A device and method for testing the performance of copper-clad steel wires

Abstract

This application belongs to the field of testing technology, specifically relating to a device and method for testing the performance of copper-clad steel wires. The device includes a placement component and a bump simulation mechanism. The placement component has a working part; the bump simulation mechanism includes pneumatic clamping devices, a telescopic mechanism, and contact components. Two pneumatic clamping devices are connected to the working part of the placement component and clamp the copper-clad steel wire at both ends. The telescopic mechanism is connected to the working part of the placement component. This application, through the design of the bump simulation mechanism, uses pneumatic clamping devices to hold the copper-clad steel wire in a suspended state, and utilizes the telescopic mechanism to drive the contact components to reciprocate up and down, applying regular contact and compression to the copper-clad steel wire, thereby simulating the bumpy environment experienced by the wire during vehicle movement.

Description

Technical Field

[0001] This application belongs to the field of testing technology, specifically relating to a device and method for testing the performance of copper-clad steel wires. Background Technology

[0002] Copper-clad steel wire is a composite conductive material in which a copper layer is coated on the surface of a steel core. It combines the high strength of steel with the good conductivity and corrosion resistance of copper, and is widely used in automotive wiring harnesses, communication cables, and other fields. In automotive applications, copper-clad steel wire is usually in a complex working environment. It needs to withstand the continuous vibration and bumps generated during vehicle operation, and may also face corrosive environments such as mud, salt spray, and alternating high and low temperatures. At the same time, it may also be in a bent state due to the wiring route.

[0003] In the process of developing this application, the applicant discovered at least the following shortcomings in the relevant technology: Testing devices that simulate the vibration of electrical wires typically use simple tapping or vibration methods. Their contact parts are mostly rigid structures, which directly and repeatedly impact the wires. This can easily cause abnormal damage to the wire sheath in the early stages of testing, resulting in test results that cannot accurately reflect the actual service life of the wires. Summary of the Invention

[0004] Based on the above-mentioned technical problems, this application provides a copper-clad steel wire performance testing device and method, which aims to at least partially solve the technical problem that the actual service life cannot be effectively tested.

[0005] In a first aspect, this application provides a copper-clad steel wire performance testing device for testing copper-clad steel wires, comprising: a placement component and a bump simulation mechanism, wherein the placement component has a working part; the bump simulation mechanism includes pneumatic clamping devices, a telescopic mechanism, and a contact component, wherein two pneumatic clamping devices are connected to the working part of the placement component and respectively clamp the two ends of the copper-clad steel wire, the telescopic mechanism is connected to the working part of the placement component and is located between the two pneumatic clamping devices, and the contact component is connected to the telescopic shaft of the telescopic mechanism and is driven by the telescopic mechanism to perform up-and-down reciprocating motion; The contact element includes a telescopic rod and a contact plate. The telescopic rod is configured to have an internal cavity structure. The contact plate is connected to the telescopic rod and makes movable contact with the copper-clad steel wire.

[0006] In some embodiments, the bump simulation mechanism further includes a multi-axis steering device, which is connected between the telescopic machine and the working part of the placement member. The multi-axis steering device is configured to drive the telescopic machine to rotate at two rotation angles. The contact member also includes a plate and a vibration sensor. The plate is connected to the telescopic shaft of the telescopic machine, the telescopic rod is connected to the plate, and the vibration sensor is connected to the plate.

[0007] In some embodiments, the detection device further includes a corrosion simulation mechanism, which includes a bidirectional moving part, a rotating part, a first bonding part, and a second bonding part. The bidirectional moving part is connected to the inner top of the placement part and has a movable part. The rotating part is connected to the movable part of the bidirectional moving part. The first bonding part is rotatably connected to the rotating part, and the second bonding part is also connected to the movable part of the bidirectional moving part. The first bonding part and the second bonding part are located at the upper and lower positions of the copper-clad steel wire, respectively.

[0008] In some embodiments, the bidirectional moving member includes a first electric track, a second electric track, and a connector. The second electric track is connected to the inner top of the placement member and has a movable portion. The first electric track is connected to the movable portion of the second electric track, and the connector is connected to the movable portion of the first electric track. The corrosion simulation mechanism also includes a connecting rod connected to the connector. The connecting rod and the connector are located between the movable portion of the bidirectional moving member and the rotating member and the second fitting member.

[0009] In some embodiments, the rotating component includes a first bearing, a spring, and a round rod; the first fitting component includes a first sponge block and an extension rod; the second fitting component includes a second sponge block and a crossbar; the first bearing is connected to the connecting rod; the round rod is rotatably connected to the first bearing; the spring is connected between the round rod and the first bearing; the round rod is connected to the extension rod; the first sponge block is connected to the extension rod; the crossbar is connected to the connecting rod; and the second sponge block is connected to the crossbar.

[0010] In some embodiments, the corrosion simulation mechanism further includes a drying element and a second support, the drying element being connected to the working part of the placement element via the second support.

[0011] In some embodiments, the detection device further includes a simulated acceleration mechanism comprising a second motor, a guide, a long rod, a second bearing, and a guide wheel. The second motor is connected to the working part of the placement component, the long rod is connected to the shaft of the second motor, the second bearing is connected to the long rod, the guide wheel is rotatably connected to the second bearing, and the guide wheel is in movable contact with the copper-clad steel wire. The guide is configured to limit the range of motion of the long rod.

[0012] In some implementations, the simulated acceleration mechanism further includes an auxiliary component comprising an arc-shaped plate and a third support. The arc-shaped plate is connected to the working part of the placement component via the third support and is positioned at the bend of the copper-clad steel wire.

[0013] In some embodiments, the guide includes a slide rail, a slider, and a vertical rod. The slide rail is connected to the working part of the placement member, the slider is slidably connected to the slide rail, the slide rail is coaxial with the center of the second motor, and a vertical rod connects the long rod to the slider.

[0014] In a second aspect, this application provides a method for testing the performance of copper-clad steel wires, applied to a copper-clad steel wire performance testing device, comprising the following steps: The two ends of the copper-clad steel wire are clamped and fixed by two pneumatic clamping devices to keep the copper-clad steel wire suspended in the air. Start the telescopic machine to drive the contact parts to move up and down reciprocatingly, so that the contact plate makes active contact with the copper-clad steel wire; When the contact plate presses against the copper-clad steel wire, the telescopic rod contracts and compresses the gas in the internal cavity, thus buffering the contact between the contact plate and the copper-clad steel wire.

[0015] This application provides a copper-clad steel wire performance testing device and method. It employs intelligent sensors and a bump simulation mechanism. A pneumatic clamping device holds the copper-clad steel wire in a suspended state, and a telescopic mechanism drives the contact element to reciprocate up and down, applying regular contact compression to the wire. This simulates the bumpy environment experienced by the wire during vehicle movement, making the testing process more realistic and improving the authenticity and accuracy of the lifespan simulation test for copper-clad steel wires. The contact element uses a telescopic rod and contact plate structure. The telescopic rod is configured as a multi-stage telescopic structure with an internal cavity. When the contact plate compresses the wire, the contraction of the telescopic rod compresses the internal gas, providing a buffering effect and preventing direct hard impact damage to the wire. This ensures effective protection of the wire while maintaining the simulation effect. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 A schematic diagram of the structure of a copper-clad steel wire performance testing device according to one or more embodiments of this application is shown; Figure 2 It shows Figure 1 A schematic diagram of the first support and the pneumatic clamping device in the middle; Figure 3 It shows Figure 1 A structural schematic diagram of the multi-axis steering device, telescopic mechanism, and contact components in the diagram; Figure 4 It shows Figure 3 A schematic diagram of the specific structure of the contact components; Figure 5 It shows Figure 1 A schematic diagram of a partial structure of the corrosion simulation mechanism in the image; Figure 6 It shows Figure 5 A schematic diagram of the specific structure of the bidirectional moving component in the diagram; Figure 7 It shows Figure 5 A schematic diagram of the rotating component, the first bonding component, and the second bonding component in the process; Figure 8 A schematic diagram of the drying component is shown; Figure 9 It shows Figure 8 A detailed structural diagram of the drying component; Figure 10 It shows Figure 1 A schematic diagram of the simulated acceleration mechanism in the diagram; Figure 11 An assembly diagram of the curved plate and the third bracket is shown; Figure 12 An assembly diagram of the guide wheel and auxiliary components is shown; Figure 13 A schematic diagram of the guide component's specific structure is shown; Figure 14 A schematic diagram of the overall detection device is shown; Figure 15 It shows Figure 14 Another perspective illustration; Figure 16 It shows Figure 14 A schematic diagram of the structure after removing the frame plate.

[0018] Explanation of reference numerals in the attached figures: 10. Detection device; 100. Placement component; 110. Frame; 120. Frame plate; 130. Control device; 140. Work plate; 150. Work light; 200. Bump simulation mechanism; 210. First support; 220. Pneumatic clamping device; 230. Multi-axis steering device; 240. Telescopic mechanism; 250. Contact element; 251. Flat plate; 252. Telescopic rod; 253. Contact plate; 254. Vibration sensor; 300. Corrosion simulation mechanism; 310. Bidirectional moving part; 311. First electric track; 312. Second electric track; 313. Connector; 320. Connecting rod; 330. Rotating part; 331. First bearing; 332. Spring; 333. Round rod; 340. First bonding part; 341. First sponge block; 342. Extension rod; 350. Second bonding part; 351. Second sponge block; 352. Crossbar; 360. Drying part; 361. First motor; 362. Airflow device; 363. Transmission device; 370. Second support; 400. Simulated acceleration mechanism; 410. Second motor; 420. Guide component; 421. Slide rail; 422. Slider; 423. Vertical rod; 430. Long rod; 440. Second bearing; 450. Guide wheel; 460. Auxiliary component; 461. Arc plate; 462. Third support; 500. Copper-clad steel wire. Detailed Implementation

[0019] To enable those skilled in the art to more clearly understand this application, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application.

[0020] A copper-clad steel wire performance testing device and method in related technologies has at least the following problems when used: Currently, performance testing of copper-clad steel wires typically requires evaluating their durability under simulated real-world usage environments. Existing testing devices suffer from the following structural design deficiencies: In existing technologies, testing devices that simulate the vibration of electrical wires typically employ simple tapping or vibration methods. Their contact components are often rigid structures, directly and repeatedly impacting the wire. This can easily cause abnormal damage to the wire's insulation in the early stages of testing, resulting in test results that do not accurately reflect the wire's actual lifespan. Furthermore, the tapping positions of these devices are usually fixed, which can easily lead to localized excessive fatigue in the wire after prolonged testing, differing from the multi-directional random impacts experienced by wires in actual use.

[0021] In terms of simulating corrosion environments, existing devices mostly use spraying or immersion to corrode wires. This method is difficult to simulate the dynamic changes in the flow and dripping of corrosive media caused by vibration during vehicle operation. At the same time, spraying can easily cause corrosive media to spread to other parts of the device, causing equipment contamination and corrosion, and it is also difficult to conduct differentiated corrosion tests on the upper and lower surfaces of the wires.

[0022] For simulating the bending state of electrical wires, existing technologies lack testing devices capable of simultaneously subjecting wires to multiple stresses such as bumps and corrosion while maintaining a suspended, bent state. Most devices can only perform single-item tests, making it difficult to comprehensively assess the combined stress state of wires in actual installation environments, which are subjected to both bending and vehicle vibrations.

[0023] In addition, the existing testing devices mostly use independent settings and individual control for each functional module, which requires manual start-up and adjustment during operation. This results in poor continuity and consistency of the testing process, making it difficult to achieve automated operation of multi-condition combined testing.

[0024] This application uses 0.22 mm² copper-clad steel wire to replace 0.35 mm² copper wire, which improves wire strength, electrical performance, and weight reduction. Taking the DHx model as an example, the entire vehicle wiring harness uses 0.35 mm² copper wire. 2 1300 meters of copper wire, weighing 5.681 kg: After replacing it with 0.22TG wire, the weight of the wire harness is reduced by 1.391 kg, while saving installation space for vehicle parts.

[0025] Figure 1 A schematic diagram of the structure of a copper-clad steel wire performance testing device 10 according to one or more embodiments of this application is shown. Figure 2 It shows Figure 1 A schematic diagram of the structure of the first support 210 and the pneumatic clamping device 220. Figure 3 It shows Figure 1 A structural schematic diagram of the multi-axis steering device 230, the telescopic mechanism 240, and the contact element 250. Figure 4 It shows Figure 3The contact element 250 is shown in the schematic diagram. The copper-clad steel wire performance testing device 10 provided in this application is used to test the copper-clad steel wire 500. It includes: a placement component 100 and a bump simulation mechanism 200. The placement component 100 has a working part. The bump simulation mechanism 200 includes a pneumatic clamping device 220, a telescopic mechanism 240 and a contact element 250. The two pneumatic clamping devices 220 are connected to the working part of the placement component 100 and clamp the copper-clad steel wire 500 at both ends. The telescopic mechanism 240 is connected to the working part of the placement component 100 and is located between the two pneumatic clamping devices 220. The contact element 250 is connected to the telescopic shaft of the telescopic mechanism 240 and is driven by the telescopic mechanism 240 to perform up-and-down reciprocating motion. The contact element 250 includes a telescopic rod 252 and a contact plate 253. The telescopic rod 252 is configured to have an internal cavity structure, and the contact plate 253 is connected to the telescopic rod 252 and makes movable contact with the copper-clad steel wire 500.

[0026] In use, the testing device 10 of this application has a placement component 100 positioned at the required location, with a support at its bottom for ground support. In practical use, bolts or other structures can be added to the bottom to fix it in place, increasing stability during testing. The placement component 100 includes a working section where various parts can be installed. A pneumatic clamping device 220 is positioned at both ends of the copper-clad steel wire 500, effectively clamping it and keeping it suspended. The telescopic mechanism 240, when powered on, drives the contact component 250 to reciprocate up and down. The contact component 250's contact and compression of the copper-clad steel wire 500 simulates the movement of a car in real-world conditions, causing the wire to bounce. This realistically simulates the lifespan of the copper-clad steel wire 500. The contact plate 253 is in contact with the copper-clad steel wire 500. In specific testing, 253 can also simulate the collision between the copper-clad steel wire 500 and other parts inside the car. Different materials can be used, for example, metal, plastic, or rubber, depending on the specific application. The contact plate 253 and the telescopic rod 252 are detachable. For example, the contact plate 253 can be fixed to the telescopic rod 252 by bolts. The telescopic rod 252 is configured as multiple hollow rods with diameters decreasing from large to small. When they are interlocked, when the contact plate 253 presses against the copper-clad steel wire 500, the contraction of the telescopic rod 252 will compress the internal gas, which will buffer the contact plate 253 pressing against the copper-clad steel wire 500. This ensures that the copper-clad steel wire 500 is not directly damaged when it is contacted. The telescopic rod 252 is only one way of buffering, and its effect is to keep the lifting and lowering of the contact plate 253 vertical while effectively providing buffering. The specific details of a copper-clad steel wire performance testing device 10 provided in this application will now be further described with reference to the accompanying drawings.

[0027] It should be noted that: regarding the structure of the telescopic rod 252, such as Figure 3 As shown, the telescopic rod 252 is composed of multiple sleeves with progressively decreasing diameters, all nested together. Sealing rings are installed between adjacent sleeves, creating a closed air chamber inside the telescopic rod 252. A return spring is installed inside the telescopic rod 252, with its two ends connected to the innermost and outermost sleeves, respectively. When the contact plate 253 presses against the copper-clad steel wire 500, the sleeves contract, compressing the internal gas to form a buffer, and the return spring is simultaneously compressed. When the contact plate 253 moves away from the wire, the return spring pushes the sleeves back to their original position, and the internal air pressure recovers synchronously.

[0028] In some of the above embodiments, a first bracket 210 is connected between the pneumatic clamping device 220 and the working part of the placement member 100. The first bracket 210 is used for support and to fix the pneumatic clamping device 220. The first bracket 210 is replaceable. In specific use, the width and length of the first bracket 210 can be changed to adapt to different working environments, thereby assisting the pneumatic clamping device 220 in effectively clamping the copper-clad steel wire 500.

[0029] Figure 3 as well as Figure 4 As shown, in some embodiments, the bump simulation mechanism 200 further includes a multi-axis steering device 230. The telescopic mechanism 240 is connected to the working part of the placement member 100 via the multi-axis steering device 230. The multi-axis steering device 230 is configured to drive the telescopic mechanism 240 to rotate at two rotational angles. In specific use, the multi-axis steering device 230 is a commercially available device, such as a robotic arm. This method is typically used to move the robotic arm by changing different angles. The multi-axis steering device 230 has two rotational angles, causing the telescopic mechanism 240 to change position. This application also mentions below the provision of a control device 130 to control the activation of all devices, thereby controlling the multi-axis steering device 230 to change position so that the contact member 250... The copper-clad steel wire 500 is struck, causing it to vibrate. Furthermore, the operating degree can be preset in the control device 130, causing the multi-axis steering device 230 to repeatedly change the position of the telescopic machine 240 along a fixed direction, striking different positions of the copper-clad steel wire 500, thus avoiding continuous striking of the same location. The telescopic machine 240 can also change the striking amplitude of the contact member 250 through the control device 130. The contact member 250 also includes a plate 251 and a vibration sensor 254. The plate 251 is connected to the telescopic shaft of the telescopic machine 240, the telescopic rod 252 is connected to the plate 251, and the vibration sensor 254 is connected to the plate 251. For example, the vibration sensor 254 in this application can be a sensor with patent number 213632399U, named "Explosion-proof Vibration Transmitter." The advantage of this sensor is that it can simultaneously acquire temperature and humidity data at the location of the vibration transmitter.

[0030] Figure 5 It shows Figure 1 A partial structural diagram of the corrosion simulation mechanism 300 in the diagram, combined with... Figure 5 and Figure 1As shown, in some embodiments, the detection device 10 further includes a corrosion simulation mechanism 300. The corrosion simulation mechanism 300 includes a bidirectional moving member 310, a rotating member 330, a first bonding member 340, and a second bonding member 350. The bidirectional moving member 310 is connected to the inner top of the placement member 100 and has a movable portion. The rotating member 330 is connected to the movable portion of the bidirectional moving member 310. The first bonding member 340 is rotatably connected to the rotating member 330. The second bonding member 350 is also connected to the movable portion of the bidirectional moving member 310. The first and second bonding components 350 are located at the upper and lower positions of the copper-clad steel wire 500, respectively. During use, the bidirectional moving component 310 can drive the rotating component 330, the first bonding component 340, and the second bonding component 350 to move up and down. Corresponding vertical holes are opened on the working part of the placement component 100, and a water tank is installed in the hole of the placement component 100. Simulated materials can be added to the water tank, such as muddy water, salt water, stone chips, and ice. When the bidirectional moving component 310 drives the first bonding component 340 and the second bonding component 350 down into the water tank, the second bonding component... The first and second adhesive components 340 and 350 absorb water from the water tank. Simulated material in the water tank then adheres to the first and second adhesive components 340 and 350. When the first and second adhesive components 340 and 350 rise, the first adhesive component 340 is positioned above the copper-clad steel wire 500, and the second adhesive component 350 is positioned below it. At this time, the bidirectional moving component 310 drives the first and second adhesive components 340 and 350 to reciprocate, causing the simulated material on them to contact the copper-clad steel wire 500, thus testing the durability of the copper-clad steel wire 500. In terms of corrosion effect, when the first bonding component 340 and the second bonding component 350 come into contact with the copper-clad steel wire 500, they will also cause the copper-clad steel wire 500 to vibrate. However, the vibration rate is lower than that of the vibration simulation mechanism 200. Therefore, it will provide vibrations of different amplitudes to the copper-clad steel wire 500, increasing the test range of the copper-clad steel wire 500. Moreover, the vibration of the copper-clad steel wire 500 by the vibration simulation mechanism 200 reduces the adhesion of simulated materials to the copper-clad steel wire 500, avoiding the presence of other materials adhering to the copper-clad steel wire 500 that may affect subsequent testing.

[0031] It should be noted that regarding the water tank setup and adsorption action in the corrosion simulation mechanism 300, such as... Figure 5As shown, a through hole is provided on the working plate 140, and a water tank is independently set below the through hole. The water tank is placed on the ground or on a support frame and contains simulated materials such as mud, salt water, stone chips or ice. When the bidirectional moving part 310 drives the first bonding part 340 and the second bonding part 350 to descend, the second bonding part 350 first enters the water tank to dip into the simulated material; as the bidirectional moving part 310 continues to descend, the first bonding part 340 contacts the copper-clad steel wire 500 and rotates backward and stands upright against the elastic force of the spring 332, and then the first sponge block 341 enters the water tank to dip into the simulated material; when the bidirectional moving part 310 rises, the first bonding part 340 leaves the water tank and loses contact with the wire, and returns to its original position directly above the wire under the action of the spring 332.

[0032] Figure 6 It shows Figure 5 A detailed structural diagram of the bidirectional moving component 310 is shown in the diagram. Figure 5 as well as Figure 6 As shown, in some embodiments, the bidirectional moving member 310 includes a first electric track 311, a second electric track 312, and a connector 313. The second electric track 312 is connected to the inner top of the placement member 100 and has a movable portion. The first electric track 311 is connected to the movable portion of the second electric track 312, and the connector 313 is connected to the movable portion of the first electric track 311. The corrosion simulation mechanism 300 also includes a connecting rod 320, which is connected to the connector 313. The connecting rod 320 and the connector 313 are located between the movable portion of the bidirectional moving member 310 and the rotating member 330 and the second fitting member 350. In specific use, the first electric track 31... The first and second electric tracks 312 adopt existing devices on the market. They can drive other devices to move through the track. The second electric track 312 can drive the first electric track 311 to move laterally. The first electric track 311 can drive the connector 313 to move vertically. The second electric track 312 can change the position of the first bonding component 340 and the second bonding component 350 laterally. When the first bonding component 340 and the second bonding component 350 come into contact with the copper-clad steel wire 500 once, some of the simulated material on them will fall off. Changing the contact position between the first bonding component 340 and the second bonding component 350 and the copper-clad steel wire 500 reduces the repeated descent of the first bonding component 340 and the second bonding component 350.

[0033] Figure 7 It shows Figure 5 A schematic diagram of the rotating component 330, the first bonding component 340, and the second bonding component 350 is shown in the figure. Figure 7 , Figure 6 as well as Figure 5In some embodiments, the rotating component 330 includes a first bearing 331, a spring 332, and a round rod 333; the first fitting component 340 includes a first sponge block 341 and an extension rod 342; the second fitting component 350 includes a second sponge block 351 and a crossbar 352; the first bearing 331 is connected to the connecting rod 320; the round rod 333 is rotatably connected to the first bearing 331; the spring 332 is connected between the round rod 333 and the first bearing 331; the round rod 333 is connected to the extension rod 342; the first sponge block 341 is connected to the extension rod 342; the crossbar 352 is connected to the connecting rod 320; and the second sponge block 351 is connected to the crossbar 352. The first bearing 331 and the round rod 333 are connected by the spring 332, which is inherently elastic, so that the extension rod 342 will return to its original position after rotation. 331 is configured such that the extension rod 342 is rotatable. When the first electric track 311 causes the first bonding member 340 and the second bonding member 350 to descend, the second sponge block 351 descends and is immersed in the water tank. Then, the material in the water tank is spread throughout the second sponge block 351. When the first sponge block 341 and the extension rod 342 follow and descend, the extension rod 342 and the copper-clad steel wire 500 are squeezed against each other. Then, the extension rod 342 rotates and stands up. The first sponge block 341, which stands up, enters the water tank and only absorbs the water in the water tank. The length of the extension rod 342 is greater than the descent length of the first sponge block 341, so the extension rod 342 will not fall off the copper-clad steel wire 500. When the first sponge block 341 rises, the elasticity of the spring 332 will drive the first sponge block 341 to return to its original position, keeping the first sponge block 341 above the copper-clad steel wire 500.

[0034] It should be noted that regarding the connection method of spring 332 in rotating component 330, such as... Figure 7 As shown, spring 332 is a torsion spring, sleeved on the rotating shaft of the first bearing 331. One end of the torsion spring is fixedly connected to the outer ring of the first bearing 331, and the other end is fixedly connected to the round rod 333. When the extension rod 342 is squeezed by the wire and rotates backward, the torsion spring is twisted and stores force; when the extension rod 342 is removed from the wire, the torsion spring releases its elastic force, causing the extension rod 342 to return to its original position. A limiting protrusion is provided on the outer ring of the first bearing 331, which cooperates with the limiting groove on the round rod 333 to limit the return position of the extension rod 342.

[0035] Figure 8 A structural schematic diagram of the drying component 360 is shown, combined with... Figure 8 , Figure 1 as well as Figure 5In some embodiments, the corrosion simulation mechanism 300 further includes a drying element 360 and a second support 370. The drying element 360 is connected to the working part of the placement element 100 via the second support 370. The drying element 360 is adjusted to face the copper-clad steel wire 500. The drying element 360 is a commercially available device that generates warm air upon startup. The warm air blows towards the copper-clad steel wire 500. At the position where the copper-clad steel wire 500 is close to the drying element 360, the warm air causes the copper-clad steel wire 500 to heat up faster, simulating the temperature rise during summer. In a complementary manner, the test of corrosion of the copper-clad steel wire 500 by the second bonding component 350 and the first bonding component 340 has just passed. The temperature rise will be combined with the corrosion by salt water and other methods to simulate the situation that occurs in the real process. The drying component 360 is facing the second bonding component 350, and some of the gas will be blown onto the second bonding component 350 and the first bonding component 340, so that the water stains generated by the second bonding component 350 and the first bonding component 340 will be blown towards the water tank by the drying component 360, reducing the spread of water stains.

[0036] Figure 9 It shows Figure 8 A detailed structural diagram of the 360-degree drying component, combined with... Figure 9 as well as Figure 8 In some embodiments, the drying component 360 includes a first motor 361, a transmission device 363, and an airflow device 362. The first motor 361 and the airflow device 362 are rotatably connected by the transmission device 363. The airflow device 362 is equipped with a heating device, which is a commercially available heating device. Then, the first motor 361 is powered on and starts to drive the airflow device 362 to generate airflow. The airflow guides the heat generated by the heating device to be discharged onto the copper-clad steel wire 500.

[0037] Figure 10 It shows Figure 1The schematic diagram of the simulated acceleration mechanism 400 is shown in some embodiments. The detection device 10 further includes the simulated acceleration mechanism 400, which comprises a second motor 410, a guide member 420, a long rod 430, a second bearing 440, and a guide wheel 450. The second motor 410 is connected to the working part of the placement member 100. The long rod 430 is connected to the rotating shaft of the second motor 410. The second bearing 440 is connected to the long rod 430. The guide wheel 450 is rotatably connected to the second bearing 440 and is in active contact with the copper-clad steel wire 500. The guide member 420 is configured to limit the range of motion of the long rod 430. The guide wheel 450 has an arc-shaped groove, into which the copper-clad steel wire 500 is inserted. In the groove of 0, the copper-clad steel wire 500 is in a bent state. The two pneumatic clamping devices 220 are set at an angle, and the copper-clad steel wire 500 is inserted into the guide wheel 450, thus keeping the copper-clad steel wire 500 suspended. The second motor 410 is powered on and started, and drives the guide wheel 450 to change position through the long rod 430. The guide wheel 450 rotates back and forth at a 45-degree angle with the axis of the second motor 410 as the center. During the rotation of the guide wheel 450, it will bend the copper-clad steel wire 500. The bending of the copper-clad steel wire 500 simulates the different positions and bending degrees of the copper-clad steel wire 500 during use. With the front end simulating various situations of the copper-clad steel wire 500, the service life of the copper-clad steel wire 500 after encountering certain conditions is effectively tested.

[0038] Figure 11 An assembly diagram of the arc-shaped plate 461 and the third bracket 462 is shown, combined with... Figure 11 as well as Figure 10 In some embodiments, the simulated acceleration mechanism 400 further includes an auxiliary component 460, which includes an arc-shaped plate 461 and a third support 462. The arc-shaped plate 461 is connected to the working part of the placement component 100 through the third support 462 and is set at the bending position of the copper-clad steel wire 500. In actual use, the arc-shaped plate 461 has a groove corresponding to the shape of the copper-clad steel wire 500. With the setting of the guide wheel 450, the copper-clad steel wire 500 is limited from two directions to prevent it from falling.

[0039] Figure 12 An assembly diagram of the guide wheel 450 and the auxiliary component 460 is shown. Figure 13A schematic diagram of the guide 420 is shown. In some embodiments, the guide 420 includes a slide rail 421, a slider 422, and a vertical rod 423. The slide rail 421 is connected to the working part of the placement member 100. The slider 422 is slidably connected to the slide rail 421. The slide rail 421 is coaxial with the center of the second motor 410. The vertical rod 423 is connected between the long rod 430 and the slider 422. The slidable connection between the slider 422 and the slide rail 421 can guide the rotation of the guide wheel 450. Moreover, the length of the slide rail 421 can limit the rotation radius of the long rod 430.

[0040] Figure 14 A schematic diagram of the detection device 10 is shown. Figure 15 It shows Figure 14 Another perspective illustration, Figure 16 It shows Figure 14 The structural diagram excluding the frame plate shows that in some embodiments, the placement component 100 includes a frame 110, a frame plate 120, a control device 130, a work plate 140, and a work light 150. The work plate 140 is the working part of the placement component 100 and is connected to the frame 110. The frame plate 120 is connected to the frame 110, the control device 130 is connected to the frame plate 120, and the work light 150 is connected to the frame 110. The control device 130 can control the activation of various devices in this application, and the work light 150 can indicate the working status, for example, by displaying a green light during operation. Figure 14 and Figure 15 A schematic diagram of the overall structure of this application is shown.

[0041] The timing control of the control device 130 is described here as an example. In actual use, it can be set as needed, such as... Figure 14 As shown, the control device 130 is electrically connected to the pneumatic clamping device 220, the telescopic machine 240, the multi-axis steering device 230, the first electric track 311, the second electric track 312, the first motor 361, and the second motor 410. The control device 130 has a preset working sequence, which is executed cyclically in the following order: First, the first electric track 311 and the second electric track 312 drive the first bonding component 340 and the second bonding component 350 to descend, pick up the simulated material, and then rise to the working position; Second, the telescopic machine 240 starts, driving the contact component 250 to strike the copper-clad steel wire 500 a set number of times; Third, the multi-axis steering device 230 adjusts the position of the telescopic machine 240; Fourth, the second motor 410 starts, driving the guide wheel 450 to reciprocate a set number of times; Fifth, it returns to the first step and changes the positions of the first electric track 311 and the second electric track 312.

[0042] A method for testing the performance of copper-clad steel wires, applied to a copper-clad steel wire performance testing device 10, includes the following steps: The two ends of the copper-clad steel wire 500 are clamped and fixed by two pneumatic clamping devices 220 respectively, so that the copper-clad steel wire 500 is kept in a suspended state. Start the telescopic machine 240 to drive the contact member 250 to move up and down reciprocally, so that the contact plate 253 makes active contact with the copper-clad steel wire 500. When the contact plate 253 presses against the copper-clad steel wire 500, the telescopic rod 252 contracts and compresses the gas in the internal cavity, thus buffering the contact between the contact plate 253 and the copper-clad steel wire 500.

[0043] A device and method for testing the performance of copper-clad steel wires has at least the following effects when in use: In this embodiment, a combination design of the placement component 100 and the bump simulation mechanism 200 is adopted. The copper-clad steel wire 500 is held in a suspended state by the pneumatic clamping device 220. The telescopic mechanism 240 drives the contact component 250 to move up and down reciprocally, regularly contacting and squeezing the copper-clad steel wire 500, thereby simulating the bumpy environment experienced by the wire during the movement of a car. This makes the testing process more in line with actual use scenarios and effectively improves the realism and accuracy of the lifespan simulation test of the copper-clad steel wire 500. The contact component 250 adopts a structure of telescopic rod 252 and contact plate 253. The telescopic rod 252 is configured as a multi-stage telescopic structure with an internal cavity. When the contact plate 253 squeezes the wire, the contraction of the telescopic rod 252 squeezes the internal gas, which plays a buffering role and avoids direct hard impact damage to the wire by the contact component 250. While ensuring the simulation effect, it provides effective protection for the wire. Moreover, the multi-stage structure of the telescopic rod 252 can maintain the verticality of the contact plate 253 during the lifting and lowering process, ensuring the accuracy of the striking position.

[0044] In this embodiment, the bump simulation mechanism 200 further includes a multi-axis steering device 230, which is connected between the telescopic machine 240 and the working part of the placement member 100. This device can drive the telescopic machine 240 to rotate at two different angles. Combined with a preset program in the control device 130, the contact member 250 can strike different positions on the copper-clad steel wire 500, avoiding the problem of uniform test results caused by continuously striking the same position. This more comprehensively simulates the multi-directional impacts experienced by the wire in actual use. Simultaneously, a vibration sensor 254 installed on the contact member 250 can detect vibrations during the striking process.

[0045] In this embodiment, a corrosion simulation mechanism 300 is used. A bidirectional moving component 310 moves the first and second bonding components 340 and 350 up and down, allowing them to absorb simulated materials such as mud, salt water, stone chips, or ice from the water tank and then contact the copper-clad steel wire 500. This effectively simulates the corrosion resistance of the wire in complex environments. The first and second bonding components 340 and 350 are located above and below the wire, respectively. During their reciprocating movement, they contact the wire and generate small-amplitude bumps different from those of the bump simulation mechanism 200, creating a composite bump effect with different frequencies and amplitudes. This expands the testing range and makes the test data more comprehensive. Simultaneously, the large-amplitude bumps generated by the bump simulation mechanism 200 help reduce the adhesion of simulated materials to the wire surface, preventing material residue from interfering with subsequent testing.

[0046] In this embodiment, the rotating component 330 of the corrosion simulation mechanism 300 adopts a structure of a first bearing 331, a spring 332, and a round rod 333. This allows the first bonding component 340 to automatically rotate and stand upright when it comes into contact with the copper-clad steel wire 500 during descent. This avoids rigid compression between the first bonding component 340 and the wire, while ensuring that the first sponge block 341 can smoothly enter the water tank to absorb the material. During the ascent, the elastic restoring action of the spring 332 causes the first bonding component 340 to automatically return to the position directly above the wire, realizing alternating corrosion testing of the upper and lower surfaces of the wire. This ingenious structural design achieves automatic avoidance and reset of the first bonding component 340 without an additional power source, simplifying the control program and reducing manufacturing costs.

[0047] In this embodiment, by setting the drying component 360 and directing it towards the copper-clad steel wire 500, warm air can be blown onto the wire during the corrosion simulation process, accelerating the rise in the wire's surface temperature and simulating its use under high-temperature conditions in summer. After the second bonding component 350 and the first bonding component 340 perform corrosion tests on the wire, the warm air from the drying component 360 can accelerate the drying and re-corrosion process of corrosive media such as salt water, more closely reflecting the impact of temperature changes on wire aging in real-world environments. Simultaneously, the airflow from the drying component 360 can also blow towards the second bonding component 350 and the first bonding component 340, directing the water stains adsorbed on their surfaces towards the water tank, reducing the spread and residue of water stains inside the device and maintaining a clean testing environment.

[0048] In this embodiment, a simulated acceleration mechanism 400 is used. A second motor 410 drives a long rod 430 to rotate a guide wheel 450 reciprocally, causing the copper-clad steel wire 500, which is inserted into the groove of the guide wheel 450, to undergo regular bending. This simulates the bending stress experienced by the wire in different installation positions and routes within a vehicle. The guide wheel 450, in conjunction with the angled setting of the two pneumatic clamping devices 220, maintains the wire in a stable suspended bending state. Combined with multiple tests including bump simulation and corrosion simulation, the service life of the wire under various stress conditions can be comprehensively evaluated, further improving the comprehensiveness and reliability of the testing.

[0049] In this embodiment, the simulation acceleration mechanism 400 is further provided with an auxiliary component 460. Through a groove on the arc-shaped plate 461 corresponding to the shape of the wire, it limits the bending of the copper-clad steel wire 500 from another direction. Together with the guide wheel 450, it forms a double-point support and guide, effectively preventing the wire from slipping or shifting during bending, ensuring the stability and repeatability of the bending test. The slide rail 421 in the guide component 420 is coaxially arranged with the center of the second motor 410. The sliding connection between the slider 422 and the slide rail 421 effectively guides and limits the rotational movement of the long rod 430, ensuring the accuracy of the guide wheel 450's trajectory and improving the accuracy of the bending simulation.

[0050] This application has at least the following combined effects: In this embodiment, the bump simulation mechanism 200 and the corrosion simulation mechanism 300 are configured together. When the corrosion simulation mechanism 300 tests the copper-clad steel wire 500 in a corrosive environment such as mud or salt water, the knocking action of the bump simulation mechanism 200 causes the copper-clad steel wire 500 to vibrate, which causes the corrosive medium adhering to the surface of the wire to flow or drip off, reducing the situation where the corrosive medium accumulates in a local position on the surface of the wire for a long time.

[0051] In this embodiment, the bidirectional moving part 310 in the corrosion simulation mechanism 300 adopts a combination structure of a first electric track 311 and a second electric track 312. After the first bonding part 340 and the second bonding part 350 come into contact with the copper-clad steel wire 500 once, the second electric track 312 is used to adjust the position of the first bonding part 340 and the second bonding part 350 laterally, so that the contact point with the copper-clad steel wire 500 is changed, thereby reducing the situation where the simulated material adsorbed on the first bonding part 340 and the second bonding part 350 repeatedly contact the same position, which would cause the simulated material to be consumed too quickly.

[0052] In this embodiment, the guide wheel 450 of the simulated acceleration mechanism 400 and the contact member 250 of the bump simulation mechanism 200 act on different parts of the copper-clad steel wire 500. The guide wheel 450 keeps the wire in a bent state, and the contact member 250 strikes other parts of the wire, so that the wire is simultaneously subjected to bending stress and vibration impact.

[0053] In this embodiment, the drying component 360 is used in conjunction with the corrosion simulation mechanism 300. The hot air from the drying component 360 acts on the copper-clad steel wire 500 while blowing towards the first bonding component 340 and the second bonding component 350, accelerating the evaporation of the moisture adsorbed on the first sponge block 341 and the second sponge block 351, which facilitates the storage of the first sponge block 341 and the second sponge block 351 after the work is completed.

[0054] In this embodiment, the multi-axis steering device 230 of the bump simulation mechanism 200 drives the contact member 250 to change the striking position, and the guide wheel 450 of the simulation acceleration mechanism 400 keeps the copper-clad steel wire 500 in a bent state. When the contact member 250 strikes at different positions, the wire produces differentiated vibration responses due to the different bending shapes.

[0055] In this embodiment, the control device 130 is connected to the bump simulation mechanism 200, the corrosion simulation mechanism 300, and the simulation acceleration mechanism 400. The timing coordination of the multiple mechanisms is achieved through a preset program. For example, after the corrosion simulation mechanism 300 completes the dipping action, it pauses above the copper-clad steel wire 500. The bump simulation mechanism 200 knocks to make the wire vibrate, and then the simulation acceleration mechanism 400 performs a bending test.

[0056] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0057] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", and "counterclockwise" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and 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 this application.

[0058] In this application, unless otherwise expressly specified and limited, the terms "connection," "fixed," etc., should be interpreted broadly. For example, "fixed" can mean a fixed connection, a detachable connection, or an integral part; it can mean a mechanical connection or an electrical connection; it can mean a direct connection or an indirect connection through an intermediate medium; it can mean the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0059] Furthermore, the use of terms such as "first" and "second" in this application is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, features defined with "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified. Although embodiments of this application have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of this application, the scope of which is defined by the claims and their equivalents.

Claims

1. A performance testing device for copper-clad steel wires, used for testing copper-clad steel wires (500), characterized in that, include: Placement member (100), said placement member (100) having a working part; The bump simulation mechanism (200) includes a pneumatic clamping device (220), a telescopic mechanism (240), and a contact element (250). The two pneumatic clamping devices (220) are connected to the working part of the placement part (100) and clamp the two ends of the copper-clad steel wire (500) respectively. The telescopic mechanism (240) is connected to the working part of the placement part (100) and is located between the two pneumatic clamping devices (220). The contact element (250) is connected to the telescopic shaft of the telescopic mechanism (240) and is driven by the telescopic mechanism (240) to perform up-and-down reciprocating motion. The contact element (250) includes a telescopic rod (252) and a contact plate (253). The telescopic rod (252) is configured to have an internal cavity structure. The contact plate (253) is connected to the telescopic rod (252) and makes movable contact with the copper-clad steel wire (500).

2. The copper-clad steel wire performance testing device according to claim 1, characterized in that, The bump simulation mechanism (200) also includes a multi-axis steering device (230). The multi-axis steering device (230) is connected between the telescopic machine (240) and the working part of the placement member (100). The multi-axis steering device (230) is configured to drive the telescopic machine (240) to rotate at two rotation angles. The contact member (250) also includes a plate (251) and a vibration sensor (254). The plate (251) is connected to the telescopic shaft of the telescopic machine (240). The telescopic rod (252) is connected to the plate (251). The vibration sensor (254) is connected to the plate (251).

3. The copper-clad steel wire performance testing device according to claim 2, characterized in that, The detection device (10) further includes a corrosion simulation mechanism (300), which includes a bidirectional moving part (310), a rotating part (330), a first bonding part (340), and a second bonding part (350). The bidirectional moving part (310) is connected to the inner top of the placement part (100). The bidirectional moving part (310) has a movable part. The rotating part (330) is connected to the movable part of the bidirectional moving part (310). The first bonding part (340) is rotatably connected to the rotating part (330). The second bonding part (350) is also connected to the movable part of the bidirectional moving part (310). The first bonding part (340) and the second bonding part (350) are located at the upper and lower positions of the copper-clad steel wire (500), respectively.

4. The copper-clad steel wire performance testing device according to claim 3, characterized in that, The bidirectional moving member (310) includes a first electric track (311), a second electric track (312), and a connector (313). The second electric track (312) is connected to the inner top of the placement member (100). The second electric track (312) has a movable part. The first electric track (311) is connected to the movable part of the second electric track (312). The connector (313) is connected to the movable part of the first electric track (311). The corrosion simulation mechanism (300) also includes a connecting rod (320). The connecting rod (320) is connected to the connector (313). The connecting rod (320) and the connector (313) are located between the movable part of the bidirectional moving member (310) and the rotating member (330) and the second fitting member (350).

5. The copper-clad steel wire performance testing device according to claim 4, characterized in that, The rotating component (330) includes a first bearing (331), a spring (332), and a round rod (333). The first fitting component (340) includes a first sponge block (341) and an extension rod (342). The second fitting component (350) includes a second sponge block (351) and a crossbar (352). The first bearing (331) is connected to the connecting rod (320). The round rod (333) is rotatably connected to the first bearing (331). The spring (332) is connected between the round rod (333) and the first bearing (331). The round rod (333) is connected to the extension rod (342). The first sponge block (341) is connected to the extension rod (342). The crossbar (352) is connected to the connecting rod (320). The second sponge block (351) is connected to the crossbar (352).

6. The copper-clad steel wire performance testing device according to claim 5, characterized in that, The corrosion simulation mechanism (300) further includes a drying component (360) and a second support (370), wherein the drying component (360) is connected to the working part of the placement component (100) via the second support (370).

7. The copper-clad steel wire performance testing device according to claim 6, characterized in that, The detection device (10) further includes a simulation acceleration mechanism (400), which includes a second motor (410), a guide (420), a long rod (430), a second bearing (440), and a guide wheel (450). The second motor (410) is connected to the working part of the placement part (100), the long rod (430) is connected to the shaft of the second motor (410), the second bearing (440) is connected to the long rod (430), the guide wheel (450) is rotatably connected to the second bearing (440), and the guide wheel (450) is in active contact with the copper-clad steel wire (500). The guide (420) is configured to limit the range of motion of the long rod (430).

8. The copper-clad steel wire performance testing device according to claim 7, characterized in that, The simulated acceleration mechanism (400) also includes an auxiliary component (460), which includes an arc plate (461) and a third support (462). The arc plate (461) is connected to the working part of the placement component (100) via the third support (462) and is located at the bending position of the copper-clad steel wire (500).

9. The copper-clad steel wire performance testing device according to claim 8, characterized in that, The guide (420) includes a slide rail (421), a slider (422) and a vertical rod (423). The slide rail (421) is connected to the working part of the placement part (100). The slider (422) is slidably connected to the slide rail (421). The slide rail (421) is coaxial with the center of the second motor (410). The vertical rod (423) is connected between the long rod (430) and the slider (422).

10. A method for testing the performance of copper-clad steel wires according to any one of claims 1-9, applied to a copper-clad steel wire performance testing device (10), characterized in that, Includes the following steps: The two ends of the copper-clad steel wire (500) are clamped and fixed by two pneumatic clamping devices (220) respectively, so that the copper-clad steel wire (500) is kept in a suspended state; Start the telescopic mechanism (240) to drive the contact member (250) to move up and down, so that the contact plate (253) makes active contact with the copper-clad steel wire (500); wherein, when the contact plate (253) squeezes the copper-clad steel wire (500), the telescopic rod (252) contracts and squeezes the gas in the internal cavity to buffer the contact between the contact plate (253) and the copper-clad steel wire (500).

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