An electrical cabinet cable connection tension test tool and test method

Abstract

The application discloses an electric appliance cabinet cable connection tension test tool and a test method, and belongs to the tension detection technical field. The application solves the problem that there is currently a lack of detection tools that can simultaneously realize universal clamping of multiple types of terminals, standard tension force feedback and detection-training-examination integration. The tool body in the application includes a plurality of tension detection components, each tension detection component includes a terminal connection mechanism, a tension detection mechanism connected with the terminal connection mechanism, and a terminal connection line component; the terminal connection line component includes a plurality of terminal connection lines, each terminal connection line is different in at least one of terminal shape, terminal size and wire diameter; the terminal connection mechanism includes a base connected with the tension detection mechanism, and at least one terminal connecting piece adapted to the corresponding terminal shape and terminal size is arranged on the base. The application can help the operator to quickly establish the muscle memory of the corresponding standard tension of different terminals and wire diameters, and realize the detection-training-examination integration.

Description

Technical Field

[0001] This invention belongs to the field of tensile testing technology, specifically relating to a tensile testing fixture and method for electrical cabinet cable connections. Background Technology

[0002] In the electrical systems of rail transit vehicles, terminals, as key connecting components between wires and electrical elements, directly affect the safety and reliability of the entire vehicle's operation due to their mechanical connection strength. According to current standards such as GB / T 14048.7-2020, IEC 60947-7-1:2018, and UL 486E-2023, 0.50 mm... 2 The minimum pull-out force for the conductor is 50 N, 0.75 mm. 2 80 N, 1.00 mm 2 100 N, 1.50 mm 2 150 N, 2.50 mm 2 200 N, 4.00 mm 2 270 N, 6.00 mm 2 450 N, 10.00 mm 2 A force of 500 N is required, and this force value is widely used in traction systems, high-voltage circuits, and control circuits, especially for 6 mm... 2 Strict constraints are imposed on the connection reliability of terminals with wire diameters of 200 mm and above.

[0003] In existing technologies, the inspection of terminal crimping quality generally relies on manual pulling operations. The operator's subjective feel determines whether the standard pull-out force requirement is met. This method suffers from drawbacks such as a lack of objectivity in the inspection results, significant differences in perception thresholds among different personnel, and poor consistency in judgment. Furthermore, existing testing fixtures mostly employ rigid clamping structures, adapting only to a single terminal type and unable to accommodate the widely used Φ4 mm to Φ8 mm terminals in rail vehicles. For mm ring-shaped and tubular terminals, frequent changes of specialized clamps are required for type conversion, resulting in low efficiency. Furthermore, existing devices only provide tensile force measurement and lack a force feedback system corresponding to standard force values. Operators cannot develop standardized force memory through repeated operations, hindering continuous calibration of testing capabilities. The testing process is disconnected from personnel training, and test results rely on manual comparison with standard tables, making it prone to misreading or missed detections, leading to defective products entering the assembly stage. Although some patents disclose terminal tensile force testing devices, such as CN224500188U, CN223597378U, CN224247292U, CN119043914A, and CN119880626A, their technical solutions still lack a systematic integration of force training mechanisms and universal clamping structures. Therefore, there is an urgent need for a testing fixture that can simultaneously achieve universal clamping of multiple types of terminals, standard tensile force feedback, and integrated testing-training-assessment to meet the compliance, consistency, and traceability requirements for connection reliability testing in the rail transit manufacturing field. Summary of the Invention

[0004] To address the problem of how to obtain a testing fixture that simultaneously achieves universal clamping of multiple types of terminals, standard tensile force feedback, and integrated testing-training-assessment in existing technologies, this invention provides a tensile testing fixture and method for electrical cabinet cable connections.

[0005] The technical solution adopted in this invention is as follows:

[0006] An electrical cabinet cable connection tensile testing fixture includes a fixture body, the fixture body including several tensile testing components, each tensile testing component including a terminal connection mechanism, a tensile testing mechanism connected to the terminal connection mechanism, and a terminal connection wire assembly;

[0007] The terminal connection wire assembly includes several terminal connection wires, and each terminal connection wire is different in at least one of the following: terminal shape, terminal size, and wire diameter;

[0008] The terminal connection mechanism includes a base connected to a tensile testing mechanism. At least one terminal connector adapted to the shape and size of the corresponding terminal is provided on the base. The terminal connection wire assembly is detachably connected to the terminal connector.

[0009] By adopting this technical solution, several tensile testing components are set on the tooling body. Each component is equipped with an independent terminal connection mechanism, tensile testing mechanism, and terminal connection wire assembly. The terminal connection wire assembly contains multiple terminal connection wires that differ in at least one of the terminal shape, terminal size, and wire diameter. At the same time, terminal connectors that are adapted to the terminal shape and size are set on the base connected to the tensile testing mechanism. This achieves one-stop compatible testing of multiple terminal specifications without the need for frequent changes of special fixtures, greatly expanding the applicable scenarios of the tooling. It effectively solves the industry pain point that traditional tooling can only adapt to a single terminal specification. The multi-component parallel structure can support multiple tasks. This synchronous operation significantly improves the testing efficiency in the production of multi-variety, small-batch wire harnesses for rail transit electrical cabinets, greatly reducing measurement errors caused by manual operation. At the same time, while completing compliant tensile testing, this structure helps operators quickly develop muscle memory for the standard tensile force corresponding to different terminals and wire diameters, realizing the integration of testing and force training. This reduces human error at the source and ensures the long-term operational reliability of electrical cabinet cable connections. Moreover, the overall modular and compact design has no complex and redundant structure, and each component can be disassembled and replaced individually, resulting in low maintenance costs. It can be quickly implemented without additional modifications to existing electrical cabinet wire harness assembly production lines.

[0010] Preferably, the terminal connection wire assembly includes a terminal connection wire with tubular terminals, and the terminal connector includes a tubular terminal connector, the tubular terminal connector including a pressure block detachably connected to the base, the pressure block also being provided with a fixing member for fixing the tubular terminals.

[0011] After adopting this technical solution, the detachable structure is easy to maintain in the later stage. If the terminal connection wire is damaged, it can be replaced in time, which effectively reduces the maintenance cost of the tooling throughout its entire life cycle and further improves the practicality and economy of the tooling in mass production testing scenarios.

[0012] Preferably, when the pressure block is connected to the base, a receiving groove is formed between the base and the pressure block. The pressure block is provided with an abutment bolt connection hole corresponding to the receiving groove. The abutment bolt connection hole communicates with the receiving groove. The fixing member is an abutment bolt that is threadedly connected to the abutment bolt connection hole.

[0013] After adopting this technical solution, the receiving groove can form a precise circumferential surrounding limit for the tubular terminal. With the abutment bolt screwed into the abutment bolt connection hole, a uniform and controllable clamping force can be applied to the outer wall of the tubular terminal from the radial direction. This completely avoids the axial movement and circumferential slippage problems that occur when clamping tubular terminals with traditional fixtures. It ensures that the terminal always maintains a pure axial force state during the tensile test, eliminates the test data deviation caused by lateral force from the root of the clamping structure, ensures that the tensile value fully meets the standard requirements, and greatly improves the stability and repeatability of the test results.

[0014] Preferably, the pressure block is bolted to the base.

[0015] Preferably, the terminal connection wire assembly includes a terminal connection wire with an annular terminal, and the terminal connector includes an annular terminal connector, wherein the annular terminal connector includes a connecting post connected to the base, and the diameter of the connecting post matches the inner diameter of its corresponding annular terminal.

[0016] After adopting this technical solution, the connecting post with a diameter that precisely matches the inner diameter of the annular terminal can be directly inserted into the inner hole of the annular terminal to achieve zero-play positioning, completely avoiding the slippage and skew problems that are easy to occur when the traditional clamp holds the outer wall of the annular terminal, and making the tensile loading direction completely coincide with the terminal axis, eliminating the interference of lateral force on the test data from the structural root, and ensuring the accuracy and consistency of the tensile test results.

[0017] Preferably, the tooling body also includes a base, and several tensile testing components are disposed on the base. The tensile testing mechanism of each tensile testing component includes two tensile sensors connected to the base, and the force-receiving ends of the two tensile sensors are respectively connected to the two ends of the base.

[0018] With this technical solution, the integrated base provides a high-rigidity installation benchmark for the entire fixture, allowing for the orderly integration of multiple tensile testing components of different specifications. This avoids the need for dispersed testing units to occupy excessive workspace, resulting in a compact and stable overall structure that is highly adaptable to limited workshop space. Simultaneously, the base effectively counteracts the reaction force generated during tensile loading, preventing the fixture from shifting or tipping over, ensuring operational safety and stability during the testing process. The structural design, featuring dual tensile sensors symmetrically arranged at both ends of the base, enables simultaneous dual-side tensile force acquisition. Compared to traditional single-sensor solutions, this not only doubles the overall range redundancy and effectively avoids the risk of single-sensor overload damage, but also automatically identifies abnormal conditions such as uneven loading or uneven stress on the base through real-time comparison of dual-side data. This eliminates data deviation caused by unilateral force at its source, significantly improving the accuracy and stability of tensile force acquisition. Furthermore, the dual-sensor symmetrical force application structure allows the base to maintain a horizontal and stable displacement throughout the entire process, preventing unilateral tilting or tilting. This ensures that the terminals under test clamped on the base are always under pure axial force, completely eliminating terminal slippage and data jumps caused by base misalignment, significantly reducing the probability of invalid tests and improving the smoothness of batch testing.

[0019] Preferably, the tensile testing mechanism is also electrically connected to a control system, which is electrically connected to an operation display screen, a work indicator light, and a voice broadcaster. The real-time tensile display screen, work indicator light, and voice broadcaster are located on or around the tooling body.

[0020] After adopting this technical solution, the fully visualized operation display screen can dynamically display the current tensile force value in real time, allowing for an intuitive understanding of the current test status and completely avoiding the risk of misjudgment caused by manual reading and table lookup. Through the operation display screen, training mode or assessment mode can be selected, and parameters such as the terminal type and wire diameter to be trained can be selected. The voice broadcaster can broadcast success prompts, start training prompts, etc.

[0021] A method for testing the tensile strength of terminal blocks, based on a tensile strength testing fixture for electrical cabinet cable connections, includes a training mode and an assessment mode. The tensile strength testing method in the training mode includes the following steps:

[0022] S101: Select either basic training mode or advanced training mode, and select the terminal type and wire diameter to be trained according to the training requirements. The terminal type and wire diameter will be automatically and randomly selected, and the position of the terminal connection wire will be determined automatically based on the selection result.

[0023] S102: Pull each terminal connection wire in sequence. When the basic training mode is selected, the real-time pulling force and the number of training times corresponding to that terminal connection wire are displayed each time the tubular terminal is pulled. When the pulling force reaches the standard pulling force range, a success signal is issued, and the training of that terminal connection wire ends after it is detected that it is held for more than 1 second. This process is repeated until all terminal connection wires are trained. When the advanced training mode is selected, it automatically judges whether the standard pulling force range has been reached. When it is detected that it is held for more than 1 second, the training of that terminal connection wire ends and the training data is recorded.

[0024] The tensile testing method for the assessment mode includes the following steps:

[0025] S201: Automatically and randomly selects the terminal type and wire diameter, and automatically selects the position of the corresponding terminal connection wire according to the selection result;

[0026] S202: Pull each terminal connection wire in sequence and judge whether the standard tension range is reached. When the measured tension value is maintained for more than 1 second, the test score is obtained based on the difference between the measured tension value and the standard tension range and the standard tension value.

[0027] After adopting this technical solution, the dual-mode terminal tensile testing method based on the aforementioned tooling breaks through the single-function limitation of traditional tensile testing, which can only complete numerical measurement. It deeply integrates standardized force perception training, ability assessment, and compliance testing. By dividing the training into basic and advanced training modes, it constructs a hierarchical and progressive force perception training path. In the basic mode, the tensile force value and training count are displayed in real time. When the tensile force enters the standard range, a success prompt is triggered, guiding novice operators to quickly establish muscle memory of the standard tensile force corresponding to different terminals and wire diameters. This completely solves the pain points of long training cycles and large differences in force perception in the traditional experience-based training model. In the advanced mode, the real-time tensile force prompt is turned off, and the process ends only after the tensile force reaches the standard and is held stably for 1 second. This forces operators to move away from numerical assistance and rely entirely on their hand touch to autonomously control the tensile force. This gradually forms a standardized force perception memory that does not require instrument assistance, realizing a leap from numerical operation to precise hand feel. Meanwhile, the assessment mode employs a system that randomly selects terminal types and wire diameters, completely avoiding the test-oriented training loopholes inherent in traditional assessments with fixed questions. It realistically replicates the actual working conditions of random testing of multiple terminal specifications on the production line. Operational data is automatically recorded during the assessment, and quantitative scores are directly output upon completion, completely eliminating the bias of subjective scoring in traditional manual assessments. This achieves standardized and quantifiable evaluation of personnel's testing capabilities, providing an objective and traceable basis for the qualification certification of production line operators. The 1-second hold-on-the-fly rule after achieving the required tensile strength avoids misjudgments caused by operators rapidly pulling the wires.

[0028] As a preferred option, the system automatically generates a set of 5 terminal types and wire diameters. The tester then locates the corresponding cable position on the device based on the selected terminal type and wire diameter (by judging the cable diameter and terminal type on the device; the cable diameter is marked on the cable, thus simulating the actual work scenario of personnel in maintenance and the process of self-judgment).

[0029] As a preferred option, the assessment mode can generate a final score, with the score report automatically created with the individual's account and printable. This device can serve as a component of the annual skills assessment for operators, enriching the assessment methods and content.

[0030] As a preferred option, the S202 assessment results include two forms: The first form is that if the measured tensile force exceeds the standard tensile force range or the terminal connection wire is selected incorrectly, the assessment for that terminal connection wire is immediately terminated, and the assessment score is 0 points; the second form is that if the measured tensile force is within the standard tensile force range, the assessment score is calculated according to the following formula, with a minimum score of 60 points and a maximum score of 100 points:

[0031] Calculate the standard tensile test result according to formula (1). , The value ranges from 0 to 100:

[0032] (1)

[0033] in, To measure the tensile force value, This is the standard tensile force value;

[0034] Calculate the lower limit of the tensile force according to formula (2). , The value ranges from 0 to 100:

[0035] (2)

[0036] in, This is the lower limit of the tensile force.

[0037] Calculate the upper limit of the pulling force according to formula (3). , The value ranges from 0 to 100:

[0038] (3)

[0039] in, This is the upper limit of the tensile force;

[0040] Calculate the assessment score according to formula (4) Y :

[0041] (4).

[0042] As a preferred option, the training data recorded in the advanced training mode of S102 includes the measured tensile force value, the highest tensile force value, the lowest tensile force value, and the median tensile force value.

[0043] Preferably, the standard tensile force range is ±8% to 20% of the standard tensile force value, and the standard tensile force value corresponds to 60% of the minimum pull-out force of the terminal connection wire.

[0044] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0045] This fixture supports direct clamping of tubular terminals, ring terminals, etc., eliminating the need for frequent changes of specialized clamps. It features fast clamping speed and high testing efficiency. Utilizing a symmetrical dual-force sensor installation structure, it ensures accurate force data acquisition, preventing off-center loading and maintaining stable test results over the long term. Equipped with an operation display screen, indicator lights, and voice broadcaster, it provides prompts throughout the operation process, eliminating the need for repeated reference to the manual. Even beginners can quickly learn to use it. It includes both training and assessment modes, allowing newcomers to practice without occupying the production line's formal testing equipment, significantly shortening the training cycle. The multi-component parallel structure supports simultaneous operation at multiple workstations, significantly improving testing efficiency in scenarios involving the production of various types and small batches of wire harnesses for rail transit electrical cabinets. It also greatly reduces measurement errors caused by manual operation. Simultaneously, this structure helps operators quickly develop muscle memory for the standard tensile forces corresponding to different terminals and wire diameters while performing compliant tensile force testing, achieving integrated testing and force perception training. This fundamentally reduces human error and ensures the long-term operational reliability of electrical cabinet cable connections. Furthermore, the overall modular and compact design eliminates complex and redundant structures, allowing for individual disassembly and replacement of each component, resulting in low maintenance costs. Attached Figure Description

[0046] Figure 1 This is a top view of the tooling body in this invention when no pressure block is provided;

[0047] Figure 2 This is a cross-sectional view of the tooling body with a pressure block installed in this invention;

[0048] Figure 3 This is a circuit diagram of the PCL in this invention;

[0049] Figure 4 This is an interface diagram showing the tensile process defined in this invention.

[0050] Figure 5 This is an interface diagram for setting analog quantities in this invention;

[0051] Figure 6 This is an interface diagram of channel coefficient calibration in this invention;

[0052] Figure 7 This is an interface diagram of zero-point calibration in this invention;

[0053] Figure 8 This is an interface diagram of the basic training parameter settings in this invention;

[0054] Figure 9 This is an interface diagram of the basic training operation display screen in this invention;

[0055] Figure 10 This is an interface diagram of the basic training tensile force recording in this invention;

[0056] Figure 11This is an interface diagram of the advanced training parameter settings in this invention;

[0057] Figure 12 This is an interface diagram of the real-time recording of advanced training in this invention;

[0058] Figure 13 This is an interface diagram of the advanced training tensile force recording in this invention;

[0059] Figure 14 This is an interface diagram of the advanced training results in this invention;

[0060] Figure 15 This is a screenshot of the interface at the start of the assessment mode in this invention;

[0061] Figure 16 This is an interface diagram of the current round's tensile strength performance in the assessment mode of this invention;

[0062] Figure 17 This is a diagram of the performance report for the assessment mode in this invention;

[0063] Among them, 1-base, 2-tension sensor, 3-base platform, 4-connecting column, 5-accommodating groove, 6-pressure block, 7-terminal connecting wire. Detailed Implementation

[0064] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely represents selected embodiments of this application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0065] In the description of the embodiments of this application, it should be noted that the terms "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0066] Example 1

[0067] like Figure 1-2 As shown, an electrical cabinet cable connection tensile testing fixture includes a fixture body, which includes a base 1. In this embodiment, the base 1 is 300mm long, 128.5mm wide, and 125mm high. The fixture body includes four tensile testing components. Each tensile testing component includes a terminal connection mechanism, a tensile testing mechanism connected to the terminal connection mechanism, and a terminal connection wire assembly.

[0068] The terminal connection wire assembly includes 16 terminal connection wires 7. Each terminal connection wire 7 is different in at least one of the following: terminal shape, terminal size, and wire diameter. The shape, wire diameter, and corresponding standard tensile strength data of each terminal connection wire 7 are shown in Table 1. The terminal connection wire assembly covers the full range of wire diameters from 0.5mm to 6mm commonly used in rail transit electrical cabinets. It also includes all mainstream terminal types such as tubular open terminals and circular closed ring terminals, and fully matches the specifications of all types of wire harnesses that are assembled on the production line daily.

[0069] In this embodiment, there are a total of 16 terminal connection wires 7, and their standard pressures are shown in Table 1:

[0070] Table 1

[0071]

[0072] The terminal connection mechanism includes a base 3 connected to the tensile testing mechanism, such as... Figure 1 As shown in this embodiment, each of the four bases 3 is provided with four terminal connectors that are adapted to the corresponding terminal shapes and sizes;

[0073] In this embodiment, as Figure 1 and 2As shown, the terminal connector includes a tubular terminal connector, which includes a pressure block 6 detachably connected to the base 3 by bolts. The pressure block 6 is also provided with a fixing member for fixing the tubular terminal. When the pressure block 6 is connected to the base 3, a receiving groove 5 is formed between the base 3 and the pressure block 6. Specifically, the base 3 is provided with a first groove, and the pressure block 6 is provided with a second groove that mates with it. The first groove and the second groove together form the receiving groove 5. The size of the receiving groove 5 is set according to the size of different tubular terminals so that the tubular terminal can fit snugly. The pressure block 6 is connected to the receiving groove 5. A connecting hole for the abutment bolt is provided on the pressure block 6 at the location corresponding to the receiving groove 5. The connecting hole for the abutment bolt is connected to the receiving groove 5. The fixing member is an abutment bolt that is threaded to the connecting hole for the abutment bolt. The size of the connecting hole for the abutment bolt and the abutment bolt are also set according to the size of the tubular terminal. In a preferred case, the diameter of the abutment bolt is equal to or slightly larger than the diameter of the tubular terminal. In other embodiments, the end of the abutment bolt can also be provided in an arc-shaped groove that fits the tubular terminal to increase the contact surface between the abutment bolt and the tubular terminal and improve the fixed connection.

[0074] In this embodiment, the terminal connection wire assembly includes a terminal connection wire 7 with a ring-shaped terminal, and the terminal connector includes a ring-shaped terminal connector. The ring-shaped terminal connector includes a connecting post 4 connected to the base 3. The connecting post 4 has a cylindrical structure, and the diameter of the connecting post 4 matches the inner diameter of its corresponding ring-shaped terminal, so that the ring-shaped terminal can be sleeved on the connecting post 4.

[0075] In this embodiment, four tensile testing components are arranged horizontally in a row on the base 1, with all four components at the same horizontal height and equal spacing between adjacent components. The four tensile testing components are configured from left to right according to their range gradient, each adapting to the testing requirements of different terminal specifications: the first tensile testing component is equipped with two 10kg high-precision tensile sensors 2, suitable for low tensile threshold testing of small-diameter terminals, with dual tensile sensors 2 arranged symmetrically on both sides to collect data synchronously. The second and third tensile testing components are each equipped with two 25kg high-precision tensile sensors 2, suitable for general tensile testing of conventional wire diameter terminals, representing the main tensile range for daily testing on the production line. The redundant design of the dual tensile sensors 2 effectively avoids the risk of single-sensor overload damage under high-frequency use, resulting in stronger long-term operational stability. The fourth tensile testing component is equipped with two 50kg high-precision tensile sensors 2, adapted for high tensile threshold testing of large-diameter heavy-duty terminals. Its symmetrical force-bearing structure prevents the base from tilting under heavy tensile loads, ensuring accurate and reliable test data even under high loads. The fixed ends of all the tensile sensors 2 are bolted to the base 1, and the force-bearing ends of the two sensors 2 are bolted to the left and right ends of the corresponding base 3. During testing, the two sensors 2 can simultaneously collect tensile data, doubling the overall range redundancy and automatically identifying whether the base is unevenly loaded through real-time comparison of the data from both sides. This ensures the base maintains a horizontal and stable displacement throughout the test, preventing unilateral tilting or lifting. From a hardware perspective, this guarantees the accuracy and consistency of tensile testing data across the entire range, fully meeting the stringent accuracy requirements of the rail transit industry for terminal tensile testing.

[0076] In this embodiment, as Figure 1 As shown, to accommodate the range gradient configuration of the tension sensor 2, the first base 3 from left to right has four receiving slots 5, meaning that four tubular terminal connecting wires can be connected to the first base 3; the second base 3 has three receiving slots 5 and one connecting post 4 (located between the second and third receiving slots), meaning that three tubular terminal connecting wires and one annular terminal connecting wire can be connected to the second base 3; the third base 3 has four receiving slots 5, meaning that four tubular terminal connecting wires can be connected to the third base 3. Figure 1 It can be seen that the size of the receiving groove 5 on the third base 3 is significantly larger than the size of the receiving groove 5 on the first base 3; the fourth base 3 is provided with 4 connecting posts 4, that is, 4 ring-shaped terminal connecting wires can be connected to the fourth base 3. Figure 2As shown, when the terminal connection line 7 is connected to the base 3, the terminal connection line 7 is located on the horizontal extension line of the middle of the tension sensor 2. The self-weight of the base 3 and its auxiliary structures is downward. The tension sensor 2 detects the horizontal tension when the terminal connection line 7 is pulled. That is, the tension sensor 2 detects the horizontal tension component. The self-weight of the base 3 and its auxiliary structures is a vertically downward force. The two are perpendicular to each other in physical dimension and will not be directly superimposed on the measured value of the horizontal tension. However, the self-weight of the base 3 will directly increase the vertical normal force on the detection surface. According to the sliding friction formula f=μN, the sliding friction of the contact surface will increase accordingly. Finally, the horizontal tension measured by the tension sensor 2 will include this additional friction force, which will bring about systematic error. In order to eliminate systematic error, the tension sensor 2 can be zeroed under no-load in the horizontal installation state according to the specification to offset the initial deformation error caused by the self-weight of the base 3 and its auxiliary structures.

[0077] In another embodiment, all eight signal outputs of the tension sensor 2 of the tension detection components are connected to a matching signal amplifier via shielded cables to amplify the millivolt-level weak signals. These signals are then aggregated and connected to an industrial-grade control system composed of a Siemens S7-200 SMARTSR20 AC / DC / RLY main control unit and an EM AE08 (6ES7 288-3AE08-0AA0) analog expansion module (control logic as follows). Figure 3 As shown in the figure, relying on the industrial-grade anti-interference performance of the PLC, it can operate stably under the complex working conditions of strong electromagnetic interference in the workshop, and process the tensile data of all four groups of components in real time.

[0078] The control system's peripheral interfaces are electrically connected to a high-definition touchscreen display, indicator lights, and a high-definition voice announcer. All interactive components are conveniently located on the upper part of the fixture or in the surrounding operating area. The high-definition display screen dynamically shows the current tensile force value and current training count of the four components in real time. The display screen also allows selection of training or assessment modes, training counts, and terminal types. Hierarchical indicator lights use different colors and flashing frequencies to intuitively reflect the standby, testing, pass, and fail status of the corresponding components. Even in noisy workshop environments, operators can quickly identify the test status through light signals, even if their eyes are not focused on the display screen. The voice announcer automatically issues standardized voice prompts at key points such as test completion, tensile force exceeding limits, and equipment malfunction, completely solving the problem of insufficient visibility of purely light-based prompts in high-noise workshop environments. This provides dual-dimensional visual and auditory status feedback, significantly reducing operator fatigue.

[0079] Meanwhile, this PLC control system can automatically store all data from each test. Leveraging the native industrial Ethernet communication capabilities of the S7-200 SMART, it can directly interface with the workshop MES system to automatically generate traceable inspection reports, fully meeting the compliance requirements of the rail transit industry for end-to-end product quality traceability. The additional dual-sensor verification logic can compare the values ​​collected by the two sensors for each tension component in real time. When the difference exceeds a set threshold, it automatically determines an off-center load fault and triggers an alarm to lock the test process, further improving the safety and data accuracy of the testing process.

[0080] Example 2

[0081] A method for testing the tensile strength of wiring terminals is based on the electrical cabinet cable connection tensile strength testing fixture of Embodiment 1. It should be noted that the testing fixture of Embodiment 1 is assembled in advance before use, and the corresponding terminal connection wires 7 on each base 3 are numbered sequentially. The terminal type, wire diameter, standard tensile strength and other information of each numbered terminal connection wire 7 are input into the control system (as shown in Table 1). The control system automatically moves the device according to the preset information. The method includes training mode and assessment mode.

[0082] The operating method of this device is as follows:

[0083] 1. Scope of application

[0084] This is used to train operators to pull on the terminals and improve their terminal inspection skills.

[0085] 2. Main Technical Parameters

[0086] Input voltage: AC220V (1±10%), 50Hz;

[0087] Tensile force measurement range: 0~500N;

[0088] Tensile force measurement accuracy: ±0.5% FS

[0089] Applicable wire diameter range: 0.5mm² ~ 16mm²;

[0090] Applicable terminal types: metal ring tubular terminals, pre-insulated OT terminals;

[0091] Training / Assessment Frequency: 5, 10, or 15 sessions (Basic / Advanced Training); 5 sessions (Assessment Training)

[0092] Display method: LCD screen, displaying tension value and training progress in real time.

[0093] Indication method: Green indicator light + voice prompt + buzzer sound

[0094] Data storage: Supports automatic recording of training / assessment scores and automatic storage of assessment scores.

[0095] 3. The device has the main functions

[0096] Standard values ​​for pull-out force of terminal and wire crimping are queried and determined.

[0097] Basic training mode: assists operators in developing a tactile understanding of the inspection force corresponding to different terminals and wire diameters.

[0098] Advanced training (blind pull) mode: Deep training of pulling force judgment ability without visual cues.

[0099] Assessment and training mode: Randomly select 5 combinations of terminals and wire diameters to conduct a comprehensive assessment of the operators and automatically score them.

[0100] Real-time tensile force display and voice-guided announcement.

[0101] Training / assessment results are automatically recorded, including statistical information such as actual pulling force value, maximum value, minimum value, and median value for each session.

[0102] The buzzer and green indicator light on the tooling provide immediate feedback on whether the tension is within the specified range.

[0103] 4. Software Operation Instructions

[0104] S101: Double-click the "Terminal Block Tensile Testing Fixture" shortcut on the desktop or Start Menu to bring up the user login dialog box; enter the correct username and password to enter the main screen. After logging in as an administrator, you can add process engineers and operators in the user management program. The menu functions differ depending on the user's permissions.

[0105] Pressing the tensile process setting button will bring up the tensile process setting program. This program allows you to add, delete, modify, and search for wire diameter, terminal type, etc., as well as set the effective tensile force time and range for basic, advanced, and evaluation levels. The interface is as follows: Figure 4 As shown;

[0106] Pressing the analog input setting button will bring up the analog input setting program. Within this program, you can modify and calibrate information such as the zero point and proportional coefficient. The user interface is as follows: Figure 5 As shown;

[0107] Pressing the calibration button will bring up the channel coefficient calibration program. Using this program with the appropriate fixtures, the zero point and proportional coefficient can be determined. The user interface is as follows: Figure 6 As shown;

[0108] Note: When measuring the zero point, the calibration tension (N) must be kept at 0. When measuring the proportional coefficient, the calibration tension (N) must not be 0 and must be consistent with the actual force applied on the corresponding channel.

[0109] When measuring zero point, such as Figure 6 As shown, select channel number 1 and calibrate tension (N) to 0;

[0110] Click the zero-point calibration button, then click the save button. The interface will look like this. Figure 7 As shown;

[0111] The system displays a successful save and indicates that the zero point of channel 1 has changed. Repeat the steps to measure the zero points and scale factors of other channels, but instead of the scale factor, click the scale factor calibration button.

[0112] Pressing the User Management button will bring up the User Management program;

[0113] The program has three user levels: administrators can set all experimental parameters, process engineers have all permissions except for simulation settings and user management, and experimental personnel only have basic training and advanced training permissions.

[0114] Clicking on the user row you want to operate on will automatically fill the user's data into the input box on the right. After modifying the data, pressing the modify button will write the new data into the database; pressing the delete button will clear the current user.

[0115] Connect the 16 terminal connecting wires 7 to each base 3 in advance. During use, press the basic training button to bring up the basic training parameter setting program. This program allows you to select the wire gauge and terminal type, and specify the position of the tooling cables used for training. Its interface is shown below. Figure 8 As shown;

[0116] S102: The operator clicks [Start Training] and pulls each terminal connection wire 7 horizontally in sequence. When the basic training mode is selected, the operation display screen shows the pulling force value and "Xth time" in real time each time the tubular terminal is pulled. Figure 9 As shown in the image, when the tension reaches the standard tension range, the green indicator light on the fixture illuminates and emits a "beep" success sound. After detecting and maintaining the tension for more than one second, the training of terminal connection 7 ends. This process is repeated until all terminal connection 7s are trained. At the end of this round of training, a basic training tension recording program pops up. This program records the results of this round of training, and its interface is shown in the image. Figure 10 As shown:

[0117] When advanced training mode is selected, pressing the advanced training button will bring up the advanced training parameter setting program. This program allows you to select the wire gauge and terminal type, and specify the location of the tooling cable used for training. Its interface is as follows: Figure 11 As shown; select the terminal and wire diameter to be trained (voice prompt "Please select the terminal and wire diameter to be trained"). Select the number of times for this round of tensile training (optional: 5, 10, or 15 times; voice prompt "Please select the number of training times"). Click [Start Training], voice prompt "Start Training" and "Please turn the monitor to the back", the advanced training real-time recording program will pop up, the interface will display the tensile value and "Xth time" in real time, as shown in the details. Figure 12 As shown; the personnel begin blind pull training. When the personnel's pulling force reaches the standard pulling force range and is maintained for more than 1 second, the tool records the completion of one training session. When the personnel complete the set number of repetitions, a voice announces "This round of training is over," and the advanced training pulling force recording program pops up, with the interface as shown. Figure 13 As shown; the interface displays the pulling force results for this round, including the actual pulling force values ​​from the 1st to the Nth round, the highest value, the lowest value, and the median value. Pressing the assessment and training button will bring up the start assessment program. This program aims to assess the operator's pulling force control ability and provide a score, such as... Figure 14 As shown.

[0118] The tensile testing method for the assessment mode includes the following steps:

[0119] S201: The display screen enters the training interface. Click on [Assessment Training]. The tooling will automatically and randomly select 5 types of terminals and wire diameters. The interface will display these 5 types of terminals and wire diameters (each type of terminal and wire diameter will undergo one tensile test, for a total of 5 tests; press the refresh test question button to update the test questions). Click on [Start Assessment]. The voice will announce "Start Assessment." The operation interface is as follows: Figure 15 As shown;

[0120] S202: Pull each terminal connection 7 horizontally in sequence, automatically judging whether the standard tensile force range has been reached. Once the tension is maintained for more than 1 second, the assessment for that terminal connection 7 ends. After all 5 assessments are completed, a voice announcement will say "This round of assessment is over." If the tension is not maintained within the allowable fluctuation range for more than 1 second within the limited time, the fixture records one training session completed, scoring 0 points. After all 5 sessions are completed, a voice announcement will say "This round of assessment is over." The display screen shows the tensile force score for this round (operation interface as shown). Figure 16 (As shown), the tensile test score includes whether the cable position is correct in these 5 tests, the measured tensile force values ​​from the 1st to the 5th test, the highest value, the lowest value, and the median value. If the measured tensile force value exceeds the standard tensile force range or the cable position is incorrect, the score is 0. If the measured tensile force value is within the standard tensile force range, the score is calculated according to the following formula, with a minimum score of 60 points and a maximum score of 100 points:

[0121] Calculate the standard tensile test result according to formula (1). , The value ranges from 0 to 100:

[0122] (1)

[0123] in, To measure the tensile force value, This is the standard tensile force value;

[0124] Calculate the lower limit of the tensile force according to formula (2). , The value ranges from 0 to 100:

[0125] (2)

[0126] in, This is the lower limit of the tensile force.

[0127] Calculate the upper limit of the pulling force according to formula (3). , The value ranges from 0 to 100:

[0128] (3)

[0129] in, This is the upper limit of the tensile force;

[0130] Calculate the assessment score according to formula (4) Y :

[0131] (4).

[0132] The final report card is as follows Figure 17 As shown.

[0133] The embodiments described above merely illustrate specific implementation methods of this application, and while the descriptions are detailed and specific, they should not be construed as limiting the scope of protection of this application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the technical solution of this application, and these modifications and improvements all fall within the scope of protection of this application.

Claims

1. A fixture for testing the tensile strength of electrical cabinet cable connections, characterized in that: The tooling body includes several tensile testing components, each of which includes a terminal connection mechanism, a tensile testing mechanism connected to the terminal connection mechanism, and a terminal connection wire assembly. The terminal connection wire assembly includes several terminal connection wires (7), and each terminal connection wire (7) is different in at least one of terminal shape, terminal size, and wire diameter; The terminal connection mechanism includes a base (3) connected to a tensile testing mechanism. At least one terminal connector adapted to the shape and size of the corresponding terminal is provided on the base (3). The terminal connection wire assembly is detachably connected to the terminal connector.

2. The electrical cabinet cable connection tensile testing fixture according to claim 1, characterized in that: The terminal connection wire assembly includes a terminal connection wire (7) with tubular terminals, and the terminal connector includes a tubular terminal connector, the tubular terminal connector including a pressure block (6) detachably connected to the base (3), the pressure block (6) also being provided with a fixing member for fixing the tubular terminals.

3. The electrical cabinet cable connection tensile testing fixture according to claim 2, characterized in that: When the pressure block (6) is connected to the base (3), a receiving groove (5) is formed between the base (3) and the pressure block (6). Abutment bolt connection hole is provided on the pressure block (6) at the location corresponding to the receiving groove (5). The abutment bolt connection hole is connected to the receiving groove (5). The fixing member is an abutment bolt that is threadedly connected to the abutment bolt connection hole.

4. The electrical cabinet cable connection tensile testing fixture according to any one of claims 1-3, characterized in that: The terminal connection wire assembly includes a terminal connection wire (7) with an annular terminal, and the terminal connector includes an annular terminal connector, the annular terminal connector including a connecting post (4) connected to the base (3), the diameter of the connecting post (4) matching the inner diameter of its corresponding annular terminal.

5. The electrical cabinet cable connection tensile testing fixture according to any one of claims 1-3, characterized in that: The tooling body also includes a base (1), and several tensile testing components are disposed on the base (1). The tensile testing mechanism of each tensile testing component includes two tensile sensors (2) connected to the base (1). The force-bearing ends of the two tensile sensors (2) are respectively connected to the two ends of the base (3).

6. The electrical cabinet cable connection tensile testing fixture according to any one of claims 1-3, characterized in that: The tensile testing mechanism is also electrically connected to a control system, which is electrically connected to an operation display screen, a work indicator light, and a voice broadcaster. The real-time tensile display screen, work indicator light, and voice broadcaster are located on or around the tooling body.

7. A method for testing the tensile force of a terminal block, characterized in that: The tensile testing method for electrical cabinet cable connections is based on the fixture described in any one of claims 1-6, including a training mode and an assessment mode. The tensile testing method in the training mode includes the following steps: S101: Select the basic training mode or the advanced training mode, and select the terminal type and wire diameter to be trained according to the training requirements. The position of the corresponding terminal connection wire (7) will be prompted according to the selection result. S102: Pull each terminal connection line (7) in sequence. When the basic training mode is selected, the real-time pulling force and the number of training times corresponding to the terminal connection line (7) are displayed each time the tubular terminal is pulled. When the pulling force reaches the standard pulling force range, a success signal is issued. After detecting that it is held for more than 1 second, the training of the terminal connection line (7) ends. Repeat this process until the training of all terminal connection lines (7) is completed. When the advanced training mode is selected, it will automatically determine whether the standard pulling force range has been reached. After detecting that it is held for more than 1 second, the training of the terminal connection line (7) ends and the training data is recorded. The tensile testing method for the assessment mode includes the following steps: S201: Automatically and randomly selects the terminal type and wire diameter, and determines the position of the terminal connection wire (7) based on the selection result; S202: Pull each terminal connection line (7) in sequence and judge whether the standard tension range is reached. When the measured tension value is held for more than 1 second, the assessment score is obtained based on the difference between the measured tension value and the standard tension range and the standard tension value.

8. The method for testing the tensile strength of electrical cabinet cable connections according to claim 7, characterized in that: The S202 assessment results include two forms: The first form is that if the measured tensile force exceeds the standard tensile force range or the terminal connection wire (7) is selected in the wrong position, the assessment of the terminal connection wire (7) will be terminated directly, and the assessment score will be 0 points; The second form is that if the measured tensile force is within the standard tensile force range, the assessment score will be calculated according to the following formula, with a minimum score of 60 points and a maximum score of 100 points: Calculate the standard tensile test result according to formula (1). , The value ranges from 0 to 100: （1）； in, To measure the tensile force value, This is the standard tensile force value; Calculate the lower limit of the tensile force according to formula (2). , The value ranges from 0 to 100: （2）； in, This is the lower limit of the tensile force; Calculate the upper limit of the pulling force according to formula (3). , The value ranges from 0 to 100: （3）； in, This is the upper limit of the tensile force; Calculate the assessment score according to formula (4) Y : （4）。 9. The method for testing the tensile strength of electrical cabinet cable connections according to claim 7, characterized in that: The training data recorded in the advanced training mode of S102 includes the measured tensile force value, the highest tensile force value, the lowest tensile force value, and the median tensile force value.

10. The method for testing the tensile strength of electrical cabinet cable connections according to claim 7, characterized in that: The standard tensile force range is ±8% to 20% of the standard tensile force value, and the standard tensile force value corresponds to 60% of the minimum pull-out force of the terminal connection wire (7).

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