Clamping and core wire shaping device and method for double-core cable with plug

Abstract

The invention discloses a device and method for clamping a double-core cable with a plug and shaping a core wire, and the device comprises a wire fixing mechanism, a pressing device, and a shaping mechanism. Wherein the shaping mechanism is connected with the bottom of the wire fixing mechanism; and the pressing device is arranged at the upper part of the wire fixing mechanism. The defects that in the prior art, cable core wire shaping and core wire positioning consistency control is difficult, the labor cost is high, and the efficiency is low are overcome.

Description

Technical Field

[0001] This invention belongs to the field of pyrotechnics manufacturing technology, and particularly relates to a device and method for clamping and shaping a double-core cable with a plug. Background Technology

[0002] Electro-pyrotechnics, powered by electricity as their initial energy source, possess advantages such as compact structure, small size, and low ignition capability. They are widely used in launch vehicles, satellites, and spacecraft to perform various detonation and ignition functions. Among these, pyrotechnics employing plugged two-core cables for power transmission are a key component. Their typical structure involves lap welding between the plugged two-core cable and the pyrotechnic's electrode pins (including both internally inserted and externally exposed pins). Given that electro-pyrotechnics rely on electricity as their initial energy source, the welding quality has a decisive impact on the product's functionality and is a core process for ensuring product reliability.

[0003] The lap welding of plugged two-core cables with pyrotechnic components employs an electric arc furnace (EAF) for heating and soldering. This process primarily involves fixing the pyrotechnic component, applying flux, lap welding the cable cores to the electrode pins, applying solder to the EAF, welding, visual inspection, and product unloading. For a long time, due to limitations in technological capabilities, the lap welding process for plugged two-core cables with pyrotechnic components has relied mainly on manual operation using tools and fixtures. In the cable core-to-electrode lap welding stage, the two cable cores are first manually separated. Then, one cable core is manually shaped and pressed against the electrode pin for welding (to avoid reducing the welding space due to the unwelded cable core, the unwelded cable core is usually manually bent to the outside of the product's welding cavity). Finally, the other cable core is manually shaped and pressed against the electrode pin for welding.

[0004] Current methods for shaping and positioning cable cores have drawbacks such as difficulty in controlling consistency, high labor costs, and low efficiency. Summary of the Invention

[0005] The technical problem solved by this invention is to overcome the shortcomings of the prior art and provide a device and method for clamping and shaping a double-core cable with a plug, which solves the problems of difficulty in controlling the consistency of cable core shaping and core positioning, high labor costs and low efficiency in the prior art.

[0006] The objective of this invention is achieved through the following technical solution: a clamping and core wire shaping device for a double-core cable with a plug, comprising: a wire fixing mechanism, a clamping device, and a shaping mechanism; wherein, the shaping mechanism is connected to the bottom of the wire fixing mechanism; and the clamping device is disposed on the upper part of the wire fixing mechanism.

[0007] The cable clamping and core shaping device with plug double-core cable comprises a fixed line mechanism, a pressing device and a shaping mechanism. The fixed line mechanism comprises a bottom plate, a buckle one, a buckle two, a positioning block, a rotary knob quick lock lock core, a connecting block, a lock buckle, two vertical mushroom buckles, a horizontal mushroom buckle, a handle, a magic tape and a hanging buckle. The bottom plate is provided with a plurality of grooves in a rectangular array mode. The buckle one, the buckle two and the positioning block constitute a cable clamping positioning combined unit arranged in each groove. The buckle one, the buckle two and the positioning block are connected and fixed with the bottom plate by screws from top to bottom in the groove. The rotary knob quick lock lock core is arranged at the front of the bottom plate. The connecting block is fixed at the front of the two sides of the bottom plate. The handle is fixed at the middle of the two sides of the bottom plate. The lock buckle is fixed on the side of the connecting block. One vertical mushroom buckle is pasted on the left edge of the upper part of the bottom plate. The other vertical mushroom buckle is pasted on the right edge of the upper part of the bottom plate. One end of the horizontal mushroom buckle is overlapped with the middle part of one vertical mushroom buckle. The other end of the horizontal mushroom buckle is overlapped with the middle part of the other vertical mushroom buckle. The magic tape is arrayed and pasted on the upper surface of the rear part of the bottom plate. The magic tape is corresponding to the buckle one in the length direction of the bottom plate. The hanging buckle is arranged on the lower surface of the bottom plate.

[0008] The pressing device comprises a pressing plate, a rotary knob quick lock lock rod and a pressing block. The pressing plate is provided with a plurality of second grooves in an array mode in the length direction. The pressing block is arranged in the second groove. The pressing block is positioned in cooperation with the second groove. The rotary knob quick lock lock rod is arranged on the pressing plate. After the rotary knob quick lock lock rod penetrates into the rotary knob quick lock lock core of the shaping mechanism, the pressing device is fixed on the upper part of the fixed line mechanism by rotating the rotary knob quick lock lock core.

[0009] The shaping mechanism comprises a shaping block, two positioning pins and two lock rings. One positioning pin is arranged on one side of the upper part of the shaping block. The other positioning pin is arranged on the other side of the upper part of the shaping block. One lock ring is arranged at one end of the shaping block. The other lock ring is arranged at the other end of the shaping block. The upper part of the shaping block is provided with a plurality of shaping holes in an array mode in the length direction. The positioning pin is embedded in the pin hole of the connecting block. The lock ring is sleeved on the lock buckle to connect the shaping mechanism with the fixed line mechanism.

[0010] The shaping holes are distributed in groups. Each group of shaping holes comprises two equidistantly distributed stepped holes. Each stepped hole comprises a rounded aperture, a guide conical surface one, a hole one, a transition conical surface two and a hole two. The rounded aperture, the guide conical surface one, the hole one, the transition conical surface two and the hole two are sequentially connected.

[0011] The wire fixing mechanism is in the form of a rectangular thin plate.

[0012] The bottom plate is in the form of a rectangular thin plate.

[0013] The horizontal mushroom buckle is perpendicular to the vertical mushroom buckle; one end of the horizontal mushroom buckle is connected to the middle part of one vertical mushroom buckle through a mushroom head embedding mode, and the other end of the horizontal mushroom buckle is connected to the middle part of another vertical mushroom buckle through a mushroom head embedding mode.

[0014] The pressing plate is in the form of a rectangular thin plate.

[0015] A method for clamping and shaping a double-core cable with a plug according to the double-core cable clamping and shaping device with a plug, comprising:

[0016] The wire fixing mechanism is fixed by a hanging buckle;

[0017] The positioning pin of the shaping mechanism is inserted into the pin hole of the connecting block of the wire fixing mechanism, the locking ring is pulled up and locked on the lock buckle, and the shaping mechanism is fixed on the wire fixing mechanism;

[0018] The outer conductor part of the double-core cable with a plug is wound into a ring shape, and the outer conductor part of the connection core part is left with a predetermined length after winding;

[0019] The ring-shaped part of the double-core cable with a plug wound into a ring shape is locked on the magic tape, the reserved connection core part of the double-core cable with a plug is sequentially clamped into the buckle one and the buckle two, and then the core wire of the double-core cable with a plug is inserted into the shaping hole of the shaping mechanism and kept for a predetermined time;

[0020] The horizontal mushroom buckle is pressed against the outer conductor of the clamped double-core cable with a plug, and then the two ends of the outer conductor are embedded in the vertical mushroom buckle for fixation;

[0021] The knob quick lock lock rod is inserted into the knob quick lock lock cylinder, and the presser is locked on the wire fixing mechanism by rotating the knob quick lock lock rod;

[0022] The locking ring is removed from the lock buckle, and then the shaping mechanism is removed from the wire fixing mechanism.

[0023] Compared with the prior art, the present application has the following beneficial effects:

[0024] The present application solves the problems of cable core shaping, core positioning consistency control difficulty, high labor cost and low efficiency in the prior art, and adopts integrated clamping and shaping operation for the double-core cable with plug, avoids the introduction of secondary clamping positioning error, improves the clamping positioning precision, reduces the labor operation cost, and improves the efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0025] Various other advantages and benefits will become apparent to those of ordinary skill in the art upon reading the following detailed description of the preferred embodiments. The accompanying drawings are included to provide a description of the preferred embodiments and are not intended to limit the scope of the present application. Moreover, like reference numerals are intended to represent like parts throughout the various drawings. In the drawings:

[0026] Figure 1 is a structural schematic diagram of a double-core cable with plug clamping and core shaping device provided by the embodiment of the present application;

[0027] Figure 2 is a structural schematic diagram of a fixed line mechanism (front view) provided by the embodiment of the present application;

[0028] Figure 3 is a structural schematic diagram of a fixed line mechanism (back view) provided by the embodiment of the present application;

[0029] Figure 4 is a schematic diagram of a presser provided by the embodiment of the present application;

[0030] Figure 5 is a schematic diagram of a shaping mechanism provided by the embodiment of the present application;

[0031] Figure 6 is a structural and dimensional schematic diagram of a double-core cable with plug provided by the embodiment of the present application;

[0032] Figure 7 is a schematic diagram of a double-core cable with plug clamping and shaping process provided by the embodiment of the present application;

[0033] Figure 8 is a schematic diagram of a double-core cable with plug pressurizing and fixing process provided by the embodiment of the present application;

[0034] Figure 9 is a schematic diagram of a shaping mechanism dismounting process provided by the embodiment of the present application;

[0035] Figure 10 is a schematic diagram of a double-core cable with plug core and pole needle lap provided by the embodiment of the present application;

[0036] Figure 11 is a schematic diagram of shaping block shaping hole size design provided by the embodiment of the present application. DETAILED DESCRIPTION

[0037] Exemplary embodiments of the present disclosure will be described in greater detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it is understood that the present disclosure can be embodied in various forms and should not be limited by the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art. It is noted that the embodiments in the present disclosure and the features in the embodiments can be combined with each other without conflict. The present disclosure will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.

[0038] Figure 1 is a structural schematic diagram of a plug-in double-core cable clamp and core wire shaping device provided by an embodiment of the present disclosure. As shown in Figure 1 , the plug-in double-core cable clamp and core wire shaping device comprises a wire fixing mechanism 1, a presser 2, and a shaping mechanism 3; wherein the shaping mechanism 3 is connected with the bottom of the wire fixing mechanism 1; the presser 2 is arranged on the upper part of the wire fixing mechanism 1.

[0039] The wire fixing mechanism 1 is a rectangular thin plate structure. After the positioning pin 20 of the shaping mechanism 3 is matched with the pin hole of the connecting block 9 of the wire fixing mechanism 1, the shaping mechanism 3 is fixed on the front of the wire fixing mechanism 1 by sleeving the lock ring 21 on the lock catch 10. After the knob quick lock lock rod 17 of the presser 2 penetrates into the knob quick lock lock cylinder 8 of the shaping mechanism 1, the presser 2 is fixed on the upper part of the wire fixing mechanism 1 by rotating the knob quick lock lock cylinder 8.

[0040] As shown in Figure 2 and Figure 3 , the wire fixing mechanism 1 comprises a bottom plate 4, a buckle one 5, a buckle two 6, a positioning block 7, a knob quick lock lock cylinder 8, a connecting block 9, a lock catch 10, two vertical mushroom buckles 11, a horizontal mushroom buckle 12, a handle 13, a magic tape 14, and a hanging buckle 15; wherein a plurality of recesses are arranged on the upper surface of the bottom plate 4 in a rectangular array manner; the buckle one 5 and the buckle two 6 are structural members with U-shaped clamping grooves, and the positioning block 7 is a structural member with a V-shaped clamping groove; the buckle one 5, the buckle two 6, and the positioning block 7 constitute a cable clamp positioning combined unit arranged in each recess; wherein the buckle one 5, the buckle two 6, and the positioning block 7 are connected and fixed with the bottom plate 4 from top to bottom in the recess of the bottom plate 4 by screws.

[0041] The knob quick lock lock cylinder 8 is arranged at the front of the bottom plate 4; the connecting blocks 9 are fixed at the front of the left and right sides of the bottom plate 4, and the handles 13 are fixed at the middle of the left and right sides of the bottom plate 4; the lock buckles 10 are fixed at the side of the connecting blocks 9; one vertical mushroom buckle 11 is pasted at the left edge of the upper part of the bottom plate 4, and the other vertical mushroom buckle 11 is pasted at the right edge of the upper part of the bottom plate 4; one end of the horizontal mushroom buckle 12 is overlapped with the middle part of one vertical mushroom buckle 11, and the other end of the horizontal mushroom buckle 12 is overlapped with the middle part of the other vertical mushroom buckle 11; the magic tapes 14 are arrayed and pasted on the upper surface of the rear part of the bottom plate 4, and the magic tapes 14 correspond to the buckles 5 one by one in the length direction of the bottom plate 4; the hanging buckles 15 are arranged on the lower surface of the bottom plate 4. The horizontal mushroom buckle 12 is perpendicular to the vertical mushroom buckle 11; one end of the horizontal mushroom buckle 12 is overlapped with the middle part of one vertical mushroom buckle 11 by the mushroom head embedding mode, and the other end of the horizontal mushroom buckle 12 is overlapped with the middle part of the other vertical mushroom buckle 11 by the mushroom head embedding mode.

[0042] The wire fixing mechanism 1 comprises a bottom plate 4, buckles 5, buckles 6, positioning blocks 7, a knob quick lock lock cylinder 8, connecting blocks 9, lock buckles 10, vertical mushroom buckles 11, horizontal mushroom buckles 12, handles 13, magic tapes 14 and hanging buckles 15; the bottom plate 4 is a rectangular thin plate structure, and grooves are arranged on the upper part of the bottom plate 4 in a rectangular array mode according to the length and width directions of the bottom plate 4; the buckles 5, the buckles 6 and the positioning blocks 7 are respectively matched with the grooves on the upper part of the bottom plate 4 to realize positioning, and the positioning blocks 7 are located on the upper part of the buckles 6 and are fixed by the buckles 5 and the positioning blocks 7 through screws; the front of the upper part of the bottom plate 4 is provided with a groove, the knob quick lock lock cylinder 8 is positioned by being matched with the groove on the front of the upper part of the bottom plate 4 and is locked by a screw; the connecting blocks 9 and the handles 13 are respectively fixed in the middle and front of the left and right sides of the bottom plate 4 by screws, and the lock buckles 10 are fixed on the side of the connecting blocks 9 by screws; the vertical mushroom buckles 11 are pasted on the left and right edges of the upper part of the bottom plate 4, and the horizontal mushroom buckles 12 are vertically overlapped on the vertical mushroom buckles 11 by the mushroom head embedding mode; the magic tapes 14 are arrayed and pasted on the rear edge of the upper part of the bottom plate 4, and the magic tapes 14 correspond to the buckles 5 one by one in the length direction of the bottom plate 4; the hanging buckles 15 are fixed on the lower part of the bottom plate 4 in a rectangular array mode according to the length and width directions of the bottom plate 4 by screws.

[0043] As shown in Figure 4 The presser 2 comprises a pressing plate 16, a knob quick lock lock rod 17 and a pressing block 18; the pressing plate 16 is provided with a plurality of second grooves in an array mode in the length direction; the pressing block 18 is arranged in the second groove and is positioned by being matched with the second groove; the knob quick lock lock rod 17 is arranged on the pressing plate 16, penetrates into the knob quick lock lock cylinder 8 of the shaping mechanism, and fixes the presser 2 on the upper part of the wire fixing mechanism 1 by rotating the knob quick lock lock cylinder 8.

[0044] The pressure plate 16 is a rectangular thin plate structure. Based on the length direction of the pressure plate 16, grooves are set on the upper part of the pressure plate 16 in an array. The pressure block 18 is positioned by cooperating with the grooves on the upper part of the pressure plate 16 and is locked by screws. The pressure plate 16 is set with grooves on the upper part. The knob quick lock rod 17 is positioned by cooperating with the grooves on the upper part of the pressure plate 16 and is locked by screws.

[0045] like Figure 5 As shown, the shaping mechanism 3 includes a shaping block 19, two positioning pins 20, and two locking rings 21; wherein, one positioning pin 20 is located on one side of the upper part of the shaping block 19, and the other positioning pin 20 is located on the other side of the upper part of the shaping block 19; one locking ring 21 is located at one end of the shaping block 19, and the other locking ring 21 is located at the other end of the shaping block 19; the upper part of the shaping block 19 has multiple shaping holes arranged in an array along its length; the positioning pins 20 are embedded in the pin holes of the connecting block 9, and the locking rings 21 are sleeved on the latch 10 to connect the shaping mechanism 3 to the wire fixing mechanism 1.

[0046] The shaping block 19 has a square strip structure. Pin holes are provided at the upper left and right ends of the shaping block 19. Shaping holes are arranged in an array on the upper part of the shaping block 19 with the length direction of the shaping block 19 as the reference. The positioning pin 20 is fixed by transition fit with the pin hole on the upper part of the shaping block 19. The locking ring 21 is fixed to the left and right sides of the shaping block 19 by screws.

[0047] like Figure 11 As shown, the shaping holes are distributed in groups, and each group of shaping holes consists of two stepped holes that are equidistantly distributed. Each stepped hole includes a rounded opening 24, a guide cone surface 1 25, a hole 1 26, a transition cone surface 27, and a hole 28. The rounded opening 24, the guide cone surface 1 25, the hole 1 26, the transition cone surface 27, and the hole 28 are connected in sequence.

[0048] This embodiment also provides a method for clamping and shaping a plugged two-core cable using a plugged two-core cable clamping and core wire shaping device, including:

[0049] The cable fixing mechanism 1 is fixed by the hook 15;

[0050] Insert the positioning pin 20 of the shaping mechanism 3 into the pin hole of the connecting block 9 of the wire fixing mechanism 1, pull up the locking ring 21 and put it on the locking buckle 10 to fix the shaping mechanism 3 on the wire fixing mechanism 1.

[0051] The outer conductor portion of the plugged two-core cable 22 is coiled into a loop, ensuring that the outer conductor at the connection core part is left with a preset length after coiling.

[0052] Hang the looped portion of the plugged double-core cable 22 onto the Velcro 14 and lock it in place. Pull the reserved connecting core of the plugged double-core cable 22 and insert it into the first clip 5 and the second clip 6 in sequence. Then insert the core of the plugged double-core cable 22 into the shaping hole of the shaping mechanism 3 and hold it for a preset time. This step needs to be repeated multiple times until all channels are clamped with the plugged double-core cable 22.

[0053] Press the outer conductor of the plugged two-core cable 22 with the horizontal mushroom buckle 12, and then insert both ends of the outer conductor into the vertical mushroom buckle 11 for fixation;

[0054] Insert the knob quick-lock lever 17 into the knob quick-lock cylinder 8, and rotate the knob quick-lock lever 17 to lock the clamping device 2 onto the wire fixing mechanism 1;

[0055] Remove the locking ring 21 from the latch 10, and then remove the shaping mechanism 3 from the wire fixing mechanism 1.

[0056] Specifically, the method includes the following steps:

[0057] 1) such as Figure 1 , Figure 3 Using the hook 15 as the positioning structure, the wire fixing mechanism 1 is fixed by the pressure fixing mechanism 1 behind it;

[0058] 2) such as Figure 1 , Figure 2 , Figure 5 Insert the positioning pin 20 of the shaping mechanism 3 into the pin hole of the connecting block 9 of the wire fixing mechanism 1. After the assembly is in place, pull up the locking ring 21 and put it on the locking buckle 10 to fix the shaping mechanism 3 on the wire fixing mechanism 1.

[0059] 3) such as Figure 6 The outer conductor of the plugged two-core cable 22 is coiled into a loop, ensuring that a certain length of the outer conductor is left at the connection point of the core wire after coiling.

[0060] 4) such as Figure 1 , Figure 2 , Figure 7 Hang the looped part of the plugged double-core cable 22 on the Velcro 14 and lock it. Pull the reserved connecting core part of the plugged double-core cable 22 and insert it into the buckle 5 and buckle 6 in sequence. Then insert the core of the plugged double-core cable 22 into the shaping hole of the shaping mechanism 3 with a certain force and hold it for a period of time.

[0061] 5) such as Figure 1 , Figure 2 , Figure 7 Repeat step 4) multiple times until all channels are clamped with plugged two-core cables 22;

[0062] 6) such as Figure 1 ,Figure 2 , Figure 7 Press the horizontal mushroom-shaped latch 12 against the outer conductor of the clamped double-core cable 22 with plug, and then insert both ends of it into the vertical mushroom-shaped latch 11 for fixation;

[0063] 7) such as Figure 1 , Figure 2 , Figure 8 Insert the knob quick lock lever 17 into the knob quick lock cylinder 8, and rotate the knob quick lock lever 17 to lock the clamp 2 onto the wire fixing mechanism 1;

[0064] 8) such as Figure 1 , Figure 2 , Figure 9 Remove the locking ring 21 from the latch 10, and then remove the shaping mechanism 3 from the wire fixing mechanism 1.

[0065] A method for clamping and shaping a plugged double-core cable using the above-mentioned device, wherein in steps 4), 5), 6), and 7), the pressure and holding time of inserting the plugged double-core cable 22 into the shaping hole of the shaping block 19 are used to control the consistency of the core wire shaping size, and the plugged double-core cable 22 is clamped and fixed while the core wire is shaped.

[0066] Taking a certain type of plugged two-core cable (total cable length 1500±10mm, lap pin spacing d=4.24±0.05mm, core wire diameter d2=0.59mm~0.74mm, core wire length L=3mm~3.5mm, inner conductor diameter d3=1.1±0.05mm, total length of inner conductor and core wire L1=8mm~8.6mm) as an example, the specific steps of a method for clamping and shaping the core wires of a plugged two-core cable are as follows:

[0067] 1) Determine the main parameters of the shaping hole (e.g.) Figure 10 , Figure 11 (as shown);

[0068] a) Determine the hole spacing d4: The hole spacing is equal to the sum of the electrode spacing and the shaping rebound amount. Through experiments, under the condition of inserting and shaping with a pressure of about 10N and a pressure holding time of 3s, the shaping rebound amount is about 0.35mm. According to the electrode spacing d = 4.24±0.05mm, the hole spacing d4 is taken as 4.59±0.05mm.

[0069] b) Determine the diameter d5 of hole one: Hole one is the core wire shaping hole, and its diameter should be greater than the maximum value of the core wire diameter d2. Since the core wire diameter d2 = 0.59mm to 0.74mm, d5 should be greater than 0.74mm. Considering that the gap is too large and will affect the shaping effect, the core wire shaping hole diameter d5 is taken as 0.8mm to 0.85mm.

[0070] c) Determine the hole depth L2: The core wire shaping hole depth should be greater than the maximum value of the total length L1 of the inner conductor and the core wire. Since the total length L1 of the inner conductor and the core wire is 8mm to 8.6mm, L2 should be greater than 8.6mm. In order to reduce the difficulty of deep hole processing, the core wire shaping hole depth L2 is taken as 9mm to 9.5mm here.

[0071] d) Determine the diameter d6 of hole 2: Hole 2 is the shaping hole for the inner conductor. Its diameter should be greater than the maximum value of the inner conductor diameter d3. Since the inner conductor diameter d3 = 1.1 ± 0.05 mm, d6 should be greater than 1.15 mm. Considering that an excessively large gap will affect the shaping effect, the inner conductor shaping hole diameter d6 is taken as 1.2 mm to 1.3 mm.

[0072] e) Determine the depth L3 of hole 2: The depth L3 of the inner conductor shaping hole should be greater than the maximum value of the inner conductor and core wire length. From the total length L1 of the inner conductor and core wire = 8mm~8.6mm and the core wire length L = 3mm~3.5mm, we know that L3 should be greater than 5.6mm. In order to ensure the shaping length of the core wire as much as possible, the depth L3 of the inner conductor shaping hole is taken as 6mm here.

[0073] f) Determine the depth L4 of the guide cone: When the two cable cores are sent into the shaping hole, they are bifurcated and guided by the guide cone. In order to ensure the shaping length of the inner conductor as much as possible, its depth should not exceed 1 / 2 of the inner conductor shaping hole depth L3. Since the inner conductor shaping hole depth L3 is 6mm, L4 should not be greater than 3mm. Here, the depth L4 of the guide cone is 3mm.

[0074] g) Determine the angle α of the guide cone surface: To ensure that the guide cone surfaces of two adjacent shaping holes do not interfere with each other, α should be less than 2arctan(d4 / 2L4-d6 / 2L4). From d4=4.59±0.05mm, d6=1.2mm~1.3mm, and L4=3mm, we know that α should be greater than 0° and less than 58°. Here, the angle α of the guide cone surface is taken as 25°.

[0075] h) Determine the radius R of the rounded hole: To ensure that the rounded holes of two adjacent shaping holes do not interfere with each other, R should be less than (d4 / 2-d6 / 2-L4tan(α / 2))tan(π / 4+α / 4). From d4=4.59±0.05mm, d6=1.2mm~1.3mm, L4=3mm, and α is taken as 25°, we know that R should be less than 1.25mm. On the other hand, the larger the radius R of the rounded hole, the better the bending and shaping effect of the inner wire. Here, the radius R of the rounded hole is taken as 1.1mm~1.2mm.

[0076] 2) such as Figure 1 , Figure 3 Using the hook 15 as the positioning structure, the wire fixing mechanism 1 is fixed by the pressure fixing mechanism 1 behind it;

[0077] 3) such asFigure 1 , Figure 2 , Figure 5 Insert the positioning pin 20 of the shaping mechanism 3 into the pin hole of the connecting block 9 of the wire fixing mechanism 1. After the assembly is in place, pull up the locking ring 21 and put it on the locking buckle 10 to fix the shaping mechanism 3 on the wire fixing mechanism 1.

[0078] 4) such as Figure 6 The outer conductor of the plugged two-core cable 22 is coiled into a loop, ensuring that 100mm of the outer conductor is left at the connection point of the core wire after coiling.

[0079] 5) such as Figure 1 , Figure 2 , Figure 7 Hang the looped part of the plugged double-core cable 22 on the Velcro 14 and lock it. Pull the reserved connecting core part of the plugged double-core cable 22 and insert it into the buckle 1 5 and buckle 2 6 in sequence. Then insert the core of the plugged double-core cable 22 into the shaping hole of the shaping mechanism 3 with a force of about 10N and hold it for 3s.

[0080] 6) such as Figure 1 , Figure 2 , Figure 7 Repeat sequence 4) 10 times until all channels are clamped with plugged two-core cables 22;

[0081] 7) such as Figure 1 , Figure 2 , Figure 7 Press the horizontal mushroom-shaped latch 12 against the outer conductor of the clamped double-core cable 22 with plug, and then insert both ends of it into the vertical mushroom-shaped latch 11 for fixation;

[0082] 8) such as Figure 1 , Figure 2 , Figure 8 Insert the knob quick lock lever 17 into the knob quick lock cylinder 8, and rotate the knob quick lock lever 17 to lock the clamp 2 onto the wire fixing mechanism 1;

[0083] 9) such as Figure 1 , Figure 2 , Figure 9 Remove the locking ring 21 from the latch 10, and then remove the shaping mechanism 3 from the wire fixing mechanism 1.

[0084] The plugged two-core cable in this embodiment uses pressure and holding time to control the shaping quality, which improves the consistency of the shaped structure and size of the plugged two-core cable and solves the problem of difficult consistency control in the shaping of plugged two-core cables. The plugged two-core cable in this embodiment adopts an integrated clamping and shaping operation, which avoids the introduction of secondary clamping and positioning errors, improves the clamping and positioning accuracy, reduces manual operation costs, and improves efficiency.

[0085] Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make possible changes and modifications to the technical solutions of the present invention by utilizing the methods and techniques disclosed above without departing from the spirit and scope of the present invention. Therefore, any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the content of the technical solutions of the present invention shall fall within the protection scope of the technical solutions of the present invention.

Claims

1. A device for clamping and shaping a two-core cable with a plug, characterized in that... include: The wire fixing mechanism (1), the clamping device (2), and the shaping mechanism (3) are included; among them, The shaping mechanism (3) is connected to the bottom of the wire fixing mechanism (1); The clamping device (2) is located on the upper part of the wire fixing mechanism (1).

2. The device for clamping and shaping a two-core cable with a plug according to claim 1, characterized in that: The wire-fixing mechanism (1) includes a base plate (4), a first buckle (5), a second buckle (6), a positioning block (7), a rotary quick-lock cylinder (8), a connecting block (9), a latch (10), two vertical mushroom-shaped hooks (11), a horizontal mushroom-shaped hook (12), a handle (13), Velcro (14), and a hook (15); among which, The base plate (4) is provided with multiple grooves in a rectangular array; The first buckle (5), the second buckle (6), and the positioning block (7) form a cable clamping and positioning assembly unit, which is set in each groove; wherein, the first buckle (5), the second buckle (6), and the positioning block (7) are connected and fixed to the base plate (4) from top to bottom in the groove by screws. The knob quick-lock cylinder (8) is located at the front of the base plate (4); The connecting block (9) is fixed to the front part of both sides of the base plate (4), and the handle (13) is fixed to the middle part of both sides of the base plate (4); The latch (10) is fixed to the side of the connecting block (9); A vertical mushroom hook (11) is attached to the left edge of the upper part of the base plate (4), and another vertical mushroom hook (11) is attached to the right edge of the upper part of the base plate (4). One end of the horizontal mushroom hook (12) overlaps with the middle of the vertical mushroom hook (11), and the other end of the horizontal mushroom hook (12) overlaps with the middle of the other vertical mushroom hook (11). The array of hook and loop fasteners (14) is attached to the upper surface of the rear part of the base plate (4), and the hook and loop fasteners (14) are aligned with the buckles (5) one by one in the length direction of the base plate (4); The hook (15) is disposed on the lower surface of the base plate (4).

3. The device for clamping and shaping a two-core cable with a plug according to claim 1 or 2, characterized in that: The clamping device (2) includes a pressure plate (16), a knob quick-lock lever (17), and a pressure block (18); wherein, The pressure plate (16) has a plurality of second grooves arranged in an array along its length; The pressure block (18) is disposed in the second groove, and the pressure block cooperates with the second groove to achieve positioning; The knob quick-lock lever (17) is mounted on the pressure plate (16). After the knob quick-lock lever (17) passes through the knob quick-lock cylinder (8) of the shaping mechanism, the clamping device (2) is fixed to the upper part of the wire fixing mechanism (1) by rotating the knob quick-lock cylinder (8).

4. The device for clamping and shaping a two-core cable with a plug according to claim 2, characterized in that: The shaping mechanism (3) includes a shaping block (19), two positioning pins (20), and two locking rings (21); wherein, One positioning pin (20) is provided on one side of the upper part of the shaping block (19), and another positioning pin (20) is provided on the other side of the upper part of the shaping block (19); One locking ring (21) is disposed at one end of the shaping block (19), and the other locking ring (21) is disposed at the other end of the shaping block (19); The upper part of the shaping block (19) has multiple shaping holes arranged in an array along its length. The positioning pin (20) is embedded in the pin hole of the connecting block (9), and the locking ring (21) is sleeved on the buckle (10) to connect the shaping mechanism (3) and the fixing mechanism (1).

5. The device for clamping and shaping a two-core cable with a plug according to claim 4, characterized in that: The shaping holes are distributed in groups. Each group of shaping holes consists of two stepped holes that are equidistantly distributed. Each stepped hole includes a rounded opening (24), a guide cone surface one (25), a hole one (26), a transition cone surface two (27), and a hole two (28). The rounded opening (24), the guide cone surface one (25), the hole one (26), the transition cone surface two (27), and the hole two (28) are connected in sequence.

6. The device for clamping and shaping a two-core cable with a plug according to claim 1, characterized in that: The wire fixing mechanism (1) is a rectangular thin plate structure.

7. The device for clamping and shaping a two-core cable with a plug according to claim 2, characterized in that: The base plate (4) is a rectangular thin plate structure.

8. The device for clamping and shaping a two-core cable with a plug according to claim 2, characterized in that: The horizontal mushroom-shaped buckle (12) is perpendicular to the vertical mushroom-shaped buckle (11); One end of the horizontal mushroom buckle (12) is connected to the middle of a vertical mushroom buckle (11) by a mushroom head embedding method, and the other end of the horizontal mushroom buckle (12) is connected to the middle of another vertical mushroom buckle (11) by a mushroom head embedding method.

9. The device for clamping and shaping a two-core cable with a plug according to claim 3, characterized in that: The pressure plate (16) is a rectangular thin plate structure.

10. A method for clamping and shaping a plugged two-core cable using the clamping and core wire shaping device according to any one of claims 1-9, characterized in that... include: The wire fixing mechanism (1) is fixed by hook (15); Insert the positioning pin (20) of the shaping mechanism (3) into the pin hole of the connecting block (9) of the wire fixing mechanism (1), pull up the locking ring (21) and put it on the lock buckle (10) to fix the shaping mechanism (3) on the wire fixing mechanism (1); The outer conductor portion of the plugged two-core cable (22) is coiled into a loop, and after coiling, the outer conductor portion of the connecting core wire is left with a preset length. Hang the looped part of the plugged double-core cable (22) coiled into a ring on the Velcro (14) and lock it. Pull the reserved connecting core part of the plugged double-core cable (22) and insert it into the first buckle (5) and the second buckle (6) in sequence. Then insert the core of the plugged double-core cable (22) into the shaping hole of the shaping mechanism (3) and hold it for a preset time. Press the outer conductor of the clamped plug-in dual-core cable (22) with the horizontal mushroom buckle (12) pressed down, and then insert both ends of the outer conductor into the vertical mushroom buckle (11) for fixation; Insert the knob quick lock lever (17) into the knob quick lock cylinder (8), and rotate the knob quick lock lever (17) to lock the clamp (2) onto the wire fixing mechanism (1); Remove the locking ring (21) from the latch (10), and then remove the shaping mechanism (3) from the wire fixing mechanism (1).

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