Test tool and test method for flaring of aluminum sheath
By designing a test fixture for flaring aluminum sheaths, employing a flaring conical structure, a detachable weld seam receiving groove, and a visual monitoring system, the problems of long testing time and large errors in traditional testing methods are solved, achieving efficient and reliable aluminum sheath flaring testing.
Patent Information
- Application Number
- CN202511423867.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-30
- Publication Date
- 2025-12-16
AI Technical Summary
Traditional aluminum sheath flaring test methods are time-consuming, inefficient, and have large measurement errors, which affect the reliability of the test results.
Design a test fixture for flaring aluminum sheaths. It adopts a flared conical structure, combined with a detachable weld seam receiving groove, lubrication oil circuit and visual monitoring system to automatically identify the outer diameter of the aluminum sheath and weld defects, reducing human interference.
It improves the efficiency and reliability of aluminum sheath flaring tests, reduces measurement errors, and adapts to the testing needs of aluminum sheaths of different specifications.
Smart Images
Figure CN121141340A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of cable production and testing technology, specifically to a testing fixture and method for flaring aluminum sheaths. Background Technology
[0002] In the production of aluminum-sheathed railway signaling cables, to meet the requirements for water resistance, shielding, and mechanical protection, the cable core is typically covered with an aluminum sheath for insulation. Currently, the manufacturing methods for the aluminum sheath include using aluminum strips to form a tubular shape via a longitudinal wrapping device, followed by welding to create a complete aluminum sheath covering the cable core, or employing continuous extrusion wrapping technology to create a seamless aluminum sheath covering the cable core at the extrusion point. According to the requirements of TB / T 2476-2017 and TB / T 3100-2017 standards, the aluminum sheath should be sealed and airtight, and after a flaring test (the outer diameter of the flared aluminum tube is 1.3 times its original outer diameter), it should be free of cracks or defects.
[0003] Traditional testing methods use tensile testing machines, requiring the operator to repeatedly measure the outer diameter of the flared aluminum tube with calipers and visually inspect for cracks and defects. This process is not only time-consuming and inefficient, but also prone to significant measurement errors, affecting the reliability of the test results. Summary of the Invention
[0004] To address the problems in the prior art, this invention provides a test fixture and test method for flaring aluminum sheaths.
[0005] This invention is achieved through the following technical solution: A test fixture for flaring aluminum sheaths includes a body, which has a flared conical structure. A weld receiving groove is provided at the cone head of the body, and parallel outer diameter marking lines before and after flaring are provided on the outer side of the body.
[0006] Preferably, the weld seam receiving groove is detachably connected to the body.
[0007] Preferably, the main body is provided with a lubricating oil passage, which is connected to an external oil supply device.
[0008] Preferably, the external oil supply equipment includes an oil supply tank and an oil supply pipeline. The oil supply tank is connected to the lubricating oil circuit through the oil supply pipeline, and a CNC oil pump is installed on the oil supply pipeline.
[0009] Preferably, a pressure sensor is also installed on the oil supply line.
[0010] Preferably, a flow meter is also installed on the oil supply line.
[0011] A test method for flaring aluminum sheaths, using a test fixture for flaring aluminum sheaths, comprising: S1, Cut an aluminum sleeve of appropriate length and grind the inside of the end of the aluminum sleeve; S2, install the test fixture on the tensile testing machine, and place the protruding part of the weld inside the aluminum sheath into the flared conical weld receiving groove; S3 uses a visual monitoring system to identify the outer diameter of the aluminum sheath before reaming and the outer diameter after the 1.3 times reaming test is successful, as well as whether there are any defects at the weld of the aluminum sheath.
[0012] Preferably, in S1, the length of the aluminum sheath is 10cm.
[0013] Preferably, in S1, the two ends of the aluminum sheath are flush.
[0014] Preferably, in S3, the condition of the aluminum sheath weld is tracked throughout the flaring test, and after the outer diameter reaches 1.3 times the successful flaring test, the weld is automatically identified for cracks or defects based on the accumulated image data, and the test is determined to be passed.
[0015] Compared with the prior art, the present invention has the following beneficial effects: The present invention provides a test fixture for flaring aluminum sheaths. Through a specially designed flaring conical structure, it can automatically evaluate that the outer diameter of the flared aluminum sheath reaches 1.3 times the outer diameter of the unflared aluminum sheath during the flaring test, thereby reducing the interference of human factors and improving the reliability of test results.
[0016] The replaceable modular structure is achieved by using detachable weld seam receiving grooves. Various groove types are designed for weld seam dimensions (such as protrusion height and width) of different aluminum sheath specifications, and the test requirements of multiple cable models can be adapted by quickly replacing modules.
[0017] Furthermore, the lubricating oil circuit is used to lubricate the inner wall of the aluminum sheath during testing. The oil circuit is connected to a CNC oil pump via pipelines, and is equipped with a pressure sensor and flow feedback system to monitor the delivery pressure and flow rate of the lubricating oil in real time, avoiding fluctuations in the flaring resistance caused by uneven lubrication, and further reducing test errors.
[0018] This invention discloses a testing method for flaring aluminum sheaths. It utilizes a specialized testing fixture with a flared conical structure. The cone has a weld seam support groove to ensure stress stability at the weld. A lubricating oil passage is located in the center of the cone, through which a CNC oil pump evenly delivers lubricating oil to the interior of the aluminum sheath, ensuring uniform coating during the test. Furthermore, a visual monitoring system is employed to intelligently identify and determine whether cracks or defects are present at the weld seam of the aluminum sheath after the test. Attached Figure Description
[0019] Figure 1 This is a schematic diagram of a test fixture for flaring aluminum sheaths according to the present invention.
[0020] Figure 2 This is a schematic diagram of a test method for flaring aluminum sheaths according to the present invention.
[0021] In the diagram: 1. Body; 2. Weld seam receiving groove; 3. Lubricating oil circuit; 4. Detachable module; 5. CNC oil pump; 6. Visual monitoring system; 7. Outer diameter marking line before flaring; 8. Outer diameter marking line after flaring. Detailed Implementation
[0022] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification.
[0023] Exemplary embodiments of the present invention will now be described with reference to the accompanying drawings. However, the present invention may be embodied in many different forms and is not limited to the embodiments described herein. These embodiments are provided to fully and completely disclose the invention and to fully convey its scope to those skilled in the art. The terminology used in the exemplary embodiments illustrated in the drawings is not intended to limit the invention. In the drawings, the same units / elements are referred to by the same reference numerals.
[0024] Unless otherwise stated, the terms used herein (including technical terms) have their common meaning as understood by one of ordinary skill in the art. Furthermore, it is understood that terms defined in commonly used dictionaries should be understood to have a meaning consistent with the context of their relevant field, and not to be interpreted as having an idealized or overly formal meaning.
[0025] The present invention will be further described in detail below with reference to specific embodiments. These descriptions are for explanation purposes only and are not intended to limit the scope of the invention.
[0026] This invention discloses a test fixture for flaring aluminum sheaths. The test fixture for flaring aluminum sheaths includes a body 1, which has a flared conical structure. The cone head of the body 1 is provided with a detachable weld receiving groove 2. The cone head and the weld receiving groove 2 form a detachable module 4. The cone head and the weld receiving groove 2 can be assembled using screws or snap-fit structures. Alternatively, a split body can be used, in which the cone head and the weld receiving groove 2 are integrally formed, and the cone head is connected to other parts of the body by screws, snap-fits, or threads.
[0027] Parallel outer diameter marking lines 7 (before flaring) and 8 (after flaring) are provided on the outer side of the main body 1.
[0028] The main body 1 is equipped with a lubricating oil passage 3, which is connected to an external oil supply device. The external oil supply device includes an oil supply tank and an oil supply pipeline. The oil supply tank is connected to the lubricating oil passage 3 through the oil supply pipeline. A CNC oil pump 5 is installed on the oil supply pipeline. The CNC oil pump 5 is used to uniformly deliver lubricating oil to the inside of the aluminum sheath through the oil passage to ensure uniform coating during the test.
[0029] The oil supply line is also equipped with a pressure sensor and a flow meter, which can monitor the delivery pressure and flow of lubricating oil in real time, avoid fluctuations in the flaring resistance caused by uneven lubrication, and further reduce test errors.
[0030] This invention discloses a test method for flaring aluminum sheaths, using a test fixture for flaring aluminum sheaths, comprising: S1. Cut an aluminum sheath to a suitable length and grind the inside of the aluminum sheath end. Specifically, before the test begins, use a circumferential cutter to remove the finished end of the aluminum sheathed cable, ensuring this end is flush. Remove the cable outer sheath, steel tape armor layer, and inner lining layer of the aluminum sheath. Use the circumferential cutter again to flush the other end, ensuring the remaining aluminum sheath length is 10cm. Finally, use a flat file to grind the inside of both ends of the aluminum sheath smooth. This ensures that during the flaring test, the aluminum sheath experiences uniform longitudinal force on the flaring cone. Unevenness of the aluminum sheath end face during the test, causing the aluminum sheath to tilt, or excessive force on the weld end, will not affect the judgment of the test results. Conversely, unevenness between the aluminum sheath and the flaring cone contact end faces, resulting in the weld end being too short and the opposite side too long, or insufficient force on the weld end, will also affect the judgment of the test results.
[0031] S2, the test fixture is installed on the tensile testing machine, and the protruding part of the weld inside the aluminum sheath is placed in the flared conical weld receiving groove 2. At the same time, the CNC oil pump 5 is used to evenly deliver lubricating oil to the inside of the aluminum sheath through the lubricating oil circuit 3 to ensure uniform coating during the test.
[0032] S3, using a visual monitoring system 6, identifies the outer diameter of the aluminum sheath before flaring and the outer diameter after a successful 1.3 times flaring test, as well as whether there are defects at the weld of the aluminum sheath. The visual monitoring system 6 is positioned directly over the weld of the aluminum sheath. This system automatically calculates the outer diameter of the aluminum sheath before flaring and the outer diameter after a successful 1.3 times flaring test using an algorithm. Throughout the flaring test, the system tracks the condition of the aluminum sheath weld. After reaching the outer diameter after a successful 1.3 times flaring test, it automatically identifies cracks or defects at the weld based on previously accumulated image data, determining whether the test has passed. This avoids the influence of human factors. When using calipers for measurement, the tightness of the caliper varies from person to person, which affects the measurement of the outer diameter of the flared opening. Human visual judgment is subjective and cannot accurately determine minor cracks.
[0033] The above description is merely a preferred embodiment of the present invention and is not intended to limit the technical solution of the present invention in any way. Those skilled in the art should understand that, without departing from the spirit and principles of the present invention, the technical solution can be modified and replaced in several simple ways, and these modifications and replacements are all within the scope of protection covered by the claims.
Claims
1. A test fixture for flaring aluminum sheaths, characterized in that, Includes a body (1), which has a flared conical structure. A weld receiving groove (2) is provided at the cone head of the body (1). Parallel outer diameter marking lines (7) before flaring and outer diameter marking lines (8) after flaring are provided on the outside of the body (1).
2. The test fixture for flaring aluminum sheaths according to claim 1, characterized in that, The weld seam receiving groove (2) is detachably connected to the body (1).
3. The test fixture for flaring aluminum sheaths according to claim 1, characterized in that, The main body (1) is equipped with a lubricating oil passage (3), which is connected to an external oil supply device.
4. The test fixture for flaring aluminum sheaths according to claim 3, characterized in that, The external oil supply equipment includes an oil supply tank and an oil supply pipeline. The oil supply tank is connected to the lubricating oil circuit (3) through the oil supply pipeline, and a CNC oil pump (5) is installed on the oil supply pipeline.
5. The test fixture for flaring aluminum sheaths according to claim 4, characterized in that, Pressure sensors are also installed on the oil supply lines.
6. The test fixture for flaring aluminum sheaths according to claim 4, characterized in that, A flow meter is also installed on the oil supply pipeline.
7. A test method for flaring an aluminum sheath, using the test fixture for flaring an aluminum sheath as described in any one of claims 1 to 6, characterized in that, include: S1, Cut an aluminum sleeve of appropriate length and grind the inside of the end of the aluminum sleeve; S2, install the test fixture on the tensile testing machine, and place the protruding part of the weld inside the aluminum sheath into the flared conical weld receiving groove (2); S3, using a visual monitoring system (6) to identify the outer diameter of the aluminum sheath before reaming and the outer diameter after the 1.3 times reaming test is successful, as well as whether there are defects at the weld of the aluminum sheath.
8. The test method for flaring aluminum sheaths according to claim 7, characterized in that, In S1, the aluminum sheath is 10cm long.
9. The test method for flaring aluminum sheaths according to claim 7, characterized in that, In S1, the two ends of the aluminum sheath are flush.
10. The test method for flaring aluminum sheaths according to claim 7, characterized in that, In S3, the condition of the aluminum sheath weld is tracked throughout the flaring test. After the outer diameter reaches 1.3 times the flaring test result, the system learns from the accumulated image data and automatically identifies whether there are cracks or defects in the weld to determine whether the test is passed.