CN114361904B - Saturated filling wire crimping process - Google Patents
Saturated filling wire crimping process Download PDFInfo
- Publication number
- CN114361904B CN114361904B CN202210027540.3A CN202210027540A CN114361904B CN 114361904 B CN114361904 B CN 114361904B CN 202210027540 A CN202210027540 A CN 202210027540A CN 114361904 B CN114361904 B CN 114361904B
- Authority
- CN
- China
- Prior art keywords
- saturated
- filling
- crimping
- wire
- conductive medium
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 238000002788 crimping Methods 0.000 title claims abstract description 66
- 229920006395 saturated elastomer Polymers 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims abstract description 25
- 230000008569 process Effects 0.000 title claims abstract description 22
- 238000003825 pressing Methods 0.000 claims abstract description 4
- 238000007781 pre-processing Methods 0.000 claims abstract description 3
- 238000007789 sealing Methods 0.000 claims description 43
- 238000010438 heat treatment Methods 0.000 claims description 31
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 26
- 229910052782 aluminium Inorganic materials 0.000 claims description 26
- 229910000831 Steel Inorganic materials 0.000 claims description 23
- 239000011248 coating agent Substances 0.000 claims description 23
- 238000000576 coating method Methods 0.000 claims description 23
- 239000010959 steel Substances 0.000 claims description 23
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims description 10
- 239000011701 zinc Substances 0.000 claims description 10
- 229910052725 zinc Inorganic materials 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 8
- 239000002390 adhesive tape Substances 0.000 claims description 7
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 claims description 6
- 238000004804 winding Methods 0.000 claims description 6
- 239000012530 fluid Substances 0.000 claims description 5
- 230000000149 penetrating effect Effects 0.000 claims description 4
- 238000003780 insertion Methods 0.000 claims description 2
- 230000037431 insertion Effects 0.000 claims description 2
- 230000006835 compression Effects 0.000 abstract description 14
- 238000007906 compression Methods 0.000 abstract description 14
- 230000007797 corrosion Effects 0.000 abstract description 5
- 238000005260 corrosion Methods 0.000 abstract description 5
- 230000008901 benefit Effects 0.000 abstract description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 11
- 239000007789 gas Substances 0.000 description 10
- 230000005540 biological transmission Effects 0.000 description 8
- 238000005253 cladding Methods 0.000 description 5
- 229920001971 elastomer Polymers 0.000 description 5
- 239000010410 layer Substances 0.000 description 5
- 239000002245 particle Substances 0.000 description 3
- 238000004321 preservation Methods 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- 238000009825 accumulation Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000003487 electrochemical reaction Methods 0.000 description 2
- 238000006056 electrooxidation reaction Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000004381 surface treatment Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 230000003628 erosive effect Effects 0.000 description 1
- 238000005429 filling process Methods 0.000 description 1
- 230000008014 freezing Effects 0.000 description 1
- 238000007710 freezing Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 230000008595 infiltration Effects 0.000 description 1
- 238000001764 infiltration Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012768 molten material Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000009738 saturating Methods 0.000 description 1
- 238000005482 strain hardening Methods 0.000 description 1
- 230000001502 supplementing effect Effects 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
Landscapes
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
Abstract
The application discloses a saturated filling wire crimping process which is characterized by comprising the following steps of: s1, pretreatment: preprocessing the head end of the wire to form a crimping connector; s2, saturated filling: filling conductive medium into the gap of the crimping connector and forming a compact rod body structure; s3, crimping: and pressing and butting the two sections of the press joint connectors after the saturated filling is finished. Has the advantage of preventing frost heaving and corrosion of the compression joint cavity.
Description
Technical Field
The application relates to the technical field of power engineering, in particular to a wire crimping process.
Background
The connection quality of the transmission line is one of the keys for safe operation of the transmission line. The transmission conductor is generally formed by twisting an aluminum wire and a steel core, and the crimping technology for conducting wire connection by adopting hardware fittings such as wire clamps, splicing sleeves and the like is the only means for realizing long-distance uninterrupted transmission of the ultra-high voltage transmission line. The existing crimping technology generally removes aluminum wires on the periphery of a steel core before crimping two transmission wires, sequentially penetrates through an aluminum splicing sleeve and a steel splicing sleeve, and finally crimping the steel splicing sleeve and the aluminum splicing sleeve through a hydraulic press.
However, in extreme weather such as low-temperature ice disaster, the tensile strength of the crimping part of the transmission conductor can be reduced, so that the hardware is frozen and swelled to crack, a broken wire and tower falling accident can occur at any time, and the line safety is seriously endangered. Therefore, the crimping quality and the later operating condition (up to 30 years) of a huge number of crimping pipes (splicing sleeves) become important factors affecting the safe operation of the power grid.
Therefore, how to improve the existing wire crimping process to overcome the above problems is a problem to be solved by those skilled in the art.
Disclosure of Invention
An object of the present application is to provide a saturated filled wire crimping process that prevents frost heaving and corrosion of the crimp cavity.
In order to achieve the above purpose, the application adopts the following technical scheme: the saturated filling wire crimping process is characterized by comprising the following steps of:
s1, pretreatment: preprocessing the head end of the wire to form a crimping connector;
S2, saturated filling: filling conductive medium into the gap of the crimping connector and forming a compact rod body structure;
s3, crimping: and pressing and butting the two sections of the press joint connectors after the saturated filling is finished.
Further, the step S2 specifically includes the following steps:
S21, coating: sealing and coating the surface of the crimping connector by adopting a coating sheet, and forming a columnar gas channel;
s22, seal insertion step: sealing and inserting the coated crimping connector into a saturated filling bag filled with a fluid-state conductive medium;
s23, positive pressure filling: increasing the air pressure in the saturated filling bag and being higher than the atmospheric pressure so that a fluid-state conductive medium enters a gap of the crimping connector along a columnar gas channel to be filled;
s24, subsequent processing steps: and taking the filled crimp joint out of the saturated filling bag, and removing the coating sheet on the surface of the crimp joint after the conductive medium is solidified or coagulated.
In the step 21, the wrapping sheet is wrapped around the crimp connector, and the wrapping sheet has a winding number of not less than three; a plurality of adhesive tapes are arranged on the inner side of the wrapping sheet at intervals, and the adhesive tapes are used for winding and fixing the wrapping sheet.
In the step 21, the wrapping sheet extends towards the tail end of the wire and forms an elongated wrapping section; in step 22, the elongated wrapping section extends beyond the saturated filling bag.
The crimping connector comprises a steel core section and an aluminum strand section; in the step S21, a small-size coating sheet is used for sealing and coating the surface of the steel core segment, a large-size coating sheet is used for sealing and coating the surface of the aluminum strand segment, and two columnar gas channels are formed.
The saturated filling bag has a temperature control function and is used for changing or maintaining the material state of the conductive medium.
Specifically, the saturated filling bag comprises a furnace body, a sealing cap, a crucible, a heating pipe and a positive pressure protection air tap; the sealing cap is sealed on the furnace body, and the covered crimping connector is suitable for penetrating through the sealing cap in a sealing manner and entering the furnace body; the crucible is arranged in the furnace body and is suitable for containing the conductive medium; the heating pipe is arranged on the outer side of the crucible in a surrounding mode, and the heating pipe releases heat to enable the conductive medium to be in a fluid state; the positive pressure protection air tap penetrates through the furnace body, and is suitable for being connected with an air supply system and used for increasing the air pressure in the saturated filling bag.
Further, the saturated filling bag further comprises a control system, the control system comprises a cap temperature sensor, a temperature sensor in the furnace, a heating pipe controller and a pressure controller, the heating pipe controller is used for controlling the heating temperature of the heating pipe according to temperature data obtained by the cap temperature sensor and the temperature sensor in the furnace, and the pressure controller is used for controlling the air inflow of the positive pressure protection air tap, so that the saturated filling bag is guaranteed to keep stable air pressure.
As a conventional step, the wire is cut, stripped and surface-treated in the step S1 to form the crimp connector; the step S24 further includes performing surface precision processing on the filled crimp joint.
Preferably, the conductive medium is a conductive paste or zinc or tin or lead, and is adapted to fill in a molten state into the gap of the crimp fitting.
Compared with the prior art, the application has the beneficial effects that: (1) By saturation filling of the air gap in the crimping connector, the air gap of the cavity after crimping is eliminated, and the phenomena of frost heaving and corrosion caused by erosion and infiltration of rainwater and moisture are prevented. (2) The filling of the conductive medium can also effectively improve the conductive performance of the crimping connector and the overcurrent capacity through the beneficial physical characteristics of the conductive medium. (3) The filling structure of the conductive medium optimizes the mechanical characteristics of the crimping connector, forms effective package of all sections, and improves the overall strength of the crimping connector. (4) In addition, the saturated filling bag has the advantages of simple structure, convenient operation, safety and practicability.
Drawings
Fig. 1 is a schematic view of the structure of a wire after a pretreatment step according to a preferred embodiment of the present application;
fig. 2 is a schematic view of a wire structure at the coating step according to a preferred embodiment of the present application;
FIG. 3 is a schematic illustration of the structure of a two gauge cover sheet as it is being unfolded in accordance with a preferred embodiment of the present application;
FIG. 4 is a schematic diagram of the structure of a saturated pack in accordance with a preferred embodiment of the present application;
Fig. 5 is a control diagram of a saturated pack in accordance with a preferred embodiment of the present application.
In the figure: 100. a wire; 101. a crimping joint; 111. an aluminum strand segment; 112. a steel core section; 200. a saturated filling bag; 300. a conductive medium; 400. coating the thin sheet; 401. an adhesive tape; 400a, large-size cladding sheets; 400b, small-size coated sheets; 500. lengthening the cladding section; 1. a furnace body; 11. a furnace shell; 12. a heat-preserving furnace lining; 2. a sealing cap; 21. tying the mouth section; 3. a crucible; 4. heating pipes; 5. positive pressure protection air tap; 6. sealing the rubber ring; 61. sealing grooves; 7. a control system; 7a, a temperature control system; 7b, a pressure control system; 71. a cap temperature sensor; 72. an in-furnace temperature sensor; 73. a heating pipe controller; 74. and a pressure controller.
Detailed Description
The present application will be further described with reference to the following specific embodiments, and it should be noted that, on the premise of no conflict, new embodiments may be formed by any combination of the embodiments or technical features described below.
In the description of the present application, it should be noted that, for the azimuth words such as terms "center", "lateral", "longitudinal", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., the azimuth and positional relationships are based on the azimuth or positional relationships shown in the drawings, it is merely for convenience of describing the present application and simplifying the description, and it is not to be construed as limiting the specific scope of protection of the present application that the device or element referred to must have a specific azimuth configuration and operation.
The terms "comprises" and "comprising," along with any variations thereof, in the description and claims, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
As is well known, the press-bonding operation is a cold deformation operation, and the material to be pressed is plastically deformed and cold-set. Because of the cold work hardening effect, the mechanical property of the pressed material is greatly changed, and the pressing operation force cannot realize the required deformation.
Meanwhile, the lead has the structural characteristics that: the pressed material, whether it is a steel core, an aluminum strand or a splicing sleeve, is in point contact or line contact, but not in surface contact, so that structural gaps naturally exist.
In addition, during wire crimping, the lattice orientation of the crimped material is random, rather than deforming according to our subjective requirements. Axial and radial deformations are present in all crimping processes. Axial deformation is the extension of the crimp tube we see, and radial deformation causes the structural gaps in the wire to become smaller and smaller. However, since the axial deformation of the wire has strict size limitation, the radial deformation cannot be infinitely deformed in a compression joint in a seamless compacting direction, so that the compression joint is not completely filled and compacted, and the existence of the compression joint is of course.
The existence of the compression joint gap can cause water accumulation or condensation in the compression joint pipe, even ice formation and volume expansion. And in addition, the temperature difference of the running environment of the power transmission line is large, and the effect of repeated circulation accumulation (freezing expansion and water supplementing) is achieved, so that rainwater, dew or snow water infiltrates into the inner layer steel core from the outer layer aluminum strands of the lead (steel core aluminum stranded wire), infiltrates and drips along gaps between layers and strands (capillary phenomenon), gathers in the compression joint cavity of the wire clamp or the connecting tube, and frost heaving damage occurs. And the accumulated water and condensed water formed by the compression joint gap form a primary cell with the steel core and the aluminum strand, and electrochemical reaction causes electrochemical corrosion and rust of the wire clamp or the splicing sleeve or the wire. In addition, accumulated water and condensed water formed by the compression joint gaps form a primary cell with the steel core and the aluminum wire, and electrochemical reaction causes electrochemical corrosion and rust of the wire clamp steel core and the wire steel strand. The frost heaving and corrosion cause the reduction or loss of the compression strength, and the accidents of broken wires and tower falling can be caused, so that the line safety is seriously endangered.
Based on the above-described problems, the present inventors improved the crimping process of the wire, and performed the saturation filling before the wire crimping. The saturated filling refers to filling conductive medium into all gaps of the crimping connector, extruding and exhausting air, so that the crimping connector part becomes a section of compact non-uniform rod body, and the rod body is compact and deformed no matter how compressed. And the saturated filling can realize the surface contact between the steel core and the aluminum strand, so that the original gap is not generated at the beginning of the crimping, and no air gap exists at the end of the crimping. The saturated filling can also realize complete filling of the aluminum strand gaps on the surface of the wire, so that the surface of the wire forms a continuous columnar surface, and the continuous columnar surface and the inner surface of the splicing sleeve also form surface contact, so that no air gap is left between the splicing sleeve and the crimping surface of the wire after crimping operation. The pressure welding gap in the lead and the pressure welding gap between the lead and the splicing sleeve are eliminated, and the pressure welding joint part also forms an effective airtight space, so that the inflow of water vapor or condensed water is thoroughly isolated. Therefore, the saturated filling compression joint can eliminate compression joint gaps and stop frost heaving and corrosion damage of compression joint parts.
The specific process flow of this embodiment is as follows:
In this embodiment, a saturation filling step is inserted in the existing wire crimping process, and other operation steps and requirements are unchanged before the saturation filling step is inserted in the existing wire crimping process, which is not described herein, but is not an obstacle to the present application.
As shown in fig. 1, a crimp joint 101 including an aluminum strand segment 111 and a steel core segment 112 is formed at one end of a wire 100 by performing pretreatment steps such as cutting, stripping, surface treatment, and the like on the wire 100. Then, the saturated filling step is started for the crimp fitting 101.
The saturated filling step comprises the steps of cladding, sealing and inserting, heating, positive pressure filling and subsequent treatment, and key equipment is needed in the saturated filling step: and (5) saturating the filling bag. First, a specific structure and function of the saturated filled packet will be described:
as shown in fig. 4, the saturated filling bag 200 comprises a furnace body 1, a sealing cap 2, a crucible 3, a heating pipe 4 and a positive pressure protection air tap 5; the sealing cap 2 is sealed on the furnace body 1, and the covered crimping connector 101 is suitable for penetrating through the sealing cap 2 in a sealing manner and entering the furnace body 1; the crucible 3 is arranged in the furnace body 1, and the crucible 3 is suitable for containing the conductive medium 300; the heating pipe 4 is arranged on the outer side of the crucible 3 in a surrounding manner, and the heating pipe 4 releases heat to enable the conductive medium 300 to be in a fluid state; the positive pressure protection air tap 5 is arranged on the furnace body 1 in a penetrating way, and the positive pressure protection air tap 5 is suitable for being connected with an air supply system and is used for increasing the air pressure in the saturated filling bag 200. Wherein the gas supply system is adapted to supply a protective gas (inert gas) to the positive pressure protection gas tap 5 to prevent oxidation of the conductive medium 300.
Further specifically, the furnace body 1 includes a furnace shell 11 at an outer layer and a heat-insulating lining 12 at an inner layer. The sealing cap 2 is made of heat-resistant flexible materials, the upper end of the sealing cap 2 extends out of the tying section 21, and the tying section 21 is suitable for sealing and binding with the lead 100 through fasteners such as wire ties, wire hoops and the like. The upper end of the furnace body 1 is also provided with a sealing rubber ring 6, and the sealing cap 2 is suitable for sealing and sleeving the outer side of the sealing rubber ring 6; the sealing rubber ring 6 is also provided with a sealing groove 61 on the periphery thereof to increase the sealing property. Wherein, the sealing cap 2, the sealing rubber ring 6, the furnace shell 11 and the positive pressure protection air tap 5 form an airtight structure of the saturated filling bag 200; the crucible 3, the heating pipe 4 and the heat-preserving furnace liner 12 form a heating system of the saturated filling bag 200.
In addition, as shown in fig. 5, the saturated-filling bag 200 further includes a control system 7, and the control system 7 includes a cap temperature sensor 71, an in-furnace temperature sensor 72, a heating pipe controller 73, and a pressure controller 74; the heating pipe controller 73 controls the heating temperature of the heating pipe 4 as a temperature control system 7a based on the temperature data obtained by the cap temperature sensor 71 and the in-furnace temperature sensor 72; the pressure controller 74 is used for controlling the air inflow of the positive pressure protection air tap 5, so as to ensure that the saturated filling bag 200 maintains stable air pressure, and the saturated filling bag is used as a pressure control system 7b.
The saturation filling step is performed by using the above-mentioned saturation filling packet 200, and the specific flow is as follows:
1. Coating
As shown in fig. 2, the surface of the crimp fitting 101 is hermetically covered with a cover sheet 400, and a columnar gas passage is formed. In this embodiment, the wrapping sheet 400 is made of a heat-resistant plastic sheet material (e.g., tin foil) and is wrapped around the crimp connection 101, and the number of windings of the wrapping sheet 400 is not less than three; wherein, a plurality of adhesive tapes 401 are arranged at intervals on the inner side of the wrapping sheet 400, and the adhesive tapes 401 are used for winding and fixing the wrapping sheet 400, so as to ensure that the wrapping part is airtight.
In addition, the coating sheet 400 extends toward the tail end of the wire 100 to form an elongated coating section 500, and the elongated coating section 500 extends out of the saturated filling package 200, so that the conductive medium 300 can fully enter the gap of the crimp connector 101, and excessive overflow of the conductive medium 300 is avoided.
In this embodiment, the crimp joint 101 includes a steel core segment 112 and an aluminum strand segment 111; therefore, the small-sized clad sheet 400b is used for sealing and cladding the surface of the steel core segment 112, and the large-sized clad sheet 400a is used for sealing and cladding the surface of the aluminum strand segment 111, and two columnar gas passages are formed. As shown in fig. 3, a size comparison of the large-size wrapping sheet 400a and the small-size wrapping sheet 400b in the unfolded state is shown.
2. Seal insert
As shown in fig. 4, the covered crimp fitting 101 is sealed and inserted into the saturated filled bag 200 containing the conductive medium 300 in a fluid state, and sealing binding between the sealing cap 2 and the wire 100 is made.
3. Heating
The furnace temperature is reduced due to the addition of the crimp connection 101 in the saturated filling bag 200, and the control system 7 is started and controls the heating pipe 4 to heat. When the temperature parameter obtained by the cap temperature sensor 71 reaches the set temperature, the control system 7 controls the heating pipe 4 to keep the saturated filling bag 200 in a heat preservation state, and sets a corresponding heat preservation time period.
4. Positive pressure filling
After the heat preservation duration meets the requirement, the positive pressure protection air tap 5 is opened to input protective gas with stable positive pressure (pressure higher than atmospheric pressure), so that the conductive medium 300 enters the gap of the compression joint 101 along the columnar gas channel formed by the wrapping sheet 400 to be filled.
Since the temperature of the sealing cap 2 at the cap opening is lower than the temperature point at which the conductive medium 300 flows, when the filling reaches the point, the conductive medium 300 will solidify and no longer flow, and positive pressure will push the conductive medium 300 to go to the part which is not filled to continue filling until all air gaps are filled, and the input positive pressure will remain unchanged at the moment, so that it can be determined that all the conductive medium 300 has been filled.
5. Post-treatment
After the complete filling, the heating and pressurizing system is turned off, and the conductive wire 100 completed with the conductive medium 300 is taken out in time. And removing the coating sheet 400 on the surface of the wire after the conductive medium 300 is solidified or condensed, and performing surface precision treatment on the surface of the wire 100 under the coating layer to meet the crimping requirement.
Since the gap of the crimp connector 101 is small, the conductive medium 300 in a fluid state can be attached to the gap of the crimp connector 101 by surface tension and does not flow out by being taken out from the saturated filled bag 200.
Through the above-mentioned five steps, the whole operation of the saturated filling step can be completed, and the subsequent crimping operation of the wire 100 can be continued. The embodiment can be applied to intermediate connection of wires and end crimping of wires.
It should be noted that, the reasonable choice of the conductive medium 300 in this embodiment is also important, and first, the conductive medium 300 must meet the following requirements:
(1) The electric conductivity is good;
(2) The low-temperature fluidity is good;
(3) Good compatibility with steel and aluminum;
(4) The chemical stability (protection state) is good;
(5) The environmental protection performance is good.
The conductive medium capable of satisfying the above requirements generally includes: conductive pastes, zinc, tin, lead, and the like.
When the conductive paste is used as the conductive medium 300, since the conductive paste is a viscous paste-like mixture, conductive particles are doped therein. Therefore, the following matters need to be paid attention to in the heating and filling process: (1) Firstly, measuring a temperature value of the conductive particles heated to a flowing state without liquefying, ensuring that the conductive particles are not layered and precipitated, and influencing the conductivity; (2) The conductive paste is a molten material, and the pressure is not stable during positive pressure filling, and whether saturated filling is completed or not should be determined by checking whether or not there is an overflow at the mouth of the sealing cap 2.
The melting points of zinc, tin and lead are far lower than that of aluminum, and the conductive performance is also achieved, so that the method can be used for saturated filling. However, tin has poor low-temperature stability and is forbidden in high and cold regions. Lead is volatile and toxic when heated, and is not recommended. Thus, zinc is most preferably used as the conductive medium 300.
The use of zinc as the conductive medium 300 additionally has the following benefits: (1) Zinc has a resistivity of one time that of aluminum and aluminum has a resistivity of one time that of copper, so that the overcurrent capacity can be not affected by the surface treatment; (2) Zinc has the same chemical reducibility as aluminum, does not chemically damage aluminum strands, and can also effectively protect the steel core and the splicing sleeve; (3) After the liquid zinc is filled in a saturated manner, the steel core and the aluminum strands can be tightly wrapped, so that the mechanical strength of the crimping part is effectively improved; (4) Because of the temperature difference between the high inside and the low outside at the outlet of the sealing cap, a conical zinc filling structure can be formed, and the fatigue strength of the crimping transition part is effectively enhanced.
The foregoing has outlined the basic principles, features, and advantages of the present application. It will be understood by those skilled in the art that the present application is not limited to the embodiments described above, and that the above embodiments and descriptions are merely illustrative of the principles of the present application, and various changes and modifications may be made therein without departing from the spirit and scope of the application, which is defined by the appended claims. The scope of the application is defined by the appended claims and equivalents thereof.
Claims (8)
1. The saturated filling wire crimping process is characterized by comprising the following steps of:
s1, pretreatment: preprocessing the head end of the wire to form a crimping connector;
S2, saturated filling: filling conductive medium into the gap of the crimping connector and forming a compact rod body structure;
s3, crimping: pressing and butting the two sections of the press joint connectors after the saturated filling is finished;
the step S2 specifically includes the following steps:
S21, coating: sealing and coating the surface of the crimping connector by adopting a coating sheet, and forming a columnar gas channel;
s22, seal insertion step: sealing and inserting the coated crimping connector into a saturated filling bag filled with a fluid-state conductive medium;
s23, positive pressure filling: increasing the air pressure in the saturated filling bag and being higher than the atmospheric pressure so that a fluid-state conductive medium enters a gap of the crimping connector along a columnar gas channel to be filled;
s24, subsequent processing steps: taking the filled crimp joint out of the saturated filling bag, and removing the coating sheet on the surface of the crimp joint after the conductive medium is solidified or condensed;
The saturated filling bag comprises a furnace body, a sealing cap, a crucible, a heating pipe and a positive pressure protection air tap; the sealing cap is sealed on the furnace body, and the covered crimping connector is suitable for penetrating through the sealing cap in a sealing manner and entering the furnace body; the crucible is arranged in the furnace body and is suitable for containing the conductive medium; the heating pipe is arranged on the outer side of the crucible in a surrounding mode, and the heating pipe releases heat to enable the conductive medium to be in a fluid state; the positive pressure protection air tap penetrates through the furnace body, and is suitable for being connected with an air supply system and used for increasing the air pressure in the saturated filling bag.
2. The saturated-filling wire crimping process of claim 1, wherein: in the step 21, the wrapping sheet is wrapped around the crimp connector, and the wrapping sheet has a winding number of not less than three; a plurality of adhesive tapes are arranged on the inner side of the wrapping sheet at intervals, and the adhesive tapes are used for winding and fixing the wrapping sheet.
3. The saturated-filling wire crimping process of claim 1, wherein: in the step 21, the wrapping sheet extends towards the tail end of the wire and forms an elongated wrapping section; in step 22, the elongated wrapping section extends beyond the saturated filling bag.
4. The saturated-filling wire crimping process of claim 1, wherein: the crimping connector comprises a steel core section and an aluminum strand section; in the step S21, a small-size coating sheet is used for sealing and coating the surface of the steel core segment, a large-size coating sheet is used for sealing and coating the surface of the aluminum strand segment, and two columnar gas channels are formed.
5. The saturated-filling wire crimping process of claim 1, wherein: the saturated filling bag has a temperature control function and is used for changing or maintaining the material state of the conductive medium.
6. The saturated charging wire crimping process of claim 5, wherein: the saturated filling bag further comprises a control system, the control system comprises a cap temperature sensor, a temperature sensor in the furnace, a heating pipe controller and a pressure controller, the heating pipe controller is used for controlling the heating temperature of the heating pipe according to temperature data obtained by the cap temperature sensor and the temperature sensor in the furnace, and the pressure controller is used for controlling the air inflow of the positive pressure protection air tap, so that the saturated filling bag is guaranteed to keep stable air pressure.
7. The saturated-filling wire crimping process of claim 1, wherein: in the step S1, the wire is cut, stripped and surface-treated to form the crimp joint; the step S24 further includes performing surface precision processing on the filled crimp joint.
8. The saturated charging wire crimping process of claim 4, wherein: the conductive medium is conductive paste or zinc or tin or lead, and is suitable for being filled into the gap of the crimping connector in a molten state.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210027540.3A CN114361904B (en) | 2022-01-11 | 2022-01-11 | Saturated filling wire crimping process |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210027540.3A CN114361904B (en) | 2022-01-11 | 2022-01-11 | Saturated filling wire crimping process |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN114361904A CN114361904A (en) | 2022-04-15 |
| CN114361904B true CN114361904B (en) | 2024-07-26 |
Family
ID=81109268
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210027540.3A Active CN114361904B (en) | 2022-01-11 | 2022-01-11 | Saturated filling wire crimping process |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN114361904B (en) |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102782940A (en) * | 2010-02-05 | 2012-11-14 | 古河电气工业株式会社 | Connecting structure |
| CN104541408A (en) * | 2012-07-31 | 2015-04-22 | 矢崎总业株式会社 | Aluminum cable provided with crimping terminal |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4813878B2 (en) * | 2005-08-09 | 2011-11-09 | 三菱電線工業株式会社 | Aluminum electric wire with terminal and manufacturing method thereof |
| DE102006010622B3 (en) * | 2006-03-08 | 2007-08-02 | Schulte & Co. Gmbh | Connecting copper battery terminal to aluminum cable, inserts stripped cable into terminal bush and injects molten zinc through radial bore to encapsulate conductor |
| CN113690709A (en) * | 2021-08-27 | 2021-11-23 | 江苏正恺电子科技有限公司 | Crimping method of multi-core cable and connector and joint protection injection molding process |
-
2022
- 2022-01-11 CN CN202210027540.3A patent/CN114361904B/en active Active
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102782940A (en) * | 2010-02-05 | 2012-11-14 | 古河电气工业株式会社 | Connecting structure |
| CN104541408A (en) * | 2012-07-31 | 2015-04-22 | 矢崎总业株式会社 | Aluminum cable provided with crimping terminal |
Also Published As
| Publication number | Publication date |
|---|---|
| CN114361904A (en) | 2022-04-15 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| JP2006286385A (en) | Crimped connection structure of terminal fitting and stranded wire | |
| CN101630828B (en) | Middle connector process of oil-immersed cable lapping | |
| US20150190954A1 (en) | Strain relief for connector and cable interconnection | |
| CN200953455Y (en) | Electric cable heat-shrinkable middle joint | |
| CN107302142A (en) | Low-melting-point metal cable connecting arrangement and its application method, attachment structure | |
| EP4002619A1 (en) | Reinforced water barrier over a joint | |
| CN103326142A (en) | Low-melting-point metal cable continuation device | |
| CN113937589A (en) | Cable connection construction process | |
| CN114361904B (en) | Saturated filling wire crimping process | |
| CN111383796B (en) | Novel mineral insulated cable and preparation method thereof | |
| CN117878698A (en) | Cable butt joint process | |
| CN216794209U (en) | Saturated filling bag for wire compression joint | |
| CN106936016A (en) | A kind of waterproof leakproof electrical connecting wire and its processing method | |
| TWI569551B (en) | A method for producing cables with water resistant core wire structures | |
| CN111697405B (en) | Cold connection method for grounding lead of intermediate joint of high-voltage cable | |
| CN207183548U (en) | Low-melting-point metal cable connecting arrangement and attachment structure | |
| CN113488286A (en) | Wire repairing method and wire repairing structure of mineral magnesium oxide insulated copper sheathed cable | |
| CN208445262U (en) | A kind of transition joint restoring the connection of cable body structure | |
| CN203056527U (en) | Cable traction head | |
| JP4330008B2 (en) | Superconducting cable pooling eye and laying method of superconducting cable using pooling eye | |
| CN109473225A (en) | Termite-proof extra-high-tension cable of the crosslinked polyetylene insulated protection against rodents of 220kV and preparation method thereof | |
| JP2009231293A (en) | Compression connecting method of electric wire and compression sleeve | |
| JP5104245B2 (en) | Splice waterproofing method | |
| CN210838115U (en) | High-voltage cable joint welding structure | |
| CN219626899U (en) | Waterproof joint for aluminum wire shielding aluminum core cable |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| GR01 | Patent grant | ||
| GR01 | Patent grant |