Device and method for connecting split conductors

Abstract

This application discloses a device and method for connecting split conductors. The device includes: at least two connecting structures, each connecting structure having a conductor cavity at one end for accommodating the split conductor and a connecting cavity at the other end; a connecting block, with its two ends respectively located within the connecting cavities of the two connecting structures; and a filling block located within the connecting cavities of the connecting structures and engaging with the end of the connecting block; wherein the inner diameter of the conductor cavity is larger than the outer diameter of the split conductor. By optimizing the connecting structure and the engaging engagement method, this application effectively improves the reliability and stability of the split conductor connection while achieving rapid installation.

Description

Technical Field

[0001] This application relates to the technical field of high-voltage cable manufacturing equipment, and in particular to a conductor splitting connection device and method. Background Technology

[0002] Currently, due to production length limitations, large-section segmented conductors need to be spliced ​​using connecting devices in VCV (Vertical Continuous Vulcanization) production lines. Existing technology uses a mother-daughter type connecting device with pins for fixing, requiring the removal of the outer monofilament of the segmented conductor before crimping during installation.

[0003] However, this method has problems such as inconvenient operation and insufficient connection stability, which restricts the production efficiency and reliability of large cross-section segmented conductors used in major projects such as ultra-high voltage cables and offshore wind power transmission cables, and makes it difficult to meet the needs of continuous and efficient production of VCV production lines. Summary of the Invention

[0004] This application provides a segmented conductor connection device and method adapted to the needs of high-end equipment and new power equipment industries, in order to solve the technical problems of low connection efficiency and poor product quality stability of existing segmented conductor connection devices.

[0005] The first aspect of this application provides a device for connecting split conductors, comprising: At least two connection structures, each connection structure having a conductor cavity at one end for accommodating the segmented conductor, and a connection cavity at the other end; The connecting block has its two ends located within the connecting cavities of the two connecting structures, respectively. The filler block is located inside the connecting cavity of the connecting structure and is engaged with the end of the connecting block; In this case, the inner diameter of the conductor cavity is larger than the outer diameter of the segmented conductor.

[0006] In some embodiments, the connecting block includes a main body and limiting portions respectively disposed at both ends of the main body, wherein the outer diameter of the limiting portions is larger than the outer diameter of the main body.

[0007] In some embodiments, the filler block includes a vertical portion and a horizontal portion, the vertical portion being located within the connecting cavity and engaging with the end of the connecting block, and the horizontal portion extending toward the opening of the connecting cavity.

[0008] In some embodiments, the conductor cavity is a cylindrical blind hole opened along the axial direction of the connection structure, and a positioning surface is formed at its bottom to define the insertion depth of the dividing conductor.

[0009] In some embodiments, the outer peripheral sidewall of the conductor cavity is a crimping area, which deforms when subjected to radial pressure to enclose the segmented conductor inserted into the conductor cavity.

[0010] In some embodiments, the connecting cavity is provided with a snap-fit ​​structure for engaging with the end of the connecting block and the filling block.

[0011] In some embodiments, the connecting structure has an inner rounded corner and an outer rounded corner, the inner rounded corner and the outer rounded corner are staggered and rounded, and the radius of the outer rounded corner is greater than the radius of the inner rounded corner.

[0012] The second aspect of this application proposes a method for connecting split conductors, comprising: The ends of the first segmented conductor and the second segmented conductor are respectively inserted into the conductor cavity of a connecting structure. One end of the connecting structure is provided with a conductor cavity, and the other end is provided with a connecting cavity. Radial pressure is applied to the connecting structure, causing the conductor cavity to contract radially to enclose the first segment conductor and the second segment conductor; The two ends of the connecting block are respectively embedded into the connecting cavities of the two connecting structures, and the filling block is placed into the connecting cavity so that the filling block is engaged with the corresponding end of the connecting block.

[0013] In some embodiments, after the filler block is placed into the connecting cavity, the method further includes: wrapping a covering layer around the outer periphery of the connecting structure so that the outer diameter after wrapping is smaller than the inner diameter of the cross-linked mold core.

[0014] In some embodiments, before the first and second segmented conductors are inserted into the conductor cavity, the process further includes: rounding the ends of the first and second segmented conductors and removing the end wrapping to expose the bare conductors.

[0015] The present application provides a split conductor connection device and method. The device includes: at least two connection structures, each connection structure having a conductor cavity at one end for accommodating the split conductor and a connection cavity at the other end; a connection block, with both ends located within the connection cavities of the two connection structures respectively; and a filler block located within the connection cavities of the connection structures and engaging with the ends of the connection block; wherein the inner diameter of the conductor cavity is larger than the outer diameter of the split conductor. The split conductor connection device provided in this application, by optimizing the connection structure and engagement method, effectively improves the reliability and stability of the split conductor connection while achieving rapid installation. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the conductor splitting connection device 1000 provided in the embodiments of this application.

[0017] Figure 2 This is a first structural schematic diagram of the connection structure 100 provided in the embodiments of this application.

[0018] Figure 3 This is a schematic diagram of the second structure of the connection structure 100 provided in the embodiments of this application.

[0019] Figure 4 This is a schematic diagram of the third structure of the connection structure 100 provided in the embodiments of this application.

[0020] Figure 5 This is a schematic diagram of the structure of the connecting block 200 provided in the embodiment of this application.

[0021] Figure 6 This is a schematic diagram of the structure of the filling block 300 provided in the embodiment of this application.

[0022] Figure 7 This is a schematic flowchart of the method for connecting split conductors provided in the embodiments of this application.

[0023] Explanation of main component symbols: conductor splitting connection device 1000, connection structure 100, connecting block 200, filling block 300, conductor cavity 110, positioning surface 111, connecting cavity 120, inner rounded corner 130a, outer rounded corner 130b, conductor splitting 100a, main body 210, limiting part 220, vertical part 310, horizontal part 320. Detailed Implementation

[0024] It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the scope of this application.

[0025] Currently, in the high-voltage cable manufacturing field, the manufacturing length of large-section segmented conductors is often insufficient to meet the requirements of long-distance transmission line laying due to limitations in equipment capacity and production processes. Therefore, it is necessary to use specialized connecting devices in VCV (Vertical Continuous Vulcanization) production lines to achieve conductor splicing and ensure production continuity. In existing technologies, this splicing operation is typically achieved using a female-female connector with pin fixing. During actual installation, operators first need to strip the outer monofilament of the segmented conductor, then insert the exposed conductor core into the connecting device and crimp it in place.

[0026] However, this connection method has significant shortcomings in practical applications: on the one hand, the process of stripping the monofilaments is cumbersome, increasing the complexity and time cost of on-site operations; on the other hand, relying solely on pin fixing and crimping, the connection is prone to loosening or falling off under long-term traction and high-intensity operation conditions, making it difficult to fully guarantee connection stability. Therefore, it is evident that existing technology cannot meet the actual needs of VCV production lines for continuous, efficient, and stable production.

[0027] Therefore, this application provides a device and method for connecting split conductors. The device includes: at least two connecting structures, each connecting structure having a conductor cavity at one end for accommodating the split conductor and a connecting cavity at the other end; a connecting block, with its two ends respectively located within the connecting cavities of the two connecting structures; and a filling block located within the connecting cavity of the connecting structure and engaging with the end of the connecting block; wherein the inner diameter of the conductor cavity is larger than the outer diameter of the split conductor. The split conductor connecting device provided in this application belongs to the field of high-voltage cable manufacturing equipment technology, and is particularly suitable for continuous production lines of ultra-high voltage and large-section power cables (VCV). It can be classified into the new power equipment industry chain and strategic emerging industries such as high-end equipment manufacturing and new material application, meeting the needs of major power transmission and transformation projects for continuous production of long-length, highly stable split conductors. By optimizing the connecting structure and engaging method, it effectively improves the reliability and stability of the split conductor connection while achieving rapid installation.

[0028] Please refer to Figure 1 , Figure 1 This is a schematic diagram of the structure of the split conductor connecting device 1000 provided in an embodiment of this application. In some embodiments, the split conductor connecting device 1000 includes a connecting structure 100, a connecting block 200, and a filling block 300.

[0029] In some embodiments, the split conductor connection device 1000 may include two oppositely arranged connection structures 100, a connection block 200, and two filler blocks 300. The two connection structures 100 may have identical structures and be symmetrically arranged on both sides of the connection block 200.

[0030] It is understood that one end of the connecting structure 100 has a conductor cavity 110 for accommodating the segmented conductor 100a, and the other end has a connecting cavity 120. The inner diameter of the conductor cavity 110 is larger than the outer diameter of the segmented conductor 100a, allowing the segmented conductor 100a to be directly inserted into the conductor cavity 110 without stripping the outer monofilament. Both ends of the connecting block 200 extend into the connecting cavities 120 of the two connecting structures 100, achieving axial docking and positioning of the two connecting structures 100. Two filling blocks 300 are respectively disposed within the connecting cavities 120 of the two connecting structures 100, and each filling block 300 forms a snap-fit ​​engagement with the end of the corresponding connecting block 200, achieving locking and fixation. This segmented conductor connecting device 1000 can achieve rapid, stripping-free installation while effectively improving the reliability and stability of the segmented conductor connection through a snap-fit ​​method.

[0031] In some embodiments, the two connecting structures 100 included in the same split conductor connecting device 1000 adopt the same innovative structural design, that is, they are completely identical in shape, size, material, and layout of each functional part, and are symmetrically arranged on both sides of the connecting block 200. The purpose of this design is twofold: firstly, it reduces the types and number of parts, lowering processing costs and simplifying spare parts management; secondly, it eliminates the need to distinguish left from right or front from back on the construction site, allowing operators to use either connecting structure for installation, simplifying the assembly process and improving work efficiency. Furthermore, the symmetrical and consistent connecting structure also helps ensure the balance of the two split conductors 100a under crimping, snap-fit, and stress conditions, thereby improving the reliability and consistency of the connecting device.

[0032] In some embodiments, the connection structure 100 may be made of metal, such as carbon structural steel (e.g., Q235 low-carbon steel) or alloy structural steel (e.g., 40Cr alloy steel). Carbon structural steel has good weldability and toughness, and is relatively inexpensive, making it suitable for conductor connection requirements under normal operating conditions. Alloy structural steel, after heat treatment, has higher strength and wear resistance, making it suitable for high-intensity operating scenarios involving large traction forces or frequent start-stop operations. Both materials can be formed by machining or forging processes and subjected to galvanizing or bluing for rust prevention to meet corrosion resistance requirements during long periods of non-use.

[0033] In some embodiments, the first segmented conductor 100a inserted into the left connecting structure 100 of the connecting device and the second segmented conductor 100a inserted into the right connecting structure 100 are both bare conductors after removing all wrapping tape, i.e., removing the outer protective tape and semi-conductive tape of the conductor, but without needing to strip the outermost single filament of each strand. This design fully utilizes the structural feature that the inner diameter of the conductor cavity 110 is larger than the outer diameter of the segmented conductor 100a, allowing the segmented conductor 100a to be directly inserted into the conductor cavity 110, eliminating the cumbersome process of stripping single filaments in traditional connection methods, and significantly improving on-site installation efficiency.

[0034] In some embodiments, the two segmented conductors 100a connected by the same segmented conductor connecting device 1000 can be of different specifications, that is, they can be different in cross-sectional dimensions, number of strands, or outer diameter, as long as the inner diameter of their respective conductor cavities 110 is greater than their outer diameter. This design allows the segmented conductor connecting device 1000 to adapt to the emergency splicing or transitional connection needs between different batches and different specifications of segmented conductors 100a, thus broadening the applicability of the segmented conductor connecting device 1000.

[0035] The conductor segmentation device 1000 provided in this embodiment not only improves the continuous production efficiency of the VCV production line, but also significantly enhances the connection reliability. It can meet the urgent needs of the UHV cable industry chain for long-length, high-stability conductors and help promote the high-quality development of the new power equipment industry cluster.

[0036] Please refer to Figure 2 and Figure 3 , Figure 2 This is a first structural schematic diagram of the connection structure 100 provided in the embodiments of this application; Figure 3 This is a second structural schematic diagram of the connection structure 100 provided in an embodiment of this application. In some embodiments, the connection structure 100 has a conductor cavity 110 at one end for accommodating the dividing conductor 100a, and a connection cavity 120 at the other end.

[0037] Each connecting structure 100 is understood to be cylindrical, with one end (the right end in the figure) having a conductor cavity 110 recessed along its axis into the connecting structure, and the other end (the left end in the figure) having a connecting cavity 120 similarly recessed along its axis into the connecting structure. The conductor cavity 110 is used to accommodate the end of the dividing conductor 100a, and the connecting cavity 120 is used to accommodate the connecting block 200 and the filling block 300. To facilitate the rapid insertion of the dividing conductor, the inner diameter of the conductor cavity 110 is designed to be larger than the outer diameter of the dividing conductor 100a, thus allowing direct insertion without stripping the outer monofilament of the dividing conductor, simplifying the installation process. For example, the inner diameter of the conductor cavity 110 can be designed to be 0.5mm to 1.0mm larger than the outer diameter of the dividing conductor 100a, thereby forming a gap fit, which facilitates insertion without affecting the subsequent crimping effect due to excessive gap.

[0038] In some embodiments, the conductor cavity 110 is a cylindrical blind hole opened along the axial direction of the connection structure, and a positioning surface 111 is formed at its bottom to define the insertion depth of the dividing conductor 100a.

[0039] It can be understood that the conductor cavity 110 is a cylindrical blind hole opened along the axial direction of the connecting structure 100. Its bottom is not simply a flat sealed bottom, but is provided with a positioning surface 111. This positioning surface is used to abut against the end face of the dividing conductor 100a when the dividing conductor 100a is inserted into the conductor cavity 110, thereby precisely controlling the insertion depth of the dividing conductor 100a, preventing the insertion from being too shallow and causing misalignment of the crimping area, or the insertion from being too deep and affecting the snap-fit ​​fit in the connecting cavity.

[0040] In some embodiments, the positioning surface 111 can be one or more combinations of a plane, a conical surface, a stepped surface, or an arc surface. Its specific shape can be flexibly designed according to processing technology and assembly requirements. The implementation methods include, but are not limited to: a planar annular bottom surface, where the bottom of the conductor cavity 110 is a complete plane perpendicular to the axis, forming a surface contact limit with the end face of the dividing conductor 100a; a simple structure, easy to process, and suitable for most conventional working conditions; a conical inclined surface, where the bottom of the conductor cavity 110 is an inner conical surface, cooperating with the chamfered or naturally formed conical surface at the end of the dividing conductor 100a to achieve self-centering limit, helping to correct slight angular deviations; and a stepped surface, where the conductor cavity 110... The inner wall of the 10 has an inwardly protruding annular step near the bottom, with the end face of the step serving as a positioning surface. This design provides a clear axial stop without changing the diameter of the blind hole. The spherical or arc-shaped recess has a concave spherical or arc-shaped bottom that fits against the arc-shaped edge of the end of the dividing conductor 100a. This design is suitable for dividing conductors 100a whose end faces have not been strictly flattened, and still provides a certain limiting effect. In addition, multiple small bosses are evenly distributed at the bottom of the multi-point boss. The top surfaces of the bosses together form a positioning reference surface. This design reduces the contact area, lowers the requirements for the flatness of the end face of the dividing conductor 100a, and facilitates the removal of any debris or foreign objects that may be present in the cavity.

[0041] In some embodiments, the positioning surface 111 can be a conical positioning surface, with the angle between its conical surface and the axis of the conductor cavity 110 being 150° to 180°. Specifically, when the angle of the positioning surface 111 is 180°, the positioning surface 111 is a plane perpendicular to the axis; when the angle of the positioning surface 111 is between 150° and 180°, the positioning surface 111 is an inner conical surface, forming line contact or toroidal contact with the chamfer or natural conical surface at the end of the segmented conductor 100a. This angle range design, on the one hand, achieves a self-centering effect during conductor insertion through conical guidance, thereby correcting slight insertion deviation; on the other hand, it can still provide reliable axial limiting even when the conductor end face is not completely flat, thus ensuring consistent insertion depth of the segmented conductor 100a. The larger the angle, i.e., the closer to 180°, the closer the positioning surface 111 is to a plane, with direct limiting but weaker centering effect; the smaller the angle, i.e., the closer to 150°, the stronger the conical guiding ability, but the higher the requirement for consistency of the conductor end chamfer. Therefore, in practical applications, a specific angle value can be selected within the range of 150° to 180° based on the end processing accuracy and assembly requirements of the segmented conductor 100a.

[0042] In some embodiments, the inner wall of the connecting structure 100 is provided with an internal thread. This internal thread is specially machined during the manufacturing process of the segmented conductor connecting device 1000. The pitch of the thread is controlled between 1.0 mm and 2.0 mm, depending on the cross-sectional dimensions of the segmented conductor 100a, the diameter of the single wire, the stranding pitch, and the traction tension requirements of the VCV production line. The thread depth can be controlled between 0.3 mm and 0.8 mm, depending on the dimensions of the segmented conductor 100a. The function of the internal thread is to increase the friction between the inner wall of the connecting structure 100 and the inserted segmented conductor 100a, thereby effectively preventing the segmented conductor 100a from sliding relative to the segmented conductor connecting device 1000 or falling off due to force during the production process.

[0043] In some embodiments, the outer peripheral sidewall of the conductor cavity 110 is a crimping area, which deforms when subjected to radial pressure to wrap the segmented conductor 100a inserted into the conductor cavity 110.

[0044] It is understood that the conductor cavity 110 of the connecting structure 100 is also provided with a crimping area. This crimping area is the crimping part of the segmented conductor connecting device 1000. The wall thickness and axial length of the crimping area need to be designed according to the cross-section and pull-out force requirements of the segmented conductor 100a to ensure that it does not loosen or crack under long-term traction conditions. For example, the axial length of the crimping area can be 50mm to 60mm depending on the size of the segmented conductor; the wall thickness of the crimping area can be 2.0mm to 3.0mm depending on the size of the segmented conductor 100a. When the hydraulic press applies radial pressure to the outer peripheral sidewall of the conductor cavity 110, the crimping area and the segmented conductor 100a are subjected to force and undergo inward deformation, thereby tightly crimping the segmented conductor 100a to meet the tensile strength requirements required for continuous traction operation of the VCV production line. The outer contour of the crimping area after crimping should be round, and the outer diameter after crimping should not be greater than the outer diameter of the segmented conductor 100a to meet the subsequent extrusion and die-cutting requirements of the VCV production line.

[0045] In some embodiments, the split conductor connection device 1000 may include two connection structures 100, which may employ the same innovative structure and be symmetrically arranged on both sides of the connection block 200. Each connection structure 100 has a conductor cavity 110, a connection cavity 120, an internal thread, and a crimping area. Its specific dimensions, such as the inner diameter of the conductor cavity 110, the length of the crimping area, and the wall thickness, may be set to be the same or different according to the cross-sectional specifications of the split conductors 100a to accommodate the connection between split conductors 100a of the same or different specifications.

[0046] In some embodiments, the connecting cavity 120 is provided with a snap-fit ​​structure for engaging with the end of the connecting block 200 and the filling block 300.

[0047] It can be understood that the connecting cavity 120 is a groove opened at the other end of the connecting structure 100, and its interior is provided with a snap-fit ​​structure for cooperating with the end of the connecting block 200 and the filling block 300 respectively. During assembly, the filling block 300 is first placed into the connecting cavity 120 and initially positioned with the snap-fit ​​structure. Then, the corresponding end of the connecting block 200 extends into the connecting cavity 120 and fits into the filling block 300. At the same time, the outer periphery of the filling block 300 is locked with the snap-fit ​​structure in the connecting cavity 120, thereby forming a tensile limit in the axial direction and an anti-rotation constraint in the circumferential direction, preventing relative disengagement or rotation between the connecting structure 100 and the connecting block 200.

[0048] In some embodiments, the specific form of the snap-fit ​​structure of the connecting cavity 120 includes, but is not limited to, claw grooves, trapezoidal stepped surfaces, or wedge-shaped anti-retraction surfaces distributed along the inner wall of the connecting cavity 120. The axial width and depth of the snap-fit ​​structure are designed to match the mating dimensions of the connecting block 200 and the filling block 300 to ensure that there is no axial movement after snap-fitting.

[0049] Please refer to Figure 4 , Figure 4 This is a third structural schematic diagram of the connection structure 100 provided in an embodiment of this application. In some embodiments, the connection structure 100 has an inner rounded corner portion 130a and an outer rounded corner portion 130b, the inner rounded corner portion 130a and the outer rounded corner portion 130b are staggered with rounded corners, and the radius of the rounded corner of the outer rounded corner portion 130b is greater than the radius of the rounded corner of the inner rounded corner portion 130a.

[0050] In some embodiments, the connecting structure 100 has an inner rounded corner portion 130a and an outer rounded corner portion 130b at the outer and inner edges where the conductor cavity 110 intersects with the crimping area, respectively. Furthermore, the inner rounded corner portion 130a and the outer rounded corner portion 130b are staggered rounded corner structures, meaning the inner and outer rounded corners are not symmetrically arranged on the same cross-section, but are staggered along the axial direction to avoid stress concentration at weak points in the connecting structure wall. The radius of the outer rounded corner portion 130b is larger than that of the inner rounded corner portion 130a. The larger outer rounded corner helps reduce the risk of the outer contour of the connecting device scratching the cable insulation layer and extrusion die core, facilitating smooth passage through the VCV production line guide rollers and crosslinking machine head. The smaller inner rounded corner helps ensure the effective length of the segmented conductor 100a inserted into the conductor cavity 110 and the crimping area. This staggered rounded corner design improves the overall mechanical properties of the connecting structure and enhances its resistance to crimping cracking, while also meeting the process requirements for a smooth transition of the outer contour of the connecting device during cable production.

[0051] Please refer to Figure 5 , Figure 5This is a schematic diagram of the structure of the connecting block 200 provided in an embodiment of this application. In some embodiments, the connecting block 200 includes a main body portion 210 and limiting portions 220 respectively disposed at both ends of the main body portion 210, wherein the outer diameter of the limiting portions 220 is larger than the outer diameter of the main body portion 210.

[0052] In some embodiments, the connecting block 200 may have an I-shaped or dumbbell-shaped structure, including a cylindrical main body 210 and two limiting portions 220 respectively disposed at both ends of the main body 210. The outer diameter of the limiting portion 220 is larger than the outer diameter of the main body 210, thereby forming a stepped structure between the main body 210 and the limiting portion 220. This shape design allows the two connecting structures 100 to rotate 360° relative to the connecting block 200 within the connecting cavity 120, thereby releasing the torsional internal stress generated by stranding, unwinding and guiding of the split conductor during the VCV production line traction process, avoiding stress concentration that could lead to conductor loosening, twisting or uneven loading at the connection point, and improving the safety and stability of the continuous production process.

[0053] It is understood that the main body 210 of the connecting block 200 can be a slender rod-shaped structure, with a length sufficient to allow the limiting portions 220 at both ends to extend into the connecting cavities 120 of the two connecting structures 100, thereby achieving docking and traction connection of the two connecting structures 100. This structure enables the connecting block 200 to perform axial series connection while also having a limiting and anti-detachment function, thus improving the reliability and stability of the connection.

[0054] It is understood that the limiting part 220 is located at both ends of the main body part 210. Its larger outer diameter can form an axial stop with the snap-fit ​​structure or the filling block 300 in the connecting cavity 120 after assembly, so as to prevent the connecting block 200 from coming out of the connecting cavity 120 axially, and at the same time provide a positioning reference for the snap-fit ​​locking of the filling block 300.

[0055] Please refer to Figure 6 , Figure 6 This is a schematic diagram of the structure of the filling block 300 provided in an embodiment of this application. In some embodiments, the filling block 300 includes a vertical portion 310 and a horizontal portion 320. The vertical portion 310 is located in the connecting cavity 120 and is engaged with the end of the connecting block 200. The horizontal portion 320 extends toward the opening of the connecting cavity 120.

[0056] In some embodiments, the filler block 300 includes a vertical portion 310 and a horizontal portion 320, which are integrally formed or fixedly connected, and the overall structure may be L-shaped. The vertical portion 310 is located within the connecting cavity 120 and engages with the limiting portion 220 of the connecting block 200 to achieve axial locking. The horizontal portion 320 extends from the vertical portion 310 toward the opening of the connecting cavity 120, extending outside the connecting cavity 120 or flush with the opening of the connecting cavity 120. After assembly, the L-shaped filler block 300 can, on the one hand, fill the gap between the connecting block 200 and the connecting structure 100, preventing the connecting device from falling off due to force when passing through the guide wheel or being pulled; on the other hand, by filling the gap in the connecting block 200, it can reduce the abrupt change in the outer diameter of the cross-linked core at the connecting device, thereby making the outer diameter change at the connecting part more gradual, which is beneficial to the smooth progress of subsequent cross-linking processes. Furthermore, the horizontal section 320 extends towards the opening of the connecting cavity 120, serving as a guide and auxiliary positioning feature. This facilitates on-site installation or removal by operators using tools to clamp or tap the connector, allowing the second connecting block 300 to be installed or removed without disassembling the entire split conductor connecting device 1000. This improves the convenience of on-site construction and maintenance efficiency. Please refer to [reference needed]. Figure 7 , Figure 7 This is a schematic flowchart of the method for connecting split conductors provided in an embodiment of this application. Specifically, as shown... Figure 7 As shown, the test method includes the following steps: Step S10: Insert the ends of the first segmented conductor and the second segmented conductor into the conductor cavities of a connecting structure, with a conductor cavity at one end and a connecting cavity at the other end.

[0057] It is understandable that a connection structure with an inner diameter of the conductor cavity larger than the outer diameter of the segmented conductor is selected. The bare conductor end is inserted straight into the conductor cavity along the axial direction until the end face abuts against the positioning surface at the bottom of the cavity, ensuring that the insertion depth covers the subsequent crimping area. During the insertion process, the conductor and the connection structure should be kept coaxial to avoid single wire jamming or skew. After the conductors on both sides are inserted into the corresponding connection structures, they are then snapped together in the connection cavity by the connection block and the filler block, and finally crimped and fixed.

[0058] It should be noted that after the split conductor is inserted into the conductor cavity, the gap formed between the conductor cavity and the split conductor can be used to compensate for the deformation of the split conductor and to achieve rapid insertion of the split conductor's monofilament without stripping. Furthermore, the insertion depth of the split conductor must meet the requirements of the effective bearing length of the crimping area of ​​the connection structure. After the insertion of the split conductor is completed, the crimping process must be initiated promptly. For example, a regular dodecagonal die should be used to crimp the inserted connection cavity until the outer diameter of the connection cavity is no greater than the outer diameter of the bare conductor, and the cavity should be inspected for defects such as cracks or loosening.

[0059] Step S20: Apply radial pressure to the connection structure to cause the conductor cavity to contract radially to enclose the first segment conductor and the second segment conductor.

[0060] It is understandable that for a connection device that has completed the insertion and snap-fit ​​assembly of the segmented conductors, a special hydraulic crimping machine or a regular dodecagonal crimping die can be used to apply radial pressure to the crimping area on the outer periphery of the corresponding conductor cavity on the connection structure, causing the connection structure to undergo plastic deformation, which causes the conductor cavity wall to shrink inward, thereby tightly wrapping and pressing the inserted first segmented conductor and second segmented conductor into the conductor cavity, forming mechanical locking and electrical conduction.

[0061] It should be noted that during crimping, the length of opposite sides of the crimping die must be less than or equal to the outer diameter of the bare conductor, the outer diameter of the conductor cavity after crimping must not be greater than the outer diameter of the split conductor, and the outer contour of the crimping area of ​​the conductor cavity must be round and free of cracks.

[0062] It should also be noted that the process of controlling the crimping direction when applying radial pressure to the connecting structure includes, but is not limited to, performing axial segmented crimping first, and then rotating the mold by 30° for supplementary crimping. This method ensures that the conductor cavity shrinks uniformly and is fully wrapped, meeting the tensile strength requirements for continuous traction in the VCV production line.

[0063] Step S30: Embed both ends of the connecting block into the connecting cavities of the two connecting structures respectively, and place the filling block into the connecting cavity so that the filling block engages with the corresponding end of the connecting block.

[0064] In some embodiments, the two ends of the connecting block are first embedded into the connecting cavities of the two connecting structures, so that the connecting block passes through the two connecting structures axially and connects them in series. Then, the filler block is placed into the connecting cavity, so that the vertical part of the filler block and the corresponding end of the connecting block, such as the limiting part, form a snap-fit ​​engagement. Simultaneously, the horizontal part of the filler block extends towards the opening of the connecting cavity, facilitating installation and disassembly. Through this snap-fit ​​engagement, the connecting block and the filler block form an axial lock and circumferential limit within the connecting cavity, preventing relative disengagement or rotation between the connecting structures and the connecting block, thereby achieving a stable connection between the two segmented conductors.

[0065] Furthermore, after the filler block is placed into the connecting cavity, the process also includes: wrapping a coating layer around the outer periphery of the connecting structure so that the outer diameter after wrapping is smaller than the inner diameter of the cross-linked mold core.

[0066] It is understandable that after the filler block is placed into the connecting cavity and snapped in place, a covering layer needs to be wrapped around the outer periphery of the connecting structure. This process includes, but is not limited to, first wrapping a layer of non-woven protective tape, such as polypropylene non-woven tape or EVA protective tape (ethylene-vinyl acetate copolymer protective tape), around the outside of the connecting structure, with an overlap rate of 15%–50%, and wrapping at least two layers; then wrapping two layers of strong adhesive tape around the outer layer of the non-woven or EVA protective tape, with an overlap rate of 10%–30%. After wrapping, use calipers to measure the overall outer diameter of the connecting device, ensuring that the outer diameter after wrapping is at least 1.0 mm smaller than the inner diameter of the cross-linking mold core, to avoid the connecting device jamming the mold core in subsequent cross-linking processes on the VCV production line, causing abnormal shutdowns. Then, add another protective layer. This covering layer not only provides cushioning protection for the connecting device but also prevents impurities from adhering to the connecting device when it passes the guide rollers. Note that this layer should be removed before the connecting device passes through the cross-linking machine head.

[0067] Furthermore, before the first and second segmented conductors are inserted into the conductor cavity, the process further includes: rounding the ends of the first and second segmented conductors and removing the end wrapping tape to expose the bare conductors.

[0068] It is understandable that before inserting the ends of the first and second segmented conductors into the conductor cavity of the connecting structure, the ends of the segmented conductors need to be rounded. That is, first check the roundness of the end face of the segmented conductor, then peel off the wrapping tape 10-15mm from the end face to expose the bare conductor, and at the same time peel off the wrapping tape about 100mm from the end face to allow for proper insertion.

[0069] It should be understood that the above are merely illustrative examples and do not constitute any limitation on the technical solution of this application. In specific applications, those skilled in the art can make settings as needed, and this application does not impose any restrictions on this.

[0070] It should be noted that the workflow described above is merely illustrative and does not limit the scope of protection of this application. In practical applications, those skilled in the art can select some or all of it to achieve the purpose of this embodiment according to actual needs, and no restrictions are imposed here.

[0071] In addition, for technical details not described in detail in this embodiment, please refer to the conductor connection device and method provided in any embodiment of this application, which will not be repeated here.

[0072] Furthermore, it should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or system that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or system. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or system that includes that element.

[0073] The sequence numbers of the embodiments in this application are for description only and do not represent the superiority or inferiority of the embodiments.

[0074] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A split conductor connection device, characterized by include: At least two connection structures, each of which has a conductor cavity at one end for accommodating a split conductor and a connection cavity at the other end; The connecting block has its two ends located within the connecting cavities of the two connecting structures, respectively. A filler block is located inside the connecting cavity of the connecting structure and is engaged with the end of the connecting block; The inner diameter of the conductor cavity is larger than the outer diameter of the segmented conductor.

2. The split conductor connection device of claim 1, wherein The connecting block includes a main body and limiting parts respectively disposed at both ends of the main body, wherein the outer diameter of the limiting parts is larger than the outer diameter of the main body.

3. The split conductor connection device of claim 2, wherein, The filling block includes a vertical portion and a horizontal portion. The vertical portion is located inside the connecting cavity and engages with the end of the connecting block. The horizontal portion extends toward the opening of the connecting cavity.

4. The split conductor connection apparatus of claim 1, wherein The conductor cavity is a cylindrical blind hole opened along the axial direction of the connection structure, and a positioning surface is formed at its bottom to limit the insertion depth of the dividing conductor.

5. The split conductor connection apparatus of claim 4, wherein The outer peripheral sidewall of the conductor cavity is a crimping area, which deforms when subjected to radial pressure to wrap the segmented conductor inserted into the conductor cavity.

6. The split conductor connection apparatus of claim 1, wherein The connecting cavity is provided with a snap-fit ​​structure, which is used to snap-fit ​​with the end of the connecting block and the filling block.

7. The split conductor connection device of any one of claims 1 to 5, wherein, The connecting structure has an inner rounded corner and an outer rounded corner. The inner rounded corner and the outer rounded corner are staggered and rounded, and the radius of the outer rounded corner is larger than the radius of the inner rounded corner.

8. A method of splitting a conductor connection, characterized by include: The ends of the first segmented conductor and the second segmented conductor are respectively inserted into the conductor cavity of a connecting structure, wherein one end of the connecting structure is provided with a conductor cavity and the other end is provided with a connecting cavity. Radial pressure is applied to the connection structure, causing the conductor cavity to contract radially to enclose the first segmented conductor and the second segmented conductor; The two ends of the connecting block are respectively embedded into the connecting cavities of the two connecting structures, and the filling block is placed into the connecting cavity so that the filling block is engaged with the corresponding end of the connecting block.

9. The split conductor connection method of claim 8, wherein, After the filler block is placed into the connecting cavity, the method further includes: wrapping a coating layer around the outer periphery of the connecting structure so that the outer diameter after wrapping is smaller than the inner diameter of the cross-linked mold core.

10. The split conductor connection method of claim 8, wherein Before the first and second segmented conductors are inserted into the conductor cavity, the process further includes: rounding the ends of the first and second segmented conductors and removing the end wrapping to expose the bare conductors.

Images