Cable Joint Insulation Machining Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for forming joints between high-voltage cable ends are manual and time-consuming, resulting in suboptimal quality and increased preparation time.
Innovation Solution
A robot-controlled method that measures and adjusts the geometry of insulation cones and additional insulation layers to achieve a smooth transition, determining and removing material as needed to achieve a precise desired geometry, thereby improving the joint's properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual methods are used for forming joints between cable ends, then flexibility and adaptability are maintained, but preparation time increases and quality is suboptimal
Solution Approach 1:
The patent replaces manual mechanical operations with an automated robot system that performs measurement, material removal, and geometry adjustment. The robot uses sensors to measure the cones and additional insulation layer, then automatically removes material using a cutting tool to achieve the desired smooth transition geometry, eliminating manual intervention and improving both precision and efficiency
Solution Approach 2:
The system performs self-measurement and self-adjustment through the robot's integrated sensors and control system. The robot measures the actual geometry of the cones and additional insulation layer, automatically calculates the required material removal based on the deviation from desired geometry, and executes the correction without external intervention, enabling the system to service itself
2Productivity
If multiple machines are used for different operations, then specialized functions are achieved, but production time increases due to machine changes
Solution Approach 1:
The robot system is designed to perform multiple functions within a single device: it measures the geometry of cones and additional insulation layer using sensors, determines the desired geometry and material removal requirements through computational processing, and executes material removal using an integrated cutting tool. This multi-functional capability eliminates the need for separate specialized machines and reduces production time by avoiding machine changes
3Reliability
If geometry deviations are not corrected, then production time is reduced, but electric field smoothness and joint reliability deteriorate
Solution Approach 1:
The system implements a closed-loop feedback mechanism where sensors continuously measure the actual geometry of the cones and additional insulation layer, the control system compares these measurements against the desired geometry specifications, and the robot automatically adjusts material removal operations based on the detected deviations. This feedback loop ensures that the final geometry meets the required precision for smooth electric field transitions and joint reliability
Data Source
AI summary
A method for improving the properties of a joint between two cable ends having obtaining two cable ends, having uncovered conductors being joined in a connection zone, each cable end also including an uncovered insulation zone including uncovered insulation formed as a cone adjacent the uncovered conductor, covering the conductors with an additional insulation layer, measuring the additional insulation layer and the cones, determining the geometry of the cones and the additional insulation layer based on the measurements, determining a deviation of the geometry from a desired geometry of the cones and the additional insulation layer, where the desired geometry includes a smooth transition between two zones, determining, based on the deviation determination, material to be removed from the cones and the additional insulation layer achieving the desired geometry, and removing the material from the cones and the additional insulation layer.