Cable joint connector and crimping die

Abstract

The invention discloses a cable joint connector which comprises a conductive pipe body, the section of the inner wall of the pipe body is circular, and convex parts and concave parts which are alternately arranged at intervals are arranged in the circumferential direction of the outer wall of the pipe body. Materials of the convex parts of the pipe body are extruded and flow to the adjacent concave parts through applied pressure F of up-down involution of an external mold and first partial pressure F11 and F12 which are parallel to the tangent line of the most convex point and are opposite in direction, the outer wall of the pipe body forms a quasi-circular shape, corner and tip discharge is avoided, and secondary corner and tip polishing work is not needed. Meanwhile, in the extrusion flowing process of materials of the convex parts, pressure F acting on the convex parts generates second partial pressure F2 pointing to the circle center of the inner wall, after the second partial pressure F2 of each convex part is crimped, the inner wall of the pipe body extrudes and is attached to a wire in the inner wall, and due to the fact that stress is uniform, the inner wall of the crimped pipe body is similar to a circle, the contact area is increased, and the contact strength of the wire is improved. And the working resistance of the crimped connector is reduced.

Description

Technical Field

[0001] This invention relates to the technical field of medium and high voltage power transmission, and in particular to a cable joint connector and crimping module. Background Technology

[0002] In 10kV power distribution systems, cables are core transmission components, and the reliability of their conductor connections directly determines the operational stability and service life of the entire power system. Currently, the mainstream 10kV cable conductor connection methods in the industry are mainly divided into two categories: fusion splicing and crimping. However, both of these traditional connection methods have inherent technical defects that are difficult to overcome, and crimping can easily lead to additional insulation hazards, making the connection points a weak link in the power system, which urgently requires targeted improvements.

[0003] In existing technologies, fusion splicing (such as argon arc welding and capacitor energy storage welding) melts the contact area between the cable conductor and the terminal by releasing high heat instantaneously. After cooling, a metallurgical bond is formed to achieve electrical conductivity. The initial design intention of this method is to eliminate contact gaps through the metal melting-solidification process, theoretically achieving lower contact resistance. However, in practical applications, the core drawback of fusion splicing lies in the material damage caused by the instantaneous high temperature: the insulation layer of 10kV cables is mostly made of XLPE cross-linked polyethylene, whose long-term allowable operating temperature is only 90℃, while the instantaneous temperature of fusion splicing can reach thousands of degrees Celsius. Even with tooling shielding, the high temperature will still be conducted to the insulation layer, causing the molecular chains of the insulation material to break, the degree of cross-linking to decrease, and obvious thermal aging phenomena to occur. Specifically, the insulation layer becomes hard, brittle, and the dielectric strength is reduced. At the same time, the high temperature will also cause the metal grains at the conductor joint to coarsen rapidly, destroying the original excellent conductivity and mechanical properties of the metal, increasing the brittleness of the conductor, making it prone to cracks during long-term operation, laying hidden dangers for subsequent electrical breakdown, and ultimately significantly shortening the overall service life of the cable.

[0004] Crimping involves using hydraulic or mechanical crimping pliers to segmentally press the terminals fitted onto the cable conductor, causing plastic deformation between the terminals and conductor. This mechanical interlocking and microscopic adhesion between the terminals and metal contact surfaces achieves electrical conductivity. While this method avoids the high-temperature issues of fusion welding, it has inherent technical limitations: Firstly, due to the segmented pressure application, combined with the surface roughness differences between the terminals and conductor, the contact interface cannot achieve ideal surface contact, instead exhibiting multiple local contact points or segments, resulting in uneven effective contact area. Reduced local effective contact area significantly increases the total contact resistance at the joint. During normal operation of a 10kV cable with a constant current, increased contact resistance generates substantial Joule heat at the joint, causing local temperatures far exceeding the cable's normal operating temperature and accelerating the aging of the surrounding insulation layer. Secondly, the crimping process inevitably produces sharp edges / corners, including metal burrs and flash formed on the terminal edges due to uneven material flow during crimping, and steps or protrusions between adjacent crimped sections due to insufficient mold precision.

[0005] In 10kV medium-high voltage environments, the aforementioned sharp points / edges can cause serious risks of corona discharge. The tiny sharp points at the crimping point are sufficient to cause the local electric field strength to exceed the air breakdown field strength, inducing air ionization and corona discharge, accompanied by the generation of ozone and nitrogen oxides and energy loss. The strong oxidizing substances generated by the discharge will continuously corrode the insulation layer and sheath around the crimping point, further damaging the insulation integrity. The heat released during the discharge process is superimposed with the heat generated by the contact resistance, forming a dual aging mechanism of "discharge heating + resistance heating", which aggravates the damage to the insulation layer. In environments with high humidity, such as outdoors and underground cable trenches, the discharge intensity will be significantly increased, which may directly break down the insulation layer, causing conductor short circuits and leading to equipment damage or large-scale power outages.

[0006] Although the industry has adopted post-crimping grinding as a routine process in an attempt to eliminate the aforementioned tip discharge hazards, traditional grinding methods often only focus on basic optimization of surface flatness and fail to make precise designs for core requirements such as electric field distribution and contact resistance control in medium and high voltage scenarios. As a result, the combined hazards of tip discharge and excessive contact resistance have not been fundamentally resolved.

[0007] See Figure 8In existing cable connectors 100, both the inner and outer radial cross-sectional profiles are circular. They utilize upper and lower molds for crimping, with the force applied perpendicularly upwards and downwards. The crimping surface of the crimping module 200 is polygonal, typically hexagonal. When the circular outer contour of the cable connector contacts, at the included angle α of the two edges of the hexagonal crimping surface, a gap often appears between the inner wall of the connector and the wire after crimping. This reduces the contact area between the wire and the cable connector, increasing the resistance at the connection point and consequently increasing the heat generated. Prolonged high-temperature operation can damage the cable's lifespan. The included angle α of the two edges of the hexagonal crimping surface creates sharp edges and points on the outer wall of the connector 100, requiring secondary processing and polishing to prevent the high-voltage discharge mentioned above.

[0008] In summary, existing 10kV cable connection technologies suffer from a complex interplay of issues: high-temperature aging in fusion splicing, excessive contact resistance in crimping, and tip discharge. These problems result in insufficient reliability and shortened service life at cable connections, failing to meet the stringent requirements of modern power systems for stable operation. Therefore, there is an urgent need to develop a cable connection solution that can simultaneously address these multiple technical shortcomings. This would overcome the inherent limitations of existing fusion splicing and crimping processes, improve the insulation performance and conductivity stability of 10kV cable connections, and ensure the safe and long-term operation of the power system. Summary of the Invention

[0009] This invention provides a cable connector and a crimping mold, which addresses the above-mentioned problems by avoiding severe tip discharge caused by sharp points / corners, reducing the working resistance of the connector after crimping, and lowering the working temperature.

[0010] In a first aspect, the present invention provides a cable connector comprising a conductive tube body, the inner wall of the tube body having a circular cross-section, and the outer wall of the tube body having alternating convex and concave portions circumferentially spaced.

[0011] In this scheme, the pressure F applied by the external mold is decomposed into a first component pressure F1, and a second component pressure F2 generates an extrusion force F parallel to the tangent of the most convex point and in the opposite direction. 21 and F 22The material from the convex portion of the tube body is squeezed and flows to the adjacent concave portion, forming a near-circular shape on the outer wall of the tube body. This avoids the generation of sharp edges and points, eliminating the need for secondary grinding to remove these edges and points. Simultaneously, during the material squeezing and flowing process on the convex portion, the pressure F acting on the convex portion generates a second component pressure F2 pointing towards the center of the inner wall. After crimping, the second component pressure F2 on each convex portion causes the inner wall of the tube body to press against the conductor within the inner wall. Due to the uniform force distribution, the inner wall shape of the tube body after crimping is near-circular. This means that the contact area between the cable connector's peripheral wall and the connector's inner wall is larger than in the background technology where the crimping surface is hexagonal. The weak force at the corners under the action of the die leads to gaps between the connector's inner wall and the conductor, thereby increasing current flow, reducing resistance, lowering the operating temperature at the crimped point after cable crimping, and improving cable lifespan.

[0012] For cables with multiple bare wires, after crimping, the inner wall of the tube body will be penetrated by the gaps between the bare wires, which will further increase the contact area between the inner wall of the connector and the cable joint wires, increase the current flow, and reduce the resistance value.

[0013] Preferably, the protrusions are arranged in pairs symmetrically with respect to the center of the inner wall. This design allows the second component pressure F2 of the crimping module pointing towards the center of the inner wall of the tube body to be balanced, so that the second component pressure F2 on the bare cable wire in the circumferential direction is uniform during crimping, and the crimped bare cable wire tends to be circular, maximizing the contact area between the bare cable wire and the inner wall of the connector.

[0014] Furthermore, the protrusions are arranged in pairs symmetrically around the center of the inner wall, and the outer contour of the protrusions is arc-shaped. The number of pairs of protrusions is 2n+1, where n is a non-zero natural number. One pair of protrusions is located directly above and directly below. The arrangement of the protrusions in this design ensures that the concave parts are opposite each other on the horizontal line. When the upper and lower pressing modules are joined and pressed together, the outer wall of the tube body is more likely to form a near-circular shape, avoiding the generation of sharp corners and tip discharge.

[0015] Preferably, the number of pairs of protrusions is three.

[0016] Furthermore, the arc angles of the convex parts directly above and below gradually increase as they move towards the horizontal line passing through the center of the inner wall. In this design, the arc angle of the convex part directly above gradually increases as it moves clockwise towards the horizontal line passing through the center of the inner wall. The arc angle of the convex part directly above gradually increases as it moves counterclockwise towards the horizontal line. The same applies to the convex parts directly below. Since the first horizontal component pressure of the convex parts located directly above and below is relatively small, while the second component pressure pointing towards the center is relatively large, when the other pairs of convex parts are subjected to the combined pressure F of the upper and lower pressing modules, in order for their generated second component pressure to be equivalent to the second component pressure of the convex parts located directly above and below, the arc angles of the other pairs of convex parts must be large, thereby balancing the magnitude of the circumferential force on the inner wall of the tube.

[0017] Furthermore, the concave portion located on the horizontal line passing through the center of the inner wall gradually decreases in arc angle towards the outer contours of the concave portions directly above and below. In this design, when the pressure F is applied to the mating of the upper and lower pressing modules, the concave portion on the horizontal line receives relative compression from the large-arc convex portions of the upper and lower outer contours, requiring more space in the concave portion to achieve a near-circular shape after pressing.

[0018] Optionally, the arc angle of the outer contour of the protrusion when it is directly above and directly below is 0-90 degrees, and the arc angle of the outer contour of the other protrusions is 0-90 degrees.

[0019] Preferably, the outer contour of the protrusion is arc-shaped, with the arc angle of the outer contour of the protrusion located directly above and directly below being 47.72 degrees, and the arc angle of the outer contour of the other pairs of protrusions being 66.14 degrees.

[0020] Optionally, the arc angle of the outer contour of the concave portion located on the horizontal line passing through the center of the inner wall is 0-90 degrees, and the arc angle of the outer contour of other concave portions is 0-90 degrees.

[0021] Preferably, the arc angle of the outer contour of the concave portion located on the horizontal line passing through the center of the inner wall is 18 degrees, and the arc angle of the outer contour of the other pairs of convex portions is 0 degrees.

[0022] Optionally, the number of protrusions is 2n+1, where n is a non-zero natural number; the protrusions are subjected to crimping pressure from the crimping module pointing towards the center of the inner wall. In this scheme, each protrusion is subjected to crimping pressure F from the crimping module pointing towards the center of the inner wall; this makes the radial pressure on the cable connector uniform and controllable, and makes it easier to crimp the cable connector and the bare cable into a near-circular shape.

[0023] Secondly, this invention provides a crimping mold comprising an upper mold and a lower mold. The crimping surfaces of the upper and lower molds are both arc-shaped, and when joined together, they form a circle to accommodate the cable connector tube body for crimping. In this solution, by using two molds with arc-shaped crimping surfaces, multiple protrusions can be crimped into a near-circular shape, avoiding the formation of sharp points / edges in the crimped cable connector that could cause severe tip discharge. Simultaneously, each protrusion is subjected to a crimping force F in the mating direction of the upper and lower crimping molds, generating a second component force F2. This causes the bare cable wire on the inner wall of the connector to be uniformly subjected to radial pressure, thereby crimping the bare cable wire into a near-circular shape and increasing the contact area between the connector and the bare cable wire.

[0024] Thirdly, the present invention provides a crimping mold comprising a plurality of crimping modules. The crimping pressure of the crimping modules is directed towards the center of the inner wall of the tube body of the cable connector. The crimping surfaces of the crimping modules are all arc surfaces. All crimping modules are joined together to form a circle to accommodate the tube body for crimping. In this solution, corresponding crimping modules are provided for the protrusion of the cable connector subjected to the crimping pressure directed towards the center of the inner wall, making the radial pressure on the cable connector uniform and controllable, and making it easier to crimp the cable connector and the bare cable into a near-circular shape.

[0025] As an improvement to the above solution, the number of crimping modules is the same as the number of protrusions on the cable connector, and they are set in a one-to-one correspondence. In this solution, the number of crimping modules is the same as the number of protrusions on the cable connector. This can be understood as each protrusion corresponding to one crimping module, thereby applying force evenly. The curvature of the protrusions can be equal, and the pressure F applied by the corresponding crimping modules is also equal. The direction of the applied pressure F of each module is all pointing towards the center of the inner wall of the tube body. The curvature of the protrusions can be unequal, and the direction of the equal applied pressure F of each crimping module is all pointing towards the center of the inner wall of the tube body. The second pressure component is of equal magnitude to ensure that the bare cable wire is subjected to uniform circumferential extrusion. By matching large-curvature protrusions with large-curvature concave parts and small-curvature protrusions with small-curvature concave parts, the outer wall of the tube body is balanced to form a near-circular shape after crimping, avoiding the generation of sharp edges and tip discharge, and eliminating the need for secondary grinding to remove sharp edges and tips.

[0026] As an improvement to the above solution, the number of crimping modules is less than the number of protrusions in the cable connector, and the crimping surface of the crimping module contacts the highest point of the protrusion. In this solution, since the direction of the uniform pressure F applied by each crimping module is all directed towards the center of the inner wall of the tube body, the number of each crimping module can be set according to requirements, thus saving production costs. Attached Figure Description

[0027] Figure 1 This is an axial cross-sectional view of the cable connector and cable joint connection provided by the present invention.

[0028] Figure 2 This is a radial cross-sectional view of a cable connector provided in Embodiment 1 of the present invention;

[0029] Figure 3 This is a schematic diagram of the radial cross-sectional relationship between a cable connector and a crimping module provided in Embodiment 1 of the present invention;

[0030] Figure 4 This is a schematic diagram of the structure of a cable connector subjected to radial force by a crimping module according to Embodiment 1 of the present invention;

[0031] Figure 5 This is a radial cross-sectional view of the cable connector before it is crimped with the bare cable, as provided in Embodiment 1 of the present invention.

[0032] Figure 6 This is a radial cross-sectional view of a cable connector after it has been crimped with a bare cable, as provided in Embodiment 1 of the present invention.

[0033] Figure 7 This is a radial cross-sectional view of a cable connector provided in Embodiment 2 of the present invention;

[0034] Figure 8 This is a schematic diagram of the radial cross-sectional relationship between a cable connector and a crimping mold provided in Embodiment 3 of the present invention;

[0035] Figure 9 This is a radial cross-sectional view of the existing cable connector and crimping mold. Detailed Implementation

[0036] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.

[0037] In the description of this invention, the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used solely for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0038] It should be noted that after the cable connector is crimped, see [reference needed]. Figure 1 The main current flow is sequentially through the first cable 41, the contact area between the first cable connector and the inner wall of the connector tube, the connector tube body 1, the contact surface between the second cable connector and the inner wall of the connector tube, and the second cable 42. Therefore, the contact area between the cable connector and the inner wall of the cable connector directly affects the current flow rate; that is, the larger the contact area, the greater the current flow rate.

[0039] See Figure 1This invention provides a radial cross-sectional view of a cable connector according to Embodiment 1. The cable connector includes a conductive tube body 1, preferably a copper tube. The inner wall 2 (i.e., the inner tube wall) of the tube body has a circular cross-section with a diameter of 20.57 mm. The outer wall 3 of the tube body has alternating protrusions 31 and concave portions 32. One pair of protrusions is symmetrical about the center of the inner wall of the tube body, located directly above and below the tube body. The other two pairs of protrusions are symmetrical about the center of the inner wall of the tube body. The number of pairs of protrusions is 2n+1, where n is a non-zero natural number. In this embodiment, n=1. The values ​​of other n are obtained by those skilled in the art through limited experiments based on the technical solution of this invention, and will not be elaborated here.

[0040] The outer contours of the top and bottom convex sections have an arc angle of 47.72 degrees and a radius of 6 mm; the outer contours of the other two pairs of convex sections have an arc angle of 66.14 degrees and a radius of 8 mm; the dimension between the horizontally symmetrical concave sections is 27.40 mm, and the dimension between the other two pairs of concave sections is 30.75 mm. The outer contour of the concave section located on the horizontal line has an arc angle of 18 degrees and a radius of 20.57 mm. The tangent connecting the top convex section and the adjacent convex section results in an angle of 0 degrees for the concave section. The angle between this tangent and the horizontal line passing through the center of the inner wall is 24.41 degrees.

[0041] The crimping die 5 includes an upper die 51 and a lower die 52. The crimping surfaces of the upper die and the lower die are arc surfaces, which fit together to form a circle to accommodate the tube body for crimping the connector and the bare cable wire 4 (first cable connector and second cable connector) to connect them.

[0042] After multiple or single strands of bare cable wire 4 are inserted into both ends of the cable connector tube body, the upper die's crimping surface applies downward pressure to the outer wall of the cable connector, and the lower die's crimping surface applies upward pressure to the outer wall of the cable connector, so that the crimping surface first contacts the most prominent point of the protrusion. Under the relative pressure F of the upper and lower dies, the pressure F is decomposed into a first component pressure F1 and a second component pressure F2. The first component pressure F1 is parallel to the tangent of the most prominent point of the tube body protrusion that contacts the die's crimping surface, and the second component pressure F2 points towards the center of the inner wall of the tube. Under the action of the second component pressure F2, the most prominent point generates a compressive force F parallel to the tangent of the most prominent point and in the opposite direction. 21 and F 22 At the first partial pressure F1, the compressive force F 21 and F 22Under the action of the pressure, the material at the most convex point of the protrusion flows to the two adjacent concave parts, filling the adjacent concave parts with each protrusion, thus making the outer wall of the tube body achieve a near-circular shape. The actual measured longitudinal diameter of the outer wall of the crimped cable connector is 28.6mm, and the transverse diameter is 28.8mm. Under the action of the second component pressure F2 generated by each protrusion, the inner wall of the tube body is pressed against the wire close to the inner wall, and the shape of the inner wall of the tube body after crimping is near-circular; especially for multi-strand wires, according to the law of resistance... R is the resistance at the connection point of the cable connector after crimping. Resistivity, where L is the conductor length and A is the contact area between the inner wall of the conductor tube and the wire. The inner wall is squeezed into the gaps between the multiple strands of wire. See [reference needed]. Figure 5 and Figure 6 This further increases the contact area A between the inner wall and the conductor, improves current flow, and reduces the resistance R at the cable connector joint; according to Joule's law Q= I 2 Rt and Q represent the heat at the cable connector connection, I represents the constant current, and R represents the resistance at the cable connector connection. Over time t, the resistance R at the cable connector connection decreases, thereby reducing the operating heat Q and ensuring normal cable operation. In this embodiment, compared to the resistance R0 of a conductor of the same length, the resistance R at the cable connector connection after crimping is 67% of the resistance R0 of the conductor of the same length, far exceeding manufacturer specifications or industry standards (such as ISO or IEC standards). Generally, the contact resistance should not exceed 1.2 times the conductor resistance.

[0043] See Figure 7 This invention provides a radial cross-sectional view of a cable connector according to Embodiment 2. The cable connector includes a conductive tubular body, preferably a copper tube. The inner wall 200 of the tubular body has a circular cross-section. The outer wall of the tubular body has alternating protrusions and concave portions. The protrusions are arranged in pairs symmetrically with respect to the center of the inner wall, and the concave portions are also arranged in pairs symmetrically with respect to the center of the inner wall. In this embodiment, two pairs of protrusions are arranged circumferentially on the outer wall. The outer contours of the protrusions directly above and below are arc-shaped. The protrusions located on the horizontal line passing through the center of the inner wall are vertical edges 310. The tangents 320 of adjacent arc-shaped protrusions connect the two ends of the vertical edges 310. The inner wall of the tube has a radius of 11 mm. The arc angle of the convex parts at the top and bottom is 90 degrees, with a radius R of 8 mm and a tangent of 14.21 mm. The vertical edge length is 7.17 mm, and the distance between two vertical edges is 31.71 mm. The arc angle of the convex part located on the horizontal line passing through the center of the inner wall is 0 degrees. The distance between the highest points of the convex parts at the top and bottom is 33.36 mm. The angle of each concave part is 0 degrees. The angle between the tangent and the vertical edge is 135 degrees.

[0044] After inserting multiple or single strands of bare cable wire 4 into both ends of the cable connector tube body, the upper die's crimping surface applies downward pressure to the outer wall of the cable connector, and the lower die's crimping surface applies upward pressure to the outer wall of the cable connector. The force analysis of the top and bottom protrusions is the same as in Example 1. At the most convex point of the protrusion located on the horizontal line passing through the center of the inner wall, that is, at the intersection of the tangent and the vertical edge, the tube body material is subjected to extrusion force F. 21 and F 22 Under the influence of the force, the fluid flows towards the adjacent recesses (tangents) to thicken the adjacent recesses, and towards the center of the adjacent vertical edge 310 to thicken the center of the vertical edge 310, thereby making the outer wall of the tube body achieve a near-circular shape and avoiding the generation of sharp corners and tip discharge. The force analysis is the same as in Example 1. Under the circumferential action of the second component force F2 pointing towards the center of the inner wall, the inner wall of the tube body squeezes the wire close to the inner wall. After compression, the shape of the inner wall of the tube body is near-circular, which increases the contact area A between the inner wall and the wire, reduces the resistance R at the connection of the cable connector, and reduces the working heat Q at that point.

[0045] Embodiment 3 of the present invention provides a schematic diagram of the structure of a cable connector. The cable connector includes a conductive tubular body, preferably a copper tubing. The inner wall of the tubular body has a circular cross-section, and the outer wall of the tubular body has alternating protrusions and concave portions. 2n+1 protrusions are arranged circumferentially on the outer wall, where n is a non-zero natural number. In this embodiment, three protrusions are provided, and the outer contour of each protrusion is arc-shaped. The value of n is 1. Other values ​​of n are obtained by those skilled in the art based on a limited number of experiments using the technical solution of this invention, and will not be elaborated here. Each protrusion corresponds to a matching crimping module. The crimping surfaces of the modules are arc-shaped, and when fitted together, they form a circle to accommodate the tubular body.

[0046] Each module applies a pressure F to the center of the inner wall of the tube body. The pressure F is decomposed into a component pressure F2 pointing towards the center of the inner wall of the tube, and a compressive force F2 generated at the most convex point under the action of the second component pressure F2, parallel to the tangent of the most convex point and in the opposite direction. 21 and F 22 Under the extrusion pressure F 21 and F 22 Under the influence of the force, the material at the most prominent point of the convex part flows to the two adjacent concave parts, filling the adjacent concave parts with each convex part, thus making the outer wall of the tube achieve a near-circular shape. The partial pressure F2 generated by each convex part causes the inner wall of the tube to press against the wires close to the inner wall; especially for multi-strand wires, according to the law of resistance... R is the resistance at the connection point of the cable connector after crimping. Resistivity, L is the conductor length, A is the contact area between the inner wall of the conductor tube and the wire. The inner wall is squeezed into the gaps of the multiple wires, further increasing the contact area A between the inner wall and the wire, increasing the current flow, and reducing the resistance R at the cable connector joint; according to Joule's law Q = I 2 Rt and Q represent the heat at the connection point of the cable connector, I represents the constant current, and R represents the resistance at the connection point of the cable connector. Over time t, the resistance R at the connection point of the cable connector decreases, thereby reducing the working heat Q at that point and ensuring the normal operation of the cable.

[0047] Embodiment 4 of the present invention provides a cable connector. The difference between Embodiment 4 and Embodiment 3 is that when the number of protrusions in the cable connector is sufficiently large, the number of crimping modules is less than the number of protrusions in the cable connector, and the crimping surface of the crimping module contacts the highest point of the protrusion.

[0048] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. A cable connector, characterized in that, It includes a conductive tube body, the inner wall of which has a circular cross-section, and the outer wall of which has alternating convex and concave portions around its circumference.

2. The cable connector as described in claim 1, characterized in that, The protrusions are arranged in pairs symmetrically with respect to the center of the inner wall.

3. The cable connector as described in claim 1, characterized in that, The outer contour of the protrusion is arc-shaped. The protrusions are arranged in pairs symmetrically with respect to the center of the inner wall. The number of pairs of protrusions is 2n+1, where n is a non-zero natural number. One pair of protrusions is located directly above and directly below.

4. The cable connector as described in claim 3, characterized in that, There are three pairs of convex parts.

5. The cable connector as described in claim 3, characterized in that, The convex parts directly above and directly below each other sequentially extend to the convex parts along the horizontal line passing through the center of the inner wall, with their arc angles gradually increasing.

6. The cable connector as described in claim 3, characterized in that, The concave portion located on the horizontal line passing through the center of the inner wall, and the outer contours of the concave portions in the directions directly above and below, have gradually decreasing arc angles.

7. The cable connector as described in claim 1, characterized in that, The arc angle of the outer contour of the protrusion when it is directly above and directly below is 0-90 degrees, and the arc angle of the outer contour of the other protrusions is 0-90 degrees.

8. The cable connector as described in claim 7, characterized in that, The arc angle of the outer contour of the convex parts located directly above and below is 47.72 degrees, and the arc angle of the outer contour of the other convex parts is 66.14 degrees.

9. The cable connector as described in claim 1, characterized in that, The arc angle of the outer contour of the concave part located on the horizontal line passing through the center of the inner wall is 0-90 degrees, and the arc angle of the outer contour of other concave parts is 0-90 degrees.

10. The cable connector as described in claim 9, characterized in that, The arc angle of the outer contour of the concave part located on the horizontal line passing through the center of the inner wall is 18 degrees, while the arc angle of the outer contour of the other pairs of convex parts is 0 degrees.

11. The cable connector as claimed in claim 1, characterized in that, The number of protrusions is 2n+1, where n is a non-zero natural number; the protrusions are subjected to pressing pressure from the pressing module pointing towards the center of the inner wall.

12. A pressing die, characterized in that, It includes two parts: an upper mold and a lower mold. The pressing surfaces of the upper mold and the lower mold are both arc surfaces. They are joined together to form a circle to accommodate the cable connector tube body as described in any one of claims 1-11 for pressing.

13. A pressing die, characterized in that, It includes several crimping modules, the crimping pressure of the crimping modules is directed towards the center of the inner wall of the tube body of the cable connector as described in claim 11, the crimping surfaces of the crimping modules are arc surfaces, and all the crimping modules are joined together to form a circle to accommodate the tube body for crimping.

14. The pressing die as described in claim 13, characterized in that, The number of crimping modules is the same as the number of protrusions of the cable connector, and they are set in a one-to-one correspondence.

15. The pressing die as described in claim 13, characterized in that, The number of crimping modules is less than the number of protrusions in the cable connector, and the crimping surface of the crimping module contacts the highest point of the protrusion.

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