Power distribution connector installation system and method

Abstract

The invention relates to a power distribution connector installation system which comprises a positioning guide module, an intelligent fastening module, a state monitoring module, a control module and an adaptive adjustment module. The positioning and guiding module can realize rapid positioning and guiding of the power distribution connector and a butt joint component; the intelligent fastening module is used for automatically fastening a connecting bolt of the power distribution connector and a butt joint component; the state monitoring module is used for monitoring operation state parameters of the power distribution connector after installation in real time; the control module is connected with the positioning and guiding module, the intelligent fastening module, the state monitoring module and the adaptive adjusting module so as to achieve control installation of the power distribution connector and a butt joint component. The adaptive adjusting module can adapt to power distribution connectors of different specifications. The installation system provided by the invention not only can realize rapid and accurate installation, but also has a real-time monitoring function and is high in universality.

Description

Technical Field

[0001] This invention belongs to the field of high-voltage power equipment connection technology, and particularly relates to a connector installation system and method for power distribution. Background Technology

[0002] During the operation of a power distribution system, the connectors used for power distribution are key components for realizing current transmission between cables and between cables and power distribution equipment (such as switch cabinets, transformers, distribution boxes, etc.). Their installation quality directly affects the stability, safety, and operating efficiency of the power distribution system.

[0003] Currently, existing connector installation methods for power distribution have several shortcomings: First, the installation process relies on manual operation, requiring workers to tighten the bolts of the connector one by one with tools such as wrenches and screwdrivers. This is not only inefficient, but also makes it difficult to accurately control the tightening torque. Excessive torque can damage the connector shell or internal conductors, while insufficient torque can cause poor contact, leading to localized overheating, electric arcing, and other safety hazards. Second, the installation process lacks an effective positioning and guiding structure. Workers need to repeatedly adjust the position of the connector and mating parts, especially in the confined space of the power distribution cabinet, which further increases the difficulty and prolongs the installation time. Third, after the connector is installed, its operating status, such as temperature, current, and contact resistance, cannot be monitored in real time. When abnormalities occur in the connector, they cannot be detected and warned in time, which can easily lead to power distribution faults or even serious safety accidents such as fires. Fourth, existing connector installation systems have poor versatility. One installation structure is usually only applicable to specific models or specifications of connectors. When different types of connectors are used in the power distribution system, corresponding installation tools and equipment need to be changed, increasing construction costs and complexity.

[0004] In view of the problems existing in the above-mentioned technologies, there is an urgent need to develop a power distribution connector installation system and method that can achieve rapid and accurate installation, has real-time monitoring function, and is highly versatile, so as to improve the installation efficiency and operational safety of power distribution systems. Summary of the Invention

[0005] (a) Technical problems to be solved

[0006] To address the aforementioned problems in the prior art, this invention provides a power distribution connector installation system and method. This system overcomes the shortcomings of the prior art, such as low installation efficiency, poor installation accuracy, lack of status monitoring function, and poor versatility in power distribution connector installation.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, the main technical solutions adopted by the present invention include:

[0009] A connector installation system for power distribution includes a positioning and guiding module, an intelligent fastening module, a status monitoring module, a control module, and an adapter adjustment module;

[0010] The positioning and guiding module enables rapid positioning and guiding of the power distribution connector and the docking components;

[0011] The intelligent fastening module is used to automatically fasten the connecting bolts between the power distribution connector and the mating component;

[0012] The status monitoring module is used to monitor the operating status parameters of the power distribution connector in real time after installation.

[0013] The control module is connected to the positioning and guiding module, the intelligent fastening module, the status monitoring module and the adaptation and adjustment module respectively to realize the controlled installation of the power distribution connector and the docking component;

[0014] The adapter adjustment module can adapt to power distribution connectors of different specifications.

[0015] Preferably, the positioning and guiding module includes: a positioning base, a guide post, and a position sensor;

[0016] The positioning seat is fixed to the docking component;

[0017] The positioning base has a positioning groove that is adapted to the housing of the power distribution connector;

[0018] The guide post is disposed on the inner wall of the positioning groove;

[0019] The housing of the power distribution connector has a guide hole that matches the guide post;

[0020] The position sensor is installed at the bottom of the positioning slot and is used to detect whether the power distribution connector is inserted in place and to send a signal to the control module.

[0021] Preferably, the intelligent fastening module includes: a fastening drive assembly, a torque sensor, and a displacement sensor;

[0022] The fastening drive assembly includes a servo motor, a reducer, and a fastening sleeve;

[0023] The servo motor is connected to the fastening sleeve via the reducer;

[0024] The fastening sleeve can drive the connecting bolts to complete the fastening;

[0025] The torque sensor is located between the reducer and the fastening sleeve and is used to detect the fastening torque;

[0026] The displacement sensor is installed on the side wall of the fastening sleeve and is used to detect the axial displacement of the connecting bolts.

[0027] Preferably, the status monitoring module includes: a temperature sensor, a current sensor, a contact resistance sensor, and a wireless transmission unit;

[0028] The temperature sensor is embedded in the conductive terminal of the power distribution connector;

[0029] The current sensor is mounted on the cable of the power distribution connector;

[0030] The contact resistance sensor is located on the contact surface between the conductive terminal and the mating component;

[0031] The wireless transmission unit is disposed in the housing of the power distribution connector;

[0032] The temperature sensor, the current sensor, and the contact resistance sensor are respectively connected to the wireless transmission unit;

[0033] The wireless transmission unit is used to transmit parameter signals to the control module.

[0034] Preferably, the control module includes: a microprocessor, a memory, a display screen, and an alarm unit;

[0035] The microprocessor can receive signals from the positioning and guiding module, the intelligent fastening module, the status monitoring module, and the adaptation and adjustment module respectively, and control the operation of each module.

[0036] The microprocessor can be connected to the memory, the display screen, and the alarm unit respectively;

[0037] The memory can store parameters and data;

[0038] The display screen can show installation progress and parameters;

[0039] The alarm unit can issue an audible and visual alarm when parameters or installation are abnormal.

[0040] Preferably, the adapter adjustment module includes: an adjustment bracket, a clamping assembly, and a size detection unit;

[0041] The adjustment bracket includes a fixed bracket and a movable bracket;

[0042] The movable frame is mounted on the fixed frame;

[0043] The clamping assembly is mounted on the movable frame;

[0044] The size detection unit is mounted on the clamping assembly.

[0045] The clamping assembly includes a clamping cylinder and a clamping block;

[0046] An elastic buffer pad is provided on the inner side of the clamping block;

[0047] The clamping block can clamp the power distribution connector;

[0048] The size detection unit has a laser rangefinder sensor for detecting the size of the power distribution connector.

[0049] This technical solution also provides an installation method for a power distribution connector installation system, including the following steps:

[0050] S1. System initialization and parameter setting: After the control module self-tests, the staff inputs and stores the parameters of the power distribution connector.

[0051] S2. Positioning and clamping of power distribution connectors: the size detection unit detects the connector size, the adapter adjustment module clamps and fixes the connector, and the positioning guide module realizes the positioning of the power distribution connector.

[0052] S3. Intelligent fastening operation: The intelligent fastening module automatically tightens the connecting bolts until the torque and displacement reach the target range.

[0053] S4. Operation status monitoring and early warning: The status monitoring module detects parameters in real time and alarms when abnormalities occur.

[0054] S5. Install data storage and retrieval; the control module stores data, which staff can query and export.

[0055] Preferably, in step S2, when the position sensor detects that the power distribution connector is inserted into place, it sends a position signal to the control module, and the control module indicates that the positioning is complete.

[0056] Preferably, in S3, the control module compares the real-time detected tightening torque and displacement with the target tightening torque range and target displacement range, respectively. When both meet the target, the control module stops the servo motor from working.

[0057] Preferably, in S5, when the temperature exceeds 85°C, the current exceeds 1.25 times the rated current, or the contact resistance exceeds 55μΩ, the alarm unit issues an audible and visual alarm.

[0058] (III) Beneficial Effects

[0059] The beneficial effects of this invention are:

[0060] 1. Improved installation efficiency and accuracy: The positioning guide module uses positioning slots, guide posts, and position sensors to quickly position the connector and mating parts, avoiding repeated manual adjustments and significantly shortening the positioning time. The intelligent fastening module uses a servo motor drive and dual-parameter monitoring of torque and displacement to accurately control the tightening torque and depth of the connecting bolts, ensuring consistent fastening quality and avoiding installation problems caused by human error. At the same time, the automatic fastening method improves installation efficiency by at least 3 times compared to manual fastening.

[0061] 2. Real-time monitoring and early warning of operating status: The status monitoring module can detect key operating parameters of the connector in real time, such as temperature, current, and contact resistance, and transmit the data to the control module through the wireless transmission unit. When the parameters exceed the preset threshold, an alarm signal is issued in a timely manner. Staff can quickly discover and deal with potential faults, effectively avoid power distribution accidents caused by connector abnormalities, and improve the operational safety and reliability of the power distribution system.

[0062] 3. High versatility and compatibility with various connectors: The adapter adjustment module, through its retractable adjustment bracket, adjustable clamping components, and size detection unit, can automatically adjust the installation structure according to the size parameters of different models and specifications of connectors. It does not require the replacement of special installation tools and is suitable for various types of power distribution connectors, reducing construction costs and improving the applicability of the system.

[0063] 4. Convenient operation and high degree of intelligence: The entire installation process is completed automatically under the unified control of the control module. The staff only needs to set parameters and perform simple auxiliary operations, which reduces the skill requirements of the staff. The touch screen displays the installation progress and operating parameters in real time, which makes it easy for the staff to keep track of the system status in real time. At the same time, the historical data storage function facilitates subsequent data management and analysis. Attached Figure Description

[0064] Figure 1 This invention provides a schematic diagram of the structure of a connector mounting system for power distribution.

[0065] Figure 2 This is a schematic diagram of a power distribution connector installation system provided by the present invention. Detailed Implementation

[0066] To better explain and facilitate understanding of the present invention, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0067] like Figure 1 and Figure 2 As shown: This embodiment discloses a connector installation system for power distribution, including a positioning and guiding module, an intelligent fastening module, a status monitoring module, a control module, and an adapter adjustment module.

[0068] In detail, the positioning and guiding module enables rapid positioning and guidance of the power distribution connector and the mating component; the intelligent fastening module is used to automatically fasten the connecting bolts of the power distribution connector and the mating component.

[0069] In this embodiment, the status monitoring module is used to monitor the operating status parameters of the power distribution connector in real time after installation.

[0070] The control module is connected to the positioning and guiding module, the intelligent fastening module, the status monitoring module, and the adaptation and adjustment module to control the installation of the power distribution connector and the mating components. The adaptation and adjustment module can adapt to power distribution connectors of different specifications.

[0071] The positioning and guiding module in this embodiment includes: a positioning seat, a guide post, and a position sensor; the positioning seat is fixed to the docking component; the positioning seat has a positioning groove adapted to the housing of the power distribution connector; the guide post is disposed on the inner wall of the positioning groove.

[0072] Specifically, the housing of the power distribution connector has a guide hole that matches the guide post; the position sensor is installed at the bottom of the positioning groove to detect whether the power distribution connector is inserted into place and to send a signal to the control module.

[0073] In practical applications, the positioning and guiding module is used to achieve rapid positioning and guidance of the power distribution connector and the mating parts. The power distribution connector housing has a guide hole adapted to the guide post. The guide post and the guide hole are fitted with a clearance to ensure that the power distribution connector can be smoothly inserted into the positioning slot along the guide post. The position sensor is installed at the bottom of the positioning slot. The position sensor is an infrared sensor used to detect whether the connector is inserted into the correct position. When the connector is inserted into the positioning slot and reaches the preset position, the position sensor sends a position signal to the control module.

[0074] The intelligent fastening module in this embodiment includes a fastening drive assembly, a torque sensor, and a displacement sensor. The fastening drive assembly includes a servo motor, a reducer, and a fastening sleeve; the servo motor is connected to the fastening sleeve via the reducer; the fastening sleeve drives the connecting bolt to complete the fastening; the torque sensor is located between the reducer and the fastening sleeve and is used to detect the fastening torque; the displacement sensor is installed on the side wall of the fastening sleeve and is used to detect the axial displacement of the connecting bolt.

[0075] This intelligent fastening module is used to automatically tighten the connecting bolts of power distribution connectors and mating components. A servo motor is connected to a fastening sleeve via a reducer. The fastening sleeve is fitted to the head of the connecting bolt. Under the control of the control module, the servo motor drives the fastening sleeve to rotate, thus tightening the connecting bolt. A torque sensor is placed between the reducer and the fastening sleeve to detect the tightening torque of the connecting bolt in real time and sends the torque signal to the control module. A displacement sensor is installed on the side wall of the fastening sleeve to detect the axial displacement of the connecting bolt, thereby determining the tightening depth. The displacement sensor sends the displacement signal to the control module. The control module has preset target tightening torque range and target displacement range for the connecting bolt. When the tightening torque detected by the torque sensor reaches the target tightening torque range, and the displacement detected by the displacement sensor reaches the target displacement range, the control module controls the servo motor to stop working, completing the bolt tightening.

[0076] The status monitoring module described in this embodiment includes a temperature sensor, a current sensor, a contact resistance sensor, and a wireless transmission unit.

[0077] The temperature sensor is embedded in the conductive terminal of the power distribution connector; the current sensor is fitted onto the cable of the power distribution connector. The contact resistance sensor is located on the contact surface between the conductive terminal and the mating component; the wireless transmission unit is located in the housing of the power distribution connector; the temperature sensor, the current sensor, and the contact resistance sensor are respectively connected to the wireless transmission unit; the wireless transmission unit is used to transmit parameter signals to the control module.

[0078] In practical applications, this status monitoring module is used to monitor the operating status parameters of the connector in real time after installation. A temperature sensor is embedded in the conductive terminals of the connector to detect the real-time temperature of the conductive terminals. The temperature sensor uses a platinum resistance temperature sensor, which offers high measurement accuracy and stability. A current sensor is mounted on the connector's cable to detect the real-time current flowing through the connector. The current sensor is a Hall effect current sensor, featuring non-contact measurement and fast response. A contact resistance sensor is placed between the conductive terminals of the connector and the conductive contact surfaces of the mating parts to detect the contact resistance between them. The contact resistance sensor uses a four-wire measurement method to ensure measurement accuracy. A wireless transmission unit is connected to the temperature sensor, current sensor, and contact resistance sensor respectively, to wirelessly transmit the status parameter signals detected by each sensor to the control module. The wireless transmission unit uses LoRa wireless communication technology, which has the advantages of low power consumption and long-distance transmission, making it suitable for signal transmission in power distribution scenarios.

[0079] The control module in this embodiment includes a microprocessor, a memory, a display screen, and an alarm unit. The microprocessor can receive signals from the positioning and guiding module, the intelligent fastening module, the status monitoring module, and the adaptation and adjustment module, and control the operation of each module. The microprocessor can be connected to the memory, the display screen, and the alarm unit; the memory can store parameters and data; the display screen can display the installation progress and parameters; and the alarm unit can issue an audible and visual alarm when parameters or installation abnormalities occur.

[0080] In practical applications, the control module serves as the core control unit of the entire installation system. The microprocessor connects to the position sensors of the positioning and guiding module, the servo motor, torque sensor, and displacement sensor of the intelligent fastening module, and the wireless transmission unit of the status monitoring module. It receives signals from each module and controls them according to preset programs. The memory stores preset installation parameters (such as the target fastening torque range and target displacement range), historical data detected by each sensor, and system operation logs. The display screen is a touchscreen that shows the connector installation progress, real-time parameters detected by each sensor (such as fastening torque, displacement, temperature, current, and contact resistance), and system operating status. Operators can set parameters and perform operational controls through the display screen. The alarm unit is connected to the microprocessor. When parameters detected by the status monitoring module exceed preset thresholds (such as temperature exceeding 85℃, current exceeding 1.25 times the rated current, or contact resistance exceeding 55μΩ) or when abnormalities occur during installation (such as the connector not being inserted correctly or the fastening torque not reaching the target range), the microprocessor controls the alarm unit to issue audible and visual alarm signals to alert operators.

[0081] The adapter adjustment module in this embodiment includes: an adjustment bracket, a clamping assembly, and a size detection unit. The adjustment bracket includes a fixed frame and a movable frame; the movable frame is mounted on the fixed frame; the clamping assembly is mounted on the movable frame; and the size detection unit is mounted on the clamping assembly. The clamping assembly includes a clamping cylinder and a clamping block; the clamping block has an elastic buffer pad on its inner side; the clamping block is capable of clamping the power distribution connector; and the size detection unit has a laser rangefinder sensor for detecting the size of the power distribution connector.

[0082] In practical applications, the adaptation and adjustment module is used to adapt the installation system to connectors of different models and specifications. The adjustment bracket is a telescopic structure, including a fixed bracket and a movable bracket. The movable bracket is connected to the fixed bracket via a sliding guide rail and can slide along the length of the fixed bracket. Locking bolts are provided on the adjustment bracket to fix the movable bracket in a preset position. The clamping assembly is mounted on the movable bracket and includes a clamping cylinder and a clamping block. The clamping cylinder drives the clamping block to clamp and fix the connector. An elastic buffer pad is provided on the inner side of the clamping block to prevent excessive clamping force from damaging the connector shell. The size detection unit includes a laser rangefinder sensor, which is mounted on the side wall of the clamping assembly. It is used to detect the connector's length, width, height, and other dimensional parameters and sends the size signals to the control module. The control module automatically adjusts the telescopic length of the adjustment bracket and the clamping position of the clamping assembly according to the size parameters, enabling the installation system to adapt to the current connector model.

[0083] like Figure 2 As shown: This embodiment also provides an installation method for a power distribution connector installation system, including the following steps:

[0084] S1. System initialization and parameter setting: After the control module self-tests, the staff inputs and stores the parameters of the power distribution connector.

[0085] S2. Positioning and clamping of power distribution connectors: the size detection unit detects the connector size, the adapter adjustment module clamps and fixes the connector, and the positioning guide module realizes the positioning of the power distribution connector.

[0086] S3. Intelligent fastening operation: The intelligent fastening module automatically tightens the connecting bolts until the torque and displacement reach the target range.

[0087] S4. Operation status monitoring and early warning: The status monitoring module detects parameters in real time and alarms when abnormalities occur.

[0088] S5. Install data storage and retrieval; the control module stores data, which staff can query and export.

[0089] In detail, in S2, when the position sensor detects that the power distribution connector is inserted into place, it sends a position signal to the control module, and the control module indicates that the positioning is complete.

[0090] In detail, in S3, the control module compares the real-time detected tightening torque and displacement with the target tightening torque range and target displacement range, respectively. When both meet the target, the control servo motor stops working.

[0091] Specifically, in S5, when the temperature exceeds 85℃, the current exceeds 1.25 times the rated current, or the contact resistance exceeds 55μΩ, the alarm unit will issue an audible and visual alarm.

[0092] It should be noted that: In this embodiment, the control module is the core of the power distribution connector installation system. Its control algorithm needs to achieve precise and coordinated control of modules such as positioning guidance, intelligent fastening, status monitoring, and adaptation adjustment. It covers core functions such as parameter processing, logical judgment, execution control, and anomaly early warning. The specific algorithm model is as follows:

[0093] (I) Overall Framework of Algorithm Model

[0094] The control algorithm adopts a "hierarchical control + closed-loop feedback" architecture, which is divided into three levels: perception layer, decision layer, and execution layer. Each level achieves coordinated control through data interaction.

[0095] Perception Layer: Responsible for collecting real-time data from each module, including position sensor signals from the positioning and guidance module, torque / displacement sensor signals from the intelligent fastening module, temperature / current / contact resistance sensor signals from the status monitoring module, and laser ranging sensor signals from the adaptation and adjustment module. It removes data noise through filtering algorithms to ensure the accuracy of the original data.

[0096] Decision layer: Based on the preprocessed data collected by the perception layer, combined with preset parameters (such as the target tightening torque range, temperature threshold, etc.), control commands are generated through logical judgment algorithms, and anomaly detection and early warning decision-making are realized at the same time.

[0097] Execution layer: Receives control commands from the decision layer, drives each module to perform corresponding actions, such as controlling the start and stop of servo motors, extension and retraction of clamping cylinders, and triggering of alarm units, and feeds back the execution status to the decision layer to form closed-loop control.

[0098] (II) Core Sub-algorithm

[0099] 1. Adaptive control algorithm (for compatibility with different connector models)

[0100] The algorithm obtains the connector size parameters (length L, width W, height H) through a laser rangefinder sensor, and automatically calculates and adjusts the bracket extension and clamping component position. The specific steps are as follows:

[0101] Data Acquisition and Preprocessing: The laser rangefinder sensor acquired three sets of dimensional data (L1 / L2 / L3, W1 / W2 / W3, H1 / H2 / H3). Outliers were removed using a mean filtering algorithm. The calculation formula is: L - = (L1+L2+L3) / 3, W - = (W1+W2+W3) / 3, H - = (H1+H2+H3) / 3; (L - W - H - These are the average length, width, and height after processing, respectively.

[0102] Calculation of adjustment parameters: Adjustment bracket extension / retraction amount ΔL 支架 Based on the average length L - Calculation of the difference between the standard support length L0 and ΔL 支架 =L - -L0(if ΔL 支架 Positive value indicates the support extends; negative value indicates the support shortens; clamping assembly spacing ΔW 夹紧 Based on average width W - Calculate ΔW 夹紧 =W - +2d (d is the thickness of the clamping block's elastic buffer pad, taken as 2mm, to reserve buffer space).

[0103] Execution control: The control module outputs a PWM signal to drive the stepper motor of the adjustment bracket, which in turn moves the movable frame by ΔL. 支架 Simultaneously, the clamping cylinder is controlled to move, so that the clamping assembly spacing reaches ΔW. 夹紧 After the adaptation and adjustment are completed, a "adaptation complete" signal is sent to the decision-making level.

[0104] 2. Intelligent fastening closed-loop control algorithm (for precise control of bolt tightening)

[0105] This algorithm, based on real-time feedback from torque and displacement sensors, achieves closed-loop control of "torque-displacement" dual parameters, avoiding excessive tightness or looseness. The specific logic is as follows:

[0106] Parameter initialization: Read the preset target tightening torque range [M] min M max [,] (e.g., 15 N·m ~ 18 N·m), target displacement range [S min S max (e.g., 5mm to 6mm, bolt insertion depth).

[0107] Real-time feedback and judgment:

[0108] A servo motor drives the fastening sleeve to rotate, and a torque sensor collects the fastening torque M in real time. 实时 The displacement sensor collects the axial displacement S of the bolt. 实时 ;

[0109] If M 实时 <M min And S 实时 min : Control the servo motor to maintain the current speed (e.g., 100 r / min) and continue tightening;

[0110] If M 实时 ∈[M min M max But S 实时 <S​min : Reduce the speed of the servo motor (e.g., 50 r / min), and tighten it slowly until S 实时 ∈[S min , S max ;

[0111] If M 实时 > M max or S 实时 > S max : Immediately control the servo motor to brake, issue an "overtightening threshold" alarm, and avoid damaging the connector;

[0112] If M 实时 ∈[M min , M max and S 实时 ∈[S min , S max : Control the servo motor to stop, record the tightening data of this bolt, switch to the next bolt (if any), until all bolts are tightened.

[0113] 3. State monitoring and abnormal warning algorithm (for real-time monitoring of the operating state of the connector)

[0114] This algorithm realizes abnormal detection and hierarchical warning by comparing the real-time parameters of the sensor with the preset thresholds. The specific rules are as follows:

[0115] Parameter threshold setting: Preset three levels of thresholds (normal threshold T1, warning threshold T2, alarm threshold T3). For example: Temperature: T1 ≤ 60 °C (normal), 60 °C < T2 ≤ 85 °C (warning), T3 > 85 °C (alarm); Current: T1 ≤ 1.0I rated (normal), 1.0I rated < T2 ≤ 1.25I rated (warning), T3 > 1.25I rated (alarm); Contact resistance: T1 ≤ 30 μΩ (normal), 30 μΩ < T2 ≤ 55 μ (warning), T3 > 50 μΩ (alarm).

[0116] Abnormal judgment and handling:

[0117] If the parameter is within the T1 range: The display shows "Normal", and the data is stored normally;

[0118] If the parameter is within the T2 range: Control the alarm unit to make the yellow warning light flash, the display prompts "Parameter is on the high side, it is recommended to pay attention", and record the warning time and parameter value;

[0119] If the parameter is within the T3 range: Control the alarm unit to make the red alarm light flash + beep (frequency 2 Hz), the display pops up an "Emergency abnormality" pop-up window, mark the abnormal parameter (such as "Temperature 85 °C") and the position of the connector, and at the same time send an alarm message to the operation and maintenance terminal through the wireless transmission unit.

[0120] II. Specific Examples of Practical Applications

[0121] Taking the installation of cable connectors in a 10kV distribution switchgear as an example, this paper details the actual application process of this system. The project requires the installation of 30 JXT-10 / 250 distribution connectors (rated current 250A, bolt size M8, target tightening torque 16N·m~18N·m, temperature threshold 80℃). The implementation steps are as follows:

[0122] (I) Preparations before implementation

[0123] Equipment deployment: Fix the positioning seat of the positioning guide module on the docking terminal of the switch cabinet, install the intelligent fastening module on the movable guide rail on the outside of the switch cabinet (to facilitate bolt alignment), embed the temperature sensor of the status monitoring module into the conductive terminal of the connector, mount the current sensor on the cable, and place the adapter adjustment module on the operating platform next to the switch cabinet.

[0124] System initialization: Start the control module and input the connector model "JXT-10 / 250" through the touch screen. The system will automatically load preset parameters (target tightening torque [16,18] N·m, target displacement [5.2,5.8] mm, temperature threshold 80℃, current threshold 300A (1.2×250A), contact resistance threshold 50μΩ). At the same time, the system will complete the self-test of each module (positioning guide module position sensor response is normal, intelligent fastening module servo motor has no jamming, status monitoring module sensor signal is stable).

[0125] (II) On-site installation and implementation

[0126] 1. Adaptor Adjustment (Installation of the first connector)

[0127] Place the JXT-10 / 250 connector between the clamping components of the adapter adjustment module. The control module activates the laser rangefinder sensor to collect connector dimension data: length.

[0128] L - =120mm, width W - =80mm, Height H - =50mm;

[0129] The adaptive adjustment algorithm calculates the adjustment parameters: adjusting the extension and retraction of the support bracket.

[0130] ΔL 支架 =120mm-100mm=20mm (the bracket needs to be extended by 20mm), clamping component spacing ΔW 夹紧 =80mm + 2 × 2mm = 84mm;

[0131] The control module drives the stepper motor of the adjustment bracket to extend the bracket by 20mm. At the same time, it controls the clamping cylinder to push the clamping block until the gap reaches 84mm. The elastic buffer pad of the clamping block fits into the connector shell, and the display shows "Adaptation complete".

[0132] 2. Positioning and fastening

[0133] Positioning: The control module moves the positioning seat to the front of the switch cabinet docking terminal. The operator pushes the connector to align the connector guide hole with the positioning seat guide post and inserts it into the positioning slot along the guide post. When the position sensor (infrared sensor) detects that the connector insertion depth reaches 30mm (preset positioning depth), it sends a "positioning in place" signal, and the display screen prompts "tightening can begin".

[0134] Intelligent fastening:

[0135] The control module starts the servo motor, which drives the fastening sleeve (compatible with M8 bolts) to rotate via a reducer, with an initial speed of 100 r / min; the torque sensor provides real-time torque feedback: when M... 实时 =15Nm (close to M) min When the torque reaches 16 Nm, the system automatically reduces the rotation speed to 50 r / min; continue tightening to M. 实时 =17Nm (located in [16,18]Nm), displacement sensor detects S 实时 =5.5mm (within [5.2, 5.8]mm), the control module immediately stops the servo motor and completes the tightening of one bolt;

[0136] Repeat the above steps to tighten the four bolts on the connector (total time is about 40 seconds, which is more than 3 times more efficient than manual tightening). The display screen will show "Tightening complete".

[0137] 3. Operational status monitoring

[0138] After the connector is installed, the status monitoring module is activated: the temperature sensor detects the temperature of the conductive terminals in real time (initial value 25℃), the current sensor detects the cable current (stable at 200A during operation), the contact resistance sensor detects the contact resistance (initial value 20μΩ), and the data is uploaded to the control module every 30 seconds via the LoRa wireless transmission unit;

[0139] After two hours of operation, due to cable load fluctuations, the current of a certain connector briefly rose to 310A (exceeding the threshold of 300A). The control module immediately triggered a red alarm (flashing light + buzzer), and the display showed "Abnormal current: 310A, location: switch cabinet No. 5". The maintenance personnel adjusted the load in time, and the current returned to 200A after 10 seconds, and the alarm was cleared.

[0140] All installation data (such as the tightening torque and operating temperature of each connector) is automatically stored in the memory. Staff can export the data via USB interface to generate an "Installation Quality Report" for easy traceability later.

[0141] (III) Implementation Results

[0142] This project used this system to install 30 connectors, compared to traditional manual installation:

[0143] Efficiency improvement: The installation time for a single unit has been reduced from 120 seconds to 40 seconds by manual labor, and the total installation time has been reduced from 60 minutes to 20 minutes, resulting in a 3-fold increase in efficiency;

[0144] Precision assurance: The pass rate of bolt tightening torque has been increased from 85% by manual operation to 100% (no overtightening / loosening). The contact resistance is stable at 20μΩ~35μΩ (far below the threshold of 55μΩ).

[0145] Safety alert: Two current anomalies were successfully detected (both were handled within 1 minute), and no power distribution failures caused by connector problems occurred, ensuring the stable operation of the switchgear.

[0146] The technical principles of the present invention have been described above with reference to specific embodiments. These descriptions are merely for explaining the principles of the invention and should not be construed as limiting the scope of protection of the invention in any way. Based on this explanation, those skilled in the art can conceive of other specific embodiments of the invention without creative effort, and these embodiments will all fall within the scope of protection of the present invention.

Claims

1. A connector mounting system for power distribution, characterized in that, It includes a positioning and guidance module, an intelligent fastening module, a status monitoring module, a control module, and an adaptation and adjustment module; The positioning and guiding module enables rapid positioning and guiding of the power distribution connector and the docking components; The intelligent fastening module is used to automatically fasten the connecting bolts between the power distribution connector and the mating component; The status monitoring module is used to monitor the operating status parameters of the power distribution connector in real time after installation. The control module is connected to the positioning and guiding module, the intelligent fastening module, the status monitoring module, and the adaptation and adjustment module respectively to realize the controlled installation of the power distribution connector and the docking component; The adapter adjustment module can adapt to power distribution connectors of different specifications.

2. The power distribution connector mounting system according to claim 1, characterized in that, The positioning and guiding module includes: a positioning base, a guide post, and a position sensor; The positioning seat is fixed to the docking component; The positioning base has a positioning groove that is adapted to the housing of the power distribution connector; The guide post is disposed on the inner wall of the positioning groove; The housing of the power distribution connector has a guide hole that matches the guide post; The position sensor is installed at the bottom of the positioning slot and is used to detect whether the power distribution connector is inserted in place and to send a signal to the control module.

3. The power distribution connector installation system according to claim 1, characterized in that, The intelligent fastening module includes: a fastening drive assembly, a torque sensor, and a displacement sensor; The fastening drive assembly includes a servo motor, a reducer, and a fastening sleeve; The servo motor is connected to the fastening sleeve via the reducer; The fastening sleeve can drive the connecting bolts to complete the fastening; The torque sensor is located between the reducer and the fastening sleeve and is used to detect the fastening torque; The displacement sensor is installed on the side wall of the fastening sleeve and is used to detect the axial displacement of the connecting bolts.

4. The power distribution connector installation system according to claim 1, characterized in that, The status monitoring module includes: a temperature sensor, a current sensor, a contact resistance sensor, and a wireless transmission unit; The temperature sensor is embedded in the conductive terminal of the power distribution connector; The current sensor is mounted on the cable of the power distribution connector; The contact resistance sensor is located on the contact surface between the conductive terminal and the mating component; The wireless transmission unit is disposed in the housing of the power distribution connector; The temperature sensor, the current sensor, and the contact resistance sensor are respectively connected to the wireless transmission unit; The wireless transmission unit is used to transmit parameter signals to the control module.

5. The power distribution connector mounting system according to claim 1, characterized in that, The control module includes: a microprocessor, a memory, a display screen, and an alarm unit; The microprocessor can receive signals from the positioning and guiding module, the intelligent fastening module, the status monitoring module, and the adaptation and adjustment module respectively, and control the operation of each module. The microprocessor can be connected to the memory, the display screen, and the alarm unit respectively; The memory can store parameters and data; The display screen can show installation progress and parameters; The alarm unit can issue an audible and visual alarm when parameters or installation are abnormal.

6. The power distribution connector mounting system according to claim 1, characterized in that, The adapter adjustment module includes: an adjustment bracket, a clamping assembly, and a size detection unit; The adjustment bracket includes a fixed bracket and a movable bracket; The movable frame is mounted on the fixed frame; The clamping assembly is mounted on the movable frame; The size detection unit is mounted on the clamping assembly. The clamping assembly includes a clamping cylinder and a clamping block; An elastic buffer pad is provided on the inner side of the clamping block; The clamping block can clamp the power distribution connector; The size detection unit has a laser rangefinder sensor for detecting the size of the power distribution connector.

7. An installation method for a power distribution connector installation system, based on the installation system according to any one of claims 1-6, characterized in that, Includes the following steps: S1. System initialization and parameter setting: After the control module self-tests, the staff inputs and stores the parameters of the power distribution connector. S2. Positioning and clamping of power distribution connectors: the size detection unit detects the connector size, the adapter adjustment module clamps and fixes the connector, and the positioning guide module realizes the positioning of the power distribution connector. S3. Intelligent fastening operation: The intelligent fastening module automatically tightens the connecting bolts until the torque and displacement reach the target range. S4. Operation status monitoring and early warning: The status monitoring module detects parameters in real time and alarms when abnormalities occur. S5. Install data storage and retrieval; the control module stores data, which staff can query and export.

8. The method for installing a power distribution connector according to claim 7, characterized in that, In S2, when the position sensor detects that the power distribution connector is inserted into place, it sends a position signal to the control module, and the control module indicates that the positioning is complete.

9. The method for installing a power distribution connector according to claim 7, characterized in that, In S3, the control module compares the real-time detected tightening torque and displacement with the target tightening torque range and target displacement range, respectively. When both meet the target, the control servo motor stops working.

10. The method for installing a power distribution connector according to claim 7, characterized in that, In S5, when the temperature exceeds 85℃, the current exceeds 1.25 times the rated current, or the contact resistance exceeds 55μΩ, the alarm unit will issue an audible and visual alarm.

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