Cable End Insulator With Notched Pin For Stress Resistance
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Solution Overview
Problem
Insulators for cable ends face challenges with high electrical and thermal stresses, particularly during overvoltage events, leading to potential damage of the connector system.
Innovation Solution
The insulator features a connector system with a notched internal surface on the connection pin, a composite electrically insulating body with an epoxy resin and silicone composition, and a compression system, including a pusher and flange, to enhance connection quality and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connector system is designed to handle high electrical and thermal stresses, then the reliability of the insulator is improved, but the complexity of the connector system increases
Solution Approach 1:
The connector system is divided into distinct functional components: a pin with notched internal surface for electrical connection, a clamping shell for mechanical securing, and a compression system with pusher and flange for thermal stress management. This segmentation allows each component to be optimized for its specific function while collectively providing robust stress resistance.
Solution Approach 2:
The insulator body employs a composite structure with an inner layer of epoxy resin and hardener providing electrical insulation, and an outer layer of silicone material providing thermal and mechanical protection. This composite material approach enables the insulator to simultaneously withstand high electrical voltages and thermal stresses without excessive complexity in the connector system.
2Reliability
If the internal surface of the pin is notched to improve connection quality, then the connection between strand and pin is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The notched internal surface is applied locally to the pin where it contacts the cable strand, rather than requiring precision throughout the entire pin structure. The notches create localized mechanical interlocking zones that enhance connection quality while allowing the rest of the pin to be manufactured with standard tolerances, thereby reducing overall manufacturing precision requirements.
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 solution provides a robust and reliable connection that minimizes damage from overvoltage and thermal stress, ensuring effective electrical insulation and environmental sustainability while facilitating easy cable connection.
Implementation Method 1
the serration of the internal surface, i.e. the surface in contact with the strand, makes it possible to ensure a very good connection between the strand and the pin while limiting damage to the pin, in particular in the event of an overvoltage
Implementation Method 2
an inner layer in which is formed a central channel inside which is housed a connector system of the insulator, the inner layer being in a material formed from a composition comprising an epoxy resin and a hardener, and an outer layer covering the inner layer, said outer layer being of a material formed from a composition comprising a silicone
Data Source
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AI summary
The invention relates to an insulator for one end of a cable, the insulator having a longitudinal body (2) in which a central channel (3) is provided, the insulator comprising a connector system arranged in the central channel, said system comprising a connection pin (7) intended to house a strand of the end of the cable, said pin being shaped so as to present a notched internal surface.