A modular deep-sea wet-plug electrical connector plug and its manufacturing method

Abstract

This invention discloses an electrical connector technology, aiming to provide a modular deep-sea wet-plug electrical connector plug and its manufacturing method. The key technical features include a plug front housing, a plug rear housing, a pin assembly, an ROV handle, a tail cable sealing assembly, a cable sealing sleeve, and a cable. The front end of the plug front housing has a guide structure for mechanical alignment and initial sealing with a matching socket housing, and its interior has a cavity for accommodating and fixing the pin assembly. The plug rear housing is connected to the rear end of the plug front housing via threads or snap-fit, and a radial sealing ring is provided at the connection point. The plug rear housing also has an oil injection hole. The pin assembly is fixed to the cavity of the plug front housing via a snap ring or threads. The pin assembly includes an insulating base and at least two pins that pass parallel to the insulating base, with the tail of the pins configured as an open soldering end. This invention is applicable to the field of electrical connector technology.

Description

Technical Field

[0001] This invention relates to an electrical connector technology, and more specifically, to a modular deep-sea wet-plug electrical connector plug and its manufacturing method. Background Technology

[0002] With the deepening development of marine development, underwater observation, and national defense, the requirements for the reliability and functionality of underwater equipment are increasing. Wet-plug electrical connectors are key interfaces for the transmission of electrical energy and signals between underwater devices, requiring direct mating and disassembly in pressurized seawater environments, presenting extremely high technical challenges. Currently, deep-sea wet-plug connectors on the market generally suffer from the following technical difficulties: 1. Low degree of customization and poor flexibility: The pin definitions and internal wiring methods of traditional plugs are fixed at the factory; if users need to change the electrical logic, they must make special orders from the manufacturer, resulting in long delivery cycles, high costs, and the inability to make quick adjustments on-site according to task requirements.

[0003] 2. Complex pressure compensation structure limits reliability: The pressure in the deep-sea environment is enormous, and the connector needs to be filled with insulating oil for pressure compensation. Traditional compensation structures often use bellows or piston seals, which are complex and require extremely high machining precision and materials. Furthermore, moving parts may suffer from high frictional resistance, slow response, and easy jamming, affecting the immediacy and reliability of pressure balance.

[0004] 3. Inconvenient maintenance and assembly: The sealing and stress relief structure at the cable connection at the rear of the plug is usually a one-time potting or complex assembly. Once the internal solder joint fails or the cable needs to be replaced, it is almost impossible to repair on-site and must be returned to the factory for processing, which greatly affects the equipment uptime.

[0005] 4. Insulation and reliability risks: The welding points of the cable and the pins are directly exposed to compensating oil and are subject to long-term cable bending stress and pressure fluctuations, which may lead to short circuits due to weld fatigue and insulation wear. Summary of the Invention

[0006] To address the shortcomings of existing technologies, the present invention aims to provide a customized and highly reliable modular deep-sea wet-plug electrical connector plug and its manufacturing method.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a modular deep-sea wet-plug electrical connector plug, comprising a plug front housing, a plug rear housing, a pin assembly, an ROV handle, a tail cable sealing assembly, a cable sealing sleeve, and a cable; The front end of the plug housing is provided with a guide structure for achieving mechanical alignment and initial sealing with the matching socket housing, and its interior is provided with a cavity for accommodating and fixing the pin assembly. The rear housing of the plug is connected to the rear end of the front housing of the plug by a threaded or snap-fit ​​connection, and a radial sealing ring is provided at the connection; the rear housing of the plug is also provided with an oil injection hole. The pin assembly is fixed to the cavity of the front housing of the plug by a retaining ring or thread. The pin assembly includes an insulating base and at least two pins that pass parallel to the insulating base. The tail of the pin is set as an open soldering end. The tails of the pins are regularly arranged at the tail of the insulating base and a space is reserved for soldering operations. The cable forms a custom electrical connection mode between the soldering ends by soldering. The cable sealing sleeve is tightly fitted outside the soldering point between the cable and the soldering end of the pin tail to achieve mechanical protection and insulation reinforcement. The ROV handle is fixedly installed on the outside of the rear housing of the plug, and is used to provide a mechanical interface for the ROV's robotic arm to grip. The cable tail sealing assembly includes a tail shank, a first sealing ring, a second sealing ring, a sealing plug, and a locking nut. The front end of the tail shank is connected to the rear housing of the plug via threads. The first and second sealing rings are sequentially disposed at the connection between the tail shank and the rear housing of the plug to form a closed sealing cavity. The sealing plug is located in a hollow channel inside the tail shank, and its outer diameter precisely matches the inner diameter of the tail shank. The middle section of the sealing plug is provided with at least one semi-circular cross-section sealing step, which forms a line contact seal with the inner wall of the tail shank and allows the sealing plug to slide along the tail shank axial direction to achieve pressure compensation. The two ends of the sealing plug are set as spherical or large arc rounded structures. The locking nut acts on the rear end of the tail shank to achieve cable positioning. The sealing cavity is filled with insulating pressure compensation oil. The locking nut has a through hole. The two ends of the cable are soldered to the wire ends of the different pins of the pin assembly.

[0008] The present invention is further configured such that: the number of semi-circular cross-section sealing steps in the middle section of the sealing plug is 1-3, the ratio of the cross-sectional radius R of the semi-circular cross-section sealing step to the outer diameter D of the sealing plug satisfies 0.05≤R / D≤0.1, and the radius of curvature r of the spherical or large circular arc rounded structure at both ends of the sealing plug satisfies r≥1.5R, which is used to optimize the distribution of sealing contact stress and reduce sliding friction resistance.

[0009] The present invention is further configured such that: the cable sealing sleeve is made of silicone rubber or fluororubber, and the inner diameter of the cable sealing sleeve is interference-fitted with the outer diameter of the welding point of the cable and the welding end of the pin tail, and the interference amount is 3%-8% of the original inner diameter of the cable sealing sleeve.

[0010] The present invention is further configured such that: the number of the pins is 2-12, and the spacing between the tails of the pins at the tails of the insulating base is 1.5-3 times the diameter of the pins.

[0011] A method for manufacturing a modular deep-sea wet-pluggable electrical connector plug, characterized by comprising the following steps: S1. Housing pretreatment: Clean and dry the front and rear housings of the plug, and apply an appropriate amount of grease to the guide structure of the front housing. S2. Pin assembly pre-installation: Press the pins into the preset holes of the insulating base, and then fix the pin assembly in the inner cavity of the front housing of the plug by means of a retaining ring or thread, while ensuring that the tail cavity of the insulating base of the pin assembly faces the rear housing of the plug. S3. Customized soldering: According to the wiring diagram, use cables to solder between the open solder ends of the pins of the pin assembly to achieve short circuit, series or independent connection of the pins. S4. Weld joint protection treatment: After each weld is completed, a cable sealing sleeve is put on the weld joint to achieve tight wrapping and stress buffering. S5. Housing Assembly: After the pin assembly with the welded cable is installed in place, the rear housing of the plug and the front housing of the plug are fastened together by threads or snaps, and the main watertight barrier is formed by the radial sealing ring at the connection. S6. Assembly of tail cable sealing assembly and installation of sealing plug: First, tighten the tail shank onto the rear housing of the plug, and rely on the first sealing ring and the second sealing ring to achieve static sealing; then, insert the sealing plug from the rear end of the tail shank into the middle of the hollow channel of the tail shank to reserve the axial sliding range of the sealing plug. The sealing plug uses the semi-circular cross-section sealing step to form a dynamic sealing pair with the inner wall of the tail shank; finally, tighten the lock nut to the tail shank. S7. Oil injection and pressure compensation initialization: Inject insulating pressure compensation oil into the sealed cavity formed by the plug rear housing, tail stick and sealing plug through the oil injection hole reserved on the plug rear housing until it is full and all gas is discharged, and then seal the oil injection hole. S8. Final Inspection and ROV Handle Installation: Perform airtightness and electrical performance tests on the assembled connector. After passing the tests, fix the ROV handle on the rear housing of the plug.

[0012] The present invention is further configured such that: the S3 customized welding and S4 weld point protection treatment steps embed a three-level linkage dynamic judgment logic of welding temperature-weld point morphology-sealing sleeve coverage; a welding temperature real-time acquisition sensing module, a weld point three-dimensional morphology visual inspection module, and a cable sealing sleeve pressure sensing unit are configured; firstly, the real-time temperature parameter T(t) of the welding process is collected, and an ideal welding temperature curve model of the deep-sea electrical connector weld point is constructed: when the welding time t1 < 2s, T1 = 280 + 60t1; when 2s ≤ t1 < 5s, T1 = 400 - 40(t1 - 2); when t1 ≥ 5s, welding is terminated and the weld point three-dimensional morphology data S(x,y,z) is collected; the spatial deviation value ΔS between the actual weld point morphology and the standard morphology is calculated in real time = √[(S -S 0) -S 0)0) 2 +(S 2 +(Sz-Sz 2 Simultaneously collect the assembly pressure value F corresponding to the cable sealing sleeve covering stroke; if ΔS is between 0.02mm and 0.05mm and F increases linearly with the cable sealing sleeve covering stroke, the weld point formation and sealing sleeve covering are deemed qualified, and proceed to S5; if ΔS > 0.05mm but the linear increase rate of F is ≥ 85%, the weld point micro-grinding correction unit is activated, and the covering operation is re-executed after correction, with only a single correction allowed; if ΔS < 0.02mm but the linear increase rate of F is < 60%, the cable sealing sleeve elasticity is deemed abnormal, and the sealing sleeve is replaced and re-covered; if ΔS > 0.05mm and the linear increase rate of F is < 60%, the needle assembly is directly rejected and proceed to S2 to re-execute the needle assembly pre-installation.

[0013] The beneficial effects of this invention are: 1. Compared to existing technologies, the modular deep-sea wet-plug electrical connector plug of this invention integrates the front and rear housings and pin assemblies independently through a modular structural design, facilitating assembly and maintenance. The front-end guiding structure ensures precise socket docking and initial sealing, guaranteeing the reliability of deep-sea wet-plugging. The sealed connection between the front and rear housings, along with a radial sealing ring and a double-sealing cavity, constructs multiple watertight barriers, adapting to the high-pressure environment of the deep sea. The oil injection hole, combined with the sealing plug, provides pressure compensation, balancing internal and external water pressure and preventing housing deformation and failure. The open welding end of the pin assembly supports custom electrical connections, flexibly enabling loops, short circuits, series connections, etc., offering strong versatility. The cable sealing sleeve wraps around the welding points, improving insulation and mechanical strength. The ROV handle is compatible with robotic arm operation, meeting the needs of unmanned deep-sea operations. The semi-circular sealing step of the sealing plug in the tail cable sealing assembly achieves line contact dynamic sealing, ensuring both sealing and axial sliding pressure compensation. The overall structure is compact, reliably sealed, and adaptable to extreme deep-sea conditions.

[0014] 2. The modular deep-sea wet-plug electrical connector plug of this invention optimizes sealing and sliding performance by limiting the semi-circular sealing steps of the sealing plug to 1-3, the ratio of the cross-sectional radius R to the outer diameter D to be 0.05≤R / D≤0.1, and the radius of curvature at both ends r≥1.5R. When R / D<0.05, the sealing step cross-section is too small, the line contact sealing pressure is insufficient, and oil and water leakage are prone to occur under the high pressure of deep sea, resulting in seal failure. When R / D>0.1, the sealing step is too wide, the contact area with the inner wall of the tail shank increases, the sliding friction resistance increases sharply, the sealing plug cannot move smoothly axially, the pressure compensation is prone to failure, resulting in pressure imbalance and damage to the shell. The arc structure with r≥1.5R reduces assembly and sliding wear and avoids stress concentration tearing of the seal. This ratio range accurately balances the sealing effectiveness, sliding smoothness and structural durability, ensuring long-term stability of the deep-sea dynamic seal.

[0015] 3. In this invention, the cable sealing sleeve is made of silicone rubber / fluororubber, with an interference fit between the inner diameter and the outer diameter of the weld point of 3%-8% of the original inner diameter, achieving reliable protection of the weld point. When the interference fit is <3%, the cable sealing sleeve is loosely wrapped, and the fit with the weld point and cable is not tight, resulting in gaps that can easily lead to insulation failure. Furthermore, the mechanical protection is insufficient, and the sleeve is prone to falling off when pulled. When the interference fit is >8%, the interference fit is too large, making it difficult to assemble the cable sealing sleeve. It is easy to be squeezed and deformed or even cracked, which can damage the sealing structure. At the same time, excessive compression of the weld point can easily cause poor welding or wire breakage, affecting the stability of the electrical connection. Silicone rubber / fluororubber is corrosion-resistant and anti-aging. The 3%-8% interference fit ensures tight wrapping, insulation sealing, and stress buffering, while also facilitating assembly without damaging the weld point, thus comprehensively improving the reliability of the weld point.

[0016] 4. The present invention has a reasonable structure, is easy to manufacture and operate, avoids the defects of the prior art, and is suitable for promotion and application. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall design of the modular deep-sea wet-plug electrical connector plug of the present invention.

[0018] Figure 2 This is an internal schematic diagram of the plug of the modular deep-sea wet-plug electrical connector of the present invention.

[0019] Figure 3 This is a schematic diagram of a sealing plug.

[0020] Figure 1-3 Reference numerals: 1. Front housing of plug; 2. Rear housing of plug; 3. Pin assembly; 4. ROV handle; 5. Tail cable sealing assembly; 6. Cable sealing sleeve; 7. Cable; 8. Guide structure; 9. Insulating base; 10. Pin; 11. Tail handle; 12. First sealing ring; 13. Second sealing ring; 14. Sealing plug; 15. Locking nut; 16. Sealing step; 17. Through hole. Detailed Implementation

[0021] Reference Figure 1-3 The embodiments of the modular deep-sea wet-plug electrical connector plug and its manufacturing method of the present invention are further described.

[0022] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0023] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0024] Figures 1 to 3 The modular deep-sea wet-plug electrical connector plug shown includes a front plug housing 1, a rear plug housing 2, a pin assembly 3, an ROV handle 4, a tail cable sealing assembly 5, a cable sealing sleeve 6, and a cable 7. The front end of the plug housing 1 is provided with a guide structure 8 for mechanical alignment and initial sealing with the matching socket housing, and its interior is provided with a cavity for accommodating and fixing the pin assembly 3. The rear housing 2 of the plug is connected to the rear end of the front housing 1 of the plug by means of threads or snaps, and a radial sealing ring is provided at the connection; the rear housing 2 of the plug is also provided with an oil injection hole; The pin assembly 3 is fixed to the cavity of the front housing 1 of the plug by a retaining ring or thread. The pin assembly 3 includes an insulating base 9 and at least two pins 10 that pass through the insulating base 9 in parallel. The tail of the pin 10 is set as an open welding end. The tails of each pin 10 are regularly arranged at the tail of the insulating base 9 and a welding operation space is reserved. The cable 7 forms a custom electrical connection mode between the welding ends by welding. The cable sealing sleeve 6 is tightly fitted outside the welding point between the cable 7 and the welding end of the pin 10, and is used to achieve mechanical protection and insulation reinforcement. The ROV handle 4 is fixedly installed on the outside of the plug rear housing 2 to provide a mechanical interface for the ROV's robotic arm to grip. The tail cable sealing assembly 5 includes a tail shank 11, a first sealing ring 12, a second sealing ring 13, a sealing plug 14, and a locking nut 15. The front end of the tail shank 11 is connected to the rear housing 2 of the plug via threads. The first sealing ring 12 and the second sealing ring 13 are sequentially arranged at the connection between the tail shank 11 and the rear housing 2 of the plug to form a closed sealing cavity. The sealing plug 14 is located in the hollow channel inside the tail shank 11, and its outer diameter is precisely matched with the inner diameter of the tail shank 11. The middle section of the sealing plug 14 is provided with at least one semi-circular cross-section sealing step 16. The semi-circular cross-section sealing step 16 forms a line contact seal with the inner wall of the tail shank 11 and allows the sealing plug 14 to slide along the axial direction of the tail shank 11 to achieve pressure compensation. The two ends of the sealing plug 14 are set as spherical or large arc rounded structures. The locking nut 15 acts on the rear end of the tail shank 11 to realize the positioning of the sealing plug 14 and prevent it from falling off. The sealing cavity is filled with insulating pressure compensation oil. The locking nut 15 is provided with a through hole 17. The two ends of the cable 7 are soldered to the tail wire ends of different pins 10 of the pin assembly 3; Through modular structural design, the plug front housing 1, plug rear housing 2, and pin assembly 3 are independently integrated, making assembly and maintenance convenient. The front-end guide structure 8 ensures precise socket docking and initial sealing, guaranteeing reliability for wet plugging and unplugging in deep sea. The sealed connection between the plug front housing 1 and plug rear housing 2, along with the radial sealing ring and double sealing ring cavity, constructs multiple watertight barriers, adapting to the high-pressure environment of deep sea. The oil injection hole, in conjunction with the sealing plug 14, achieves pressure compensation, balancing internal and external water pressure and preventing housing deformation and failure. The open welding end of the pin assembly 3 supports custom electrical connections, flexibly realizing loops, short circuits, series connections, etc., with strong versatility. The cable sealing sleeve 6 wraps the welding point, improving insulation and mechanical strength. The ROV handle 4 is adapted for robotic arm operation, meeting the needs of unmanned deep-sea operations. The semi-circular sealing step 16 in the sealing plug 14 of the tail cable sealing assembly 5 achieves line contact dynamic sealing, ensuring both sealing and axial sliding pressure compensation. The overall structure is compact, reliable in sealing, and adaptable to extreme deep-sea conditions. Furthermore, if internal solder joints fail, cable 7 is damaged, or electrical configuration needs to be changed, simply unscrew the tailstock 11 and the plug housing 2 to directly expose the tail of the pin assembly 3 for soldering. Replacing damaged modules is also very convenient, enabling on-site maintenance without the need for specialized tools or factory returns. This significantly improves the efficiency of underwater equipment maintenance and reduces the total lifecycle cost. The number of semi-circular cross-section sealing steps 16 in the middle section of the sealing plug 14 is 1-3. The ratio of the cross-sectional radius R of the semi-circular cross-section sealing step 16 to the outer diameter D of the sealing plug 14 satisfies 0.05≤R / D≤0.1, and the radius of curvature r of the spherical or large arc rounded structure at both ends of the sealing plug 14 satisfies r≥1.5R, which is used to optimize the distribution of sealing contact stress and reduce sliding friction resistance. By limiting the semi-circular sealing steps 16 of the sealing plug 14 to 1-3, the ratio of the cross-sectional radius R to the outer diameter D to be 0.05 ≤ R / D ≤ 0.1, and the radius of curvature at both ends r ≥ 1.5R, the sealing and sliding performance is optimized, making the sealing plug 14 extremely rapid and sensitive to changes in deep-sea pressure. It can balance internal and external pressures in real time and efficiently, avoiding seal failure or insulating oil leakage caused by pressure differences. When R / D < 0.05, the cross-section of the sealing step 16 is too small, the line contact sealing pressure is insufficient, and oil seepage and water leakage are prone to occur under the high pressure of deep sea, leading to seal failure. When R / D > 0.1, the sealing steps... If the width of 16 is too large, the contact area with the inner wall of the tailstock 11 increases, the sliding friction resistance increases dramatically, the sealing plug 14 cannot move smoothly axially, the pressure compensation is prone to failure, and the shell pressure imbalance damages itself. However, the radius of curvature r of the spherical or large arc rounded structure at both ends of the sealing plug 14 satisfies r≥1.5R, which optimizes the dynamic environment of the insulating oil, provides a self-lubricating effect, and ensures the smoothness and reliability of the long-term movement of the sealing plug 14, fundamentally avoiding the stubborn problem of jamming in traditional piston structures. This ratio range accurately balances the sealing effectiveness, sliding smoothness and structural durability, ensuring the long-term stability of the deep-sea dynamic seal.

[0025] The cable sealing sleeve 6 is made of silicone rubber or fluororubber. The inner diameter of the cable sealing sleeve 6 is interference-fitted with the outer diameter of the welding point of the cable 7 and the tail welding end of the pin 10. The interference amount is 3%-8% of the original inner diameter of the cable sealing sleeve 6. The cable sealing sleeve 6 is made of silicone rubber / fluororubber, with an interference fit of 3%-8% between its inner diameter and the outer diameter of the weld joint, ensuring reliable protection of the weld joint. When the interference fit is less than 3%, the cable sealing sleeve 6 is loosely wrapped, and does not fit tightly with the weld joint and cable 7, resulting in gaps that can easily lead to insulation failure. Furthermore, it provides insufficient mechanical protection and is prone to detachment when pulled. When the interference fit is greater than 8%, the excessive interference makes the cable sealing sleeve 6 difficult to assemble, easily causing deformation or even cracking, which in turn damages the sealing structure. At the same time, excessive compression of the weld joint can easily cause poor soldering or wire breakage, affecting the stability of the electrical connection. Silicone rubber / fluororubber is corrosion-resistant and anti-aging. The 3%-8% interference fit ensures tight wrapping, insulation sealing, and stress buffering, while also facilitating assembly without damaging the weld joint, thus comprehensively improving the reliability of the weld joint.

[0026] The number of pins 10 is 2-12, and the spacing between the tails of each pin 10 at the tail of the insulating base 9 is 1.5-3 times the diameter of the pin 10. By limiting the number of pins 10 to 2-12, with the spacing at the tail end being 1.5-3 times the diameter of the pins 10, both electrical performance and welding operability are considered. When the spacing is less than 1.5 times the diameter of the pins 10, the pins 10 at the tail end of the insulating base 9 are too dense, resulting in a small welding operation space, which easily leads to solder adhesion, short circuits, and difficulty in ensuring welding quality. Furthermore, the cable sealing sleeve 6 cannot be completely covered, resulting in insulation protection failure. When the spacing is greater than 3 times the diameter of the pins 10, the pins 10 are arranged too sparsely, resulting in an increased volume of the insulating base 9 and the plug housing, a bulky structure that does not meet the miniaturization requirements, and also increases the difficulty of watertight sealing, reducing structural compactness. The 2-12 pins 10 in this application meet the requirements of multi-circuit electrical transmission and are compatible with various deep-sea equipment. The 1.5-3 times spacing provides sufficient welding space, ensuring welding quality and sealing sleeve fit, achieving the optimal balance between electrical performance, structural compactness, and manufacturability.

[0027] A method for manufacturing a modular deep-sea wet-pluggable electrical connector plug, characterized by comprising the following steps: S1. Housing pretreatment: Clean and dry the front housing 1 and the rear housing 2 of the plug, and apply an appropriate amount of grease to the guide structure 8 of the front housing 1 of the plug. S2. Pre-installation of pin assembly 3: Press the pin 10 into the preset hole of the insulating base 9, and then fix the pin assembly 3 in the inner cavity of the front housing 1 of the plug by means of a retaining ring or thread, while ensuring that the tail cavity of the insulating base 9 of the pin assembly 3 faces the rear housing 2 of the plug. S3. Customized soldering: According to the wiring diagram, use cable 7 to solder between the open solder ends of the pins 10 of the pin assembly 3 to achieve short circuit, series or independent connection of the pins 10. S4. Weld joint protection treatment: After each weld is completed, a cable sealing sleeve 6 is put on the weld joint to achieve tight wrapping and stress buffering. S5. Housing assembly: After the pin assembly 3 of the welded cable 7 is installed in place, the rear housing 2 of the plug and the front housing 1 of the plug are fastened together by threads or snaps, and the main watertight barrier is formed by the radial sealing ring at the connection. S6. Assembly of Tail Cable Sealing Assembly 5 and Installation of Sealing Plug 14: First, tighten the tail shank 11 onto the rear housing 2 of the plug, and achieve static sealing by relying on the first sealing ring 12 and the second sealing ring 13; then, insert the sealing plug 14 from the rear end of the tail shank 11 into the middle of the hollow channel of the tail shank 11 to reserve the axial sliding range of the sealing plug 14. The sealing plug 14 forms a dynamic sealing pair with the inner wall of the tail shank 11 by using the semi-circular cross-section sealing step 16; finally, tighten the locking nut 15 onto the tail shank 11. S7. Oil injection and pressure compensation initialization: Inject insulating pressure compensation oil into the sealed cavity formed by the plug rear housing 2, tail shank 11 and sealing plug 14 through the oil injection hole reserved on the plug rear housing 2 until it is full and all gas is discharged, and then seal the oil injection hole. S8. Final inspection and ROV handle 4 installation: Perform airtightness and electrical performance tests on the assembled connector. After passing the tests, fix the ROV handle 4 on the plug rear housing 2. This manufacturing process is standardized and controllable, ensuring the connector's deep-sea adaptability and reliability. The shell pretreatment (cleaning and drying) and guide structure 8 (grease application) reduce insertion and removal wear and improve docking accuracy. Pre-installation of the pin assembly 3 ensures precise positioning and pin concentricity, preventing damage during insertion and removal. Customized welding enables customized electrical connections, flexibly adapting to different equipment requirements. Solder joint protection with sealing sleeves enhances insulation and mechanical protection. Multiple seals during shell assembly create a primary watertight barrier, and precise control of the tail cable sealing assembly 5 ensures dynamic sealing and pressure compensation functions. Oil injection and gas venting ensure the pressure compensation oil fills the sealing cavity, effectively balancing the high pressure in the deep sea. Final testing and ROV handle 4 installation verify airtightness and electrical performance, meeting the requirements for unmanned ROV operation. The entire process is tightly integrated, with strong process controllability, adapting to harsh deep-sea conditions.

[0028] The S3 customized welding and S4 weld point protection treatment steps embed a three-level linkage dynamic judgment logic of welding temperature, weld point morphology, and sealing sleeve coverage: A real-time welding temperature acquisition sensor module, a three-dimensional weld point morphology visual inspection module, and a cable sealing sleeve 6 assembly pressure sensing unit are configured; firstly, the real-time temperature parameter T(t) of the welding process is collected to construct an ideal welding temperature curve model for the deep-sea electrical connector weld point: when the welding time t1 < 2s, T1 = 280 + 60t1; when 2s ≤ t1 < 5s, T1 = 400 - 40(t1 - 2); when t1 ≥ 5s, welding is terminated and the three-dimensional morphology data S(x,y,z) of the weld point is collected; the spatial deviation value ΔS between the actual weld point morphology and the standard morphology is calculated in real time: ΔS = √[(S -S 0) -S 0)0) 2 +(S 2 +(Sz-Sz 2, synchronously collect the assembly pressure value F corresponding to the wrapping stroke of the synchronous acquisition cable seal 6; if ΔS is between 0.02 mm and 0.05 mm and F shows a linear increasing trend with the wrapping stroke of the cable seal 6, it is determined that the solder joint formation and seal wrapping are qualified, and proceed to S5; if ΔS > 0.05 mm but the linear increasing rate of F ≥ 85%, start the solder joint micro-grinding correction unit, and after correction, re-perform the wrapping operation, and only single correction is allowed; if ΔS < 0.02 mm but the linear increasing rate of F < 60%, it is determined that the elastic adaptation of the cable seal 6 is abnormal, and after replacing the seal, re-wrap; if ΔS > 0.05 mm and the linear increasing rate of F < 60%, directly reject this pin assembly 3 and proceed to S2 to re-perform the pre-installation of the pin assembly 3; The above dynamic judgment logic realizes the intelligent quality control of the whole process of welding-solder joint-seal, greatly improving the product qualification rate and reliability; real-time collect the welding temperature, match the ideal temperature curve, and avoid overheating and burning out the pin 10 or underheating and causing false soldering; three-dimensional topography detects the solder joint deviation ΔS to accurately determine the forming quality; the assembly pressure monitors the wrapping state of the cable seal 6 for multi-dimensional collaborative judgment; when ΔS is between 0.02 and 0.05 mm and the pressure increases linearly, it is determined to be qualified; start targeted correction for single parameter abnormality, and directly rework for double abnormalities to prevent unqualified products from flowing into the next process; this logic avoids manual detection errors and realizes automatic precise control, ensuring both reliable electrical connection of the solder joint and effective wrapping and sealing of the cable seal 6, solving the problems of solder joint failure and poor sealing of deep-sea connectors at the source, and improving the product stability and service life. The above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any normal changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included in the protection scope of the present invention.

Claims

1. A modular deep-sea wet-mate electrical connector plug, characterized by: Includes a front plug housing (1), a rear plug housing (2), a pin assembly (3), an ROV handle (4), a tail cable sealing assembly (5), a cable sealing sleeve (6), and a cable (7); The front end of the plug housing (1) is provided with a guide structure (8) for mechanical alignment and initial sealing with the matching socket housing, and the interior of the guide structure (8) is provided with a cavity for accommodating and fixing the pin assembly (3). The rear housing (2) of the plug is connected to the rear end of the front housing (1) of the plug by means of threads or snaps, and a radial sealing ring is provided at the connection; the rear housing (2) of the plug is also provided with an oil injection hole; The pin assembly (3) is fixed to the cavity of the front housing (1) of the plug by a retaining ring or thread. The pin assembly (3) includes an insulating base (9) and at least two pins (10) that pass through the insulating base (9) in parallel. The tail of the pin (10) is set as an open welding end. The tails of each pin (10) are arranged regularly at the tail of the insulating base (9) and a welding operation space is reserved. The cable (7) forms a custom electrical connection mode between the welding ends by welding. The cable sealing sleeve (6) is tightly fitted outside the welding point between the cable (7) and the welding end of the pin (10) to achieve mechanical protection and insulation reinforcement. The ROV handle (4) is fixedly installed on the outside of the plug rear housing (2) to provide a mechanical interface for the ROV's robotic arm to grip; The tail cable sealing assembly (5) includes a tail stick (11), a first sealing ring (12), a second sealing ring (13), a sealing plug (14), and a locking nut (15); the front end of the tail stick (11) is connected to the rear housing (2) of the plug via threads, and the first sealing ring (12) and the second sealing ring (13) are sequentially arranged at the connection between the tail stick (11) and the rear housing (2) of the plug to form a closed sealing cavity; the sealing plug (14) is located in the hollow channel inside the tail stick (11) and its outer diameter is precisely matched with the inner diameter of the tail stick (11). The middle section of 14) is provided with at least one semi-circular cross-section sealing step (16), which forms a line contact seal with the inner wall of the tail shank (11) and allows the sealing plug (14) to slide along the tail shank (11) axially to achieve pressure compensation; the two ends of the sealing plug (14) are set as spherical or large arc rounded structures; the locking nut (15) acts on the rear end of the tail shank (11) to realize the positioning of the cable (7); the sealing cavity is filled with insulating pressure compensation oil; the locking nut (15) is provided with a through hole (17); The two ends of the cable (7) are welded to the wire ends of the different pins (10) of the pin assembly (3).

2. The modular deep-sea wet-plug electrical connector plug according to claim 1, characterized in that, The number of semi-circular cross-section sealing steps (16) in the middle section of the sealing plug (14) is 1-3. The ratio of the cross-sectional radius R of the semi-circular cross-section sealing step (16) to the outer diameter D of the sealing plug (14) satisfies 0.05≤R / D≤0.

1. The radius of curvature r of the spherical or large circular arc rounded structure at both ends of the sealing plug (14) satisfies r≥1.5R. This is used to optimize the distribution of sealing contact stress and reduce sliding friction resistance.

3. The modular deep-sea wet-plug electrical connector plug according to claim 1, characterized in that, The cable sealing sleeve (6) is made of silicone rubber or fluororubber. The inner diameter of the cable sealing sleeve (6) is interference-fitted with the outer diameter of the welding point of the cable (7) and the welding end of the pin (10). The interference amount is 3%-8% of the original inner diameter of the cable sealing sleeve (6).

4. The modular deep-sea wet-plug electrical connector plug according to claim 1, characterized in that, The number of the pins (10) is 2-12, and the spacing between the tails of the pins (10) at the tails of the insulating base (9) is 1.5-3 times the diameter of the pins (10).

5. A method for manufacturing a plug suitable for the modular deep-sea wet-plug electrical connector according to any one of claims 1-4, characterized in that, Includes the following steps: S1. Housing pretreatment: Clean and dry the front housing (1) and rear housing (2) of the plug, and apply an appropriate amount of grease to the guide structure (8) of the front housing (1); S2, Pre-installation of the pin assembly (3): Press the pin (10) into the preset hole of the insulating base (9), and then fix the pin assembly (3) in the inner cavity of the front housing (1) of the plug by means of a retaining ring or thread, while ensuring that the tail cavity of the insulating base (9) of the pin assembly (3) faces the rear housing (2) of the plug. S3. Customized welding: According to the wiring diagram, use cable (7) to weld between the open solder ends of the pins (10) of the pin assembly (3) to achieve short circuit, series connection or independent connection of the pins (10). S4. Weld joint protection treatment: After each welding is completed, a cable sealing sleeve (6) is put on the welding joint to achieve tight wrapping and stress buffering of the welding joint; S5. Housing assembly: After the pin assembly (3) with the welded cable (7) is installed in place, the rear housing (2) of the plug and the front housing (1) of the plug are fastened together by threads or snaps, and the main watertight barrier is formed by the radial sealing ring at the connection. S6. Assembly of the tail cable sealing assembly (5) and installation of the sealing plug (14): First, tighten the tail shank (11) onto the rear housing (2) of the plug, and achieve static sealing by relying on the first sealing ring (12) and the second sealing ring (13); then, insert the sealing plug (14) from the rear end of the tail shank (11) into the middle of the hollow channel of the tail shank (11) to reserve the axial sliding range of the sealing plug (14). The sealing plug (14) forms a dynamic sealing pair with the inner wall of the tail shank (11) by using the semi-circular cross section sealing step (16); finally, tighten the lock nut (15) onto the tail shank (11). S7. Oil injection and pressure compensation initialization: Inject insulating pressure compensation oil into the sealed cavity formed by the plug rear housing (2), tail stick (11) and sealing plug (14) through the oil injection hole reserved on the plug rear housing (2) until it is full and all gas is discharged, and then seal the oil injection hole. S8. Final inspection and ROV handle (4) installation: Perform airtightness and electrical performance tests on the assembled connector. After passing the tests, fix the ROV handle (4) on the plug rear housing (2).

6. The manufacturing method of the modular deep-sea wet-plug electrical connector plug according to claim 5, characterized in that, The S3 customized welding and S4 weld point protection treatment steps embed a three-level linkage dynamic judgment logic of welding temperature-weld point morphology-sealing sleeve coverage: configure a welding temperature real-time acquisition sensing module, a weld point three-dimensional morphology visual inspection module and a cable sealing sleeve (6) assembly pressure sensing unit; firstly, collect the real-time temperature parameter T(t) of the welding process, and construct an ideal welding temperature curve model of the deep-sea electrical connector weld point: when the welding time t1 < 2s, T1 = 280 + 60t1; when 2s ≤ t1 < 5s, T1 = 400 - 40(t1 - 2); when t1 ≥ 5s, terminate the welding and collect the weld point three-dimensional morphology data S(x,y,z); calculate the spatial deviation value ΔS between the actual morphology and the standard morphology of the weld point in real time. -S 0) -S 0)0) 2 +(S 2 +(Sz-Sz 2 Simultaneously collect the assembly pressure value F corresponding to the covering stroke of the cable sealing sleeve (6); if ΔS is between 0.02mm and 0.05mm and F increases linearly with the covering stroke of the cable sealing sleeve (6), the weld point formation and sealing sleeve covering are deemed qualified, and proceed to S5; if ΔS > 0.05mm but the linear increase rate of F is ≥ 85%, the weld point micro-grinding correction unit is activated, and the covering operation is re-executed after correction, and only one correction is allowed; if ΔS < 0.02mm but the linear increase rate of F is < 60%, the elasticity of the cable sealing sleeve (6) is deemed abnormal, and the sealing sleeve is replaced and re-covered; if ΔS > 0.05mm and the linear increase rate of F is < 60%, the needle assembly (3) is directly removed and proceed to S2 to re-execute the pre-installation of the needle assembly (3).

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