross section to form a flat tube, wherein the waist-shaped cross section is 15 mm long and 5 mm wide; expanding the two ends of the flat tube to the same width, so that the opening lengths of the two ends of the flat tube are greater than the inner opening length, so that two straight line segments appear on the left and right sides of the flat tube. The side walls are smoothly connected by arc segments, and the axis angles of the two straight line segments on the same side are 145° to 180°, or the axis angles of the two straight line segments on the same opening side are 0° to 45°, so as to form an expanded flat tube; S3, passing the two ends of the stranded wire around the heart-shaped ring through the expanded flat tube respectively, and making the opening of the expanded flat tube collide with the edge of the heart-shaped ring, and maintaining this position; S4, using a mold to apply pressure to the upper and lower surfaces of the flared flat tube, to press the flared flat tube and the stranded wire, and to fit the middle of the flared flat tube with the stranded wire, so that two symmetrical and closed crimping multi-segment lines are formed in the middle of the flared flat tube, and a pair of crimping channels are formed, wherein the crimping multi-segment lines each include an arc segment and two straight line segments, wherein the arc segment is a chamfer at the connection of the two straight line segments, and the openings of the two arc segments are both facing the outside of the flared flat tube, and the sliding load of the stranded wire in the crimping channel is at least greater than 2kN.

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