A pressure-resistant electrical penetration component assembly for deep-water environments and its manufacturing method.

Abstract

This invention discloses an underwater equipment sealing and electrical connection technology, aiming to provide a pressure-resistant electrical penetration component assembly for deep-water environments and its manufacturing method. The key technical points include a penetration component housing, an electrical sealing unit disposed within the penetration component housing, and an integrated locking component connected to the penetration component housing for locking. The penetration component housing is a thick-walled flange structure with a central through hole. Radial grooves and end face grooves are formed on its mounting surface to the tank wall. Rectangular cross-section metal O-rings or high-performance rubber O-rings are disposed within the radial and end face grooves. The central through hole of the penetration component housing has an internal thread at the front and a stepped structure adapted to several electrical sealing units at the rear. The tail of the penetration component housing has an external thread. The electrical sealing unit includes a first sealing part and a second sealing part. This invention is applicable to the field of underwater equipment sealing and electrical connection technology.

Description

Technical Field

[0001] This invention relates to underwater equipment sealing and electrical connection technology, and more specifically, to a pressure-resistant electrical penetration component assembly for deep-water environments and its manufacturing method. Background Technology

[0002] With the development of technologies such as deep-sea exploration, underwater robots, and seabed observation networks, the application of electrical equipment in deep-water environments is increasing. These devices need to introduce power and signals from outside the pressure chamber into the chamber through transom components. The core challenge lies in coping with the extremely high hydrostatic pressure brought by deep water and ensuring long-term, absolute sealing reliability.

[0003] Common deep-water electrical penetration solutions in existing technologies mainly include:

[0004] 1. Integral welding / brazing: The metal sheath of one or more wires is directly welded to the metal cover of the bulkhead. This method is reliable in sealing, but has a fatal flaw: once a single wire is damaged, the entire through-buoy must be scrapped, cannot be repaired or replaced, and the maintenance cost is extremely high.

[0005] 2. Integral epoxy potting: Epoxy resin is injected into the casing of the transom to fix and seal the cables; however, this method suffers from problems under deep-water and high-pressure conditions.

[0006] Material compatibility issues: The coefficients of thermal expansion of epoxy resin, cable insulation layer and metal shell are different. Under temperature cycling and pressure cycling, micro-cracks are easily generated at the interface, forming leakage channels.

[0007] The "water tree" phenomenon: Under long-term high voltage, moisture can penetrate into epoxy resin or cable insulation layer through micro-gap along the direction of electric field, forming dendritic conductive channels, which eventually leads to insulation breakdown.

[0008] Non-maintainability: Similar to welded types, any single point of failure requires the entire unit to be replaced.

[0009] Therefore, there is an urgent need for an electrical transshipment component that can withstand the extremely high pressure in deep water and has modular and independently maintainable characteristics. Summary of the Invention

[0010] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a pressure-resistant electrical penetration component assembly for deep-water environments and its manufacturing method.

[0011] To achieve the above objectives, the present invention provides the following technical solution: a pressure-resistant electrical penetration component assembly for deep-water environments, comprising a penetration component housing, an electrical sealing unit disposed within the penetration component housing, and an integrated locking component connected to the penetration component housing for locking;

[0012] The through-hole housing is a thick-walled flange structure with a central through hole. Radial grooves and end face grooves are provided on the mounting surface of the through-hole housing and the mounting surface of the through-hole housing. A rectangular cross-section metal O-ring or a high-performance rubber O-ring is provided in the radial grooves and the end face grooves. The front part of the central through hole of the through-hole housing is provided with an internal thread, and the rear part is provided with a stepped structure adapted to several electrical sealing units. The tail part of the through-hole housing is provided with an external thread.

[0013] The electrical sealing unit includes a first sealing part and a second sealing part. The first sealing part includes a metal spindle with a through hole in the center for a cable to pass through. A flat washer, a rubber washer, another flat washer, and a locking ring are sequentially fitted onto the metal spindle. The locking ring is fixed to the metal spindle and has a locking groove. The second sealing part includes a metal spindle with a through hole in the center for a cable to pass through. A fastening ring is fixedly fitted onto the metal spindle. The fastening ring has a locking protrusion that matches the locking groove. A plurality of flat washers and rubber washers arranged at intervals are also fitted onto the metal spindle.

[0014] The integrated locking component includes a conical ring tail clamp that is fixedly connected to the outer thread of the through-hull housing for fixing and locking the electrical sealing unit. A pressure ring is provided between the through-hull housing and the conical ring tail clamp. The tail of the conical ring tail clamp is also provided with an outer thread. A three-lobed conical ring for clamping the cable is placed inside the conical ring tail clamp. The tail of the conical ring tail clamp is provided with a tail clamp that is fixedly connected to the outer thread for further fixing and locking the electrical sealing unit. The integrated locking component also includes a vulcanized bag covering the connection between the through-hull housing and the integrated locking component.

[0015] When the integrated locking component is tightened, the pressure pressing the electrical sealing unit generates an axial thrust, which causes the flat washer and rubber gasket to undergo axial compression and radial expansion within the through hole of the housing of the through-hole component.

[0016] The present invention is further configured such that: the first metal mandrel and the second metal mandrel are pressure self-tightening conical surfaces, and the taper of the pressure self-tightening conical surface is 1:8-1:12.

[0017] The present invention is further configured such that the ratio of the thickness of the thick-walled flange structure of the through-hole shell to the diameter of the central through hole is 2:1-3:1.

[0018] A method for manufacturing a pressure-resistant electrical penetration component assembly for deep-water environments, characterized by comprising the following steps:

[0019] S1. Component Preparation and Initial Structural Proportion Inspection: Prepare the through-hull shell, electrical sealing unit components, integrated locking components, rectangular cross-section sealing O-rings, and vulcanized packaging material; check the ratio K of the through-hull shell's thick-walled flange thickness to the central through-hole diameter. The preset ratio thresholds are K1=2:1 and K2=3:1. If K1≤K≤K2, the pressure-resistant structure of the through-hull shell is deemed to meet the requirements, and proceed to S2; if K<K1 or K>K2, return to the component preparation stage to adjust the wall thickness or through-hole diameter of the through-hull shell until the ratio K satisfies K1≤K≤K2.

[0020] S2: Shell Groove Machining and O-ring Installation Inspection: Machin radial and end face grooves on the mounting surfaces of the through-hull shell and bulkhead. After cleaning impurities and burrs from the grooves, embed the O-rings into the grooves. Detect the O-ring's installation compression C. The preset compression threshold C0 is 80%-120% of the O-ring's rated compression. If C is within the range of C0, the O-ring installation is considered qualified, and proceed to S3. If C < C0, adjust the O-ring's installation position or replace it with a compatible O-ring and retest. If C > C0, remove the O-ring, clean the groove surface, and reinstall it until the compression C meets C0.

[0021] S3: Assembly of the first sealing part and detection of the conical surface parameters: A flat washer, a rubber washer, and another flat washer are sequentially interference-fitted onto the metal mandrel, and then a locking ring is fixedly fitted onto the metal mandrel; the taper T1 of the pressure self-tightening conical surface of the metal mandrel is detected, with preset taper thresholds T1a=1:8 and T1b=1:12. If T1a≤T1≤T1b, the conical surface of the metal mandrel is determined to meet the pressure self-tightening requirements, and the assembly of the first sealing part is completed, proceeding to S4; if T1<T1a or T1>T1b, the metal mandrel is replaced or the conical surface is re-machined until the taper T1 satisfies T1a≤T1≤T1b;

[0022] S4: Assembly of the second sealing part and detection of the conical surface parameters: First, a fastening ring is fixedly sleeved on the metal mandrel two, and then several flat washers and rubber washers arranged at intervals are sequentially interference-fitted; the taper T2 of the pressure self-tightening conical surface of the metal mandrel two is detected. The preset taper thresholds are T2a=1:8 and T2b=1:12. If T2a≤T2≤T2b, it is determined that the conical surface of the metal mandrel two meets the pressure self-tightening requirements, and the assembly of the second sealing part is completed, proceeding to S5; if T2<T2a or T2>T2b, the metal mandrel two is replaced or the conical surface is re-machined until the taper T2 satisfies T2a≤T2≤T2b;

[0023] S5: Sealing Part Insertion and Docking Gap Inspection: Insert the first sealing part into the stepped structure inside the housing from the tail end of the housing according to the design direction, so that the locking ring faces the tail end of the housing; then insert the second sealing part from the tail end of the housing according to the design direction, so that the locking protrusion of the fastening ring aligns with the locking groove of the fastening ring; then inspect the mating gap G after docking, with a preset gap threshold G0≤0.1mm. If G≤G0, the docking and locking are deemed qualified, and proceed to S6; if G>G0, adjust the placement angle of the second sealing part and re-inspect; if G is still>G0 after multiple adjustments, replace the locking ring or fastening ring, re-dock, and inspect the gap until G≤G0;

[0024] S6: Installation and Fit Test of Conical Ring Tail Clamp: Place the pressure ring inside the conical ring tail clamp and screw the conical ring tail clamp into the external thread at the tail of the through-hole component housing to fix it; test the fit S between the conical ring tail clamp and the through-hole component housing. The preset fit threshold is S0≥95%. If S≥S0, the connection fit is deemed qualified and proceed to S7; if S<S0, loosen the conical ring tail clamp and adjust the position of the pressure ring, tighten it again and test the fit S until S≥S0; if S is still <S0 after adjusting the pressure ring, replace the pressure ring and reinstall and test.

[0025] S7: Cable insertion: Place a three-lobed conical ring inside the tail of the conical ring clamp, insert the cable through the three-lobed conical ring until the cable exits from the other end of the housing.

[0026] S8: Tail clip installation and locking force test: Insert the cable from the rear of the self-penetrating compartment housing into the tail clip and screw it into the external thread at the tail of the cone ring tail clip; test the locking force F of the tail clip on the three-lobed cone ring. The preset locking force threshold F0 is 90%-110% of the rated locking force of the three-lobed cone ring. If F is within the range of F0, the locking is deemed qualified and proceed to S9; if F < F0, tighten the tail clip until F reaches the range of F0; if F > F0, loosen the tail clip and finely adjust the position of the three-lobed cone ring, tighten it again and test the locking force F until F meets the range of F0.

[0027] S9: Vulcanized Packing and Bonding Strength Test: Vulcanized packing material is applied to the connection between the through-cabin shell and the integrated locking component, and vulcanization is performed. The bonding strength B between the vulcanized packing and the connector is tested. The preset bonding strength threshold B0 ≥ 5MPa is set. If B ≥ B0, the vulcanized packing is deemed qualified, and the manufacturing of the pressure-resistant electrical through-cabin component is completed. If B < B0, the residual material at the connection is cleaned, the vulcanized packing material is reapplied, and vulcanization is performed until the bonding strength B ≥ B0.

[0028] The present invention is further configured as follows: In step S3, when detecting the taper T1 of the pressure self-tightening conical surface of the metal mandrel, the temperature detection module is simultaneously activated to collect the real-time temperature t1 of the metal mandrel after processing, with a preset temperature threshold t10≤50℃; if t1≤t10 and T1a≤T1≤T1b, the conical surface and thermal state of the metal mandrel are deemed to meet the requirements; if t1>t10, the metal mandrel is allowed to cool to t1≤t10, and the taper T1 is detected again; if T1a≤T1≤T1b after cooling, it is deemed to be qualified; if T1 after cooling still does not meet the requirement of T1a≤T1≤T1b, the conical surface is reprocessed and the above temperature monitoring and taper detection steps are repeated.

[0029] In step S4, when detecting the taper T2 of the pressure self-tightening conical surface of the metal mandrel two, the surface roughness detection module is simultaneously activated to collect the surface roughness Ra of the conical surface of the metal mandrel two, with a preset roughness threshold Ra0≤1.6μm; if Ra≤Ra0 and T2a≤T2≤T2b, then the conical surface and surface condition of the metal mandrel two are determined to meet the requirements; if Ra>Ra0, then the conical surface of the metal mandrel two is subjected to fine grinding treatment, and Ra and T2 are re-detected after grinding until Ra≤Ra0 and T2 satisfies T2a≤T2≤T2b.

[0030] The present invention is further configured as follows: during the vulcanization process in S9, the vulcanization parameter control module is activated, and the vulcanization temperature range T0 = 120-150℃ and the vulcanization time t0 = 30-60min are preset; firstly, the vulcanization temperature T is adjusted to T∈T0, and vulcanization is carried out at this temperature for a duration t∈t0; during the vulcanization process, the real-time temperature Tactual and real-time shrinkage rate Ractual of the vulcanization package are continuously monitored, and the preset fluctuation threshold ΔT ≤ ±5℃ and shrinkage rate threshold R0 = 2%-5% are set.

[0031] If the actual value (Tactual) remains within T0±ΔT and the actual value (Ractual) ∈ R0 during the vulcanization process, the bond strength (B) can be directly tested after vulcanization is completed.

[0032] If Tactual exceeds T0±ΔT, adjust the heating power to bring Tactual back to the T0 range, and extend the vulcanization time by Δt = the duration of temperature exceedance × 1.2. Continue monitoring after Tactual returns to normal.

[0033] If Ractual < R0, then increase the vulcanization temperature at a rate of 0.5℃ / min until Ractual ∈ R0; if Ractual > R0, then decrease the vulcanization temperature at a rate of 0.5℃ / min until Ractual ∈ R0.

[0034] After completing the above parameter adjustments, continue with the remaining vulcanization time. After vulcanization, check whether the bond strength B is ≥ B0. If not, repeat S9.

[0035] The beneficial effects of this invention are:

[0036] 1. Compared to existing technologies, the pressure-resistant electrical penetration assembly for deep-water environments of this invention achieves multiple seals and reliable locking through an integrated structural design, adapting to high-pressure deep-water environments. The thick-walled flange structure and double-groove sealing design of the penetration assembly shell, combined with O-rings, significantly improve radial and end-face sealing performance, preventing deep-water leakage. The stepped through-holes can accurately position the electrical sealing unit, ensuring installation stability. The electrical sealing unit adopts a combination structure of bimetallic mandrel with flat washers and rubber washers, forming a double sealing barrier through locking grooves and locking protrusions. The interference fit design enhances the overall structural integrity. The integrated locking component's conical ring tail clamp, three-lobed conical ring, and tail clamp work together to achieve a firm grip on the cable and axial compression of the sealing unit. The vulcanized coating further strengthens the sealing and corrosion resistance at the connection. When locked, the axial thrust causes the washer to compress axially and expand radially, forming a self-tightening sealing effect, effectively resisting the impact of deep-water high pressure on the penetration assembly, ensuring the safety of electrical cable transmission, and suitable for the electrical penetration requirements of various deep-water operation equipment.

[0037] 2. In the pressure-resistant electrical penetration component assembly for deep-water environments, the first and second metal mandrels of this invention adopt a pressure self-tightening conical surface design of 1:8-1:12, which combines pressure self-tightening effect with installation adaptability. If the taper is <1:12, the inclination angle of the conical surface is too small, making it difficult to generate sufficient radial self-tightening force under deep-water pressure, and the sealing performance improves only slightly with increasing pressure, making leakage easy. If the taper is >1:8, the inclination angle of the conical surface is too large, although it can generate a large self-tightening force, it will lead to excessive clearance between the mandrel and the sealing unit and the housing, making it difficult to accurately position during installation, and structural deformation is prone to occur under high pressure, affecting sealing stability. The taper range of 1:8-1:12 can form optimal pressure transmission under deep-water pressure, making the mandrel, gasket, and housing fit tightly. The higher the pressure, the better the sealing effect, while ensuring accurate docking during installation, avoiding sealing failure caused by fit deviation, and significantly improving the adaptability and reliability of the component under different deep-water pressure scenarios.

[0038] 3. In this invention, the ratio of the thickness of the thick-walled flange of the hull to the diameter of the central through hole is designed to be 2:1-3:1, achieving a balance between pressure resistance and structural lightweight. If the ratio is less than 2:1, the flange thickness is insufficient, and the high pressure in deep water will cause excessive stress concentration in the hull, which is prone to deformation, cracking and other problems, and cannot meet the pressure resistance requirements in deep water. If the ratio is greater than 3:1, the excessive flange thickness will increase the weight of the hull, which will not only increase the difficulty of installation and the load on the equipment, but also cause material waste. Moreover, the excessively thick structure is prone to internal stress due to thermal expansion and contraction, which will affect the fitting accuracy with the hull and sealing unit, and indirectly reduce the sealing performance. The ratio of 2:1-3:1 can ensure that the stress distribution of the hull is uniform when subjected to high pressure in deep water, and has sufficient structural strength to resist pressure impact, while avoiding the disadvantages of excessive thickness. It takes into account both the convenience of installation and the economy of materials, and ensures the structural stability and pressure resistance reliability of the hull in the long-term deep water environment.

[0039] 4. The present invention has a simple and reasonable structure, is easy to manufacture and operate, avoids the defects of the prior art, and is suitable for promotion and application. Attached Figure Description

[0040] Figure 1 This is a structural diagram of the pressure-resistant electrical penetration component assembly for deep-water environments according to the present invention.

[0041] The reference numerals in the figure are as follows: 1. Through-hull shell; 2. Radial groove; 3. End face groove; 4. Internal thread; 5. Metal mandrel one; 6. Flat washer; 7. Rubber washer; 8. Locking ring; 9. Locking groove; 10. Metal mandrel two; 11. Fastening ring; 12. Locking protrusion; 13. Conical ring tail clamp; 14. Pressure ring; 15. Three-lobed conical ring; 16. Tail clamp; 17. Vulcanizing bag. Detailed Implementation

[0042] Reference Figure 1 The embodiments of the pressure-resistant electrical penetration component assembly for deep-water environments and its manufacturing method are further described below.

[0043] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0044] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0045] Figure 1 The pressure-resistant electrical penetration component assembly for deep-water environments shown includes a penetration component housing 1, an electrical sealing unit disposed within the penetration component housing 1, and an integrated locking component connected to the penetration component housing 1 for locking.

[0046] The through-hole housing 1 is a thick-walled flange structure with a central through hole. Radial grooves 2 and end face grooves 3 are provided on its mounting surface with the cabin wall. A rectangular cross-section metal O-ring or a high-performance rubber O-ring is provided in the radial grooves 2 and the end face grooves 3. An internal thread 4 is provided at the front of the central through hole of the through-hole housing 1, and a stepped structure adapted to several electrical sealing units is provided at the rear. An external thread is provided at the tail of the through-hole housing 1.

[0047] The electrical sealing unit includes a first sealing part and a second sealing part. The first sealing part includes a metal mandrel 5 with a through hole in the center for a cable to pass through. A flat washer 6, a rubber washer 7, another flat washer 6, and a locking ring 8 are sequentially fitted onto the metal mandrel 5. The locking ring 8 is fixed to the metal mandrel 5 and has a locking groove 9. The second sealing part includes a metal mandrel 10 with a through hole in the center for a cable to pass through. A fastening ring 11 is fixedly fitted onto the metal mandrel 10. The fastening ring 11 has a locking protrusion 12 that matches the locking groove 9. Several flat washers 6 and rubber washers 7 are also fitted onto the metal mandrel 10 at intervals. The fastening ring 11 is located on the left side of the outer periphery of the metal mandrel 10. The combination of the metal mandrel, the flat washer 6, and the rubber washer 7 can better absorb the energy brought by the pressure cycle and has a long fatigue life.

[0048] The integrated locking component includes a conical ring tail clamp 13 that is fixedly connected to the external thread of the through-hub housing 1 for fixing and locking the electrical sealing unit. A pressure ring 14 is provided between the through-hub housing 1 and the conical ring tail clamp 13. The tail of the conical ring tail clamp 13 is also provided with an external thread 2. A three-lobed conical ring 15 for clamping the cable is placed inside the conical ring tail clamp 13. The tail of the conical ring tail clamp 13 is provided with a tail clamp 16 that is fixedly connected to the external thread 2 for further fixing and locking the electrical sealing unit. The integrated locking component also includes a vulcanized bag 17 covering the connection between the through-hub housing 1 and the integrated locking component.

[0049] When the integrated locking component is locked, the pressure pressing the electrical sealing unit generates an axial thrust, which causes the flat washer 6 and the rubber washer 7 to undergo axial compression and radial expansion within the through hole of the housing 1 of the through-hole component.

[0050] This deep-water pressure-resistant electrical penetration component assembly features an integrated structural design, achieving multiple seals and reliable locking. It is suitable for deep-water, high-pressure environments and offers simple and quick maintenance and replacement, eliminating the need to replace the entire penetration component. The thick-walled flange structure and double-groove sealing design of the penetration component housing 1, combined with O-rings, significantly improve radial and end-face sealing performance, preventing deep-water leakage. The stepped through-holes allow for precise positioning of the electrical sealing unit, ensuring installation stability. The electrical sealing unit employs a combination structure of a bimetallic mandrel, a flat washer 6, and a rubber gasket 7, secured by a locking groove 9 and a locking mechanism. The tight protrusion 12 forms a double sealing barrier, and the interference fit design enhances the overall structural integrity. The integrated locking component, with its conical ring tail clamp 13, three-lobed conical ring 15, and tail clamp 16 working together, achieves a firm grip on the cable and axial compression of the sealing unit. The vulcanized jacket 17 further strengthens the sealing and corrosion resistance of the connection. When locked, the axial thrust causes the gasket to compress axially and expand radially, forming a self-tightening sealing effect. This effectively resists the impact of deep-water high pressure on the penetration components, ensuring the safety of electrical cable transmission. It is suitable for the electrical penetration requirements of various deep-water operation equipment.

[0051] The metal mandrel 5 and the metal mandrel 10 are pressure self-tightening conical surfaces, and the taper of the pressure self-tightening conical surface is 1:8-1:12;

[0052] Metal mandrel 1 (5) and metal mandrel 2 (10) adopt a pressure self-tightening conical surface design of 1:8-1:12, which combines pressure self-tightening effect with installation adaptability. If the taper is <1:12, the inclination angle of the conical surface is too small, and it is difficult to generate sufficient radial self-tightening force under deep water pressure. The sealing performance improves only slightly with increasing pressure, and leakage is likely to occur. If the taper is >1:8, the inclination angle of the conical surface is too large. Although it can generate a large self-tightening force, it will lead to an excessively large clearance between the mandrel and the sealing unit and the housing. It is difficult to accurately position during installation, and structural deformation is likely to occur under high pressure, affecting the sealing stability. The taper range of 1:8-1:12 can form optimal pressure transmission under deep water pressure, so that the mandrel, gasket and housing fit tightly. The higher the pressure, the better the sealing effect. At the same time, it ensures accurate docking during installation, avoids sealing failure caused by misalignment, and significantly improves the adaptability and reliability of the components under different deep water pressure scenarios.

[0053] The ratio of the thickness of the thick-walled flange structure of the through-hole shell 1 to the diameter of the central through hole is 2:1-3:1;

[0054] The design of the thickness of the thick-walled flange of the hull section and the diameter of the central through hole are in a ratio of 2:1 to 3:1 to achieve a balance between pressure resistance and structural lightweighting. If the ratio is less than 2:1, the flange thickness is insufficient, and the high pressure in deep water will cause excessive stress concentration in the hull, which is prone to deformation and cracking, and cannot meet the pressure resistance requirements in deep water. If the ratio is greater than 3:1, the flange thickness is too large, which increases the weight of the hull, not only increasing the difficulty of installation and the load on the equipment, but also causing material waste. In addition, the excessively thick structure is prone to internal stress due to thermal expansion and contraction, which affects the fitting accuracy with the bulkhead and sealing unit, and indirectly reduces the sealing performance. The ratio of 2:1 to 3:1 can ensure that the stress distribution of the hull is uniform when subjected to high pressure in deep water, and has sufficient structural strength to resist pressure impact, while avoiding the disadvantages of excessive thickness. It takes into account the convenience of installation and material economy, and ensures the structural stability and pressure resistance reliability of the hull section in the long-term deep water environment.

[0055] A method for manufacturing a pressure-resistant electrical penetration component assembly for deep-water environments, characterized by comprising the following steps:

[0056] S1. Component Preparation and Initial Structural Proportion Inspection: Prepare the through-hull shell 1, electrical sealing unit components, integrated locking components, rectangular cross-section sealing O-rings, and vulcanizing package 17 material; check the ratio K of the thickness of the thick-walled flange to the diameter of the central through hole of the through-hull shell 1. The preset ratio thresholds are K1=2:1 and K2=3:1. If K1≤K≤K2, the pressure-resistant structure of the through-hull shell 1 is deemed to meet the requirements, and proceed to S2; if K<K1 or K>K2, return to the component preparation stage to adjust the wall thickness or through hole diameter of the through-hull shell 1 until the ratio K satisfies K1≤K≤K2.

[0057] S2: Shell Groove Machining and O-ring Installation Inspection: Machining radial grooves 2 and end face grooves 3 on the mounting surfaces of the through-hull shell 1 and the bulkhead. After cleaning impurities and burrs from the grooves, embed the O-ring into the grooves. Inspect the installation compression amount C of the O-ring. The preset compression threshold C0 is 80%-120% of the rated compression amount of the O-ring. If C is within the range of C0, the O-ring installation is deemed qualified, and proceed to S3. If C < C0, adjust the installation position of the O-ring or replace it with an O-ring of suitable specifications and retest. If C > C0, remove the O-ring, clean the groove surface, and reinstall it until the compression amount C meets C0.

[0058] S3: Assembly of the first sealing part and detection of the conical surface parameters: A flat washer 6, a rubber washer 7, and another flat washer 6 are sequentially interference-fitted onto the metal mandrel 5. Then, a locking ring 8 is fixedly fitted onto the metal mandrel 5. The taper T1 of the pressure self-tightening conical surface of the metal mandrel 5 is detected. Preset taper thresholds T1a = 1:8 and T1b = 1:12. If T1a ≤ T1 ≤ T1b, the conical surface of the metal mandrel 5 is determined to meet the pressure self-tightening requirements, completing the assembly of the first sealing part and proceeding to S4. If T1 < T1a or T1 > T1b, the metal mandrel 5 is replaced or the conical surface is re-machined until the taper T1 satisfies T1a ≤ T1 ≤ T1b.

[0059] S4: Assembly of the second sealing part and detection of the conical surface parameters: First, fix the fastening ring 11 on the metal mandrel 10, and then sequentially insert several spaced flat washers 6 and rubber washers 7 with interference fit; detect the taper T2 of the pressure self-tightening conical surface of the metal mandrel 10, with preset taper thresholds T2a=1:8 and T2b=1:12. If T2a≤T2≤T2b, it is determined that the conical surface of the metal mandrel 10 meets the pressure self-tightening requirements, and the assembly of the second sealing part is completed, proceeding to S5; if T2<T2a or T2>T2b, replace the metal mandrel 10 or re-machine the conical surface until the taper T2 satisfies T2a≤T2≤T2b;

[0060] S5: Sealing Part Insertion and Docking Gap Inspection: Insert the first sealing part into the internal stepped structure of the housing 1 through the design direction, with the locking ring 8 facing the tail of the housing 1; then insert the second sealing part into the housing 1 through the design direction, with the locking protrusion 12 of the fastening ring 11 engaging with the locking groove 9 of the fastening ring 8; then inspect the mating gap G after docking, with a preset gap threshold G0 ≤ 0.1mm. If G ≤ G0, the docking and locking are deemed qualified, and proceed to S6; if G > G0, adjust the placement angle of the second sealing part and re-inspect; if G is still > G0 after multiple adjustments, replace the locking ring 8 or the fastening ring 11, re-dock, and inspect the gap until G ≤ G0;

[0061] S6: Installation and fit test of conical ring tail clamp 13: Place pressure ring 14 inside conical ring tail clamp 13, and screw conical ring tail clamp 13 into the external thread at the tail of the through-hole housing 1; test the fit S between conical ring tail clamp 13 and through-hole housing 1. The preset fit threshold S0≥95% is used. If S≥S0, the connection fit is deemed qualified and proceed to S7; if S<S0, loosen conical ring tail clamp 13 and adjust the position of pressure ring 14, tighten it again and test the fit S until S≥S0; if S is still <S0 after adjusting pressure ring 14, replace pressure ring 14 and reinstall and test.

[0062] S7: Cable insertion: Place a three-lobed cone ring 15 inside the tail of the cone ring tail clamp 13, insert the cable through the three-lobed cone ring 15 until the cable exits from the other end of the housing 1.

[0063] S8: Tail clip 16 installation and locking force test: Insert the cable from the tail of the self-piercing compartment housing 1 into the tail clip 16 and screw it into the external thread of the tail of the conical ring tail clip 13; test the locking force F of the tail clip 16 on the three-lobed conical ring 15. The preset locking force threshold F0 is 90%-110% of the rated locking force of the three-lobed conical ring 15. If F is within the range of F0, the locking is deemed qualified and proceed to S9; if F < F0, tighten the tail clip 16 until F reaches the range of F0; if F > F0, loosen the tail clip 16 and finely adjust the position of the three-lobed conical ring 15, tighten it again and test the locking force F until F meets the range of F0.

[0064] S9: Vulcanized Pack 17 Covering and Bonding Strength Test: Vulcanized Pack 17 material is covered at the connection between the through-cabin shell 1 and the integrated locking component, and vulcanization treatment is performed; the bonding strength B between the vulcanized Pack 17 and the connector is tested. The preset bonding strength threshold B0≥5MPa is used. If B≥B0, the vulcanized Pack 17 covering is deemed qualified, and the manufacturing of the pressure-resistant electrical through-cabin component is completed; if B<B0, the residual material at the connection is cleaned, the vulcanized Pack 17 material is re-covered, and vulcanization treatment is performed until the bonding strength B≥B0.

[0065] Through precise step-by-step control and multi-parameter testing, the manufacturing precision and performance consistency of the transom components are ensured. The initial structural proportion inspection (S1) ensures the pressure resistance foundation of the hull from the outset, preventing subsequent pressure failure due to improper proportions. The groove machining and O-ring installation inspection (S2) ensures the reliability of the initial sealing process. S3 and S4 rigorously test the conical surface parameters of the sealing unit to ensure the pressure self-tightening function meets standards. The mating gap inspection (S5), fitting degree inspection (S6), and locking force inspection (S8) respectively ensure the connection accuracy and locking effect of each component. The vulcanized plate bonding strength inspection (S9) strengthens the sealing and corrosion resistance of the joints. Each step has clearly defined threshold standards and non-conforming handling plans, forming a comprehensive quality control process that effectively avoids problems such as component mismatch deviations and improper installation, ensuring that the manufactured transom components meet core requirements such as deep-water pressure resistance and sealing.

[0066] In step S3, when detecting the taper T1 of the pressure-tightening conical surface of the metal mandrel-5, the temperature detection module is simultaneously activated to collect the real-time temperature t1 of the metal mandrel-5 after processing, with a preset temperature threshold t10≤50℃. If t1≤t10 and T1a≤T1≤T1b, the conical surface and thermal state of the metal mandrel-5 are deemed to meet the requirements. If t1>t10, the metal mandrel-5 is allowed to cool to t1≤t10, and the taper T1 is detected again. If T1a≤T1≤T1b after cooling, it is deemed to be qualified. If T1 still does not meet the requirement of T1a≤T1≤T1b after cooling, the conical surface is reprocessed and the above temperature monitoring and taper detection steps are repeated.

[0067] In step S4, when detecting the taper T2 of the pressure self-tightening conical surface of the metal mandrel 10, the surface roughness detection module is simultaneously activated to collect the surface roughness Ra of the conical surface of the metal mandrel 10. The preset roughness threshold Ra0≤1.6μm is used. If Ra≤Ra0 and T2a≤T2≤T2b, the conical surface and surface condition of the metal mandrel 10 are determined to meet the requirements. If Ra>Ra0, the conical surface of the metal mandrel 10 is subjected to fine grinding. After grinding, Ra and T2 are re-detected until Ra≤Ra0 and T2 satisfies T2a≤T2≤T2b.

[0068] In S3, the temperature of the metal mandrel 5 after machining is simultaneously detected to avoid errors in taper detection under high temperature conditions. High temperatures can cause thermal expansion of the metal mandrel, causing the detected taper to deviate from the actual value. After cooling, the taper may exceed the standard, affecting the sealing effect. Controlling the temperature below 50℃ ensures the accuracy of taper detection and avoids residual thermal stress that could cause deformation of the conical surface during subsequent use. In S4, the surface roughness of the conical surface of the metal mandrel 10 is simultaneously detected. If the roughness is greater than 1.6μm, it will cause tiny gaps between the mandrel and the mating surfaces of the gasket and the housing, which can easily lead to leakage under deep water and high pressure, and also affect the pressure self-tightening effect. By controlling the roughness to ≤1.6μm through fine grinding, the tightness of the fit between the mandrel and the mating parts can be enhanced, improving the sealing reliability.

[0069] During the vulcanization process in S9, the vulcanization parameter control module is activated, with a preset vulcanization temperature range of T0 = 120-150℃ and a vulcanization time of t0 = 30-60min. First, the vulcanization temperature T is adjusted to T∈T0, and this temperature is maintained for vulcanization for a duration t∈t0. During the vulcanization process, the real-time temperature Tactual and real-time shrinkage rate Ractual of the vulcanization package 17 are continuously monitored, with preset fluctuation thresholds for Tactual ΔT ≤ ±5℃ and shrinkage rate thresholds for R0 = 2%-5%.

[0070] If the actual value (Tactual) remains within T0±ΔT and the actual value (Ractual) ∈ R0 during the vulcanization process, the bond strength (B) can be directly tested after vulcanization is completed.

[0071] If Tactual exceeds T0±ΔT, adjust the heating power to bring Tactual back to the T0 range, and extend the vulcanization time by Δt = the duration of temperature exceedance × 1.2. Continue monitoring after Tactual returns to normal.

[0072] If Ractual < R0, then increase the vulcanization temperature at a rate of 0.5℃ / min until Ractual ∈ R0; if Ractual > R0, then decrease the vulcanization temperature at a rate of 0.5℃ / min until Ractual ∈ R0.

[0073] After completing the above parameter adjustments, continue with the remaining vulcanization time. After vulcanization, check whether the bond strength B is ≥ B0. If not, repeat S9.

[0074] Precise control and process monitoring of vulcanization parameters in S9 significantly improve the bonding quality and stability of vulcanizing package 17. A vulcanization temperature of 120-150℃ and a vulcanization time of 30-60 minutes ensure sufficient vulcanization of the vulcanizing package 17 material, forming a high-strength adhesive layer. Real-time monitoring of temperature and shrinkage rate during the process prevents incomplete or excessive vulcanization due to excessive temperature fluctuations. Controlling the shrinkage rate within 2%-5% prevents cracking or weak bonding of the vulcanizing package 17 due to abnormal shrinkage. Adjusting the power and extending the vulcanization time when the temperature exceeds the threshold, and fine-tuning the temperature when the shrinkage rate is abnormal, ensures the vulcanization process remains optimal. Failure to adjust temperature fluctuations or excessive shrinkage rate in time will result in insufficient bonding strength and easy detachment of the vulcanizing package 17, failing to provide sealing and protection. Strict parameter control ensures a strong bond between the vulcanizing package 17 and the connector, with a bonding strength ≥5MPa, effectively resisting the effects of harsh environments such as deep water pressure and corrosion, extending component lifespan, and ensuring long-term sealing reliability at the connection. The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any ordinary changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included within the protection scope of the present invention.

Claims

1. A pressure-resistant electrical penetration component assembly for deep-water environments, characterized in that: It includes a through-hole housing (1), an electrical sealing unit disposed within the through-hole housing (1), and an integral locking member connected to the through-hole housing (1) for locking; The through-hole housing (1) is a thick-walled flange structure with a central through hole. Radial grooves (2) and end face grooves (3) are provided on the mounting surface of the through-hole housing (1) and the mounting surface of the through-hole housing (1). A metal O-ring or a high-performance rubber O-ring with a rectangular cross section is provided in the radial grooves (2) and the end face grooves (3). An internal thread (4) is provided at the front of the central through hole of the through-hole housing (1), and a stepped structure adapted to several electrical sealing units is provided at the rear. An external thread is provided at the tail of the through-hole housing (1). The electrical sealing unit includes a first sealing part and a second sealing part. The first sealing part includes a metal spindle (5) with a through hole in the center for a cable to pass through. A flat washer (6), a rubber washer (7), a flat washer (6), and a locking ring (8) are sequentially fitted on the metal spindle (5). The locking ring (8) is fixed on the metal spindle (5) and has a locking groove (9). The second sealing part includes a metal spindle (10) with a through hole in the center for a cable to pass through. A fastening ring (11) is fixedly fitted on the metal spindle (10). The fastening ring (11) has a locking protrusion (12) that matches the locking groove (9). A number of flat washers (6) and rubber washers (7) are also fitted on the metal spindle (10) at intervals. The integrated locking component includes a conical ring tail clamp (13) that is fixedly connected to the external thread of the through-hole housing (1) for fixing and locking the electrical sealing unit. A pressure ring (14) is provided between the through-hole housing (1) and the conical ring tail clamp (13). The tail of the conical ring tail clamp (13) is also provided with an external thread. A three-lobed conical ring (15) for clamping the cable is placed inside the conical ring tail clamp (13). The tail of the conical ring tail clamp (13) is provided with a tail clamp (16) that is fixedly connected to the external thread for further fixing and locking the electrical sealing unit. The integrated locking component also includes a vulcanized bag (17) covering the connection between the through-hole housing (1) and the integrated locking component. When the integrated locking element is locked, the pressure of the electrical sealing unit generates an axial thrust, which causes the flat washer (6) and the rubber washer (7) to undergo axial compression and radial expansion within the through hole of the housing (1) of the transom.

2. A pressure-resistant electrical penetration component assembly for deep-water environments according to claim 1, characterized in that, The first metal mandrel (5) and the second metal mandrel (10) are pressure self-tightening conical surfaces, and the taper of the pressure self-tightening conical surface is 1:8-1:

12.

3. A pressure-resistant electrical penetration component assembly for deep-water environments according to claim 1, characterized in that, The ratio of the thickness of the thick-walled flange structure of the through-hole shell (1) to the diameter of the central through hole is 2:1-3:

1.

4. A method for manufacturing a pressure-resistant electrical penetration component assembly for deep-water environments as described in any one of claims 1-3, characterized in that, Includes the following steps: S1. Component preparation and initial structural ratio inspection: Prepare the materials for the through-hole shell (1), electrical sealing unit components, integrated locking components, rectangular cross-section sealing O-rings, and vulcanizing package (17); check the ratio K of the thickness of the thick-walled flange and the diameter of the central through hole of the through-hole shell (1). The preset ratio thresholds are K1=2:1 and K2=3:

1. If K1≤K≤K2, it is determined that the pressure-resistant structure of the through-hole shell (1) meets the requirements and proceeds to S2; if K<K1 or K>K2, return to the component preparation stage to adjust the wall thickness or through hole diameter of the through-hole shell (1) until the ratio K satisfies K1≤K≤K2. S2: Shell Groove Machining and O-ring Installation Inspection: Machining radial grooves (2) and end face grooves (3) on the mounting surfaces of the through-hull shell (1) and the bulkhead. After cleaning the impurities and burrs in the grooves, embed the O-rings into the grooves. Detect the installation compression amount C of the O-rings. The preset compression threshold C0 is 80%-120% of the rated compression amount of the O-rings. If C is within the range of C0, the O-rings are deemed to be installed correctly and proceed to S3. If C < C0, adjust the installation position of the O-rings or replace them with O-rings of suitable specifications and re-inspect. If C > C0, remove the O-rings, clean the groove surface, and reinstall them until the compression amount C meets C0. S3: Assembly of the first sealing part and detection of the conical surface parameters: On the metal mandrel (5), the flat washer (6), the rubber washer (7), and the flat washer (6) are sequentially interference fitted, and then the locking ring (8) is fixedly fitted on the metal mandrel (5); the taper T1 of the pressure self-tightening conical surface of the metal mandrel (5) is detected. The preset taper thresholds are T1a=1:8 and T1b=1:

12. If T1a≤T1≤T1b, it is determined that the conical surface of the metal mandrel (5) meets the pressure self-tightening requirements, and the assembly of the first sealing part is completed, and proceed to S4; if T1<T1a or T1>T1b, the metal mandrel (5) is replaced or the conical surface is reprocessed until the taper T1 satisfies T1a≤T1≤T1b; S4: Assembly of the second sealing part and detection of the conical surface parameters: First, a fastening ring (11) is fixedly sleeved on the metal mandrel (10), and then several flat washers (6) and rubber washers (7) are sequentially interference-fitted; the taper T2 of the pressure self-tightening conical surface of the metal mandrel (10) is detected. The preset taper thresholds are T2a=1:8 and T2b=1:

12. If T2a≤T2≤T2b, it is determined that the conical surface of the metal mandrel (10) meets the pressure self-tightening requirements, and the assembly of the second sealing part is completed, and proceed to S5; if T2<T2a or T2>T2b, the metal mandrel (10) is replaced or the conical surface is reprocessed until the taper T2 satisfies T2a≤T2≤T2b; S5: Sealing part insertion and docking gap detection: Insert the first sealing part into the internal stepped structure of the housing (1) from the tail end of the housing (1) according to the design direction, so that the locking ring (8) faces the tail end of the housing (1); then insert the second sealing part into the housing (1) from the tail end of the housing (1) according to the design direction, so that the locking protrusion (12) of the fastening ring (11) docks with the locking groove (9) of the locking ring (8); then detect the mating gap G after docking. The preset gap threshold G0≤0.1mm. If G≤G0, the docking lock is qualified and proceed to S6; if G>G0, adjust the placement angle of the second sealing part and re-detect; if G is still>G0 after multiple adjustments, replace the locking ring (8) or fastening ring (11), re-dock and detect the gap until G≤G0; S6: Installation and fit test of cone ring tail clamp (13): Place pressure ring (14) inside cone ring tail clamp (13), and screw cone ring tail clamp (13) into the external thread at the tail of the through-hole housing (1) to fix it; test the fit S between cone ring tail clamp (13) and through-hole housing (1), preset fit threshold S0≥95%, if S≥S0, the connection fit is qualified, and proceed to S7; If S < S0, loosen the cone ring tail clamp (13) and adjust the position of the pressure ring (14), tighten it again and check the fit S until S ≥ S0; if S is still < S0 after adjusting the pressure ring (14), replace the pressure ring (14) and reinstall and test. S7: Cable insertion: Place a three-lobed cone ring (15) inside the tail of the cone ring tail clamp (13), insert the cable through the three-lobed cone ring (15) until the cable exits from the other end of the housing (1). S8: Tail clip (16) installation and locking force test: Insert the cable from the tail of the self-penetrating compartment housing (1) into the tail clip (16) and screw it into the external thread of the tail of the conical ring tail clip (13) to fix it; test the locking force F of the tail clip (16) on the three-lobed conical ring (15). The preset locking force threshold F0 is 90%-110% of the rated locking force of the three-lobed conical ring (15). If F is within the range of F0, the locking is qualified and proceed to S9; if F < F0, tighten the tail clip (16) until F reaches the range of F0; if F > F0, loosen the tail clip (16) and finely adjust the position of the three-lobed conical ring (15), tighten it again and test the locking force F until F meets the range of F0. S9: Vulcanized Pack (17) Covering and Bonding Strength Test: Vulcanized pack (17) material is covered at the connection between the through-cabin shell (1) and the integrated locking part, and vulcanization treatment is performed; the bonding strength B between the vulcanized pack (17) and the connecting part is tested. The preset bonding strength threshold B0≥5MPa is used. If B≥B0, the vulcanized pack (17) is deemed to be qualified, and the manufacturing of the pressure-resistant electrical through-cabin component is completed. If B < B0, clean the residual material at the joint, re-cover with vulcanizing material (17) and vulcanize until the bonding strength B ≥ B0.

5. The method for manufacturing a pressure-resistant electrical penetration component assembly for deep-water environments according to claim 4, characterized in that, In step S3, when detecting the taper T1 of the pressure self-tightening conical surface of the metal mandrel (5), the temperature detection module is simultaneously activated to collect the real-time temperature t1 of the metal mandrel (5) after processing, with a preset temperature threshold t10≤50℃; if t1≤t10 and T1a≤T1≤T1b, the conical surface and thermal state of the metal mandrel (5) are deemed to meet the requirements; if t1>t10, the metal mandrel (5) is allowed to cool to t1≤t10, and the taper T1 is detected again; if T1a≤T1≤T1b after cooling, it is deemed to be qualified; if T1 after cooling still does not meet the requirement of T1a≤T1≤T1b, the conical surface is reprocessed and the above temperature monitoring and taper detection steps are repeated. In step S4, when detecting the taper T2 of the pressure self-tightening conical surface of the metal mandrel two (10), the surface roughness detection module is simultaneously activated to collect the surface roughness Ra of the conical surface of the metal mandrel two (10). The preset roughness threshold Ra0≤1.6μm is used. If Ra≤Ra0 and T2a≤T2≤T2b, the conical surface and surface condition of the metal mandrel two (10) are determined to meet the requirements. If Ra>Ra0, the conical surface of the metal mandrel two (10) is finely polished. After polishing, Ra and T2 are re-detected until Ra≤Ra0 and T2 satisfies T2a≤T2≤T2b.

6. The method for manufacturing a pressure-resistant electrical penetration component assembly for deep-water environments according to claim 4, characterized in that, When vulcanizing in S9, the vulcanizing parameter control module is activated, and the vulcanizing temperature range T0 = 120-150℃ and the vulcanizing time t0 = 30-60min are preset. First, the vulcanizing temperature T is adjusted to T∈T0, and the vulcanization is carried out at this temperature for a duration t∈t0. During the vulcanization process, the real-time temperature Tactual and real-time shrinkage rate Ractual of the vulcanizing package (17) are continuously monitored, and the preset fluctuation threshold ΔT≤±5℃ and shrinkage rate threshold R0 = 2%-5% are set. If the actual value (Tactual) remains within T0±ΔT and the actual value (Ractual) ∈ R0 during the vulcanization process, the bond strength (B) can be directly tested after vulcanization is completed. If Tactual exceeds T0±ΔT, adjust the heating power to bring Tactual back to the T0 range, and extend the vulcanization time by Δt = the duration of temperature exceedance × 1.

2. Continue monitoring after Tactual returns to normal. If Ractual < R0, increase the vulcanization temperature at a rate of 0.5℃ / min until Ractual ∈ R0; if Ractual > R0, decrease the vulcanization temperature at a rate of 0.5℃ / min until Ractual ∈ R0; after completing the above parameter adjustment, continue for the remaining vulcanization time. After the vulcanization is completed, check whether the bond strength B is ≥ B0. If not, repeat S9.

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