Novel moisture-proof alarm wire harness

Abstract

The utility model discloses a novel moisture-proof alarm wire harness, and belongs to the technical field of wires and cables. Comprising a wire harness core wire, the wire harness core wire is coated with a waterproof wear-resistant protective sleeve, the wire harness core wire comprises a plurality of power control single-core wires of various specifications, a punching alarm wire and a standby core wire, and gaps of the wire harness core wire are filled with waterproof filling ropes. According to the utility model, the locomotive power transmission cable is endowed with the characteristics of excellent moisture resistance, corrosion resistance, wear resistance, long service life and the like through the arrangement design of a large number of single-core power lines of different specifications laid in the locomotive body and the unique design of integrating the punching alarm line, the standby core wire, the water-blocking filling rope, the waterproof wear-resistant protective sleeve and the like. According to the utility model, the wire harness wiring has the characteristics of convenient construction, beautiful appearance, convenient later wire harness maintenance, shortened maintenance time and the like, the service life of the product is greatly prolonged, and safer and more reliable transmission performance is provided for rolling stock. And a plurality of potential safety hazards in the train running process are avoided.

Description

Technical Field

[0001] This utility model relates to the field of wire and cable technology, specifically to a novel moisture-proof alarm wire harness. Background Technology

[0002] Locomotive and rolling stock cables are mainly used inside the locomotive body, serving as the main connection channels for vehicle signal control, power transmission, and network communication. Their quality directly affects train operation safety.

[0003] Locomotive and rolling stock cables (on-board cables) are primarily installed inside the locomotive body, where the laying space is limited and the environment is extremely complex. Often, various different cables (closely packed without protection) need to be laid simultaneously in the same cable tray. For the numerous single-core power lines laid inside the car body, users typically use direct laying or simple bundling methods. Because these products lack outer sheath protection and have thin-walled insulation (generally only 0.18–0.25 mm thick to save space), the insulation layer is frequently damaged by vibration and friction during long-term train operation, affecting product quality and creating safety hazards. Furthermore, the high humidity in humid southern regions, coupled with the fact that locomotive cables often use halogen-free, low-smoke, flame-retardant, radiation-crosslinked polyolefin insulation materials, leads to a rapid decline in insulation performance, especially when there is significant moisture in the cable tray, posing a significant safety hazard to train operation. Utility Model Content

[0004] The purpose of this invention is to provide a novel moisture-proof alarm wiring harness that integrates different single-core cables, replacing the original direct laying or bundling methods with a harness integration approach. Special perforated moisture-proof alarm core wires are added, with gaps filled with water-blocking cotton (to prevent longitudinal moisture), and a 0.2mm waterproof and wear-resistant protective sleeve is extruded onto the outermost layer of the harness (to prevent radial moisture). This novel integration method increases the cable's service life and significantly improves its moisture resistance. It also ensures that an alarm signal is issued immediately upon moisture intrusion into the harness, allowing for timely troubleshooting and providing a more reliable guarantee for train safety. Furthermore, a certain number of spare core wires can be added to the harness according to user needs, facilitating emergency replacement in case of unexpected core wire failures, maximizing the safety and reliability of train operation, and buying time for emergency rescue. In addition, this integrated harness design also increases the convenience and aesthetics of wiring, thereby solving the problems mentioned in the background art.

[0005] The technical solutions adopted in this utility model are as follows:

[0006] A novel moisture-proof alarm wire harness includes a wire harness core wire, which is covered with a waterproof and wear-resistant protective sleeve 1. The wire harness core wire includes several single-core power control wires of various specifications 2, a drilled alarm wire 3, and a spare core wire 4. The gaps between the wire harness core wires are filled with water-resistant filling rope 5.

[0007] There are two perforated alarm lines 3, located on both sides of the core wire of the wire harness. The perforated alarm line 3 includes a solid soft round copper wire with a diameter of 0.5mm. A layer of PE insulating sleeve is extruded on the solid soft round copper wire. Multiple holes are evenly spaced on the insulating sleeve along its length.

[0008] The spare core wire 4 includes a single core wire with the same specifications as the largest single core wire in the power control single core wire 2.

[0009] The power control single-core wire 2 includes four 0.5mm² wires. 2 Power control core wire, 5 strands of 0.75mm² 2 Power control core wire, 3 strands of 1.0mm² 2 Power control core wire, 5 strands of 1.5mm² 2 Power control core wire, 4 strands of 2.5mm² 2 The power control core wire, the spare core wire 4 includes one 1.0mm² core wire. 2 Spare core wire and a 2.5mm² wire 2 Spare core wire.

[0010] The waterproof and wear-resistant protective sleeve 1 is an elastomer protective sleeve with a thickness of 0.2mm.

[0011] The waterproof and wear-resistant protective sleeve 1 contains several single-core power control wires 2 of various specifications and spare core wires 4 arranged from the inside to the outside according to their specifications from smallest to largest.

[0012] The water-blocking filling rope 5 is made of water-blocking yarn. Multiple water-blocking filling ropes 5 are filled between the core wires of the wire harness to participate in the bundling, so that the core wires of the wire harness are dense and without gaps.

[0013] The two ends of the power control single-core wire 2 are crimped with equipment connection terminals, the two ends of the drilled alarm wire 3 are connected to the alarm, and the two ends of the spare core wire 4 are sealed with insulating caps.

[0014] In summary, due to the adoption of the above technical solution, the beneficial effects of this utility model are:

[0015] This utility model arranges and designs a large number of single-core power cables of different specifications laid inside the locomotive body, and gives the locomotive power transmission cable excellent moisture-proof, corrosion-proof, wear-resistant and long-life characteristics by combining a perforated alarm line, spare core wire, water-blocking filling rope and waterproof and wear-resistant protective sleeve. The spare core wires are designed for emergency replacement in case of unexpected core wire failure during later use of the wiring harness, shortening maintenance time and maximizing the safety and reliability of train operation. They also provide valuable time for emergency rescue in special circumstances. The water-blocking filling rope ensures a tight, gapless fit between the core wires, preventing longitudinal water penetration and meeting the requirements for bundle roundness. The perforated alarm line provides immediate warning signals, ensuring timely detection and troubleshooting of potential problems, offering more reliable quality assurance for train safety. The waterproof and wear-resistant protective sleeve improves the wear resistance of the wiring harness within the wiring trough, preventing wear on the outer core wires due to long-term vibration during operation, significantly extending the harness's lifespan. Simultaneously, the sleeve's excellent isolation properties protect the core wires from external moisture, oil, and other corrosive environments, further ensuring train operation safety.

[0016] Meanwhile, the wiring harness of this invention also features convenient construction, aesthetic appeal, easy subsequent maintenance, and reduced repair time, significantly improving product lifespan and providing safer and more reliable transmission performance for locomotives and rolling stock. It avoids many safety hazards during train operation and provides a safer and more reliable information transmission channel for the country's railway construction. Attached Figure Description

[0017] Figure 1 It is a structural diagram of the utility model;

[0018] Figure 2 This is a schematic diagram of the structure of the punch alarm wire of this utility model;

[0019] In the picture: 1. Waterproof and wear-resistant protective sleeve; 2. Power control single-core wire; 3. Drilling alarm wire; 4. Spare core wire; 5. Water-blocking filler rope. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0022] In the description of this utility model, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model 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 utility model.

[0023] Example 1

[0024] like Figure 1-2 This embodiment provides a novel moisture-proof alarm wire harness, including a wire harness core wire, which is covered with a waterproof and wear-resistant protective sleeve 1. The wire harness core wire includes several power control single-core wires 2 of various specifications, a drilled alarm wire 3, and a spare core wire 4. The gaps between the wire harness core wires are filled with water-blocking filling rope 5.

[0025] There are two perforated alarm lines 3, located on both sides of the core wire of the wire harness. The perforated alarm line 3 includes a solid soft round copper wire with a diameter of 0.5mm. A layer of PE insulating sleeve is extruded on the solid soft round copper wire. Multiple holes are evenly spaced on the insulating sleeve along its length.

[0026] The spare core wire 4 includes a single core wire with the same specifications as the largest single core wire in the power control single core wire 2.

[0027] The power control single-core wire 2 includes four 0.5mm² wires. 2 Power control core wire, 5 strands of 0.75mm² 2 Power control core wire, 3 strands of 1.0mm² 2 Power control core wire, 5 strands of 1.5mm² 2 Power control core wire, 4 strands of 2.5mm² 2 The power control core wire, the spare core wire 4 includes one 1.0mm² core wire. 2 Spare core wire and a 2.5mm² wire 2 Spare core wire.

[0028] The waterproof and wear-resistant protective sleeve 1 is an elastomer protective sleeve with a thickness of 0.2mm.

[0029] The waterproof and wear-resistant protective sleeve 1 contains several single-core power control wires 2 of various specifications and spare core wires 4 arranged from the inside to the outside according to their specifications from smallest to largest.

[0030] The water-blocking filling rope 5 is made of water-blocking yarn. Multiple water-blocking filling ropes 5 are filled between the core wires of the wire harness to participate in the bundling, so that the core wires of the wire harness are dense and without gaps.

[0031] The two ends of the power control single-core wire 2 are crimped with equipment connection terminals, the two ends of the drilled alarm wire 3 are connected to the alarm, and the two ends of the spare core wire 4 are sealed with insulating caps.

[0032] Figure 1 A typical assembly diagram of a novel moisture-proof alarm wiring harness designed for this embodiment:

[0033] The product model is: WDZ-FCBJXS-DCYJ-125℃

[0034] The product specifications are: 0.5 / 4 + 0.75 / 5 + 1.0 / 3 + 1.5 / 5 + 2.5 / 4 + 1.0B + 2.5B (4 strands of 0.5mm) 2 Power control core wire, 5 strands of 0.75mm² 2 Power control core wire, 3 strands of 1.0mm² 2 Power control core wire, 5 strands of 1.5mm² 2 Power control core wire, 4 strands of 2.5mm² 2 Power control core wire, 1 x 1.0mm 2 Spare core wire, one 2.5mm² wire 2 (Spare core wire)

[0035] The required length and terminal type of the wiring harness can be customized according to the actual equipment connected by the user. The product specifications can also be customized according to different usage requirements, while the arrangement principle remains unchanged.

[0036] This embodiment designs a novel moisture-proof alarm wiring harness and its integration method, specifically including several single-core control wires of different specifications, spare wires, drilled alarm wires, water-blocking fillers, and an outer waterproof and wear-resistant protective sleeve covering the entire wire. The two ends of the power control wires are crimped with equipment connection terminals, the two ends of the drilled alarm wires are connected to alarms, and the two ends of the spare wires are sealed with insulating caps (reserved for future use). This wiring harness is mainly designed for the wiring integration of multi-specification single-core thin-walled locomotive power control cables installed inside the locomotive body, achieving convenient, aesthetically pleasing, and easy-to-replace wiring, while giving the wires excellent moisture-proof and wear-resistant properties, significantly improving product lifespan and providing safer and more reliable transmission performance for locomotives and rolling stock.

[0037] The specifications of the locomotive power control core wires involved in this embodiment refer to the locomotive cable standard, which specifies that the specifications of the power core wires for thin-walled locomotive cables are 0.5 to 2.5 mm. 2 The overall wiring harness is composed of single-core wires of various specifications arranged in a special combination according to the different functional requirements of the locomotive. All power core wires are based on blue (0.5mm) 2 ), orange (0.75mm 2 Green (1.0mm) 2 ), Brown (1.5mm) 2 ), gray (2.5mm) 2 The standard color spectrum is used for differentiation, and a combination of color and number is used for grouping. That is, single wires of the same specification are designed into the same color group, distinguished by different numerical sequences. The arrangement rule is smaller inside and larger outside; that is, single wires with smaller outer diameters are twisted together at a certain pitch to form the central group, while single wires with larger outer diameters participate in the twisting as the outer layer. Single wires of different diameters must be arranged crosswise according to the design order to ensure that the overall cable core is as round as possible (e.g., ...). Figure 1 (As shown).

[0038] Meanwhile, this utility model incorporates water-blocking yarn (water-blocking filler rope) into the wire harness stranding process to ensure a tight, gapless connection between the wire cores, preventing longitudinal moisture penetration and meeting the requirements for bundle roundness. The water-blocking filler rope is made of halogen-free, low-smoke, flame-retardant cross-linked polyolefin material. This type of material is prone to moisture absorption, especially in humid environments like those in the south. When there is significant moisture in the cable tray, the insulation performance of unsheathed single-core wires deteriorates rapidly, posing a significant hazard to train safety.

[0039] To further ensure product safety, this invention incorporates a perforation alarm wire invented by our company (see [link to product details]). Figure 2 ), placed on both sides of the wire harness core wire to participate in bundling (see Figure 1 The perforated alarm wire uses 0.5mm solid TR soft round copper wire, extruded with a layer of PE insulation of appropriate thickness. The insulation surface is continuously and evenly perforated (hole spacing ≤ 15mm, perforations should penetrate to the conductor surface without damaging the conductor). Its main function is to ensure that if moisture intrudes into the wiring harness connection area or the outer sheath is accidentally damaged, allowing water vapor to enter, the alarm device connected to it can issue an alarm signal immediately by monitoring the change in insulation resistance between the two alarm wires. This ensures timely detection of problems and troubleshooting of potential faults, providing more reliable quality assurance for driving safety. The working principle of the perforated alarm wire is that under dry conditions, the insulation resistance between a pair of moisture-proof alarm wires in the wiring harness will consistently be greater than 1000MΩ·km. However, when the wiring harness becomes damp or water enters, the insulation resistance between the pair of moisture-proof alarm wires will rapidly decrease, ≤ 1000KΩ·km, indicating severe internal moisture in the wiring harness, rendering it unusable and triggering an alarm.

[0040] This utility model incorporates a spare core wire to facilitate emergency replacement in case of unexpected core wire failure during subsequent use of the wiring harness, shortening repair time and maximizing the safety and reliability of train operation. It also provides valuable time for emergency rescue in special circumstances. The rule for adding the spare core wire is: if the wiring harness contains 0.5–2.5mm² core wires… 2 For various core wire specifications, select 2.5mm². 2 and 1.0mm 2 One single wire is used as a spare core wire; if it is only 1.0mm² 2 For sizes of 1 and below, select 1.0mm. 2 As a spare core wire. For easy identification, the spare core wire is designed with black insulation, and multiple spare core wires are distinguished by numerical serial numbers (e.g., ...). Figure 1 The design of spare core wires mainly considers cost and specification coverage.

[0041] Considering that other cables (with sheaths) for various purposes also exist within the wiring channels inside the train body, this utility model designs a wiring harness with an added outer sheath to prevent wear on the outer core wires due to long-term vibration during train operation. The outermost layer of the wiring harness is extruded with a 0.2mm elastomer protective sleeve (waterproof and wear-resistant protective sleeve). While ensuring the overall flexibility of the wiring harness, this improves its wear resistance within the wiring channels, significantly extending its service life. Simultaneously, the excellent isolation performance of the protective sleeve also protects the wiring harness core wires from external moisture, oil, and other corrosive environments, further ensuring the safety of train operation.

[0042] This utility model redesigns and integrates the numerous single-core power cables laid inside the locomotive body, replacing the original direct laying or simple bundling wiring methods with a new type of moisture-proof alarm cable harness. The product features a unique design that arranges core wires of different specifications, incorporating punched alarm wires, spare core wires, and wear-resistant protective sleeves. This gives the locomotive power transmission cable excellent moisture-proof, corrosion-resistant, wear-resistant, and long-life characteristics. Furthermore, the cable harness wiring method offers convenient construction, aesthetics, and easy maintenance. This significantly extends the product's lifespan, avoids many safety hazards during train operation, and provides a safer and more reliable information transmission channel for the country's railway construction.

Claims

1. A novel moisture-proof alarm wiring harness, comprising wiring harness core wires, characterized in that, The wire harness core wire is covered with a waterproof and wear-resistant protective sleeve (1). The wire harness core wire includes several power control single core wires of various specifications (2), a drilling alarm wire (3) and a spare core wire (4). The gaps between the wire harness core wires are filled with water-blocking filling rope (5).

2. The novel moisture-proof alarm wiring harness according to claim 1, characterized in that: There are two perforated alarm lines (3), located on both sides of the core wire of the wire harness. The perforated alarm line (3) includes a solid soft round copper wire with a diameter of 0.5 mm. A layer of PE insulating sleeve is extruded on the solid soft round copper wire. Multiple holes are equally spaced on the insulating sleeve along its length.

3. The novel moisture-proof alarm wiring harness according to claim 1, characterized in that: The spare core wire (4) includes a single core wire with the same specifications as the largest specification in the power control single core wire (2).

4. The novel moisture-proof alarm wiring harness according to claim 3, characterized in that: The power control single-core wire (2) includes four 0.5mm² wires. 2 Power control core wire, 5 strands of 0.75mm² 2 Power control core wire, 3 strands of 1.0mm² 2 Power control core wire, 5 strands of 1.5mm² 2 Power control core wire, 4 strands of 2.5mm² 2 The power control core wire, the spare core wire (4) includes one 1.0mm² core wire. 2 Spare core wire and one 2.5mm² wire 2 Spare core wire.

5. The novel moisture-proof alarm wiring harness according to claim 1, characterized in that: The waterproof and wear-resistant protective sleeve (1) is an elastomer protective sleeve with a thickness of 0.2mm.

6. The novel moisture-proof alarm wiring harness according to claim 1, characterized in that: The waterproof and wear-resistant protective sleeve (1) contains several single-core power control wires (2) of various specifications and spare core wires (4) arranged from the inside to the outside according to their specifications from smallest to largest.

7. The novel moisture-proof alarm wiring harness according to claim 1, characterized in that: The water-blocking filler rope (5) is made of water-blocking yarn.

8. A novel moisture-proof alarm wiring harness according to claim 1, characterized in that: The two ends of the power control single-core wire (2) are crimped with equipment connection terminals, the two ends of the punched alarm wire (3) are connected to the alarm, and the two ends of the spare core wire (4) are sealed with insulating caps.

Images