Reliable Induction Cable Core Production with High-Temperature Insulation
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Summary
Problems
Current methods for producing induction cables for inductive heating of oil sand and extra-heavy oil deposits are not reliable or cost-effective for large-scale industrial applications, particularly in ensuring consistent separation points and high-temperature resistance.
Innovation solutions
A method for producing cable cores with defined separation points using a continuous process where raw wire is severed and reconnected with an insulating connector, ensuring airtight and mechanically strong connections, and using high-temperature-resistant materials like PFA and PTFE for insulation and connectors, with online quality control and rewinding for efficient production.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If wire ends are connected with a connector at separation points during continuous production, then the cable can be produced in a continuous automated process, but the connection point may create a weak point in the insulation or mechanical strength
Why choose this principle:
The wire ends are inserted into the hollow connector body, nesting the conductors within the connector structure. This ensures secure mechanical retention and proper positioning of the wire ends within the insulating material, creating a reliable connection that maintains insulation integrity.
Principle concept:
If wire ends are connected with a connector at separation points during continuous production, then the cable can be produced in a continuous automated process, but the connection point may create a weak point in the insulation or mechanical strength
Why choose this principle:
The wire ends are pre-inserted into the connector before the insulating material is applied. This preliminary positioning ensures that the conductors are correctly aligned and secured before the final insulation step, preventing misalignment or exposure that would compromise connection reliability.
Application Domain
Data Source
AI summary:
A method for producing cable cores with defined separation points using a continuous process where raw wire is severed and reconnected with an insulating connector, ensuring airtight and mechanically strong connections, and using high-temperature-resistant materials like PFA and PTFE for insulation and connectors, with online quality control and rewinding for efficient production.
Abstract
The invention relates to a production method for producing a cable core (2) for an induction cable (24) in a simple and simultaneously reliable manner, in which a raw conductor (14) is fed continuously to a processing machine (38) and separated in a recurring manner at specified length positions at a separating point (6) so that there are two wire ends (16). Said ends are then pulled apart from each other in the longitudinal direction of the cable (4) and then connected again by a connector (8) which has an insulating spacer (20) which separates the wire ends (16) from each other by a specified distance. The connector (8) is preferably designed as an injection molded part, in particular using the online process. A plurality of such cable cores (2) are connected to each other via a cabling process and then enclosed by a cable sleeve (34) to produce the induction cable (24).