A device and method for detecting waterproof sealing performance of a cable branch box

Abstract

This invention discloses a device and method for testing the waterproof sealing performance of cable branch boxes, including a first testing mechanism and a second testing mechanism arranged side by side, as well as a transfer mechanism. The first testing mechanism includes a testing housing with a testing chamber. The testing chamber is equipped with a positioning component, and a spraying component is arranged above the positioning component. Both the spraying component and the spraying component are connected to a water supply mechanism. The second testing mechanism includes a base and a positioning bracket, as well as a vibration component arranged between the base and the positioning bracket. A leakage detection mechanism is arranged on one side of the positioning bracket for detecting air pressure changes inside the cable branch box. The spraying process reproduces the external immersion condition, the air pressure detection identifies micropores and leaks, and the vibration loading helps to identify interface or seal fatigue leaks. It can more comprehensively discover sealing defects under simulated actual environmental humid and mechanical vibration conditions, reduce the risk of missed detection, and improve the detection rate and inspection reliability.

Description

Technical Field

[0001] This invention relates to the field of testing technology, and in particular to a device and method for testing the waterproof sealing performance of cable branch boxes. Background Technology

[0002] With the increasing demands for reliable power supply and protection in urban power distribution networks, rail transit, wind and solar power plants, building power distribution, and outdoor communication base stations, cable distribution boxes, as crucial terminal equipment for power and signal distribution and cable interfaces, are widely used in harsh outdoor and semi-outdoor environments. Distribution boxes are constantly exposed to complex conditions such as rain, dust, temperature cycling, and vibration (from transportation, construction, or wind). Once the seal fails, it can lead to water ingress, short circuits, equipment damage, and even power outages. Therefore, factory and online batch waterproof sealing performance testing is not only a necessary part of quality control but also a key measure to extend the reliable lifespan of equipment, reduce maintenance costs, and ensure electrical safety.

[0003] Currently, common devices used in the industry for testing the waterproofness of branch boxes include external spray / immersion test equipment to simulate rain or rain intensity, and airtight / vacuum leak testers to measure the box's air pressure retention capacity; there are also independent vibration tables for vibration or shock durability testing. While each of these solutions is mature and reliable in its respective field, most existing testing systems suffer from isolated testing methods and cannot reproduce the combined "wet immersion + mechanical disturbance" conditions. Simple spray tests have limited sensitivity in identifying minute leaks (especially pinhole-level or interface fatigue cracks), while air pressure / vacuum leak testing, although sensitive, cannot reveal the risk of interface fatigue leaks under wet loads unless coupled with external wet immersion conditions; vibration tests, applied alone, are also insufficient to reflect the aging of sealing materials or changes in the permeability characteristics of contact surfaces in wet environments.

[0004] Therefore, it is necessary to improve the existing detection devices to solve the technical problem that their ability to detect minor leaks and condition-related sealing defects is relatively limited when using a single detection method. Summary of the Invention

[0005] The purpose of this invention is to provide a device and method for testing the waterproof sealing performance of cable branch boxes, thereby solving the above-mentioned technical problems.

[0006] To achieve this objective, the present invention adopts the following technical solution:

[0007] A device for testing the waterproof sealing performance of a cable branch box includes a first testing mechanism and a second testing mechanism arranged side by side, as well as a transfer mechanism;

[0008] The first detection mechanism includes a detection housing, the detection housing having a detection chamber, the detection chamber being provided with a positioning component, a spray component being provided above the positioning component, a recovery funnel being provided below the positioning component, and both the spray component and the spray component being connected to a water supply mechanism.

[0009] The second detection mechanism includes a base and a positioning bracket, as well as a vibration assembly disposed between the base and the positioning bracket. A leakage detection mechanism is provided on one side of the positioning bracket. The leakage detection mechanism is provided with an air connector assembly for connecting to the cable port of the cable branch box. The air connector assembly is connected to an air pump assembly and an air pressure sensor. The air pressure sensor is used to detect changes in air pressure inside the cable branch box.

[0010] Optionally, an ultrasonic testing mechanism is also provided on one side of the positioning bracket. The ultrasonic testing mechanism includes an ultrasonic probe assembly and a signal processing module. The ultrasonic probe assembly is electrically connected to the signal processing module and is used to perform ultrasonic flaw detection on the welded parts of the cable branch box.

[0011] Optionally, the transfer mechanism includes a conveyor plate, and the conveyor plate is provided with a conveyor belt along its length;

[0012] The first and second detection mechanisms are each provided with a set of pushing components, which are arranged perpendicular to the length direction of the conveyor plate.

[0013] The pushing assembly includes a push cylinder, and the piston rod of the push cylinder is provided with a suction cup assembly, which is used to adsorb the cable branch box.

[0014] Optionally, the water supply mechanism includes a water storage tank and a return pipe. A filter screen is provided on the upper surface of the water storage tank. One end of the return pipe is connected to the recovery funnel, and the other end is positioned towards the filter screen.

[0015] The water storage tank is connected to a water supply pump, the water supply pump is equipped with a water outlet pipe, the water outlet pipe is equipped with a pressure control valve, and one end of the water outlet pipe is connected to the spray assembly.

[0016] Optionally, the positioning component includes a material loading track, with a first base plate and a second base plate disposed below the material loading track. The first base plate is provided with a lifting component, and the driving end of the lifting component is connected to the second base plate. The lifting component is used to drive the track component to move vertically.

[0017] A pressure plate is provided above the material loading track, and a positioning post is provided at a preset position on the pressure plate. A buffer spring is provided between the positioning post and the pressure plate.

[0018] Optionally, the positioning component further includes two side plates, which are respectively fixedly connected to the two sides of the first base plate. One side plate is slidably connected to a push plate, and the push plate is connected to a driving component for pushing the push plate to slide.

[0019] This invention also provides a method for testing the waterproof sealing performance of cable branch boxes, which is implemented using the cable branch box waterproof sealing performance testing device described above. The testing method includes the following steps:

[0020] The transfer mechanism transports the cable branch box to be tested to the testing chamber of the first testing mechanism, and positions and clamps the branch box using the positioning component;

[0021] The spray assembly is activated to spray the outer surface of the branch box, and the liquid is recovered through the recovery funnel. After completion, the branch box is transferred to the second testing unit through the transfer mechanism.

[0022] The branch box is clamped and positioned using the positioning bracket of the second testing mechanism. The air connector assembly is then used to connect to the cable interface of the branch box to establish an air circuit connection, and the air circuit sealing and clamping status are confirmed.

[0023] The air pump assembly controls the internal pressure of the branch box in multiple stages, and the vibration assembly is activated simultaneously to apply mechanical vibration, and the internal pressure change curve and vibration time series are collected and recorded.

[0024] The leakage rate is calculated based on the pressure change curve. Combined with vibration events and spray data, the sealing performance is determined to be qualified, and sorting signals and test reports are output.

[0025] Optionally, the activation of the spray assembly sprays the outer surface of the branch box, while simultaneously recovering the liquid through a recovery funnel. After completion, the branch box is transferred to the second detection mechanism via a transfer mechanism, including the following steps:

[0026] According to the model of the cable branch box, the preset spray parameter combination is called, the spray angle, flow rate and coverage mode of the spray component are adjusted, and the water supply pump is started to deliver water in the water storage tank to the spray component through the pressure control valve.

[0027] The drive spray assembly sprays the outer surface of the branch box according to the set parameters. During the process, the water pressure and flow rate are monitored in real time, and the spray state is dynamically adjusted according to the feedback. At the same time, the recovery funnel begins to collect the sprayed liquid and guides it to the filter screen through the return pipe for preliminary filtration.

[0028] Spraying stops after the set time or water volume is reached. The actual spraying curve and total water consumption are collected and recorded. The recovery funnel continues to collect residual droplets until the liquid flow stops. The filtered water is returned to the water storage tank to complete the cycle.

[0029] The transfer mechanism is activated, adsorbing and transferring the sprayed branch box to the designated location of the second testing agency. During the transfer process, the branch box is kept moist and the start and arrival times of the transfer are recorded.

[0030] Optionally, the step of controlling the internal pressure of the branch box through the air pump assembly in multiple stages, simultaneously activating the vibration assembly to apply mechanical vibration, and collecting and recording the internal pressure change curve and vibration time series specifically includes the following steps:

[0031] Retrieve the preset detection program according to the model of the cable branch box, and initialize the parameters of the air pump assembly, air pressure sensor and vibration assembly;

[0032] The air pump assembly inflates the branch box to the first pressure threshold, maintains it for a set time to establish an initial steady state, and records the pressure baseline and ambient temperature data.

[0033] Once the static pressure holding phase begins, the gas circuit valves are closed, static pressure decay data is collected, and the static phase pressure change rate is calculated as a baseline leakage reference value.

[0034] Optionally, the step of collecting static pressure decay data and calculating the static stage pressure change rate as a baseline leakage reference value further includes:

[0035] Start the vibration assembly and apply mechanical vibration according to the preset frequency-amplitude curve. Simultaneously monitor pressure changes, identify vibration-induced pressure fluctuation events, and mark them with time stamps.

[0036] One or more negative pressure steps are applied during or at intervals of vibration to induce potential intermittent leakage, and the instantaneous pressure response characteristics are recorded.

[0037] The vibration stops and the recovery monitoring phase begins. Pressure recovery or attenuation curves are continuously collected for a set duration to obtain the system balance characteristics.

[0038] By integrating overall pressure-time data, vibration timing, and event markers, a sealing performance dataset with excitation response is generated.

[0039] Compared with the prior art, the present invention has the following beneficial effects: During operation, the cable branch box to be tested is transported to the testing chamber of the first testing mechanism. The positioning component fixes the branch box in place and starts clamping. The spray component above sprays the exterior of the box according to the preset working conditions by the water supply mechanism. At the same time, the recovery funnel below recovers the sprayed water and returns it to the water supply / recovery system. After the spraying is completed or during the spraying process, the system transfers the branch box to the position of the second testing mechanism. The positioning bracket of the second testing mechanism further positions and clamps the box. The vibration component applies vibration to the positioning bracket at a set frequency to simulate the vibration during operation / transportation. The leakage detection mechanism is then activated. The air connector assembly connects to the cable port, establishing airflow communication with the internal cavity of the branch box. The air pump assembly pressurizes or evacuates the branch box, while the air pressure sensor collects and records the internal air pressure change curve in real time. Based on the comparison between the air pressure decay rate or recovery rate and a preset threshold, it is determined whether the branch box is leaking. This device replicates the external immersion condition through a spraying process. The air pressure detection has high sensitivity to tiny pores and leaks, and vibration loading helps identify interface or seal fatigue leaks. It can more comprehensively and sensitively detect sealing defects under simulated actual humid and mechanical disturbance conditions, reducing the risk of missed detection and improving the detection rate and inspection reliability. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0041] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0042] Figure 1 This is a front view schematic diagram of the cable branch box waterproof sealing performance testing device in this embodiment 1;

[0043] Figure 2 This is a side view of the cable branch box waterproof sealing performance testing device in this embodiment.

[0044] Figure 3 This is a schematic diagram of the overall structure of the cable branch box waterproof sealing performance testing device in this embodiment 1;

[0045] Figure 4 This is a schematic diagram of the positioning component of the cable branch box waterproof sealing performance testing device in this embodiment.

[0046] Illustration: First detection mechanism 10, second detection mechanism 20, transfer mechanism 30, detection housing 11, detection chamber 12, positioning assembly 13, spray assembly 14, recovery funnel 15, water supply mechanism 40, base 21, positioning bracket 22, vibration assembly 23, leakage detection mechanism 50, air connector assembly 51, ultrasonic probe assembly 60, conveying plate 31, pushing assembly 32, water storage tank 41, return pipe 42, filter screen 43, water supply pump 44, water outlet pipe 45, pressure control valve 4, material loading track 131, first base plate 132, second base plate 133, lifting assembly 134, pressure plate 135, positioning column 136, side plate 137, drive assembly 138, top push plate 139. Detailed Implementation

[0047] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0048] In the description of this invention, it should be understood that the terms "upper," "lower," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. It should be noted that when a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be a component positioned centrally in the connection.

[0049] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0050] Example 1:

[0051] Combination Figures 1 to 4As shown, this embodiment of the invention provides a cable branch box waterproof sealing performance testing device, including a first testing mechanism 10 and a second testing mechanism 20 arranged side by side, and a transfer mechanism 30; the first testing mechanism 10 includes a testing housing 11, the testing housing 11 has a testing chamber 12, the testing chamber 12 is provided with a positioning component 13, a spraying component 14 is provided above the positioning component 13, a recovery funnel 15 is provided below the positioning component 13, and the spraying component 14 and the spraying component 15 are both connected to a water supply mechanism 40.

[0052] It should be noted that a spray assembly 14 is installed above the positioning assembly 13 to simulate rainfall or water spraying tests on the exterior of the branch box according to predetermined spraying conditions (such as spraying angle, spraying flow rate and duration); a recycling funnel 15 is installed below the positioning assembly 13 to collect spray water and feed the recycled water back to the water supply mechanism 40 or wastewater treatment unit to realize the recycling and utilization of water resources and on-site cleaning control.

[0053] The spray assembly 14 is a spray plate with multiple spray holes. The spray assembly 14 is connected to the water supply mechanism 40, which may include a water pump, a flow control valve, and a filter to ensure stable water supply and controllable pressure.

[0054] The second testing mechanism 20 includes a base 21 and a positioning bracket 22, as well as a vibration component 23 disposed between the base 21 and the positioning bracket 22. The vibration component 23 is used to drive the positioning bracket 22 to vibrate at a preset frequency.

[0055] The positioning bracket 22 is used to reliably clamp and mechanically align the branch box; a vibration component 23 is set between the base 21 and the positioning bracket 22. The vibration component 23 drives the positioning bracket 22 to vibrate at a set frequency and amplitude via a power mechanism (such as an electromagnetic vibrator, an eccentric motor or a servo vibration unit), thereby simulating the stress effect of mechanical vibrations such as transportation, installation or on-site wind vibration on the seals and interfaces.

[0056] A leakage detection mechanism 50 is provided on one side of the positioning bracket 22. The leakage detection mechanism 50 is provided with an air connector assembly 51 for connecting to the cable port of the cable branch box. The air connector assembly 51 is connected to an air pump assembly and an air pressure sensor. The air pressure sensor is used to detect changes in air pressure inside the cable branch box.

[0057] It should be noted that the leak detection unit 50 is equipped with an air connector assembly 51 for connecting to the cable port of the cable branch box. The air connector assembly 51 is a standardized, quick-plug tooling plug or quick-change connector that can establish an air passage connection with the internal cavity of the branch box without damaging the box body. The air connector assembly 51 is connected to the air pump assembly (providing a positive pressure or vacuum source) and the air pressure sensor via an air pipe; the air pressure sensor is used to collect pressure change signals inside the branch box in real time to determine whether there is a leak.

[0058] To improve detection sensitivity and identification capability, this embodiment can adopt a segmented air pressure strategy (e.g., pre-pressurization—static pressure holding—vibration synchronous observation—pulse excitation) and maintain physical isolation between the air and water circuits to prevent mutual interference during testing. When vibration and air pressure are running synchronously, intermittent or fatigue-induced leaks induced by vibration can be identified by comparing the pressure decay rate before and after vibration or detecting pressure transient events. To ensure safety and reliability, this testing mechanism is preferably equipped with positioning detection, air joint sealing pre-inspection, pressure over-limit protection, and equipment interlock logic, and can be optionally configured with pressure range (e.g., preferably gauge pressure 5-50 kPa as an example) and vibration frequency range (e.g., preferably 5-200 Hz as an example) for process calibration.

[0059] The working principle of this invention is as follows: During operation, the cable branch box to be tested is transported to the testing chamber 12 of the first testing mechanism 10. The positioning component 13 fixes the branch box in place and starts clamping. The spray component 14 above sprays the exterior of the box with water according to the preset working conditions by the water supply mechanism 40. At the same time, the recovery funnel 15 below recovers the sprayed water and returns it to the water supply / recovery system. After the spraying is completed or during the spraying process, the system transfers the branch box to the position of the second testing mechanism 20. The positioning bracket 22 of the second testing mechanism 20 further positions and clamps the box. The vibration component 23 applies vibration to the positioning bracket 22 at a set frequency to simulate the vibration during operation / transportation, and initiates leakage detection. Mechanism 50 connects to the cable port via air connector assembly 51, enabling air communication with the internal cavity of the branch box. The air pump assembly pressurizes or evacuates the interior of the branch box, while the air pressure sensor collects and records the internal air pressure change curve in real time. Based on the comparison between the air pressure decay rate or recovery rate and a preset threshold, it is determined whether the branch box has leaked. This device replicates the external immersion condition through a spraying process. The air pressure detection has high sensitivity to micropores and leaks. Vibration loading helps to identify interface or seal fatigue leaks. It can more comprehensively and sensitively detect sealing defects under simulated actual humid and mechanical disturbance conditions, reducing the risk of missed detection and improving the detection rate and inspection reliability.

[0060] In this embodiment, it is further explained that an ultrasonic testing mechanism is also provided on one side of the positioning bracket 22. The ultrasonic testing mechanism includes an ultrasonic probe assembly 60 and a signal processing module. The ultrasonic probe assembly 60 is electrically connected to the signal processing module and is used to perform ultrasonic flaw detection on the welded parts of the cable branch box.

[0061] It should be noted that the ultrasonic probe assembly 60 is a contact or dry-coupled probe (selectable as a straight probe or angled probe / wedge), mounted on the positioning bracket 22, so that the probe can be placed on the surface of the welded part of the cable branch box for scanning. The ultrasonic probe achieves good energy transfer with the workpiece surface through a coupling agent (or a dry coupling device); the echo signal received by the probe is pre-amplified, bandpass filtered, and then input to the signal processing module. The signal processing module can automatically detect and alarm for common defects in the weld, such as cracks, lack of fusion, porosity, or slag inclusions. Optimal parameter example: probe center frequency range 2-10MHz (selected according to weld thickness), threshold / gain can be calibrated based on a good product baseline; the system also has probe coupling status detection and self-test functions to reduce false judgments.

[0062] In this embodiment, the transfer mechanism 30 includes a conveyor plate 31, and a conveyor belt is provided on the conveyor plate 31 along its length direction; the first detection mechanism 10 and the second detection mechanism 20 are respectively provided with a set of pushing components 32, and the pushing components 32 are arranged perpendicular to the conveyor plate 31 along its length direction; the pushing components 32 include a push cylinder, and the piston rod of the push cylinder is provided with a suction cup assembly, which is used to adsorb the cable branch box.

[0063] The pushing component 32 works in conjunction with the conveyor belt position sensor and positioning component 13 for motion control: after the conveyor belt accurately aligns and confirms the positioning of the workpiece, the pushing cylinder extends and the suction cup picks up the workpiece. The cylinder then pushes the workpiece into the detection chamber or positioning bracket 22, where the positioning component 13 completes the positioning. Subsequently, the air path releases the suction cup to complete the transfer. The advantages of this structure are: the pushing method facilitates short-stroke, rapid repositioning between workstations; the suction cup reduces the risk of scratches to the box surface from mechanical clamps; and the entire operation can be easily pneumatically controlled, facilitating maintenance and protection. In other words, through the cooperation of the conveyor belt and the pushing component 32, the branch box to be tested is transferred and transported between the first detection mechanism 10 and the second detection mechanism 20.

[0064] In this embodiment, the water supply mechanism 40 includes a water storage tank 41 and a return pipe 42. A filter screen 43 is provided on the upper surface of the water storage tank 41. One end of the return pipe 42 is connected to the recovery funnel 15, and the other end is set towards the filter screen 43. The water storage tank 41 is connected to a water supply pump 44. The water supply pump 44 is provided with a water outlet pipe 45. The water outlet pipe 45 is provided with a pressure control valve 46. One end of the water outlet pipe 45 is connected to the spray assembly 14.

[0065] It should be noted that the water supply pump 44 supplies water to the spray assembly 14 through the outlet pipe 45. A pressure control valve 46 (or pressure stabilizing valve) is installed on the outlet pipe 45 to control the spray pressure and flow rate. At the same time, a flow meter and a pressure sensor can be connected in parallel on the outlet pipe 45 to monitor the spray condition in real time and send the data back to the controller for recording and closed-loop adjustment.

[0066] The system should also be equipped with a liquid level sensor and an automatic water replenishment port to ensure that the water level in the water storage tank 41 is maintained within the set range during long-term operation. In addition, it is recommended to install a check valve and a filter screen between the return pipe 42 and the water supply pump 44 to prevent backflow and foreign objects from entering the spray assembly 14, so as to realize the recycling of spray water, reduce the on-site water supply and drainage burden and ensure stable spray pressure.

[0067] In this embodiment, the positioning component 13 includes a material loading track 131. A first base plate 132 and a second base plate 133 are disposed below the material loading track 131. A lifting component 134 is disposed on the first base plate 132. The driving end of the lifting component 134 is connected to the second base plate 133. The lifting component 134 is used to drive the material loading track 131 to move in the vertical direction. A pressure plate 135 is disposed above the material loading track 131. A positioning post 136 is disposed at a preset position of the pressure plate 135. A buffer spring is disposed between the positioning post 136 and the pressure plate 135.

[0068] After the workpiece is loaded and the cable branch box is placed on the loading track 131 by the conveyor belt, the lifting assembly 134 drives the second base plate 133 to rise with the loading track 131 until the branch box contacts the pressure plate 135 / positioning column 136; at this time, the buffer spring generates elastic pretension, and the positioning column 136 applies a constant and adjustable vertical preload to the branch box to achieve top surface positioning and gentle clamping.

[0069] The advantages of this structure are: on the one hand, the height of the workpiece and the pressure plate 135 can be automatically compensated through the lifting component 134, which can adapt to branch boxes with different heights and manufacturing tolerances; on the other hand, the buffer spring provides elastic buffering to avoid damage to the surface of the box or internal components caused by excessive clamping, while ensuring that the pre-pressure of each clamping is repeatable and stable.

[0070] In this embodiment, the positioning component 13 further includes two side plates 137, which are fixedly connected to the two sides of the first base plate 132 respectively. One side plate 137 is slidably connected to a push plate 139, and the push plate 139 is connected to a drive component 138. The drive component 138 is used to push the push plate 139 to slide.

[0071] It should be noted that the pusher plate 139 moves horizontally under the push of the drive assembly 138 (e.g., a slide rail mechanism driven by a cylinder or servo motor), pushing the branch box into the positioning position towards the positioning post 136 or the reference surface. The advantages of this side pusher plate 139 structure include: (1) achieving precise alignment of the workpiece in the horizontal direction, ensuring concentric docking of the cable port and the air connector assembly 51; (2) in conjunction with the drive assembly 138, it can achieve adjustable thrust and controllable speed, thereby taking into account both positioning accuracy and protection of the box.

[0072] Example 2:

[0073] The present invention also provides a method for testing the waterproof sealing performance of cable branch boxes, which is implemented using the cable branch box waterproof sealing performance testing device as described in Embodiment 1. The testing method includes the following steps:

[0074] S1, the transfer mechanism 30 transports the cable branch box to be tested to the testing chamber 12 of the first testing mechanism 10, and positions and clamps the branch box through the positioning component 13.

[0075] Once in position, the positioning component 13 operates: the lifting component 134 raises the material loading track 131 until the branch box contacts the pressure plate 135 / positioning column 136, and the buffer spring provides flexible pre-tightening force to achieve top surface positioning; the two side plates 137 and the push plate 139 simultaneously perform lateral constraint and push to ensure the axial and radial concentricity of the cable port and the subsequent leak detection docking position.

[0076] S2, start the spray assembly 14 to spray the outer surface of the branch box, and at the same time recover the liquid through the recovery funnel 15. After completion, the branch box is transferred to the second detection mechanism 20 through the transfer mechanism 30.

[0077] It should be noted that the spray assembly 14 is activated to conduct a spray test on the exterior of the branch box under predetermined working conditions (the spray pressure, nozzle angle, spray duration, and total flow rate can be set to simulate different rainfall levels). During the spraying process, the recovery funnel 15 collects the falling water and guides it back to the water storage tank 41 through the return pipe 42. The filter screen 43 at the top of the water storage tank 41 initially intercepts the return water. The liquid level sensor, flow meter, and pressure sensor of the return system are used to monitor the spraying conditions in real time and transmit the data back to the host computer for recording. After the spraying is completed, the system records the spraying start and end time, cumulative water consumption, pump pressure, and other working condition parameters. The transfer mechanism 30 then quickly transports the still "wet" branch box to the second detection mechanism 20 to ensure that the subsequent air pressure / vibration test is carried out under wet load conditions, maximizing the simulation of the real working conditions under stress after water immersion on site.

[0078] S3, the branch box is clamped and positioned by the positioning bracket 22 of the second detection mechanism 20, the air connector assembly 51 is used to connect to the cable interface of the branch box to establish an air circuit connection, and the air circuit sealing status and clamping status are confirmed.

[0079] After the branch box reaches the second inspection unit 20, the positioning bracket 22 clamps the branch box and re-verifies the clamping force and positioning accuracy. The operator or automated device connects the air connector assembly 51 (or a special plug) to the cable port of the branch box to establish air communication with the internal cavity of the box. After the connection is completed, the system performs a pre-test of the air circuit seal—a short-term low-pressure gas is introduced and the initial leakage is monitored by a pressure sensor or micro-flow meter. Only after confirming that the air connector and the workpiece interface have acceptable sealing and no leakage can the formal inspection process begin. If the pre-test finds poor sealing, the system automatically prompts for reset or reconnection to prevent misjudgment due to tooling connection errors.

[0080] S4, through the air pump assembly, performs multi-stage pressure control inside the branch box, and simultaneously starts the vibration assembly 23 to apply mechanical vibration, and collects and records the internal pressure change curve and vibration time series.

[0081] It should be noted that the multi-stage pressure control includes: ① rapid pre-pressurization to the set reference pressure P0 (for establishing a baseline); ② recording the static attenuation rate during the static pressure holding stage (for common leak assessment); ③ continuing sampling at a preset frequency / amplitude during the vibration induction stage to observe the dynamic changes in the pressure curve after vibration initiation; ④ short-time pulse or small-amplitude pressure drop excitation to trigger intermittent leaks and capture instantaneous responses.

[0082] S5 calculates the leakage rate based on the pressure change curve, combines vibration events and spray data for joint analysis, determines whether the sealing performance is qualified, and outputs sorting signals and inspection reports.

[0083] Based on the pressure-time curve and vibration time series obtained in step S4, the system calculates leakage-related quantities (e.g., estimating the static and dynamic attenuation rates dP / dt using linear fitting or least squares method, and converting the leakage rate Q ≈ -V·dP / dt under known or estimated internal effective volume V, or directly using the standardized attenuation rate as the judgment quantity). Simultaneously, the vibration stage and spraying conditions are jointly compared: if the vibration stage attenuation rate is significantly higher than the static baseline (e.g., the ratio R exceeds a preset multiple) or if a transient pulse event occurs and coincides with the vibration time point, it is determined to be a vibration-induced leakage; if the static stage has exceeded the threshold, it is also determined to be a regular leakage. The final judgment result drives the sorting mechanism to reject / rework non-conforming workpieces, and the inspection package is saved as an inspection report for traceability and maintenance reference.

[0084] In this embodiment, step S2 specifically includes the following steps:

[0085] S21, according to the model of the cable branch box, call the preset spray parameter combination, adjust the spray angle, flow rate and coverage mode of the spray assembly 14, and start the water supply pump 44 to deliver the water in the water storage tank 41 to the spray assembly 14 through the pressure control valve 46.

[0086] The system retrieves the corresponding spray parameter combination (including spray angle, water flow rate of a single nozzle / head, spray coverage mode such as rotation / fixed point / stepped type, total spray duration, etc.) from the process library built into the controller according to the model of the cable branch box under test or the workpiece ID, and sets the angle and mode of the mechanical positioning mechanism and nozzle array of the spray assembly 14 accordingly.

[0087] Water supply is provided by water storage tank 41. Water storage tank 41 pressurizes water outlet pipe 45 through water supply pump 44. Pressure control valve 46 (preferably an electronically controlled proportional valve or a pressure stabilizing valve) and flow meter are connected in series on water outlet pipe 45. The controller issues target pressure / flow setpoints according to the called spray parameters. Pressure sensor and flow meter transmit the measured values ​​back to controller in real time, providing feedback for subsequent closed-loop regulation.

[0088] S22, drive the spray assembly 14 to spray the outer surface of the branch box according to the set parameters. During the process, monitor the water pressure and flow rate in real time, and dynamically adjust the spray state based on the feedback. At the same time, the recovery funnel 15 starts to collect the spray liquid and guides it through the return pipe 42 to the filter screen 43 for preliminary filtration.

[0089] During the spraying process, the controller uses real-time feedback from pressure sensors and flow meters as input, and performs closed-loop regulation (e.g., using a PID control algorithm) on the output of the water supply pump 44 through pressure control valve 46 and / or variable frequency pump to maintain the target spraying pressure and flow rate, thereby ensuring consistent spray coverage. The spraying mode can achieve phased switching or angle adjustment of the nozzle group according to process requirements to ensure that different surfaces and seams are thoroughly rinsed. At the same time, the recovery funnel 15 located below the branch box collects the fallen water, and the recovered liquid is guided to the filter screen 43 through the return pipe 42 for preliminary solid interception; during the return process, a flow direction sensor and particle alarm are set up to trigger automatic backwashing or maintenance prompts when necessary.

[0090] S23, the spraying stops after the set time or water volume is reached, the actual spraying curve and total water consumption are collected and recorded, the recovery funnel 15 continues to collect residual droplets until the liquid flow stops, and the filtered water is returned to the water storage tank 41 to complete the cycle.

[0091] The system automatically collects and saves the actual spray curve (pressure-time and flow-time curves) and total water consumption data, and archives the record with the workpiece ID. After spraying stops, the recovery funnel 15 continues to operate and collects residual drips. The return pipe 42 continuously leads the collected liquid to the filter screen 43 at the top of the water storage tank 41 for preliminary filtration. The filtered water can be recycled after being subjected to grit removal or secondary filtration in the water storage tank 41.

[0092] S24, the transfer mechanism 30 is started, adsorbs and transfers the sprayed branch box to the designated position of the second detection mechanism 20, keeps the branch box wet during the transfer process and records the start and arrival time of the transfer.

[0093] In practice, the suction cup assembly or the push assembly causes the branch box to detach from the material loading track 131 and transfer it to the positioning range of the second detection mechanism 20 according to the set trajectory. The entire transfer process is monitored by the position sensor and the positioning photoelectric switch. The start time and the arrival time of the transfer are recorded by the controller to form transfer delay data and are saved together with the spray timestamp in order to evaluate the impact of the spray-air detection interval on the detection results.

[0094] In this embodiment, step S4 specifically includes the following steps:

[0095] S41, retrieve the preset detection program according to the model of the cable branch box, and initialize the parameters of the air pump assembly, air pressure sensor and vibration assembly 23.

[0096] It should be noted that the initialization includes: performing self-test and zero-point calibration on the air pressure sensor, confirming that there is no obvious leakage in the air pump and pipeline (short-term inflation and monitoring stability), detecting and removing residual moisture in the air circuit (if water droplets are detected, they should be discharged first), and performing no-load vibration test on the vibration component 23 to confirm that the drive unit and displacement / acceleration sensor are working properly.

[0097] S42, the air pump assembly inflates the branch box to the first pressure threshold, maintains it for a set time to establish an initial steady state and records the pressure baseline and ambient temperature data.

[0098] The air pump assembly injects gas into the docked branch box, rapidly raising the internal pressure to a preset first pressure threshold P1 and maintaining it for a certain period to establish an initial steady state. This first pressure threshold can be set according to the box specifications and process requirements (preferred example range: gauge pressure 5–50 kPa, specific values ​​specified in the model library). After reaching the target pressure, it is maintained for several seconds to tens of seconds (for pressure stabilization and temperature adaptation), during which the pressure baseline P(t) and environmental parameters (including ambient temperature and atmospheric pressure near the chamber) are collected and recorded. This baseline data is used for subsequent attenuation rate calculation and temperature compensation.

[0099] S43, enter the static pressure holding stage, close the gas circuit valve, collect static pressure decay data, and calculate the static stage pressure change rate as the basic leakage reference value.

[0100] Static pressure holding measurement phase: After disconnecting the gas source from the branch box or closing the main gas supply valve, the system continuously collects the pressure decay curve P(t) over time without applying mechanical disturbance. The pressure change rate dP / dt during the static phase is calculated using the static sampling data (obtainable through linear fitting or least squares method), and this is used as the basic leakage reference value. If the internal effective volume V of this model is known beforehand or stored in the process library, the pressure drop rate can be converted into the physical leakage rate Q (e.g., the approximate relationship Q ≈ -V·dP / dt, or compensation using a model considering temperature and the gas state equation), and this static leakage amount is used as the basis for determining the threshold.

[0101] S44, start the vibration component 23, apply mechanical vibration according to the preset frequency-amplitude curve, synchronously monitor pressure changes, identify vibration-induced pressure fluctuation events and mark them with time stamps.

[0102] The vibration assembly 23 is activated according to a pre-set frequency-amplitude curve, allowing the positioning bracket 22 and the branch box to jointly withstand controllable mechanical vibration (e.g., multiple frequency segments or a scanning spectrum can be set to cover possible resonance / density damage frequency bands). Before and after vibration activation, the pressure sensor continuously records the pressure time series at a high sampling rate and marks the vibration activation / deactivation time points. Data processing focuses on identifying the dynamic characteristics of the pressure curve during vibration, including abrupt changes in the decay rate, pressure pulses, periodic fluctuations, or transient events related to the vibration phase; these characteristics help identify vibration-induced leaks or transient leakage behavior of interfaces under stress.

[0103] S45, apply one or more negative pressure steps during or at intervals of vibration to excite potential intermittent leakage and record the instantaneous pressure response characteristics; after each negative pressure excitation, the system records the instantaneous pressure response (including instantaneous amplitude, rise / fall rate and overshoot characteristics) with high time resolution and compares these transient characteristics with the vibration time axis.

[0104] S46, stop vibration and enter the recovery monitoring phase, continuously collect pressure recovery or decay curves for a set time to obtain system balance characteristics.

[0105] Data from the recovery phase is used to assess the system’s equilibrium and residual leakage behavior after the disturbance has ceased, including metrics such as pressure recovery rate or decay duration; these metrics help distinguish between short-term anomalies caused by transient turbulence and persistent leakage problems.

[0106] S47 integrates overall pressure-time data, vibration timing, and event markers to generate a sealing performance dataset with excitation response.

[0107] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A device for testing the waterproof sealing performance of a cable branch box, characterized in that, It includes a first and second testing facility set up side by side, as well as a transfer facility; The first detection mechanism includes a detection housing, the detection housing having a detection chamber, the detection chamber being provided with a positioning component, a spray component being provided above the positioning component, a recovery funnel being provided below the positioning component, and both the spray component and the spray component being connected to a water supply mechanism. The second detection mechanism includes a base and a positioning bracket, and a vibration assembly disposed between the base and the positioning bracket. A leakage detection mechanism is provided on one side of the positioning bracket. The leakage detection mechanism is provided with an air connector assembly for connecting to the cable port of the cable branch box. The air connector assembly is connected to an air pump assembly and an air pressure sensor. The air pressure sensor is used to detect changes in air pressure inside the cable branch box. The water supply mechanism includes a water storage tank and a return pipe. A filter screen is provided on the upper surface of the water storage tank. One end of the return pipe is connected to the recovery funnel, and the other end is positioned towards the filter screen. The water storage tank is connected to a water supply pump, the water supply pump is equipped with a water outlet pipe, the water outlet pipe is equipped with a pressure control valve, and one end of the water outlet pipe is connected to the spray assembly. During operation, the spray assembly is sprayed on the exterior of the tank by the water supply mechanism according to preset working conditions. The pressure control valve controls the spray pressure and flow rate. At the same time, a flow meter and a pressure sensor are connected in parallel on the water outlet pipe to monitor the spray working conditions in real time and transmit the data back to the controller for recording and closed-loop adjustment. After spraying is completed, the transfer mechanism transports the still wet branch box to the second detection mechanism. The positioning bracket of the second detection mechanism positions and clamps the box. The vibration component applies vibration to the positioning bracket at a set frequency to simulate the vibration during operation / transportation. The leakage detection mechanism is activated and connected to the cable port through the air connector assembly. The air pump assembly pressurizes or evacuates the inside of the branch box. At the same time, the air pressure sensor collects and records the internal air pressure change curve in real time. Based on the comparison between the air pressure decay rate or recovery rate and the preset threshold, it is determined whether the branch box has leaked.

2. The cable branch box waterproof sealing performance testing device according to claim 1, characterized in that, An ultrasonic testing mechanism is also provided on one side of the positioning bracket. The ultrasonic testing mechanism includes an ultrasonic probe assembly and a signal processing module. The ultrasonic probe assembly is electrically connected to the signal processing module and is used to perform ultrasonic flaw detection on the welded parts of the cable branch box.

3. The cable branch box waterproof sealing performance testing device according to claim 1, characterized in that, The transfer mechanism includes a conveyor plate, and the conveyor plate is provided with a conveyor belt along its length. The first and second detection mechanisms are each provided with a set of pushing components, which are arranged perpendicular to the length direction of the conveyor plate. The pushing assembly includes a push cylinder, and the piston rod of the push cylinder is provided with a suction cup assembly, which is used to adsorb the cable branch box.

4. The cable branch box waterproof sealing performance testing device according to claim 1, characterized in that, The positioning component includes a material loading track, and a first base plate and a second base plate are disposed below the material loading track. The first base plate is provided with a lifting component, and the driving end of the lifting component is connected to the second base plate. The lifting component is used to drive the material loading track to move in the vertical direction. A pressure plate is provided above the material loading track, and a positioning post is provided at a preset position on the pressure plate. A buffer spring is provided between the positioning post and the pressure plate.

5. The cable branch box waterproof sealing performance testing device according to claim 4, characterized in that, The positioning component also includes two side plates, which are respectively fixedly connected to the two sides of the first base plate. One side plate is slidably connected to a push plate, and the push plate is connected to a driving component, which is used to push the push plate to slide.

6. A method for testing the waterproof sealing performance of a cable branch box, implemented using the cable branch box waterproof sealing performance testing device as described in any one of claims 1 to 5, the testing method comprising the following steps: The transfer mechanism transports the cable branch box to be tested to the testing chamber of the first testing mechanism, and positions and clamps the branch box using the positioning component; The spray assembly is activated to spray the outer surface of the branch box, and the liquid is recovered through the recovery funnel. After completion, the branch box is transferred to the second testing unit through the transfer mechanism. The branch box is clamped and positioned using the positioning bracket of the second testing mechanism. The air connector assembly is then used to connect to the cable interface of the branch box to establish an air circuit connection, and the air circuit sealing and clamping status are confirmed. The air pump assembly controls the internal pressure of the branch box in multiple stages, and the vibration assembly is activated simultaneously to apply mechanical vibration, and the internal pressure change curve and vibration time series are collected and recorded. The leakage rate is calculated based on the pressure change curve. Combined with vibration events and spray data, the sealing performance is determined to be qualified, and sorting signals and test reports are output.

7. The method for testing the waterproof sealing performance of cable branch boxes according to claim 6, characterized in that, The activation spray assembly sprays the outer surface of the branch box, while simultaneously recovering the liquid through a recovery funnel. After completion, the branch box is transferred to the second testing unit via a transfer mechanism, including the following steps: According to the model of the cable branch box, the preset spray parameter combination is called, the spray angle, flow rate and coverage mode of the spray component are adjusted, and the water supply pump is started to deliver water in the water storage tank to the spray component through the pressure control valve. The drive spray assembly sprays the outer surface of the branch box according to the set parameters. During the process, the water pressure and flow rate are monitored in real time, and the spray state is dynamically adjusted according to the feedback. At the same time, the recovery funnel begins to collect the sprayed liquid and guides it to the filter screen through the return pipe for preliminary filtration. Spraying stops after the set time or water volume is reached. The actual spraying curve and total water consumption are collected and recorded. The recovery funnel continues to collect residual droplets until the liquid flow stops. The filtered water is returned to the water storage tank to complete the cycle. The transfer mechanism is activated, adsorbing and transferring the sprayed branch box to the designated location of the second testing agency. During the transfer process, the branch box is kept moist and the start and arrival times of the transfer are recorded.

8. The method for testing the waterproof sealing performance of cable branch boxes according to claim 6, characterized in that, The process of controlling the internal pressure of the branch box through a multi-stage air pump assembly, simultaneously activating a vibration assembly to apply mechanical vibration, and collecting and recording the internal pressure change curve and vibration time series specifically includes the following steps: Retrieve the preset detection program according to the model of the cable branch box, and initialize the parameters of the air pump assembly, air pressure sensor and vibration assembly; The air pump assembly inflates the branch box to the first pressure threshold, maintains it for a set time to establish an initial steady state, and records the pressure baseline and ambient temperature data. Once the static pressure holding phase begins, the gas circuit valves are closed, static pressure decay data is collected, and the static phase pressure change rate is calculated as a baseline leakage reference value.

9. The method for testing the waterproof sealing performance of a cable branch box according to claim 8, characterized in that, The process of collecting static pressure decay data and calculating the static stage pressure change rate as a baseline leakage reference value includes: Start the vibration assembly and apply mechanical vibration according to the preset frequency-amplitude curve, synchronously monitor pressure changes, identify vibration-induced pressure fluctuation events and mark them with time stamps; One or more negative pressure steps are applied during or at intervals of vibration to induce potential intermittent leakage, and the instantaneous pressure response characteristics are recorded. The vibration stops and the recovery monitoring phase begins. Pressure recovery or attenuation curves are continuously collected for a set duration to obtain the system balance characteristics. By integrating overall pressure-time data, vibration timing, and event markers, a sealing performance dataset with excitation response is generated.

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