Bimetallic Power Cable Conductor Jointing Through Metal Transition
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Solution Overview
Problem
Joining a bimetallic conductor with another conductor is challenging due to difficulties in welding different metallic materials.
Innovation Solution
A power cable design with a bimetallic conductor section transitioning into a single-metal section at the interface, facilitated by a weld metal, allowing for jointing with a second conductor section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a bimetallic conductor is used to reduce costs and optimize current distribution, then economic efficiency and electrical performance are improved, but the difficulty of joining with other conductors increases due to welding challenges between different metallic materials
Solution Approach 1:
The conductor is divided into multiple sections with different metal compositions. The first conductor section has a bimetallic structure (first metal central element with second metal outer structure), while the second conductor section has a different metal composition. This segmentation allows each section to be optimized for its specific function: the bimetallic section for cost-effective current carrying, and the second section for ease of joining with other conductors through friction welding.
Solution Approach 2:
Different sections of the conductor have different metal compositions tailored to their specific requirements. The first conductor section uses a bimetallic structure where the central element is made of one metal and the outer structure is made of another metal, optimizing for electrical performance and cost. The second conductor section uses a different metal composition specifically optimized for joining characteristics, allowing friction welding to be performed effectively at the connection point without compromising the overall conductor performance.
2Ease of operation
If friction welding is used to join different metal conductors, then the ease of joining is improved, but the requirement for precise material matching and interface design increases
Solution Approach 1:
The conductor is designed in advance with a second conductor section that has specific joining characteristics optimized for friction welding. The interface between the first and second conductor sections is pre-configured with appropriate material composition and geometry, so that when joining is needed, the friction welding process can be performed effectively without requiring complex real-time adjustments or precise manual alignment during the actual joining operation.
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 the jointing of bimetallic conductors by ensuring a seamless transition and effective welding, suitable for high voltage AC power cables.
Implementation Method 1
the second end of the first axial part is friction welded to the first end of the second axial part
Implementation Method 2
the second end of the second axial part and the first outer metal structure are welded to the second conductor section by means of the weld metal
Data Source
Figure 1~3
Figure 4~5g
AI summary
A power cable (21) comprising: a conductor (1-1) comprising: a first conductor section (3) comprising an elongated first central element (3a) made of a first metal and a first outer metal structure (3b) made of a second metal surrounding the first central element (3a), a second conductor section (5-1) comprising the second metal, a weld metal (9) located axially between the first conductor section (3) and the second conductor section (5-1), wherein the first conductor section (3) has a first axial end section (3c) extending to the weld metal (9), wherein the first axial end section (3c) comprises: a central axially extending first metal member (3d) surrounded by the first outer metal structure (3b), the first metal member (3d) including a first axial part (4a) made of the first metal and a second axial part (4b) made of the second metal, wherein the first axial part (4a) has a first end that is welded to the first central element (3a) and a second end that is welded to a first end of the second axial part (4b), and wherein the second axial part (4b) has a second end, wherein the second end (4b) of the second axial part (4b) and the first outer metal structure (3b) are welded to the second conductor section (5-1) by means of the weld metal (9).