Power Cable Connector Assembly to Prevent Insulation Shrinkback
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Solution Overview
Problem
Existing power cable accessories face issues with insulation shrinkback due to mechanical stresses and temperature, leading to electrical breakdown risks, particularly in cross-linked polyethylene (XLPE) insulation systems.
Innovation Solution
A power cable accessory assembly featuring a fastening device attached to the electrical insulation layer, with a connector that engages via a structure such as a circumferential groove or pins, ensuring an axially fixed position to prevent shrinkback, using thermosetting or thermoplastic polymers and bayonet connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the insulation layer is mechanically connected to the connector using anchor elements and flanges, then the connection strength is improved, but the reliability deteriorates due to bending and disengagement at elevated temperatures
Solution Approach 1:
A restraining element is introduced as an intermediary component between the flange and the connector. This restraining element prevents the flange from bending radially outward and disengaging from the anchor elements when thermal expansion occurs, thereby maintaining reliable connection at elevated temperatures while preserving the mechanical strength provided by the flange-connector assembly
Solution Approach 2:
The solution changes the mechanical parameters of the connection system by adding a restraining element that alters the stress distribution and movement characteristics of the flange under thermal load, preventing the harmful radial bending motion that occurs in conventional designs
2Ease of manufacture
If the insulation layer is allowed to shrink freely, then the ease of manufacture is improved, but the reliability deteriorates due to shrinkback and electrical breakdown risks
Solution Approach 1:
The restraining element is pre-installed on the connector before the insulation layer is positioned. This preliminary action ensures that when the insulation layer is later installed and subjected to thermal shrinkage, the restraining element is already in place to prevent shrinkback, thereby maintaining electrical reliability without complicating the insulation installation process
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 assembly effectively prevents or reduces insulation shrinkback, maintaining electrical integrity and facilitating intuitive installation by ensuring a secure connection between the connector and insulation layer.
Implementation Method 1
the connector has an inner surface provided with a structure that engages with the fastening device to maintain an axially fixed position between the connector and the electrical insulation layer
Implementation Method 2
The electrical insulation layer may comprise a thermosetting polymer such as crosslinked polythyelene. Thermosetting polymers are hardened, making the solution in which the connector engages with the electrical insulation layer by means of the fastening device more durable
Data Source
Figure 1~2
Figure 3
AI summary
A power cable accessory assembly (1.1) comprising: a power cable (3) comprising: a conductor (5), and an electrical insulation layer (7) arranged around the conductor (5); a fastening device (11a) attached to an end face (7.1) of the electrical insulation layer (7), and a connector (9) mechanically connected to the conductor (5), wherein the connector (9) has an inner surface provided with a structure that engages with the fastening device (11a) to maintain an axially fixed position between the connector (9) and the electrical insulation layer (7).