Angled Power Pin Alignment Fixture for ESP Cables
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Solution Overview
Problem
Existing crimping fixtures for electrical submersible pump cables require lengthy stripping of armor to align power pins correctly, increasing the risk of damaging rigid conductors and limiting the versatility of connectors.
Innovation Solution
An angled power pin alignment and crimping fixture with diverging channels in a symmetrical shape allows secure positioning of power pins without bending conductors, reducing the need for extensive stripping and enabling standard crimping tools to be used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing crimping fixtures are used to align power pins, then proper pin alignment is achieved, but the cable armor must be stripped back a relatively long distance which increases the risk of damaging conductors
Solution Approach 1:
The patent introduces a diverging angle dimension to the channel configuration. Channels are arranged at angles (e.g., 30, 45, or 60 degrees) rather than parallel, creating a diverging pattern from a common origin point. This angular arrangement in a new dimensional configuration allows conductors to be positioned correctly without requiring extensive stripping, thereby resolving the contradiction between alignment precision and conductor damage risk
Solution Approach 2:
Instead of bending conductors out and then back into parallel position as in existing fixtures, this invention inverts the approach by having channels diverge naturally from a common origin. The conductors follow the diverging channel paths directly without requiring reverse bending manipulation, eliminating the harmful manipulation steps while maintaining alignment precision
2Manufacturing precision
If existing crimping fixtures manipulate conductors into parallel position, then alignment is achieved, but the complexity of the process increases and time is lost
Solution Approach 1:
The fixture channels are pre-configured in a diverging arrangement that naturally guides conductors into their final positioned orientation. This preliminary structural configuration eliminates the need for time-consuming manipulation steps (bending out and back), as the diverging channel geometry itself performs the alignment function, thereby reducing process time while maintaining precision
Solution Approach 2:
The invention extracts and eliminates the harmful manipulation steps (bending conductors out and back) from the crimping process. By using diverging channels that naturally position conductors, the complex manipulation sequence is removed entirely, leaving only the essential crimping action, thus reducing time loss while preserving alignment precision
3Quantity of substance
If heavy gauge rigid conductors are used in ESP cables, then adequate current carrying capacity is achieved, but the conductors become very rigid and difficult to manipulate
Solution Approach 1:
The diverging channel configuration introduces an angular dimension that accommodates the rigidity of heavy gauge conductors. Instead of requiring conductors to bend in tight parallel configurations, the diverging angles provide sufficient space and geometric accommodation for rigid conductors to be positioned and crimped without excessive manipulation, thus maintaining ease of operation while preserving current carrying capacity
Data Source
AI summary
A power pin alignment and crimping fixture having a fixture body. The fixture body includes a plurality of channels each having a first open end and a second open end. The plurality of channels are disposed at an angle diverging away from one another in a direction from the first open end to the second open end such that each of the plurality of channels are disposed along a corresponding side edge of a symmetrical shape.