Angled Sleeve Fitting for High-Voltage MI Cable Splices
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mineral insulated (MI) cable splice designs are not suitable for high voltages above 1000 volts, 1500 volts, or 2000 volts and fail at elevated temperatures, requiring improved compaction of mineral insulation to match the level in MI cables, and need higher bending and tensile strengths to withstand subsurface conditions.
Innovation Solution
A fitting system with a sleeve configured to couple insulated conductors, featuring a longitudinal opening for filling and compacting electrically insulating material, and angled ends for enhanced mechanical and electrical integrity, reducing electric field intensities and increasing the operating voltage and temperature range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional MI cable splice designs are used, then the structure is simple and easy to manufacture, but they fail at high voltages above 1000 volts and elevated temperatures
Solution Approach 1:
The splice assembly is divided into distinct functional components: a body portion containing the core connection, an insulating material layer, and a metallic shield portion. This segmentation allows each component to be optimized for its specific function while maintaining overall reliability at high voltages and temperatures.
Solution Approach 2:
The splice employs a composite structure combining multiple materials: electrically insulating material (such as ceramic or polymer) surrounded by a conductive metallic shield (such as copper or aluminum mesh). This composite design provides both electrical insulation and electromagnetic shielding necessary for high-voltage operation.
2Strength
If conventional splice designs are used, then manufacturing is easier, but compaction of mineral insulation is insufficient and bending/tensile strength is inadequate
Solution Approach 1:
The insulating material and metallic shield are pre-assembled in specific layers around the core connection before final installation. This preliminary structuring ensures proper compaction and alignment, providing the necessary mechanical strength while simplifying the overall manufacturing process.
Solution Approach 2:
The metallic shield is configured as a flexible mesh or thin-walled structure that can be compacted around the core connection. This flexible design allows the shield to conform to the core geometry while providing tensile strength and resistance to bending forces.
3Object-generated harmful factors
If conventional splice designs are used, then the structure is simpler, but electric field intensities are higher causing increased leakage currents
Solution Approach 1:
An intermediate metallic shield layer is introduced between the core connection and the external environment. This shield acts as an intermediary that redistributes and contains the electric field, preventing field intensification at critical points and reducing leakage currents.
Solution Approach 2:
The electric field distribution is modified by changing the geometric parameters of the insulation structure. The multi-layer configuration with specific thickness ratios and radial arrangements alters the field intensity profile, reducing peak electric field values that cause leakage.
Data Source
AI summary
A fitting for coupling ends of insulated conductors includes a sleeve to couple an end of a jacket of a first insulated conductor to an end of a jacket of a second insulated conductor. The sleeve is located between end portions of the insulated conductors. At least one of the ends of the sleeve is angled relative to the longitudinal axis of the sleeve. The sleeve has a longitudinal opening that extends along the length of the sleeve substantially the distance between end portions of the jackets of the insulated conductors. The longitudinal opening allows electrically insulating material to be filled into the sleeve.