Power cable and charging cable detection device based on air pressure insulation detection

Abstract

The application discloses a power cable insulation damage detection device based on pressure detection, which comprises a pressure sensor, a sealed rubber tube and an inflation system. The sealed rubber tube wrapped in the outer insulation layer of the cable is inflated to a preset air pressure through the inflation system, and the pressure sensor monitors the air pressure change in the tube in real time. When the rubber tube leaks due to insulation damage, the damage degree is analyzed according to the pressure drop speed, and an alarm is given through the 485 communication linkage charger control unit, and information is uploaded to the operation platform by using the 4G module. The device can detect the insulation state of the cable outer skin as a whole, does not need a high-voltage circuit, has a simple structure, is suitable for scenes such as coal mines and new energy charging piles, and solves the problems that traditional insulation detection cannot cover the whole cable and the circuit is complex.

Description

Technical Field

[0001] This utility model relates to the field of power cable testing technology, specifically to a power cable and charging cable testing device based on air pressure insulation testing, which is suitable for scenarios such as coal mines and new energy charging piles that require real-time monitoring of cable insulation status. Background Technology

[0002] In power transmission systems, damage to the insulation layer of power cables can lead to safety hazards such as leakage and short circuits, seriously threatening equipment operation and personnel safety. Traditional insulation testing methods typically employ high-voltage circuits, which have the following shortcomings: Firstly, high-voltage testing methods pose safety risks, especially limiting their use in flammable and explosive environments such as coal mines; secondly, traditional testing methods often only test specific parts of the cable, failing to cover the entire cable and creating blind spots; furthermore, traditional testing devices have complex circuit structures, high maintenance costs, and are difficult to adapt to scenarios such as new energy charging piles where cables need to be frequently moved and dragged.

[0003] For example, in the underground environment of coal mines, power cables are constantly exposed to complex physical conditions, and the insulation layer is prone to damage due to friction, compression, and other factors. Traditional detection devices, due to their complex circuitry and lack of explosion-proof performance, cannot meet the safety requirements of coal mines. In the scenario of new energy charging piles, cables are frequently dragged, and traditional detection methods cannot monitor the insulation layer damage in real time. Furthermore, the complex circuit structure is easily damaged during frequent movement. Therefore, there is an urgent need for an insulation damage detection device that is simple in structure, safe and reliable, and capable of detecting all cables. Utility Model Content

[0004] The technical problem solved by this utility model is to provide a power cable and charging cable testing device based on air pressure insulation testing, so as to realize the full cable insulation status testing without high voltage circuit and with simple structure, and solve the technical problem that traditional testing methods cannot cover the entire cable and the complex circuit.

[0005] To solve the above-mentioned technical problems, the technical solution of this utility model is: a power cable insulation damage detection device based on pressure detection, including a sealing rubber tube, an inflation system, a pressure sensor, a data processing unit and an alarm linkage module.

[0006] The sealing rubber tube wraps around the outer insulation layer of the power cable, forming a sealed air pressure space. The inflation system is connected to the sealing rubber tube and is used to inflate it with a preset air pressure. The pressure sensor is installed on the sealing rubber tube and is used to monitor the air pressure inside the tube in real time. The data processing unit is electrically connected to the pressure sensor and is used to determine the insulation layer damage and analyze the degree of damage based on air pressure changes. The alarm linkage module is electrically connected to the data processing unit and is used to send a signal to the charger control unit via 485 communication when an anomaly is detected, and to upload alarm information via a 4G module.

[0007] The sealing rubber tube is made of weather-resistant rubber material, and its inner diameter is adapted to the outer diameter of the power cable. Both ends are fixed to the cable through sealing joints to ensure a good sealed space.

[0008] The inflation system includes an air pump, an air pressure regulating valve, and an air pressure gauge. The air pump is connected to a sealed rubber tube via an air pipe, and the air pressure regulating valve is used to adjust the inflation pressure to a preset value to achieve precise inflation control.

[0009] The pressure sensor is a high-precision absolute pressure sensor, installed in the middle of the rubber tube to accurately monitor changes in air pressure inside the tube.

[0010] The data processing unit has a built-in threshold comparison module. When the air pressure drop rate exceeds a preset threshold, it determines that the insulation layer is damaged and calculates the size of the damaged hole based on the drop rate, thereby achieving a quantitative analysis of the degree of damage.

[0011] The alarm linkage module includes a relay output unit for cutting off the charger power supply, and a 4G communication module whose communication frequency band covers 2G / 3G / 4G networks to ensure timely transmission of alarm information.

[0012] The detection device also includes an explosion-proof housing, and the pressure sensor, data processing unit and alarm linkage module are integrated inside the explosion-proof housing.

[0013] The outer side of the sealing rubber tube is provided with a wear-resistant protective layer, which adopts a Kevlar fiber braided structure to improve the durability of the device.

[0014] The device also includes a temperature compensation module, which is used to correct the air pressure detection value according to the ambient temperature and eliminate the influence of temperature changes on the detection results.

[0015] The data processing unit communicates with the charger control unit via an RS485 bus. The communication protocol conforms to the GB / T18487.1 standard, ensuring communication compatibility and stability.

[0016] The innovations of this utility model are as follows: it adopts the principle of air pressure detection, eliminating the need for high-voltage circuits and improving detection safety; by wrapping the cable with a sealed rubber tube, it achieves overall detection of the insulation status of the entire cable; the device has a simple structure, making it easy to install and maintain; it has explosion-proof and wear-resistant properties, making it suitable for various complex scenarios; and it achieves alarm linkage and information uploading through multiple communication methods, improving the intelligence and reliability of the system.

[0017] Its features include: real-time monitoring of air pressure changes to quickly detect insulation damage; accurate assessment of the degree of damage based on the rate of air pressure drop; temperature compensation function to improve detection accuracy; explosion-proof housing design to meet safety requirements in special scenarios; wear-resistant protective layer to extend the device's service life; and multiple communication methods to ensure timely transmission of alarm information. Attached Figure Description

[0018] Figure 1 is a schematic diagram of the structure of the device of this utility model.

[0019] Figure 2 is a schematic diagram of the structure of the processing unit of this utility model.

[0020] Figure 3 is a structural schematic diagram of the inflation module of this utility model. Detailed Implementation

[0021] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this utility model, but are not intended to limit its scope.

[0022] In practical application, this novel testing device first selects a sealing rubber tube with an inner diameter matching the outer diameter of the power cable, wraps it around the outer insulation layer of the cable, and fixes both ends with sealing joints to form a sealed air pressure space. The sealing rubber tube is made of weather-resistant rubber material to ensure sealing and durability in different environments. The Kevlar fiber braided wear-resistant protective layer on its outer side can effectively resist wear from frequent dragging of the charging pile cable.

[0023] The inflation system is connected to a sealed rubber tube via an air pipe. After the air pump is started, the inflation pressure is adjusted to the preset value through the air pressure regulating valve. The air pressure gauge displays the inflation pressure in real time, ensuring that the preset air pressure is achieved. A high-precision absolute pressure sensor is installed in the middle of the rubber tube to monitor changes in air pressure inside the tube in real time and transmits the data to the data processing unit.

[0024] The data processing unit has a built-in threshold comparison module. When the rate of air pressure drop exceeds a preset threshold, it determines that the insulation layer is damaged and calculates the size of the damaged hole based on the rate of drop.

[0025] The temperature compensation module collects ambient temperature data in real time and corrects the air pressure readings to eliminate the impact of temperature changes on air pressure. For example, when the ambient temperature rises, the air pressure will rise accordingly. The temperature compensation module adjusts the detected air pressure value according to a temperature-pressure correction algorithm to ensure the accuracy of the detection results.

[0026] When the data processing unit determines that the insulation layer is damaged, the alarm linkage module is activated. The relay output unit cuts off the charger power supply to prevent safety accidents such as leakage; the 4G communication module uploads the alarm information to the operation platform via 2G / 3G / 4G network, and simultaneously sends the signal to the charger control unit via RS-485 communication, realizing local and remote alarm linkage.

[0027] In underground coal mine scenarios, the pressure sensor, data processing unit, and alarm linkage module of the detection device are integrated into an explosion-proof enclosure, meeting the explosion-proof safety requirements of coal mines. In charging pile scenarios, the wear-resistant protective layer effectively protects the sealing rubber tube, preventing damage during frequent dragging and ensuring the long-term stable operation of the detection device.

[0028] The data processing unit communicates with the charger control unit via an RS485 bus. The communication protocol conforms to the GB / T18487.1 standard, ensuring good compatibility and communication stability with the charger control unit.

[0029] Obviously, the above examples are for illustrative purposes only and are not intended to limit the implementation. Those skilled in the art will recognize that various modifications and adjustments can be made based on the above description. It is not necessary to list all possible implementations exhaustively. Therefore, forms obvious from these variations still fall within the scope of protection of this invention.

Claims

1. A testing device for power cables and charging cables based on air pressure insulation testing, characterized in that, include: A sealed rubber tube is wrapped around the outside of the power cable's outer insulation layer to form a closed air pressure space; An inflation system, connected to the sealing rubber tube, is used to inflate it with a preset air pressure; a pressure sensor, installed on the sealing rubber tube, is used to monitor the air pressure inside the tube in real time. The data processing unit, electrically connected to the pressure sensor, is used to determine the insulation layer damage and analyze the degree of damage based on changes in air pressure. The alarm linkage module, electrically connected to the data processing unit, is used to send a signal to the charger control unit via 485 communication when an anomaly is detected, and to upload alarm information via a 4G module.

2. The detection device according to claim 1, characterized in that, The sealing rubber tube is made of weather-resistant rubber material, its inner diameter is adapted to the outer diameter of the power cable, and both ends are fixed to the cable through sealing joints.

3. The detection device according to claim 1, characterized in that, The inflation system includes an air pump, an air pressure regulating valve, and an air pressure gauge. The air pump is connected to a sealed rubber tube via an air pipe, and the air pressure regulating valve is used to adjust the inflation pressure to a preset value.

4. The detection device according to claim 1, characterized in that, The pressure sensor is a high-precision absolute pressure sensor, installed in the middle of the rubber tube.

5. The detection device according to claim 1, characterized in that, The data processing unit has a built-in threshold comparison module. When the air pressure drop rate exceeds a preset threshold, it determines that the insulation layer is damaged and calculates the size of the damaged hole based on the drop rate.

6. The detection device according to claim 1, characterized in that, The alarm linkage module includes a relay output unit for cutting off the charger power supply, and a 4G communication module whose communication frequency band covers 2G / 3G / 4G networks.

7. The detection device according to claim 1, characterized in that, The detection device also includes an explosion-proof housing, and the pressure sensor, data processing unit and alarm linkage module are integrated inside the explosion-proof housing.

8. The detection device according to claim 1, characterized in that, The outer side of the sealing rubber tube is provided with a wear-resistant protective layer, which is made of Kevlar fiber braided structure.

9. The detection device according to claim 1, characterized in that, The device also includes a temperature compensation module for correcting the air pressure detection value based on the ambient temperature.

10. The detection device according to claim 1, characterized in that, The data processing unit communicates with the charger control unit via an RS485 bus, and the communication protocol conforms to the GB / T 18487.1 standard.

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