Power Cable End Tooling for Precise Cross-Sectional Joint Treatment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The challenge in power cable termination and joining, particularly for large diameter cables, is the complexity of cross-sections, risk of quality reduction due to high temperature welding, and the need for skilled labor, leading to potential failure and increased repair costs.
Innovation Solution
A cable treatment device with a kinematic means that allows fully controllable motion relative to the cable end, enabling precise and repeatable treatments, including welding and material addition, while ensuring alignment and reducing exposure to heavy tools and toxic fumes, using a tooling system that can move cross-sectionally and be adapted to various cable diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to join large diameter cables, then electrical connection is achieved, but the high temperature negatively influences the quality of cable insulation material close to the welding point
Solution Approach 1:
The welding process is segmented into multiple zones with different temperature controls. The patent applies selective heating where only the conductor strands are heated to welding temperature while the surrounding insulation remains below degradation temperature, achieved through localized heating zones and controlled heat distribution patterns.
Solution Approach 2:
Different thermal treatments are applied to different parts of the cable cross-section. The conductor strands receive high temperature welding heat while the insulation material receives protective low-temperature treatment or remains untouched, creating localized quality zones that optimize both welding strength and insulation integrity.
2Object-affected harmful factors
If active cooling is applied to the cable conductor close to the welding point, then thermal damage to insulation is reduced, but the quality of the welding process is reduced
Solution Approach 1:
The cooling system is segmented to apply cooling only in specific zones away from the active welding area. The patent uses spatially distributed cooling elements that provide thermal protection to the insulation while leaving the conductor welding zone thermally isolated to maintain optimal welding temperature and quality.
Solution Approach 2:
A thermal barrier or intermediary zone is introduced between the welding point and the cooling elements. This intermediary layer allows heat to be managed progressively, protecting the insulation from excessive heat while not interfering with the welding process at the conductor interface.
3Reliability
If manual welding is performed on large diameter cables, then joint quality can be achieved, but it requires extremely qualified and well-trained labour and is extremely time consuming
Solution Approach 1:
The welding system incorporates self-aligning mechanisms and automated positioning that allow the equipment to automatically adapt to cable variations without requiring skilled manual intervention. The apparatus uses self-regulating features such as automatic strand distribution and self-adjusting welding parameters that eliminate the need for highly trained operators while maintaining consistent quality.
Solution Approach 2:
Manual welding operations are replaced with an automated mechanical welding system. The patent employs mechanically driven strand alignment, automated welding electrode positioning, and computer-controlled welding parameters that substitute skilled manual labor with automated machinery, dramatically reducing time while maintaining or improving joint quality.
4Adaptability or versatility
If cable expansion and contraction is allowed throughout its life, then temperature changes are accommodated, but surface contact is reduced and surfaces may oxidize
Solution Approach 1:
The cable construction uses composite material structures with different thermal expansion coefficients arranged to maintain constant contact pressure. The patent incorporates layered composite designs where outer layers compensate for inner layer expansion, and uses oxidation-resistant composite coatings that maintain electrical contact while protecting against oxidative degradation during thermal cycles.
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 device improves the quality and reliability of cable joints, reduces the need for skilled labor, and minimizes exposure risks, enabling automated and efficient treatment of power cable ends with enhanced precision and safety.
Implementation Method 1
a welding tool head (496) adapted to melt and join cable conductor strands
Implementation Method 2
a flame treatment tool head (483) adapted to clean a cable end surface by burning off contaminants
Data Source
AI summary
A cable treatment device including: an affixing device for reversibly securing to a circumference of a power cable a kinematic device having attachment structure for attaching to the affixing member, the kinematic device adapted to provide kinematic motion relative to the attachment structure, the kinematic motion being fully controllable through a plurality of force input connections, and a tooling device attached to the kinematic device, the tooling device adapted to receive said kinematic motion, wherein the kinematic device allows the tooling to move cross-sectionally relative to the extension of a power cable secured by the affixing device. Thereby, a well-controlled and reproducible process is achieved, employing a portable device being user friendly, while simultaneously reducing technician exposure to toxic particulates.