Cable fusion system based on high frequency electromagnetic induction heating

Abstract

The application discloses a cable fusion system based on high-frequency electromagnetic induction heating, and relates to the technical field of cable connection.The cable fusion system comprises a mold, an electromagnetic heating device and a control device.The mold comprises an A mold provided with an axially divided fusion channel one, a B mold provided with an axially divided fusion channel two, and a locking mechanism for connecting and locking the A mold and the B mold.The fusion channel one and the fusion channel two are folded towards each other to form a fusion channel.A feeding channel is formed on the mold and is communicated with the fusion channel.The feeding channel and the fusion channel form an included angle.The electromagnetic heating device comprises a plurality of heating coils.The plurality of heating coils are divided into two groups and are arranged on the A mold and the B mold respectively.After the mold is installed on a cable conductor, the plurality of heating coils are left-right symmetrical.The current phases of adjacent heating coils located on the same side of the cable conductor are different.The heating coils are electrically connected to the control device.The application has the effects of improving the safety and efficiency of cable welding.

Description

Technical Field

[0001] This application relates to the field of cable connection technology, and in particular to a cable welding system based on high-frequency electromagnetic induction heating. Background Technology

[0002] In electrical engineering projects such as photovoltaic systems, a large number of cables need to be laid to transmit current. Therefore, there is a need for cable splicing in both the construction phase and the later operation and maintenance phase.

[0003] The general procedure for cable splicing is as follows: After stripping the cable conductors, bring the two conductors to be welded close to the clamping mold, pour welding powder, flux and other materials into the mold, ignite the welding materials in the mold with a spray gun, then cool with a cold air gun, disassemble the mold, cut off the excess parts on the conductors, and then polish.

[0004] Compared to the construction phase, the site often lacks the same comprehensive infrastructure conditions as before during the later inspection and maintenance phases. In addition, many electrical equipment have already been installed and put into place. The above-mentioned welding process will spray fire and cause sparks to splash, which poses safety risks. Furthermore, it requires subsequent grinding, resulting in relatively poor welding efficiency. Therefore, this application proposes a new technical solution. Summary of the Invention

[0005] To improve the safety and efficiency of cable welding, this application provides a cable welding system based on high-frequency electromagnetic induction heating.

[0006] This application provides a cable welding system based on high-frequency electromagnetic induction heating, which adopts the following technical solution:

[0007] A cable welding system based on high-frequency electromagnetic induction heating includes a mold, an electromagnetic heating device, and a control device, wherein the mold includes:

[0008] Mold A has an axially segmented welding channel.

[0009] Mold B has an axially segmented welding channel two;

[0010] The locking mechanism is used to connect and lock molds A and B together.

[0011] The welding channel 1 and welding channel 2 converge towards each other to form a welding channel. The mold has a feeding channel that connects to the welding channel, and the feeding channel forms an angle with the welding channel. The electromagnetic heating device includes multiple heating coils, which are divided into two groups and respectively set in mold A and mold B. After the mold is installed on the cable conductor, the multiple heating coils are symmetrical from left to right, and the current phases of adjacent heating coils on the same side of the cable conductor are different.

[0012] The heating coil is electrically connected to the control device, and the control device is electrically connected to the interaction unit and configured as follows:

[0013] Obtain the material of the conductor of the cable to be fused, and search the preset database according to the material to obtain the heating temperature and current parameters that match the current conditions;

[0014] The output heating temperature prompts the interactive unit to issue a verification prompt and receive temperature verification feedback;

[0015] If the temperature verification feedback passes, the heating coil will be controlled to operate according to the corresponding current parameters.

[0016] Optionally, the A mold is provided with multiple inserts facing the B mold, at least one insert is located below the welding channel and is called the bottom heating block, a heating coil is located in the bottom heating block as the center, and other heating coils are distributed around the heating coil in the bottom heating block.

[0017] Optionally, mold A and mold B are respectively recessed with adjustment grooves, and adjustment blocks are detachably connected in the adjustment grooves. Welding channel one and welding channel two are respectively disposed in the two adjustment blocks.

[0018] Optionally, the mold has end-sealing units at both ends. Each end-sealing unit includes an outer end block, a middle tube, and an inner end block. The outer and inner end blocks are frustoconical structures with their large ends facing away from each other and are respectively located at both ends of the middle tube. The outer end block has an inner cavity with a frustoconical structure, with the large end of the frustum facing the section of the cable conductor that is not exposed. The inner end block is rotatably connected to the middle tube and has a structural channel. The structural channel is open at both ends of the outer end block and the mold. A roller is rotatably connected to the inner end block, and a high-temperature resistant sheet is wound on the roller. The free end of the high-temperature resistant sheet is used to fix it to the surface of the cable conductor. The middle tube is provided with a locking element for locking the inner end block.

[0019] Optionally, the intermediate tube is a telescopic tube, and the inner end block is a heat insulation block.

[0020] Optionally, a detection module for detecting the material of the cable conductor is installed on the intermediate tube, and the detection module is electrically connected to the control device.

[0021] Optionally, the control device is configured as follows:

[0022] Pre-stored data on the relationship between cable diameter, material, and heating time;

[0023] Obtain the diameter of the cable and find the corresponding heating time from the records;

[0024] The heating coil is started and stopped according to the heating time.

[0025] Optionally, the control device is electrically connected to an encoder, an attitude sensor, and a distance sensor mounted on the inner end block. The encoder shaft is coaxially fixed to the rotating shaft of the drum, and the detection direction of the distance sensor is parallel to the radial direction of the drum and faces the drum. The encoder, attitude sensor, and distance sensor are electrically connected to the control device, and the control device is configured as follows:

[0026] If the current moment is before the inner end block rotates, then obtain the detection value L2 of the ranging sensor and the initial attitude data of the attitude sensor.

[0027] If the detected value is the preset standard value L1, and the diameter of the high-temperature resistant sheet wound on the drum is d1, then the current high-temperature resistant sheet wound on the drum is d2 = d1 - (L2 - L1).

[0028] When the attitude sensor's next attitude data matches the initial attitude data, the encoder's degree is read to obtain the number of rotations n of the drum during the process;

[0029] The diameter of the cable conductor = n * d².

[0030] In summary, this application includes the following beneficial technical effects:

[0031] 1. High-frequency current can be passed through the heating coil to heat and weld the parts of the cable conductor to be welded. Because no open flame is used, it is safer.

[0032] 2. The reasonable distribution and phase adjustment of multiple heating coils make the heating more uniform, resulting in higher welding quality and higher heating efficiency;

[0033] 3. Heating parameters can be adjusted according to the material of the cable conductor to make the heating operation more suitable, reduce energy waste, and improve welding quality and efficiency. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the control structure of this application;

[0035] Figure 2 This is a front view of the control device of this application;

[0036] Figure 3 This is a schematic diagram of the structure of the mold of this application;

[0037] Figure 4 This is a schematic diagram of the heating coil distribution in this application;

[0038] Figure 5 This is another structural schematic diagram of the mold of this application;

[0039] Figure 6 This is a longitudinal section diagram of the end cap unit of this application.

[0040] Explanation of reference numerals in the attached drawings: 1. Mold; 11. Insert block; 12. Adjusting block; 2. Electromagnetic heating device; 21. Heating coil; 3. Control device; 4. End sealing unit; 41. Outer end block; 42. Intermediate tube; 421. Detection module; 43. Inner end block; 44. Locking component; 5. Drum; 6. Encoder; 7. Attitude sensor; 8. Distance sensor. Detailed Implementation

[0041] The following is in conjunction with the appendix Figures 1-6 This application will be described in further detail.

[0042] This application discloses a cable welding system based on high-frequency electromagnetic induction heating.

[0043] Reference Figure 1 and Figure 2 The cable welding system based on high-frequency electromagnetic induction heating includes a mold 1, an electromagnetic heating device 2, and a control device 3. In this embodiment, the control device 3 is an independent structure, housed in a box. The front panel integrates a display panel, while the upper and front panels are equipped with various function switches and input / output terminals, such as power switches and phase switches. It is understood that the box structure houses a mainboard, which integrates a processor and corresponding peripheral circuits, connecting to the display panel, various function switches, and input / output terminals to serve as a controller to meet basic requirements. Peripheral circuits include, for example, transistor switching circuits, whose control terminals are connected to the processor, with the collector connected in series with a relay. The relay contacts serve as terminals, enabling small current control of large current to improve safety and facilitating subsequent use for current on / off control. The controller is existing technology and will not be described in detail here.

[0044] Reference Figure 3 and Figure 4 The aforementioned mold 1 includes mold A and mold B that are spliced ​​together. The two can be considered as being obtained by axially dividing mold 1. A welding channel one is provided on mold A, and a welding channel two is provided on mold B. After mold A and mold B are closed together, welding channel one and welding channel two are closed together to form a complete welding channel.

[0045] Vertical feeding channels (described in terms of usage posture) are present on molds A and B. The lower end of the feeding channel is connected to the welding channel, allowing the user to pour the metal powder required for welding into the welding channel. The feeding channel can be conical with the small end facing down to improve the efficiency of removing residues and grinding later. The feeding channel and the welding channel form an angle, preferably 90° perpendicular.

[0046] The electromagnetic heating device 2 mentioned above includes multiple heating coils 21. In this embodiment, four heating coils are used as an example. The four heating coils 21 are divided into two groups and installed in the A and B modules respectively. Taking the usage posture as an example, the two groups of heating coils 21 are symmetrically arranged with the cable conductor as the center line. The two coils in the same group are symmetrically distributed with the perpendicular bisector of the cable conductor. The current phases of adjacent heating coils 21 on the same side of the cable conductor are different. For example, the adjacent phases are 180° apart.

[0047] The above configuration allows for simultaneous heating of both sides of the cable conductor to be welded when the heating coil 21 is energized, resulting in a more uniform temperature distribution and improved welding efficiency and quality. Furthermore, the phase difference in the current of the heating coil 21, when properly adjusted, allows for coordinated magnetic field excitation, further enhancing the heating effect. It is understood that current phase and magnitude control can be achieved through a frequency converter, which is existing technology and will not be elaborated upon further.

[0048] The aforementioned heating coil 21 is connected to the control device 3 via a relay and a frequency converter. The control device 3 is electrically connected to the interactive unit, which includes the aforementioned display panel and various function buttons. The control device 3 is configured as follows:

[0049] S11. Obtain the material of the conductor of the cable to be fused, and search the preset database according to the material to obtain the heating temperature and current parameters that match the current conditions.

[0050] It is understandable that different materials used in cable conductors result in different melting points of the metal powders they are suited for, leading to differences in the optimal heating temperature and the amount of current supplied to the heating coil 21. Relevant data can be actively recorded and uploaded by the user to the control device 3. During use, the user can select the current cable conductor material through the display panel, and then obtain the matching heating temperature and current parameters by searching the database.

[0051] S12. Output heating temperature to the interactive unit to issue a verification prompt and receive temperature verification feedback.

[0052] Example of verification prompt: The matching heating temperature and current parameters will pop up on the display panel, and a confirmation window will be opened, providing the user with "Yes" and "No" buttons to choose from; after the user selects "No", they can continue to manually modify the heating temperature and current parameters.

[0053] S13. If the temperature verification feedback is successful (i.e., as stated above), then the heating coil 21 is controlled to work according to the corresponding current parameters, that is, the heating coil 21 is energized and the current magnitude matches the current parameters.

[0054] Based on the above settings:

[0055] 1. The heating and welding of the cable conductor can be completed by passing a high-frequency current through the heating coil 21. Because no open flame is used, it is safer.

[0056] 2. The reasonable distribution and phase adjustment of the multiple heating coils 21 make the heating more uniform, resulting in higher welding quality and higher heating efficiency;

[0057] 3. Heating parameters can be adjusted according to the material of the cable conductor to make the heating operation more suitable, reduce energy waste, and improve welding quality and efficiency.

[0058] In another embodiment of this application, mold A is formed with a plurality of inserts 11 facing mold B, at least one insert 11 being located below the welding channel and referred to as a bottom heating block. The area of ​​the bottom heating block can be set to be larger than that of the other heating blocks because it is not only used for insertion locking.

[0059] In this embodiment, there are 5 heating coils 21, one of which is located in the bottom heating block as the center, and the other heating coils 21 are distributed around the heating coil 21 in the bottom heating block.

[0060] Based on the above setup, firstly, heat is no longer only conducted laterally to the part to be welded, but can also be heated directly from below, resulting in higher heating efficiency; secondly, according to the magnetic field distribution of the coils, the central area of ​​the four heating coils 21 is a weak magnetic field area, and the heating effect is relatively poor, that is, the magnetic field actually acting on the metal powder in the center is weak, and the center temperature is easily lower than the temperature rise of the periphery, resulting in welding defects; while the heating coils 21 in the bottom heating block can reduce the above situation and directly heat the middle area, resulting in more uniform heating.

[0061] In another embodiment of this application, molds A and B are respectively recessed with adjustment grooves, and adjustment blocks 12 are detachably connected to the adjustment grooves. The detachable connection method is, for example, fixing with countersunk bolts or fixing with threads on the back of the adjustment block 12. Welding channel one and welding channel two are respectively opened in the two adjustment blocks 12.

[0062] Based on the above settings, the manufacturer can provide the staff with a variety of adjustment blocks 12 that are compatible with various specifications of welding channels in advance. When using them, the staff can select the one with the highest compatibility according to the diameter of the cable conductor on site, thus making the applicability of this application stronger.

[0063] Reference Figure 5 and Figure 6In another embodiment of this application, unlike the above embodiment, the specifications of the welding channel remain unchanged. In order to adapt to more specifications of cable conductors, it is necessary to: provide end sealing units 4 at both ends of the mold 1. The end sealing units 4 are used to seal the gap between the welding channel and the cable conductor.

[0064] The end-sealing unit 4 includes an outer end block 41, an intermediate tube 42, and an inner end block 43. The outer end block 41 and the inner end block 43 are frustoconical structures with their large ends facing away from each other and are respectively disposed at both ends of the intermediate tube 42.

[0065] The outer end block 41 has an inner cavity with a frustum structure and the large end of the frustum faces the section of the cable conductor that is not exposed. Note that the cable conductor needs to be stripped before welding. When stripping the outer protection of the conductor, a conical surface can be formed near the exposed section of the conductor, which is used to fit the outer end block 41 when it is fitted over the cable conductor, helping to lock the mold 1.

[0066] The inner end block 43 is rotatably connected to the intermediate tube 42 and has a structural channel. It should be noted that the rotation is around the center of the intermediate tube 42. The structural channel is open at both ends facing the outer end block 41 and the mold 1.

[0067] A roller 5 is rotatably connected to the inner end block 43. A high-temperature resistant sheet, such as copper foil, is wound on the roller 5. Example of rotatable connection of the roller 5: A bracket is installed inside the inner end block 43, and the roller 5 is rotatably connected to the bracket through a rotating shaft.

[0068] The free end of the high-temperature resistant sheet is used to fix it to the surface of the cable conductor, for example, by bonding or welding, since the metal sheet can be easily welded temporarily with a small electric welding gun. The intermediate tube 42 is provided with a locking member 44 for locking the inner end block 43. The locking member 44 is, for example, a pin block, which is slidably connected to the outer wall of the intermediate tube 42. Multiple locking grooves are formed around the center of the outer wall of the inner end block 43 near the end of the intermediate tube 42.

[0069] In use, first, place the outer end block 41, the middle tube 42, and the inner end block 43 onto the cable conductor. Then, pull out the high-temperature resistant sheet from the large end opening of the inner end block 43 and fix its head onto the cable conductor. Next, install the mold 1 so that the inner end block 43 abuts against the mold 1. Then, rotate the inner end block 43 so that the high-temperature resistant sheet wraps around the cable conductor outside the mold 1 one circle at a time, forming a thicker structure that can seal the gap between the fusion splice channel port and the cable conductor, so that it can be used even when the diameter of the fusion splice channel is larger than the cable conductor.

[0070] In another embodiment of this application, the intermediate tube 42 is a telescopic tube, for example: the telescopic tube is composed of two pipe structures that are threaded together, or two pipe structures that are connected by a spring in the middle; at the same time, the inner end block 43 is a heat insulation block, for example: calcium silicate pressed into a pipe structure.

[0071] The above settings allow the length of the intermediate tube 42 to be adjustable to meet the usage requirements of various cable conductor stripping lengths; on the other hand, they prevent and reduce the probability of abnormal damage to the structure in the inner end block 43.

[0072] Reference Figure 6 In another embodiment of this application, a detection module 421 for detecting the material of the cable conductor is installed on the intermediate tube 42. The detection module 421 is electrically connected to the control device 3 through a wire.

[0073] Example of detection module 421: Probes, two in number, connected to Vcc and GND respectively, are installed inside the intermediate tube 42. The probes are installed radially and have a fixing spring on the outer wall to achieve retraction and ensure contact with the surface of the cable conductor; a current sensor is fitted on the wire leading out of the probes and detects and outputs the current detection value to the control device 3; at this time, the control device 3 can calculate the resistance parameter of the cable conductor according to Ohm's law, and determine the matching material by searching the pre-stored record in the database according to the resistance parameter.

[0074] Based on the above settings, this application does not require staff to manually select the cable material, as it can be automatically identified, making it more convenient to use.

[0075] In another embodiment of this application, the control device 3 is further configured as follows:

[0076] The data relationship between cable diameter, material, and heating time is pre-stored. It is understandable that different diameter cables require different amounts of material and welding times. Therefore, using a fixed working time would be wasteful. Thus, the optimal heating time for various materials and diameters of cables can be tested in the laboratory, recorded, and uploaded for use in adjusting on-site welding work.

[0077] Next, obtain the diameter of the cable and find the corresponding heating time from the records;

[0078] The heating coil is started and stopped according to the heating time.

[0079] Based on the above settings, this application can further reduce energy waste.

[0080] Reference Figure 1 and Figure 6 In another embodiment of this application, an encoder 6, an attitude sensor 7, and a distance sensor 8 are installed in the inner end block 43. The shaft of the encoder 6 is coaxially fixed to the rotating shaft of the drum 5, and the detection direction of the distance sensor 8 is parallel to the radial direction of the drum 5 and faces the drum 5.

[0081] Encoder 6, attitude sensor 7, and ranging sensor 8 are electrically connected to control device 3. Control device 3 is configured as follows:

[0082] If the current moment is before the inner end block 43 rotates (for example: the reset button of the connection control device 3 is set and the reset button is pressed), then the detection value L2 of the ranging sensor 8 is obtained, and the initial attitude data of the attitude sensor 7 is obtained.

[0083] If the detected value is the standard value L1, and the diameter of the high-temperature resistant sheet wound on the roll 5 is d1, then the current high-temperature resistant sheet wound on the roll 5 is d2 = d1 - (L2 - L1).

[0084] When the attitude data of the attitude sensor 7 matches the initial attitude data (i.e., the three-dimensional parameters and orientation are consistent), the degree of the encoder 6 is read to obtain the number of rotations n of the drum 5 during the process;

[0085] The diameter of the cable conductor = n * d².

[0086] Based on the above settings, this application does not require staff to measure the diameter of the cable conductor on-site or to manually input parameters. The control device 3 can complete the automatic measurement when the inner end block 43 rotates, making it more convenient to use.

[0087] It is immediately apparent that the calculated value is not the actual diameter of the cable conductor, but rather a nearest neighbor value. This is because the diameter in the diameter-heating time data relationship is actually a range, not a specific value. Therefore, it does not need to be too precise; it is sufficient to determine that the approximate value falls within the range.

[0088] In another embodiment of this application, it should be noted that the mold 1 in this application can be made into a square shape, and its bottom can be supported by a bracket, stone or the like during welding to ensure stable use. Therefore, a locking mechanism is also needed to connect and lock the mold A and the mold B. The locking mechanism can be a clamp to facilitate operation.

[0089] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A cable fusion system based on high frequency electromagnetic induction heating, comprising a mold (1), characterized in that: Also include electromagnetic heating device (2) and control device (3), wherein the mold (1) comprises: A mold, which is provided with an axially divided welding channel one; B mold, which is provided with an axially divided welding channel two; Locking mechanism for connecting and locking A mold, B mold; Wherein, the welding channel one and welding channel two are folded to form a welding channel, the mold (1) is provided with a feeding channel communicating with the welding channel, the feeding channel and the welding channel form an angle; the electromagnetic heating device (2) comprises a plurality of heating coils (21), a plurality of the heating coils (21) are divided into two groups and arranged in the A mold and the B mold respectively, and after the mold (1) is installed on the cable conductor, the plurality of heating coils (21) are left-right symmetrical, the adjacent heating coils (21) on the same side of the cable conductor have different current phases; The heating coil (21) is electrically connected to the control device (3), the control device (3) is electrically connected to the interaction unit, and the control device (3) is configured to: Obtain the material of the cable conductor to be welded, and find the preset database according to the material to obtain the matching current parameters and heating temperature; Output the heating temperature to make the interaction unit issue a check prompt, and receive temperature check feedback; If the temperature check feedback is passed, control the heating coil (21) to work according to the corresponding current parameters; The A mold and the B mold are respectively concave in the adjusting groove, and the adjusting block (12) is detachably connected in the adjusting groove, and the welding channel one and the welding channel two are arranged in the two adjusting blocks (12) respectively; Both ends of the mold (1) are respectively provided with an end sealing unit (4), the end sealing unit (4) comprises an outer end block (41), an intermediate pipe (42) and an inner end block (43), the outer end block (41) and the inner end block (43) are in the structure of the truncated cone with the large end of the truncated cone facing away from each other and are arranged at both ends of the intermediate pipe (42), the outer end block (41) is provided with an inner cavity in the structure of the truncated cone and the large end of the truncated cone faces the part of the cable conductor which is not exposed, the inner end block (43) is rotatably connected to the intermediate pipe (42) and is provided with a structure channel, the structure channel is open to both ends of the outer end block (41) and the mold (1), the inner end block (43) is rotatably connected with a winding drum (5), the winding drum (5) is wound with a high-temperature-resistant sheet, and the free end of the high-temperature-resistant sheet is used for fixing on the surface of the cable conductor; the intermediate pipe (42) is provided with a locking member (44) for locking the inner end block (43).

2. The high-frequency electromagnetic induction heating-based cable fusion system according to claim 1, characterized by: The A mold is provided with a plurality of plug blocks (11) facing the B mold, at least one plug block (11) is located below the welding channel and is called a bottom heating block, one heating coil (21) is located in the bottom heating block as the center, and the other heating coils (21) are distributed around the heating coil (21) in the bottom heating block.

3. The high-frequency electromagnetic induction heating-based cable fusion system according to claim 1, characterized by: The intermediate pipe (42) is a telescopic pipe, and the inner end block (43) is a heat insulation block.

4. The high-frequency electromagnetic induction heating-based cable fusion system according to claim 1, characterized by: The intermediate pipe (42) is provided with a detection module (421) for detecting the material of the cable conductor, and the detection module (421) is electrically connected to the control device (3).

5. The cable splicing system based on high-frequency electromagnetic induction heating according to claim 1, characterized in that: The control device (3) is configured to: Prestore the data relationship between cable diameter, material and heating time; Obtain the diameter of the cable, and look up the corresponding heating time in the record; According to the heating time, the start and stop of the heating coil (21) are controlled.

6. The high-frequency electromagnetic induction heating-based cable fusion system according to claim 5, characterized in that: The control device (3) is electrically connected with an encoder (6), a posture sensor (7) and a distance measuring sensor (8) installed on the inner end block (43), the shaft of the encoder (6) is coaxially fixed to the rotating shaft of the winding drum (5), the detection direction of the distance measuring sensor (8) is parallel to the radial direction of the winding drum (5) and faces the winding drum (5); the encoder (6), the posture sensor (7) and the distance measuring sensor (8) are electrically connected to the control device (3), and the control device (3) is configured to: If it is before the inner end block (43) rotates, the detection value L2 of the distance measuring sensor (8) is obtained, and the initial posture data of the posture sensor (7) is obtained; If the detection value is a preset standard value L1, the diameter of the high-temperature-resistant sheet wound on the winding drum (5) is d1, then the current high-temperature-resistant sheet wound on the winding drum (5) is d2=d1-(L2-L1); When the next posture data of the posture sensor (7) is consistent with the initial posture data, the number of rotations n of the winding drum (5) in the process is obtained by reading the degrees of the encoder (6); The diameter of the cable conductor is n*d2.

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