Bushing Adapter Segmentation for Thermal Stress Reduction

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Solution Overview

Problem

Conventional high-power bushings fail due to thermal expansion differences between copper and epoxy resin, leading to mechanical stress and increased failure rates in harsh environments, especially under extreme temperatures and vibrations, which also complicates installation and maintenance.

Innovation Solution

A bushing adapter with a modular design featuring a rotatable fastening member and insert, allowing for secure mechanical and electrical connections without requiring the entire bushing to rotate, thus reducing stress and facilitating easier installation and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a conventional high-power bushing with copper conductor and epoxy resin insulating material is used, then high electrical power transfer capability is achieved, but thermal expansion differences between copper and epoxy resin under extreme temperatures cause mechanical stress and increased failure rates

Engineering Contradiction:

Improveelectrical power transfer capabilityVSAvoidfailure rate under extreme temperatures

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The bushing is divided into separate components: a copper conductor portion and an insulating material portion, which are assembled together rather than formed as an integral component. This segmentation allows each material to independently accommodate thermal expansion without generating excessive mechanical stress at the interface, thereby maintaining reliability under extreme temperature conditions while preserving high electrical power transfer capability.

Inventive Principle:

Principle #1Segmentation

2Strength

If a robust and stiff bushing configuration is used to provide mechanical and electrical stability, then high mechanical integrity is achieved, but the bushing becomes more susceptible to damage under extreme temperatures and vibrations

Engineering Contradiction:

Improvemechanical integrityVSAvoidresistance to thermal and vibrational stress

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The bushing is segmented into a copper conductor portion and an insulating material portion that can move independently relative to each other. This segmentation prevents the transfer of excessive mechanical stresses from vibrations and thermal expansion to either component, thereby maintaining mechanical integrity while improving resistance to thermal and vibrational stress in harsh environments.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If an integral bushing component is used to simplify structure, then manufacturing simplicity is achieved, but installation and maintenance become more complex due to alignment requirements

Engineering Contradiction:

Improvestructural simplicityVSAvoidinstallation and maintenance complexity

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The bushing is designed as separable components that can be independently installed and positioned. The copper conductor portion can be inserted into the insulating material portion without requiring precise alignment of the entire assembly, thereby simplifying installation and maintenance operations while maintaining structural effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating material portion acts as an intermediary component that receives and secures the copper conductor portion. This intermediary structure facilitates easier assembly and disassembly by providing a interface that accommodates the conductor without requiring complex alignment procedures, thereby improving ease of operation during installation and maintenance.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The bushing adapter provides a reliable, durable connection that withstands environmental stresses and simplifies installation and disassembly, maintaining alignment and reducing the risk of mechanical failure, while allowing for efficient power transfer in high-power applications.

Implementation Method 1

as typically epoxy resin and the usually highly conductive copper material may have very different coefficients of thermal expansion, which may result in cracks or any other damage in the insulating epoxy resin

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS11043758B2Bushing adapter and bushing with superior mechanical characteristics

Publication Date: 2021.06.22 SECHERON SA

AI summary

A bushing adapter comprises an insert having a bore extending through the insert along a length direction of the insert and a fastening member extending through the bore. The insert is configured to be attached to a bushing conductor of a bushing. The fastening member has an operating portion positioned outside of the bore at a bushing internal end of the fastening member and a fastening portion positioned outside of the bore at a bushing external end of the fastening member.