Cable detection device

Abstract

The invention relates to a cable detection device which comprises a first clamping part, a load applying mechanism and a real-time on-off monitoring module, the first clamping part is used for fixing one end of a cable, and the load applying mechanism is arranged on the far side of the first clamping part and used for driving the other end of the cable to generate axial stretching displacement and axial torsion angular displacement in the testing process. The real-time on-off monitoring module is electrically connected with the wire harnesses at the two ends of the cable, and is used for continuously outputting a conduction state signal in the loading process. Through the above structure combination, the cable detection device can simulate the complex composite load borne by the cable in actual use, realizes line-by-line on-off real-time monitoring of each conductor in the cable, and effectively improves the working condition reduction degree and fault identification precision of detection.

Description

TECHNICAL FIELD

[0001] The present application relates to a cable detection device, in particular to a cable conductor continuity detection device. BACKGROUND

[0002] In the application fields of new energy vehicles, industrial automation equipment, charging infrastructure and high-end electronic devices, cables as key electrical connection media, their structural integrity and electrical reliability are directly related to the stable operation of the system and personal safety. With the increasing requirements for cable flexibility, fatigue resistance and safety performance, cables often face complex external load environments during use, such as frequent bending, stretching, twisting and dynamic dragging. Especially in typical working conditions such as charging guns and drag chain cables, cables need to withstand repeated torsional and tensile deformations for a long time, which can easily cause core wire breakage, outer skin wrinkling, sheath bulging and even insulation failure, resulting in abnormal conduction or safety hazards. Therefore, developing a test device that can simulate mechanical load under actual working conditions and monitor electrical continuity in real time has become an important technical requirement to improve cable design and verification capabilities.

[0003] Existing cable detection devices are mainly static loading, and are only used to perform projects such as insulation resistance testing, continuity testing, constant temperature stretching, low temperature impact, etc. Typical structures are manual / electric tension testing machines or flexible fatigue testing platforms.

[0004] However, although the existing cable detection device can verify a single load parameter of the cable, it generally cannot realize coupled and composite loading of torsion and stretching, and lacks the ability to detect the continuity of each wire bundle in the cable in real time during the loading process. In addition, national standards such as GB / T 33594 are biased towards basic performance indicators in terms of test items, and lack of electrical reliability evaluation under complex dynamic mechanical load, resulting in frequent quality problems such as core breakage and electrical leakage in actual operation of some certified products, which seriously affects the safety of terminal applications. Therefore, it is urgent to propose a new cable detection device to solve the above problems. SUMMARY

[0005] The purpose of the present application is to provide a cable detection device that can apply axial tensile displacement and torsional angular displacement around the axis to one end of the cable by structurally arranging a clamping assembly and a double-degree-of-freedom loading mechanism, and combine a multi-channel real-time continuity monitoring module to monitor and determine the continuity of each conductor in the cable under complex load, thereby truly simulating the failure risk of the cable in actual use scenarios, solving the problems of single loading dimension, lagging electrical abnormal response and lack of continuity fine detection in existing detection schemes.

[0006] The technical scheme adopted by the present application to solve the above problems is: a cable detection device, comprising: a first clamping part for fixing one end of the cable under test at a predetermined position; a load application mechanism arranged at a distal side of the first clamping part for driving the other end of the cable under test to generate controllable tensile displacement along the axial direction of the cable and controllable torsion angle displacement around the axial direction of the cable during the test; a real-time on-off monitoring module electrically connected to each wire harness at both ends of the cable under test, for continuously outputting the conduction state signal of the wire harness when the load application mechanism is working, so as to judge whether the internal wire harness of the cable under test is broken or has a leakage in real time.

[0007] Preferably, the load application mechanism comprises a rotating disc rotatable around a central axis and a power source for driving the rotating disc to rotate, and the other end of the cable under test is detachably fixed to the rotating disc and generates torsion load when the rotating disc rotates.

[0008] Preferably, the rotating disc is provided with a detachable clamp for clamping the end of the cable under test. The load application mechanism further comprises: a servo motor; a rotating output shaft coaxially connected to the output shaft of the servo motor, and the rotating disc is arranged at the end of the rotating output shaft.

[0009] The servo motor drives the rotating output shaft and the rotating disc to rotate around the longitudinal axis of the cable under test to apply torsion load to the cable under test.

[0010] Preferably, the rotating output shaft is a hollow structure, and the cable under test can be arranged in the rotating output shaft.

[0011] Preferably, the load application mechanism further comprises a linear guide rail arranged in parallel with the axial direction of the rotating disc and a linear driving assembly for driving the rotating disc to reciprocate along the linear guide rail, so as to apply controllable tensile load while torsion.

[0012] Preferably, the linear driving assembly comprises: a lead screw arranged in parallel with the axial direction of the rotating disc; a guide rod arranged in parallel with the axial direction of the lead screw; a sliding block threadedly engaged with the lead screw and slidingly arranged outside the guide rod; a motor, and the output shaft of the motor is drivingly connected to the lead screw.

[0013] When the motor drives the lead screw to rotate, the sliding block moves along the axial direction of the guide rod to drive the rotating disc to generate tensile displacement along the axial direction of the cable under test relative to the first clamping part.

[0014] Preferably, the cable detection device further comprises: a tension sensor arranged between the slider and the rotary disc to measure the tensile load applied to the cable under test in real time; a torque sensor arranged on the rotary output shaft to measure the torsional load applied to the cable under test in real time.

[0015] Preferably, the cable detection device further comprises: a controller connected with the tension sensor, the torque sensor and the real-time continuity monitoring module, respectively, the controller being configured to close-loop adjust the pulse number of the motor and the rotation speed of the motor based on the signals of the tension sensor and / or the torque sensor to achieve a preset load amplitude and cycle number, and the controller being further configured to make the load applying mechanism act and record a fault timestamp when the real-time continuity monitoring module outputs an open circuit or leakage signal.

[0016] Preferably, the cable under test comprises at least one power main conductor, at least one control signal conductor and at least one shielding layer.

[0017] The real-time continuity monitoring module comprises a constant current source and is configured to establish independent constant current detection loops and independent determination thresholds for the power main conductor, the control signal conductor and the shielding layer, respectively, to detect the continuity of the power main conductor, the control signal conductor and the shielding layer.

[0018] Preferably, the cable detection device further comprises: a plurality of pairs of sampling terminals, each of the power main conductor, the control signal conductor and the shielding layer of the cable under test having a pair of the sampling terminals arranged at both ends thereof; a multi-channel analog switch array comprising a common terminal and a plurality of independent channel terminals, the common terminal being electrically connected with the positive electrode of the constant current source, and the plurality of independent channel terminals being electrically connected with the pairs of the sampling terminals, respectively; a common return line having one end electrically connected with the negative electrode of the constant current source and the other end connected with a common ground terminal of the analog switch array; The constant current source, under the control of the controller, sequentially closes the independent channel terminals corresponding to the pairs of the sampling terminals in a preset polling sequence through the multi-channel analog switch array to form the constant current detection loops corresponding to the power main conductor, the control signal conductor and the shielding layer one by one and independently of each other, so that the continuity of the power main conductor, the control signal conductor and the shielding layer is acquired one by one in the same polling cycle and a corresponding detection result set is generated.

[0019] The cable detection device has the following advantages: 1. The application adopts clamping fixation, double-degree-of-freedom load application structure, and combined technical means of real-time on-off monitoring module, can apply controllable tensile displacement and controllable torsional angular displacement to one end of the measured cable, and can monitor the conduction state of each wire bundle in the cable in real time during the loading process, thus effectively solving the defects that the real working condition simulation of the cable under complex external force and the on-off state of the conductor cannot be monitored line by line in the prior art, and providing comprehensive, reliable and data-based failure detection support for cable structure design, material selection and service life evaluation, and significantly improving the practicability and accuracy of the detection device in high-demand application scenarios such as new energy vehicle charging gun cable.

[0020] 2. The application adopts the technical means of setting sampling terminals at both ends of each power main conductor, control signal conductor and shielding layer of the measured cable, and constructing a constant current detection loop corresponding to each conductor and independent of each other through a constant current source, a multi-channel analog switch array and a common return line, thus effectively solving the problem that the on-off state of each conductor in the cable cannot be detected independently in the prior art, and realizing the ability to accurately, synchronously and separately obtain the on-off state of each conductor during the application of composite load, and significantly improving the recognition accuracy and monitoring real-time of the overall electrical integrity and local failure of the cable. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 is a schematic structural diagram of a cable detection device in a preferred embodiment of the application.

[0022] Figure 2 is a schematic structural diagram of the connection state of the real-time on-off monitoring module and the measured cable in a preferred embodiment of the application.

[0023] Wherein: 10, first clamping part; 20, load application mechanism; 210, turntable; 221, detachable clamp; 220, servo motor; 230, output shaft; 240, linear drive assembly; 241, guide rod; 242, sliding block; 243, motor; 30, cable; 40, real-time on-off monitoring module. DETAILED DESCRIPTION

[0024] The specific embodiments of the application will be further described in detail below in combination with the drawings and examples. The following examples are used to illustrate the application, but not to limit the scope of the application.

[0025] In the description of the present application, it needs to be understood that the terms "center", "longitudinal", "transverse", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship shown in the drawings, which are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the scope of protection of the present application. In addition, the terms "first", "second" and the like are only for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined with "first", "second" and the like can be explicitly or implicitly included one or more. In the description of the present application, unless otherwise specified and limited, the term "mounting", "connection", "connection" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium, or it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood through specific circumstances.

[0026] In the description of the present application, it needs to be understood that the terms "mounting", "connection", "connection" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium, or it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood through specific circumstances.

[0027] Referring to Figures 1 to 2 In a preferred embodiment of the present application, a cable 30 detection device is provided, which is suitable for performance simulation and fault monitoring of flexible cable 30 with multi-conductor structure such as charging gun cable 30, drag chain cable, etc., and is especially suitable for evaluating the stress behavior and electrical reliability of the cable 30 under new energy vehicle charging conditions.

[0028] The cable 30 detection device comprises a first clamping part 10, a load applying mechanism 20 and a real-time on-off monitoring module, which can apply mechanical load consistent with actual application to the measured cable 30 and synchronously acquire the change of electrical conduction state thereof. The first clamping part 10 is used to fix one end of the measured cable 30 at a predetermined position; the load applying mechanism 20 is arranged on the side away from the first clamping part 10, and is used to drive the other end of the measured cable 30 to produce controllable tensile displacement along the axial direction of the cable 30 and controllable torsional angular displacement around the axial direction of the cable 30 during the test; the real-time on-off monitoring module is electrically connected with each wire harness at both ends of the measured cable 30, respectively, and is used to continuously output the conduction state signal of the wire harness when the load applying mechanism 20 is working, so as to judge whether the wire harness inside the measured cable 30 is broken or has a leakage in real time.

[0029] Specifically: The first clamping part 10 is used to stably fix one end of the cable 30 to be tested on the test platform, and its structure can include a base, a clamping arm and a flexible pad. The clamping arm can adopt a screw clamping type or a quick release type structure, so as to facilitate the replacement and fixation of cables 30 of different specifications. The pad is made of flexible rubber or foam material, which can avoid damage to the surface of the cable 30 and prevent slipping during loading.

[0030] The loading mechanism 20 is arranged on the side away from the first clamping part 10, and is used to drive the other end of the cable 30 to generate controllable tensile and torsional load. The loading mechanism 20 includes a turntable 210 assembly and a linear drive assembly 240. The turntable 210 is driven by a servo motor 220 and rotates around the longitudinal axis of the cable 30, so as to realize the torsional simulation of the cable 30. The linear drive assembly 240 is driven by a screw and a slider 242 mechanism under the constraint of a guide rod 241 to realize reciprocating linear motion, so as to drive the turntable 210 to apply tensile deformation to the cable 30 along the axial direction. The rotation speed of the motor 243 and the feed amount of the screw can be accurately adjusted by the controller, so as to realize the composite loading cycle of different amplitudes, different frequencies and different load ratios. The turntable 210 is provided with a quick connection clamp for disassembling the tail end of the cable 30. A tension sensor can be arranged between the clamp and the slider 242, so as to monitor the actual tension. The rotating shaft is a hollow structure, allowing the cable 30 to pass through, so as to avoid unexpected stress concentration caused by large-angle bending.

[0031] The real-time on-off monitoring module is used to judge whether the cable 30 is broken or has a leakage in real time during the loading process. The module includes a constant current source, a real-time on-off monitoring module 40, a sampling resistor, a differential amplifier, a comparator, a controller and an upper computer communication interface. Sampling terminals are arranged at both ends of each conductor, and each channel is sequentially closed by an analog switch to form an independent constant current detection loop corresponding to each conductor. The sampling voltage is compared with a preset threshold after being amplified, and the controller judges the on-off state of each conductor in real time according to the comparison result, and packs and uploads the detection data to the upper computer. During the detection process, the controller synchronously collects the tensile displacement, the torsional angle and the on-off state signal during the loading process, so as to realize the accurate correspondence between the fault position and the loading time. In addition, the module has a fault alarm function. Once the circuit is broken or the leakage is detected, the sound and light alarm is triggered immediately, and the loading process can be automatically paused.

[0032] The cable 30 monitoring device is suitable for a laboratory cable 30 fatigue test platform, is suitable for various cable 30 specifications, and is suitable for an indoor test environment with a temperature range of zero to forty degrees Celsius. The electrical interface is compatible with a standard power supply and an upper computer data interface, and has good scalability. If it is used for a flexible flat cable 30 or an asymmetric cable 30 structure, a customized clamp and a guide mechanism can be selected to adapt to the requirements of special clamping and loading paths.

[0033] The embodiment effectively solves the problems that the existing technology cannot apply torsional and tensile composite stress to the cable 30 and cannot detect the on-off state of the multi-conductor in real time, and further realizes fine evaluation of the structural integrity and electrical reliability of the cable 30 under simulated real working conditions, thereby significantly improving the accuracy, repeatability and engineering guidance significance of the detection results.

[0034] Referring to Figure 1 In some embodiments, the loading mechanism 20 includes a rotating disc 210 rotatable around a central axis and a power source driving the rotating disc 210 to rotate, and the other end of the measured cable 30 is detachably fixed to the rotating disc 210 and rotates with the rotating disc 210 to generate a torsional load, which is used to simulate the rotating fatigue stress borne by the cable 30 in actual use. The rotating disc 210 is provided with a detachable clamp 221 for clamping the end of the measured cable 30, and the loading mechanism 20 further includes a servo motor 220 and a rotating output shaft 230 coaxially connected with the output shaft 230 of the servo motor 220, and the rotating disc 210 is arranged at the end of the rotating output shaft 230. Wherein, the servo motor 220 drives the rotating output shaft 230 and the rotating disc 210 to rotate around the longitudinal axis of the measured cable 30 to apply a torsional load to the measured cable 30. Further, the rotating output shaft 230 is a hollow structure, and the measured cable 30 can be arranged in the rotating output shaft 230.

[0035] Specifically: The rotating disc 210 is in a disc-shaped structure, and the outer edge is provided with uniformly distributed threaded holes for installing a special clamp for clamping the cable 30. The main body of the rotating disc 210 is made of aluminum alloy or carbon steel material, which not only ensures the structural rigidity, but also controls the self-weight. The center position of the rotating disc 210 is fixedly installed at the end of the rotating output shaft 230 through a flange or key connection, which ensures that it rotates synchronously with the output shaft 230.

[0036] The servo motor 220 is fixedly installed on the support frame, and the output shaft 230 is coaxially connected with the rotating output shaft 230 through a shaft coupling. The rotating output shaft 230 is a through structure, allowing the measured cable 30 to pass through it, so as to reduce the lateral deviation of the cable 30 during torsion. The rotating output shaft 230 is a hollow cylindrical channel, and its inner diameter is one to two times larger than the diameter of the cable 30, which ensures that the cable 30 is not in friction contact and is not affected by disturbance force during the rotating load process. The rotation speed, rotation direction and start-stop state of the servo motor 220 are controlled by the main controller program, which can realize forward and reverse alternating torsion and adapt to different test loading periods.

[0037] The detachable clamp 221 includes two semicircular clamping blocks, and the inner wall of the clamping block is covered with a flexible non-slip pad to avoid damaging the cable 30 skin during clamping. The clamping block is fixed in the preset screw hole of the turntable 210 by locking screw, and the clamp assembly can be quickly replaced according to the diameter of different cables 30 to realize quick clamping and universal adaptation. The clamping mode can be selected as manual screw locking or quick release buckle structure.

[0038] When the cable 30 detection device is working, one end of the cable 30 is fixed by the first clamping part 10, and the other end is fixed on the turntable 210 by the detachable clamp 221. When the controller sends the start command, the servo motor 220 drives the rotating output shaft 230 and the turntable 210 to start rotating, and the cable 30 rotates synchronously with the turntable 210. By controlling the output pulse number and direction of the servo motor 220, constant angular velocity, programmable angular displacement or periodic positive and negative torsion can be realized, and various torsional fatigue conditions of the cable 30 in the actual environment can be simulated flexibly. During the test, combined with the tension monitoring module and the real-time on-off monitoring module, the load state and electrical state can be recorded simultaneously.

[0039] In other embodiments, the rotating output shaft 230 can also adopt a sliding sealing structure, and the multi-core cable or special-shaped cable is adapted with a sheath; the servo motor 220 can also be replaced by a stepper motor 243 with an encoder to adapt to the higher resolution angular displacement control requirement; the form of the turntable 210 can also adopt an embedded clamping groove structure with radial limiting to improve the clamping stability under high torque working condition.

[0040] In this embodiment, by adopting the technical means of the torsion loading mechanism composed of the turntable 210 drive, the servo motor 220 control and the hollow rotating output shaft 230 and the detachable clamp 221, the problems of uneven stress, inconvenient clamping and on-off state interference of the cable 30 in the torsion loading process in the prior art are effectively solved, and the structural integrity and conductor on-off state of the cable 30 under high-frequency reciprocating torsion condition are precisely tested, so as to ensure that the simulation loading effect is real and controllable, and the test data is stable and reliable.

[0041] Referring to Figure 1In some embodiments, the loading mechanism 20 is not only capable of rotating the cable 30 around the axis to apply a torsional load, but also includes a linear guide rail arranged in parallel with the axis of the rotating disc 210 and a linear drive assembly 240 driving the rotating disc 210 to reciprocate along the linear guide rail, so as to realize the reciprocating drive of the rotating disc 210 as a whole along the axial direction of the cable 30 to apply a controllable tensile load while torsion. The linear drive assembly 240 includes a lead screw, a guide rod 241, a sliding block 242 and a motor 243, wherein the lead screw is arranged in parallel with the axis of the rotating disc 210, the guide rod 241 is arranged in parallel with the axis of the lead screw, the sliding block 242 is threadedly engaged with the lead screw and is sleeved outside the guide rod 241, and the output shaft 230 of the motor 243 is in transmission connection with the lead screw. Wherein, the sliding block 242 moves along the axial direction of the guide rod when the motor 243 drives the lead screw to rotate, so as to drive the rotating disc 210 to generate a tensile displacement along the axial direction of the measured cable 30 relative to the first clamping part 10.

[0042] Specifically: The linear guide rail includes two guide rods 241 arranged in parallel along the same axis, which are fixedly installed on the base of the device rack and can be made of high-strength steel or wear-resistant alloy after chrome plating treatment. The length of the guide rod 241 matches the maximum tensile stroke of the measured cable 30, ensuring that the loading range meets the testing requirements of various flexible cables 30.

[0043] The linear drive assembly 240 includes a lead screw, a sliding block 242 and a motor 243. The lead screw is a high-precision ball screw, both ends of which are supported by bearing seats and fixed to the rack structure, maintaining strict coaxiality with the guide rod 241. The sliding block 242 is threadedly engaged with the lead screw and realizes displacement conversion through a nut pair transmission structure, and the lower part is slidably connected with the guide rod 241 through a linear bearing or a sliding sleeve, ensuring that the sliding block 242 moves smoothly along a straight line during loading. One end of the lead screw is connected with the output shaft 230 of the motor 243, and the motor 243 can be a stepper motor 243 or a servo motor 220, which is installed at the tail of the lead screw and realizes power transmission through a shaft coupling.

[0044] The rotating disc 210 is fixedly connected with the sliding block 242 through a rigid connecting plate. When the motor 243 works, the lead screw drives the sliding block 242 to move along the guide axis, and then drives the rotating disc 210 to generate axial displacement relative to the first clamping part 10 fixed at the other end, so as to apply a controlled tensile load to the measured cable 30. The whole structure forms a closed tensile loading path, which can realize the mechanical action simulation of the cable 30 along the longitudinal axis while maintaining the synchronous application of the torsional load.

[0045] The working process of the cable 30 detection device is uniformly coordinated by the controller. The motor 243 outputs corresponding pulse signals to drive the screw rod to rotate according to the set stretching stroke and loading rate, so that the sliding block 242 moves on the guide rail at the target speed. The system can be set to single stretching, periodic reciprocating stretching, or synchronous loading with twisting, and other control modes. At the same time, the motor 243 is equipped with an encoder or a position feedback element, which can feed back the actual displacement information to the controller in real time for closed-loop correction, to ensure the loading accuracy and stability. The overall motion path of the sliding block 242 and the rotating disc 210 is stable during the loading process, and does not generate eccentric side force on the cable 30.

[0046] In other embodiments, the guide rod 241 can adopt a double-rail linkage structure to improve load stability. The sliding block 242 can be replaced with a double-nut parallel or roller guide rail support structure according to the load demand, to enhance its impact resistance and guide rigidity. The motor 243 can also be selected as a closed-loop stepping type or a servo type to meet the needs of high-speed displacement response or large-stroke stretching simulation.

[0047] In this embodiment, by adopting the linear drive structure composed of the screw rod, the guide rod 241, the sliding block 242 and the motor 243, and by using the technical means of realizing stable movement of the rotating disc 210 along the axial direction through guide constraint, the technical problems of the existing cable 30 detection device, such as the inability to superimpose axial tensile load synchronously during the application of torsional load, the easy deviation of the loading path, and the unstable movement, are effectively solved, and the precise loading of the combined forces of the measured cable 30 in the simulated actual service state is realized, thereby providing a reliable experimental basis for the structural fatigue response, electrical failure triggering and life prediction of the cable 30.

[0048] In some embodiments, the cable 30 detection device further comprises a tension sensor and a torque sensor for real-time monitoring and feedback of the actual stress state of the measured cable 30 during loading, to realize closed-loop control of the applied load and synchronous identification of the failure point. The tension sensor is arranged between the sliding block 242 and the rotating disc 210 to measure the tensile load applied to the measured cable 30 in real time, and the torque sensor is arranged on the rotating output shaft 230 to measure the torsional load applied to the measured cable 30 in real time, both corresponding to the stress paths of the two degrees of freedom of stretching and twisting.

[0049] Specifically: The tension sensor is preferably an axial strain or spoke tension load cell, with a stainless steel or aluminum alloy shell, an array of high-precision strain gauges inside, and an output of analog voltage signals through a bridge. The sensor is connected between the slider 242 and the base of the turntable 210 through a flange connection or a nested structure. When the slider 242 moves axially through the screw assembly, the tension sensor is subjected to compression or tension, and the output voltage is linearly related to the force on the cable 30. The sensor signal line is led out through a wire slot or flexible drag chain, connected to the analog input interface of the data acquisition module, and converted to a digital signal by a high-resolution analog-to-digital converter.

[0050] The torque sensor is a hollow shaft structure, arranged between the rotating output shaft 230 and the turntable 210, and can be connected by keys or splines. The sensor body is embedded with a strain gauge array or a magnetostrictive measurement unit, which can accurately sense the torque change in the axial direction. The sensor shaft center hole design allows the cable 30 to pass freely without interfering with the natural deformation path of the cable 30. The sensor output signal is sent to the main controller after being processed by the amplification module, for real-time display and data recording, and can also be used as feedback for the output control of the servo motor 220.

[0051] During the operation of the cable 30 detection device, the controller starts the linear and rotary loading module, gradually loading to the target value through the program set displacement or angle. The tension sensor and torque sensor continuously output real-time load data, and the controller judges the stability of the loading curve and the risk of overload according to the sensor signal, and can automatically stop loading when the preset failure threshold is reached. With the real-time on-off monitoring module, the system can accurately associate the mechanical load with the electrical failure event, forming a three-dimensional failure feature map of "failure force-time-on-off state".

[0052] In this embodiment, by using the tension sensor arranged between the slider 242 and the turntable 210 and the torque sensor installed on the rotating output shaft 230, the problems of real-time force value sensing, lack of closed-loop control ability, and inability to synchronize with failure events in the existing cable 30 loading device are effectively solved, thereby realizing fine control of the loading process, linkage analysis of electrical abnormalities and mechanical responses, and quantifiable evaluation of cable 30 fatigue characteristics, significantly improving the precision, safety, and engineering applicability of the test system.

[0053] In some embodiments, the cable 30 detection device further comprises a controller for coordinating the closed-loop control between various sensor signals and motor 243 execution units during the tensile torsion loading process, while achieving real-time response to the on-off state of the cable 30 and failure record management. The controller can use an industrial embedded main control unit or a programmable logic controller, which internally integrates signal acquisition, operation processing, output control and communication interface modules, and has high-speed sampling and multi-task response capability. The controller is connected with the tension sensor, the torque sensor and the real-time on-off monitoring module respectively. The controller is configured to close-loop adjust the pulse number of the motor 243 and the rotating speed of the motor 243 based on the signals of the tension sensor and / or the torque sensor, so as to achieve the preset load amplitude and cycle number. In addition, the controller is also configured to make the load applying mechanism 20 act and record the fault time stamp when the real-time on-off monitoring module outputs an open circuit or leakage signal.

[0054] Specifically: The controller is connected with the tension sensor, the torque sensor and the real-time on-off monitoring module. The data collected by the tension sensor and the torque sensor are sent to the controller through the analog input port, and are subjected to digital filtering and feature extraction by the internal algorithm module to form stable and continuous load measurement values. The controller calculates the error between the current loading state and the set target in real time according to the preset target load range, load rising speed and load holding time, and adjusts the driving instruction of the motor 243 accordingly.

[0055] For the straight line loading part, the controller adjusts the frequency and step number of the stepping motor 243 through the output pulse signal, and then controls the movement of the sliding block 242 along the linear guide rail driven by the screw rod, to output the required tensile displacement. For the rotary loading part, the controller adjusts the rotating speed and direction of the servo motor 220 through analog output or communication instruction, to realize continuous or alternating rotary control of the rotating disc 210. The above two channels can be controlled respectively, or can be cooperatively linked according to the test setting, so as to realize a multi-dimensional composite loading control strategy.

[0056] The controller is also in communication connection with the real-time on-off monitoring module. The on-off state signal of each wire harness collected by the monitoring module is fed back to the controller through digital input or serial communication. Once an electrical abnormality such as open circuit or leakage is detected in the loading process, the controller immediately triggers the emergency stop process, outputs a stop signal to all motors 243, records the system state data at the time of abnormality, including tension, torque, loading direction, time stamp and on-off result, and stores them in the internal memory or sends them to the upper computer.

[0057] The whole control system has multiple functions such as task management, dynamic determination, fault processing and communication recording, and is adapted to different cable 30 test protocols. The controller supports configuration of operation parameters through a man-machine interface or a host computer software platform, and an operator can set loading period, loading direction, amplitude range, detection sensitivity and alarm threshold to realize control of a customized test process.

[0058] In this embodiment, the controller is connected with the tension sensor, the torque sensor and the real-time on-off monitoring module respectively, and based on real-time mechanical signals, closed-loop regulation of the loading motor 243 is performed, and according to the on-off signal state, the loading is automatically terminated and the fault time point is recorded. Therefore, the problems of feedback lag, untimely invalid reaction, lack of linkage control of loading and monitoring in the prior art are effectively solved, and precise matching of the loading path and the electrical failure state, fine regulation and control of the loading process, and data, structure and traceability analysis of the test results are realized, which greatly improves the test stability, safety response capability and engineering adaptation efficiency of the detection device.

[0059] In order to accurately monitor the electrical continuity state of different types of conductors inside the cable 30 one by one, the cable 30 detection device is provided with a real-time on-off monitoring module. The module is suitable for detecting the conduction state of the power main conductor, the control signal conductor and the shielding layer included in the measured cable 30, and can synchronously feed back the on-off change during the loading process, and is used to identify potential core breakage, open circuit or poor contact and other fault conditions. Referring to Figure 2In some embodiments, the cable 30 under test includes at least one power main conductor, at least one control signal conductor, and at least one shielding layer; the real-time on-off monitoring module includes a constant current source, and is configured to establish an independent constant current detection loop and an independent determination threshold for the power main conductor, the control signal conductor, and the shielding layer, respectively, to detect the on-off state of the power main conductor, the control signal conductor, and the shielding layer. Further, the cable 30 detection device also includes a plurality of pairs of sampling terminals and a common return line, wherein each of the two ends of each of the power main conductors, each of the two ends of each of the control signal conductors, and each of the two ends of each of the shielding layers of the cable 30 under test is respectively provided with a pair of the sampling terminals, the real-time on-off monitoring module 40 includes a common terminal and a plurality of independent channel terminals, the common terminal is electrically connected to the positive electrode of the constant current source, and the plurality of independent channel terminals are respectively electrically connected to each pair of the sampling terminals; one end of the common return line is electrically connected to the negative electrode of the constant current source, and the other end is connected to the common ground terminal of the analog switch array; wherein the constant current source, under the control of the controller, sequentially closes the independent channel terminals corresponding to each pair of the sampling terminals in a predetermined polling order through the real-time on-off monitoring module 40, to form the constant current detection loop corresponding to and independent of the power main conductor, the control signal conductor, and the shielding layer, thereby obtaining the on-off state of the power main conductor, the control signal conductor, and the shielding layer one by one in the same polling cycle and generating a corresponding detection result set.

[0060] Specifically: The cable 30 under test includes at least one power main conductor, one control signal conductor, and one shielding layer, and each conductor is usually structured and layered or bundled and integrated inside the cable 30 sheath. To achieve independent detection of each conductor, a plurality of pairs of sampling terminals are arranged at the corresponding conductor welding or crimping positions at both ends of the cable 30, and the sampling terminals respectively contact the electrical connection parts of each power main conductor, control conductor, and shielding layer, for building a corresponding detection loop.

[0061] The real-time on-off monitoring module includes a constant current source, a real-time on-off monitoring module 40, a common return line, and a signal determination and control processing unit. The constant current source is used to provide a stable low-current excitation signal for the detection loop, and the positive electrode thereof is connected in series with each detection channel through a common terminal of a real-time on-off monitoring module 40. The analog switch array has a plurality of independent channel terminals, which are respectively connected to each pair of sampling terminals. When a certain channel is closed, the excitation current of the constant current source flows through the sampling terminals at both ends of the conductor to form a loop.

[0062] To build a complete loop, the negative pole of the constant current source is connected to the common ground of the analog switch array through a common return line, completing the detection loop closure. Under the scheduling of the controller, the analog switch array closes each channel in the preset polling order, allowing the constant current source to inject current into each conductor one by one. The sampling point monitors the resistance value and conduction of the conductor through the parallel sampling resistor and amplifier. Each conductor's detection loop is independent of each other, ensuring the uniqueness and accuracy of the detection signal.

[0063] The controller collects the on-off signal of each channel in real time according to the switching state of the analog switch array and compares it with the built-in judgment threshold. When the output voltage of any detection channel exceeds the set tolerance range, it is determined that the conductor is abnormally conducting, and the corresponding conductor number, on-off state, and current polling time are immediately recorded. All detection results are sorted by conductor number and sent to the host computer or recording system in data frame form.

[0064] This detection scheme is suitable for composite cables 30 with multiple conductor structures, flexible sensing cables, shielded communication cables 30, and other test objects with complex electrical characteristics. The detection process is fully automated and can be executed in parallel with the loading program without human intervention. The device is recommended to work in a laboratory or production environment with a temperature of zero to forty degrees Celsius and a humidity of no more than eighty percent. The sampling terminal can be configured as a plug-in structure for quick sample replacement.

[0065] In other optional solutions, the constant current source can be replaced by a multi-channel adjustable output module to achieve tolerance detection in a larger voltage range. The analog switch array can be replaced by a bidirectional semiconductor switch array to accommodate bidirectional detection requirements. The controller can be expanded into an intelligent discrimination unit with learning function to achieve fault tolerance judgment and trend identification for slight contact fluctuations.

[0066] In this embodiment, by using a constant current source, a real-time on-off monitoring module 40, a common return line, and corresponding sampling terminals to build independent constant current detection loops corresponding to the power main conductor, control signal conductor, and shielding layer without interference, the problem of inability to accurately monitor each conductor in the cable 30, signal crosstalk between detection loops, and fault judgment lag in the prior art is effectively solved, thereby realizing high-frequency and high-resolution synchronous acquisition of the on-off state of each conductor under the cable 30 torsion and tension composite loading state, and significantly improving the accuracy of electrical failure positioning and the real-time of system response.

[0067] The above-described embodiments of the application are merely descriptive of its application and nothing in the present specification should be construed as a limitation on the overall scope of the application. Various modifications or changes in light thereof will be readily apparent to those skilled in the art, such as the use of alternative software programs or circuits to carry out the stated functions. It is intended to cover in the appended claims all such changes and modifications that fall within the scope of the application.

Claims

1. A cable testing device, characterized in that, include: The first clamping part is used to fix one end of the cable under test at a predetermined position; The loading mechanism is located on the side away from the first clamping part and is used to drive the other end of the cable under test to generate a controllable tensile displacement along the cable axis and a controllable torsional angular displacement around the cable axis during the test. A real-time continuity monitoring module is electrically connected to each wire harness at both ends of the cable under test. It is used to continuously output the continuity status signal of the wire harness when the loading mechanism is working, so as to determine in real time whether the wire harness inside the cable under test is broken or leaking.

2. The cable testing device according to claim 1, characterized in that, The loading mechanism includes a turntable that can rotate around a central axis and a power source that drives the turntable to rotate. The other end of the cable under test is detachably fixed to the turntable and generates a torsional load as the turntable rotates.

3. The cable testing device according to claim 2, characterized in that: The turntable is equipped with a detachable clamp for holding the end of the cable being tested; The loading mechanism also includes: Servo motor; A rotary output shaft coaxially connected to the output shaft of the servo motor, wherein the turntable is disposed at the end of the rotary output shaft; The servo motor drives the rotary output shaft and the turntable to rotate around the longitudinal axis of the cable under test, so as to apply a torsional load to the cable under test.

4. The cable testing device according to claim 3, characterized in that, The rotating output shaft has a hollow structure inside, through which the cable being tested can be threaded.

5. A cable testing device according to any one of claims 2 to 4, characterized in that, The loading mechanism also includes a linear guide rail arranged parallel to the axis of the turntable and a linear drive assembly that drives the turntable to reciprocate along the linear guide rail, so as to apply a controllable tensile load while torturing.

6. The cable testing device according to claim 5, characterized in that, The linear drive component includes: The lead screw is arranged parallel to the axis of the turntable; The guide rod is arranged parallel to the axis of the lead screw; A slider, which engages with the lead screw thread and is slidably sleeved on the outside of the guide rod; An electric motor, wherein the output shaft of the electric motor is connected to the lead screw drive; The slider moves axially along the guide shaft when the motor drives the lead screw to rotate, thereby driving the turntable to generate a tensile displacement relative to the first clamping part along the axial direction of the cable being tested.

7. A cable testing device according to claim 6, characterized in that, Also includes: A tension sensor is disposed between the slider and the turntable to measure the tensile load applied to the cable under test in real time. A torque sensor is mounted on the rotating output shaft to measure the torsional load applied to the cable under test in real time.

8. A cable testing device according to claim 7, characterized in that, Also includes: The controller is connected to the tension sensor, the torque sensor, and the real-time continuity monitoring module. The controller is configured to adjust the number of pulses and the speed of the motor based on the closed-loop signals from the tension sensor and / or the torque sensor to achieve a preset load amplitude and number of cycles. Furthermore, the controller is also configured to activate the loading mechanism and record the fault timestamp when the real-time continuity monitoring module outputs an open circuit or leakage signal.

9. A cable testing device according to claim 1, characterized in that: The cable under test includes at least one main power conductor, at least one control signal conductor, and at least one shielding layer; The real-time continuity monitoring module includes a constant current source and is configured to establish independent constant current detection loops and independent judgment thresholds for the power main conductor, the control signal conductor, and the shielding layer, respectively, in order to detect the continuity status of the power main conductor, the control signal conductor, and the shielding layer.

10. A cable testing device according to claim 9, characterized in that, Also includes: Several pairs of sampling terminals are provided, with one pair of sampling terminals provided at both ends of each of the power conductors, both ends of each of the control signal conductors, and both ends of each of the shielding layers of the cable under test; A multi-channel analog switch array includes a common terminal and several independent channel terminals. The common terminal is electrically connected to the positive terminal of the constant current source, and the several independent channel terminals are respectively electrically connected to each pair of sampling terminals. A common return line, one end of which is electrically connected to the negative terminal of the constant current source, and the other end of which is connected to the common ground terminal of the analog switch array; Under the control of the controller, the constant current source sequentially closes the independent channel terminals corresponding to each pair of sampling terminals through the multi-channel analog switch array in a preset polling order, so as to form a constant current detection circuit that corresponds one-to-one with and is independent of the power conductor, the control signal conductor and the shielding layer. Thus, the conduction status of the power conductor, the control signal conductor and the shielding layer is acquired one by one in the same polling cycle, and a corresponding set of detection results is generated.

Images