Railway signal plug-in branch cable box and construction method thereof

Abstract

This invention belongs to the field of railway signaling equipment and relates to a railway signal plug-in directional cable box and its construction method. The cable box includes: a box body for accommodating internal wiring terminals and internal grounding terminals, providing mechanical protection and electrical isolation; internal wiring terminals, fixedly installed inside the box body, for connecting the core wires of the signal cable to achieve signal transmission; internal grounding terminals, fixedly installed inside the box body, for connecting the grounding wire of the signal cable to achieve grounding protection; a heavy-duty connector, including a plug side and a base side, wherein the base side is fixedly installed on the side or bottom of the box body, and the plug side is used to connect to an external prefabricated cable plug; and a box cover, detachably installed on the top surface of the box body, for sealing the box. This invention significantly improves efficiency, ensures high quality consistency, enhances protection level, facilitates maintenance, offers flexible configuration, maintains high fault location efficiency, and adapts to modern construction concepts.

Description

Technical Field

[0001] This invention relates to the field of decoy technology, and more specifically, to a railway signal plug-in directional cable box and its construction method. Background Technology

[0002] Railway signaling systems are crucial for ensuring railway transportation safety and improving efficiency. A large number of signal cables need to be laid between outdoor signaling equipment (such as turnouts, signals, track circuits, and transponders) and indoor control equipment. To meet the requirements for cable directional routing, branching, switching, and grounding protection, directional cable boxes are widely used in railway signaling engineering.

[0003] Traditional railway signal cable distribution boxes mainly consist of a box body, cable connection terminals, grounding connection terminals, a box cover, and cable protection conduits. The cable protection conduit is located at the bottom of the box body, and consists of a protective conduit, an auxiliary protective conduit, and M-shaped fixing clamps. During construction, the signal cable is fixed between the protective conduit and the auxiliary protective conduit using fixing clips. After securing it to the protective conduit using M-shaped fixing clamps, the outer sheath of the signal cable is stripped, and a grounding connection is made to the outer sheath. Then, the cable core and grounding wire are threaded together into the box body. After threading into the box body, the cable protection conduit is connected to the box body using bolts. After the cable protection conduit is connected, the overall box and mounting bracket are adjusted and secured. The cable core is connected to the cable connection terminals using screw-type or spring-type terminals, and the grounding wire is connected to the grounding connection terminals. After the cable core and grounding wire are connected, cold-sealing adhesive is applied to the cable protection conduit. After the cold-sealing adhesive is applied, the box cover is secured to the box body using bolts.

[0004] The aforementioned traditional technical solutions have the following main drawbacks:

[0005] (1) The construction process is complicated: all operations must be completed on the railway site, including cable stripping, conduit installation, glue injection, terminal wiring, glue curing, etc. There are many procedures and the time is long. The on-site construction of a common branch cable box usually requires 2 workers to spend 3 to 4 hours.

[0006] (2) Unstable on-site construction quality: The on-site environment is complex (wind, sand, rain, snow, large temperature difference). The stripping length, glue density, terminal clamping, etc. all depend on the worker's experience, which can easily lead to hidden dangers such as poor contact and sealing failure.

[0007] (3) Low protection level: The cable inlet of the traditional box is sealed by cold injection. After long-term use, the adhesive may crack and shrink, resulting in a decrease in protection level, usually only IP55, which is difficult to resist heavy rain or water immersion environment.

[0008] (4) Inconvenient maintenance: When it is necessary to replace the cable or add a new branch, the box must be opened, the old glue removed, the wires stripped and reconnected, and the glue reapplied, which requires a lot of maintenance work.

[0009] (5) Incompatible with modern construction concepts: Current railway signaling engineering advocates modular prefabricated construction and balanced construction at workstations, that is, to transfer on-site work to the factory assembly line as much as possible, and only simple installation and connection are carried out on-site. Traditional branched cable boxes do not meet this requirement at all.

[0010] Therefore, there is an urgent need for a new type of railway signal directional cable box and its construction method, which can achieve factory prefabrication, rapid on-site connection, high protection level, and easy maintenance. Summary of the Invention

[0011] To address the aforementioned deficiencies in the prior art, this invention provides a railway signal plug-in branch cable box, comprising:

[0012] The enclosure body is used to house the internal wiring terminals and internal grounding terminals, and to provide mechanical protection and electrical isolation.

[0013] Internal wiring terminals are fixedly installed inside the box body and are used to connect the core wires of the signal cable to realize signal transmission;

[0014] An internal grounding terminal is fixedly installed inside the enclosure body and is used to connect the grounding wire of the signal cable to achieve grounding protection.

[0015] A heavy-duty connector, including a plug side and a base side, wherein the base side is fixedly installed on the side or bottom surface of the housing body, and the plug side is used to connect with an external prefabricated cable plug; a housing cover, detachably installed on the top surface of the housing body, for closing the housing;

[0016] The internal wiring terminal is electrically connected to the base side of the heavy-duty connector via an internal wire, and the internal grounding terminal is electrically connected to the grounding terminal of the base side of the heavy-duty connector; the plug side includes a gland, a plug housing, and a female ferrule, and the female ferrule has at least two grounding terminals; the base side includes a base housing and a male ferrule; a polarity identification structure is provided between the male ferrule and the female ferrule.

[0017] Preferably, the materials of the box body and the box lid are selected from one or more of the following: metallic materials, inorganic non-metallic materials, organic materials, or composite materials; wherein, metallic materials include cast aluminum alloy, die-cast zinc alloy, stainless steel, carbon steel, and brass; inorganic non-metallic materials include ceramic matrix composites and glass fiber reinforced cement; organic materials include polycarbonate, acrylonitrile-butadiene-styrene copolymer, polyamide, and polybutylene terephthalate; and composite materials include sheet molding compound, bulk molding compound, glass fiber reinforced plastic, and carbon fiber reinforced plastic.

[0018] Preferably, the fixing method of the internal wiring terminals is selected from the following: bolt fixing, guide rail buckle fixing, riveting fixing, and snap ring fixing; the number of the internal wiring terminals is 6 to 72; the wiring method of the internal wiring terminals is selected from the following: screw crimping, spring clamping, cage spring connection, direct insertion connection, and insulation displacement connection.

[0019] Preferably, the fixing method of the internal grounding terminal is selected from the following: bolt fixing, guide rail buckle fixing, riveting fixing, and snap ring fixing; the number of internal grounding terminals is 2 to 6; the wiring method of the internal grounding terminal is selected from the following: screw crimping, spring clamping, cage spring connection, and direct insertion connection.

[0020] Preferably, the number of heavy-duty connectors is 2 to 7, and their protection level is ≥ IP65; in the plug side of the heavy-duty connector, the number of female ferrules is 6 to 72, the current range is 0.1A to 16A, and the withstand voltage range is AC 48V to 600V and DC 24V to 110V; the locking method of the plug side and the base side of the heavy-duty connector is selected from the following: snap-on locking, threaded locking, bayonet locking, push-pull locking, and lever locking.

[0021] Preferably, the connection method between the female plug and the cable core, and the connection method between the male plug and the internal conductor, are each independently selected from the following: direct insertion connection, plug-in connection, spring connection, screw connection, bolt connection, crimp connection, wrap connection, and welding connection.

[0022] Preferably, the connection method between the box lid and the box body is selected from the following: bolt connection, pin connection, snap-fit ​​connection, hinge connection, quick-clamp connection; a sealing structure is provided between the box lid and the box body, and the sealing structure is selected from the following: molded rubber sealing ring, foamed silicone sealing strip, liquid sealant injection, labyrinth seal, conductive rubber sealing ring; through the sealing structure, the overall protection level of the box reaches IP66 or above.

[0023] Preferably, the polarity identification structure is selected from one of the following: foolproof keyway and key position, guide pins and guide holes of different diameters, asymmetrically arranged pins and holes, shell markings of different colors, magnetic code identification structure, and mechanical code identification structure.

[0024] On the other hand, the present invention provides a construction method for a railway signal plug-in branch cable box, which uses the above-mentioned railway signal plug-in branch cable box and is characterized by including the following steps:

[0025] S1, Factory prefabrication step, completes the assembly and internal wiring of the box body, internal wiring terminals, internal grounding terminals, base side of heavy-duty connectors and box cover in the factory;

[0026] S2, On-site installation steps: Fix the prefabricated box as a whole onto the installation bracket at the railway site;

[0027] S3, Field insertion step: Directly insert and lock the pre-made heavy-duty connector plug side to the base side fixed on the box.

[0028] S4: Inspection steps. After completing the electrical connection inspection, the construction is complete.

[0029] Preferably, in step S1, factory prefabrication further includes the following sub-steps:

[0030] S11, the internal wiring terminals and internal grounding terminals are installed in the enclosure body by a fixing method selected from bolts, guide rails, rivets, and snap rings;

[0031] S12, fix the base side of the heavy-duty connector to the side or bottom of the box body with bolts or rivets;

[0032] S13, according to the electrical schematic diagram, use wires to electrically connect the internal terminals to the corresponding core wires of the male connector on the base side. The connection method is selected from one of crimping, welding, screw crimping, and spring clamping.

[0033] S14, electrically connect the internal grounding terminal to the grounding-specific core wire in the male connector on the base side;

[0034] S15, after completing the internal connection, perform a 100% electrical continuity test and an insulation resistance test;

[0035] S16, Pre-install the box cover onto the box body, and temporarily or finally fix it using a method selected from bolts, pins, buckles, hinges, and quick clips;

[0036] In step S3, the method for preparing the heavy-duty connector plug side includes the following sub-steps:

[0037] S31, pass the end of the signal cable through the sealing ring, clamping nut and cable clamp of the gland;

[0038] S32, strip the outer sheath of the cable to expose the core wire and shielding layer. The stripping length is determined according to the wiring requirements of the female core, and is 5mm to 15mm.

[0039] S33. Connect the core wires to the corresponding sockets of the female connector according to the core sequence table. The connection method can be selected from crimping, screw, spring, straight insertion, or welding. Connect the shielding layer or dedicated grounding wire to the preset grounding terminals (at least 2) in the female connector.

[0040] S34, Insert the female connector into the plug housing and secure it with bolts or clips;

[0041] S35, tighten the clamping nut of the gland head to make the cable clamp press against the outer sheath of the cable to achieve tensile strength and sealing effect;

[0042] S36, align the prepared plug side with the base side, use the polarity identification structure to prevent misinsertion, and lock it in place by a locking method selected from buckle, thread, bayonet, push-pull, lever.

[0043] The railway signal plug-in branch cable box of the present invention has the following advantages:

[0044] (1) Significant efficiency improvement: Traditional construction: 2 people × 4 hours = 8 person-hours / box. This invention: Factory prefabrication time is about 1.2 person-hours / box (batch advantage), and on-site construction time is 2 people × 0.5 hours = 1 person-hour / box. The overall efficiency improvement is about (8-1) / 8 = 87.5%. Even without considering factory time, the on-site efficiency improvement is about (4-0.5) / 4 = 87.5%, which is consistent with the conservative estimate of "improvement of about 70%".

[0045] (2) High quality consistency: The factory environment is constant temperature and humidity. Special crimping tools, torque screwdrivers and automatic testing equipment are used. The terminal crimping force and bolt torque can be quantitatively controlled to eliminate fluctuations caused by human factors.

[0046] (3) Improved protection level: Traditional IP55 (limited dust protection, limited water spray protection) → This invention is IP66 (strong dust protection, strong water spray protection) or even IP67 (short-term immersion). The sealing structure is clear, and there is no risk of aging and cracking due to glue aging.

[0047] (4) Convenient maintenance: Traditional maintenance requires "opening the cover → cleaning the glue → disconnecting the wire → replacing the wire → applying glue → waiting for curing → closing the cover", which takes at least half a day. Maintenance of this invention only requires "unplugging the old plug → plugging in the new plug", which can be completed in 2 minutes.

[0048] (5) Flexible configuration: The number of heavy-duty connectors can be customized from 2 to 7, the number of cores can be selected from 6 to 72, the voltage is AC 48V~600V / DC 24V~110V, and the current is 0.1A~16A, which can cover all common scenarios of railway signaling (track circuits, turnouts, signal lights, axle counters, transponders, etc.).

[0049] (6) Fault finding efficiency is not reduced: The internal wiring terminals (2) retain the testing convenience of traditional terminals. Maintenance personnel can open the box cover to measure on the terminals without unplugging the heavy-duty connector, thus avoiding interruption caused by measurement.

[0050] (7) Adapting to modern construction concepts: It fully complies with the modular prefabricated construction and work station balanced construction requirements promoted by China Railway Corporation. The on-site procedures are extremely simplified, which helps to shorten the track window time and improve railway transportation efficiency. Attached Figure Description

[0051] 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 or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort. The present invention will be further described below in conjunction with the drawings and embodiments. In the drawings:

[0052] Figure 1 This is a cross-sectional view of the railway signal plug-in branch cable box of the present invention;

[0053] Figure 2 This is a perspective view of the railway signal plug-in directional cable box of the present invention;

[0054] Figure 3 This is a top view of the railway signal plug-in branch cable box of the present invention;

[0055] Figure 4 This is a bottom view of the railway signal plug-in branch cable box of the present invention;

[0056] Figure 5 This is a front view of the railway signal plug-in branch cable box of the present invention;

[0057] Figure 6 This is a left view of the railway signal plug-in branch cable box of the present invention;

[0058] Figure 7 This is a schematic diagram of the railway signal plug-in directional cable box of the present invention.

[0059] In the diagram, 1-box body, 2-internal wiring terminal, 3-heavy-duty connector, 4-internal grounding terminal, 5-box cover. Detailed Implementation

[0060] 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 a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0061] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0062] Furthermore, if the embodiments of this invention involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0063] Example 1

[0064] Figure 1 This is a cross-sectional view of the railway signal plug-in branch cable box of the present invention; Figure 2 This is a perspective view of the railway signal plug-in directional cable box of the present invention; Figure 3 This is a top view of the railway signal plug-in branch cable box of the present invention; Figure 4 This is a bottom view of the railway signal plug-in branch cable box of the present invention; Figure 5 This is a front view of the railway signal plug-in branch cable box of the present invention; Figure 6 This is a left view of the railway signal plug-in branch cable box of the present invention; Figure 7 This is a schematic diagram of the railway signal plug-in branch cable box of the present invention. Please refer to [link / reference]. Figures 1-7 The railway signal plug-in branch cable box provided in the first embodiment of the present invention includes at least:

[0065] The enclosure body 1 is used to house the internal wiring terminals 2 and the internal grounding terminals 4, and to provide mechanical protection and electrical isolation.

[0066] Internal wiring terminal 2 is fixedly installed inside the box body 1 and is used to connect the core wire of the signal cable to realize signal transmission;

[0067] The internal grounding terminal 4 is fixedly installed inside the box body 1 and is used to connect the grounding wire of the signal cable to achieve grounding protection.

[0068] The heavy-duty connector 3 includes a plug side and a base side, wherein the base side is fixedly installed on the side or bottom of the housing body 1, and the plug side is used to connect with an external prefabricated cable plug; the housing cover 5 is detachably installed on the top surface of the housing body 1 for closing the housing.

[0069] The internal wiring terminal 2 is electrically connected to the base side of the heavy-duty connector 3 via an internal wire, and the internal grounding terminal 4 is electrically connected to the grounding terminal of the base side of the heavy-duty connector 3; the plug side includes a gland, a plug housing and a female core, and the female core is provided with at least two grounding terminals; the base side includes a base housing and a male core; a polarity identification structure is provided between the male core and the female core.

[0070] The functions of the box body 1 are as follows: to serve as the skeleton of the entire cable box, providing mechanical strength and rigidity; to house and protect the internal wiring terminals, grounding terminals and internal wires; to provide physical isolation from the external environment, preventing the intrusion of dust, moisture, salt spray, mold, etc.; to provide electromagnetic shielding (when metal material is used), reducing the impact of external electromagnetic interference on signals; to provide a mounting interface for fixing on the mounting bracket; and to provide a mounting surface on the side of the heavy-duty connector base.

[0071] The materials of the box body 1 and the box lid 5 are selected from one or more of the following: metallic materials, inorganic non-metallic materials, organic materials, or composite materials; wherein, metallic materials include cast aluminum alloy, die-cast zinc alloy, stainless steel, carbon steel, and brass; inorganic non-metallic materials include ceramic matrix composites and glass fiber reinforced cement; organic materials include polycarbonate, acrylonitrile-butadiene-styrene copolymer, polyamide, and polybutylene terephthalate; and composite materials include sheet molding compound, bulk molding compound, glass fiber reinforced plastic, and carbon fiber reinforced plastic.

[0072] The characteristics of cast aluminum alloy are: good heat dissipation, strong electromagnetic shielding, and corrosion resistance (requires surface treatment). It is suitable for applications such as strong electromagnetic interference environments and high current applications.

[0073] The characteristics of die-cast zinc alloy metal materials are: high dimensional accuracy and the ability to form complex shapes. Applicable scenarios include: mass production and standard-sized boxes.

[0074] The characteristics of stainless steel 304 / 316 are: extremely strong corrosion resistance and high mechanical strength. It is suitable for use in coastal areas, near chemical plants, and high humidity areas.

[0075] The characteristics of carbon steel (hot-dip galvanized or powder coated) are: low cost and high strength. It is suitable for: economical projects and dry environments.

[0076] The characteristics of brass, a metallic material, are: good electrical conductivity and easy processing. It is suitable for applications with high special grounding requirements.

[0077] The characteristics of inorganic non-metallic ceramic matrix composites are: high temperature resistance, arc resistance, and excellent insulation. They are suitable for high-voltage signal or power supply applications.

[0078] The characteristics of inorganic non-metallic glass fiber reinforced cement are: extremely low cost, compression molding, and applicable scenarios such as: temporary lines and low-requirement occasions.

[0079] The characteristics of organic material polycarbonate (PC) are: transparent, impact-resistant, and good insulation. It is suitable for maintenance wells where internal conditions need to be observed.

[0080] The characteristics of organic material ABS are: low cost and easy processing. It is suitable for use indoors or in protective sheds.

[0081] The characteristics of organic material polyamide (PA, nylon) are: wear resistance and oil resistance, and it is suitable for railway sections with oily environments.

[0082] The characteristics of organic material PBT are: heat resistance and dimensional stability, making it suitable for high-temperature environments.

[0083] The characteristics of composite material SMC (sheet molding compound) are: excellent comprehensive performance, mature application in the railway industry, and applicable scenarios: general preferred choice.

[0084] The characteristics of BMC (bulk molding compound) composite material are: it can be injection molded into complex shapes, and its applicable scenarios are: small boxes.

[0085] The characteristics of glass fiber reinforced plastic (GFRP) composite material are: high strength and good insulation, and it is suitable for use in highly corrosive environments.

[0086] The characteristics of carbon fiber reinforced plastic (CFRP) composite materials are: extremely high strength and extremely light weight, and they are suitable for special requirements (such as weight reduction in bridges).

[0087] The fixing method of the internal wiring terminal 2 is selected from the following: bolt fixing, guide rail buckle fixing, riveting fixing, and snap ring fixing; the number of internal wiring terminals 2 is 6 to 72; the wiring method of the internal wiring terminal 2 is selected from the following: screw crimping, spring clamping, cage spring connection, direct insertion connection, and insulation displacement connection.

[0088] In practice, the bottom or side of the box body 1 is provided with multiple mounting rails (standard 35mm DIN rails) or threaded holes for fixing the internal wiring terminals 2 and the internal grounding terminals 4.

[0089] The side or bottom surface of the housing body 1 has through holes or threaded holes for fixing the base side of the heavy-duty connector 3 with bolts (M4~M8 stainless steel bolts). The hole size matches the selected heavy-duty connector model.

[0090] The top surface of the box body 1 has sealing grooves around its perimeter for placing a sealing ring. Screw holes or pin holes are provided at the four corners or sides of the top surface for connecting the box cover 5.

[0091] The back or bottom of the box body 1 is provided with mounting ears. The ears have elongated holes, which facilitate on-site adjustment and fixation to the bracket by bolts.

[0092] The function of internal terminal 2 is to provide electrical connection points between cable cores to realize signal convergence, branching, and transfer; as a test point, maintenance personnel can measure voltage, current, and continuity here to quickly locate faults; and according to different needs, permanent or detachable connections can be realized.

[0093] In practice, the internal wiring terminal 2 uses screw-type crimp terminals, with 24 terminals arranged on a 35mm DIN rail. Each terminal can connect 2 wires (1.5mm²~6mm²).

[0094] In practice, the internal wiring terminal 2 is fixed to the DIN rail by a snap-fit, and the rail is then fixed to the box body 1 by screws.

[0095] The incoming side of each internal terminal 2 is connected to a pin of the male connector core on the base side of the heavy-duty connector 3 via an internal wire (usually a multi-strand copper core flexible wire with a cross-section of 0.5mm²~2.5mm², color-coded for differentiation).

[0096] Each internal terminal 2 has a reserved wiring position on the outgoing side, but no external cable is connected during the factory prefabrication stage. Only when parallel wiring or transfer is required inside the box, the factory will pre-connect different terminals with shorting wires according to the drawings.

[0097] The function of internal grounding terminal 4 is to: connect all conductors that need to be grounded, including cable shielding grounding wire, lightning protection grounding wire, and equipment protection grounding wire; provide a centralized grounding point for easy connection to external grounding electrode; and ensure low impedance and reliability of the grounding system.

[0098] The fixing method of the internal grounding terminal 4 is selected from the following: bolt fixing, guide rail buckle fixing, riveting fixing, and snap ring fixing; the number of internal grounding terminals 4 is 2 to 6; the wiring method of the internal grounding terminal 4 is selected from the following: screw crimping, spring clamping, cage spring connection, and direct insertion connection.

[0099] In practice, the internal grounding terminal 4 is a brass tin-plated screw-type grounding terminal block with 4 terminals, which are used for cable shielding grounding, lightning protection grounding, enclosure grounding, and backup grounding, respectively.

[0100] The internal grounding terminal 4 is fixed inside the box body 1 by bolts or guide rails, usually near the cable inlet or heavy-duty connector side, to shorten the grounding path.

[0101] One end of the internal grounding terminal 4 is connected to the grounding pins (at least 2) preset in the male core of the heavy-duty connector 3 base via an internal wire (yellow-green, cross-section 2.5mm²~6mm²).

[0102] The other end of the internal grounding terminal 4 can be connected to the grounding bolt of the box body 1 (if the box is a metal shell, the shell needs to be grounded), or it can be reserved for connecting an external grounding wire.

[0103] The function of the heavy-duty connector 3 is to: enable a fast, pluggable, and highly reliable electrical connection between the box and the external signal cable; provide sealing protection to prevent moisture and dust from entering the connection interface; provide mechanical locking to resist vibration and impact at the railway site; and prevent incorrect insertion through a polarity identification structure.

[0104] The number of heavy-duty connectors 3 is 2 to 7, and their protection level is ≥ IP65; On the plug side of the heavy-duty connector 3, the number of female cores is 6 to 72, the current range is 0.1A to 16A, and the withstand voltage range is AC 48V to 600V and DC 24V to 110V; The locking method of the plug side and the base side of the heavy-duty connector 3 is selected from the following: snap-on locking, threaded locking, bayonet locking, push-pull locking, and lever locking.

[0105] In practice, the base is fixed to the box body 1 by passing four M5 bolts through the flange holes of the base shell, and a sealing gasket or O-ring is installed between the two.

[0106] The male connector pins on the base side are soldered to the PCB adapter board or directly crimped to the internal wires, which are then connected to the internal terminal 2 and the internal grounding terminal 4.

[0107] The female core on the plug side is connected to the external cable core by crimping or welding. After being installed in the plug housing, the gland locks the cable in place.

[0108] When mated, the male ferrule's pins are inserted into the female ferrule's socket, achieving electrical continuity; the locking mechanism on the outer casing secures the two together.

[0109] The connection method between the female plug and the cable core, and the connection method between the male plug and the internal conductor, can be selected independently from the following: direct insertion connection, plug-in connection, spring connection, screw connection, bolt connection, crimp connection, wrap connection, and welding connection.

[0110] The function of the box cover 5 is to: close the box and protect the internal components; achieve a high level of protection in conjunction with the sealing structure; and provide an access point for maintenance.

[0111] The connection method between the box lid 5 and the box body 1 is selected from the following: bolt connection, pin connection, snap-fit ​​connection, hinge connection, quick-clamp connection; A sealing structure is provided between the box lid 5 and the box body 1, and the sealing structure is selected from the following: molded rubber sealing ring, foamed silicone sealing strip, liquid sealant injection, labyrinth seal, conductive rubber sealing ring; Through the sealing structure, the overall protection level of the box reaches IP66 or above.

[0112] The purpose of the polarity identification structure is to prevent plugs with different pin sequences or types from being inserted into the wrong socket, thus avoiding equipment damage or signal errors.

[0113] The polarity identification structure is selected from one of the following: foolproof keyway and key position, guide pins and guide holes of different diameters, asymmetrically arranged pins and holes, shell markings of different colors, magnetic coding identification structure, and mechanical coding identification structure.

[0114] The working process of this embodiment can be understood from two dimensions: the working principle of the factory prefabrication stage and the working principle of the on-site construction and use stage.

[0115] 1. Working principle of the factory prefabrication stage:

[0116] Inside the factory, workers assemble the boxes into a "semi-finished product" according to the design drawings. The specific electrical circuit setup process is as follows:

[0117] Signal loop construction: Each signal pin in the male connector core on the base side of the heavy-duty connector 3 is connected to the input side of one of the terminals of the internal terminal block 2 via an internal wire (e.g., red, 0.75mm² cross-section). Since the internal terminal block 2 has multiple terminals, the same signal can be directly connected from the input side to the output side through the terminal's conductive structure, or connected to other terminals via jumpers, thus achieving parallel or switching of signals. In this way, when the external cable signal travels from the plug side → base side → internal wire → internal terminal block 2, the signal is ready to be led out to another cable.

[0118] Grounding loop construction: At least two dedicated grounding pins (for redundancy) in the male connector core on the base side of the heavy-duty connector 3 are connected to the busbar of the internal grounding terminal 4 via a yellow-green internal wire. The internal grounding terminal 4 is then connected to the grounding bolt of the enclosure body 1 (if it is a metal enclosure) via a thicker wire (4mm² cross-section). Simultaneously, the internal terminals 2 that do not require grounding are isolated from the grounding loop.

[0119] Sealing and protection mechanisms: Spring washers or threadlockers are installed at all fixing bolts to prevent loosening. A sealing gasket is installed between the base of heavy-duty connector 3 and the housing body 1 to ensure that moisture cannot enter through installation gaps. A sealing ring is installed between the housing cover 5 and the housing body 1. The sealing ring is compressed after the bolts are tightened, achieving IP66 protection.

[0120] 2. Working principle during on-site construction and use:

[0121] Once the on-site construction workers receive the prefabricated boxes and pre-made plug-side cable assemblies, they complete the work according to the following signal flow:

[0122] Installation and fixing: Fix the box to the railway subgrade or bridge using brackets. At this time, all wiring inside the box has been completed, and there is no need to open the box cover.

[0123] Plug-in connection: Align the plug side with the external cable with the base side on the enclosure. Due to the polarity identification structure, the plug can only be inserted in the correct orientation. Once inserted, a locking mechanism (such as a threaded ring) secures both. At this point, each core of the external cable is electrically connected via the path: female plug → male base → internal wire → internal terminal 2. Multiple cores are connected all at once during the plugging process, eliminating the need for individual connection steps.

[0124] Signal transmission: The signal current flows out from one cable, passes through the plug-in connector and enters the internal terminal 2 of the box. If it needs to be branched to another cable, the same signal is simultaneously connected to the base side of another heavy-duty connector 3 by shorting or paralleling on the internal terminal 2, and then output to the next cable through another plug side, thus realizing the signal branching.

[0125] Grounding protection: The shielding layer of the external cable is connected to the grounding terminal through the inside of the plug, then enters the internal grounding terminal 4 through the grounding pin of the heavy-duty connector 3, and finally connects to the grounding electrode of the earth through the box grounding bolt or lead wire. In the event of lightning strike or leakage, the fault current can be quickly discharged through the grounding path to protect the equipment.

[0126] Maintenance and Inspection: When signal inspection is required, maintenance personnel can open the box cover 5 and directly use a multimeter probe to contact the test points of the internal wiring terminal 2 without disconnecting any connections. If an external cable needs to be replaced, simply unplug the corresponding plug side and replace it with the newly made plug side; there is no need to open the box for gluing.

[0127] Example 2

[0128] This embodiment provides a construction method for a railway signal plug-in branch cable box, using the railway signal plug-in branch cable box of Embodiment 1, including the following steps:

[0129] S1, Factory prefabrication step, completes the assembly and internal wiring of the box body 1, internal wiring terminals 2, internal grounding terminals 4, heavy-duty connector 3 base side and box cover 5 in the factory.

[0130] In step S1, factory prefabrication further includes the following steps:

[0131] S11, Component fixing: The internal wiring terminal 2 and the internal grounding terminal 4 are installed in the box body 1 by a fixing method selected from bolts, guide rails, rivets, and snap rings.

[0132] The purpose of step S11 is to establish a basic installation structure, ensure accurate terminal positioning, and resist vibration.

[0133] S12, Base side mounting: Fix the base side of the heavy-duty connector 3 to the side or bottom of the box body 1 with bolts or rivets.

[0134] The purpose of step S12 is to provide a mechanical interface for subsequent insertion while ensuring a seal between the box body 1 and the connector.

[0135] S13, Internal wiring (signal section): According to the electrical schematic diagram, use wires to electrically connect the internal terminal 2 to the corresponding core wire of the male connector on the base side. The connection method is selected from one of crimping, welding, screw crimping, and spring clamping.

[0136] The purpose of step S13 is to establish an internal path for the signal from the connector to the terminal.

[0137] S14, Internal wiring (grounding part): Connect the internal grounding terminal 4 to the grounding core wire in the male connector on the base side.

[0138] The purpose of step S14 is to establish a low-impedance grounding path.

[0139] S15, Quality Inspection: Perform 100% continuity test using a multimeter or continuity tester; test insulation resistance using a 500V megohmmeter (should be ≥50MΩ).

[0140] The purpose of step S15 is to ensure that the internal wiring is correct, without short circuits or loose connections, and to remove defective products before they leave the factory.

[0141] S16, Pre-installation of cover plate: The box cover 5 is pre-installed on the box body 1 and temporarily or finally fixed using a method selected from bolts, pins, buckles, hinges, and quick clips;

[0142] The purpose of step S16 is to protect the internal components from damage during transportation.

[0143] S2, install the box onto the bracket on site.

[0144] Transport the prefabricated box to the designated location on the railway site, place it on the mounting bracket, adjust the level and orientation of the box (so that the heavy-duty connector 3 faces outward for easy insertion and removal), and tighten the fixing bolts with a wrench.

[0145] The purpose of step S2 is to complete the mechanical fixing and prepare for cable connection.

[0146] S3, Field insertion step: Directly insert and lock the pre-made heavy-duty connector 3 plug side to the base side fixed on the box.

[0147] The core of this step lies in the prefabrication of the cable head on the plug side and the on-site connection.

[0148] In step S3, the fabrication method of the heavy-duty connector 3 plug side includes the following sub-steps:

[0149] S31, pass the end of the signal cable through the sealing ring, clamping nut and cable clamp of the gland;

[0150] S32, strip the outer sheath of the cable to expose the core wire and shielding layer. The stripping length is determined according to the wiring requirements of the female core, and is 5mm to 15mm.

[0151] S33. Connect the core wires to the corresponding sockets of the female connector according to the core sequence table. The connection method can be selected from crimping, screw, spring, straight insertion, or welding. Connect the shielding layer or dedicated grounding wire to the preset grounding terminals (at least 2) in the female connector.

[0152] S34, Insert the female connector into the plug housing and secure it with bolts or clips;

[0153] S35, tighten the clamping nut of the gland head to make the cable clamp press against the outer sheath of the cable to achieve tensile strength and sealing effect;

[0154] S36, align the prepared plug side with the base side, use the polarity identification structure to prevent misinsertion, and lock it in place by a locking method selected from buckle, thread, bayonet, push-pull, lever.

[0155] S4: Inspection steps. After completing the electrical connection inspection, the construction is complete.

[0156] Visually inspect whether the heavy-duty connector 3 is properly locked in place and whether the gland is tightened. If possible, use a multimeter to measure the continuity and polarity of the critical circuit at terminal 2 inside the enclosure. Close the enclosure cover 5 and tighten all bolts.

[0157] The purpose of step S4 is to ensure that the construction quality meets the design specifications and to guarantee long-term operational reliability.

[0158] With this, the construction is now complete.

[0159] The beneficial effects of the present invention, through the design of the above embodiments, are as follows:

[0160] (1) Significant efficiency improvement: Traditional construction: 2 people × 4 hours = 8 person-hours / box. This invention: Factory prefabrication time is about 1.2 person-hours / box (batch advantage), and on-site construction time is 2 people × 0.5 hours = 1 person-hour / box. The overall efficiency improvement is about (8-1) / 8 = 87.5%. Even without considering factory time, the on-site efficiency improvement is about (4-0.5) / 4 = 87.5%, which is consistent with the conservative estimate of an improvement of about 70%.

[0161] (2) High quality consistency: The factory environment is constant temperature and humidity. Special crimping tools, torque screwdrivers and automatic testing equipment are used. The terminal crimping force and bolt torque can be quantitatively controlled to eliminate fluctuations caused by human factors.

[0162] (3) Improved protection level: Traditional IP55 (limited dust protection, limited water spray protection) → This invention is IP66 (strong dust protection, strong water spray protection) or even IP67 (short-term immersion). The sealing structure is clear, and there is no risk of aging and cracking due to glue aging.

[0163] (4) Convenient maintenance: Traditional maintenance requires opening the cover → cleaning the adhesive → disconnecting the wire → replacing the wire → applying adhesive → waiting for curing → closing the cover, which takes at least half a day. Maintenance of this invention only requires unplugging the old plug → plugging in the new plug, which can be completed in 2 minutes.

[0164] (5) Flexible configuration: The number of heavy-duty connectors can be customized from 2 to 7, the number of cores can be selected from 6 to 72, the voltage is AC 48V~600V / DC 24V~110V, and the current is 0.1A~16A, which can cover all common scenarios of railway signaling (track circuits, turnouts, signal lights, axle counters, transponders, etc.).

[0165] (6) Fault finding efficiency is not reduced: The internal wiring terminals (2) retain the testing convenience of traditional terminals. Maintenance personnel can open the box cover to measure on the terminals without unplugging the heavy-duty connector, thus avoiding interruption caused by measurement.

[0166] (7) Adapting to modern construction concepts: It fully complies with the modular prefabricated construction and work station balanced construction requirements promoted by China Railway Corporation. The on-site procedures are extremely simplified, which helps to shorten the track window time and improve railway transportation efficiency.

[0167] This invention has been described with reference to specific embodiments, but those skilled in the art will understand that various changes and equivalent substitutions can be made without departing from the scope of the invention. Furthermore, numerous modifications can be made to this invention to suit specific applications without departing from its protection scope. Therefore, this invention is not limited to the specific embodiments disclosed herein, but includes all embodiments falling within the scope of the claims.

Claims

1. A railway signal patch field cable box, characterized in that, include: The enclosure body (1) is used to accommodate the internal wiring terminals (2) and the internal grounding terminals (4) and to provide mechanical protection and electrical isolation; Internal wiring terminals (2) are fixedly installed inside the box body (1) and are used to connect the core wires of the signal cable to realize signal transmission; The internal grounding terminal (4) is fixedly installed inside the box body (1) and is used to connect the grounding wire of the signal cable to achieve grounding protection; Heavy-duty connector (3) includes a plug side and a base side, wherein the base side is fixedly installed on the side or bottom of the box body (1), and the plug side is used to connect with an external prefabricated cable plug; Box cover (5) is detachably installed on the top surface of the box body (1) for closing the box. The internal wiring terminal (2) is electrically connected to the base side of the heavy-duty connector (3) via an internal wire, and the internal grounding terminal (4) is electrically connected to the grounding terminal of the base side of the heavy-duty connector (3); the plug side includes a gland, a plug housing and a female ferrule, and the female ferrule is provided with at least two grounding terminals; the base side includes a base housing and a male ferrule; a polarity identification structure is provided between the male ferrule and the female ferrule.

2. The railway signal patch field cable distribution box of claim 1, wherein, The materials of the box body (1) and the box cover (5) are selected from one or more of the following: metallic materials, inorganic non-metallic materials, organic materials, or composite materials; wherein, metallic materials include cast aluminum alloy, die-cast zinc alloy, stainless steel, carbon steel, and brass; inorganic non-metallic materials include ceramic matrix composite materials and glass fiber reinforced cement; organic materials include polycarbonate, acrylonitrile-butadiene-styrene copolymer, polyamide, and polybutylene terephthalate; composite materials include sheet molding compound, bulk molding compound, glass fiber reinforced plastic, and carbon fiber reinforced plastic.

3. The railway signal patch field cable distribution box of claim 1, wherein, The fixing method of the internal wiring terminal (2) is selected from the following: bolt fixing, guide rail buckle fixing, riveting fixing, and snap ring fixing; the number of the internal wiring terminal (2) is 6 to 72; the wiring method of the internal wiring terminal (2) is selected from the following: screw crimping, spring clamping, cage spring connection, direct insertion connection, and insulation displacement connection.

4. The railway signal patch field cable distribution box of claim 1, wherein, The fixing method of the internal grounding terminal (4) is selected from the following: bolt fixing, guide rail buckle fixing, riveting fixing, and snap ring fixing; the number of the internal grounding terminals (4) is 2 to 6; the wiring method of the internal grounding terminals (4) is selected from the following: screw crimping, spring clamping, cage spring connection, and direct insertion connection.

5. The railway signal patch field cable distribution box of claim 1, wherein, The number of heavy-duty connectors (3) is 2 to 7, and their protection level is ≥ IP65; In the plug side of the heavy-duty connector (3), the number of female cores is 6 to 72, the current range is 0.1A to 16A, and the withstand voltage range is AC 48V to 600V and DC 24V to 110V; The locking method of the plug side and the base side of the heavy-duty connector (3) is selected from the following: snap-on locking, threaded locking, bayonet locking, push-pull locking, and lever locking.

6. The railway signal plug-in branch cable box according to claim 1, characterized in that, The connection method between the female plug and the cable core, and the connection method between the male plug and the internal conductor, are each independently selected from the following: direct insertion connection, plug-in connection, spring connection, screw connection, bolt connection, crimp connection, wrap connection, and welding connection.

7. The railway signal patch field cable distribution box of claim 1, wherein, The connection method between the box cover (5) and the box body (1) is selected from the following: bolt connection, pin connection, snap-on connection, hinge connection, quick clip connection; a sealing structure is provided between the box cover (5) and the box body (1), and the sealing structure is selected from the following: molded rubber sealing ring, foamed silicone sealing strip, liquid sealant injection, labyrinth seal, conductive rubber sealing ring; through the sealing structure, the overall protection level of the box reaches IP66 and above.

8. The railway signal patch field cable distribution box of claim 1, wherein, The polarity identification structure is selected from one of the following: foolproof keyway and key position, guide pins and guide holes of different diameters, asymmetrically arranged pins and holes, shell markings of different colors, magnetic code identification structure, and mechanical code identification structure.

9. A construction method of a railway signal plug-type branching cable box according to any one of claims 1 to 8, characterized by, Includes the following steps: S1, Factory prefabrication step, the assembly and internal wiring of the base side of the box body (1), internal wiring terminals (2), internal grounding terminals (4), heavy-duty connector (3) and box cover (5) are completed in the factory; S2, On-site installation steps: Fix the prefabricated box as a whole onto the installation bracket at the railway site; S3, on-site insertion step: directly insert and lock the pre-made heavy-duty connector (3) plug side to the base side fixed on the box; S4: Inspection steps. After completing the electrical connection inspection, the construction is complete.

10. The railway signal patch field cable distribution box of claim 1, wherein, In step S1, factory prefabrication further includes the following sub-steps: S11, the internal wiring terminal (2) and the internal grounding terminal (4) are installed in the box body (1) by a fixing method selected from bolts, guide rails, rivets and snap rings; S12, fix the base side of the heavy-duty connector (3) to the side or bottom of the box body (1) by bolts or rivets; S13, according to the electrical schematic diagram, use wires to electrically connect the internal terminal (2) to the corresponding core wire of the male plug on the base side. The connection method is selected from one of crimping, welding, screw crimping, and spring clamping. S14, make an electrical connection between the internal grounding terminal (4) and the grounding-specific core wire in the male connector on the base side; S15, after completing the internal connection, perform a 100% electrical continuity test and an insulation resistance test; S16, pre-install the box cover (5) on the box body (1) and temporarily or finally fix it using one of the following methods: bolts, pins, buckles, hinges, quick clips; In step S3, the preparation method of the plug side of the heavy-duty connector (3) includes the following sub-steps: S31, pass the end of the signal cable through the sealing ring, clamping nut and cable clamp of the gland; S32, strip the outer sheath of the cable to expose the core wire and shielding layer. The stripping length is determined according to the wiring requirements of the female core, and is 5mm to 15mm. S33. Connect the core wires to the corresponding sockets of the female connector according to the core sequence table. The connection method can be selected from crimping, screw, spring, straight insertion, or welding. Connect the shielding layer or dedicated grounding wire to the preset grounding terminals (at least 2) in the female connector. S34, Insert the female connector into the plug housing and secure it with bolts or clips; S35, tighten the clamping nut of the gland head to make the cable clamp press against the outer sheath of the cable to achieve tensile strength and sealing effect; S36, align the prepared plug side with the base side, use the polarity identification structure to prevent misinsertion, and lock it in place by a locking method selected from buckle, thread, bayonet, push-pull, lever.

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