Multi-core cable manufacturing process for high-speed train braking system

Abstract

The invention discloses a multi-core cable manufacturing process for a high-speed train braking system, and relates to the technical field of cable production and processing, and the multi-core cable manufacturing process comprises the steps of cable cutting, single-wall heat-shrinkable tube installation, double-wall heat-shrinkable tube installation, contact end installation, plug installation, pouring sealant pouring, single-wall heat-shrinkable tube heat shrinkage, double-wall heat-shrinkable tube heat shrinkage and the like. According to the invention, through close cooperation of the steps, optimization is carried out aiming at the defects of the traditional technology, and through the synergistic effect of the links, the anti-extrusion and anti-deformation capability of the cable is enhanced, so that the cable is not easy to damage and break in a complex environment, the reliability and mechanical performance of the multi-core cable of the high-speed train braking system are improved, and the stability of signal transmission is ensured.

Description

Technical Field

[0001] The present application relates to the technical field of cable production and processing, and in particular to a process for manufacturing multi-core cables for high-speed train braking systems. Background Art

[0002] Multi-core cables play a crucial role in the braking system, carrying the heavy responsibility of transmitting control signals and power, directly impacting the proper functioning of the braking system. A fault in a multi-core cable could cause the braking system to malfunction, seriously threatening the safety of the train and its passengers. Therefore, high-speed train braking systems place extremely high demands on the reliability and performance of multi-core cables.

[0003] The traditional multi-core cable manufacturing process typically involves applying potting compound to the connector ends after each cable is connected to the plug. Heat shrink tubing is then applied directly over each cable, wrapping the connector ends. While this manufacturing process provides some protection for the cables, it lacks structural strength and is prone to damage and breakage over time, compromising the cable's performance. This process fails to meet the high reliability and performance requirements of high-speed train braking systems for multi-core cables. Summary of the Invention

[0004] In response to the problems existing in the prior art, the present application provides a multi-core cable manufacturing process for a high-speed train braking system.

[0005] This application provides a multi-core cable manufacturing process for a high-speed train braking system, which adopts the following technical solutions: A process for manufacturing a multi-core cable for a high-speed train braking system comprises the following steps: Step 1: Cable cutting: Cut multiple locomotive cables as needed; Step 2: Install the single-wall heat shrink tubing and put it on each cable. Step 3: Install the double-wall heat shrink tubing. Cut two sections of double-wall heat shrink tubing and place each section on the single-wall heat shrink tubing. Step 4: Install the contact terminals. Connect the contact terminals at both ends of each cable and ensure that the contact terminals at both ends of the same cable correspond to each other. Step 5: Install the plugs. Connect the plugs at both ends of each cable and insert the contact ends into the corresponding holes on the plugs. Step 6: Fill the gaps between the plug and the cables, as well as the inside of the single-wall heat shrink tubing with potting glue. Step 7: After the single-wall heat shrink tubing is shrunk and the potting glue is poured in, but before the potting glue is completely solidified, heat shrink the single-wall heat shrink tubing to ensure that there are no gaps inside the single-wall heat shrink tubing. Step 8: After the double-wall heat shrink tube shrinks and the potting glue solidifies, slide the two double-wall heat shrink tubes to the connection between each cable and the plug, and put the double-wall heat shrink tube on the plug and the single-wall heat shrink tube, and then heat shrink the double-wall heat shrink tube.

[0006] Optionally, when cutting locomotive cables, ensure that the outer insulation layer of the cut cable is intact without bubbles or bulges.

[0007] Optionally, before use, the single-wall heat shrink tube is printed with a corresponding line number identification and functional properties corresponding to the cable on the surface of the single-wall heat shrink tube by a printer.

[0008] Optionally, the length of the single-wall heat shrink tube needs to correspond to the length of each cable. When both ends of the cable are connected to the plugs, the distance between the two ends of the single-wall heat shrink tube and the plugs on the corresponding side is controlled between 2-6 mm.

[0009] Optionally, after the contact terminals are connected at both ends of the cable, a tension test is performed between the cable and the contact terminals to ensure that the cable and the contact terminals are firmly connected.

[0010] Optionally, a plurality of elastic pressure strips are provided in the single-wall heat shrink tube, and the elastic pressure strips are distributed along the circumference of the single-wall heat shrink tube and inserted between the cables.

[0011] Optionally, when the single-wall heat shrink tube is sleeved on each cable, a layer of nylon cloth is first wrapped on the outside of each cable. After the single-wall heat shrink tube is sleeved on each cable, the nylon cloth is located between the single-wall heat shrink tube and each cable.

[0012] Optionally, when the cables are connected to the plug, a wire locker is used to limit the position of the cables to prevent the cables from being entangled during the installation of the plug.

[0013] Optionally, after both ends of each cable are connected to the plug, the connection between each cable and the plug is tested by a continuity detector to ensure that the connection between each cable and the plug is stable.

[0014] Optionally, before heat shrinking, the potting glue between the single-wall heat shrink tube and the plug is polished and scraped flat. After heat shrinking, the surface of the double-wall heat shrink tube is even and free of bulges.

[0015] In summary, this application includes at least one of the following beneficial technical effects: 1. This application improves the reliability and mechanical properties of the multi-core cable of the high-speed train braking system and ensures the stability of signal transmission. Specifically, by pouring potting glue into the gap between the plug and each cable, the gap between the plug and each cable can be effectively filled, and by pouring potting glue into the single-wall heat shrink tube, and before the potting glue is completely solidified, the single-wall heat shrink tube is heat-shrunk. During the heat shrinkage process, the single-wall heat shrink tube squeezes the potting glue inside, thereby ensuring that there are no gaps inside the single-wall heat shrink tube and enhancing the cable's ability to resist extrusion and deformation. By arranging a double-wall heat shrink tube at the connection between the cable and the plug, and sleeve the double-wall heat shrink tube on the plug and the single-wall heat shrink tube, the connection between the cable and the plug is further reinforced, making the cable less prone to damage, breakage, etc., thereby effectively improving the reliability and mechanical properties of the cable and ensuring the stability of signal transmission.

[0016] 2. This application controls the distance between the two ends of the single-wall heat shrink tube and the plug between 2-6 mm, ensuring that the potting glue can be potted while minimizing the gap between the single-wall heat shrink tube and the plug, so that the single-wall heat shrink tube can better adapt to the cable length, which helps to improve the reliability and mechanical performance of the connection between the cable and the plug.

[0017] 3. This application improves the cable's ability to resist extrusion and deformation by circumferentially arranging multiple elastic pressure strips interspersed between the cables in a single-wall heat shrink tube, while also improving the cable's mechanical properties, allowing multi-core cables to better adapt to the complex environment of high-speed train braking systems, improving cable reliability, and enhancing signal transmission stability.

[0018] 4. This application achieves a protective effect on the single-wall heat shrinkable tube by wrapping nylon cloth on the outside of each cable and placing it between the single-wall heat shrinkable tube and each cable. After the potting glue is poured into the single-wall heat shrinkable tube, the nylon cloth adheres to the inner surface of the single-wall heat shrinkable tube when the single-wall heat shrinkable tube shrinks, thereby improving the tear resistance of the single-wall heat shrinkable tube and further improving the overall mechanical properties and reliability of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic diagram of the structure of a single-wall telescopic tube and a double-wall telescopic tube used in an embodiment of the present application; Figure 2 This is a schematic diagram of the structure of the contact terminal used in the embodiment of the present application; Figure 3 This is a schematic diagram of the structure of the plug used in the embodiment of the present application; Figure 4 This is a cross-sectional view of the structure of the plug used in the embodiment of the present application; Figure 5 This is a structural cross-sectional view of an embodiment of the present application, mainly used to express the internal structure of a single-wall telescopic tube.

[0020] Explanation of the accompanying symbols: 1. cable; 2. single-wall heat shrink tube; 3. double-wall heat shrink tube; 4. contact terminal; 5. plug; 6. potting compound; 7. elastic pressure strip; 8. nylon cloth. DETAILED DESCRIPTION

[0021] The following will be combined with the Figure 1 -Attached Figure 5 The technical solutions in the embodiments of the present invention are clearly and completely described. The described embodiments are only possible technical implementations of the present invention and do not constitute a complete set of implementations. Those skilled in the art can combine the embodiments of the present invention to derive other embodiments without inventive work, and such embodiments are also within the scope of protection of the present invention.

[0022] The inventors of this application have discovered that, while the traditional multi-core cable manufacturing process can protect the cables to a certain extent, the cables have low structural strength and are prone to damage and breakage during long-term use, affecting the normal use of the cables. This process cannot meet the high reliability and high performance requirements of high-speed train braking systems for multi-core cables. To this end, this application discloses a multi-core cable manufacturing process for high-speed train braking systems, which mainly adopts the following scheme: The present application discloses a process for manufacturing a multi-core cable for a high-speed train braking system, comprising the following steps: Step 1: Cutting Cable 1 Reference Figure 1 , cut multiple locomotive cables 1 as needed, and the outside of each cable 1 is individually wrapped with insulating material. When cutting locomotive cables 1, it is necessary to ensure that the outer insulation layer of cable 1 is intact and free of defects such as bubbles and bulges. This can be determined visually, or non-destructive testing equipment can be used to assist in inspecting the internal condition of cable 1 to ensure the quality of cable 1. In addition to choosing common locomotive cables 1, other types of cables 1 can also be selected. As long as the cable 1 meets the signal and power transmission requirements of the high-speed train braking system, it can also be substituted.

[0023] Step 2: Install single-wall heat shrink tubing 2 Reference Figure 1 , put the single-wall heat shrink tube 2 on each cable 1. The single-wall heat shrink tube 2 is generally white. The single-wall heat shrink tube 2 here can be made of polyethylene. Of course, it can also be replaced by a single-wall heat shrink tube 2 made of other materials such as polyvinyl chloride. Before installing the single-wall heat shrink tube 2, first put the single-wall heat shrink tube 2 into the line number tube printer, and then print the corresponding line number identification and the corresponding functional properties of the cable on the surface of the single-wall heat shrink tube 2. The printed content should be clear and complete to facilitate cable identification, which will help with later installation, maintenance and troubleshooting, and improve work efficiency and accuracy.

[0024] Step 3: Double-wall heat shrink tubing installation Reference Figure 1 Cut two equal lengths of double-wall heat shrink tubing 3. Double-wall heat shrink tubing 3 is typically transparent and has a two-layer structure, with an inner layer of hot-melt adhesive and an outer layer of insulating material, providing excellent sealing and insulation. A three-layer structure can also be used for even better protection. When cutting, ensure the cut ends are smooth. Then, place each double-wall heat shrink tubing 3 over the single-wall heat shrink tubing 2.

[0025] Step 4: Install contact terminal 4 Reference Figure 2 Connect contact terminals 4 to both ends of each cable 1, ensuring that the contact terminals 4 at both ends of the same cable 1 correspond to each other. Contact terminals 4 are generally made of metal with good conductivity. The contact terminals 4 and cable 1 are connected by crimping using a crimping machine. Welding can also be used to connect the contact terminals 4, but attention must be paid to the quality control of the welding process. After the cable 1 and contact terminals 4 are connected, a tensile test is performed between the cable 1 and the contact terminals 4 using a tensile testing machine. For example, for a cable 1 with a cross-sectional area of 0.5mm², the tensile force must be ≥70N to ensure that the cable 1 and the contact terminals 4 are firmly connected.

[0026] Step 5: Install plug 5 Reference Figure 3 and Figure 4 Plugs 5 are connected to both ends of each cable 1, and each contact terminal 4 is inserted into the corresponding hole on the plug 5. During installation, ensure that the contact terminal 4 is correctly installed in the hole and is properly assembled, and the wiring relationship meets the requirements of the wiring diagram. Plug 5 generally adopts a structure with a plastic shell and metal pins. The metal pins have good conductivity, and the plastic shell provides insulation and protection. Plugs 5 with ceramic shells can also be used to improve high temperature resistance and insulation performance. When each cable 1 is connected to the plug 5, each cable 1 must be limited in position using a wire lock. The wire lock prevents each cable 1 from getting tangled during the installation of the plug 5, ensuring a smooth installation process. The wire lock can be a common plastic or metal clip, as long as it can provide a limiting function. After the two ends of each cable 1 are connected to the plug 5, the connection between each cable 1 and the plug 5 is tested using a continuity detector to ensure a stable connection between each cable 1 and the plug 5.

[0027] Step 6: Filling the potting compound Reference Figure 4The gaps between the plug 5 and the cables 1, as well as the interior of the single-wall heat shrink tubing 2, are filled with potting compound 6. The potting compound 6 may be an epoxy resin potting compound 6, which has excellent sealing and insulation properties. After the potting compound 6 is poured, it is necessary to ensure that there are no defects such as bubbles, air bubbles, cracks, or wrinkles in the potting compound 6. Silicone potting compound 6 may also be used, as it has better flexibility.

[0028] Step 7: Heat shrink the single-wall heat shrink tube 2 Reference Figure 4 After the potting glue 6 is poured and before the potting glue 6 is completely solidified, the single-wall heat shrink tube 2 is heat-shrunk to ensure that there are no gaps inside the single-wall heat shrink tube 2; a hot air gun can be used to heat the single-wall heat shrink tube 2, and the hot air gun should be moved evenly during heating to ensure that the single-wall heat shrink tube 2 shrinks evenly; during the heat shrinking process, the single-wall heat shrink tube 2 squeezes the potting glue 6 inside, thereby ensuring that there are no gaps inside the single-wall heat shrink tube 2 and enhancing the cable's ability to resist extrusion and deformation.

[0029] Step 8: Heat shrink the double-wall heat shrink tube 3 Reference Figure 4 After the potting glue 6 solidifies, slide the two double-wall heat shrink tubes 3 to the connection between each cable 1 and the plug 5, and then put the double-wall heat shrink tubes 3 on the plug 5 and the single-wall heat shrink tube 2. Then, heat shrink the double-wall heat shrink tubes 3. Before heat shrinking, the potting glue 6 between the single-wall heat shrink tube 2 and the plug 5 should be polished and smoothed to ensure that the surface of the double-wall heat shrink tube 3 is uniform and free of bulges after heat shrinking. This can strengthen the connection between the cable and the plug 5, improve the reliability and mechanical performance of the cable, and ensure the good appearance quality of the double-wall heat shrink tube 3. The double-wall heat shrink tube 3 can also be heat-shrunk using a hot air gun.

[0030] Reference Figure 3 and Figure 4 In addition, the length of the single-wall heat shrink tubing 2 must also correspond to the length of each cable 1 to ensure that when both ends of the cable are connected to the plug 5, the distance between the two ends of the single-wall heat shrink tubing 2 and the corresponding plug 5 is controlled between 2-6mm. By controlling the distance between the two ends of the single-wall heat shrink tubing 2 and the plug 5 between 2-6mm, since the potting glue 6 has not yet shrunk during potting, the potting glue 6 can be poured through the gap between the single-wall heat shrink tubing 2 and the plug 5 by sliding the single-wall heat shrink tubing 2. At the same time, it can also prevent the gap between the single-wall heat shrink tubing 2 and the plug 5 from being too large, resulting in too low mechanical strength at the connection between the cable and the plug 5.

[0031] Reference Figure 5Multiple elastic pressure strips 7 are installed within the single-wall heat shrink tubing 2. These strips 7 are distributed along the circumference of the tubing and interspersed between the cables 1. These strips 7 are typically made of an elastic material such as rubber or silicone. These strips 7 enhance the cable's resistance to extrusion and deformation, while also improving its mechanical properties. This allows the multi-core cable to better adapt to the complex environment of high-speed train braking systems, improves cable reliability, and enhances signal transmission stability.

[0032] Reference Figure 5 When the single-wall heat shrink tube 2 is sleeved on each cable 1, a layer of nylon cloth 8 is first wrapped on the outside of each cable 1. The nylon cloth 8 has good wear resistance and tear resistance. After the nylon cloth 8 is wrapped, it is pre-fixed with tape to preliminarily position each cable 1 and the elastic pressure strip 7. After the single-wall heat shrink tube 2 is sleeved on each cable 1, the nylon cloth 8 is located between the single-wall heat shrink tube 2 and each cable 1. After the potting glue 6 is poured into the single-wall heat shrink tube 2, and the single-wall heat shrink tube 2 is heat-shrunk, the nylon cloth 8 will adhere to the inner surface of the single-wall heat shrink tube 2, thereby protecting the single-wall heat shrink tube 2, improving the tear resistance of the single-wall heat shrink tube 2, and further improving the overall mechanical performance and reliability of the cable.

[0033] The implementation principle of the multi-core cable manufacturing process for the high-speed train braking system in the embodiment of the present application is as follows: by injecting potting glue 6 into the gap between the plug 5 and each cable 1, the gap between the plug 5 and each cable 1 can be effectively filled, and by arranging a single-wall heat shrink tube 2, and injecting potting glue 6 into the single-wall heat shrink tube 2, and before the potting glue 6 is completely solidified, the single-wall heat shrink tube 2 is heat-shrunk. During the heat shrinkage process, the single-wall heat shrink tube 2 squeezes the potting glue 6 inside, thereby ensuring that there are no gaps inside the single-wall heat shrink tube 2, and enhancing the cable's ability to resist extrusion and deformation. By arranging a double-wall heat shrink tube 3 at the connection between the cable and the plug 5, and the double-wall heat shrink tube 3 is sleeved on the plug 5 and the single-wall heat shrink tube 2, the connection between the cable and the plug 5 is further reinforced, making the cable less likely to be damaged or broken, thereby effectively improving the reliability and mechanical properties of the cable and ensuring the stability of signal transmission.

[0034] The above are all preferred embodiments of the present application, and are not intended to limit the scope of protection of the present application. Therefore, any equivalent changes made based on the structure, shape, and principle of the present application should be included in the scope of protection of the present application.

Claims

1. A process for manufacturing a multi-core cable for a high-speed train braking system, characterized in that: The following steps are involved: Step 1, cutting the cables (1), cutting a plurality of locomotive cables (1) as needed; Step 2: installing the single-wall heat shrink tube (2) and sleeve the single-wall heat shrink tube (2) on each cable (1); Step 3: Install the double-wall heat shrink tube (3), cut two sections of the double-wall heat shrink tube (3), and sleeve each double-wall heat shrink tube (3) on the single-wall heat shrink tube (2); Step 4: Install the contact terminals (4). Connect the contact terminals (4) at both ends of each cable (1), and ensure that the contact terminals (4) at both ends of the same cable (1) correspond to each other. Step 5: Install the plug (5), connect the plug (5) at both ends of each cable (1), and insert each contact end (4) into the corresponding hole on the plug (5); Step 6: pouring the potting glue (6) into the gaps between the plug (5) and each cable (1), as well as the inside of the single-wall heat shrink tube (2); Step 7: After the single-wall heat shrink tube (2) is heat-shrunk and the potting glue (6) is poured, and before the potting glue (6) is completely solidified, the single-wall heat shrink tube (2) is heat-shrunk to ensure that there is no gap inside the single-wall heat shrink tube (2); Step 8: After the double-wall heat shrink tube (3) is heat-shrunk and the potting glue (6) is solidified, two double-wall heat shrink tubes (3) are respectively slid to the connection between each cable (1) and the plug (5), and the double-wall heat shrink tube (3) is sleeved on the plug (5) and the single-wall heat shrink tube (2), and then the double-wall heat shrink tube (3) is heat-shrunk.

2. The process for manufacturing a multi-core cable for a high-speed train braking system according to claim 1, characterized in that: When cutting the locomotive cable (1), it is necessary to ensure that the outer insulation layer of the cut cable (1) is intact without bubbles or bulges.

3. The process for manufacturing a multi-core cable for a high-speed train braking system according to claim 1, characterized in that: Before use, the single-wall heat shrink tube (2) is printed with a corresponding line number identification and the functional attributes corresponding to the cable on the surface of the single-wall heat shrink tube (2) by a printer.

4. The process for manufacturing a multi-core cable for a high-speed train braking system according to claim 1, characterized in that: The length of the single-wall heat shrink tube (2) needs to correspond to the length of each cable (1). When both ends of the cable are connected to the plug (5), the distance between the two ends of the single-wall heat shrink tube (2) and the plug (5) on the corresponding side is controlled to be between 2-6 mm.

5. The process for manufacturing a multi-core cable for a high-speed train braking system according to claim 1, characterized in that: After both ends of the cable (1) are connected to the contact terminals (4), a tension test is performed between the cable (1) and the contact terminals (4) to ensure that the cable (1) and the contact terminals (4) are firmly connected.

6. The process for manufacturing a multi-core cable for a high-speed train braking system according to claim 1, characterized in that: A plurality of elastic pressure strips (7) are provided in the single-wall heat shrink tube (2), and each of the elastic pressure strips (7) is distributed along the circumference of the single-wall heat shrink tube (2) and is inserted between each cable (1).

7. The process for manufacturing a multi-core cable for a high-speed train braking system according to claim 6, characterized in that: When the single-wall heat shrink tube (2) is sleeved on each cable (1), a layer of nylon cloth (8) is firstly coated on the outside of each cable (1); after the single-wall heat shrink tube (2) is sleeved on each cable (1), the nylon cloth (8) is located between the single-wall heat shrink tube (2) and each cable (1).

8. The process for manufacturing a multi-core cable for a high-speed train braking system according to claim 7, characterized in that: When each of the cables (1) is connected to the plug (5), the cable locker is used to limit the position of each cable (1) to prevent the cables (1) from being entangled during the installation of the plug (5).

9. The process for manufacturing a multi-core cable for a high-speed train braking system according to claim 1, characterized in that: After both ends of each cable (1) are connected to the plug (5), the connection between each cable (1) and the plug (5) is detected by a continuity detector to ensure that the connection between each cable (1) and the plug (5) is stable.

10. The process for manufacturing a multi-core cable for a high-speed train braking system according to claim 1, characterized in that: Before the double-wall heat shrink tube (3) is heat-shrinked, the potting glue (6) between the single-wall heat shrink tube (2) and the plug (5) is polished and flattened. After the heat shrinkage of the double-wall heat shrink tube (3) is completed, the surface of the double-wall heat shrink tube (3) is uniform and free of bulges.

Images