High-voltage line clamp posture and pressure cooperative function test system and method

Abstract

This invention relates to the field of high-voltage line clamp testing technology, specifically disclosing a high-voltage line clamp attitude and pressure coordinated function testing system and method. The system includes: a multi-source feature sensing unit for collecting feature data during the line clamp installation process, including pressure data, attitude deflection data, visual image data, environmental data, and tooling status data; a processing unit for identifying conflict states based on the feature data and generating linkage decision commands; and an execution unit for receiving the linkage decision commands and executing the attitude adjustment and fastening parameter adjustment of the line clamp. This invention achieves dynamic coordinated optimization and real-time self-correction of spatial attitude and contact pressure during high-voltage line clamp installation by constructing a real-time closed-loop intervention mechanism that integrates multi-source feature sensing, intelligent identification of abnormal states, and proactive adjustment of the execution mechanism.

Description

Technical Field

[0001] This invention relates to the field of high-voltage line clamp testing technology, and in particular to a high-voltage line clamp attitude and pressure coordination function testing system and method. Background Technology

[0002] The safe and stable operation of high-voltage transmission lines is highly dependent on the reliability of clamp installation, and the installation quality of clamps is directly determined by the coordinated state of their spatial orientation and contact pressure.

[0003] Traditional clamp testing and construction acceptance are often disconnected, typically relying on manual experience or static thresholds from a single sensor for post-construction quality inspection. This approach not only struggles to capture minute attitude shifts and uneven internal pressure distribution during installation in real time, but also lacks a real-time closed-loop linkage mechanism from problem discovery to proactive intervention and adjustment. As a result, hidden internal defects are difficult to eliminate in a timely manner, posing significant safety hazards to the long-term high-load operation of the power grid.

[0004] Under the complex construction and testing conditions of outdoor high-voltage transmission lines, existing technologies face extremely prominent and challenging technical problems:

[0005] On the one hand, there is a serious conflict between the static judgment threshold preset by the system and the dynamic and ever-changing environmental alternating loads, such as sudden crosswinds and light wind vibrations. When the monitoring data is at the critical point and fluctuates due to environmental interference, the system is very likely to fall into high-frequency command oscillations, forcing the rigid execution hardware to be overloaded, damaged or even fail under the superposition of contradictory commands and external transient alternating stress.

[0006] On the other hand, existing infrared thermal imaging-based reverse detection technology relies entirely on steady-state electrical loads (Joule heating) during energized operation. This fundamentally conflicts with the actual scenario of newly built lines that have not yet been energized and accepted or are in a non-energized shutdown verification, causing conventional steady-state thermal radiation mapping models to be completely paralyzed under passive operating conditions, resulting in serious detection blind spots and misjudgment risks. Summary of the Invention

[0007] This invention aims to at least partially solve one of the technical problems in related technologies. Therefore, the purpose of this invention is to propose a high-voltage line clamp attitude and pressure coordinated function testing system and method to ensure the safety and stability of high-voltage transmission lines throughout their entire lifecycle.

[0008] To achieve the above objectives, a first aspect of the present invention provides a high-voltage line clamp attitude and pressure coordination function testing system, comprising:

[0009] A multi-source feature sensing unit is used to collect feature data during the installation process of the wire clamp. The feature data includes pressure data, attitude deflection data, visual image data, environmental data, and tooling status data.

[0010] The processing unit is used to identify the conflict state based on the feature data and generate a linkage decision instruction;

[0011] The execution unit is used to receive the linkage decision command and execute the attitude adjustment and fastening parameter adjustment of the line clamp;

[0012] The generation and execution process of the linkage decision-making instruction includes:

[0013] In response to the start command, the multi-source feature sensing unit synchronously collects real-time test data;

[0014] The processing unit analyzes the real-time test data. If a first conflict state that meets the first preset condition is detected, the attitude correction amount and the fastening adjustment value are calculated and sent to the execution unit as the linkage decision command.

[0015] If a second conflict state that meets the second preset condition is detected, a pause command is generated and an early warning is triggered. The conflict severity corresponding to the second preset condition is higher than that of the first preset condition.

[0016] After executing the linkage decision instruction, the execution unit sends back the execution result. The multi-source feature perception unit re-collects feature data as verification data to determine whether the first conflict state has been eliminated. If it has not been eliminated, the iterative adjustment process is triggered.

[0017] To achieve the above objectives, a second aspect of the present invention provides a method for testing the coordinated function of high-voltage line clamp attitude and pressure, the method comprising the following steps:

[0018] In response to the start command, characteristic data during the clamp installation process are synchronously collected as real-time test data; the characteristic data includes pressure data, attitude deflection data, visual image data, environmental data, and tooling status data;

[0019] The real-time test data is analyzed to identify conflict states. If a first conflict state that meets the first preset condition is detected, the attitude correction amount and the fastening adjustment value are calculated and issued as a linkage decision command.

[0020] If a second conflict state that meets the second preset condition is detected, a pause command is generated and an early warning is triggered, wherein the conflict severity corresponding to the second preset condition is higher than that of the first preset condition;

[0021] Based on the linkage decision command, the attitude adjustment and fastening parameter adjustment of the clamp are executed, and the execution result is returned after execution;

[0022] Feature data is re-collected as verification data to determine whether the first conflict state has been eliminated. If it has not been eliminated, an iterative adjustment process is triggered.

[0023] To achieve the above objectives, a third aspect of the present invention provides an electronic device, including a memory, a processor, and a computer program stored in the memory, wherein when the computer program is executed by the processor, it implements the above-described high-voltage clamp attitude and pressure coordination function testing method.

[0024] The high-voltage clamp attitude and pressure coordination function testing system and method of this invention realizes dynamic coordination optimization and real-time self-correction of spatial attitude and contact pressure during the installation of high-voltage clamps by constructing a real-time closed-loop intervention mechanism of multi-source feature perception, intelligent identification of abnormal state and active adjustment of actuator.

[0025] Faced with complex and ever-changing field conditions, this invention introduces environmental degradation parameters for dynamic threshold drift and hysteresis anti-oscillation control, and links it with the hardware's pulse-type compensation output mode. This effectively resolves the conflict between system decision-making oscillations caused by dynamic alternating loads and overload failure of the execution hardware. At the same time, by pioneering the integration of active transient thermal pulse excitation and dynamic thermal conductivity mapping technology, it completely breaks the passive dependence of traditional infrared detection methods on steady-state electrical loads. It successfully overcomes the technical bottleneck of not being able to quantitatively back-calculate the internal contact pressure of the clamp under no-power load conditions, greatly expanding the system's applicable boundaries and fundamentally ensuring the safety and stability of high-voltage transmission lines throughout their entire life cycle. Attached Figure Description

[0026] Figure 1 This is a schematic diagram illustrating the implementation of the high-voltage clamp attitude and pressure coordination function testing system provided by the present invention;

[0027] Figure 2 This is a pseudo-color cloud map of the two-dimensional contact pressure distribution matrix of the high-voltage clamp in the high-voltage clamp attitude and pressure coordination function test system provided by the present invention.

[0028] Figure 3 This is a three-dimensional surface diagram of the nonlinear mapping between surface temperature rise and internal contact pressure based on a steady-state heat conduction model in the high-voltage clamp attitude and pressure coordination function testing system provided by this invention.

[0029] Figure 4 This is a long-term decay trend curve of the clamp conflict risk level based on a dynamic evolution model in the high-voltage clamp attitude and pressure coordination function test system provided by this invention.

[0030] Figure 5 This is a waveform diagram of the anti-decision oscillation control logic of the high-voltage clamp attitude and pressure coordination function test system provided by the present invention, which introduces a hysteresis comparison interval under extreme working conditions.

[0031] Figure 6 This is a timing diagram of the external alternating load phase tracking and pulse-type compensation torque output in the high-voltage clamp attitude and pressure coordination function test system provided by the present invention;

[0032] Figure 7 This is a graph showing the acquisition points and fitting curves of the exponential decay of the clamp surface temperature under transient thermal pulse excitation in the high-voltage clamp attitude and pressure coordination function testing system provided by this invention.

[0033] Figure 8 This is a flowchart illustrating the high-voltage clamp attitude and pressure coordination function testing method provided by the present invention.

[0034] Figure 9 This is a schematic diagram of the structure of the electronic device provided by the present invention. Detailed Implementation

[0035] Embodiments of the present invention are described in detail below, examples of which are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0036] The following describes, with reference to the accompanying drawings, an electronic device for testing the coordinated function of high-voltage clamp attitude and pressure according to embodiments of the present invention.

[0037] Example 1:

[0038] This embodiment provides a high-voltage clamp attitude and pressure coordination function testing system. This high-voltage system, as a physical entity hardware architecture, integrates mechanical control technology, multi-dimensional sensing technology, and artificial intelligence data processing technology.

[0039] To achieve absolute control over the installation quality of high-voltage clamps and eliminate potential hazards, this high-voltage clamp attitude and pressure coordinated function testing system includes a multi-source feature sensing unit, a processing unit, and an execution unit. These units are interconnected via a high-speed industrial Ethernet bus, forming a complete closed-loop control hardware architecture from data acquisition to intelligent analysis and physical execution.

[0040] Specifically, the aforementioned multi-source feature sensing unit is used to collect feature data during the installation process of the wire clamp. This feature data includes pressure data, attitude deflection data, visual image data, environmental data, and tooling status data. Since the installation quality of high-voltage wire clamps is not determined by a single-dimensional force, but rather by the complex coupling of three-dimensional spatial attitude and internal multi-point contact pressure, a single sensor cannot meet the testing requirements of such complex scenarios. In this embodiment, the multi-source feature sensing unit is designed as a highly integrated composite sensor array. Its core function is to capture comprehensive, all-around data on the microscopic physical state and macroscopic environmental state of the wire clamp installation.

[0041] The aforementioned multi-source feature sensing unit includes a pressure acquisition module, an attitude acquisition module, a vision acquisition module, an environment acquisition module, and a tooling status acquisition module. Each module performs its specific function and maintains strict clock synchronization in the time dimension. The pressure acquisition module is used to acquire the 2D contact pressure distribution matrix of the contact area between the wire clamp and the wire. This pressure acquisition module consists of a high-density flexible thin-film resistive sensor array, which is tightly fitted to the inner pressing surface of the wire clamp. During each physical pressing action, this module can convert the physical compression deformation into a minute change in resistance value, and output a value with a size of [missing information - likely a value] through the downstream analog-to-digital converter circuit. The 2D contact pressure distribution matrix, where each element represents the absolute pressure value at a specific tiny physical coordinate point.

[0042] The aforementioned attitude acquisition module is used to collect attitude deflection data of the cable clamp in three dimensions: roll, pitch, and yaw. This module incorporates an industrial-grade, high-precision microelectromechanical system (MEMS) inertial measurement unit. By fusing the raw signals from the three-axis accelerometer and three-axis gyroscope, and filtering out high-frequency mechanical jitter noise from the field using a Kalman filter algorithm, it outputs the absolute roll angle, absolute pitch angle, and absolute yaw angle of the cable clamp in a Cartesian coordinate system in real time.

[0043] The aforementioned visual acquisition module is used to acquire visual image data of the wire clamp and extract visual pose features. Deployed on an external fixed bracket of the test system, this module includes a high-resolution industrial camera and an active light source. The acquired visual image data is processed using edge detection and sub-pixel contour extraction algorithms to extract the spatial straight-line equations of the physical geometric edges of the wire clamp. Then, through spatial geometric mapping relationships, another set of independent visual pose features is calculated, serving as a redundant backup and cross-validation source for the pose acquisition module's data.

[0044] The aforementioned environmental acquisition module is used to collect environmental data, including ambient temperature, humidity, vibration parameters, and air pressure parameters. The metallic material properties of the high-voltage clamp and the temperature drift characteristics of the sensor are both severely affected by the external environment. The environmental acquisition module continuously records the temperature and humidity at the test site, the vibration acceleration caused by wind load, and the altitude and air pressure, providing a physical reference for subsequent data compensation.

[0045] The aforementioned tooling status acquisition module is used to collect self-test data on the position of components on the tooling board and the connection status of sensors. This module acts as a health monitoring guardian at the system's bottom layer. By reading the impedance values ​​of each sensor interface and the packet loss rate of the communication bus in real time, it ensures the validity and legality of all the aforementioned characteristic data, preventing misjudgments caused by sensor damage or loosening.

[0046] Specifically, the aforementioned processing unit is used to identify the conflict state based on the feature data and generate linkage decision commands. The processing unit is the core of the entire high-voltage line clamp attitude and pressure coordination function testing system, and its physical form can be a field edge computing gateway equipped with a high-performance tensor processing unit. This processing unit receives massive feature data from multi-source feature sensing units, aligns data scattered across different dimensions and sampling frequencies to a unified timestamp, and constructs a high-dimensional data feature vector. The aforementioned processing unit includes a conflict feature database server, which stores a historical conflict feature database. Because the hidden conflict patterns of high-voltage line clamps are extremely complex, traditional rule-based threshold judgments are prone to failure; therefore, this embodiment introduces a large historical conflict feature database as a comparison benchmark.

[0047] For example, the historical conflict feature database contains associated matching data of attitude deflection parameters, pressure distribution anomalies, local conflict locations, and conflict levels. Here, conflict essentially refers to the deviation between the ideal crimping state and the actual crimping state of the clamp under external mechanical tightening force. The conflict levels are divided into a conflict-free level, a first conflict level corresponding to the first preset condition, and a second conflict level corresponding to the second preset condition, for the processing unit to match and generate the corresponding linkage decision command. A conflict-free level indicates that the current feature data points to a perfect installation state, with neither local stress concentration nor attitude deflection.

[0048] Optionally, to accurately quantify the conflict level to which the current feature data belongs, the processing unit needs to execute a rigorous numerical metric algorithm. Let the currently acquired and fused feature data vector be... A specific historical feature data vector in the historical conflict feature database is... The processing unit first calculates the Mahalanobis distance between the current feature data vector and the centroids of various typical sample sets in the historical conflict feature database. Mahalanobis distance effectively eliminates interference from inconsistencies in the dimensions of data across different dimensions and the correlation between features. Let the covariance matrix be... The formula for calculating Mahalanobis distance is:

[0049] ;

[0050] The first precondition mentioned above is strictly defined as: when the calculated minimum Mahalanobis distance If the pressure falls within the set medium confidence interval, and there are connected regions in the current 2D contact pressure distribution matrix where the local pressure gradient exceeds the set gradient, while the overall deviation of the attitude deflection data has not exceeded the critical limit for mechanical failure, the first preset condition is determined to be met, and the system enters the first conflict state. The first conflict state means that there is a defect in the clamp installation that requires intervention, but this defect is still within the range that can be salvaged by adjusting the current fastening parameters and physical attitude.

[0051] The second precondition mentioned above is strictly defined as: when the calculated minimum Mahalanobis distance... The system enters a second conflict state when the following conditions are met: the system points to a historical set of severe fault samples; a zero-pressure cliff region appears in the current 2D contact pressure distribution matrix, indicating a large area of ​​uncontacted suspension inside the clamp; or a single angle in the attitude deflection data exceeds the yield limit angle of irreversible plastic deformation. As defined by the system logic, the conflict severity corresponding to the second preset condition is higher than that of the first preset condition. Once the second conflict state is triggered, it indicates that the current physical installation process has undergone severe uncontrollable distortion, and any continued routine adjustments may lead to clamp breakage or permanent damage to the conductor insulation.

[0052] Specifically, the aforementioned execution unit is used to receive the linkage decision command and execute the attitude adjustment and fastening parameter adjustment of the clamp. The execution unit is the physical action output terminal of the testing system, directly mechanically coupled with the high-voltage clamp and construction fixtures. The execution unit includes an electric fastening device and an attitude positioning adjustment unit. The electric fastening device is used to adjust the clamp torque parameter according to the fastening adjustment value. This electric fastening device has a built-in high-precision servo motor and a bidirectional torque sensor, enabling it to operate in extremely small torque steps. It can not only increase the fastening torque to eliminate internal gaps but also perform a reverse relaxation action to release stress concentration. The attitude positioning adjustment unit is used to adjust the spatial attitude of the clamp according to the attitude correction amount. The attitude positioning adjustment unit uses a precision displacement platform based on a non-orthogonal six-axis parallel mechanism, which can drive the clamp to perform extremely complex translational and rotational coupled movements in space, thereby correcting the macroscopic distortion of the clamp caused by unbalanced bolt forces.

[0053] Specifically, the generation and execution process of the system's dynamic closed-loop linkage decision-making instructions is as follows:

[0054] In response to the start command, the multi-source feature sensing unit synchronously collects real-time test data. After the test operator or the automated main control program issues the start command, all sensing modules are awakened within a one-millisecond time window, the current sensor state is frozen, and the data is packaged and reported. The processing unit analyzes the real-time test data. If a first conflict state that meets the first preset condition is detected, the attitude correction amount and the fastening adjustment value are calculated and sent to the execution unit as the linkage decision command.

[0055] Here, the calculation of attitude correction and fastening adjustment values ​​is not a simple table lookup, but rather involves solving an inverse physics minimization equation for the local deformation energy of the clamp. Based on the characteristic data of the current deviation, the system calculates how much reverse torque vector and reverse spatial displacement vector need to be applied to reduce the system deformation potential energy of the clamp to the global minimum point. The calculated results are encapsulated into a linkage decision command message containing the multi-axis target position and target torque.

[0056] Optionally, if a second conflict state that meets the second preset condition is detected, a pause command is generated and an early warning is triggered. Since the system faces an extremely high risk of physical damage at this time, the processing unit will immediately cut off the servo motor enable signal of the execution unit, forcibly stop all mechanical movements, and send an advanced early warning data packet containing fault characteristic codes to the audible and visual alarms at the test site and the remote dispatch center, awaiting manual intervention for investigation.

[0057] It is also important to note that after executing the linkage decision command, the execution unit sends back the execution result. The multi-source feature sensing unit re-collects feature data as verification data to determine whether the first conflict state has been eliminated. If it has not been eliminated, an iterative adjustment process is triggered. After reaching the target torque and target position, the execution unit needs to undergo a set mechanical stress release stabilization time. Subsequently, the sensing unit initiates a second round of comprehensive scanning to obtain new verification data. The processing unit repeats the aforementioned Mahalanobis distance calculation and condition judgment logic. If the verification data no longer meets the first preset condition and approaches the sample center of the conflict-free level, the first conflict state is determined to have been successfully eliminated, and the closed-loop process ends successfully. If the verification data still remains within the trigger range of the first preset condition, it indicates that the previous physical adjustment failed to achieve the expected result due to the nonlinear hysteresis effect of the material. The system will increment the iteration counter, recalculate the adjustment value based on the new residual, and trigger the iterative adjustment process again. To prevent the system from falling into an infinite loop, the iterative adjustment process usually has an upper limit protection mechanism.

[0058] To address invisible internal defects during live operation or power outage re-inspection, the testing system further includes a visualization and fault diagnosis unit for receiving infrared thermal imaging data collected by the inspection equipment. Since the contact pressure distribution inside the clamp is completely obscured by the metal casing, conventional optical cameras cannot penetrate it for observation. The visualization and fault diagnosis unit constructs a mapping model between the infrared thermal imaging temperature distribution and the internal pressure distribution, enabling the inverse deduction of the clamp's internal pressure state based on the infrared thermal imaging data. The physical basis of this mapping model lies in thermodynamic conduction theory and electrical contact resistance theory. Under energized conditions, the area with lower contact pressure inside the clamp has a smaller actual microscopic contact area, leading to a sharp increase in contact resistance. Current flowing through this high-resistance area generates concentrated Joule heat, which is conducted through the lattice of the aluminum alloy clamp to the outer surface of the clamp, forming externally visible high-temperature infrared radiation spots.

[0059] For example, suppose a coordinate point on the surface of a wire clamp is extracted from infrared thermal imaging data. The steady-state temperature is The ambient background temperature is The thermal conductivity is The thickness of the wire clamp material is Based on a discretized simplified model of Fourier's steady-state heat conduction law, the power of the heat source at the internal contact point is... The inversion can be approximated by surface temperature rise:

[0060] ;

[0061] heat source power And the contact resistance of this local area and the square of the current flowing through Proportional. Meanwhile, according to the classical Hertzian contact model in solid mechanics, the contact resistance... Local normal contact pressure It is inversely proportional to a certain power. This is achieved through reverse derivation of the physical relationships layer by layer, combined with experimental calibration coefficients. The complete formula for the mapping model constructed by the visualization and fault diagnosis unit can be expressed as:

[0062] ;

[0063] In the formula This refers to the nonlinear hardening index of material contact. Through this complex mapping model, the system can directly transform the seemingly ordinary infrared temperature and color depth captured by the inspection equipment into a highly intuitive contour map of the physical pressure distribution inside the clamp, making contact defects hidden inside thick metal impossible to hide.

[0064] like Figure 3 By combining the nonlinear mapping of surface temperature rise and internal contact pressure based on a steady-state heat conduction model into a three-dimensional surface plot, it can be observed that this scheme achieves a quantitative transformation from the apparent thermal characteristics to the underlying microscopic mechanical state. The horizontal axis of this three-dimensional surface plot represents the magnitude of the load current flowing through the high-voltage clamp, the vertical axis represents the temperature rise of the clamp surface relative to the ambient background, and the vertical axis and the legend color bar on the right jointly map the internal contact pressure value of the clamp derived through the core algorithm, measured in megapascals (MPa).

[0065] Observing the three-dimensional spatial morphology and color gradient evolution of the surface plot reveals that under a large load current of up to 1000 amperes, when the surface temperature of the clamp gradually rises to a high temperature range of 50 degrees Celsius, the spatial surface concaves downwards and exhibits a cool color tone ranging from light blue to dark blue, representing low pressure. At this point, the internal contact pressure is deduced to drop to a relatively low level of about 5.7 MPa. This confirms the physical deduction logic in the embodiment that the lower contact pressure leads to a reduction in the actual microscopic contact area, thereby generating concentrated Joule heating.

[0066] Conversely, when the surface temperature rise is maintained in the low-temperature range of around 5 degrees Celsius, the curved surface bulges and presents a deep red warm color representing high pressure, implying a tight pressing state with a pressure value of over 22 MPa.

[0067] Furthermore, the smooth, nonlinear warping shape of the surface as a whole intuitively demonstrates the multidimensional coupling relationship between current heating and material micro-contact hardening, indicating that the mapping model constructed in this system integrates the cross-physical laws of thermodynamic heat conduction and solid mechanics contact model.

[0068] The inversion results of this three-dimensional surface visualization demonstrate that the test system can calculate the three-dimensional stress distribution inside the metal under energized operating conditions by using infrared temperature data and power grid load data obtained from external inspection equipment. This effectively fills the blind spot in the detection of hidden defects and enhances the feasibility of the technical solution in practical engineering applications.

[0069] Optionally, the testing system further includes a multimodal verification unit for performing pressure verification, attitude verification, and torque verification after confirming that the first conflict state has been eliminated. The multimodal verification unit acts as the final rigorous quality inspection checkpoint before system delivery. Simply eliminating the conflict state is insufficient; multimodal quantitative indicators must demonstrate that the current installation quality meets high-standard engineering acceptance specifications.

[0070] It should also be noted that the passing criterion for the pressure verification is that the pressure uniformity is greater than or equal to a first preset threshold. Pressure uniformity The calculation requires accessing the entire 2D contact pressure distribution matrix obtained from the pressure acquisition module. Let the matrix contain a total of... Calculate the arithmetic mean of the pressures at all effective stress points. and the standard deviation of pressure Pressure uniformity is then defined as:

[0071] ;

[0072] The closer this value is to 1, the smoother the pressure distribution. Only when the calculated value is... The pressure verification is considered passed only when the deviation between the fused attitude deflection data and the visual attitude features is greater than or equal to a first preset threshold. The passing standard for the attitude verification is that the deviation is less than or equal to a second preset threshold. Let the roll, pitch, and yaw angles output by the attitude acquisition module be... The spatial angles extracted by the visual acquisition module are respectively . Deviation Calculate the Euclidean distance between two vectors in three-dimensional space:

[0073] ;

[0074] when When the reading is less than or equal to the second preset threshold, it indicates that the two heterogeneous sensors have achieved highly consistent observation results, there are no false readings, and the attitude verification is passed. The passing standard for the torque verification is that the deviation between the actual torque and the target torque is within a preset error range. Let the actual detected locking torque be... The target torque specified in the process document is Then the percentage of absolute error is required. It must fall within an extremely stringent preset error range. When any review fails to meet the corresponding pass standard, the multimodal review unit automatically issues a corresponding correction instruction, forcing the system to re-optimize the single dimension that failed to meet the standard.

[0075] Specifically, to extend the testing reach to the long service life of the cable clamps, the testing system further includes a full-cycle inspection and correlation analysis unit. This unit correlates the inspection data collected by the inspection equipment with the characteristic data from the installation phase and calculates the conflict risk level through a dynamic evolution model. Most cable clamp failures do not occur at the moment of installation, but rather gradually deteriorate over time due to the erosion of harsh weather conditions. The full-cycle inspection and correlation analysis unit uses historical installation data as a foundation for good performance, continuously incorporating new data reflecting the wear and tear of time.

[0076] For example, the conflict risk level is determined by multiplying the initial conflict level, the aging factor characterizing the severity of the actual environment, and the time decay factor characterizing the duration of the installation. This can be expressed as:

[0077] ;

[0078] In the formula, This is the final output quantification value for the conflict risk level. The initial conflict level is a basic risk base given by the system based on the residual minor defects when the wire clamp is installed and passes the multi-modal verification unit test. The aging factor is calculated based on historical data accumulated over a long period by the environmental data acquisition module, particularly the number of typhoons, extreme high and low temperature cycles, and the cumulative duration of significant vibration. The harsher the environment, the stronger the cumulative mechanical fatigue damage effect. The value then grows exponentially; The time decay coefficient increases monotonically with the number of days the clamp has been in operation, reflecting the unavoidable natural creep and stress relaxation physical laws of metallic materials.

[0079] When the calculated conflict risk level When the system falls into the preset high-risk zone, it triggers an early warning command, prompting the power grid operation and maintenance department that the high-voltage clamp at that specific coordinate location is on the verge of breaking or burning out at any time, and that power outage maintenance or replacement work must be arranged immediately.

[0080] For example, suppose the system is performing installation testing on a certain type of high-voltage suspension clamp, where:

[0081] The multi-source feature sensing unit started synchronous acquisition, first acquiring environmental data. The ambient temperature was 35 degrees Celsius, the relative humidity was 80%, the wind-induced vibration acceleration was 1.2 meters per square second, and the tooling status acquisition module's self-test showed everything was normal.

[0082] The pressure acquisition module outputs a value of The local 2D contact pressure distribution matrix is ​​obtained. The arithmetic mean of the pressure at all current nodes is extracted through matrix operations. MPa, pressure standard deviation Megapascals. The coordinates of the upper right corner of the matrix were also found to be... to Within the sub-region, the pressure value suddenly dropped to 1.1 MPa, forming a significant pressure trough area, which means that there is a serious loose connection on the upper right side of the clamp.

[0083] like Figure 2 By combining the pseudo-color cloud map of the two-dimensional contact pressure distribution matrix of the high-voltage line clamp, the micro-defect localization effect of the multi-source feature sensing unit of this scheme under actual complex testing conditions can be clearly seen. The horizontal and vertical physical coordinate nodes in this figure correspond to the independent acquisition points of the 10x10 flexible thin-film resistive sensor array that is tightly attached to the inner pressing surface of the line clamp. The legend color bars on the side of the figure and their corresponding values ​​map the pressure of each contact node inside the line clamp, in megapascals.

[0084] In the graph, large areas of warm colors, such as red and yellow, represent the normal crimping range where the clamp and conductor have a relatively tight contact and smooth stress distribution. This corresponds to the previously calculated arithmetic mean of the 8.5 MPa pressure. Following the isopleth curve of the pressure gradient, a significant abrupt change in color occurs within the sub-regions at the upper right corner of the matrix, on both the horizontal and vertical axes 8 to 10, plunging into a deep blue, cool-toned trough. This deep blue, cool-toned area reflects the pressure trough region where the pressure value drops sharply to 1.1 MPa. Its clear boundary and color contrast help confirm the risk of a loose connection and suspension defect on the upper right side of the clamp.

[0085] By using the contrast of this color gradient and the location of the trough pattern, the system visualizes the microscopic uneven stress phenomenon that was originally hidden inside the metal shell, thus providing an effective data reference for the subsequent processing unit to reverse calculate the spatial compensation posture and fastening adjustment torque, and enhancing the technical feasibility of the real-time closed-loop intervention mechanism of this solution.

[0086] The attitude deflection data after fusion of the attitude acquisition module and the vision acquisition module is: roll angle degrees, pitch angle degrees, yaw angle Spend.

[0087] The system packages the aforementioned pressure features, attitude features, and environmental features into a feature data vector acquired in real time. .

[0088] The processing unit received Immediately afterwards, start the Mahalanobis distance calculation. Set the inverse matrix of the covariance matrix. Given a diagonal unit weight matrix. The feature vectors for a standard perfect installation state from the historical feature database. The corresponding roll angle should be 0 degrees, and the pressure trough area should be 0. Feature vector of historical severely damaged states. The corresponding roll angle is greater than 8 degrees or the pressure value is 0.

[0089] System Calculation Distance from the feature of perfect state The system presets the Mahalanobis distance trigger threshold as follows: a lower limit of 2.0 and an upper limit of 7.0 for the first preset condition; and a lower limit of 7.0 for the second preset condition. Clearly, The current feature data perfectly matches the mathematical definition of the first preset condition.

[0090] Therefore, the processing unit determines that the first preset condition is met, and the system officially enters the first conflict state. This means that the current 3.5-degree roll skew and the local 1.1 MPa loose connection can be automatically repaired by the system.

[0091] Next, the processing unit executes the inverse physics algorithm. For a roll angle skew of 3.5 degrees, it calculates the attitude correction amount that the execution unit needs to compensate in the opposite direction. Degree. Regarding the pressure low point in the upper right corner, the system analysis indicated that the corresponding bolt group was not providing sufficient clamping force. Based on the material's elastic modulus, the required tightening adjustment value was calculated. Newtons. The processing unit will contain... Degree and The coordinated decision-making instructions of Newton's rice were issued.

[0092] Upon receiving the command, the execution unit activates the electric fastening device, which drives a high-precision servo motor to apply an additional 4.5 Nm of torque to the target bolt. Simultaneously, the six-axis mechanism of the attitude positioning adjustment unit works in tandem, causing the entire clamp to slowly roll backward by 3.5 degrees.

[0093] After the mechanical action is completed and a 2-second stress stabilization period has elapsed, the execution result is transmitted back. The multi-source feature sensing unit immediately re-collects feature data as verification data.

[0094] In the new validation data, the troughs in the stress matrix disappeared, and a completely new arithmetic mean of stress was achieved. Megapascals, pressure standard deviation significantly reduced to Megapascals. The roll angle changed to 0.05 degrees.

[0095] The system recalculates the Mahalanobis distance between the new feature vector and the perfect state. .because The verification data no longer meets the first preset condition, and the system successfully determines that the first conflict state has been completely eliminated.

[0096] Subsequently, the system seamlessly integrates into the multimodal verification unit's workflow:

[0097] 1. Perform pressure verification: Set the first preset threshold to 0.90. Substitute the values ​​into the formula to calculate the current pressure uniformity. .because The stress test passed perfectly.

[0098] 2. Perform posture verification: The deviation between the posture deflection data and the visual posture features is calculated to be 0.08 degrees using Euclidean distance. A second preset threshold is set to 0.15 degrees. Because... The attitude verification was successfully completed.

[0099] 3. Torque verification: Actual torque is 24.5 Nm, target torque is 24.0 Nm. The absolute error percentage is... The preset error range is set to within three percent. Because... The torque verification is passed as it is within the error range.

[0100] At this point, the installation and intelligent error correction process of the wire clamp is completed with high quality. After passing multimodal verification, the system extracts the extremely small residual error of the wire clamp and generates the initial conflict level. The data is stored in the end-to-end data archiving system.

[0101] As time goes by, assuming the clamp has been in operation for 1095 days, or 3 years, the full-cycle inspection and correlation analysis unit initiates an automatic analysis process via the backend server. The system extracts the past 3 years' meteorological and vibration historical records for the clamp's corresponding geographical location. It discovers that it has experienced two strong typhoons and 500 hours of high-frequency vibration in light winds. At this point, the system applies a complex fatigue integral algorithm to calculate the current aging coefficient under heavy operating conditions. .

[0102] Based on the 1095 days of operation, the time decay coefficient was calculated using the natural logarithmic decay model. The system extracts the initial conflict level recorded during installation. Substituting into the conflict risk level calculation formula:

[0103] ;

[0104] The system's preset lower limit for the high-risk range is 3.0. This is based on the calculated conflict risk level. The value was 3.381, clearly falling into the preset high-risk range of 3.0 or higher. At this moment, the full-cycle inspection and correlation analysis unit immediately triggered the highest-level early warning command, popping up a red alarm on the power grid central control screen and dispatching an emergency repair work order to the maintenance team, accurately preventing a major high-voltage line drop accident from occurring.

[0105] like Figure 4 To illustrate the long-term attenuation trend curve of the line clamp conflict risk level based on the dynamic evolution model, the risk warning effect of the full-cycle inspection and correlation analysis unit of this solution during its long service life can be demonstrated. The horizontal axis of the graph represents the number of days since the high-voltage line clamp was officially put into operation, and the vertical axis represents the quantitative value of the conflict risk level calculated by the system through the dynamic evolution model.

[0106] The solid blue line in the figure represents the conflict risk evolution curve. Its starting point corresponds to the initial conflict level of 1.15 recorded after the clamp installation was completed and multimodal verification was performed. As the number of days in operation increases, the solid blue line generally shows a gentle upward trend, reflecting the time decay effect brought about by the physical laws of natural creep and stress relaxation of metal materials.

[0107] The step-like increases that appear on the blue curve reveal the mechanical fatigue impact caused by the severity of the actual meteorological environment on the service life of the clamp. These step-like increases correspond to the increase in the aging coefficient caused by strong typhoon attacks and long-term high-frequency vibrations in light winds during the service period.

[0108] The horizontal red dashed line in the diagram represents the system's preset high-risk warning threshold of 3.0. Following the timeline of the blue curve, it can be seen that when the clamp has been in operation for 1095 days, after experiencing the combined effects of alternating meteorological loads, the vertical axis of the blue curve climbs to 3.381, exceeding the red high-risk warning threshold.

[0109] The graphical representation of the cross-breakthrough corresponds to the logic of the system triggering corresponding early warnings and pushing rectification instructions. This proves that the dynamic evolution model proposed in this solution can not only quantitatively assess the physical state, but also predict and track the deterioration trend of hidden conflicts within a certain time span. This allows for advance planning of maintenance actions before risk incidents occur, thereby enhancing the engineering application value of the test system in full life cycle safety protection.

[0110] In summary, this embodiment of the system, by constructing a rigorous multi-dimensional data flow channel, precise mathematical modeling of physical characteristics, and a closed-loop intelligent hardware feedback correction execution logic, completely upgrades the traditional extensive and manual high-voltage clamp construction into a highly controllable, quantifiable, and predictable digital precision engineering system with predictable life cycle risks. This greatly ensures the robustness and effectiveness of the technical solution in real-world complex transmission line environments.

[0111] Example 2:

[0112] Building upon the basic architecture of Embodiment 1, this embodiment further addresses the technical challenges of system decision-making oscillations and hardware overload failures encountered during the construction and testing of high-voltage transmission lines in complex and extremely harsh dynamic weather environments in the field. It proposes a highly original underlying defense and compensation mechanism.

[0113] Because high-voltage clamps are typically installed on transmission towers tens of meters high or in open canyon wind tunnels, the system inevitably encounters strong crosswinds and high-frequency vibrations of the conductors themselves when collecting feature data and issuing linkage decision commands. These external dynamic alternating loads not only introduce massive amounts of sensor noise but also directly change the real-time mechanical stress state of the clamps, causing the originally static threshold judgment logic to completely fail.

[0114] To completely resolve this conflicting technical problem, the processing unit in this embodiment also includes a dynamic hierarchical anti-vibration compensation module. This module, as an advanced algorithm component embedded in the processing unit, is dedicated to handling data fluctuations and command smoothing under extreme operating conditions, and deeply controlling the output mode of the underlying mechanical hardware.

[0115] For example, the dynamic graded anti-vibration compensation module is used to extract the wind speed change rate and vibration acceleration from the environmental data. In the environmental data stream, the absolute wind speed or absolute displacement alone is insufficient to reflect the transient impact and destructive force caused by the external environment on the clamp system. The core physical quantities that truly lead to system instability are the instantaneous and violent fluctuations in wind speed and the high-frequency mechanical vibration of the structure itself. The dynamic graded anti-vibration compensation module first establishes a sliding data window with a preset time length in the time domain. Let the discrete wind speed time series acquired in real time by the environmental acquisition module be... This module uses a first-order difference algorithm combined with low-pass filtering technology to calculate the rate of change of wind speed, which reflects the intensity of sudden gusts. The formula for calculating the rate of change of wind speed is:

[0116] ;

[0117] In the formula This represents the discrete sampling time interval for environmental data acquisition. Additionally, it includes raw triaxial acceleration data uploaded by the attitude acquisition module or a dedicated accelerometer. This module uses Fast Fourier Transform to convert the time domain to the frequency domain, eliminating low-frequency slow swaying components and specifically extracting high-frequency vibration components in the 10 Hz to 150 Hz frequency band. It then calculates the root mean square value of these components as the vibration acceleration characterizing the severity of the current structure's high-frequency flutter. These two deeply extracted derived physical quantities form the computational benchmark for subsequent dynamic defense mechanisms.

[0118] Optionally, when the wind speed change rate or the vibration acceleration exceeds a preset steady-state reference value, an environmental degradation coefficient is calculated, and this coefficient is introduced as a proportional adjustment factor into the judgment thresholds of the first and second preset conditions, thereby correspondingly reducing the trigger boundary between adjacent conflict levels. In an ideal calm wind laboratory environment, the system relies on a fixed characteristic distance to classify conflict-free levels, first conflict levels, and second conflict levels. However, in strong winds and vibrations in the field, metal fatigue of the clamps is easily accelerated. Even minor internal pressure unevenness or slight attitude deviation can rapidly evolve into irreversible damage under repeated stress. Therefore, the system must possess environmentally adaptive sensitivity adjustment capabilities.

[0119] Specifically, the system pre-programs the steady-state reference value of the wind speed change rate into its memory. Compared with the steady-state reference value of vibration acceleration When extracted in real time Greater than or Greater than At that time, the dynamic graded anti-vibration compensation module is immediately activated. This module calculates the current environmental degradation coefficient through a nonlinear environmental degradation mapping function. The formula for calculating the environmental degradation coefficient is:

[0120] ;

[0121] In the formula and These represent the penalty allocation coefficients for sudden wind speed changes and high-frequency vibrations on the damage weight of the clamps, respectively. and These represent exponential scaling factors that indicate the nonlinear worsening of two severe working conditions with increasing intensity. The calculated environmental degradation coefficients... It is always greater than or equal to 1.

[0122] It should also be noted that the processing unit will use this dynamically generated environmental degradation coefficient. As the core proportional adjustment factor, it directly affects the mathematical reconstruction of the judgment threshold. Assume the first Mahalanobis distance threshold for triggering the first preset condition in the original system is... The second Mahalanobis distance threshold that triggers the second preset condition is The first dynamic judgment threshold after dynamic adjustment. With the second dynamic judgment threshold Calculated separately as follows:

[0123] ;

[0124] ;

[0125] Through the rigorous division logic described above, when the external environment deteriorates drastically, causing the environmental degradation coefficient to surge, the Mahalanobis distance trigger boundaries used to determine the conflict level will be proportionally compressed and reduced. This means the system becomes extremely sensitive. Minor, conflict-free deviations that were initially considered perfectly acceptable under calm conditions will, in strong winds, trigger the lowered thresholds and be decisively escalated to a first-level conflict state. Similarly, first-level conflict states that were initially thought to be repairable through fine-tuning will be rapidly escalated to second-level conflict states requiring immediate suspension and alarms due to environmental deterioration. This unique mechanism, which dynamically reduces thresholds to improve environmental adaptability, eliminates physical damage caused by system sluggishness in extreme weather conditions at the algorithmic level.

[0126] For example, a hysteresis comparison interval with a tolerance range is set at the trigger boundary of the adjusted adjacent conflict levels. When the feature data fluctuates within the hysteresis comparison interval, the system maintains the linkage decision command of the previous sampling period unchanged. Although the aforementioned steps solve the safety sensitivity problem by reducing the trigger boundary, they bring about a more critical engineering control challenge. When the field environment is in a windy state, the clamp body will swing irregularly at high altitude. The multi-source feature sensing unit uploads feature data hundreds of times per second. When these feature data with environmental noise happen to be near a certain adjusted dynamic judgment threshold, even a tiny pressure sampling noise of 0.01 MPa can cause the system to determine a conflict-free state and issue a command to continue tightening in the previous millisecond, and then determine a first conflict state and issue a linkage decision command for attitude correction in the next millisecond.

[0127] This kind of decision oscillation, occurring dozens of times per second between two adjacent conflict levels, is called system decision oscillation. Decision oscillation can cause the lower-level electric fastener driver to receive wildly changing opposing control signals, which in turn causes the internal insulated gate bipolar transistor to overheat and burn out due to frequent switching, or causes the servo motor to stall and jam, ultimately leading to complete hardware failure.

[0128] Optionally, to fundamentally eliminate this fatal decision-making oscillation, the dynamic hierarchical anti-oscillation compensation module introduces a hysteresis comparison interval with a width memory effect into the software decision architecture. The trigger boundary is defined by the conflict-free state and the first conflict state. For example, the system no longer uses a single numerical line as the cutting tool, but instead uses this dynamic value as the center, extending upwards and downwards to form a line with tolerance factors. The determined interval width is used to construct a range that includes the upper trigger limit. With lower trigger limit The hysteresis comparison interval. Specifically, it is calculated as follows:

[0129] ;

[0130] ;

[0131] Under the operating logic of this hysteresis comparison interval, the system's state transition must satisfy a strict one-way penetration rule. Assuming the current system is in a conflict-free state, as the feature data deteriorates, the calculated Mahalanobis distance gradually increases. When this distance merely exceeds the lower trigger limit... At that time, the system will not immediately change the judgment state, but will require that the distance must continue to increase and completely break through the trigger limit. Only then will the system officially transition to the first conflict state. Conversely, if the system is already in the first conflict state and is performing corrective actions, as the feature data improves and the feature distance gradually decreases, it must completely fall below the lower trigger limit. Only then will the system revert to a conflict-free state.

[0132] When the feature data is and When the hysteresis comparison interval fluctuates irregularly, the state machine within the processing unit will be forcibly locked, and the system will maintain the linkage decision instruction from the previous sampling period unchanged. This software-level dead-zone filtering mechanism acts like an impenetrable firewall, completely shielding instruction oscillations caused by high-frequency environmental noise and ensuring the stable operation and lifespan of the physical execution hardware under harsh conditions.

[0133] like Figure 5The waveform diagram of the anti-decision oscillation control logic, which incorporates a hysteresis comparison interval under extreme operating conditions, illustrates the command smoothing and anti-oscillation effects of this scheme when dealing with complex conditions such as strong crosswinds and high-frequency light wind vibrations. This figure is a dual-vertical-axis waveform diagram. The horizontal axis uniformly represents the system's continuous sampling time in milliseconds, while the vertical axis on the left represents the feature deviation distance calculated in real time by the system. The blue curves, exhibiting irregular fluctuations, represent the real-time feature data fluctuations including environmental noise.

[0134] To suppress numerical fluctuations caused by external environment, the system sets an upper trigger limit indicated by a red dashed line and a lower trigger limit indicated by a green dashed line at the dynamic trigger boundary. In this embodiment, the upper trigger limit is set to a value of 2.3 and the lower trigger limit is set to a value of 1.7. The two dashed lines form a hysteresis comparison interval with a tolerance range.

[0135] The vertical axis on the right side of the graph represents the discrete decision states of the system, where a value of 0 represents a conflict-free state, a value of 1 represents the first conflict state, and the purple solid step line represents the decision state transition curve of the final output of the system.

[0136] Observing along the timeline, it can be seen that even though the blue real-time feature data fluctuation curve fluctuated frequently within the hysteresis comparison range of 1.7 to 2.3, the purple judgment state transition curve remained stable without high-frequency switching. Only when the blue feature data fluctuation curve breaks through the upper trigger limit of 2.3 due to actual physical force changes, does the purple judgment state transition curve jump from a conflict-free state to the first conflict state; and when it falls back, it also needs to break through the lower trigger limit of 1.7 to return to its original state.

[0137] This one-way penetration dead zone filtering mechanism can, to a certain extent, block the path of high-frequency environmental noise near the critical point to the underlying hardware, avoiding the problem of motor abnormality caused by the lower-level electric fastening device receiving frequently changing control signals, and helping to ensure the reliability of the physical execution hardware in field weather conditions.

[0138] Specifically, this embodiment further extends the defense mechanism to the lowest level of physical electromechanical control. When the first preset condition is met and the execution unit is executing a torque adjustment command, in response to the continued existence of the vibration acceleration, the electric fastening device switches from a continuous torque output mode to a pulse-compensated torque output mode. The pulse-compensated torque output mode is configured to output peak torque during the time interval when the external alternating load is detected to be in a trough. In traditional fastening construction logic, once the system determines that a compensating torque needs to be applied to the clamp bolt, the electric fastening device will drive the motor with a constant current, outputting a smooth and continuous rotational torque until the target value is reached. However, under strong conductor vibration or even galloping conditions, the entire high-voltage conductor acts like a giant spring, applying periodically and violently alternating external tensile stress to the clamp suspension point.

[0139] It is also important to note that if the electric fastening device continues to apply continuous tightening torque rigidly at the exact moment the external alternating stress reaches its peak tensile state, a terrifying transient physical superposition will occur at the root of the bolt's fine threads. This transient superposition can easily cause the local stress to instantly exceed the yield strength of high-strength steel, leading to brittle fracture of the bolt or bursting of the clamp itself. To mitigate this extremely dangerous physical conflict, the dynamic graded anti-vibration compensation module in this embodiment constantly monitors vibration acceleration. The module will send a mode switching hard interrupt to the execution unit via the high-speed fieldbus as long as the high-frequency vibration persists and does not decay below the safety threshold. Upon receiving the interrupt, the electric fastening device immediately abandons the traditional continuous force application method and switches the current loop of the servo controller to an extremely high-frequency pulse output logic.

[0140] For example, this pulse-compensated torque output mode is not a blind hammering, but rather based on extremely precise phase-locked loop time synchronization. The accelerometers in the attitude acquisition module delineate the external alternating load in real time at frequencies of several kilohertz. The system accurately predicts the next peak and trough of the external alternating load waveform using an envelope extraction algorithm and a zero-crossing point detection algorithm. Assuming the external alternating load is in a periodic decaying oscillation, its mathematical model is approximately:

[0141] ;

[0142] In the formula The angular frequency of vibration, This is the initial phase; the system software will track the phase angle change of this sine wave in real time.

[0143] Optionally, the pulse-compensated torque output mode is strictly configured such that: when the phase angle is at... Within its defined minimum phase neighborhood—that is, when the external alternating load exerts the minimum downward tensile force and the clamp is in the trough of instantaneous stress relaxation—a massive instantaneous pulse current is injected into the servo motor, causing the electric fastening device to output peak torque within an extremely short timeframe of a few milliseconds, completing a tightening action at a slight angle; and when the phase angle approaches... When the external alternating load reaches the maximum tensile peak, the current of the electric fastening device is instantly cut off, and the motor rotor is in a free-moving unloading state, and absolutely no additional superimposed torque is output.

[0144] like Figure 6 To illustrate the timing coordination diagram of external alternating load phase tracking and pulsed compensation torque output, the underlying hardware phase-locked loop coordination and control mechanism under conditions such as light wind vibration can be demonstrated. This diagram is a dual-vertical-axis waveform diagram, with the horizontal axis representing the underlying hardware control timing in milliseconds. The vertical axis on the left represents the amplitude of the external alternating tensile load applied to the clamp by the high-voltage conductor galloping; the blue sine curve in the diagram simulates this periodic alternating external tensile stress process. The vertical axis on the right represents the magnitude of the compensation torque output by the servo motor inside the electric fastening device; the red pulse curve in the diagram visually reproduces the sudden change in the motor's instantaneous output.

[0145] By comparing the phase correspondence of the two curves along the time axis, it can be seen that when the blue external alternating load waveform rises and reaches the peak range, it means that the conductor is applying a large physical tensile force to the clamp. At the same time, the red pulse compensation torque waveform remains on the zero baseline, with no additional torque output. This confirms the defensive logic in the embodiment that the motor performs follow-up unloading when the external stress is large to avoid stress superposition.

[0146] Conversely, when the blue external alternating load waveform dips to its trough, it indicates that the external downward tensile force has reached a low level and the clamp is in a relatively relaxed stress phase. Within this brief millisecond-level timing window, the red waveform rises rapidly, outputting a peak pulse torque of up to 45 Newton-meters. This correspondence between the blue trough and the red peak on the time axis demonstrates that the software phase-locked loop algorithm of this system can capture the timing of the periodic weakening of the external environmental load and guide the underlying execution hardware to complete the tightening and repair action within the appropriate window. This reduces the risk of damage to high-strength bolts under complex working conditions and provides engineering data support for the feasibility of the underlying electromechanical control scheme of this patent.

[0147] Through this ingenious pulse output logic based on the phase of the external environment, the system can safely, discreetly, and efficiently tighten and repair loose connections inside the clamps by utilizing every millisecond-level window during the periodic weakening of the external environmental load, even in extreme environments. This completely breaks through the technical barrier of not being able to perform precise live-load testing and adjustment of high-voltage clamps under harsh operating conditions, achieving a major breakthrough in the underlying hardware control logic of high-voltage transmission engineering.

[0148] Example 3:

[0149] This embodiment is based on the system architecture of Embodiment 1 and Embodiment 2. It further addresses the technical pain point that hidden conflicts faced by high-voltage transmission lines during the new construction and acceptance stage, power outage maintenance stage, or extremely low grid load operation stage cannot be detected by conventional infrared means. It proposes a highly original passive transient thermal detection and reverse inference mechanism.

[0150] In conventional live-line inspection operations, multi-source feature sensing units or inspection equipment rely on Joule heating generated by the contact resistance inside the clamps to visualize defects. However, for main lines that have just been installed but not yet connected to the high-voltage power grid, there is absolutely no current flowing inside the clamps. At this time, the traditional steady-state thermal radiation mapping model will completely lose the input of physical data sources, resulting in a serious blind spot in the system's testing and verification process. In order to completely eliminate this physical limitation and achieve absolutely reliable testing throughout the entire life cycle and under all operating conditions, this embodiment has carried out a revolutionary hardware expansion and algorithm reconstruction of the sensing dimension and processing core of the test system.

[0151] It is also important to note that, in order to break away from the passive reliance on Joule heating from external power grid loads, the system architecture of this embodiment has undergone targeted hardware upgrades. The inspection equipment is equipped with an active thermal excitation module. This active thermal excitation module is not an ordinary lighting source, but a pulsed broadband light source or high-energy laser generator capable of instantly releasing extremely high energy density. Its core function is to physically heat the metal outer surface of the target high-voltage clamp within a very short time window, without relying on any external electrical conditions, using an independent energy storage unit carried by the UAV platform. The module contains a high-voltage charging and discharging capacitor array and a xenon flash lamp tube, which can convert the stored electrical energy into broadband thermal radiation photons within milliseconds and project them directionally onto the clamp surface. Through this proactive approach at the hardware level, the system is no longer a silent data receiver, but becomes the thermodynamic master of the testing environment.

[0152] Specifically, the processing unit in this embodiment has set up an extremely rigorous logic judgment gateway for this special test condition. When the visualization and fault diagnosis unit determines that the clamp is in a non-energized, no-current load condition, it automatically triggers the transient detection mode. This judgment is implemented through two independent logic branches:

[0153] The first branch is the system dispatch information verification branch. The processing unit reads the line operation status data packets from the power grid dispatch center in real time through the industrial-grade wireless Ethernet interface. If the data packet indicates that the current line switch cabinet is in the open state, it is directly determined to be a non-powered condition.

[0154] The second branch is a direct physical quantity detection branch. The front end of the UAV inspection equipment is equipped with a highly sensitive three-dimensional spatial magnetic field sensor, which can measure the power frequency alternating magnetic field strength around the clamp in real time. If the measured magnetic field strength is lower than the preset background magnetic field noise threshold, it indicates that there is no alternating current inside the clamp, and the visualization and fault diagnosis unit makes a judgment based on this.

[0155] This dual-redundancy decision logic ensures the absolute accuracy of transient detection mode triggering.

[0156] For example, once the system's judgment conditions are met, the test system will immediately enter an extremely tight timing-based collaborative working state. In the transient detection mode, the active thermal excitation module projects a transient thermal pulse onto the outer surface of the clamp. The UAV flight control system first hovers itself at the optimal observation distance of 3 to 5 meters from the front of the high-voltage clamp and activates the gimbal's mechanical locking function. Subsequently, the processing unit issues a thermal pulse trigger command. The active thermal excitation module closes the high-voltage discharge switch within one clock cycle, generating a transient thermal pulse with a duration of only 5 to 10 milliseconds. This transient thermal pulse, containing thousands of joules of energy, strikes the aluminum alloy outer surface of the clamp at the speed of light. The radiant energy it carries is instantly absorbed by the surface material, causing the extremely thin surface layer of the clamp to experience a rapid temperature rise of several to tens of degrees Celsius in an instant. Due to the extremely short duration of the thermal pulse, the heat has not yet had time to conduct to the deep structure inside the clamp and the conductor core, forming an extremely ideal initial surface heat source boundary condition on the clamp surface.

[0157] As the thermal pulse projection ends instantly, the data acquisition process seamlessly transitions on a microsecond-level timescale. The inspection equipment acquires continuous time-series infrared images of the clamps after being excited by the thermal pulse, extracting the transient temperature decay curves of each pixel on the surface. The high-frequency cooled infrared thermal imager on the inspection equipment enables continuous recording at an extremely high frame rate of over 100 Hz, continuously recording the entire cooling process of the clamp surface after heating, with the total recording time typically set to 2 to 10 seconds. Due to the inevitable slight drift caused by airflow disturbances when the drone hovers in the air, the relative positions of the clamps in the continuous time-series infrared images at different times change. To extract accurate pixel-level data, the visualization and fault diagnosis unit first uses phase correlation or feature point matching algorithms to perform rigorous spatial registration and geometric alignment on these hundreds of images. After pixel-level alignment, the system extracts the temperature value of each independent pixel along the time axis within the region of interest of the image, thereby constructing a transient temperature decay curve that includes the correspondence between the time and temperature dimensions. This curve visually records how the heat at the physical location corresponding to the pixel dissipates inward over time.

[0158] Obtaining a massive amount of transient temperature decay curves is only the first step in data acquisition; the more crucial step is the complete transformation of the physical model. In traditional power-on detection, the system uses a static model based on Joule heating equilibrium. However, in the case of passive excitation, the visualization and fault diagnosis unit adaptively switches the mapping model of infrared thermal imaging temperature distribution and internal pressure distribution to a dynamic mapping model of transient thermal conductivity and internal pressure distribution.

[0159] This adaptive switching action represents a revolutionary shift in the system's core algorithm. The dynamic mapping model no longer focuses on the final stable temperature, but rather on the microscopic resistance encountered by heat during its conduction from the outside in. If the wires inside the clamp are pressed extremely tightly against the clamp body under immense pressure, the microscopic physical gaps between them will be completely squeezed out, and the metal lattices will fuse together. At this point, the transient thermal conductivity of the interface is extremely high, and the surface heat will rapidly pour into the massive internal metal thermal capacity of the wires, causing the surface temperature to drop sharply. Conversely, if the internal pressure is insufficient and there are tiny gaps, even just a few micrometers thick air layer, a huge thermal resistance barrier will form, resulting in extremely low transient thermal conductivity. Heat will be blocked and accumulated in the shallow surface of the clamp, causing the surface temperature to decay extremely slowly.

[0160] It is also important to note that, in order to rigorously quantify the aforementioned physical phenomena, algorithm-level computations are deeply activated. The processing unit calculates and extracts the cooling time constant based on the transient temperature decay curve. In thermodynamic system theory, assuming that the shallow surface layer of the wire clamp and its internal conductor heat dissipation substrate constitute a lumped-parameter heat capacity and thermal resistance system, the decay process of its surface temperature over time relative to the ambient temperature can be approximately described by an exponential decay equation. Let the time variable be... The surface temperature rise of this pixel at the current moment is The highest temperature rise at the instant the heat pulse projection ends, i.e., at the initial moment, is The first-order exponential decay theory model is expressed as follows:

[0161] ;

[0162] In the formula This is the core physical quantity characterizing the rate of temperature decay, known as the cooling time constant. To accurately extract this constant from the original transient temperature decay curve, which contains some observational noise... The visualization and fault diagnosis unit employs a nonlinear least squares fitting algorithm. The system linearizes the above exponential decay theoretical model by taking the natural logarithm of both sides:

[0163] ;

[0164] The system substitutes data from multiple discrete time points collected into the linearized equation, calculates the slope parameter of the line by minimizing the sum of squared residuals, and the reciprocal of the absolute value of the slope parameter is the precise cooling time constant corresponding to that pixel. . The higher the value, the slower the heat dissipation, and the more likely there are gaps and pressure loss inside.

[0165] like Figure 7 By combining the data acquisition points and fitted curves of the exponential decay of the wire clamp surface temperature under transient thermal pulse excitation, this method can demonstrate how relevant thermal parameters are extracted from physical data over time under no-current load conditions. The horizontal axis of the graph represents the recording time (in seconds) of the UAV-mounted infrared thermal imager with continuous recording function enabled; the vertical axis represents the surface temperature rise of the wire clamp surface relative to the ambient background after being excited by the transient thermal pulse (in degrees Celsius).

[0166] The scattered blue dots in the figure represent discrete data points of the actual surface temperature extracted by the system from continuous time-series infrared images. Observing along the time axis, it can be seen that these blue dots reach the highest surface temperature rise of about 15 degrees Celsius at the moment the thermal pulse projection ends, and then show a non-linear decreasing trend over time. Furthermore, due to airflow disturbances and equipment measurement errors in the actual test site, the blue dots exhibit a certain degree of fluctuation in the decreasing channel.

[0167] The smooth red solid line passing through these blue scattered points and reflecting their core cooling trajectory is the exponential decay fitting curve obtained after the system processes the original discrete data using a nonlinear least squares fitting algorithm. The downward slope of this red curve reflects the magnitude of the physical resistance to heat conduction from the wire clamp surface to the internal conductor metal heat capacity. The slope of the decay characteristic of this red fitting curve extracted by the core algorithm is the cooling time constant. The relatively gentle downward trend of the red line in the figure indicates that the cooling time constant corresponding to the test coordinate point is relatively large and the heat dissipation is relatively slow. This reflects, from an algorithmic perspective, the increased thermal resistance caused by possible small gaps and pressure loss between the shallow surface of the wire clamp and the heat dissipation substrate of the internal conductor.

[0168] This waveform fitting and extraction process, which transforms noisy discrete points into smooth mathematical curves, demonstrates the system's data processing capabilities and confirms the feasibility of quantitatively inverting the internal contact pressure under metal enclosures during power outages or new construction acceptance tests without relying on grid steady-state Joule heating. This enhances the scientific validity of this passive transient thermal detection mechanism in practical applications.

[0169] For example, after obtaining the cooling time constant, the system algorithm enters the cross-domain mapping stage of the physical domain and converts the cooling time constant into an interfacial contact thermal resistance characteristic value. The thermodynamic properties of the interface depend on the physical properties of the material and the degree of obstruction to the heat conduction path. Assume the effective surface layer thickness of the wire clamp involved in heat conduction is... The physical density of the wire clamp material is The specific heat capacity of the clamp material is Based on the lumped parameter model of transient heat conduction theory, the cooling time constant is derived. This is directly related to the contact thermal resistance characteristics of the interface. The visualization and fault diagnosis unit uses the following conversion formula to calculate the characteristic value of the interface contact thermal resistance. :

[0170] ;

[0171] In this calculation, density With specific heat capacity All of these are pre-stored as known constants in the system database. Through this formula, the purely temporal feature data originally extracted from the pixel brightness of infrared images is rigorously transformed into a single thermodynamic parameter describing the physical barrier properties of the material's microscopic interface—namely, the interfacial contact thermal resistance characteristic value. This laid a crucial mathematical foundation for the subsequent connection of the mechanical system.

[0172] Optionally, the ultimate goal of the testing system is to quantify the quality of mechanical installation, thus requiring a final interdisciplinary mathematical derivation. Finally, the dynamic mapping model is used to inversely map the interfacial contact thermal resistance characteristic value to the internal pressure state. In the theory of microscopic contact surfaces in solid mechanics, when two rough metal surfaces come into contact, only microscopic peaks actually make contact. The greater the macroscopic compressive pressure, the larger the area of ​​the microscopic peaks that are crushed and deformed, the larger the actual contact area between the metals, and the correspondingly larger the cross-sectional area through which heat flow can pass. Consequently, the interfacial contact thermal resistance characteristic value decreases sharply. The well-known Cooper thermodynamic contact theory model accurately describes this highly nonlinear inverse proportional relationship. Let the comprehensive surface roughness parameter of the contact surface between the clamp and the conductor be... The harmonic effective elastic modulus of the material is The surface micro-yield strength of the material is The complete inverse calculation formula for the dynamic mapping model constructed by the visualization and fault diagnosis unit is as follows:

[0173] ;

[0174] In the formula This is the final internal pressure state value that the system desires to obtain; in the formula... The intrinsic thermal conductivity of the metal matrix is ​​given by [the material's intrinsic thermal conductivity]. and as well as All of these are dimensionless empirical constants obtained after extensive laboratory bench fatigue tests calibrating specific high-voltage clamp materials and stranded wire structures.

[0175] Using the dynamic mapping model formula described above, the microprocessor inside the processing unit processes the interface contact thermal resistance characteristic value corresponding to each pixel. The system performs complex floating-point operations one by one, ultimately outputting an internal pressure state matrix that perfectly corresponds to the real physical world. At this point, the system seems to have X-ray vision, calculating the true three-dimensional force distribution under the thick metal enclosure remotely, without connecting any test power or disconnecting any physical connections, based solely on a single thermal pulse flashed by the drone in the air.

[0176] It is also important to note that the calculated internal pressure state matrix will be seamlessly integrated into the multimodal verification unit and the full-cycle inspection and correlation analysis unit described in Example 1. The system calculates the pressure uniformity of this pressure matrix obtained by back-deriving from the transient thermal pulse. If the calculated pressure uniformity is lower than the system's preset qualified threshold, or if a large area of ​​zero-pressure suspended zone is found in the matrix, the system will also trigger targeted linkage decision commands.

[0177] At this point, the processing unit generates a digital diagnostic report containing the three-dimensional coordinates of the defect, the quantitative value of the local pressure loss, and repair suggestions. This report is then sent to the ground construction personnel via a 5G communication interface or directly to the electric fastening device of the execution unit. After receiving the adjustment command derived from the power-off condition, the execution unit can still accurately start the high-precision servo motor to apply preset torque compensation to the bolt at a specific location, or adjust the roll and pitch attitude of the clamp until it passes the UAV's thermal pulse inspection again.

[0178] In summary, the passive transient thermal excitation back-inference method of this embodiment completely fills the gap in quality monitoring technology for high-voltage transmission lines during construction and acceptance periods and low-load shutdown periods. The system utilizes actively projected transient thermal pulses, extracts the cooling time constant in the time dimension, and successively bridges the theoretical bridges of thermodynamics and solid mechanics to achieve a highly innovative non-contact quantitative internal pressure inversion.

[0179] This not only greatly expands the all-weather and all-condition applicability of the system testing function, but also subverts the passive limitations of traditional methods from the underlying physical testing means, making the attitude and pressure coordination function test of the high-voltage clamp truly foolproof.

[0180] Example 4:

[0181] like Figure 8 As shown, this embodiment provides a method for testing the coordinated function of high-voltage line clamp attitude and pressure. This method aims to fundamentally solve a series of conflicting technical problems mentioned in the background art, such as the disconnect between traditional testing and construction acceptance, the tendency of static thresholds to cause decision oscillations under dynamic alternating loads, and the high dependence of conventional infrared thermal imaging technology on steady-state electrical loads. Through the execution sequence of this method embodiment, a real-time closed-loop linkage mechanism from problem discovery to proactive intervention and adjustment is realized.

[0182] Specifically, after the process of this high-voltage clamp attitude and pressure coordinated function test method is started, the information acquisition step is executed first. In response to the start command, characteristic data during the clamp installation process are synchronously collected as real-time test data; the characteristic data includes pressure data, attitude deflection data, visual image data, environmental data, and tooling status data. In this step, after the operator or automated scheduling system issues the start command, all multi-source sensing devices are synchronously awakened and their current state is frozen within a unified, extremely short time window. This step completely breaks the limitations of traditional static quality inspection relying on a single sensor or post-event manual experience. By comprehensively and without blind spots acquiring the multi-dimensional physical stress state inside and outside the clamp, as well as disturbance factors such as temperature and humidity, wind speed change rate, and high-frequency vibration in the field environment, this step provides an absolutely reliable and dimension-rich raw data foundation for subsequent intelligent analysis, directly overcoming the problem that hidden defects are difficult to detect in a timely manner.

[0183] For example, after acquiring all the data, the process enters the core intelligent computation and decision-making stage. The real-time test data is analyzed to identify conflict states. If a first conflict state meeting a first preset condition is detected, the attitude correction amount and fastening adjustment value are calculated and issued as a linkage decision command. During the data analysis stage, the system does not use rigid static rule comparisons but fully integrates a massive historical conflict feature database for feature distance calculation. More importantly, facing complex and changing field conditions, this analysis step can call upon the environmental degradation parameters described in Example 2 for dynamic threshold drift and hysteresis anti-vibration control.

[0184] Once it is confirmed that the actual crimping state of the clamp deviates from the perfect state, and this deviation belongs to the first conflict state that can be salvaged by micro-adjustments, the core algorithm will immediately and accurately calculate the attitude angle and torque that need to be compensated through the inverse physics minimization equation. This action not only realizes the dynamic coordinated optimization of spatial attitude and contact pressure, but also endows the entire testing and construction process with a powerful ability for real-time self-correction.

[0185] It is also important to note that in complex high-altitude construction operations in the field, serious physical distortions that could endanger the entire power transmission network security may occur at any time. Therefore, the method has established an extremely strict safety tripping mechanism. If a second conflict state that meets the second preset condition is detected, a pause command is generated and an early warning is triggered. The conflict severity corresponding to the second preset condition is higher than that of the first preset condition. When the real-time collected feature data shows large-area internal suspension, irreversible metal plastic deformation, or when extreme environmental conditions cause the dynamic judgment threshold to shrink sharply, thus posing an extremely high risk of physical damage to the system, this method will decisively cut off all conventional physical adjustment processes. Generating a pause command and triggering audible and visual warnings and remote alarms can effectively resolve the conflict between system decision oscillations caused by dynamic alternating loads and overload failure of execution hardware, thereby preserving the structural integrity of the high-voltage clamp body and conductor insulation layer at the most critical moment.

[0186] Optionally, for deviations determined to be correctable, the system translates the instructions into actual physical correction actions. Based on the linked decision instructions, the system performs attitude adjustments and fastening parameter adjustments on the clamps, and sends back the execution results after execution. In this physical action implementation stage, the underlying execution device strictly applies high-precision mechanical displacement and torque according to the values ​​calculated in the preceding decision steps.

[0187] As extended to extreme conditions in Example 2, if strong dynamic alternating loads such as high-frequency vibrations of the conductor in a light breeze are encountered during the execution of this attitude and parameter adjustment step, the execution step will automatically switch the linkage hardware to a pulse-type compensation output mode, outputting peak torque in the trough of external stress waves to avoid catastrophic superposition with external stress. After execution, the action of sending back the execution result constitutes a reverse closed loop of information flow, notifying the upper-level system that the mechanical command has been physically implemented and is ready to enter the acceptance and judgment stage.

[0188] Specifically, this testing method cannot simply stop at blindly applying actions; it must verify the actual effect of the intervention through closed-loop physical measurements. Feature data is re-acquired as verification data to determine whether the first conflict state has been eliminated. If not, an iterative adjustment process is triggered. If, after re-analysis of the re-acquired verification data, local stress concentration or attitude deviation still exists, the system will recalculate the adjustment parameters based on the latest residual error and enter the next round of iterative adjustment. This spiraling, closed-loop iterative correction mechanism ensures that regardless of the nonlinear hysteresis effect or assembly gaps in the metal material, the wire clamp can ultimately be approximated to a conflict-free, perfect installation state.

[0189] Furthermore, in certain passive operating scenarios such as the completion and acceptance of newly built high-voltage lines or the re-inspection of low-load power outages, the above-mentioned method can innovatively utilize drone-mounted equipment to project active transient thermal pulses during data collection and effect verification. This allows for the extraction of the time constant of the cooling curve and the switching to a dynamic mapping model of transient thermal conductivity and internal pressure distribution. This method completely breaks the passive dependence of traditional infrared detection methods on steady-state electrical loads and successfully overcomes the technical bottleneck of the inability to quantitatively back-calculate the internal contact pressure of the clamp under powerless load conditions.

[0190] In summary, the high-voltage clamp attitude and pressure coordination function testing method provided in this embodiment greatly expands the applicability of the system and fundamentally ensures the safety and stability of high-voltage transmission lines throughout their entire life cycle.

[0191] Example 5:

[0192] Corresponding to the above embodiments, the present invention also proposes an electronic device.

[0193] like Figure 8 The diagram shows a structural schematic of an electronic device according to the present invention. The electronic device 100 includes a processor 101 and a memory 103. The processor 101 and the memory 103 are connected, for example, via a bus 102. Optionally, the electronic device 100 may further include a transceiver 104. It should be noted that in practical applications, the transceiver 104 is not limited to one unit, and the structure of this electronic device 100 does not constitute a limitation on the embodiments of the present invention.

[0194] Processor 101 may be a CPU, a general-purpose processor, a DSP, an ASIC, an FPGA, or other programmable logic device, transistor logic device, hardware component, or any combination thereof. It may implement or execute the various exemplary logic blocks, modules, and circuits described in connection with this disclosure. Processor 101 may also be a combination that implements computational functions, such as including one or more microprocessor combinations, a combination of a DSP and a microprocessor, etc.

[0195] Bus 102 may include a pathway for transmitting information between the aforementioned components. Bus 102 may be a PCI bus or an EISA bus, etc. Bus 102 may be divided into an address bus, a data bus, a control bus, etc. For ease of representation, Figure 9 The bus is represented by a single thick line, but this does not mean that there is only one bus or one type of bus.

[0196] The memory 103 stores a computer program corresponding to a high-voltage clamp attitude and pressure coordination function testing method according to the above embodiments of the present invention. This computer program is controlled and executed by the processor 101. The processor 101 executes the computer program stored in the memory 103 to implement the content shown in the aforementioned method embodiments.

[0197] Among them, electronic devices 100 include, but are not limited to: mobile terminals such as laptops and PADs (tablet computers) and fixed terminals such as desktop computers. Figure 9 The electronic device 100 shown is merely an example and should not be construed as limiting the functionality and scope of the embodiments of the present invention.

[0198] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A high-voltage line clamp attitude and pressure coordination function testing system, characterized in that, include: A multi-source feature sensing unit is used to collect feature data during the installation process of the wire clamp. The feature data includes pressure data, attitude deflection data, visual image data, environmental data, and tooling status data. The processing unit is used to identify the conflict state based on the feature data and generate a linkage decision instruction; The execution unit is used to receive the linkage decision command and execute the attitude adjustment and fastening parameter adjustment of the line clamp; The visualization and fault diagnosis unit is used to receive infrared thermal imaging data collected by the inspection equipment; the visualization and fault diagnosis unit constructs a mapping model between infrared thermal imaging temperature distribution and internal pressure distribution, which is used to reverse the internal pressure state of the clamp based on the infrared thermal imaging data. The generation and execution process of the linkage decision-making instruction includes: In response to the start command, the multi-source feature sensing unit synchronously collects real-time test data; The processing unit analyzes the real-time test data. If a first conflict state that meets the first preset condition is detected, the attitude correction amount and the fastening adjustment value are calculated and sent to the execution unit as the linkage decision command. If a second conflict state that meets the second preset condition is detected, a pause command is generated and an early warning is triggered. The conflict severity corresponding to the second preset condition is higher than that of the first preset condition. After executing the linkage decision instruction, the execution unit sends back the execution result. The multi-source feature perception unit re-collects feature data as verification data to determine whether the first conflict state has been eliminated. If it has not been eliminated, the iterative adjustment process is triggered. The inspection equipment is equipped with an active thermal excitation module; when the visualization and fault diagnosis unit determines that the clamp is in a non-energized, no-current load condition, it automatically triggers the transient detection mode. In the transient detection mode, the active thermal excitation module projects transient thermal pulses onto the outer surface of the clamp; the inspection device acquires continuous time-series infrared images of the clamp after it is excited by the thermal pulse, and extracts the transient temperature decay curve of each pixel on the surface. The visualization and fault diagnosis unit adaptively switches the mapping model of infrared thermal imaging temperature distribution and internal pressure distribution to a dynamic mapping model of transient thermal conductivity and internal pressure distribution. The cooling time constant is calculated and extracted based on the transient temperature decay curve, and the cooling time constant is converted into the interface contact thermal resistance characteristic value. Finally, the interface contact thermal resistance characteristic value is back-mapped into the internal pressure state using the dynamic mapping model.

2. The high-voltage line clamp attitude and pressure coordination function testing system according to claim 1, characterized in that, The multi-source feature sensing unit includes: The pressure acquisition module is used to acquire a two-dimensional contact pressure distribution matrix in the contact area between the clamp and the conductor; The attitude acquisition module is used to acquire attitude deflection data of the cable clamp in three dimensions: roll, pitch, and yaw. The vision acquisition module is used to acquire visual image data of the wire clamp and extract visual pose features; An environmental acquisition module is used to collect the environmental data, which includes ambient temperature, humidity, vibration parameters, and air pressure parameters. The tooling status acquisition module is used to collect self-test data on the position of components and the connection status of sensors on the tooling board.

3. The high-voltage line clamp attitude and pressure coordination function testing system according to claim 1, characterized in that, The processing unit includes a conflict feature database server, which stores a historical conflict feature database. The historical conflict feature database contains correlation and matching data of attitude deflection parameters, pressure distribution anomaly features, local conflict locations, and conflict levels. The conflict levels are divided into a non-conflict level, a first conflict level corresponding to the first preset condition, and a second conflict level corresponding to the second preset condition, so that the processing unit can match and generate the corresponding linkage decision instruction.

4. The high-voltage line clamp attitude and pressure coordination function testing system according to claim 3, characterized in that, The execution unit includes an electric fastening device and an attitude positioning adjustment unit; The electric fastening device is used to adjust the clamp torque parameter according to the fastening adjustment value; The attitude positioning adjustment unit is used to adjust the attitude of the clamp space according to the attitude correction amount.

5. The high-voltage line clamp attitude and pressure coordination function testing system according to claim 4, characterized in that, The processing unit also includes a dynamic hierarchical anti-vibration compensation module; The dynamic graded anti-vibration compensation module is used to extract the wind speed change rate and vibration acceleration from the environmental data. When the wind speed change rate or the vibration acceleration exceeds the preset steady-state reference value, the environmental degradation coefficient is calculated, and the environmental degradation coefficient is introduced as a proportional adjustment factor into the judgment threshold of the first preset condition and the second preset condition, so that the trigger boundary between adjacent conflict levels is reduced accordingly. A hysteresis comparison interval with a tolerance range is set at the trigger boundary of the adjusted adjacent conflict level. When the feature data fluctuates within the hysteresis comparison interval, the system maintains the linkage decision command of the previous sampling period unchanged. When the first preset condition is met and the execution unit is executing the torque adjustment command, in response to the continuous existence of the vibration acceleration, the electric fastening device switches from continuous torque output mode to pulse-compensated torque output mode. The pulse-compensated torque output mode is configured to output peak torque during the time sequence when the external alternating load is detected to be in the trough range.

6. The high-voltage line clamp attitude and pressure coordination function testing system according to claim 1, characterized in that, It further includes a full-cycle inspection and correlation analysis unit, used to correlate the inspection data collected by the inspection equipment with the feature data during the installation phase, and to calculate the conflict risk level through a dynamic evolution model; The conflict risk level is determined by the product of the initial conflict level, the working condition aging coefficient representing the severity of the actual environment, and the time decay coefficient representing the duration of the installation span. When the calculated conflict risk level falls into the preset high-risk range, the system triggers an early warning command.

7. The high-voltage line clamp attitude and pressure coordination function testing system according to claim 1, characterized in that, It further includes a multimodal verification unit, used to perform pressure verification, attitude verification and torque verification after confirming that the first conflict state has been eliminated; The passing standard for the pressure verification is that the pressure uniformity is greater than or equal to a first preset threshold. The pass criterion for posture verification is that the deviation between the fused posture deflection data and the visual posture features is less than or equal to a second preset threshold. The passing standard for torque verification is that the deviation between the actual torque and the target torque is within a preset error range; When any review fails to meet the corresponding pass standard, the multimodal review unit automatically issues the corresponding correction instruction.

8. A method for testing the coordinated function of high-voltage clamp attitude and pressure, applied to the high-voltage clamp attitude and pressure coordinated function testing system as described in claim 1, characterized in that, Includes the following steps: In response to the start command, characteristic data during the clamp installation process are synchronously collected as real-time test data; the characteristic data includes pressure data, attitude deflection data, visual image data, environmental data, and tooling status data; The real-time test data is analyzed to identify conflict states. If a first conflict state that meets the first preset condition is detected, the attitude correction amount and the fastening adjustment value are calculated and issued as a linkage decision command. If a second conflict state that meets the second preset condition is detected, a pause command is generated and an early warning is triggered, wherein the conflict severity corresponding to the second preset condition is higher than that of the first preset condition; Based on the linkage decision command, the attitude adjustment and fastening parameter adjustment of the clamp are executed, and the execution result is returned after execution; Re-collect feature data as verification data to determine whether the first conflict state has been eliminated. If it has not been eliminated, trigger the iterative adjustment process. The system receives infrared thermal imaging data collected by the inspection equipment and constructs a mapping model between the infrared thermal imaging temperature distribution and the internal pressure distribution to reverse-engineer the internal pressure state of the clamp based on the infrared thermal imaging data. The inspection equipment is equipped with an active thermal excitation module, and the step of reverse deduction of the internal pressure state of the clamp further includes: when it is determined that the clamp is in a non-energized no-current load condition, the transient detection mode is automatically triggered. In the transient detection mode, the active thermal excitation module is controlled to project transient thermal pulses onto the outer surface of the clamp; continuous time-series infrared images of the clamp after being excited by the thermal pulse are acquired, and the transient temperature decay curves of each pixel on the surface are extracted. The mapping model between infrared thermal imaging temperature distribution and internal pressure distribution is adaptively switched to a dynamic mapping model between transient thermal conductivity and internal pressure distribution. The cooling time constant is calculated and extracted based on the transient temperature decay curve, and the cooling time constant is converted into the interface contact thermal resistance characteristic value. Finally, the interface contact thermal resistance characteristic value is back-mapped into the internal pressure state using the dynamic mapping model.

Images