Aluminothermic Tube Cable Connection Anchoring Mechanism
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Solution Overview
Problem
Existing methods for making electric connections between conductive cables and steel tubes of different diameters often result in excessive surface temperature, leading to structural changes and potential defects in the steel, which can cause contraction cracks and inflammation of volatile components in gas pipelines.
Innovation Solution
A system and process utilizing an anchoring mechanism with magnets and traction springs to secure the mold-crucible to the tube, combined with low-fusion-point alloy plates for welding, allowing for the same mold-crucible to be used across various diameters without exceeding a predetermined temperature, ensuring structural integrity and preventing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional welding methods are used to make electric connections between cables and steel tubes, then electric connection is achieved, but the tube surface temperature exceeds the predetermined value causing structural changes and defects
Solution Approach 1:
The patent introduces a mold-crucible as an intermediary device between the cable and steel tube. This mold-crucible contains the welding materials and controls the welding process, allowing the welding heat to be contained within the mold rather than directly heating the tube surface. The mold acts as a mediator that enables the welding reaction while protecting the tube from excessive temperature
Solution Approach 2:
The patent changes the physical state and containment parameters of the welding process by enclosing it within a mold-crucible. By controlling the confinement and material placement parameters within the mold, the welding reaction parameters (temperature distribution, heat concentration) are modified to prevent tube surface overheating while maintaining connection quality
2Device complexity
If a single mold-crucible is used for various tube diameters, then device complexity is reduced, but the anchoring mechanism must adapt to different surfaces
Solution Approach 1:
The patent designs the mold-crucible with a universal anchoring mechanism that can adapt to different tube diameters. The anchoring elements are configured to engage with the tube surface through magnetic attraction and mechanical contact, allowing the same mold design to function across various tube sizes without requiring multiple specialized molds for each diameter
3Reliability
If a complex anchoring mechanism with multiple components is used to secure the mold-crucible, then anchoring reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple anchoring functions into an integrated anchoring mechanism that is part of the mold-crucible assembly. The anchoring elements (including magnetic components and mechanical contact elements) are merged into a unified structure that secures the mold to the tube while maintaining simplicity. This integration allows reliable anchoring without requiring separate complex components
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables reliable and efficient electric connections between cables and steel tubes of different diameters without causing structural changes in the steel, maintaining the steel's internal structure and reducing the risk of inflammation, while being economically advantageous due to its consumable nature and adaptability to any tube diameter.
Implementation Method 1
a piece that is mobile longitudinally with respect to the mold-crucible set, which is located on the lower part of said set and in whose lower part there is at least one magnet placed, adapted for the creation of a magnetic field to generate a connection force between the tube's surface and the anchoring system
Implementation Method 2
at least a traction spring that extends between the fixed piece and the mobile piece
Implementation Method 3
a small metal plate is placed between the cable and the area where the welding is to be made, which incorporates, on the side in contact with the steel surface, an alloy with a fusion point lower than the temperature at which the structural changes in the steel occur. The heat produced by the aluminothermic reaction will melt the low fusion point alloy
Implementation Method 4
an alloy with a fusion point lower than the temperature at which the structural changes in the steel occur
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
System (1) and process for connecting cables (18) and tubes (19), which comprises a mold-crucible set adapted for the performance of an aluminothermic reaction which takes place inside said mold-crucible set to generate the connection of the tube (19) and the cable (18), wherein the system comprises an anchoring mechanism adapted for its attachment to the surface of the tube (19) which comprises a fixed piece (101) anchored to the mold-crucible set and a mobile piece (102) that is placed on the lower part of the mold-crucible set and in whose lower part there is at least one magnet adapted for the creation of a magnetic field to generate the connection force between the surface of the tube (19) and the anchoring mechanism, and at least one traction spring (103) that extends between the fixed piece (101) and the mobile piece (102).