Method and system for detecting cable connectors

Abstract

The application discloses a kind of detection method and system of cable connector. Method is by obtaining cable connector structure and material parameter, establishes first, second finite element model, determines the theoretical deformation response of model under first, second external load;According to the size of grid, determine the strain monitoring point, obtain the actual deformation response by strain gauge, and determine the theoretical deformation response of unmonitored part by comparison and verification;After cable crimping, load is applied again to obtain the actual deformation response, the response difference of different aperture regions is calculated to determine the optimal cable installation position and load application position. The system includes model construction, theoretical and actual response determination and other functional modules. The application realizes comprehensive and accurate detection and optimization of cable connector performance, effectively improves its performance and reliability, and has important application value and technical innovation.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of finite element analysis, and particularly relates to a detection method and system for a cable connector. BACKGROUND

[0002] With the continuous development of power transmission and signal transmission fields, as a key component for realizing cable connection, the performance of a cable connector directly affects the stability and safety of a system. Traditional detection methods for cable connectors mostly rely on empirical detection means, such as simple appearance inspection, local stress testing, etc., and lack accurate evaluation of the overall performance of the cable connector. In actual applications, a cable connector will be subjected to the combined action of installation load, complex working condition load, and electrical load, etc. However, the existing technology is difficult to comprehensively and accurately simulate the mechanical behavior and electrical characteristics of the cable connector under these complex load conditions, and cannot accurately obtain the deformation response, load distribution, and electrical performance changes of each part of the connector. At the same time, for cable connectors of different structures and sizes, especially different aperture cable connection holes, the existing detection methods cannot effectively analyze the performance differences, and it is difficult to determine the optimal cable installation position and load application position, which may cause performance instability, shortened service life, etc. of the cable connector in actual use, and cannot meet the growing demand for high-quality power transmission and signal transmission. SUMMARY

[0003] In view of the above problems, the present application provides a detection method and system for a cable connector.

[0004] In a first aspect of the present application, a detection method for a cable connector is provided, comprising the following steps:

[0005] S1, obtaining the structure and material parameters of the cable connector, establishing a first finite element model, the first finite element model comprising a finite length shell model and a finite length cable conductor model;

[0006] S2, determining a first theoretical deformation response of the first finite element model under a first external load;

[0007] S3, setting strain gauges at the positions of the corresponding strain monitoring points of the shell and the cable conductor, and simultaneously applying a first external load to the shell and the cable conductor to obtain a first actual deformation response;

[0008] S4, determining a second theoretical deformation response of a non-strain monitoring point in the first finite element model according to the first theoretical deformation response and the first actual deformation response;

[0009] S5, after the cable is connected, applying a second external load at the preset positions of the shell and the cable conductor, calculating the actual deformation at each strain gauge position to obtain a second actual deformation response;

[0010] S6、according to the second actual deformation response, respectively calculating the load response, deformation response and electrical response characteristic difference of the corresponding regions of two groups of different size cable connection holes in the limited length shell model;

[0011] S7, according to the position of the applied load and the different position of the cable with different aperture in the shell, determining the cable installation position and installation load application position in the fixed aperture shell to obtain the optimal electrical performance.

[0012] As a preferred mode, the first external load and the second external load both include a preset installation load, a simulated working condition load and an electrical load;

[0013] The preset installation load includes:

[0014] The first action force arranged at the contact area between the limited length shell model and the cable conductor;

[0015] The second action force arranged at the compression side of the cross section of the limited length cable conductor model;

[0016] The simulated working condition load is an external action force or temperature change load applied to at least one side of the limited length shell model and / or the limited length cable conductor model, and the load received by each model after the action of the external action force or temperature change load is less than the maximum allowable load of each model;

[0017] The electrical load is a preset current applied to the limited length cable conductor model.

[0018] As a preferred mode, the preset installation load further includes the following arrangement:

[0019] The first action force includes the pressure received by the limited length shell model at the crimping side, and the pressure is equal to the component of the simulated installation crimping force in the direction of the crimping side;

[0020] The second action force includes the pressure received by the limited length cable conductor model at the compression side, and the pressure is equal to the component of the simulated crimping force of the shell in the direction of the compression side.

[0021] As a preferred mode, the preset installation load further includes the mass compensation when the strain gauge is arranged as a whole after the strain gauge is arranged.

[0022] As a preferred mode, before step S5 is executed, the following steps are further included:

[0023] S51, calculating the difference of the peak deformation between the first theoretical deformation response and the first actual deformation response;

[0024] S52, calculate the difference between the contact pressure variation trend of the first theoretical deformation response and the first actual deformation response;

[0025] S53, if the peak deformation fitting error between the first theoretical deformation response and the first actual deformation response is within 10%, and the contact pressure error at the peak deformation is within 10%, it is considered that the first finite element model meets the preset requirements, and the next step is executed, otherwise the setting of the strain gauge, the material performance parameter and the model parameter are checked and returned to S1;

[0026] S54, a second finite element model is constructed, the second finite element model comprises:

[0027] the finite length shell model;

[0028] the finite length cable conductor model;

[0029] a finite insulator model sleeved outside the finite length shell model, used to provide insulation capability;

[0030] S55, the same steps as steps S1-S3 are executed on the second finite element model;

[0031] S56, the same steps as steps S51-S53 are executed on the second finite element model;

[0032] S57, the error value between the first finite element model and the second finite element model at each strain monitoring point is calculated, and the error value and the upper and lower threshold values of 10% thereof are taken as the reference range for judging the error between the cable connector and the finite element model when S5-S6 are executed.

[0033] As a preferred mode, when the modeling of the first finite element model or the second finite element model is executed, the connection between the shell model and the cable conductor model is set according to the maximum crimping force of the model contact surface in the cross-sectional structure.

[0034] As a preferred mode, S6 comprises the following steps:

[0035] S61, according to the double-hole space layout in the shell, a grid area in the double-hole space is divided in a preset grid size, and at least one monitoring point is arranged in each grid area;

[0036] S62, the contact pressure difference, the contact deformation difference and the resistance increment between any two monitoring points are obtained, and a linear coupling relationship between the resistance increment and the contact pressure difference, the contact deformation difference between any two monitoring points is established;

[0037] S63, determining the actual contact pressure difference and the actual contact deformation difference of each monitoring point under different installation load sizes and different installation load application positions of the shell, simultaneously determining the actual axial position of the two cables in the double hole, mapping the axial position to the corresponding monitoring point, and calculating the current resistance increment;

[0038] S64, determining the intervention position of the load bearing body under the actual load application, and calculating the second resistance increment caused by the load bearing body according to the intervention position;

[0039] S65, determining the third resistance increment caused by the cable deformation in the double hole under the actual load application;

[0040] S66, determining the optimal cable installation position and installation load application position according to the current resistance increment, the second resistance increment and the third resistance increment.

[0041] The second aspect of the present application is a cable connector detection system, comprising:

[0042] A first model construction module is configured to construct a first finite element model according to the cross-sectional structure of the cable connector and the performance parameters of each material before the cable is connected, wherein the first finite element model comprises a finite length shell model and a finite length cable conductor model;

[0043] A first theoretical response determination module is configured to determine a first theoretical deformation response of the first finite element model under a first external load;

[0044] A first actual response acquisition module is configured to set strain gauges at positions corresponding to the strain monitoring points inside the shell and the cable conductor, and to apply a first external load to the shell and the cable conductor to obtain a first actual deformation response;

[0045] A second theoretical response calculation module is configured to determine a second theoretical deformation response of an indirectly monitored part in the first finite element model according to the first theoretical deformation response and the first actual deformation response;

[0046] A second actual response acquisition module is configured to apply a second external load to the shell and the cable conductor at a preset position after the cable is connected and crimped, and to calculate the actual deformation at each strain gauge position to obtain a second actual deformation response.

[0047] As a preferred mode, a second model construction module is included, which is configured to:

[0048] construct a second finite element model, wherein the second finite element model comprises:

[0049] the finite length shell model;

[0050] The finite length cable conductor model;

[0051] A finite insulator model is sleeved outside the finite length shell model to provide insulation capacity.

[0052] The system further comprises a load setting module for setting the first external load and the second external load, wherein the first external load and the second external load each comprise a preset installation load, a simulated working condition load and an electrical load.

[0053] The preset installation load module is configured to set a preset installation load, including a first force applied to a contact area between the finite length shell model and the cable conductor and a second force applied to a compression side of a section of the finite length cable conductor model.

[0054] The working condition load module is configured to apply a simulated working condition load, i.e., an external force or temperature change load applied to at least one side of the finite length shell model and / or the finite length cable conductor model, and the load borne by each model after the action of the external force or temperature change load is less than the maximum allowable load of each model.

[0055] The electrical load module is configured to apply an electrical load, i.e., a preset current passed into the finite length cable conductor model, and the electrical load is further used to evaluate the insulation capacity of the finite insulator model.

[0056] Compared with the prior art, the present application has the following beneficial effects:

[0057] The cable connector detection method and system have the following significant beneficial effects. In the modeling aspect, by establishing a first finite element model comprising a finite length shell model and a finite length cable conductor model, and further constructing a second finite element model considering insulation capacity, the actual structure of the cable connector can be accurately simulated, and combined with comprehensive and accurate first external load and second external load settings, including preset installation load, simulated working condition load and electrical load, the stress and working state of the cable connector under various actual working conditions can be truly restored, laying a solid foundation for accurate analysis of its performance.

[0058] In the detection process, by combining theoretical calculation with actual monitoring, the theoretical deformation response is first determined, and then the actual deformation response is obtained through the strain gauge and compared and verified, which not only can effectively detect the performance of the monitored part of the cable connector, but also can reliably infer the performance of the part not directly monitored, greatly improving the comprehensiveness and accuracy of the detection.

[0059] At the performance optimization level, by calculating the load response, deformation response and electrical response characteristic differences of the area corresponding to the cable connection hole of different aperture, and establishing a hole diameter optimization function for iterative solution, the optimal electrical performance of the cable installation position and installation load application position in the fixed hole diameter shell can be accurately determined, thereby significantly improving the overall performance and reliability of the cable connector, prolonging its service life, providing a strong guarantee for the stable operation of the power transmission and signal transmission system, effectively overcoming the limitations of traditional detection methods, and having important practical application value and technical innovation significance. BRIEF DESCRIPTION OF DRAWINGS

[0060] The application will be further described with the accompanying drawings, but the embodiments in the drawings do not constitute any limitation on the application. For ordinary skilled in the art, other drawings can be obtained without creative labor on the basis of the following drawings.

[0061] Figure 1 is a structural schematic of a cable connector provided by an embodiment of the application Figure 1 .

[0062] Figure 2 is a structural schematic of a cable connector provided by an embodiment of the application Figure 2 .

[0063] Figure 3 is a structural block diagram of a detection system of a cable connector provided by an embodiment of the application. DETAILED DESCRIPTION

[0064] The technical solutions in the embodiments of the application will be described clearly and completely below with reference to the drawings in the embodiments of the application. Obviously, the described embodiments are only part of the embodiments of the application, rather than all the embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those skilled in the art without creative labor fall within the protection scope of the application.

[0065] In a first aspect of the embodiments of the present disclosure, a detection method of a cable connector is provided, which is suitable for detecting Figures 1-2 the double-hole cable connector as shown, and includes the following steps:

[0066] S1, obtaining the structure and material parameters of the cable connector, establishing a first finite element model, the first finite element model including a finite length shell model and a finite length cable conductor model;

[0067] S2, determining a first theoretical deformation response of the first finite element model under a first external load;

[0068] S3, setting strain gauges at positions corresponding to strain monitoring points of the shell and the cable conductor, and applying a first external load to the shell and the cable conductor to obtain a first actual deformation response;

[0069] S4, determining a second theoretical deformation response of non-strain monitoring points in the first finite element model according to the first theoretical deformation response and the first actual deformation response;

[0070] S5, after the cable is connected, applying a second external load at preset positions of the shell and the cable conductor, and calculating actual deformations at positions of the strain gauges to obtain a second actual deformation response;

[0071] S6, according to the second actual deformation response, respectively calculating differences in load response, deformation response and electrical response characteristics of corresponding regions of two groups of cable connection holes with different sizes in the finite length shell model;

[0072] S7, according to positions of the applied load and different hole diameters of the cable at different positions of the shell, determining a cable installation position and an installation load application position in the shell for obtaining optimal electrical performance.

[0073] As a preferred mode, the first external load and the second external load each include a preset installation load, a simulated working condition load and an electrical load;

[0074] The preset installation load includes:

[0075] A first acting force arranged at a contact region of the finite length shell model and the cable conductor;

[0076] A second acting force arranged at a compression side of a section of the finite length cable conductor model;

[0077] The simulated working condition load is an external acting force or a temperature change load applied to at least one side of the finite length shell model and / or the finite length cable conductor model, and a load received by each model after the external acting force or the temperature change load is less than a maximum allowable load of each model;

[0078] The electrical load is a preset current input into the finite length cable conductor model.

[0079] As a preferred mode, the preset installation load further includes the following arrangement:

[0080] The first acting force includes a pressure received by the finite length shell model at a crimping side thereof, and the pressure is equal to a component of a simulated installation crimping force in a direction of the crimping side;

[0081] The second acting force includes a pressure on the limited length cable conductor model on a pressure side of the limited length cable conductor model, and the pressure is equal to a simulated pressure component of the shell in a direction of the pressure side.

[0082] As a preferred mode, the preset installation load further includes a mass compensation when the strain gauge is considered as a whole after the strain gauge is set.

[0083] As a preferred mode, before step S5 is performed, the following step is further included:

[0084] S51, calculating a difference of peak deformation between the first theoretical deformation response and the first actual deformation response;

[0085] S52, calculating a difference of contact pressure variation trend between the first theoretical deformation response and the first actual deformation response;

[0086] S53, if the peak deformation error between the first theoretical deformation response and the first actual deformation response is within 10%, and the contact pressure error at the peak deformation is within 10%, it is considered that the first finite element model meets the preset requirements, and the next step is performed, otherwise, the setting of the strain gauge, the material performance parameters and the model parameters are checked, and the step S1 is returned;

[0087] S54, constructing a second finite element model, and the second finite element model includes:

[0088] The limited length shell model;

[0089] The limited length cable conductor model;

[0090] A limited insulation model sleeved outside the limited length shell model, used for providing insulation capability;

[0091] S55, performing the same steps as steps S1-S3 on the second finite element model;

[0092] S56, performing the same steps as steps S51-S53 on the second finite element model;

[0093] S57, calculating error values between the first finite element model and the second finite element model at each strain monitoring point, and taking the error values and upper and lower threshold values of 10% of the error values as reference ranges for judging errors between the cable connector and the finite element model when steps S5-S6 are performed.

[0094] As a preferred mode, when the modeling of the first finite element model or the second finite element model is performed, the connection between the shell model and the cable conductor model is set according to the maximum pressure of the model contact surface in the cross-sectional structure.

[0095] As a preferred mode, S6 comprises the following steps:

[0096] S61, according to the double-hole space layout in the shell, dividing the grid area in the double-hole space with a preset grid size, and setting at least one monitoring point in each grid area;

[0097] S62, obtaining the contact pressure difference, contact deformation difference and resistance increment between any two monitoring points, and establishing the linear coupling relationship between the resistance increment and the contact pressure difference and the contact deformation difference between any two monitoring points;

[0098] S63, determining the actual contact pressure difference and the actual contact deformation difference of each monitoring point under different installation load sizes and different installation load application positions of the shell, simultaneously determining the actual axial position of the two cables in the double hole, mapping the axial position to the corresponding monitoring point, and calculating the current resistance increment;

[0099] S64, determining the intervention position of the load bearing body when the actual load is applied, and calculating the second resistance increment caused by the load bearing body according to the intervention position;

[0100] S65, determining the third resistance increment caused by the cable deformation in the double hole when the actual load is applied;

[0101] S66, determining the cable installation position and installation load application position with the best electrical performance according to the current resistance increment, the second resistance increment and the third resistance increment.

[0102] It should be noted that, on the basis of the data test amount, each data tested by the actual cable connector and the contact test of different cable conductors is imported into the finite element model, the minimum resistance under each different installation load position and size can be obtained to obtain the installation position and installation load size with the best structural stability and electrical performance, and then the finite element application after the current design parameters of the cable connector and the future adjustment design can be determined, so as to improve the production efficiency and installation efficiency.

[0103] Specifically, in the embodiment of the present disclosure, it is illustrated that the size parameters of the shell (material: aluminum alloy) and the cable conductor (material: copper) of a certain type of cable connector are obtained (shell length 50mm, inner diameter 10mm; conductor diameter 8mm, length 60mm), and a first finite element model (including shell model and conductor model) is established by using a finite element software.

[0104] The first external load (preset installation load: contact pressure 500N, axial pressure 300N; simulated working condition load: transverse vibration load 100N; electrical load: current 10A) is applied to the first finite element model, and the first theoretical deformation response (such as the maximum deformation of the shell 0.12mm) is calculated.

[0105] The strain gauges are pasted on the inside of the shell (20 mm from the end face) and the corresponding positions of the conductor, the same first external load is applied, and the first actual deformation response is measured (the maximum deformation of the shell is 0.11 mm, with an error of 8.3% from the theoretical value, which meets the requirement of within 10%).

[0106] The second theoretical deformation response of the non-monitoring points (such as the middle part of the shell) is determined through fitting of the first theoretical and actual responses (deformation of 0.08 mm).

[0107] The second external load is applied to the connector after crimping (installation load of 600 N, working load of 150 N, and current of 15 A), and the second actual deformation response is measured (the maximum deformation of the shell is 0.15 mm).

[0108] The resistance changes (0.02Ω and 0.03Ω, respectively) and deformation differences (0.15 mm and 0.18 mm, respectively) of the corresponding areas of the φ8 mm and φ10 mm connecting holes on the shell are calculated.

[0109] It is determined that the φ10 mm hole is in the axial center position of the shell, and the resistance is minimum (0.018Ω) when the installation load is 550 N, which is the optimal installation parameter.

[0110] In a second aspect of the embodiments of the present disclosure, a cable connector detection system, as shown in Figure 3 , comprises:

[0111] A first model construction module is configured to, before the cable connection, establish a first finite element model according to the sectional structures of the cable connector and the performance parameters of each material, wherein the first finite element model comprises a finite length shell model and a finite length cable conductor model.

[0112] A first theoretical response determination module is configured to determine a first theoretical deformation response of the first finite element model under a first external load.

[0113] A first actual response acquisition module is configured to set strain gauges at positions corresponding to the strain monitoring points on the inside of the shell and the cable conductor, and apply a first external load to the shell and the cable conductor to obtain a first actual deformation response.

[0114] A second theoretical response calculation module is configured to determine a second theoretical deformation response of the part not directly monitored in the first finite element model according to the first theoretical deformation response and the first actual deformation response.

[0115] A second actual response acquisition module is configured to, after crimping of the cable connection, apply a second external load at the preset positions of the shell and the cable conductor, and calculate the actual deformation at each strain gauge position to obtain a second actual deformation response.

[0116] As a preferred mode, a second model construction module is included, which is configured to:

[0117] construct a second finite element model, which includes:

[0118] the finite length shell model;

[0119] the finite length cable conductor model;

[0120] a finite insulator model, which is arranged outside the finite length shell model and is configured to provide insulation capability;

[0121] and the system further includes a load setting module, which is configured to set the first external load and the second external load, both of which include a preset installation load, a simulated working condition load and an electrical load; wherein,

[0122] a preset installation load module, which is configured to set a preset installation load, including a first force arranged at a contact area between the finite length shell model and the cable conductor, and a second force arranged at a compression side of a section of the finite length cable conductor model;

[0123] a working condition load module, which is configured to apply a simulated working condition load, i.e. an external force or temperature change load applied to at least one side of the finite length shell model and / or the finite length cable conductor model, and the load received by each model after the action of the external force or temperature change load is less than the maximum allowable load of each model;

[0124] an electrical load module, which is configured to apply an electrical load, i.e. to pass a preset current through the finite length cable conductor model; the electrical load is also configured to evaluate the insulation capability of the finite insulator model, and in the embodiment of the present disclosure, the electrical load module at least includes a measurement unit for measuring resistance, current and voltage, which is used to adapt to the test of the resistance increment of each item in S6.

[0125] In addition, in the embodiment of the present disclosure, a data processing module is included, which is configured to accept the data of each module of the system of the second aspect of the present disclosure and perform the steps as in S6.

[0126] The embodiments of the present disclosure can not only obtain performance data of the monitoring points, but also infer the performance of non-monitoring points through the verification of the theoretical and actual responses, so as to realize the evaluation of the overall performance of the cable connector, by establishing a finite element model and combining the measured strain gauge. By setting the preset installation load, simulating the working condition load and the electrical load, the complex stress and electrical environment of the connector during installation and working are comprehensively restored, so as to ensure that the detection result is close to the actual situation. By analyzing the response characteristic differences of different apertures and different installation positions, the optimal installation parameters are accurately determined, the electrical performance and reliability of the cable connector are significantly improved, and the service life is prolonged. Through the modular design, the integration of model construction, load application, response acquisition and analysis is realized, the operation is convenient, and the detection efficiency is high.

[0127] The above description and drawings sufficiently illustrate the embodiments of the present disclosure to enable one skilled in the art to practice them. Other embodiments can include structural, logical, electrical, process, and other changes. The embodiments represent only a few of the possible variations. Individual components and functions are optional unless explicitly required, and the order of operations can be varied. Parts and features of some embodiments can be included or substituted for parts and features of other embodiments. Also, the words used in this application are for describing the embodiments and not for limiting the claims. As used in the description of the embodiments and the claims, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. Similarly, the term "and / or" as used in this application refers to any and all possible combinations of one or more elements, introduced by the language conjunction. In addition, the term "comprise" and variations thereof, such as "comprises" and / or "comprising," as used in this application, means the presence of the stated features, integers, steps, operations, elements, and / or components, but does not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Without more limitations, an element defined by the phrase "comprising a..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus including the element. In this document, each embodiment can focus on the differences from other embodiments, and the same or similar parts between embodiments can be referred to each other. For the method, product, etc. disclosed by the embodiments, if it corresponds to the method part disclosed by the embodiments, the relevant part can be referred to the description of the method part.

[0128] Those skilled in the art can clearly understand the technical solutions of the present application from the description of the embodiments disclosed in the present application. The present application can be implemented by means of software functional modules and combined logic, and the present application can also be implemented by means of hardware. Based on the technical concepts of the present application, those skilled in the art can implement the present application by means of software and / or hardware using the technical means disclosed in the present application, and the technical solutions disclosed in the present application can be implemented by means of a combination of software and hardware. Based on the technical concepts of the present application, those skilled in the art can implement the present application by means of software and / or hardware using the technical means disclosed in the present application, and the technical solutions disclosed in the present application can be implemented by means of a combination of software and hardware.

[0129] The flowcharts and block diagrams in the drawings show the possible implementation architecture, action and operation of the apparatus, method and computer program product according to the embodiments of the present disclosure. In this regard, each block in the flowcharts or block diagrams can represent a module, a program segment or a part of code containing one or more executable instructions for implementing the specified logical function. In some alternative implementations, the actions denoted in the blocks can also occur in an order different from that denoted in the drawings. For example, two consecutive blocks can actually be executed substantially in parallel, and sometimes they can also be executed in reverse order, depending on the involved actions. In the description corresponding to the flowcharts and block diagrams in the drawings, the operations or steps corresponding to different blocks can also occur in an order different from that disclosed in the description, and sometimes there is no specific order between different operations or steps. For example, two consecutive operations or steps can actually be executed substantially in parallel, and sometimes they can also be executed in reverse order, depending on the involved actions. Each block in the block diagrams and / or flowcharts, and the combination of blocks in the block diagrams and / or flowcharts, can be implemented by a dedicated hardware-based device performing the specified actions or actions, or can be implemented by a combination of dedicated hardware and computer instructions.

Claims

1. A method for testing cable connectors, characterized in that, Includes the following steps: S1. Obtain the structural and material parameters of the cable connector and establish a first finite element model, which includes a finite length shell model and a finite length cable conductor model. S2. Determine the first theoretical deformation response of the first finite element model under the first external load; S3. Strain gauges are installed inside the housing and at the corresponding strain monitoring points of the cable conductor. At the same time, a first external load is applied to the housing and the cable conductor to obtain the first actual deformation response. S4. Determine the second theoretical deformation response of the non-strain monitoring point in the first finite element model based on the first theoretical deformation response and the first actual deformation response. S5. After the cable is connected, a second external load is applied at a preset position on the housing and the cable conductor, and the actual deformation at each strain gauge position is calculated to obtain the second actual deformation response. S6. Based on the second actual deformation response, calculate the differences in load response, deformation response, and electrical response characteristics of the regions corresponding to the two sets of cable connection holes of different sizes in the finite length shell model. S7. Based on the location of the applied load and the different positions of cables with different apertures in the housing, determine the cable installation position and the load application position within the fixed aperture housing to obtain optimal electrical performance.

2. The cable connector testing method according to claim 1, characterized in that, Both the first external load and the second external load include a preset installation load, a simulated operating condition load, and an electrical load; Preset installation load, which includes: A first force is applied in the contact area between the finite-length shell model and the cable conductor; A second force is applied to the pressure side of the cross-section of the finite-length cable conductor model. The simulated working condition load is an external force or temperature change load applied to at least one side of the finite length shell model and / or the finite length cable conductor model, and the load on each model after being subjected to the external force or temperature change load is less than the maximum allowable load of each model. An electrical load is applied to a finite-length cable conductor model by passing a preset current through it.

3. The cable connector testing method according to claim 2, characterized in that, The preset installation load also includes the following settings: The first force includes the pressure exerted on the finite-length shell model on its crimp side, which is equal to the component of the simulated installation crimp force in the direction of the crimp side; The second force includes the pressure exerted on the finite-length cable conductor model on its pressure side, which is equal to the simulated crimping force component of the shell in the direction of the pressure side.

4. The cable connector testing method according to claim 3, characterized in that, The preset installation load also includes mass compensation when the strain gauges are set as a whole.

5. The cable connector testing method according to claim 4, characterized in that, Before performing step S5, the following steps are also included: S51. Calculate the difference in peak deformation between the first theoretical deformation response and the first actual deformation response; S52. Calculate the difference in the trend of contact pressure change between the first theoretical deformation response and the first actual deformation response; S53. If the peak deformation matching error between the first theoretical deformation response and the first actual deformation response is within 10%, and the contact pressure error at the peak deformation is within 10%, then the first finite element model is considered to meet the preset requirements and the next step is executed; otherwise, after checking the strain gauge settings, material property parameters and model parameters, return to S1. S54. Construct a second finite element model, which includes: The finite-length shell model; The finite-length cable conductor model; A finite insulator model fitted outside the finite-length shell model is used to provide insulation capability; S55. Perform the same steps as steps S1-S3 on the second finite element model; S56. Perform the same steps as steps S51-S53 on the second finite element model; S57. Calculate the error value between the first finite element model and the second finite element model at each strain monitoring point, and use the error value and its upper and lower limits of 10% as the reference range for judging the error between the model and the finite element model when executing S5-S6.

6. The cable connector testing method according to claim 5, characterized in that, When performing modeling on the first finite element model or the second finite element model, the connection between the shell model and the cable conductor model is set according to the maximum compression force of the model contact surface in the cross-sectional structure.

7. The cable connector testing method according to claim 6, characterized in that, S6 includes the following steps: S61. Based on the dual-hole space layout inside the shell, divide the grid area in the dual-hole space into a preset grid size, and set at least one monitoring point in each grid area. S62. Obtain the contact pressure difference, contact deformation difference, and resistance increment between any two monitoring points, and establish a linear coupling relationship between the resistance increment and the contact pressure difference and contact deformation difference between any two monitoring points. S63. Determine the actual contact pressure difference and actual contact deformation difference of each monitoring point when the installation load size and the installation load application position are different in the shell, and at the same time determine the actual axial position of the two cables in the double hole, map the axial position to the corresponding monitoring point, and calculate the current resistance increment. S64. Determine the intervention position of the load-bearing body when the actual load is applied, and calculate the second resistance increment caused by the load-bearing body based on the intervention position; S65. Determine the third resistance increment caused by cable deformation within the double holes when the actual load is applied; S66. Based on the current resistance increment, the second resistance increment, and the third resistance increment, determine the cable installation location and the location where the installation load is applied for optimal electrical performance.

8. A cable connector testing system, characterized in that, include: First model construction module: used to establish a first finite element model based on the cross-sectional structure of the cable connector and the performance parameters of each material before cable connection. The first finite element model includes a finite length shell model and a finite length cable conductor model. First theoretical response determination module: used to determine the first theoretical deformation response of the first finite element model under the first external load; First actual response acquisition module: used to set strain gauges at the corresponding strain monitoring points inside the housing and the cable conductor, and simultaneously apply a first external load to the housing and the cable conductor to obtain the first actual deformation response; The second theoretical response calculation module is used to determine the second theoretical deformation response of the part not directly monitored in the first finite element model based on the first theoretical deformation response and the first actual deformation response. The second actual response acquisition module is used to apply a second external load to the housing and the cable conductor at preset positions after the cable connection is crimped, and calculate the actual deformation at each strain gauge position to obtain the second actual deformation response. Data processing module: Based on the second actual deformation response, calculate the differences in load response, deformation response, and electrical response characteristics of the regions corresponding to the two sets of cable connection holes of different sizes in the finite length shell model; Based on the location of the applied load and the different positions of cables with different apertures in the housing, the cable installation position and the location of the applied load to obtain the optimal electrical performance within the fixed aperture housing are determined.

9. The cable connector testing system according to claim 8, characterized in that, It also includes a second model building module, which is used for: Construct a second finite element model, which includes: The finite-length shell model; The finite-length cable conductor model; A finite insulator model fitted outside the finite-length shell model is used to provide insulation capability; The system further includes a load setting module, which is used to set the first external load and the second external load. Both the first external load and the second external load include a preset installation load, a simulated operating condition load, and an electrical load. Preset installation load module: used to set preset installation load, including a first force set in the contact area between the finite length shell model and the cable conductor, and a second force set on the pressure side of the cross section of the finite length cable conductor model; Operating condition load module: used to apply simulated operating condition load, that is, external force or temperature change load applied to at least one side of the finite length shell model and / or the finite length cable conductor model, and the load on each model after the application of the external force or temperature change load is less than the maximum allowable load of each model. Electrical load module: used to apply an electrical load, that is, to pass a preset current into the finite length cable conductor model; the electrical load is also used to evaluate the insulation capability of the finite insulator model.

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