Bimetal Cable Joint Connector With Clamp-to-Weld Transition
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Solution Overview
Problem
Existing technologies struggle to efficiently join power cables with conductors made of different metal materials, such as copper and aluminum, which are required in varying temperature conditions.
Innovation Solution
A tubular metal joint connector with a larger radius at one end for screw clamping and a smaller radius at the other end for welding, adapted to the material properties of each conductor, allowing for secure and efficient connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sleeve or collar is used to enclose the joint between two conductors, then the joining process is simplified, but the electrical conductivity and mechanical strength of the joint are insufficient
Solution Approach 1:
The joint connector is divided into two distinct parts: a first connector portion for mechanical clamping and a second connector portion for welding. This segmentation allows each part to optimize its function - the clamping portion provides secure mechanical holding while the welding portion ensures low-resistance electrical connection, thereby resolving the contradiction between ease of manufacture and joint reliability
Solution Approach 2:
The joint connector acts as an intermediary component between two dissimilar conductors. It provides transition means that accommodate different material properties (copper vs aluminum), enabling reliable connection while simplifying the overall joining process through standardized connector interfaces
2Strength
If a joint piece with friction welding is used to connect two conductors of different materials, then the mechanical strength is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The joint connector separates the mechanical connection function (clamping portion with fastening means) from the electrical connection function (welding portion). This segmentation eliminates the need for complex friction welding operations while maintaining both mechanical strength and electrical conductivity through simpler, more cost-effective connection methods
Solution Approach 2:
Different portions of the joint connector have different structural characteristics optimized for their specific functions: the clamping portion has a hollow cylindrical structure with fastening means for mechanical holding, while the welding portion has a flattened or reduced cross-section for optimal welding performance. This local quality differentiation achieves high strength without overall structural complexity
3Ease of manufacture
If a straight tubular joint connector is used, then the manufacturing is simplified, but material is wasted due to the need for larger radius throughout
Solution Approach 1:
The joint connector features an asymmetric radius distribution: a larger radius in the clamping portion to accommodate the conductor and provide structural strength, and a smaller radius in the welding portion to reduce material usage. This asymmetric design optimizes material efficiency while maintaining manufacturing simplicity through a single-piece construction
Solution Approach 2:
The connector has different radial dimensions at different locations optimized for local requirements: larger radius where mechanical strength and conductor accommodation are needed, smaller radius where material reduction is beneficial. This local quality approach minimizes overall material usage while preserving ease of manufacture through controlled geometric variation
4Adaptability or versatility
If a joint connector is designed to accommodate different conductor materials, then the adaptability is improved, but the design complexity increases
Solution Approach 1:
The joint connector is segmented into specialized portions: a clamping portion designed for mechanical attachment and a welding portion designed for electrical connection. Each portion can be optimized for specific material properties, enabling adaptability to different conductor materials (copper, aluminum, etc.) without requiring complete redesign of the entire connector
Solution Approach 2:
The joint connector serves multiple functions: mechanical clamping, electrical connection, and material transition. By integrating these functions into a single component with standardized features, the design achieves broad adaptability to different conductor materials while maintaining relatively simple overall structure through functional integration
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
Facilitates secure mechanical and electrical connection of conductors with different materials, optimizing material usage and preventing damage due to thermal expansion differences.
Implementation Method 1
the closed end comprising an end face adapted to be welded to the second conductor
Data Source
AI summary
A joint connector for connecting a first conductor of a first power cable length and a second conductor of a second power cable length, the first conductor including a first metal material and the second conductor including a second metal material, the second metal material being different from the first metal material, wherein the joint connector includes a tubular metal body being made of the second metal material and having a central axis extending from a first end of the metal body to a second end of the metal body, wherein the first end is provided with an axially extending opening adapted to receive the first conductor, and wherein the metal body includes at least one radially extending through-opening, connecting with the axially extending opening, the radially extending through-opening being adapted to receive at least one fastener for clamping the first conductor when received within the axially extending opening, and wherein the second end is a closed end, the closed end including an end face adapted to be welded to the second conductor.