Cable material performance integration test system

Abstract

The invention discloses a cable material performance integrated testing system, and belongs to the technical field of cable material testing. The device comprises an integrated test cavity, a sample bearing and transferring module, a multi-source stress applying module, a deformation and quality monitoring module and a central control data processing unit, the multi-source stress applying module is arranged in the integrated test cavity, and the multi-source stress applying module applies stress to a to-be-tested sample. According to the invention, the integrated test cavity, the sample bearing and transferring module, the multi-source stress applying module and the deformation and quality monitoring module are integrated into a test structure, and the cooperative control function of the central control data processing unit is matched; according to the integrated structure, thermal extension, thermal weight loss and mechanical property testing are integrated in the same closed testing cavity, multi-dimensional performance continuous testing can be completed only through one-time sample clamping, and automatic switching of different testing stations is achieved through the sample bearing and transferring module.

Description

Technical Field

[0001] This invention relates to the field of cable material testing technology, specifically to an integrated testing system for cable material performance. Background Technology

[0002] The performance of the insulation and sheath layers of cable materials directly determines the operational safety, stability, and service life of power transmission systems. Among these, thermal elongation, thermogravimetric analysis, tensile strength, and elongation at break are core performance indicators, widely used in cable material research and development, production quality inspection, and aging assessment. Currently, the industry generally adopts a decentralized testing approach for these properties, using multiple independent devices to perform individual performance tests: thermal elongation relies on a dedicated high-temperature tensile testing chamber, thermogravimetric analysis is tested using an independent high-temperature microbalance, and mechanical properties are tested using a universal testing machine.

[0003] This decentralized testing mode has certain technical defects that need to be improved. Its operation process is cumbersome and inefficient. The sample needs to be clamped and transferred multiple times. When switching between different devices, the test environment needs to be repeatedly positioned and adjusted. This is not only time-consuming and labor-intensive, but also cannot meet the needs of batch testing and rapid research and development. Furthermore, the sample is prone to damage and positioning deviation due to multiple clamping, which introduces human error. Moreover, the test environment has poor consistency. The high temperature control accuracy and stress application stability of different devices are different. In addition, the temperature and stress state change abruptly during the sample transfer process, which makes it impossible to correlate and analyze the thermal extension, thermogravimetric loss and mechanical property test data based on the same benchmark, affecting the accuracy and comparability of the test results. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated testing system for cable material performance. By integrating the integrated testing chamber, the sample bearing and transfer module, the multi-source stress application module, and the deformation and quality monitoring module into an integrated testing structure, the problem of cumbersome operation and low testing efficiency caused by the need for independent equipment and multiple sample transfers and clamping for testing various performance aspects of cable materials is solved.

[0005] This invention is achieved through the following technical solution: This invention is an integrated testing system for cable material properties, comprising: The integrated testing chamber provides a controllable high-temperature testing environment. A sample carrying and transfer module, located within the integrated testing chamber, clamps and moves the sample to be tested. A multi-source stress application module, also located within the integrated testing chamber, applies stress to the sample. A deformation and mass monitoring module monitors the deformation and mass change of the sample during the testing process.

[0006] Furthermore, the central control data processing unit is electrically connected to the sample bearing and transfer module, the multi-source stress application module, and the deformation and quality monitoring module.

[0007] Furthermore, the sample carrying and transfer module includes a carrying platform and a sample clamp. The sample clamp is set on the carrying platform, and the carrying platform is controlled by a central control and data processing unit to transfer the sample to be tested between the thermogravimetric testing station and the mechanical property testing station.

[0008] Furthermore, the multi-source stress application module includes a constant load application mechanism and a variable tension application mechanism. The constant load application mechanism has an electromagnetic loading device, a counterweight or a precision pneumatic loading device, and the variable tension application mechanism has a drive motor, a transmission mechanism and a tension sensor.

[0009] Furthermore, the variable tension application mechanism is designed in conjunction with the specimen load transfer module.

[0010] Furthermore, the deformation and mass monitoring module includes a deformation measurement unit and a built-in microbalance. The deformation measurement unit optically measures the deformation of the sample during the thermal stretching test, while the built-in microbalance is located below the thermogravimetric test station and measures the mass change.

[0011] Furthermore, the deformation and mass monitoring module also includes a displacement and tension sensing unit, which is integrated into the variable tension application mechanism. The displacement and tension sensing unit synchronously collects tension and displacement signals.

[0012] Furthermore, the deformation measurement unit consists of a high-speed CCD camera and an image processing system.

[0013] Furthermore, the integrated test chamber is a sealed chamber, and a uniform heating device and a temperature feedback control system are installed inside the integrated test chamber.

[0014] The present invention has the following beneficial effects: This invention integrates a test chamber, a sample carrying and transfer module, a multi-source stress application module, and a deformation and quality monitoring module into a single test structure. Combined with the collaborative control function of a central control data processing unit, this integrated structure consolidates thermal extension, thermogravimetric analysis, and mechanical property testing within a single sealed test chamber. Multi-dimensional continuous performance testing can be completed with only a single sample clamping. The sample carrying and transfer module enables automatic switching between different test positions without manual intervention, shortening the testing cycle, improving testing efficiency, and avoiding testing errors caused by sample positioning deviations and damage during multiple clamping and transfer processes. Simultaneously, the uniform high-temperature testing environment ensures consistency in the testing conditions for various performance parameters, further enhancing the accuracy and reliability of the test data.

[0015] This invention improves the accuracy and applicability of cable material performance testing by adapting the multi-source stress application module and the deformation and mass monitoring module, combined with non-contact measurement and closed-loop control technology. The constant load application mechanism adopts a precision pneumatic loading device, and the variable tension application mechanism is equipped with a servo motor and tension sensor, which can achieve precise application of different load types and load ranges. With the help of a non-contact deformation measurement unit composed of a high-speed CCD camera and a high-precision micro balance, it can simultaneously collect the deformation, mass change, tension and displacement data of the sample during the test process, avoiding the interference of contact measurement on the sample deformation.

[0016] Of course, any product implementing this invention does not necessarily need to achieve all of the advantages described above at the same time. Attached Figure Description

[0017] Figure 1 A flowchart of an integrated testing system for cable material properties; Figure 2 This is a diagram showing the composition of the deformation and quality monitoring module. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. 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.

[0019] Please see Figure 1-2This invention provides a technical solution: an integrated testing system for cable material performance, comprising an integrated testing chamber with a controllable high-temperature testing environment. The integrated testing chamber is a sealed chamber, and inside it are a uniform heating device and a temperature feedback control system. The uniform heating device uses a surrounding electric heating wire with an adjustable power of 0-2000W and a heating range of 25℃-300℃, meeting the requirements for conventional thermal performance testing of cable materials. The electric heating wire is wrapped with heat insulation cotton to prevent excessively high local temperatures. The temperature feedback control system consists of a PT100 platinum resistance temperature sensor and a temperature controller, with the platinum resistance evenly distributed within the chamber. The temperature data of the chamber is collected in real time at three positions: upper, middle, and lower, and fed back to the controller. The controller controls the start and stop of the electric heating wire to maintain a controllable high-temperature testing environment. The integrated testing chamber constructs a high-temperature environment through a surrounding electric heating wire. The PT100 platinum resistance temperature sensor collects the temperature data inside the chamber in real time and feeds it back to the central control unit. The controller adjusts the heating power by controlling the on and off time of the electric heating wire to stabilize the temperature inside the chamber at the set value (fluctuation range ±0.5℃). This provides a stable high-temperature testing environment for thermal extension and thermogravimetric analysis. The sealed chamber structure, combined with the heat insulation design, reduces temperature loss and ensures the uniformity of the testing environment.

[0020] The sample carrying and transfer module is located within the integrated testing chamber. This module clamps and moves the sample to be tested. It includes a carrying platform and sample clamps. The sample clamps are mounted on the carrying platform, which is controlled by a central control and data processing unit to transfer the sample between the thermogravimetric testing station and the mechanical property testing station. The carrying platform is a rectangular metal platform with an anodized surface to prevent oxidation and deformation at high temperatures. The sample clamps are symmetrical mechanical clamps, including fixed and movable jaws. The movable jaws are driven by a manually adjustable screw. The drive mechanism consists of a stepper motor and a roller. The system consists of a ball screw and guide rails. The central control data processing unit controls the forward and reverse rotation of the stepper motor to drive the carrier platform to translate along the guide rails, realizing the transfer of the sample between the thermogravimetric testing station and the mechanical property testing station, meeting the switching requirements of different testing stations. The central control unit controls the stepper motor to drive the ball screw to rotate, which in turn drives the carrier platform to translate along the linear guide rails. Utilizing the precise positioning characteristics of the stepper motor, the system achieves precise switching of the sample between the thermogravimetric testing station and the mechanical property testing station. The sliding fit between the carrier platform and the guide rails adopts rolling friction to reduce motion resistance, ensure a smooth transfer process, and avoid displacement or damage to the sample due to vibration.

[0021] A multi-source stress application module is installed within the integrated testing chamber. This module applies stress to the sample under test and includes a constant load application mechanism and a variable tension application mechanism. The constant load application mechanism is positioned above the mechanical performance testing station and includes an electromagnetic loading device, a counterweight, or a precision pneumatic loading device. The precision pneumatic loading device includes a pneumatic pump, a pressure regulator, and a loading rod. The lower end of the loading rod engages with the sample clamp, and constant load application is achieved by adjusting the air pressure, meeting the constant load requirements in the thermal elongation test of cable materials. The variable tension application mechanism includes a drive motor, a transmission mechanism, and a tension sensor. The drive motor is a servo motor. The variable tension application mechanism is integrated with the sample carrying and transfer module and is positioned below the mechanical performance testing station, corresponding vertically to the sample clamp on the carrying platform. The variable tension application mechanism includes a drive motor, a gear transmission mechanism, a tension sensor, and a tension rod. The drive motor, through a gear transmission mechanism, provides a tension sensor and a tension rod. The wheel drive mechanism moves the tension rod up and down, enabling variable tensile force loading on the sample. A tension sensor integrated at the top of the tension rod collects the applied tension signal in real time and feeds it back to the central control unit, forming a closed-loop tension control. This allows for various mechanical testing modes, including uniform tension and stepped tensile loading. This mechanism works in conjunction with the sample carrying and transfer module. After the carrying platform transfers the sample to the mechanical performance testing station, the tension rod automatically rises and docks with the sample clamp, completing the preparation for tensile force application. The constant load application mechanism provides air through a pneumatic pump, and the output air pressure is adjusted by a pressure regulator to convert it into a constant load on the sample. Utilizing the stability of pneumatic loading, a constant load can be applied for extended periods. The variable tensile force application mechanism uses a servo motor to drive gear transmission, causing the tension rod to rise at a uniform speed and apply variable tensile force to the sample. The tension sensor and displacement sensor collect signals in real time and feed them back to the central control unit, forming a closed-loop control. The tensile speed and tensile force can be adjusted according to testing requirements to achieve different mechanical performance testing scenarios.

[0022] The deformation and mass monitoring module monitors the deformation and mass change of the sample during the testing process. This module includes a deformation measurement unit and a built-in microbalance. The deformation measurement unit optically measures the deformation of the sample during the thermal stretching test, while the built-in microbalance, located below the thermogravimetric testing station, measures the mass change. The module also includes a displacement and tension sensing unit integrated into a variable tension application mechanism, which simultaneously acquires tensile force and displacement data. The deformation measurement unit consists of a high-speed CCD camera and an image processing system. The high-speed CCD camera is fixed to the inner side wall of the cavity, and the lens is aimed at the sample at the mechanical property testing station. By capturing images of the sample during the testing process, the image processing system identifies the positional changes of the marked points at both ends of the sample and calculates the deformation of the sample. This is suitable for non-contact optical measurement in thermal extension testing, avoiding interference from contact measurement on sample deformation. The built-in microbalance has clearance holes at corresponding positions on the balance tray and the support platform. When the support platform transfers the sample to the thermogravimetric testing station... During the test, the lower end of the sample is naturally placed on the balance tray. The balance collects the sample mass data in real time and transmits it synchronously to the central control unit to monitor the thermogravimetric changes of the sample under high temperature. In addition to the tensile sensor mentioned above, the displacement and tensile force sensing unit also includes a linear displacement sensor. The linear displacement sensor is integrated into the side of the tension rod and synchronously collects the displacement and tensile force signals during the tensile process to realize the real-time plotting of the tensile force-displacement curve in the mechanical property test. The deformation measurement adopts the non-contact optical measurement principle. A high-speed CCD camera continuously captures images of the sample. The image processing system identifies the preset marker points on the sample surface and calculates the distance change between the marker points to obtain the sample deformation, avoiding the interference of contact measurement on the sample deformation. The thermogravimetric monitoring uses a built-in micro balance to collect the sample mass data in real time. Utilizing the high-precision measurement characteristics of the balance, it captures the minute mass changes of the sample under high temperature. Mechanical parameter monitoring uses the tensile force sensor and displacement sensor integrated into the tensile mechanism to synchronously collect tensile force and displacement signals. After processing by the central control unit, a tensile force-displacement curve is generated to calculate mechanical indicators such as tensile strength and elongation at break.

[0023] The central control data processing unit is electrically connected to the sample carrier transfer module, the multi-source stress application module, and the deformation and mass monitoring module. The central control data processing unit uses an industrial-grade single-chip microcomputer (model STM32F407) as the core controller, located in a control box outside the integrated test chamber. It is electrically connected to the stepper motor of the sample carrier transfer module, the servo motor of the multi-source stress application module, and the sensors, CCD camera, and micro-balance of the deformation and mass monitoring module via shielded wires, enabling coordinated control and data acquisition of each module. The control box panel has a touch screen, which allows for setting test parameters, real-time display of the test process, and data storage and export. An internal data storage module can save test data and supports exporting it to a computer via USB for subsequent analysis. The central control unit, as the core, triggers the coordinated operation of each module according to a preset test procedure. First, it controls the chamber to heat to the set temperature and stabilize it. Then, it drives the carrier platform to transfer the sample to the corresponding station, triggering the corresponding stress application and monitoring modules to start. After the test is completed, the station is automatically switched until all performance tests are completed. The entire process requires no manual intervention, achieving automation of the test process.

[0024] The working steps of this invention are as follows: S1, Sample clamping: Open the sealed door of the integrated test chamber, clamp the cable material sample to be tested onto the sample clamp on the bearing platform, manually adjust the fine-tuning bolts to clamp the sample. If it is a thermogravimetric test, ensure that the lower end of the sample is aligned with the microbalance tray below the thermogravimetric test station, close the sealed door and lock it to complete one clamping.

[0025] S2, Chamber preheating and stabilization: The central control unit controls the start of the electric heating wire in the integrated test chamber, adjusts the heating power according to the PID algorithm, and the PT100 platinum resistance collects temperature data in real time and feeds it back until the temperature in the chamber reaches the set value. The temperature is maintained stable for a preset time to ensure a uniform and stable test environment.

[0026] S3, Thermogravimetric Analysis (TGA) Test: After the temperature stabilizes, the central control unit drives the stepper motor to move the support platform along the guide rail to the TGA test station, so that the lower end of the sample is placed stably on the built-in microbalance tray. The balance is automatically zeroed and begins to collect sample mass data in real time, which is synchronously transmitted to the central control unit to record the mass change of the sample at different time points under the set high temperature environment until the preset heat preservation time is reached. The TGA test is completed and the balance stops collecting data.

[0027] S4, Thermal Elongation Performance Test: After the thermogravimetric test is completed, the central control unit drives the load-bearing platform to the mechanical performance test station. After positioning, the constant load application mechanism is started, the pneumatic pump works, and the pressure is adjusted to the set constant load by the pressure regulator. The loading rod moves downward and docks with the upper clamp of the sample to apply the constant load. At the same time, the high-speed CCD camera is started to continuously capture images of the sample. The image processing system calculates the sample deformation in real time and records the deformation change curve over time. The constant load and high temperature environment are maintained for the preset time. The thermal elongation test is completed, the constant load application mechanism is unloaded, and the loading rod is reset.

[0028] After the S5 mechanical property test and thermal extension test are completed, the central control unit controls the variable tension application mechanism to start. The servo motor drives the tension rod to rise at a constant speed through gear transmission, applying tensile force to the sample. The tension sensor and displacement sensor synchronously collect the tension signal and displacement signal, and transmit them to the central control unit in real time to plot the tension-displacement curve. When the sample breaks or reaches the preset maximum tension threshold, the servo motor stops working, the tension rod resets, and the mechanical property test is completed. The system automatically calculates the tensile strength and elongation at break.

[0029] S6, Data Processing and Completion: After all tests are completed, the central control unit integrates and stores the thermogravimetric data, thermal extension data, and mechanical property data, and generates a test report. Real-time data and curves can be viewed via the touch screen, or data can be exported to a computer via the USB interface. After the test, the system controls the electric heating wire to turn off, the chamber cools naturally to room temperature, the sealed door is opened, the sample is removed, the test station is cleaned, and a complete test process is completed.

[0030] The preferred embodiments of the present invention disclosed above are merely illustrative of the invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the invention to the specific implementations described. Clearly, many modifications and variations can be made based on the content of this specification. This specification selects and specifically describes these embodiments to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to better understand and utilize the invention. The invention is limited only by the claims and their full scope and equivalents.

Claims

1. An integrated testing system for cable material performance, characterized in that, include: An integrated test chamber, wherein the integrated test chamber has a controllable high-temperature test environment; A sample carrier and transfer module is disposed in the integrated test chamber, and the sample carrier and transfer module clamps and moves the sample to be tested. A multi-source stress application module is disposed in an integrated test chamber and applies stress to the sample to be tested. The deformation and mass monitoring module monitors the deformation and mass change of the sample under test during the testing process.

2. The integrated testing system for cable material performance according to claim 1, characterized in that, It also includes a central control data processing unit, which is electrically connected to the sample bearing and transfer module, the multi-source stress application module, and the deformation and quality monitoring module.

3. The integrated testing system for cable material performance according to claim 2, characterized in that, The sample carrying and transfer module includes a carrying platform and a sample clamp. The sample clamp is set on the carrying platform. The carrying platform is controlled by a central control and data processing unit to transfer the sample to be tested between the thermogravimetric testing station and the mechanical property testing station.

4. The integrated testing system for cable material performance according to claim 3, characterized in that, The multi-source stress application module includes a constant load application mechanism and a variable tension application mechanism. The constant load application mechanism has an electromagnetic loading device, a counterweight or a precision pneumatic loading device, and the variable tension application mechanism has a drive motor, a transmission mechanism and a tension sensor.

5. The integrated testing system for cable material performance according to claim 4, characterized in that, The variable tensile force application mechanism is designed in conjunction with the sample bearing and transfer module.

6. The integrated testing system for cable material performance according to claim 1, characterized in that, The deformation and mass monitoring module includes a deformation measurement unit and a built-in microbalance. The deformation measurement unit optically measures the deformation of the sample during the thermal stretching test. The built-in microbalance is located below the thermogravimetric test station and measures the mass change.

7. The integrated testing system for cable material performance according to claim 6, characterized in that, The deformation and mass monitoring module also includes a displacement and tension sensing unit, which is integrated into the variable tension application mechanism. The displacement and tension sensing unit synchronously collects tension and displacement signals.

8. The integrated testing system for cable material performance according to claim 5, characterized in that, The deformation measurement unit is a high-speed CCD camera and image processing system.

9. The integrated testing system for cable material performance according to claim 1, characterized in that, The integrated test chamber is a sealed chamber, and a uniform heating device and a temperature feedback control system are installed inside the integrated test chamber.

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