Catenary wire suspension production platform

Abstract

The application relates to the technical field of rail transit power supply, and particularly discloses a contact net dropper manufacturing platform, which comprises a rectangular box type groove body workbench with a surrounding edge, provides a horizontal operation reference surface for dropper manufacturing, and can accommodate tools; a crimping device is fixedly installed at the right end of the workbench and is used for crimping and forming a dropper wire and a wire clamp and a clamp tube; the reference guide rail is in a long strip-shaped rectangular section and is horizontally fixed in the middle of the groove bottom along the length direction of the workbench, and provides a linear guide reference for dropper length positioning; the sliding length taking device is in a U-shaped groove shape with an opening downward, can be slidably sleeved on the reference guide rail, and has the functions of dropper wire end length positioning and heart-shaped ring preliminary shaping; a length scale is installed in parallel above the reference guide rail and can directly read the dropper manufacturing length; a clamp tube installation device is arranged at the lower left corner of the workbench, and a preliminary shaping device can be detachably placed on the groove bottom. The whole-process integrated operation of dropper manufacturing is realized, and the manufacturing efficiency, precision and product quality stability are improved.

Description

Technical Field

[0001] This application relates to the technical field of rail transit power supply, especially the technical field of construction and maintenance equipment for the catenary of electrified railways. Specifically, it relates to a catenary suspension string manufacturing platform. Background Art

[0002] The catenary suspension string is a key stress-bearing and connecting component in the catenary system of electrified rail transit. It undertakes the core functions of mechanical connection between the carrier cable and the contact wire, tension transmission, and adjustment of the height and sag of the contact wire. Its manufacturing precision and quality directly determine the geometric shape stability of the contact wire and the current collection quality of the pantograph, and are an important foundation for ensuring the safe and stable operation of trains. Industry standards have extremely strict technical requirements for the length precision of the suspension string, the forming quality of the heart-shaped loop, and the reliability of the crimping of the crimping tube. Quality defects in any link may cause catenary failures and endanger train operation safety.

[0003] Currently, the manufacturing of catenary suspension strings generally adopts an artificial decentralized operation mode, relying on the personal experience and manual operations of operators to complete each process. This mode has many technical defects that are difficult to overcome: First, the artificial measurement, forming, and crimping processes are significantly affected by human factors, making it difficult to ensure the consistency of the suspension string length and the standardization of the heart-shaped loop forming. The crimping quality varies, and it is difficult to stably control the product qualification rate during batch production. Second, each process is independent, and the workpiece needs to be frequently transferred between multiple workstations, which not only greatly reduces the production efficiency but also introduces cumulative errors due to multiple positioning, further affecting the manufacturing precision of the suspension string. Third, existing auxiliary tooling are mostly single-function devices that can only achieve single processes such as crimping or measurement, and cannot integrate full-process operation functions such as pre-shaping, pre-installation of crimping tubes, and precise length positioning, making it difficult to form a standardized and integrated manufacturing process. Fourth, the versatility of existing tooling is poor, and it cannot quickly adapt to the manufacturing requirements of different specifications of suspension strings, making it difficult to meet the requirements of complex and changeable construction site operations. Summary of the Invention

[0004] By providing a catenary suspension string manufacturing platform in the embodiments of this application, the technical problems in the prior art of low efficiency, poor precision, and lack of integrated tooling in artificial decentralized operations are solved, realizing full-process integrated and standardized operations for the manufacturing of suspension strings, and significantly improving the manufacturing efficiency, precision, and product quality stability.

[0005] This invention provides a contact wire dropper fabrication platform, comprising: a workbench, shaped like a rectangular box-type groove with a surrounding edge, for providing a horizontal working reference surface for dropper fabrication and storing tools; a crimping device, fixedly installed at the right end of the workbench, for crimping the dropper wire to the wire clamp and clamping tube; a reference guide rail, shaped like a long rectangular cross-section, horizontally fixedly installed in the middle of the groove bottom of the workbench along its length, for providing a linear guiding reference for dropper length positioning; and a sliding length-cutting device, shaped like a downward-opening U-shaped groove. The structure, slidably mounted on the reference guide rail, is used to position the end of the dropper wire at different length positions and to complete the initial shaping of the heart-shaped ring; the length scale, in the shape of a long strip of graduated plate, is fixedly installed parallel to the reference guide rail directly above it, for directly reading the fabrication length of the dropper wire; the clamping tube installation device is fixedly installed at the lower left corner of the worktable, for pre-fitting the clamping tube onto the dropper wire; the preliminary shaping device is detachably placed at the bottom of the slot of the worktable, for pre-bending the end of the dropper wire.

[0006] In one possible implementation, the crimping device includes: a mounting bracket, which has an L-shaped plate structure and is fixed to the top right end of the workbench by bolts; an electro-hydraulic crimping connector, which has an integrated structure of a cylindrical body and a motor drive, and is horizontally installed in the middle of the mounting bracket, with its crimping end facing the reference guide rail; a locking device, which is installed above the electro-hydraulic crimping connector and includes a spring and a pressure block, for firmly fixing the dropper wire before crimping; and a crimping mold, which has an upper and lower block structure and is detachably installed on the crimping end of the electro-hydraulic crimping connector, for adapting to dropper wire clamps and crimping tubes of different specifications.

[0007] In one possible implementation, the pressing end of the electro-hydraulic pressing connector is provided with a mold mounting groove, which is in the shape of a T-shaped cross-section groove. The rear end of the pressing mold is provided with a T-shaped protrusion that mates with the T-shaped cross-section groove, so as to realize the quick replacement and positioning of the pressing mold.

[0008] In one possible implementation, the sliding length-taking device includes: a base body with a U-shaped cross-section, opening downwards and engaging with the reference guide rail, its inner sidewall being clearance-fitted with the two sides of the reference guide rail; a heart-shaped ring shaping device, fixedly installed on the top surface of the base body, including a shaping pin and a pressure plate, for bending the end of the suspension wire into a standard heart-shaped ring shape; and a locking handwheel, in the shape of a disc with a handle, perpendicularly passing through the sidewall of the base body and abutting against the side of the reference guide rail, for fixing the sliding length-taking device at any position on the reference guide rail.

[0009] In one possible implementation, the shaping pin of the heart-shaped ring shaping device is cylindrical, and its diameter matches the inner diameter of the heart-shaped ring of the suspension string. The pressure plate is fixed above the shaping pin by bolts to press the suspension string to prevent rebound during the shaping process.

[0010] In one possible implementation, a clamping tube fixing device with a U-shaped groove structure is fixedly installed on the right end of the reference guide rail to fix the position of the clamping tube during the crimping process and prevent it from moving axially.

[0011] In one possible implementation, the crimping tube installation device includes: a fixed base, which is a rectangular plate structure and is fixed to the lower left corner of the workbench by bolts; and a manual crimping pliers, which is a scissor-type structure with a handle and is hinged to the fixed base for pre-pressing and fixing the crimping tube to the drop wire.

[0012] In one possible implementation, the reference guide rail is fixedly installed on the bottom of the workbench by a plurality of countersunk bolts, the heads of which are completely sunk below the top surface of the reference guide rail, ensuring that the sliding length measuring device slides on the reference guide rail without obstruction.

[0013] One or more technical solutions provided in the embodiments of the present invention have at least the following technical effects or advantages: When fabricating overhead contact line droppers, all tools and accessories such as droppers, clamps, and crimping tubes are first placed in a box-shaped slot on the workbench. The edged structure effectively prevents tools and accessories from slipping and being lost during operation. The internal space of the slot can also be used to temporarily store unused tools, keeping the workbench tidy. The operator first uses a preliminary shaping device to pre-bend the end of the dropper, forming an initial shape suitable for subsequent heart-shaped ring formation. Then, one end of the pre-bent dropper is passed through a sliding length-adjusting device. Depending on the required dropper length, the device is slid along the reference guide rail to the corresponding mark on the length scale. Guided by the reference guide rail, the sliding length-adjusting device maintains linear movement, ensuring accurate length measurement. The other end of the dropper is fixed to the left end of the reference guide rail. Then, a crimping tube installation device is used to pre-fit the crimping tube into the designated position on the dropper. After all preparations are complete, the crimping device is activated to crimp the dropper to the clamps and crimping tube. The entire fabrication process is completed on the same workbench without the need to transfer the workpiece.

[0014] By integrating all the functional components required for dropper fabrication into a single, edge-enclosed box-type workbench, integrated dropper fabrication is achieved, solving the technical problems of traditional dropper fabrication, such as the need to transfer workpieces between multiple workstations, cumbersome operations, and low efficiency. A reference guide rail is set along the length of the workbench, providing a stable linear guide reference for the sliding length-taking device. Combined with a length scale installed parallel to the reference guide rail directly above it, the fabricated length of the dropper can be read directly without the need for secondary measurement using additional measuring tools, effectively improving the accuracy and efficiency of length measurement. The sliding length-taking device integrates length positioning and preliminary heart-shaped ring shaping functions, reducing the space occupied by a separate heart-shaped ring forming device and making the overall structure more compact. The clamping tube installation device and preliminary shaping device also integrate the preliminary preparation steps for dropper fabrication onto the workbench, further simplifying the operation process, reducing the labor intensity of operators, and avoiding accuracy loss caused by multiple workpiece transfers. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments of the present invention or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] Figure 1 This is a schematic diagram of the manufacturing platform structure provided in an embodiment of this application; Figure 2 This is a schematic diagram of the installation of the crimping device provided in the embodiments of this application; Figure 3 This is a schematic diagram of the crimping device structure provided in the embodiments of this application; Figure 4 This is a schematic diagram of the preliminary molding device structure provided in the embodiments of this application; Figure 5 This is a schematic diagram of the sliding length-taking device provided in the embodiments of this application; Figure 6 This is a schematic diagram of the clamping tube mounting device provided in the embodiments of this application; Figure 7 This is a schematic diagram of the preliminary molding device structure provided in the embodiments of this application; Figure 8 This is a schematic diagram of the tensioning and clamping mechanism provided in the embodiments of this application.

[0017] icon: 100-Workbench; 200 - Crimping device; 210-Mounting bracket; 220-Electro-hydraulic crimping connector; 230-Locking device; 240-Crimping die; 250-Die mounting slot; 260-Motor; 300-reference guide rail; 400-Sliding length-taking device; 410 - Base; 420 - Heart-shaped ring fixing device; 430 - Locking handwheel; 500 - Length scale; 600-Clip-fitting tube installation device; 610 - Fixed base; 620 - Manual crimping pliers; 700 - Preliminary molding device; 800-Tightening Support Institution; 810 - Base; 820 - Clamping swing arm; 830 - Tension spring; 840 - Toothed lower clamp. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] In the description of the embodiments of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the embodiments of the present invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. The terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. Furthermore, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the embodiments of the present invention according to the specific circumstances.

[0020] Example 1 Please see Figures 1-6A contact wire dropper fabrication platform includes: a workbench 100, shaped like a rectangular box-type trough with a surrounding edge, used to provide a horizontal working reference surface for dropper fabrication and to store tools; a crimping device 200, fixedly installed at the right end of the workbench 100, used to crimp the dropper wire to the clamp and crimping tube; a reference guide rail 300, shaped like a long rectangular cross-section, horizontally fixedly installed along the length direction of the workbench 100 in the middle of the trough bottom, used to provide a linear guide reference for dropper length positioning; and a sliding length-cutting device 400, shaped like a U-shaped trough with an opening facing downwards, which can... A sliding sleeve is mounted on the reference guide rail 300 to position the end of the dropper wire at different length positions and to complete the initial shaping of the heart-shaped ring; a length scale 500, in the shape of a long strip scale plate, is fixedly installed parallel to the reference guide rail 300 directly above it, and is used to directly read the manufacturing length of the dropper wire; a clamping tube mounting device 600 is fixedly installed at the lower left corner of the workbench 100, and is used to pre-fit the clamping tube onto the dropper wire; a preliminary shaping device 700 is detachably placed at the bottom of the groove of the workbench 100, and is used to pre-bend the end of the dropper wire.

[0021] In the above embodiments, when fabricating contact wire droppers, all tools and accessories such as dropper wires, clamps, and clamping tubes are first placed in the box-shaped groove of the workbench 100. The edged structure effectively prevents tools and accessories from slipping and being lost during the operation. At the same time, the internal space of the groove can be used to temporarily store unused tools, keeping the workbench surface clean. The operator first uses the preliminary shaping device 700 to pre-bend the end of the dropper wire to form an initial shape that facilitates the subsequent heart-shaped ring forming. Then, one end of the pre-bent dropper wire is passed through the sliding length measuring device 400. According to the required dropper wire length, the sliding length measuring device 400 is slid along the reference guide rail 300 to the corresponding scale position of the length scale 500. Under the guidance of the reference guide rail 300, the sliding length measuring device 400 can maintain linear movement, ensuring the accuracy of length measurement. The other end of the dropper wire is fixed to the left end of the reference guide rail 300. Then, the clamping tube installation device 600 is used to pre-install the clamping tube in the designated position of the dropper wire. After all the preparations are completed, the crimping device 200 is started to crimp the dropper wire, wire clamp, and clamping tube. The entire production process is completed on the same workbench 100 without the need to transfer the workpiece.

[0022] By integrating all the functional components required for dropper fabrication onto a single box-type workbench 100 with surrounding edges, integrated dropper fabrication is achieved, solving the technical problems of traditional dropper fabrication, such as the need to transfer workpieces between multiple workstations, cumbersome operations, and low efficiency. The reference guide rail 300, set along the length of the workbench 100, provides a stable linear guide reference for the sliding length-taking device 400. Combined with the length scale 500, installed parallel to the reference guide rail 300 directly above it, the fabricated length of the dropper can be directly read without the need for secondary measurement using additional measuring tools, effectively improving the accuracy and efficiency of length measurement. The sliding length-taking device 400 integrates length positioning and preliminary heart-shaped ring shaping functions, reducing the space occupied by a separate heart-shaped ring forming device and making the overall structure more compact. The clamping tube installation device 600 and the preliminary shaping device 700 also integrate the preliminary preparation steps for dropper fabrication onto the workbench 100, further simplifying the operation process, reducing the labor intensity of operators, and avoiding accuracy loss caused by multiple workpiece transfers.

[0023] Example 2 Please see Figures 1-6 The crimping device 200 includes: a mounting bracket 210, which has an L-shaped plate structure and is fixed to the top right side of the workbench 100 by bolts; an electro-hydraulic crimping connector 220, which has an integrated structure of a cylindrical body and a motor 260, and is horizontally installed in the middle of the mounting bracket 210, with its crimping end facing the reference guide rail 300; a locking device 230, which is installed above the electro-hydraulic crimping connector 220 and includes a spring and a pressure block, for firmly fixing the dropper wire before crimping; and a crimping mold 240, which has an upper and lower block structure and is detachably installed on the crimping end of the electro-hydraulic crimping connector 220, for adapting to dropper wire clamps and crimping tubes of different specifications.

[0024] In the above embodiments, when crimping is required, the dropper wire and clamp or crimping tube to be crimped are first placed in the corresponding positions of the crimping mold 240. Then, the locking device 230 is operated. The spring inside the locking device 230 pushes the pressure block downward, firmly pressing the dropper wire onto the crimping mold 240 to prevent axial or radial displacement of the dropper wire during the crimping process. After starting the electro-hydraulic crimping connector 220, the motor 260 drives the hydraulic system to generate high-pressure oil. The high-pressure oil pushes the hydraulic piston forward, which in turn drives the upper mold of the crimping mold 240 downward. The upper mold, in conjunction with the lower mold, applies uniform pressure to the dropper wire and clamp or crimping tube, causing them to undergo plastic deformation and firmly connect together. After crimping is completed, the hydraulic system is depressurized, the piston drives the upper mold to reset, and then the locking device 230 is released, allowing the crimped dropper wire to be removed. The mounting bracket 210 has an L-shaped plate structure, which can provide stable support for the electro-hydraulic crimping joint 220. At the same time, its bottom is fixed to the workbench 100 by bolts, which facilitates installation, disassembly and maintenance.

[0025] The electro-hydraulic integrated crimping device 200, compared to traditional manual crimping tools, provides a stable and sufficiently large crimping force, ensuring consistent crimping quality and solving the technical problems of insufficient crimping force and inconsistent crimping quality inherent in manual crimping. The locking device 230 securely fixes the dropper wire before crimping, effectively preventing displacement of the dropper wire during the crimping process and improving product yield. The crimping die 240 features a detachable design, allowing for the replacement of appropriate dies according to different specifications of dropper wire clamps and crimping tubes, making the device widely applicable and eliminating the need for separate crimping equipment for different dropper wire specifications, thus reducing production costs. The L-shaped structure of the mounting bracket 210 not only ensures the installation stability of the crimping device 200 but also facilitates daily maintenance and repair of the electro-hydraulic crimping connector 220, extending the equipment's service life.

[0026] Example 3 Please see Figures 1-6 The electric hydraulic crimping connector 220 has a mold mounting groove 250 at its crimping end, which is in the shape of a T-shaped cross-section groove. The rear end of the crimping mold 240 is provided with a T-shaped protrusion that cooperates with the T-shaped cross-section groove, which is used to realize the quick replacement and positioning of the crimping mold 240.

[0027] In the above embodiments, when replacing the crimping die 240, the old crimping die 240 is first pulled out from the top of the die mounting groove 250. Then, the T-shaped protrusion at the rear end of the new crimping die 240 is aligned with the T-shaped section of the die mounting groove 250 at the crimping end of the electro-hydraulic crimping connector 220. The T-shaped protrusion is inserted into the die mounting groove 250 from above. The T-shaped protrusion fits tightly with the inner wall of the die mounting groove 250, which can restrict the displacement of the crimping die 240 in the horizontal and vertical directions, realizing the rapid positioning and fixing of the crimping die 240. During the crimping process, the crimping force is transmitted to the inner wall of the die mounting groove 250 through the T-shaped protrusion. Due to the large contact area of ​​the T-shaped section, the crimping force can be evenly distributed, avoiding damage to the die or crimping connector caused by stress concentration. When it is necessary to disassemble the die, it can be disassembled simply by lifting the die upwards. The entire replacement process does not require any tools and is simple and quick to operate.

[0028] By setting a T-shaped mold mounting groove 250 at the crimping end of the electro-hydraulic crimping connector 220 and a matching T-shaped protrusion at the rear end of the crimping mold 240, rapid replacement and precise positioning of the crimping mold 240 are achieved, solving the technical problems of cumbersome replacement and low positioning accuracy of traditional crimping molds 240. The T-shaped mating structure has good self-locking performance, ensuring that the crimping mold 240 will not loosen or shift during the crimping process, thus ensuring crimping accuracy and quality. At the same time, the large contact area of ​​the T-shaped section can effectively improve the connection strength between the mold and the crimping connector, extending the service life of both the mold and the crimping connector. Tool-free mold replacement greatly shortens mold replacement time, improves production efficiency, and reduces the labor intensity of operators, making it particularly suitable for work environments where different mold specifications need to be frequently changed on construction sites.

[0029] Example 4 Please see Figures 1-6 The sliding length-taking device 400 includes: a base 410, which has a U-shaped cross-section and an opening facing downwards, engaging with the reference guide rail 300, with its inner sidewalls clearance-fitting the two sides of the reference guide rail 300; a heart-shaped ring shaping device 420, which is fixedly installed on the top surface of the base 410, including a shaping pin and a pressure plate, for bending the end of the suspension wire into a standard heart-shaped ring; and a locking handwheel 430, which is a disc with a handle, perpendicularly passing through the sidewall of the base 410 and abutting against the side of the reference guide rail 300, for fixing the sliding length-taking device 400 at any position on the reference guide rail 300.

[0030] In the above embodiment, when positioning the dropper length, firstly, the locking handwheel 430 is loosened, allowing the seat 410 to slide freely along the reference guide rail 300. The seat 410 has a U-shaped cross-section, and its inner sidewall is clearance-fitted with the two sides of the reference guide rail 300, ensuring that the seat 410 does not wobble left or right during sliding and maintains linear motion. After sliding the seat 410 to the target length position corresponding to the length scale 500, the locking handwheel 430 is tightened. The end of the locking handwheel 430 will tightly abut against the side of the reference guide rail 300, fixing the seat 410 at that position on the reference guide rail 300 through friction, thus achieving precise positioning of the dropper length. Then, the end of the dropper wire is passed through the heart-shaped ring shaping device 420, which bends the end of the dropper wire into a standard heart-shaped ring, completing the initial shaping of the heart-shaped ring. When the length of the suspension string needs to be adjusted, simply loosen the locking handwheel 430 again and slide the seat 410 to the new scale position.

[0031] The sliding length-taking device 400 uses a U-shaped cross-section base 410 that cooperates with the reference guide rail 300, providing stable guiding performance and ensuring no deviation during sliding, thus improving the accuracy of length positioning. The locking handwheel 430 uses a side-locking method, which provides greater locking force compared to top-locking, making the sliding length-taking device 400 more securely fixed to the reference guide rail 300 and preventing positional deviation due to vibration or external forces during operation. The heart-shaped ring shaping device 420 is integrated on the top surface of the sliding length-taking device 400, completing the preliminary shaping of the heart-shaped ring simultaneously with length positioning, eliminating the need for a separate heart-shaped ring forming process, greatly simplifying the dropper wire manufacturing process and improving production efficiency. At the same time, this integrated design also reduces the overall size of the equipment, making it easier to carry and transport, suitable for mobile operations at railway construction sites.

[0032] Example 5 Please see Figures 1-6 The shaping pin of the heart-shaped ring shaping device 420 is cylindrical, and its diameter matches the inner diameter of the heart-shaped ring of the suspension string. The pressure plate is fixed above the shaping pin by bolts and is used to press the suspension string to prevent it from springing back during the shaping process.

[0033] In the above embodiments, during the heart-shaped ring shaping process, the pre-bent end of the suspension wire is first wound around the cylindrical shaping pin of the heart-shaped ring shaping device 420. The diameter of the shaping pin matches the standard inner diameter of the suspension wire heart-shaped ring, ensuring that the inner diameter of the formed heart-shaped ring meets the design requirements. Then, a pressure plate is fixed above the shaping pin with bolts. When the bolts are tightened, the pressure plate presses down on the suspension wire, making it tightly adhere to the outer surface of the shaping pin, forming a standard heart-shaped ring. The pressure of the pressure plate effectively prevents the suspension wire from springing back during the shaping process, ensuring the stability of the heart-shaped ring's shape. After shaping, the bolts are loosened, the pressure plate is removed, and the formed heart-shaped ring can be taken out from the shaping pin. The entire shaping process is simple to operate and can quickly complete the heart-shaped ring shaping operation.

[0034] By using cylindrical shaping pins that match the inner diameter of the heart-shaped ring of the dropper wire, the inner diameter of all formed heart-shaped rings is ensured to be consistent. This solves the technical problems of irregular shape and inconsistent inner diameter in traditional manual heart-shaped ring production, improving the standardization of dropper wire products. The pressure plate applies continuous clamping force to the dropper wire during the shaping process, effectively suppressing the springback deformation of the dropper wire and ensuring the shape accuracy and dimensional stability of the heart-shaped ring. Using bolts to fix the pressure plate allows adjustment of the clamping force according to dropper wires of different diameters, making this device suitable for heart-shaped ring forming operations of various dropper wire specifications. Furthermore, this structural design is simple and reliable, has low manufacturing costs, is easy to maintain, and can operate stably for a long time in harsh construction site environments.

[0035] Example 6 Please see Figures 1-6 The right end of the reference guide rail 300 is fixedly equipped with a clamping tube fixing device, which has a U-shaped groove structure and is used to fix the position of the clamping tube during the crimping process to prevent it from moving axially.

[0036] In the above embodiment, during the crimping operation, the dropper wire fitted with the crimping tube is first passed through the crimping tube fixing device at the right end of the reference guide rail 300. The crimping tube is then placed in the U-shaped groove of the crimping tube fixing device. The width of the U-shaped groove matches the outer diameter of the crimping tube, thus securing the crimping tube within the groove and restricting its axial movement. Then, the dropper wire and the crimping tube are fed together into the crimping mold 240 of the crimping device 200, and the crimping device 200 is activated for crimping. During the crimping process, the U-shaped groove acts as a barrier to prevent the crimping tube from axially shifting under the crimping force, ensuring accurate crimping positioning. After crimping, the dropper wire is removed from the U-shaped groove. The U-shaped groove structure is simple and can quickly complete the positioning and fixing of the crimping tube without the need for additional clamping devices.

[0037] By installing a U-shaped slot structure for fixing the clamping tube at the right end of the reference guide rail 300, the position of the clamping tube can be effectively fixed during the crimping process. This solves the technical problem of inaccurate crimping position and poor crimping quality caused by the axial movement of the clamping tube during traditional crimping. The U-shaped slot structure is simple and practical, easy to operate, and allows for quick placement and removal of the clamping tube without affecting work efficiency. Simultaneously, the U-shaped slot is fixedly connected to the reference guide rail 300, ensuring its positional accuracy and thus guaranteeing the accuracy of the clamping tube's crimping position. This device requires no additional power source or operating mechanism, has low manufacturing cost, is easy to maintain, and can be used stably on-site for a long time, effectively improving the quality and efficiency of dropper crimping operations.

[0038] Example 7 Please see Figures 1-6 The clamping tube installation device 600 includes: a fixed base 610, which is a rectangular plate structure and is fixed to the lower left corner of the workbench 100 by bolts; and a manual crimping pliers 620, which is a scissor-type structure with a handle and is hinged to the fixed base 610 for pre-pressing and fixing the clamping tube to the drop wire.

[0039] In the above embodiments, during the pre-installation of the crimped tube, the crimped tube is first placed on the designated position of the drop wire. Then, the drop wire with the crimped tube is placed in the jaws of the manual crimping pliers 620. The manual crimping pliers 620 has a scissor-like structure, amplifying the force applied by the hand through leverage and acting on the crimped tube. The operator holds the two handles of the manual crimping pliers 620 and forcefully closes the handles. The jaws apply pressure to the crimped tube, causing slight plastic deformation, thereby pre-pressing and fixing the crimped tube to the drop wire, preventing the crimped tube from shifting during subsequent handling and crimping. The manual crimping pliers 620 is hinged to the fixed base 610, which provides stable support for the manual crimping pliers 620, preventing the crimping pliers from shaking during crimping and ensuring the quality of pre-pressing.

[0040] By setting up a crimping tube installation device 600 consisting of a fixed base 610 and a manual crimping pliers 620, crimping tubes can be quickly and conveniently pre-pressed and fixed onto the drop wire, solving the technical problems of traditional crimping tube installation, such as the need to hold the crimping tube by hand, inconvenient operation, and unstable pre-pressing quality. The fixed base 610 allows the manual crimping pliers 620 to be stably fixed on the workbench 100, enabling operators to complete the pre-pressing operation with only one hand, freeing up the other hand and improving operational convenience and safety. The scissor-type manual crimping pliers 620 utilizes the lever principle to amplify the force, achieving sufficient pre-pressure with minimal manual effort, reducing the labor intensity of operators. Simultaneously, the device has a simple structure, low manufacturing cost, and is easy to carry and maintain, making it suitable for batch crimping tube pre-installation operations on construction sites.

[0041] Example 8 Please see Figures 1-6 The reference guide rail 300 is fixedly installed on the bottom of the workbench 100 by a plurality of countersunk bolts. The head of the countersunk bolts is completely sunk below the top surface of the reference guide rail 300 to ensure that the sliding length taking device 400 slides on the reference guide rail 300 without obstruction.

[0042] In the above embodiment, when installing the reference guide rail 300, the reference guide rail 300 is first placed at a predetermined position at the bottom of the workbench 100, and the levelness and straightness of the reference guide rail 300 are adjusted to keep it parallel to the length direction of the workbench 100. Then, countersunk bolts are used to fix the reference guide rail 300 to the workbench 100. The countersunk bolts pass through the top surface of the reference guide rail 300 and are screwed into the threaded hole of the workbench 100. After tightening the bolts, the head of the countersunk bolt will be completely sunk into the countersunk hole on the top surface of the reference guide rail 300 and will not protrude from the top surface of the reference guide rail 300. In this way, when the sliding length-taking device 400 slides along the reference guide rail 300, its bottom will not contact or rub against the bolt head, ensuring that the sliding length-taking device 400 can slide smoothly on the reference guide rail 300. Multiple countersunk bolts are evenly distributed along the length of the reference guide rail 300, which can firmly fix the reference guide rail 300 on the worktable 100 and prevent the reference guide rail 300 from loosening or deforming during use.

[0043] The reference guide rail 300 is fixed using countersunk bolts, with the bolt heads completely submerged below the top surface of the guide rail 300. This solves the technical problem of bolt heads protruding from the guide rail surface in traditional bolt fixing methods, which affects the smooth sliding of the sliding length-taking device 400. The sliding length-taking device 400 is not obstructed by the bolt heads during sliding, maintaining smooth and stable linear motion, improving the accuracy of length positioning and the fluidity of operation. The even distribution of multiple countersunk bolts ensures a firm and reliable connection between the reference guide rail 300 and the worktable 100, preventing loosening, deformation, or displacement of the reference guide rail 300 during long-term use, thus extending the equipment's service life. Simultaneously, this fixing method facilitates the installation and disassembly of the reference guide rail 300, allowing for easy replacement when it wears or is damaged, reducing equipment maintenance costs.

[0044] Example 9 Please see Figures 1-7 The preliminary shaping device 700 includes: a base plate 710, which is a rectangular strip structure and serves as the mounting base for the entire device. It can be detached and placed stably on the bottom of the workbench 100; two vertical plates 720, both of which are long strip straight plates, are vertically fixed to the top surface of the base plate 710 and are arranged parallel to each other along the length of the base plate 710. The inner sidewalls of the two vertical plates 720 and the top surface of the base plate 710 together form an upward-opening limiting bending groove 730. The groove width of the limiting bending groove 730 is adapted to the outer diameter of the suspension wire to be processed.

[0045] In the above embodiments, when performing pre-bending of the suspension wire end, the preliminary shaping device 700 is first placed in the flat working area at the bottom of the workbench 100. The end of the suspension wire to be processed is embedded in the limiting bending groove 730 between the two vertical plates 720. The inner sidewall of the vertical plate 720 serves as the lateral limiting and bending guide reference. Bending force is applied to the suspension wire along the groove direction, so that the end of the suspension wire forms a pre-bent arc that matches the subsequent heart-shaped ring forming process. During the bending process, the two vertical plates 720 can restrict the lateral movement and planar twisting of the suspension wire, ensuring that the bending arc and flatness of all workpieces after pre-bending are consistent during batch production. After the operation is completed, the preliminary shaping device 700 can be stored in the idle area of ​​the workbench 100, or it can be taken out and stored separately.

[0046] The integrated trough structure, consisting of a base plate 710 and double upright plates 720, is simple and reliable, with no moving parts or vulnerable components, resulting in low manufacturing costs and convenient on-site maintenance. Its detachable placement adapts to the box-type trough structure of the workbench 100, balancing operational and storage needs without occupying additional work space, meeting the requirements for portable operation on construction sites. The limiting bending trough 730 provides rigid constraint on the bending process of the suspension wire, solving the problems of uneven curvature, wire twisting, and poor product consistency that occur with manual bending. It provides standardized pre-bent blanks for the subsequent heart-shaped ring shaping process, effectively improving the final forming accuracy of the heart-shaped ring and overall production efficiency.

[0047] Example 10 Please see Figures 1-8 The workbench 100 is also equipped with a tensioning and clamping mechanism 800, including a base 810, a clamping swing arm 820, a tension spring 830, and a toothed lower clamp 840. The base 810 is fixedly installed on the workbench 100 at the wire inlet side of the crimping device 200. The toothed lower clamp 840 is installed on the upper part of the base 810, and the top of the toothed lower clamp 840 is provided with an arc-shaped anti-slip tooth groove for supporting the suspension wire. The tail of the clamping swing arm 820 is hinged to the rear side of the base 810, and the downward pressing end of the clamping swing arm 820 is directly above the tooth groove of the toothed lower clamp 840. One end of the tension spring 830 is connected to the tail of the clamping swing arm 820 away from the downward pressing end, and the other end of the tension spring 830 extends to the left to form a pulling operation end.

[0048] In the above embodiments, before performing the dropper crimping operation, the dropper wire with the crimping tube inserted is placed in the arc-shaped toothed groove of the toothed lower clamp 840. The pulling end of the tension spring 830 is pulled to the left in the direction of the red arrow. The tension spring 830 pulls the clamping arm 820 to rotate downward around the hinge point. The pressing end of the clamping arm 820 cooperates with the toothed lower clamp 840 to clamp the dropper wire. By continuously pulling the tension spring 830, a constant tension force can be applied to the dropper wire, so that the dropper wire is taut and straight throughout the entire process.

[0049] At this point, the electric hydraulic crimping connector 220 is activated, and the crimping die 240 crimps the clamping tube and the dropper wire. The teeth of the toothed lower clamp 840 restrict the radial torsion of the dropper wire, and the tension force provided by the tension spring 830 prevents the dropper wire from moving axially, ensuring accurate and non-offset crimping position. After the crimping process is completed, the tension spring 830 is released, and the spring rebounds, causing the clamping swing arm 820 to lift upward, automatically releasing the clamping constraint on the dropper wire, allowing the processed dropper wire to be removed.

[0050] This embodiment integrates clamping and positioning as well as wire tensioning functions at the crimping station through a spring-linked clamping arm structure. It eliminates the need for manual wire holding and fixing, effectively solving the defects of traditional crimping where wires are prone to shifting and twisting, resulting in incomplete crimping and dimensional deviations. The flexible spring tension will not stretch and damage the aluminum stranded wire, and the toothed clamping is non-slip and does not easily scratch the wire. The whole structure is purely mechanical with no electrical components, making it suitable for harsh working conditions at outdoor construction sites. The compact mechanism is integrated at the crimping inlet position without occupying extra working space on the workbench. It is highly compatible with existing crimping devices and reference guide rail structures, and is easy to disassemble and maintain.

[0051] The various embodiments in this specification are described in a progressive manner. For the same or similar parts between the various embodiments, please refer to each other. Each embodiment focuses on describing the differences from other embodiments.

[0052] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit this application. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of this application.

Claims

1. A platform for manufacturing overhead contact line droppers, characterized in that, include: The workbench (100) is a rectangular box-shaped trough with a surrounding edge, used to provide a horizontal working reference surface for the fabrication of the drop wire and to store tools; A crimping device (200) is fixedly installed at the right end of the workbench (100) and is used to crimp the suspension wire to the wire clamp and the crimping tube. The reference guide rail (300) has a long rectangular cross-section and is horizontally fixed in the middle of the groove bottom of the worktable (100) along the length direction of the worktable (100) to provide a linear guide reference for positioning the length of the suspension cable; The sliding length-cutting device (400) has a U-shaped groove structure with an opening facing downwards. It is slidably sleeved on the reference guide rail (300) and is used to position the end of the suspension wire at different length positions and complete the initial shaping of the heart-shaped ring. The length scale (500) is a long strip-shaped scale plate, which is fixedly installed above the reference guide rail (300) parallel to the reference guide rail (300) and is used to directly read the manufacturing length of the suspension string; A clamping tube installation device (600) is fixedly installed at the lower left corner of the workbench (100) for pre-fitting the clamping tube onto the dropper wire; A preliminary shaping device (700) is detachably placed at the bottom of the slot of the workbench (100) for pre-bending the ends of the suspension wire.

2. The contact wire dropper manufacturing platform according to claim 1, characterized in that, The crimping device (200) includes: The mounting bracket (210) has an L-shaped plate structure and is fixed to the top right end of the workbench (100) by bolts at the bottom. The electric hydraulic crimping connector (220) is an integrated structure with a cylindrical body and a motor (260) drive. It is horizontally installed in the middle of the mounting bracket (210), with its crimping end facing the reference guide rail (300). A locking device (230), installed above the electro-hydraulic crimping joint (220), includes a spring and a pressure block for securing the drop wire before crimping; The crimping die (240) has a block structure with upper and lower parts fitting together. It is detachably installed on the crimping end of the electro-hydraulic crimping connector (220) and is used to adapt to different specifications of dropper wire clamps and crimping tubes.

3. The contact wire dropper manufacturing platform according to claim 2, characterized in that, The electric hydraulic crimping connector (220) has a mold mounting groove (250) at its crimping end, which is in the shape of a T-shaped cross-section groove. The rear end of the crimping mold (240) is provided with a T-shaped protrusion that matches the T-shaped cross-section groove, which is used to realize the quick replacement and positioning of the crimping mold (240).

4. The contact wire dropper manufacturing platform according to claim 1, characterized in that, The sliding length-taking device (400) includes: The seat (410) has a U-shaped cross section and is opened downwards and engaged with the reference guide rail (300). Its inner side wall is in clearance fit with the two sides of the reference guide rail (300). A heart-shaped ring shaping device (420) is fixedly installed on the top surface of the base (410), including a shaping pin and a pressure plate, for bending the end of the suspension wire into a standard heart-shaped ring shape; The locking handwheel (430) is a disc-shaped device with a handle. It passes vertically through the side wall of the seat (410) and abuts against the side of the reference guide rail (300). It is used to fix the sliding length-taking device (400) at any position on the reference guide rail (300).

5. The contact wire dropper manufacturing platform according to claim 4, characterized in that, The shaping pin of the heart-shaped ring shaping device (420) is cylindrical, and its diameter matches the inner diameter of the heart-shaped ring of the suspension string. The pressure plate is fixed above the shaping pin by bolts and is used to press the suspension string to prevent it from springing back during the shaping process.

6. The contact wire dropper manufacturing platform according to claim 4, characterized in that, The right end of the reference guide rail (300) is fixedly equipped with a clamping tube fixing device, which has a U-shaped groove structure and is used to fix the position of the clamping tube during the crimping process to prevent it from moving axially.

7. The contact wire dropper manufacturing platform according to claim 1, characterized in that, The clamping tube mounting device (600) includes: The fixed base (610) has a rectangular plate structure and is fixed to the lower left corner of the workbench (100) by bolts; The manual crimping pliers (620) are scissor-type structures with handles and are hinged to the fixed base (610) for pre-pressing and fixing the crimping tube to the drop wire.

8. The contact wire dropper manufacturing platform according to claim 1, characterized in that, The reference guide rail (300) is fixedly installed in the groove bottom of the workbench (100) by a plurality of countersunk bolts. The head of the countersunk bolts is completely sunk below the top surface of the reference guide rail (300) to ensure that the sliding length taking device (400) slides on the reference guide rail (300) without obstruction.

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