High-temperature wire end processing method and processing tool
By combining a U-shaped heat remover and chip clamps, high-temperature conductor ends can be safely processed, solving the problems of conductor core damage and complex operation. This achieves efficient and low-cost conductor processing, suitable for the diverse and small-batch needs of spacecraft cables.
Patent Information
- Application Number
- CN202511050301.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-29
- Publication Date
- 2025-11-04
AI Technical Summary
Existing technologies are prone to damaging the conductor core when handling high-temperature conductor ends, and the operation is complex and costly, making it difficult to meet the diverse and small-batch requirements of spacecraft cables.
A U-shaped heat remover is used to heat the moisture-proof and wear-resistant layer of the high-temperature conductor until it melts, and the insulation layer is removed manually. The insulation layer is then cut off with chip removal pliers to avoid direct contact with the heat source and reduce mechanical stress. Nickel-chromium alloy heating wire and manual operation are used.
It enables safe and precise handling of high-temperature conductor ends, avoids damage to conductor cores, reduces operational skill requirements and equipment costs, and adapts to the flexible and convenient handling of spacecraft cables.
Smart Images
Figure CN120896055A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The application belongs to the technical field of wire processing, and particularly relates to a high-temperature wire end processing method and a processing tool. BACKGROUND
[0002] The first and second stage separation of a certain type of spacecraft rocket engine adopts thermal separation, the second stage engine adopts a large nozzle state, the second stage engine works alone for a long time, and the second stage bottom is subjected to multiple thermal environments such as thermal scouring at the time of separation, high-temperature radiation of the main engine and the engine nozzle wall for a long time, and high-altitude plume heating during the flight of the rocket, resulting in a poor thermal environment of the second stage bottom of the rocket engine. In the flight test, abnormal phenomena such as loss of telemetry data caused by inadequate heat protection measures have occurred.
[0003] Heat protection is an important part of rocket engine development. The cables of a certain type of carrier rocket engine originally use FY3 and AF250 series wires. The maximum working temperature of the wires in this series is lower than 250 DEG C. In the face of the high-temperature environment at the bottom of the rocket engine, in order to ensure the reliability of the cable, a large number of heat protection coating measures are taken for the cable. At present, the implementation workload of the heat protection measures for the cable is large, and the process stability is poor during the implementation process. The quality of the cable after the heat protection coating is completed is poor. In order to improve the heat protection performance of the cable of the carrier type rocket and reduce the risk that may be caused by inadequate heat protection measures, high-temperature SP2D series wires are used for the cable on the rocket, and the high temperature is above 800 DEG C, so as to reduce the heat protection coating layer outside the cable and strengthen the ability of the cable to resist extreme high temperature.
[0004] In the process of manufacturing high-temperature cables, the wire end of the high-temperature wire needs to be processed. The existing temperature control type thermal stripper has a maximum temperature of 400 DEG C, and the wire is continuously heated, which causes damage to the performance of the conductor. When the high-temperature wire end is processed by using a precision manual wire stripper, the insulating layer of the wire is easily damaged, and the wire core is easily scratched, notched, cut, and broken.
[0005] In order to operate the method simply, reliably and at low cost, the risk of damaging the wire core caused by using a precision manual wire stripper is avoided. Therefore, the application designs a high-temperature wire end processing method and a processing tool to solve the above problems. SUMMARY
[0006] In view of the defects in the prior art, the purpose of the application is to provide a high-temperature wire end processing method and a processing tool.
[0007] According to the high-temperature wire end processing method provided by the application, the steps include:
[0008] Step S1: the insulation layer of the high-temperature wire is composed of an inner high-temperature-resistant insulation layer and an outer moisture-proof wear-resistant layer, a U-shaped thermal stripper is sleeved at the end of the high-temperature wire, after the U-shaped thermal stripper is heated, the moisture-proof wear-resistant layer of the high-temperature wire is heated and rotated by using the U-shaped thermal stripper until it is fused;
[0009] Step S2: manually pull the moisture-proof wear-resistant layer away from the high-temperature wire in the axial direction, and manually disassemble the high-temperature-resistant insulation layer of the high-temperature wire;
[0010] Step S3: use a scrap clipper to cut off the high-temperature-resistant insulation layer at the insulation port of the high-temperature wire, and uniformly apply force during the cutting process.
[0011] Preferably, in the step S1:
[0012] The U-shaped thermal stripper is sleeved at a position 6-8 mm away from the end of the high-temperature wire.
[0013] Preferably, in the step S1:
[0014] The U-shaped thermal stripper is heated to 400-450°C to heat the moisture-proof wear-resistant layer.
[0015] Preferably, in the step S1:
[0016] The U-shaped thermal stripper is 360° rotated to heat the moisture-proof wear-resistant layer until it is fused.
[0017] Preferably, in the step S2:
[0018] Before the moisture-proof wear-resistant layer is cooled, a heat-resistant finger sleeve is worn to pull the moisture-proof wear-resistant layer away from the end of the high-temperature wire.
[0019] Preferably, in the step S3:
[0020] When the scrap clipper is used for cutting, the jaws are downward, and the cutting scrap is directly dropped into the scrap collection place by gravity.
[0021] Preferably, in the step S3:
[0022] After the high-temperature-resistant insulation layer at the insulation port of the high-temperature wire is cut off, it is checked under a microscope, the cut of the high-temperature-resistant insulation layer needs to be neat and without burrs, and the conductor of the high-temperature wire needs to be without scratches and broken strands.
[0023] According to the U-shaped thermal stripper provided by the application, based on the high-temperature wire end processing method, the U-shaped thermal stripper comprises a handle and a U-shaped heating wire;
[0024] The handle is used for hand holding;
[0025] The two ends of the U-shaped heating wire are connected to the handle to form a U-shaped ring, and the U-shaped heating wire can be electrified to heat.
[0026] Preferably, the U-shaped heating wire is a nickel-chromium alloy wire, which is stable in shape when heated to 450 DEG C.
[0027] According to the high-temperature wire provided by the application, based on the high-temperature wire end processing method, the high-temperature wire comprises a wire body, a high-temperature resistant insulation layer and a moisture-proof wear-resistant layer.
[0028] The wire body is a silver-plated stranded copper round wire.
[0029] The high-temperature resistant insulation layer is wrapped on the outer side of the wire body and is made of mica tape wrapping, quartz fiber silk wrapping or weaving and impregnated high-temperature resistant insulation impregnated paint from inside to outside layer by layer.
[0030] The moisture-proof wear-resistant layer is wrapped on the outer side of the inner layer high-temperature resistant insulation layer and is made of polytetrafluoroethylene film wrapping sintering.
[0031] Compared with the prior art, the application has the following beneficial effects:
[0032] 1. The high-temperature resistant insulation layer of the high-temperature wire can be removed by manually cooperating with the scrap leaving forceps, compared with the original precise hand stripping forceps, the stripping forceps opening adjustment link is omitted, and the operator does not need to apply pressure during stripping, compared with the original precise hand stripping forceps, the cut of the moisture-proof wear-resistant layer of the high-temperature wire is smooth, the residual amount of the high-temperature resistant insulation layer of the high-temperature wire can be accurately controlled, the inner and outer layers of the insulation layer of the high-temperature wire are not easy to be broken or layered, the uneven or burr phenomenon of the insulation layer is prevented, the risk that the core wire of the wire is directly subjected to mechanical stress and damaged is eliminated, and the skill requirement for the operator is reduced.
[0033] 2. Compared with the whole process of heating and thermally removing the inner and outer layers of the high-temperature wire insulation layer, the inner core wire of the wire does not directly contact the heat source, and the risk that the inner layer of the high-temperature wire is carbonized or the performance of the core wire conductor is reduced (such as copper oxidation) due to heat accumulation, and even the inner layer is melted and adhered to the conductor is prevented.
[0034] 3. The characteristics of the spacecraft cable are that the varieties are many and the batch is small, compared with the automatic stripping equipment such as laser stripping equipment, the high-temperature wire end is processed more flexibly and conveniently by the application, the operability is strong, and the high-cost investment of the automatic stripping equipment is omitted. BRIEF DESCRIPTION OF DRAWINGS
[0035] Other characteristics, objects and advantages of the present application will become more apparent from the following detailed description of non-limiting embodiments, made with reference to the accompanying drawings:
[0036] Figure 1 is the operation method flow chart of the present application.
[0037] Figure 2 is the structure schematic diagram of the high-temperature wire of the present application.
[0038] Figure 3 is a schematic diagram of the U-shaped wire heating device structure of the present application.
[0039] Figure 4 is an effect diagram of the manual composite wire stripping of the present application.
[0040] In the figure, 1 is a high-temperature wire; 2 is a high-temperature-resistant insulation layer; 3 is a moisture-proof wear-resistant layer; 4 is a handle; and 5 is a U-shaped heating wire. DETAILED DESCRIPTION
[0041] The present application will be described in detail below with specific embodiments. The following embodiments will help those skilled in the art to further understand the present application, but do not limit the present application in any form. It should be pointed out that those skilled in the art can make several changes and improvements without departing from the concept of the present application. These all belong to the protection scope of the present application.
[0042] As shown in Figures 1-3 , a high-temperature wire end processing method, the steps comprising:
[0043] Step S1: The insulation layer of the high-temperature wire is composed of an inner high-temperature-resistant insulation layer 2 and an outer moisture-proof wear-resistant layer 3. A U-shaped heating device is sleeved at the end of the high-temperature wire. After heating, the U-shaped heating device is used to rotate and heat the moisture-proof wear-resistant layer 3 of the high-temperature wire until it is melted.
[0044] Preferably, the U-shaped heating device is sleeved at a position 6-8 mm away from the end of the high-temperature wire; the U-shaped heating device is heated to 400-450℃; and the U-shaped heating device is rotated 360° to heat the moisture-proof wear-resistant layer 3 until it is melted.
[0045] Step S2: The moisture-proof wear-resistant layer 3 is slowly pulled away from the high-temperature wire in the axial direction by hand to reduce the mechanical stress on the high-temperature wire conductor, and the high-temperature-resistant insulation layer 2 of the high-temperature wire is gently disassembled by hand.
[0046] Preferably, the moisture-proof wear-resistant layer 3 becomes hard after cooling and needs to be operated immediately after heating. Before the moisture-proof wear-resistant layer 3 cools down, a heat-resistant finger sleeve is worn to pull the moisture-proof wear-resistant layer 3 away from the end of the high-temperature wire, avoiding direct contact with the just-heated insulation layer by hand.
[0047] Step S3: The high-temperature-resistant insulation layer 2 at the insulation port of the high-temperature wire is cut off using a scrap retaining forceps, and the cutting process is slow and uniform.
[0048] Preferably, when using the scrap retaining forceps to cut, the forceps are downward, and the cutting scrap falls directly into the scrap collection place by gravity; and the cutting scrap is prevented from splashing due to rapid cutting, and the end processing process of the high-temperature wire is finally completed.
[0049] Preferably, after cutting off the high-temperature-resistant insulation layer 2 at the high-temperature wire insulation port, the cut of the high-temperature-resistant insulation layer 2 needs to be neat and without burrs under microscope inspection, and the conductor of the high-temperature wire needs to be without scratches and broken strands and the like, and the actual effect after cutting under 40 times microscope is as follows Figure 4 .
[0050] The high-temperature-resistant insulation layer 2 of the high-temperature wire can be removed by manually cooperating with the scrap leaving forceps, compared with the original precise manual wire stripping forceps, the wire stripping forceps mouth adjusting link is omitted, and there is no need to artificially exert pressure in the wire stripping process, compared with the original precise manual wire stripping forceps, the cut of the high-temperature wire moisture-proof wear-resistant layer 3 is smooth, and the residual amount of the high-temperature wire high-temperature-resistant insulation layer 2 can be accurately controlled, the insulation layer inner and outer layers are not easy to be broken or layered, the insulation layer is prevented from being uneven or burr, the risk that the wire core is directly subjected to mechanical stress and damaged is eliminated, and the skill requirement for the operator is reduced.
[0051] Compared with the whole process of heating and thermally removing the inner and outer insulation layers of the high-temperature wire, the wire inner core is not directly contacted with the heat source, the high-temperature wire is prevented from being carbonized due to heat accumulation, the conductor performance of the high-temperature wire is prevented from being degraded (such as copper oxidation), and even the hidden danger that the inner layer is melted and adhered to the conductor is prevented.
[0052] The characteristics of the spacecraft cable are that the varieties are many and the batch is small, compared with the automatic wire stripping equipment such as laser wire stripping equipment, the high-temperature wire end is more flexible and convenient to process by the present application, and the operability is strong, and the high-cost investment of the automatic wire stripping equipment is omitted.
[0053] The present embodiment also provides a U-shaped thermal removal device, based on the high-temperature wire end processing method, comprising: a handle 4 and a U-shaped heating wire 5;
[0054] The handle 4 is used for hand holding;
[0055] The U-shaped heating wire 5 is connected to the handle 4 at both ends to form a U-shaped ring, and the U-shaped heating wire 5 can be electrified to be heated; the U-shaped heating wire 5 is a nickel-chromium alloy wire, and the shape is stable when heated to 450℃.
[0056] The present embodiment also provides a high-temperature wire, based on the high-temperature wire end processing method, comprising: a wire main body 1, a high-temperature-resistant insulation layer 2 and a moisture-proof wear-resistant layer 3;
[0057] The wire main body 1 is a silver-plated stranded copper round wire, the silver-plated copper round wire single wire diameter is (0.100±0.003) mm, the silver-plated layer thickness is (1.0-1.5) μm, and the test method refers to the requirements of JB / T3135;
[0058] The high-temperature-resistant insulation layer 2 is wrapped on the outer side of the wire main body 1, is resistant to temperature above 800℃, and is made by mica tape wrapping, quartz fiber wire wrapping or weaving, and impregnated high-temperature-resistant insulation impregnated paint from inside to outside layer by layer.
[0059] The moisture-proof wear-resistant layer 3 is coated on the outer side of the inner high-temperature-resistant insulating layer 2, has a temperature resistance of 260 DEG C, and is made of a polytetrafluoroethylene film.
[0060] In the description of the present application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the purpose of facilitating the description of the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application.
[0061] The specific embodiments of the present application are described above. It should be understood that the present application is not limited to the specific embodiments described above, and various changes or modifications can be made by those skilled in the art within the scope of the claims, which does not affect the essential content of the present application. The embodiments of the present application and the features in the embodiments can be arbitrarily combined with each other without conflict.
Claims
1. A method of high temperature wire end treatment, characterized by the steps of Comprising: Step S1: the insulation layer of the high-temperature wire is composed of an inner layer of high-temperature-resistant insulation layer (2) and an outer layer of moisture-resistant wear-resistant layer (3), a U-shaped thermal stripper is sleeved at the end of the high-temperature wire, after heating, the U-shaped thermal stripper is used to rotate and heat the moisture-resistant wear-resistant layer (3) of the high-temperature wire until it is fused; Step S2: manually pull the moisture-resistant wear-resistant layer (3) away from the high-temperature wire in the axial direction, and manually disassemble the high-temperature-resistant insulation layer (2) of the high-temperature wire; Step S3: use a scrap clipper to cut off the high-temperature-resistant insulation layer (2) at the insulation port of the high-temperature wire, and uniformly apply force during the cutting process.
2. The high temperature wire end treatment method of claim 1, wherein, In the step S1: The U-shaped thermal stripper is sleeved at a position 6-8 mm away from the end of the high-temperature wire.
3. The high temperature wire end treatment method of claim 1, wherein, In the step S1: The U-shaped thermal stripper is heated to 400-450℃ to heat the moisture-resistant wear-resistant layer (3).
4. The high temperature wire end treatment method of claim 1, wherein, In the step S1: The U-shaped thermal stripper is rotated 360° to heat the moisture-resistant wear-resistant layer (3) until it is fused.
5. The high temperature wire end treatment method of claim 1, wherein, In the step S2: Before the moisture-resistant wear-resistant layer (3) cools down, wear a heat-resistant finger sleeve to pull the moisture-resistant wear-resistant layer (3) away from the end of the high-temperature wire.
6. The high temperature wire end treatment method of claim 1, wherein, In the step S3: When using the scrap clipper to cut, the jaws are downward, and the cuttings directly fall into the debris collection area by gravity.
7. The high temperature wire end treatment method of claim 1, wherein In the step S3: After cutting off the high-temperature-resistant insulation layer (2) at the insulation port of the high-temperature wire, check under a microscope, the cut of the high-temperature-resistant insulation layer (2) needs to be neat and burr-free, and the conductor of the high-temperature wire needs to be scratch-free and broken-strand-free.
8. A U-shaped hot-chucking device based on the method of handling the end of a high-temperature wire according to any one of claims 1 to 7, characterized in that, Comprising: A handle (4) and a U-shaped heating wire (5); The handle (4) is used for hand holding; The U-shaped heating wire (5) is connected to the handle (4) at both ends to form a U-shaped ring, and the U-shaped heating wire (5) can be heated by electricity.
9. The U-shaped thermal decoupler of claim 8, wherein, The U-shaped heating wire (5) is a nickel-chromium alloy wire, which remains stable in shape when heated to 450℃.
10. A high temperature wire based on the high temperature wire end treatment method according to any one of claims 1 to 7, characterized in that, Comprising: A wire body (1), a high-temperature-resistant insulation layer (2), and a moisture-resistant wear-resistant layer (3); The wire body (1) is a silver-plated twisted copper round wire; The high-temperature-resistant insulation layer (2) is wrapped outside the wire body (1) and is made of mica tape wrapping, quartz fiber wire wrapping or braiding, and high-temperature-resistant insulation impregnation paint from inside to outside layer by layer; The moisture-resistant wear-resistant layer (3) is wrapped outside the inner layer of high-temperature-resistant insulation layer (2) and is made of polytetrafluoroethylene film wrapping sintering.