A charging optimization method and system for electromagnetic pulse connector crimping process of cables

Abstract

This invention discloses a charging optimization method and system for cable electromagnetic pulse joint crimping, belonging to the field of cable joint crimping technology. The method activates a charging control system, using a power module to provide initial charging current to a capacitor. Voltage sensors at both ends of the capacitor monitor the capacitor voltage in real time and feed the voltage data back to the charging control module. A current sensor in the charging circuit monitors the capacitor charging current in real time and feeds the current data back to the charging control module. Based on the feedback from the voltage and current sensors, the charging control module adjusts the current and voltage of the power module, causing the capacitor to charge according to a set charging curve. This invention solves the problems of inaccurate charging process control, lack of effective monitoring and feedback, and low charging efficiency in existing cable electromagnetic pulse joint crimping processes, thereby improving crimping quality, preventing equipment damage, reducing production costs, and ensuring stable and safe power transmission.

Description

Technical Field

[0001] This invention belongs to the field of cable joint crimping technology, specifically relating to a charging optimization method in the cable electromagnetic pulse joint crimping process. Background Technology

[0002] In modern power systems, the connection quality of cable joints is crucial, directly affecting the safety, stability, and reliability of power transmission. Traditional cable joint crimping processes, such as mechanical crimping and welding, have many limitations.

[0003] Mechanical crimping relies on external mechanical force to induce plastic deformation at the joint to achieve a connection. However, this method makes it difficult to ensure uniform stress across the joint during crimping, easily leading to increased localized contact resistance. This can cause overheating during long-term operation, accelerating joint aging and even causing safety accidents. While welding provides better electrical connection performance, the high temperatures generated during cable joint welding can damage the cable insulation layer, reducing its insulation performance and increasing the risk of leakage and short circuits.

[0004] As power systems evolve towards higher voltage, larger capacity, and smarter operation, the performance requirements for cable joints are becoming increasingly stringent. Traditional crimping processes can no longer meet the demands of modern cable systems for low resistance, high mechanical strength, good insulation performance, and long-term stability in joints. Therefore, electromagnetic pulse crimping technology has emerged. This technology utilizes the energy stored in a capacitor, releasing it instantaneously to generate a powerful electromagnetic pulse. This pulse causes the cable joint to undergo plastic deformation under the influence of electromagnetic force, achieving a tight connection. This method offers advantages such as fast crimping speed, high joint quality, and minimal damage to the cable insulation layer.

[0005] However, existing electromagnetic pulse (EMP) splicing processes for cables still have some problems during the charging process. For example, the charging process is not precisely controlled, which can easily lead to overcharging or undercharging of the capacitor, affecting the strength and stability of the EMP and thus the splicing quality. At the same time, the lack of an effective monitoring and feedback mechanism during charging makes it impossible to detect and handle abnormalities such as overheating, overvoltage, and overcurrent in a timely manner, potentially damaging equipment or even causing safety accidents. Furthermore, the low charging efficiency results in a long production cycle and high production costs for the entire splicing process.

[0006] Therefore, developing a charging optimization method and system for cable electromagnetic pulse joint crimping process that can accurately control the charging process, improve charging efficiency, and has a complete monitoring and feedback mechanism is of great practical significance. Summary of the Invention

[0007] Therefore, this invention provides a charging optimization method and system for the cable electromagnetic pulse joint crimping process, which solves the problems of inaccurate charging process control, lack of effective monitoring and feedback, and low charging efficiency in the existing cable electromagnetic pulse joint crimping process, so as to improve the crimping quality, avoid equipment damage, reduce production costs, and ensure the stability and safety of power transmission.

[0008] To achieve the above objectives, the present invention provides the following technical solution: a charging optimization method in the electromagnetic pulse connector crimping process of cables, comprising the following steps:

[0009] Start the charging control system and use the power module to provide the initial charging current to the capacitor;

[0010] The voltage of the capacitor is monitored in real time by voltage sensors across the capacitor terminals, and the voltage data is fed back to the charging control module.

[0011] The charging current of the capacitor is monitored in real time by a current sensor in the charging circuit, and the current data is fed back to the charging control module.

[0012] The charging control module adjusts the current and voltage of the power module based on feedback from the voltage sensor and the current sensor, so that the capacitor is charged according to the set charging curve.

[0013] As a preferred scheme for the charging optimization method in the electromagnetic pulse joint crimping process of cables, during the charging process of the capacitor, the voltage and current are sent into the power input circuit and then into the trigger circuit and silicon controlled rectifier.

[0014] Assume the resistance value of the adjusting potentiometer is Adjust the resistance value of the potentiometer to match the signal voltage in the circuit. Satisfying Relationship:

[0015] ;

[0016] In the formula, This is the total voltage input to the branch containing the adjusting potentiometer. This is the equivalent internal resistance of the branch;

[0017] The trigger circuit generates a trigger signal based on the voltage requirement set by the potentiometer, driving the SCR power regulator during the AC cycle. corresponding time Internal conduction;

[0018] The output voltage of the SCR power regulator With conduction time Input voltage satisfy:

[0019] ;

[0020] The adjustable potentiometer controls the circuit signal voltage by changing the resistance value, which in turn affects the trigger signal generated by the trigger circuit and adjusts the conduction time of the SCR power regulator to control the output voltage.

[0021] As a preferred method for optimizing charging in the electromagnetic pulse connector crimping process of cables, the conduction angle of the SCR power regulator is adjusted. To control the voltage at the load end;

[0022] Let the effective value of the load terminal voltage be... Input AC voltage RMS value ,but:

[0023] ;

[0024] The conduction angle is changed by altering the triggering time of the trigger circuit. This is to regulate the voltage at the load end to meet the voltage requirements of the capacitor charging and electromagnetic pulse generation system.

[0025] As a preferred option for the charging optimization method in the electromagnetic pulse joint crimping process of cables, it also includes:

[0026] A temperature sensor installed inside the capacitor converts the temperature signal into an electrical signal, which is then transmitted to the microcontroller of the charging control system. With voltage sensor output voltage Satisfies a linear relationship:

[0027] ;

[0028] in, This is the temperature-to-voltage conversion factor. This is the offset.

[0029] As a preferred solution for the charging optimization method in the electromagnetic pulse joint crimping process of cables, the microcontroller of the charging control system uses a temperature compensation algorithm to analyze the impact of temperature fluctuations on the charging current. and voltage The temperature compensation algorithm dynamically adjusts the PWM signal and charging parameters to mitigate the impact of temperature fluctuations. The model formula for the temperature compensation algorithm is:

[0030] ;

[0031] ;

[0032] In the formula, , For the compensated current and voltage, , To measure the current and voltage, , The temperature coefficients of current and voltage, This is a reference temperature.

[0033] As a preferred solution for the charging optimization method in the electromagnetic pulse joint crimping process of cables, the microcontroller of the charging control system receives data from temperature, current, and voltage sensors, and dynamically adjusts the PWM duty cycle of the charging parameters by running a PID control algorithm. ;

[0034] The formula for adjusting the PWM duty cycle based on the PID control algorithm is:

[0035] ;

[0036] In the formula, The initial duty cycle, This refers to the deviation between the actual and set values ​​of temperature / current / voltage. , , These are the proportional, integral, and derivative coefficients determined during the adjustment of the PWM duty cycle;

[0037] The alarm of the charging control system is controlled by the GPIO pin of the microcontroller. It activates when overheating is detected. Overvoltage Overcurrent In case of an abnormality, an alarm is triggered and the machine is automatically shut down. A reset switch is connected to the GPIO pin of the microcontroller via a pull-up resistor, allowing the operator to manually reset the device.

[0038] As a preferred scheme for the charging optimization method in the electromagnetic pulse joint crimping process of cables, when the capacitor voltage reaches a set value When the discharge circuit is closed by the switching element, the capacitor releases a high-voltage pulse current to drive the magnetic collecting coil to generate a local strong magnetic field;

[0039] Let the capacitance of the capacitor be... Discharge instantaneous current With capacitor voltage satisfy:

[0040] ;

[0041] magnetic field strength generated by the magnetizing coil With current Number of coil turns ,length satisfy:

[0042] ;

[0043] The strong magnetic field generated by the magnetizing coil is concentrated in the working chamber, and electromagnetic pulses are applied to the cable joint located in the working chamber to cause plastic deformation of the cable joint and achieve crimping.

[0044] As a preferred solution for the charging optimization method in the electromagnetic pulse joint crimping process of cables, the charging control module adopts a PID control algorithm to adjust the voltage and current output of the power supply module based on the data fed back from the voltage and current sensors.

[0045] ;

[0046] ;

[0047] In the formula, This refers to the output voltage adjustment value of the power module. , , These are the proportional, integral, and derivative coefficients for adjusting the output of the power module, respectively. Predetermine the charging voltage value for the capacitor. The voltage sensor provides real-time feedback of the actual capacitor voltage value. This refers to the output current adjustment value of the power module. This is the equivalent load resistance of the charging circuit. This is the voltage-current-resistance relationship function determined according to Ohm's law and other principles.

[0048] This invention also provides a charging optimization system for the cable electromagnetic pulse joint crimping process, used in the above-mentioned charging optimization method for the cable electromagnetic pulse joint crimping process, comprising:

[0049] The charging control unit includes a power module, a voltage sensor, a current sensor, and a charging control module. The power module provides an initial charging current to the capacitor. The voltage sensor is installed across the capacitor to monitor the voltage in real time and feed it back to the charging control module. The current sensor is installed in the charging circuit to monitor the charging current in real time and transmit it to the charging control module. The charging control module adjusts the current and voltage of the power module based on the feedback from the voltage and current sensors.

[0050] The power voltage regulation unit includes a power input circuit, a trigger circuit, a silicon controlled rectifier, an adjustment potentiometer, an SCR power voltage regulator, and a filter circuit. The power input circuit connects the trigger circuit and the silicon controlled rectifier. The trigger circuit generates a trigger signal according to the setting of the adjustment potentiometer to drive the SCR power voltage regulator to conduct. The adjustment potentiometer controls the circuit signal voltage to affect the trigger signal by changing the resistance value. The filter circuit filters current fluctuations and pulses.

[0051] The monitoring and feedback unit includes a temperature sensor, an operation panel, an alarm, a microcontroller, and a data storage device. The temperature sensor is installed inside the capacitor to transmit the temperature signal to the microcontroller. The microcontroller implements a temperature compensation algorithm and dynamically adjusts the charging parameters based on data from the voltage sensor, current sensor, and temperature sensor. The alarm is controlled by the microcontroller to trigger an alarm and stop the system in case of an abnormality. The data storage device communicates with the microcontroller via an SPI interface to store operating data. The operation panel is used to display real-time data and allow manual parameter adjustment.

[0052] As a preferred solution for the charging optimization system in the electromagnetic pulse joint crimping process of cables, it also includes a discharge control unit. The discharge control unit includes a switching element and a magnetic collection coil. When the capacitor voltage reaches a set value, the switching element closes the discharge circuit, causing the capacitor to release a high-voltage pulse current to drive the magnetic collection coil to generate a local strong magnetic field.

[0053] The present invention has the following advantages:

[0054] First, the charging control module can precisely adjust the output of the power module, so that the capacitor is charged stably according to the set curve, which greatly improves the charging efficiency, reduces energy consumption, reduces charging time, and improves the overall crimping operation efficiency.

[0055] Secondly, precise charging ensures the strength and stability of the electromagnetic pulse, ensuring that the cable joints are tightly connected under uniform electromagnetic force, reducing contact resistance, improving the mechanical strength and electrical performance of the joints, extending the service life of the cable, and reducing power transmission failures.

[0056] Third, it can monitor in real time, adjust parameters with temperature compensation algorithms, and trigger an alarm to stop the system in case of abnormalities, thus avoiding equipment damage and safety accidents. Data storage facilitates analysis and maintenance, enhancing system reliability and security. Attached Figure Description

[0057] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0058] Figure 1 This is a schematic diagram of the charging optimization method in the cable electromagnetic pulse connector crimping process provided in this embodiment of the invention;

[0059] Figure 2 This is a schematic diagram of the charging optimization method in the cable electromagnetic pulse connector crimping process provided in this embodiment of the invention;

[0060] Figure 3 This is a schematic diagram of the charging optimization system architecture in the cable electromagnetic pulse connector crimping process provided in this embodiment of the invention. Detailed Implementation

[0061] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0062] See Figure 1 and Figure 2 This invention provides a charging optimization method in the electromagnetic pulse connector crimping process of cables, comprising the following steps:

[0063] S1. Start the charging control system and use the power module to provide the initial charging current to the capacitor;

[0064] Specifically, the charging control system is the core control component of the entire charging process. When the charging control system is activated, the power module is activated and begins to work. The power module provides the capacitor with the initial charging current according to preset parameters. .

[0065] S2. The voltage of the capacitor is monitored in real time by the voltage sensor across the capacitor, and the voltage data is fed back to the charging control module.

[0066] Specifically, as the voltage of the capacitor continuously rises during the charging process, this voltage data is acquired in real time and fed back to the charging control module, which in turn can obtain the charging progress of the capacitor.

[0067] S3. Monitor the charging current of the capacitor in real time using a current sensor in the charging circuit. The current data is then fed back to the charging control module.

[0068] Specifically, the current sensor monitors the charging current in real time in the charging circuit. The current data reflects the magnitude and trend of the current during the charging process. This data is fed back to the charging control module, which can then fully grasp the dynamic situation of the charging process.

[0069] S4. The charging control module adjusts the current and voltage of the power module according to the feedback from the voltage sensor and the current sensor, so that the capacitor is charged according to the set charging curve.

[0070] Specifically, after receiving feedback data from the voltage and current sensors, the charging control module adjusts the power module's output based on this information. The set charging curve is an ideal charging process model, specifying different time points. The voltage that the capacitor should reach and current The charging control module, based on the difference between the feedback data and the set curve, uses a control algorithm (such as a PID control algorithm) to calculate how the current and voltage of the power module need to be adjusted, so that the capacitor charging process matches the set curve, achieving precise charging.

[0071] In this embodiment, during the charging process of the capacitor, the voltage is... Current After being fed into the power input circuit, it enters the trigger circuit and the silicon controlled rectifier.

[0072] Assume the resistance value of the adjusting potentiometer is Adjust the resistance value of the potentiometer to match the signal voltage in the circuit. Satisfying Relationship:

[0073] ;

[0074] In the formula, This is the total voltage input to the branch containing the adjusting potentiometer. This is the equivalent internal resistance of the branch.

[0075] Specifically, the potentiometer plays a crucial role in regulating the signal voltage in the circuit. The resistance value of the potentiometer can be manually adjusted. According to Ohm's law, changes in resistance affect the current in the circuit, which in turn affects the signal voltage. By setting the relationship between the potentiometer's resistance value and the signal voltage in the circuit, the signal voltage can be precisely controlled, providing a suitable input signal for the subsequent trigger circuit and SCR power regulator, thus achieving fine-tuning of the voltage during charging.

[0076] The trigger circuit generates a trigger signal based on the voltage requirement set by the potentiometer to drive the SCR power regulator during the AC cycle. corresponding time Internal conduction;

[0077] Specifically, the trigger circuit acts like a signal generator, operating according to the voltage requirements set by the potentiometer. Once the potentiometer is set to the appropriate voltage value, the trigger circuit generates a corresponding trigger signal. The on-time of the SCR power regulator within the AC cycle determines the output voltage. The trigger signal generated by the trigger circuit controls the on-time and duration of the SCR power regulator within the AC cycle, enabling the SCR power regulator to output a voltage that meets the charging requirements of the capacitor.

[0078] The output voltage of the SCR power regulator With conduction time Input voltage satisfy:

[0079] ;

[0080] Specifically, the working principle of an SCR power voltage regulator is based on the characteristics of a thyristor. In an AC circuit, the SCR power voltage regulator adjusts the output voltage by controlling the conduction time of the thyristor. When the SCR power voltage regulator is turned on, the input voltage is applied to the load (here, the load can be understood as a capacitor charging circuit). The longer the conduction time, the greater the average voltage applied to the load within one AC cycle.

[0081] The adjustable potentiometer controls the circuit signal voltage by changing the resistance value, which affects the trigger signal generated by the trigger circuit and adjusts the conduction time of the SCR power regulator to control the output voltage.

[0082] Specifically, adjusting the potentiometer's resistance changes the circuit signal voltage, and the trigger circuit generates a trigger signal based on this signal voltage. Therefore, adjusting the potentiometer's resistance indirectly affects the characteristics of the trigger signal generated by the trigger circuit (such as trigger timing and pulse width). These changing trigger signals act on the SCR power regulator, altering its conduction time and ultimately achieving precise control of the output voltage. This series of chain reactions allows for flexible adjustment of the voltage during the charging process by adjusting the potentiometer.

[0083] Among them, by adjusting the conduction angle of the SCR power regulator Control the voltage at the load terminal; set the effective value of the load terminal voltage. Input AC voltage RMS value ,but:

[0084] ;

[0085] Specifically, the conduction angle is a parameter describing the operating state of an SCR power voltage regulator. In an AC circuit, by changing the conduction angle of the SCR power voltage regulator, the proportion of current conduction time within one AC cycle can be altered. Since the output voltage is related to the conduction time, adjusting the conduction angle controls the voltage at the load end (in this case, the capacitor charging circuit) to meet the specific voltage requirements of capacitor charging and subsequent electromagnetic pulse generation systems. This is based on the calculation principle of the effective voltage value in AC circuits. In AC circuits, voltage changes continuously over time. To measure its actual effect on the load, the concept of the effective voltage value is introduced. The relationship between the effective voltage value at the load end and the effective voltage value of the input AC circuit is affected by the conduction angle of the SCR power voltage regulator.

[0086] Specifically, by changing the triggering time of the triggering circuit to change the conduction angle, the voltage at the load end is regulated to meet the voltage requirements of the capacitor charging and electromagnetic pulse generation system.

[0087] Specifically, the triggering time of the trigger circuit determines the on-start point of the SCR power regulator within the AC cycle, while the conduction angle is the proportion of conduction time calculated from the on-start point. Therefore, changing the triggering time changes the magnitude of the conduction angle. Since the load-side voltage is related to the conduction angle, this method allows for flexible adjustment of the load-side voltage to meet the voltage requirements at different stages of capacitor charging, as well as the specific voltage requirements of the subsequent electromagnetic pulse generation system, ensuring the stable operation of the entire system.

[0088] This embodiment also includes:

[0089] A temperature sensor installed inside the capacitor converts the temperature signal into an electrical signal, which is then transmitted to the microcontroller of the charging control system. With voltage sensor output voltage Satisfies a linear relationship:

[0090] ;

[0091] in, This is the temperature-to-voltage conversion factor. This is the offset.

[0092] Specifically, a temperature sensor is installed inside the capacitor to monitor its temperature changes in real time during charging. Capacitor performance is affected by temperature; excessively high or low temperatures can impact charging efficiency and even safety. The temperature sensor converts the temperature signal into an electrical signal for easy transmission and processing. The linear relationship between temperature and the output voltage of the voltage sensor was derived through experimental and theoretical analysis. This provides a basis for the microcontroller to calculate the capacitor temperature based on the voltage sensor's output voltage, enabling the microcontroller to monitor the capacitor's temperature in real time.

[0093] In this embodiment, the microcontroller of the charging control system analyzes the impact of temperature fluctuations on charging current and voltage using a temperature compensation algorithm, and dynamically adjusts the PWM signal and charging parameters; the model formula of the temperature compensation algorithm is:

[0094] ;

[0095] ;

[0096] In the formula, , For the compensated current and voltage, , To measure the current and voltage, , The temperature coefficients of current and voltage, This is a reference temperature.

[0097] Specifically, temperature fluctuations affect the charging current and voltage of capacitors, thus impacting charging performance. Temperature compensation algorithms are designed to eliminate or reduce this effect. The microcontroller uses temperature data collected by a temperature sensor and combines it with the temperature compensation algorithm model formula to perform calculations. Based on the calculation results, it dynamically adjusts the PWM signal (pulse width modulation signal) and other charging parameters, ensuring that the capacitor charges in optimal condition under different temperature conditions, guaranteeing the stability and reliability of the charging process.

[0098] In this embodiment, the microcontroller of the charging control system receives data from temperature, current, and voltage sensors, and dynamically adjusts the PWM duty cycle of the charging parameters by running a PID control algorithm.

[0099] The formula for adjusting the PWM duty cycle based on the PID control algorithm is:

[0100] ;

[0101] In the formula, The initial duty cycle, This refers to the deviation between the actual and set values ​​of temperature / current / voltage. , , These are the proportional, integral, and derivative coefficients determined during the adjustment of the PWM duty cycle;

[0102] Specifically, after receiving data from temperature, current, and voltage sensors, the microcontroller uses this data as input to the PID control algorithm. Based on the deviation between the current measured value and the setpoint, the PID control algorithm calculates the amount that needs adjustment through proportional, integral, and derivative operations, and then dynamically adjusts the PWM duty cycle. Changes in the PWM duty cycle affect the power module's output, thereby achieving precise control of the charging parameters and making the capacitor charging process more stable and accurate.

[0103] Among them, the initial duty cycle This refers to the initial state of the PWM signal, and the deviation between the actual and set values ​​of temperature / current / voltage. This is the input signal to the algorithm. The scaling factor. Integral coefficient and differential coefficients These coefficients determine the responsiveness of the proportional, integral, and derivative components to the deviation. Through the combined effect of these three coefficients, the PID control algorithm can calculate the PWM duty cycle that needs adjustment based on the magnitude and trend of the deviation, thereby achieving dynamic optimization of the charging parameters.

[0104] In this embodiment, the alarm of the charging control system is controlled by the GPIO pin of the microcontroller. It activates when overheating is detected. Overvoltage Overcurrent In case of an abnormality, an alarm is triggered and the machine is automatically shut down. A reset switch is connected to the GPIO pin of the microcontroller via a pull-up resistor, allowing the operator to manually reset the device.

[0105] Specifically, the alarm is a safety device in the charging control system. The microcontroller controls the alarm's operation via GPIO pins (general purpose input / output pins). When the microcontroller receives abnormal data (such as over-temperature, over-voltage, or over-current) from temperature, voltage, or current sensors, it sends a signal to the alarm via the GPIO pin, triggering the alarm and automatically shutting down the entire system to protect the equipment from damage. A reset switch is connected to the microcontroller's GPIO pin via a pull-up resistor. After the operator has handled the abnormal situation, pressing the reset switch sends a reset signal to the microcontroller, restoring the system to normal operation.

[0106] In this embodiment, when the capacitor voltage reaches a set value When the discharge circuit is closed by the switching element, the capacitor releases a high-voltage pulse current to drive the magnetic collecting coil to generate a local strong magnetic field;

[0107] Let the capacitance of the capacitor be... Discharge instantaneous current With capacitor voltage satisfy:

[0108] ;

[0109] Specifically, after charging, the capacitor stores a large amount of electrical energy. When the voltage reaches a set value, the switching element closes the discharge circuit, and the capacitor begins to release electrical energy. The released high-voltage pulse current passes through the magnetizing coil. According to the principle of electromagnetic induction, the current passing through the coil generates a magnetic field. The special design of the magnetizing coil allows the generated magnetic field to be concentrated in a specific area, forming a strong local magnetic field, providing the energy needed for subsequent crimping of the cable joint.

[0110] Among them, the magnetic field strength generated by the magnetizing coil With current Number of coil turns ,length satisfy:

[0111] ;

[0112] Specifically, the strength of the magnetic field generated by a magnetizing coil is affected by several factors. Current flowing through the coil generates a magnetic field; the greater the current, the stronger the magnetic field. The more turns the coil has, the more pronounced the magnetic field superposition effect, and the stronger the magnetic field. The coil length affects the distribution and strength of the magnetic field; all other things being equal, a shorter coil length is beneficial for increasing the magnetic field strength.

[0113] The strong magnetic field generated by the magnetic coil is concentrated in the working chamber, and electromagnetic pulses are applied to the cable joint located in the working chamber to cause plastic deformation of the cable joint to achieve crimping.

[0114] Specifically, the strong magnetic field generated by the magnetizing coil is concentrated within the specific area of ​​the working chamber. When the cable joint is located within this chamber, it is subjected to an electromagnetic pulse generated by this strong magnetic field. This electromagnetic pulse induces a current in the cable joint. According to Ampere's law, this induced current experiences a force in the magnetic field. This force causes plastic deformation of the cable joint's metal material, thus achieving crimping. This method of crimping using electromagnetic pulses has advantages such as high efficiency and uniformity, improving the quality of the crimping process.

[0115] In this embodiment, the charging control module employs a PID control algorithm to adjust the voltage and current output of the power module based on data fed back from the voltage and current sensors.

[0116] ;

[0117] ;

[0118] In the formula, This refers to the output voltage adjustment value of the power module. , , These are the proportional, integral, and derivative coefficients for adjusting the output of the power module, respectively. Predetermine the charging voltage value for the capacitor. The voltage sensor provides real-time feedback of the actual capacitor voltage value. This refers to the output current adjustment value of the power module. This is the equivalent load resistance of the charging circuit. This is the voltage-current-resistance relationship function determined according to Ohm's law and other principles.

[0119] Specifically, the PID control algorithm plays a regulatory role in the charging control module. Data from voltage and current sensors reflects the real-time state of the capacitor charging process, and the charging control module uses this data as input to the PID control algorithm. This is achieved by comparing the actual voltage... and the predetermined charging voltage value of the capacitor To address the discrepancy between the voltage output and the input voltage, the PID control algorithm utilizes proportional, integral, and derivative operations to ensure the power module outputs a more suitable voltage. and current This ensures that the capacitor is charged according to the set charging curve, improving the accuracy and stability of charging.

[0120] See Figure 3 This invention also provides a charging optimization system for the cable electromagnetic pulse joint crimping process, used in the charging optimization method for the cable electromagnetic pulse joint crimping process described in the above embodiments, comprising:

[0121] The charging control unit 001 includes a power module, a voltage sensor, a current sensor, and a charging control module. The power module provides an initial charging current to the capacitor. The voltage sensor is installed across the capacitor to monitor the voltage in real time and feed it back to the charging control module. The current sensor is installed in the charging circuit to monitor the charging current in real time and transmit it to the charging control module. The charging control module adjusts the current and voltage of the power module based on the feedback from the voltage and current sensors.

[0122] Specifically, the power module is the energy source for the entire charging process, providing the initial charging current to the capacitor, which initiates the energy storage process. A voltage sensor is installed across the capacitor to capture real-time voltage changes. Since the capacitor's voltage continuously increases during charging, timely voltage information is crucial for monitoring the charging progress. A current sensor is installed in the charging circuit to monitor the magnitude and trend of the charging current in real time. A stable and appropriate charging current has a critical impact on the safe charging of the capacitor and the final charging effect. After receiving feedback data from the voltage and current sensors, the charging control module adjusts the current and voltage output from the power module based on this real-time data, ensuring that the capacitor charges according to the preset charging curve, achieving precise charging.

[0123] The power voltage regulation unit 002 includes a power input circuit, a trigger circuit, a silicon controlled rectifier, an adjustment potentiometer, an SCR power voltage regulator, and a filter circuit. The power input circuit is connected to the trigger circuit and the silicon controlled rectifier. The trigger circuit generates a trigger signal according to the setting of the adjustment potentiometer to drive the SCR power voltage regulator to conduct. The adjustment potentiometer controls the circuit signal voltage to affect the trigger signal by changing the resistance value. The filter circuit filters current fluctuations and pulses.

[0124] Specifically, the power input circuit serves as a connection and transmission circuit, introducing the voltage and current output from the power module into subsequent circuits, providing the basis for subsequent voltage regulation operations. The trigger circuit functions similarly to a signal generator, producing a corresponding trigger signal based on the voltage requirements set by the potentiometer. The resistance value of the potentiometer can be manually adjusted; according to Ohm's law, a change in resistance leads to a change in the current in the circuit, thus affecting the signal voltage. Since the characteristics of the trigger signal (such as trigger timing and pulse width) are determined by the signal voltage, adjusting the potentiometer indirectly affects the trigger signal by changing its resistance value. The SCR power regulator is a controllable power regulation device; the trigger signal controls its conduction timing and duration within the AC cycle, thereby regulating the output voltage. The filter circuit purifies the current, filtering out fluctuations and pulse components to ensure more stable output current and voltage, providing a good electrical environment for capacitor charging.

[0125] The monitoring feedback unit 003 includes a temperature sensor, an operation panel, an alarm, a microcontroller, and a data storage device. The temperature sensor is installed inside the capacitor to transmit the temperature signal to the microcontroller. The microcontroller is used to implement a temperature compensation algorithm and dynamically adjust the charging parameters based on data from the voltage sensor, current sensor, and temperature sensor. The alarm is controlled by the microcontroller to trigger an alarm and stop the machine in case of an abnormality. The data storage device communicates with the microcontroller through an SPI interface to store operating data. The operation panel is used to display real-time data and manually adjust parameters.

[0126] Specifically, a temperature sensor is installed inside the capacitor to monitor its temperature changes in real time during charging. Capacitor performance is significantly affected by temperature; excessively high or low temperatures can threaten charging efficiency and safety. The temperature sensor converts the temperature signal into an electrical signal and transmits it to the microcontroller. Upon receiving this temperature data, the microcontroller analyzes and calculates it using a temperature compensation algorithm. Since temperature fluctuations affect charging current and voltage, the temperature compensation algorithm dynamically adjusts charging parameters based on the current temperature to eliminate or reduce the adverse effects of temperature on the charging process, ensuring stable charging of the capacitor under various temperature conditions. An alarm, controlled by the microcontroller, immediately triggers when it receives abnormal data (such as over-temperature, over-voltage, or over-current) from the voltage, current, or temperature sensors, and shuts down the entire system to protect the equipment from damage. A data memory communicates with the microcontroller via an SPI interface and stores system operating data, which can be used for subsequent data analysis and system optimization. The control panel provides operators with an interface to interact with the system, displaying real-time system data such as voltage, current, and temperature. Operators can also manually adjust system parameters through the control panel to meet different charging needs.

[0127] In this embodiment, a discharge control unit 004 is also included. The discharge control unit includes a switching element and a magnetic collecting coil. When the capacitor voltage reaches a set value, the switching element closes the discharge circuit, causing the capacitor to release a high-voltage pulse current to drive the magnetic collecting coil to generate a local strong magnetic field.

[0128] Specifically, during the charging process, a capacitor continuously stores electrical energy. When its voltage reaches a preset value, it means that the capacitor has stored enough energy. At this point, the switching element closes the discharge circuit, and the capacitor begins to release the stored high-voltage pulse current. When the high-voltage pulse current passes through it, according to the principle of electromagnetic induction, the current generates a magnetic field around the coil. Due to the special structure of the magnetic collecting coil, the generated magnetic field can be concentrated in a specific area, forming a localized strong magnetic field. This localized strong magnetic field can be used to apply an electromagnetic pulse to the cable joint, causing plastic deformation of the metal material of the cable joint, thereby achieving the crimping of the cable joint.

[0129] Although the present invention has been described in detail above with general descriptions and specific embodiments, modifications or improvements can be made to it, which will be obvious to those skilled in the art. Therefore, all such modifications or improvements made without departing from the spirit of the present invention fall within the scope of protection claimed by the present invention.

Claims

1. A charging optimization method in the electromagnetic pulse connector crimping process of cables, characterized in that, Includes the following steps: Start the charging control system and use the power module to provide the initial charging current to the capacitor; The voltage of the capacitor is monitored in real time by voltage sensors across the capacitor terminals, and the voltage data is fed back to the charging control module. The charging current of the capacitor is monitored in real time by a current sensor in the charging circuit, and the current data is fed back to the charging control module. The charging control module adjusts the current and voltage of the power module based on feedback from the voltage sensor and the current sensor, so that the capacitor is charged according to the set charging curve. Also includes: A temperature sensor installed inside the capacitor converts the temperature signal into an electrical signal, which is then transmitted to the microcontroller of the charging control system. With voltage sensor output voltage Satisfies a linear relationship: ； in, This is the temperature-to-voltage conversion factor. This is the offset; The microcontroller of the charging control system uses a temperature compensation algorithm to analyze the impact of temperature fluctuations on the charging current. and voltage The temperature compensation algorithm dynamically adjusts the PWM signal and charging parameters to mitigate the impact of temperature fluctuations. The model formula for the temperature compensation algorithm is: ； ； In the formula, , For the compensated current and voltage, , To measure the current and voltage, , The temperature coefficients of current and voltage, For reference temperature; The microcontroller of the charging control system receives data from temperature, current, and voltage sensors, and dynamically adjusts the charging parameters and PWM duty cycle by running a PID control algorithm. ; The formula for adjusting the PWM duty cycle based on the PID control algorithm is: ； In the formula, The initial duty cycle, This refers to the deviation between the actual and set values ​​of temperature / current / voltage. , , These are the proportional, integral, and derivative coefficients determined during the adjustment of the PWM duty cycle; The alarm of the charging control system is controlled by the GPIO pin of the microcontroller. It activates when overheating is detected. Overvoltage Overcurrent In case of an abnormality, an alarm is triggered and the machine is automatically shut down. A reset switch is connected to the GPIO pin of the microcontroller via a pull-up resistor, allowing the operator to manually reset the device. The charging control module employs a PID control algorithm to adjust the voltage and current output of the power module based on data feedback from voltage and current sensors. ； ； In the formula, This refers to the output voltage adjustment value of the power module. , , These are the proportional, integral, and derivative coefficients for adjusting the output of the power module, respectively. Predetermine the charging voltage value for the capacitor. The voltage sensor provides real-time feedback of the actual capacitor voltage value. This refers to the output current adjustment value of the power module. This is the equivalent load resistance of the charging circuit. This is the voltage-current-resistance relationship function determined according to Ohm's law and other principles.

2. The charging optimization method in the cable electromagnetic pulse connector crimping process according to claim 1, characterized in that, During the charging process of the capacitor, the voltage and current are sent to the power input circuit and then enter the trigger circuit and the silicon controlled rectifier. Assume the resistance value of the adjusting potentiometer is Adjust the resistance value of the potentiometer to match the signal voltage in the circuit. Satisfying Relationship: ； In the formula, This is the total voltage input to the branch containing the adjusting potentiometer. This is the equivalent internal resistance of the branch; The trigger circuit generates a trigger signal based on the voltage requirement set by the potentiometer, driving the SCR power regulator during the AC cycle. corresponding time Internal conduction; The output voltage of the SCR power regulator With conduction time Input voltage satisfy: ； The adjustable potentiometer controls the circuit signal voltage by changing the resistance value, which in turn affects the trigger signal generated by the trigger circuit and adjusts the conduction time of the SCR power regulator to control the output voltage.

3. The charging optimization method in the cable electromagnetic pulse joint crimping process according to claim 2, characterized in that, By adjusting the conduction angle of the SCR power regulator To control the voltage at the load end; Let the effective value of the load terminal voltage be... Input AC voltage RMS value ,but: ； The conduction angle is changed by altering the triggering time of the trigger circuit. This is to regulate the voltage at the load end to meet the voltage requirements of the capacitor charging and electromagnetic pulse generation system.

4. The charging optimization method in the cable electromagnetic pulse joint crimping process according to claim 1, characterized in that, When the capacitor voltage reaches the set value When the discharge circuit is closed by the switching element, the capacitor releases a high-voltage pulse current to drive the magnetic collecting coil to generate a local strong magnetic field; Let the capacitance of the capacitor be... Discharge instantaneous current With capacitor voltage satisfy: ； magnetic field strength generated by the magnetizing coil With current Number of coil turns ,length satisfy: ； The strong magnetic field generated by the magnetizing coil is concentrated in the working chamber, and an electromagnetic pulse is applied to the cable joint located in the working chamber to cause plastic deformation of the cable joint to achieve crimping.

5. A charging optimization system for the cable electromagnetic pulse joint crimping process, used in the charging optimization method for the cable electromagnetic pulse joint crimping process according to any one of claims 1 to 4, characterized in that, include: The charging control unit includes a power module, a voltage sensor, a current sensor, and a charging control module. The power module provides an initial charging current to the capacitor. The voltage sensor is installed across the capacitor to monitor the voltage in real time and feed it back to the charging control module. The current sensor is installed in the charging circuit to monitor the charging current in real time and transmit it to the charging control module. The charging control module adjusts the current and voltage of the power module based on the feedback from the voltage and current sensors. The power voltage regulation unit includes a power input circuit, a trigger circuit, a silicon controlled rectifier, an adjustment potentiometer, an SCR power voltage regulator, and a filter circuit. The power input circuit connects the trigger circuit and the silicon controlled rectifier. The trigger circuit generates a trigger signal according to the setting of the adjustment potentiometer to drive the SCR power voltage regulator to conduct. The adjustment potentiometer controls the circuit signal voltage to affect the trigger signal by changing the resistance value. The filter circuit filters current fluctuations and pulses. The monitoring and feedback unit includes a temperature sensor, an operation panel, an alarm, a microcontroller, and a data storage device. The temperature sensor is installed inside the capacitor to transmit temperature signals to the microcontroller. The microcontroller implements a temperature compensation algorithm and dynamically adjusts charging parameters based on data from the voltage sensor, current sensor, and temperature sensor. The alarm is controlled by the microcontroller to trigger an alarm and stop the system in case of an abnormality. The data storage device communicates with the microcontroller via an SPI interface to store operating data. The operation panel is used to display real-time data and allow manual parameter adjustment.

6. The charging optimization system in the electromagnetic pulse connector crimping process of a cable according to claim 5, characterized in that, It also includes a discharge control unit, which includes a switching element and a magnetic collecting coil. When the capacitor voltage reaches a set value, the switching element closes the discharge circuit, causing the capacitor to release a high-voltage pulse current to drive the magnetic collecting coil to generate a local strong magnetic field.

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