A crimping process for stranded carbon fiber composite material core conductor joint tube

Abstract

The present invention relates to the technical field of wire splicing and crimping, and more specifically, to a process for crimping a twisted carbon fiber composite material core wire splicing tube, comprising: sleeve-mounting two aluminum liner tubes on the crimping ends of two cleaned wires to be crimped; inserting the aluminum tube through the crimping end of any wire to be crimped; inserting the two wires to be crimped, sleeved with the aluminum liner tubes, into the steel tube from both ends, and bringing the crimping ends of the two wires to be crimped into contact; applying pressure to the steel tube through a crimping device to crimp the crimping ends of the two wires to be crimped in the steel tube; applying electrical grease to the surface of the wire to be inserted into the aluminum tube, and then moving the aluminum tube to the wire sleeved on the steel tube and the two wires coated with electrical grease; and applying pressure to the aluminum tube through a crimping device to crimp the aluminum tube to the wire inside. By crimping the aluminum liner tube, the steel tube, and the aluminum tube together, a multi-layer connection structure is formed, effectively increasing the mechanical strength of the material core wires after splicing.

Description

Technical Field

[0001] The present invention relates to the technical field of conductor splicing and crimping, and more particularly to a crimping process for a stranded carbon fiber composite material core conductor splicing tube. Background Art

[0002] Conductor splicing is an essential step in overhead line installation. Carbon fiber composite conductors, for example, offer excellent properties such as high strength, light weight, low sag, high conductivity, high current carrying capacity, and high operating temperature. They solve the systemic technical problem of balancing high capacity with low loss in the power transmission and transformation industry, and are hailed as a revolution in this field. With rapid economic development and the rapid growth of electricity load in some regions, carbon fiber composite conductors are gaining attention and application in line reconstruction. However, the carbon fiber composite core exhibits poor bending and torsional resistance and lateral pressure resistance, placing high demands on the corresponding conductor hardware and construction techniques. The splicing process and fittings for carbon fiber composite conductors are the most critical aspects of carbon fiber conductor engineering applications. Traditional crimping techniques are prone to damage to the carbon fiber composite core (a brittle material) during crimping due to concentrated pressure or material mismatch, resulting in low mechanical strength of the joints. Furthermore, the joints produced using traditional methods lack overall sealing and durability, leading to a high probability of joint aging. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to overcome the deficiencies of the prior art and provide a crimping process for a stranded carbon fiber composite material core conductor connecting tube.

[0004] The technical solution adopted in the present invention is:

[0005] A twisted carbon fiber composite material core conductor connecting tube crimping process, comprising:

[0006] Install two aluminum liner sleeves on the crimping ends of two cleaned wires to be crimped;

[0007] Put the aluminum tube through the crimping end of any wire to be crimped and put it on the wire;

[0008] Insert two wires to be crimped, which are sleeved with aluminum liner tubes, into the steel tube from both ends, and make the crimping ends of the two wires to be crimped contact;

[0009] The steel pipe is pressurized by the crimping device to crimp the crimping ends of the two wires to be crimped in the steel pipe;

[0010] After applying electrical grease on the surface of the wire body to be inserted into the aluminum tube, move the aluminum tube to be sleeved on the steel tube and the two wires coated with electrical grease;

[0011] The aluminum tube is pressurized by a crimping device so that the aluminum tube and the wire inside it are crimped.

[0012] Furthermore, before installing the two aluminum liner tubes on the crimping ends of the two cleaned wires to be crimped, first wipe the crimping end surfaces of the wires to be crimped with a clean cloth, and the length of the wires to be crimped should not be less than 3 times the length of the aluminum tube.

[0013] Furthermore, when two aluminum liner tubes are sleeved and installed on the crimping ends of two cleaned wires to be crimped, if the crimping ends of the wires to be crimped are damaged, deformed or contaminated, the crimping ends of the wires need to be sawed off with a hacksaw and the aluminum wires need to be stripped.

[0014] Furthermore, when stripping the aluminum wire of the crimped end of the wire, after sawing off the damaged, deformed or contaminated crimped end of the wire, the surface of the wire end with a length not less than 3 times the length of the aluminum tube is cleaned; then the wire length L1 of half the length of the steel tube is measured from the crimped end of the wire, the length L1 is added to the compressed extension length L2 of the wire to obtain the aluminum stripping marking point of the wire, and after wrapping and binding the side of the aluminum stripping marking point away from the crimped end of the wire, the aluminum single wire of the wire is sawed and stripped in layers at the aluminum stripping marking point.

[0015] Furthermore, when the two wires to be crimped with the two aluminum liner tubes are inserted into the steel pipe from both ends, the ends of the two aluminum liner tubes are controlled to be flush with the two ends of the steel pipe so that the crimping lengths of the crimping ends of the wires at both ends are consistent.

[0016] Furthermore, the steel pipe is pressurized by the crimping device so that when the crimping ends of the two wires to be crimped in the steel pipe are crimped, they are crimped in sequence from the center of the steel pipe to both ends of the steel pipe. When the crimping device applies pressure, the overlapping area between two adjacent indentation areas is not less than 5 mm.

[0017] Furthermore, after the surface of the wire body that needs to be inserted into the aluminum tube is coated with electrical grease, the aluminum tube is moved to the wire body that is sleeved on the steel tube and the two wires coated with electrical grease. First, the length of the wire to be inserted into the aluminum tube is measured. When measuring, the wire length L3 that is half the length of the aluminum tube is measured from the center of the steel tube to both sides, and the end point of the electrical grease coating is marked at L3. Then, the coating device is controlled to evenly coat the surface of the wire body where the wire contacts the inner wall of the aluminum tube from the end point mark of the electrical grease coating toward the crimping end of the wire. Then, the part coated with electrical grease is applied along the twisting direction of the wire with a wire brush. After the electrical grease is fully and evenly contacted with the wire, the wire is pushed into the aluminum tube, and the mouth of the aluminum tube is made to coincide with the end point mark of the electrical grease coating.

[0018] Furthermore, the aluminum tube is pressurized by a crimping device so that when the aluminum tube is crimped and connected to the wires inside it, the two stripping aluminum wire marking points of the aluminum tube and the two wires are crimped to the two ends of the aluminum tube. When pressure is applied by the crimping device, the overlapping area between the two adjacent indentation areas is not less than 5 mm.

[0019] As can be seen from the above scheme, the beneficial effects of the present invention are:

[0020] The present invention provides a crimping process for a twisted carbon fiber composite material core conductor connecting tube, in which an aluminum liner tube, a steel tube and an aluminum tube are crimped together to form a multi-layer connection structure, thereby effectively increasing the mechanical strength after the connection; the aluminum liner tube plays a role in preliminary protection and support of the conductor, while the steel tube provides strong mechanical strength and can withstand large tensile force; finally, the aluminum tube is crimped to further reinforce the connection part, so that the mechanical connection strength of the entire connection part is significantly improved, and it can better adapt to various complex operating environments; the conductor and the connecting tube are tightly combined, reducing the problem of mechanical performance degradation caused by looseness.

[0021] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, preferred embodiments are given below and described in detail with reference to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings:

[0023] Figure 1 A flow chart of a crimping process for a stranded carbon fiber composite material core conductor connector provided by an embodiment of the present invention;

[0024] Figure 2 This is a structural diagram of a connecting tube used in the crimping process of a stranded carbon fiber composite material core conductor connecting tube;

[0025] Figure 3 A schematic diagram of a conductor provided by an embodiment of the present invention after stripping the aluminum wire;

[0026] Figure 4 A schematic diagram of a conductor provided by an embodiment of the present invention passing through a steel pipe;

[0027] Figure 5 A schematic diagram of a crimped steel pipe according to an embodiment of the present invention;

[0028] Figure 6 A schematic diagram of a crimped aluminum tube according to an embodiment of the present invention;

[0029] Figure 7 A schematic diagram of a first direction of a crimping device provided by an embodiment of the present invention;

[0030] Figure 8 A schematic diagram of a second direction of the crimping device provided by an embodiment of the present invention;

[0031] Figure 9 A schematic diagram of a device framework provided by an embodiment of the present invention;

[0032] Figure 10 A schematic diagram of a centering pressure clamp structure provided by an embodiment of the present invention;

[0033] Figure 11 A schematic diagram of a movable pressure clamp structure in a first direction provided by an embodiment of the present invention;

[0034] Figure 12 A schematic diagram of a movable pressure clamp structure in a second direction according to an embodiment of the present invention;

[0035] Figure 13 A schematic diagram of a tube half-length measurement structure provided in an embodiment of the present invention;

[0036] Icons: Aluminum liner 1; conductor 2; aluminum tube 3; steel tube 4; aluminum wire stripping mark 5; winding and binding mark 6; device frame 100; frame base 101; load slide 102; loading screw 103; loading spring 104; load beam 105; centering clamp structure 200; upper clamp body 201; lower clamp body 202; clamp body support 203; transfer tube 204; anti-roll plate 205; rotating column 206; correction control panel 207; correction cylinder 208; centering gear 209; worm gear 210; rack plate 211; Traction motor 212; worm 213; half-length alignment line 214; movable pressure clamp structure 300; movable assembly seat 301; support 302; assembly frame 303; left clamp body 304; right clamp body 305; anti-slip horizontal shaft 306; crimping connecting rod 307; pressure control plate 308; movable pressure block 309; pressure regulating screw 310; locking screw 311; pressure stabilizing shaft 312; pressure control cylinder 313; tube half-length measuring structure 400; loading seat 401; flip measuring tube 402; flip measuring rod 403; measuring screw 404. DETAILED DESCRIPTION

[0037] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0038] It should be understood that terms such as “having”, “including” and “comprising” used herein do not preclude the existence or addition of one or more other elements or combinations thereof.

[0039] Example 1

[0040] See also Figures 1-6 The present invention provides a twisted carbon fiber composite material core conductor connecting tube crimping process, comprising:

[0041] Install two aluminum liner tubes 1 on the crimping ends of two cleaned wires 2 to be crimped;

[0042] Put the aluminum tube 3 through the crimping end of any wire 2 to be crimped and put it on the wire 2;

[0043] Insert the two wires 2 to be crimped, which are sleeved with the aluminum liner tubes 1, into the steel tube 4 from both ends, and make the crimping ends of the two wires 2 to be crimped contact with each other; apply pressure to the steel tube 4 through the crimping device to crimp the two wires 2 to be crimped in the steel tube 4;

[0044] After the wire 2 to be inserted into the aluminum tube 3 is coated with electrical grease on its surface, the aluminum tube 3 is moved to be sleeved on the steel tube 4 and the wire body coated with electrical grease on the two wires 2; pressure is applied to the aluminum tube 3 through a crimping device to crimp the aluminum tube 3 with the wire 2 inside it.

[0045] The working principle and technical effects of the above technical solution are as follows:

[0046] In a crimping process for a twisted carbon fiber composite material core conductor connecting tube of the present invention, two aluminum liner tubes 1 are sleeved and installed on the crimping ends of two cleaned conductors 2 to be crimped. The aluminum liner tube 1 can provide mechanical protection for the conductors 2 during subsequent operations, and can reduce the friction and collision suffered by the conductors 2 during the insertion of the conductors 2 into the steel pipe 4 and the subsequent crimping process, thereby preventing the outer structure and internal fibers of the conductors 2 from being damaged, and ensuring the mechanical and electrical properties of the conductors 2 themselves; the aluminum liner tube 1 is sleeved on the crimping end of the conductor 2, which helps to position the conductors 2 when they are inserted into the steel pipe 4, so that the two conductors 2 can be more accurately docked in the steel pipe 4, and provide certain support for the conductors 2, ensuring that the conductors 2 will not be excessively bent or deformed during the crimping process, thereby improving the accuracy and stability of the crimping; the aluminum tube 3 is sleeved on the crimping end of any conductor 2 to be crimped The wire 2 is sleeved on the aluminum tube 3, and after the surface of the wire body to be inserted into the aluminum tube 3 is coated with electrical grease, the aluminum tube 3 is moved to the wire body sleeved on the steel tube 4 and the two wires 2 coated with electrical grease and crimped. The aluminum tube 3 further wraps the wire 2 and the steel tube 4 to form a multi-layer crimping structure, which enhances the mechanical connection strength of the joint and improves the overall tensile strength of the joint, so that it can withstand greater tension and external force. The use of electrical grease further reduces the contact resistance between the wire 2 and the aluminum tube 3 and enhances the stability of the electrical connection. In addition, the steel tube 4 has high strength and rigidity, which can provide strong mechanical support for the joint of the wire 2, ensuring that the joint will not be easily disconnected in various complex operating environments, such as wind, vibration, etc., thereby improving the reliability and safety of the entire wire line.

[0047] In a crimping process for a twisted carbon fiber composite material core conductor connecting tube of the present invention, a stable and reliable connecting structure is formed through the coordinated cooperation of the aluminum liner tube 1, the aluminum tube 3 and the steel tube 4. The multi-layer crimping method reinforces and protects the connecting part of the conductor 2 from multiple aspects, improves the mechanical and electrical properties of the connecting part, ensures the stability and reliability of the twisted carbon fiber composite material core conductor during long-term operation, and can effectively protect the conductor 2 from damage, reduce oxidation and reduce contact resistance, thereby reducing the probability of failure at the connecting part of the conductor 2, extending the service life of the entire conductor line, and reducing maintenance costs and power outage time.

[0048] Before installing the two aluminum liner tubes 1 on the crimping ends of the two cleaned wires 2 to be crimped, first wipe the surface of the crimping ends of the wires 2 to be crimped with a clean cloth. The length of the wires 2 to be crimped should not be less than 3 times the length of the aluminum tube 3.

[0049] A clean wire surface can make the aluminum liner tube 1 fit better with the wire 2; the length of the wire to be crimped is not less than 3 times the length of the aluminum tube 3, and the wire 2 to be crimped is long enough to provide enough space and length for the crimping operation. When the aluminum tube 3 is moved to the wire body that is sleeved on the steel tube 4 and the two wires 2 coated with electrical grease and crimped, if the wire length is too short, the aluminum tube 3 may not be able to completely cover the part of the wire that needs to be crimped, or sufficient crimping force may not be formed during the crimping process, thereby affecting the quality and effect of the crimping. Controlling the wire length to be not less than 3 times the length of the aluminum tube 3 can ensure that the aluminum tube 3 can be fully crimped with the wire 2, ensure the mechanical strength and electrical performance of the crimped part, and make it easier to operate and position during the construction process.

[0050] When two aluminum liner tubes 1 are sleeved and installed on the crimping ends of two cleaned wires 2 to be crimped, if the crimping ends of the wires 2 to be crimped are damaged, deformed or contaminated, the crimping ends of the wires 2 need to be sawed off with a hacksaw and the aluminum wires need to be stripped.

[0051] When a conductor crimp end becomes damaged or deformed, its internal structure may be disrupted, leading to increased resistance. If contaminated, the contaminants also increase resistance. After sawing off the damaged and contaminated sections, the new crimp end ensures good contact with the aluminum liner and other connecting components, effectively reducing contact resistance and making the conductor's conductivity more stable. This helps maintain the stable operation of the entire transmission line and reduces voltage fluctuations and power failures caused by poor contact.

[0052] Example 2

[0053] See also Figures 1-6 In a twisted carbon fiber composite material core conductor connecting tube crimping process provided by the present invention, when stripping the aluminum wire of the crimping end of the conductor 2, the damaged, deformed or contaminated crimping end of the conductor 2 is sawed off, and the surface of the end of the conductor 2 with a length not less than 3 times the length of the aluminum tube 3 is cleaned; then the length L1 of the conductor 2, which is half the length of the steel tube 4, is measured from the crimping end of the conductor 2, and the length L1 + the compressed extension length L2 of the conductor 2 are added to obtain the aluminum stripping marking point 5 of the conductor 2. After the side of the aluminum stripping marking point 5 away from the crimping end of the conductor 2 is wrapped and tied, the aluminum monofilament of the conductor 2 is sawed and peeled off in layers at the aluminum stripping marking point 5, and the wrapping and binding marking point 6 can be wrapped and tied with tape.

[0054] The working principle and technical effects of the above technical solution are as follows:

[0055] In a crimping process for a twisted carbon fiber composite material core conductor connecting tube of the present invention, the length L1 of the conductor 2, which is half the length of the steel tube 4, is measured from the crimping end of the conductor 2, and then the length L1 is added to the compressed extension length L2 of the conductor 2 to obtain the aluminum stripping marking point 5 of the conductor 2. The method of accurately determining the marking point can ensure the accuracy and stability of the crimping structure, ensure that the carbon fiber composite core of the conductor 2 is correctly positioned and crimped in the steel tube, and at the same time match the stripping range of the aluminum monofilament with the entire connecting process, which is conducive to ensuring the mechanical and electrical properties of the connecting part; the clear aluminum stripping marking point 5 provides construction personnel with an accurate operating basis. Different construction personnel can perform the aluminum stripping operation in accordance with a unified standard, reducing the arbitrariness of the operation, ensuring that the construction quality of each connecting part has a high consistency, and improving the reliability of the entire transmission line.

[0056] Example 3

[0057] See also Figures 1-6 In the crimping process of a stranded carbon fiber composite material core conductor connecting tube provided by the present invention, when the two wires 2 to be crimped with the two aluminum liner tubes 1 are inserted into the steel tube 4 from both ends, the ends of the two aluminum liner tubes 1 are controlled to be flush with the two ends of the steel tube 4, so that the crimping lengths of the crimping ends of the wires 2 at both ends are consistent. The steel tube 4 is pressurized by the crimping device so that when the crimping ends of the two wires 2 to be crimped in the steel tube 4 are crimped, they are crimped in sequence from the center of the steel tube 4 to the two ends of the steel tube 4. Figure 5 As shown, after the first crimping of the center of the steel pipe 4, crimping is performed in sequence from the center of the steel pipe 4 to both ends of the steel pipe 4 until the crimping work is completed after n crimpings. n is the last number of crimpings, which is adjusted according to the actual length of the steel pipe 4 and the actual crimping spacing, and is not a fixed value.

[0058] The working principle and technical effects of the above technical solution are as follows:

[0059] In a crimping process of a twisted carbon fiber composite material core conductor connecting tube of the present invention, the ends of the two aluminum liner tubes 1 are flush with the two ends of the steel pipe 4, which can ensure that the crimping lengths of the crimping ends of the conductors 2 at both ends are consistent, and the electrical connection performance of the two conductors is the same. During the power transmission process, the uniform crimping length can make the current evenly distributed on the two conductors, avoiding the current concentration at one end due to the difference in crimping length, thereby reducing the contact resistance, reducing the power loss, improving the power transmission efficiency, and ensuring the stability and safety of the power transmission; crimping is carried out from the center of the steel pipe 4 to the two ends of the steel pipe 4 in sequence, so that the crimping ends of the two conductors to be crimped 2 in the steel pipe 4 are more evenly and tightly combined over the entire length. The tight and uniform crimping can reduce the contact resistance between the conductors, thereby reducing the loss of electric energy at the connection part, and because the crimping is tight and uniform, there will be no situation where the local resistance is too large or too small, avoiding electrical faults caused by local overheating or uneven electric field distribution, such as corona discharge, accelerated insulation aging, and other problems, thereby ensuring the reliable operation of the power system. Crimping from the center of the steel pipe 4 to both ends of the steel pipe 4 in sequence can make the pressure distribution of the steel pipe 4 on the wire more reasonable. During the crimping process, the center of the steel pipe is crimped first, which can form a firm connection between the wires in the center. Then, as the crimping is done towards the two ends, this firm connection is gradually extended to the entire crimping area, so that the wire 2 can be fully fixed and constrained throughout the entire crimping length, thereby enhancing the overall mechanical strength of the connection of the wire 2, enabling it to better withstand external forces such as tension, wind, and vibration, and reducing the risk of the wire breaking or loosening due to external forces during operation. If other crimping sequences are used, greater stress concentration may occur in certain parts of the steel pipe. However, crimping from the center to both ends can effectively disperse the stress. When the pressure is gradually transmitted from the center to both ends, the stress distribution inside the steel pipe 4 and the conductor 2 is more uniform, avoiding material damage or deformation caused by stress concentration, and extending the service life of the conductor and the connecting pipe. In addition, it is convenient to adjust according to the actual length of the steel pipe 4 and the actual crimping spacing. The crimping method from the center to both ends can adapt well to steel pipes of different lengths. No matter how the length of the steel pipe changes, the crimping operation can be performed starting from the center according to the same principle, which has strong versatility and flexibility.

[0060] Example 4

[0061] See also Figures 1-6In a twisted carbon fiber composite material core conductor connecting tube crimping process provided by the present invention, after the surface of the wire body to be inserted into the aluminum tube 3 is coated with electrical grease, the aluminum tube 3 is moved to the wire body sleeved on the steel tube 4 and the two wires 2 coated with electrical grease, the length of the wire 2 to be inserted into the aluminum tube 3 is first measured. During the measurement, the length L3 of the wire 2 that is half the length of the aluminum tube 3 is measured from the center of the steel tube 4 to both sides thereof, and the end point of the electrical grease coating is marked at L3. Then, the coating device is controlled to evenly coat the surface of the wire body where the wire 2 contacts the inner wall of the aluminum tube 3 from the end point mark of the electrical grease coating toward the crimping end of the wire 2, and then the part coated with electrical grease is smeared along the twisting direction of the wire 2 with a wire brush. After the electrical grease is fully and evenly contacted with the wire 2, the wire 2 is pushed into the aluminum tube 3, and the tube mouth of the aluminum tube 3 is made to coincide with the end point mark of the electrical grease coating.

[0062] The working principle and technical effects of the above technical solution are as follows:

[0063] In the present invention's twisted carbon fiber composite core conductor splice crimping process, electrical grease is evenly coated on the surface of the conductor 2 where it contacts the inner wall of the aluminum tube 3, filling the tiny gap between the conductor and the aluminum tube and increasing the effective contact area between the two, thereby reducing contact resistance. This helps reduce power loss at the splice site, improves power transmission efficiency, avoids heating at the splice site due to excessive contact resistance, and ensures the stability and safety of power transmission. In addition, the electrical grease can form a protective film on the surface of the conductor, isolating it from air and moisture, preventing oxidation of the conductor surface, extending the service life of the conductor, and maintaining long-term stable electrical performance at the splice site. In this process, by measuring the length L3 of the conductor 2, which is half the length of the aluminum tube 3, from the center of the steel tube 4 to both sides, and marking the end point of the electrical grease coating at L3, the coating range of the electrical grease can be precisely controlled, ensuring that the electrical grease is only coated on the surface of the conductor 2 where it contacts the inner wall of the aluminum tube 3, avoiding excessive or insufficient coating, ensuring the accuracy and consistency of the coating, and thus improving the splice quality.

[0064] Control the brushing device to evenly apply the electrical grease from the end point mark of the electrical grease coating toward the crimping end of the wire 2, and then use a wire brush to apply the electrical grease-coated part along the twisting direction of the wire 2. These two steps combined can make the electrical grease fully and evenly contact with the wire 2. The uniform electrical grease coating can ensure the consistency of electrical performance, avoid the difference in contact resistance caused by local uneven coating, and further improve the reliability of the connection part.

[0065] The aluminum tube 3 is pressed by the crimping device to connect the aluminum tube 3 with the wire 2 inside it. The two stripping aluminum wire marking points 5 of the aluminum tube 3 and the two wires 2 are crimped to the two ends of the aluminum tube 3. Figure 6As shown, after the first crimping is performed at the aluminum stripping mark point 5, crimping is performed on both ends of the aluminum tube 3 in sequence until the crimping work is completed after n crimpings are performed. n is the final number of crimpings, which is adjusted according to the actual length of the aluminum tube 3 and the actual crimping spacing. It is not a fixed value. When pressure is applied by the crimping device, the overlapping area between two adjacent indentation areas is not less than 5 mm.

[0066] The aluminum stripping mark point 5 is the key position for connecting the aluminum tube 3 and the conductor 2. Crimping from this position to both ends can ensure that the aluminum tube 3 and the conductor 2 are in close contact at the aluminum stripping mark point 5, forming a solid connection foundation at the key position, and then gradually expanding to the entire crimping area, so that the aluminum tube 3 and the conductor 2 can obtain a good mechanical connection throughout the entire length. In addition, according to this crimping sequence, the stress generated by crimping will gradually disperse from the aluminum stripping mark point 5 to both ends, avoiding excessive stress concentration in a certain local area; crimping from the aluminum stripping mark point 5 to both ends can make the current evenly distributed at the connection between the conductor 2 and the aluminum tube 3. The uniform current distribution can avoid overheating and insulation aging problems caused by excessive local current, extend the service life of the conductor 2 and the aluminum tube 3, and at the same time improve the safety of the entire transmission line.

[0067] In addition, for wires 2 and aluminum tubes 3 of different specifications, the aluminum stripping marking point 5 can be reasonably set according to actual conditions. Regardless of the thickness of the wire 2 or the length of the aluminum tube 3, the crimping operation is performed based on the aluminum stripping marking point 5. The crimping method has good versatility and adaptability and can meet diverse engineering needs.

[0068] The overlapping area between two adjacent indentation areas is not less than 5mm, which can connect the indentation areas to form a continuous and stable connection structure. The overlapping part increases the contact area and friction between the aluminum tube and the wire, improves the tensile and shear resistance of the crimping part, and when the crimping part is subjected to external force, the overlapping indentation area can disperse the stress to a larger range, avoiding stress concentration at a certain point or area.

[0069] Example 5

[0070] See also Figures 1-13In the crimping process of the twisted carbon fiber composite material core conductor connecting tube, the crimping device used includes: a device frame 100, on which is connected a centering clamp structure 200 and two movable clamp structures 300 that are relatively matched and arranged on both sides of the centering clamp structure 200, the centering clamp structure 200 is connected to the two movable clamp structures 300 to control the two movable clamp structures 300 to crimp and move from the two ends of the steel pipe 4 or the aluminum pipe 3 to the middle of the steel pipe 4 or the aluminum pipe 3; both movable clamp structures 300 are installed with a tube body half-length measuring structure 400, and when the tube body half-length measuring structure 400 is matched with the middle position of the centering clamp structure 200, it is the same as half the length of the steel pipe 4 or the aluminum pipe 3.

[0071] The working principle and technical effects of the above technical solution are as follows:

[0072] In the crimping process of a stranded carbon fiber composite material core conductor connecting tube of the present invention, a crimping device specially adapted for this process is used. The crimping device is particularly adapted for crimping from the two stripping aluminum wire marking points 5 of the aluminum tube 3 and the two conductors 2 to the two ends of the aluminum tube 3. The spacing between the two movable clamp structures 300 can be adjusted according to the length of the aluminum tube 3, so that the two movable clamp structures 300 are respectively clamped at the two ends of the aluminum tube 3, and then the middle of the aluminum tube 3 is fixed by the centering clamp structure 200. The centering clamp structure 200 and the two The movable clamp structure 300 is connected, and the centering clamp structure 200 can drive the two movable clamp structures 300 to move synchronously closer or farther on the device frame 100. When the aluminum tube 3 and the two wires 2 are crimped, the two movable clamp structures 300 are first controlled to move to the position where the aluminum tube 3 is close to the two stripping aluminum wire marking points 5. After the aluminum tube 3 and the two stripping aluminum wire marking points 5 of the two wires 2 are crimped by the two movable clamp structures 300, the two movable clamp structures 300 are then controlled by the centering clamp structure 200 to move synchronously to the aluminum tube 3. The two ends of the clamp are moved at a fixed distance, so that the two movable clamp structures 300 can continuously crimp the aluminum tube 3 and the two wires 2, which can improve the regularity of the crimping connection of the wires on both sides and improve the crimping effect. In addition, the two movable clamp structures 300 are equipped with a tube half-length measuring structure 400. When the tube half-length measuring structure 400 is matched with the middle position of the centering clamp structure 200, that is, the same as half the length of the steel tube 4 or the aluminum tube 3, at this time, the wires that need to be fixed in length can be directly crimped by the tube half-length measuring structure 400. Fixed length, no need to use other measuring equipment, not only saves construction time and cost, but also reduces the impact of measurement errors, and improves construction efficiency and accuracy; when crimping the steel pipe 4 and the wire 2, first determine the center position of the steel pipe 4 through the crimping device, then use a movable crimping clamp structure 300 to crimp the center of the steel pipe 4 and the two wires 2, then fix the centering crimping clamp structure 200 at the center of the steel pipe 4, and then control the two movable crimping clamp structures 300 to crimp from the center of the steel pipe 4 to the two ends of the steel pipe 4 in sequence.

[0073] Example 6

[0074] See also Figures 1-13 The device frame 100 includes: a frame seat 101, two opposite slide grooves are opened on the upper surface of the frame seat 101, two load-bearing slides 102 sliding in the two slide grooves are threadedly connected with two loading screws 103 rotated in the two slide grooves, and loading springs 104 for tensioning and limiting are fixed between the two load-bearing slides 102 and the inner walls of the two slide grooves; two load-bearing beams 105 mounted on the two load-bearing slides 102 are arranged parallel to the top of the frame seat 101; two movable pressure clamp structures 300 are relatively mounted on the two ends of the two load-bearing beams 105; the centering pressure clamp structure 200 is connected to the center of the frame seat 101.

[0075] The working principle and technical effects of the above technical solution are as follows:

[0076] In the device frame 100, two front and rear opposite slide grooves are opened on the upper surface of the frame seat 101. The two bearing slides 102 are slidably arranged in the slide grooves and are threadedly connected with the two loading screws 103 rotated in the slide grooves. When the loading screw 103 is rotated, the contact position between the loading screw 103 and the bearing slide 102 can be changed, thereby driving the bearing slide 102 to slide in the slide groove, and finally adjusting the distance between the two bearing crossbeams 105. The two movable pressure clamp structures 3 are realized by adjusting the two bearing crossbeams 105. 00 installation or disassembly; loading springs 104 are fixedly connected between the two bearing slides 102 and the inner walls of the two slide grooves. During the movement of the bearing slide 102, the loading springs 104 will produce elastic deformation, which plays a role of tensioning and limiting, so that the bearing slide 102 remains in a stable position to prevent it from shaking or shifting; the centering clamp structure 200 is connected to the center of the frame seat 101, and can fix and position the middle position of the steel pipe 4 or the aluminum pipe 3, providing a reference for the crimping operation of the movable clamp structure 300.

[0077] Example 7

[0078] See also Figures 1-13 The centering pressure clamp structure 200 includes: an upper clamp body 201 and a lower clamp body 202 arranged opposite to each other, the upper clamp body 201 and the lower clamp body 202 are connected by bolts and nuts, the adjacent ends of the upper clamp body 201 and the lower clamp body 202 are provided with a trapezoidal clamping groove, and the two trapezoidal clamping grooves form a hexagonal groove when the upper clamp body 201 and the lower clamp body 202 are docked; the lower clamp body 202 is fixed to the clamp body support 203, the bottom of the clamp body support 203 is slidably connected to the transfer tube 204, the transfer tube 204 is rotatably fitted in the center of the anti-roll plate 205, the anti-roll plate 205 is rotatably connected to the upper ends of the four rotating columns 206, and the lower ends of the four rotating columns 206 are rotatably fitted on the frame seat 101; the clamp body support 203 is fixed to the correction control board 207 On the top, the correction control plate 207 is connected to the movable end of the correction cylinder 208, and the correction cylinder 208 is fixed on the anti-roll plate 205; a centering gear 209 and a worm gear 210 are fixed on the transfer tube 204 rotated in the center of the frame seat 101, and the front and rear sides of the centering gear 209 are respectively engaged with a rack plate 211, and the two rack plates 211 are connected one by one with two movable pressure clamp structures 300; the worm gear 210 is engaged with a worm 213 connected by a key to the output end of the traction motor 212, and the traction motor 212 is installed on the frame seat 101; the outer side surface of each rack plate 211 is slidably matched with the two rotating columns 206; a half-length alignment line 214 is provided in the middle of the side surface of the lower clamp body 202, which is arranged opposite to the half-length measuring structure 400 of the tube body.

[0079] The working principle and technical effect of the above technical solution are as follows: after the traction motor 212 is started, it can drive the worm 213 to rotate, and when the worm 213 rotates, it engages the worm wheel 210 to rotate, and when the worm wheel 210 rotates, it drives the transfer tube 204 and the centering gear 209 on the transfer tube 204 to rotate, and when the centering gear 209 rotates, it engages the two rack plates 211 to move, and the two rack plates 211 drive the two movable clamp structures 300 to slide toward or away from each other on the two bearing beams 105, thereby adjusting the two movable clamp structures 300. The crimping position of 00 is convenient for centering the pressure clamp structure 200 to determine the center position of the aluminum tube 3 or steel tube 4; the upper clamp body 201 and the lower clamp body 202 are connected by bolts and nuts, and the upper clamp body 201 and the lower clamp body 202 can be separated by removing the bolts and nuts, and then the upper clamp body 201 and the lower clamp body 202 are sleeved on the outside of the steel tube 4 or aluminum tube 3, and then the bolts and nuts are installed to connect them. The trapezoidal clamping grooves at the adjacent ends of the upper clamp body 201 and the lower clamp body 202 can realize the clamping and fixing of steel tubes 4 or aluminum tubes 3 of different diameters, preventing To prevent deviation during crimping, the clamp body support 203 is fixed to the correction control plate 207, the correction control plate 207 is connected to the active end of the correction cylinder 208, and the correction cylinder 208 is fixed to the anti-roll plate 205. After the correction cylinder 208 is started, it can drive the correction control plate 207 to move up and down. The correction control plate 207 drives the clamp body support 203 to slide up and down in the transfer tube 204 and adjust the horizontal height of the lower clamp body 202 and the upper clamp body 201. When the steel pipe 4 or the aluminum pipe 3 is bent, The steel tube 4 or aluminum tube 3 is driven to move up and down by the upper clamp body 201 and the lower clamp body 202, so as to appropriately correct the steel tube 4 or the aluminum tube 3; in addition, the centering clamp structure 200 adopts a nested transmission structure of a worm gear and a gear rack to achieve precise motion control of the two movable clamp structures 300. By coupling the self-locking characteristics of the worm gear with the linear transmission characteristics of the gear rack, a double mechanical locking mechanism is formed to prevent the two movable clamp structures 300 from displacement during the crimping process, thereby ensuring the accuracy of the crimping area.

[0080] Example 8

[0081] See also Figures 1-13The movable pressure clamp structure 300 includes: a movable assembly seat 301, the movable assembly seat 301 is slidably arranged on the two bearing cross beams 105 through a left open groove and a right open groove, the movable assembly seat 301 is connected to the assembly frame 303 through a support member 302, and the assembly frame 303 is slidably connected to the left clamp body 304 and the right clamp body 305 which are relatively arranged, and the left clamp body 304 and the right clamp body 305 are connected to the side of an anti-slip horizontal shaft 306, the two anti-slip horizontal shafts 306 are relatively slidably arranged in the horizontal sliding groove on the side of the assembly frame 303, the two anti-slip horizontal shafts 306 are connected to the upper ends of the two pressing connecting rods 307, the lower ends of the two pressing connecting rods 307 are relatively rotatably connected to the pressure control plate 308, and the distance between the connecting ends of the two pressing connecting rods 307 and the pressure control plate 308 is greater than that of the two pressing connecting rods 3 07 and the distance between the connection ends of the two anti-slip horizontal shafts 306, the pressure control plate 308 is fixed to the output end of the pressure control cylinder 313, and the fixed end of the pressure control cylinder 313 is fixed on the movable assembly seat 301; the left clamp body 304 and the right clamp body 305 are both provided with pressure block slides, and the two pressure block slides are both laterally slidably connected with movable pressure blocks 309, and the outer ends of the two movable pressure blocks 309 are rotatably connected with two pressure regulating screws 310, and the two pressure regulating screws 310 are respectively threadedly connected to the left clamp body 304 and the right clamp body 305 to drive the two movable pressure blocks 309 to move toward or away from each other in the two pressure block slides; the sides of the left clamp body 304 and the right clamp body 305 are both screwed with locking screws 311, and the inner ends of the locking screws 311 are in contact with the side of the movable pressure block 309 or the side of the pressure regulating screw 310.

[0082] The working principle and technical effects of the above technical solution are as follows:

[0083] The movable assembly seat 301 is slidably arranged on the two bearing crossbeams 105 through the left open groove and the right open groove. When the spacing between the two bearing crossbeams 105 is adjusted, the two bearing crossbeams 105 can be controlled to contact or separate with the left open groove and the right open groove of the movable assembly seat 301, thereby realizing the installation or disassembly of the two movable pressure clamp structures 300, which is convenient for replacement; when the centering gear 209 rotates and engages the two rack plates 211 to move, the two rack plates 211 drive the movable assembly seats 301 of the two movable pressure clamp structures 300 to move between the two bearing crossbeams 105. The crossbeam 105 slides on the carrier to adjust the crimping position of the movable crimping clamp structure 300; when the steel pipe 4 or aluminum pipe 3 needs to be crimped by the movable crimping clamp structure 300, the pressure control cylinder 313 is first controlled to start. When the pressure control cylinder 313 drives the pressure control plate 308 to move downward, the pressure control plate 308 drives the lower ends of the two crimping connecting rods 307 to move downward, and the upper ends of the two crimping connecting rods 307 drive the two anti-slip horizontal shafts 306 to slide away from each other in the horizontal sliding groove on the side of the assembly frame 303, thereby controlling the left clamp body 304 and the right clamp body 3 05 separation, at this time the steel pipe 4 or aluminum pipe 3 can be loaded into the left and right clamp bodies 304 and 305 from above, and then the pressure control cylinder 313 is controlled to drive the pressure control plate 308 to move upward, at this time the pressure control plate 308 drives the left and right clamp bodies 304 and 305 to dock and buckle together through the cooperation of two pressure connecting rods 307 and two anti-slip horizontal shafts 306, and the left and right clamp bodies 304 and 305 are both provided with pressure block slides, and the two pressure block slides are both horizontally slidably connected with movable pressure blocks 309, which can be passed through By rotating the pressure-adjusting screw 310, the contact position between the pressure-adjusting screw 310 and the left clamp body 304 or the right clamp body 305 is changed, thereby controlling the distance that the two movable pressure blocks 309 slide inward and changing the amplitude of the crimping. When the left clamp body 304 and the right clamp body 305 are docked and fastened, the steel pipe 4 or the aluminum pipe 3 is precisely crimped by the two movable pressure blocks 309. The inner end of the locking screw 311 contacts the side of the movable pressure block 309 or the side of the pressure-adjusting screw 310, thereby ensuring the stability of the two movable pressure blocks 309 after position adjustment.

[0084] The assembly frame 303 is also fixed with a stabilizing shaft 312. When the left caliper body 304 and the right caliper body 305 are separated, the stabilizing shaft 312 passes through the guide hole above the left caliper body 304 or the right caliper body 305. When the left caliper body 304 and the right caliper body 305 are buckled into contact, the stabilizing shaft 312 passes through the two guide holes above the left caliper body 304 and the right caliper body 305. The pressure stabilizing shaft 312 passes through the guide holes above the left clamp body 304 and the right clamp body 305, providing a precise alignment mechanism for the buckling of the left clamp body 304 and the right clamp body 305. During the buckling process, the pressure stabilizing shaft 312 is similar to a positioning pin, ensuring that the left clamp body 304 and the right clamp body 305 can be accurately docked together, achieving effective crimping of the steel pipe 4 or the aluminum pipe 3, ensuring that the pressure is evenly distributed on the steel pipe 4 or the aluminum pipe 3 during crimping, improving the crimping quality, and reducing the probability of misalignment between the left clamp body 304 and the right clamp body 305 during buckling.

[0085] The tube half-length measuring structure 400 includes: a loading seat 401 fixedly connected to the outer end of the assembly frame 303, a flip measuring tube 402 hingedly connected to the loading seat 401 via a hinge shaft, an end of the flip measuring tube 402 away from the loading seat 401 is slidably connected to a flip measuring rod 403 in a tube groove, a measuring screw 404 threadedly connected to the flip measuring rod 403 is slidably set in a side sliding groove of the flip measuring tube 402, an outer end of the measuring screw 404 is fixedly connected to a turning wheel, and an inner end of the measuring screw 404 contacts the anti-slip pad on the inner wall of the tube groove of the flip measuring tube 402.

[0086] The flip measuring rod 403 can slide in the flip measuring tube 402, so as to adjust the overall length of the flip measuring tube 402 and the flip measuring rod 403. When the flip measuring rod 403 is aligned with the half-length alignment line 214 in the middle of the side of the lower clamp body 202, half the length of the steel pipe 4 or the aluminum pipe 3 can be measured. At this time, the turning wheel is turned to make the inner end of the measuring screw 404 press against the anti-slip pad on the inner wall of the tube groove of the flip measuring tube 402, so as to achieve relative fixation of the overall length of the flip measuring tube 402 and the flip measuring rod 403, and then the whole is flipped outward, so that the wire of half the length of the steel pipe 4 or the aluminum pipe 3 can be directly and accurately measured. The setting of this structure makes it possible to measure half the length of the steel pipe 4 or the aluminum pipe 3 without using a separate ruler, and it is easy to operate and effectively suitable for use in this crimping process.

[0087] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like to indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are 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, and therefore should not be understood as limiting the present invention.

[0088] In the present invention, unless otherwise specified or limited, the terms "installed," "connected," "connect," "fixed," etc. should be understood in a broad sense. For example, they can refer to fixed connection, detachable connection, or integration; mechanical connection, electrical connection, or communication; direct connection or indirect connection through an intermediate medium; internal communication between two elements or interaction between two elements, unless otherwise specified. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0089] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the description and implementation methods. They can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. A twisted carbon fiber composite material core conductor connecting tube crimping process, characterized in that: include: Install two aluminum liner sleeves on the crimping ends of two cleaned wires to be crimped; Put the aluminum tube through the crimping end of any wire to be crimped and put it on the wire; Insert two wires to be crimped, which are sleeved with aluminum liner tubes, into the steel tube from both ends, and make the crimping ends of the two wires to be crimped contact each other; apply pressure to the steel tube through the crimping device to crimp the two wires to be crimped in the steel tube; After the wire body surface to be inserted into the aluminum tube is coated with electrical grease, the aluminum tube is moved to be sleeved on the steel tube and the wire body coated with electrical grease on the two wires; the aluminum tube is pressed by the crimping device to crimp the aluminum tube to the wire inside; When installing two aluminum liner sleeves on the crimping ends of two cleaned wires to be crimped, if the crimping ends of the wires to be crimped are damaged, deformed or contaminated, use a hacksaw to cut off the crimping ends of the wires and strip the aluminum wires; When stripping the aluminum wire at the crimped end of the wire, saw off the damaged, deformed or contaminated crimped end of the wire, and clean the surface of the wire end with a length not less than 3 times the length of the aluminum tube; Then measure the conductor length L1 of half the length of the steel pipe from the conductor crimping end, add the length L1 to the conductor compression extension length L2 to obtain the conductor's aluminum stripping mark point, and after wrapping and binding the side of the aluminum stripping mark point away from the conductor crimping end, the aluminum single wire of the conductor is layered and sawed off at the aluminum stripping mark point.

2. A stranded carbon fiber composite material core conductor connector crimping process according to claim 1, characterized in that: Before installing the two aluminum liner tubes on the crimping ends of the two cleaned wires to be crimped, first wipe the crimping end surfaces of the wires to be crimped with a clean cloth. The length of the wires to be crimped should not be less than 3 times the length of the aluminum tubes.

3. The crimping process for a stranded carbon fiber composite material core conductor connector according to claim 1, characterized in that: When inserting the two wires to be crimped with the two aluminum liner tubes from both ends of the steel pipe into the steel pipe, control the ends of the two aluminum liner tubes to be flush with the two ends of the steel pipe so that the crimping lengths of the crimping ends of the wires at both ends are consistent.

4. A stranded carbon fiber composite material core conductor connector crimping process according to claim 1, characterized in that: The steel pipe is pressurized by the crimping device so that the crimping ends of the two wires to be crimped in the steel pipe are crimped in sequence from the center of the steel pipe to both ends.

5. The crimping process for a stranded carbon fiber composite material core conductor connector according to claim 1, characterized in that: After the surface of the wire body that needs to be inserted into the aluminum tube is coated with electrical grease, the aluminum tube is moved to the wire body that is sleeved on the steel tube and the two wires coated with electrical grease. First, measure the length of the wire to be inserted into the aluminum tube. When measuring, measure the wire length L3 that is half the length of the aluminum tube from the center of the steel tube to both sides, and mark the end point of the electrical grease coating at L3. Then control the coating device to evenly coat the surface of the wire body where the wire contacts the inner wall of the aluminum tube from the end point mark of the electrical grease coating toward the crimping end of the wire. Then use a wire brush to apply the electrical grease to the part that has been coated along the twisting direction of the wire. After the electrical grease is fully and evenly contacted with the wire, push the wire into the aluminum tube, and make the mouth of the aluminum tube coincide with the end point mark of the electrical grease coating.

6. The process for crimping a stranded carbon fiber composite material core conductor connector according to claim 1, characterized in that: The aluminum tube is pressurized by a crimping device so that the aluminum tube and the wires inside it are crimped and connected, and the two stripping aluminum wire marking points of the aluminum tube and the two wires are crimped to both ends of the aluminum tube.

7. A stranded carbon fiber composite material core conductor connector crimping process according to claim 6, characterized in that: When pressure is applied by the crimping device, the overlapping area between two adjacent indentation areas shall not be less than 5mm.

8. The process for crimping a stranded carbon fiber composite material core conductor connector according to claim 1, characterized in that: The crimping device includes: a device frame, on which a centering clamp structure and two movable clamp structures are connected and relatively matched on both sides of the centering clamp structure. The centering clamp structure is connected to the two movable clamp structures; both movable clamp structures are equipped with a pipe half-length measuring structure.

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