Power Cable Lead-Out Rod Connection Using Compressed Conductive Particles
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Solution Overview
Problem
The existing methods for connecting power cables and conductor lead-out rods are time-consuming and prone to quality risks due to the scattering of conductive material during insulating layer removal, requiring high work proficiency and resulting in increased electrical resistance.
Innovation Solution
A connection structure that includes a cylindrical adapter for the conductor part, a conductor lead-out rod with an accommodation groove and fastening holes, and conductive particles to minimize electrical resistance, using fracture bolts to apply pressure and ensure a stable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the insulating layers of strands are removed and strands are gathered and compressed to connect power cable and conductor lead-out rod, then the connection is achieved, but the process takes a long time and requires considerable work proficiency
Solution Approach 1:
The patent introduces an adapter as an intermediary component that simplifies the connection process. The adapter includes a receiving space that accommodates conductive particles, which serve as a mediator between the conductor part and conductor lead-out rod. This intermediary structure eliminates the need for complex strand gathering and compression, allowing workers to simply insert the components and tighten bolts, thereby reducing both time and skill requirements.
Solution Approach 2:
The connection structure is divided into distinct segmented components: the adapter, conductive particles, conductor part, and conductor lead-out rod. Each component has a specific function and can be prepared independently before assembly. This segmentation allows for pre-fabrication and standardization, making the overall connection process faster and easier to perform without requiring high proficiency.
2Ease of manufacture
If the insulating layers are removed to expose conductive material, then connection is possible, but conductive material scatters causing quality risks
Solution Approach 1:
Conductive particles serve as an intermediary material that fills the receiving space within the adapter. These particles provide a reliable conductive path between the conductor part and conductor lead-out rod without requiring the removal of insulating layers from stranded conductors. The particles are contained within the bounded receiving space, preventing scattering and ensuring consistent electrical connection quality.
Solution Approach 2:
The adapter's receiving space is specifically designed with localized properties: it has a defined volume, is positioned at a specific location, and contains conductive particles with appropriate electrical conductivity. This localized quality ensures that the conductive function is provided exactly where needed, without affecting other parts of the connection, and eliminates the quality risks associated with scattered conductive material.
3Reliability
If conventional compression method is used to connect conductor part and conductor lead-out rod, then electrical connection is established, but electrical resistance of contact surface increases
Solution Approach 1:
The patent changes the physical state and distribution parameters of the conductive material. Instead of compressing stranded conductors to create contact, conductive particles are introduced in a loose state into the receiving space and then compacted uniformly. This parameter change in how the conductive material is applied and distributed results in lower and more consistent contact surface electrical resistance.
Solution Approach 2:
Conductive particles act as an intermediary that improves the electrical contact between the conductor part and conductor lead-out rod. The particles can conform to the surfaces they contact, filling gaps and creating multiple contact points, which reduces electrical resistance more effectively than direct metal-to-metal compression of stranded conductors.
4Productivity
If adapter with receiving space and conductive particles is used, then connection time is reduced and quality risks are minimized, but device structure becomes more complex
Solution Approach 1:
The adapter serves multiple functions within a single component: it provides structural support, defines the receiving space for conductive particles, guides the conductor part into position, and provides mounting points for bolts. This multi-functionality consolidates what would otherwise require multiple separate components and steps, reducing overall device complexity while maintaining high connection efficiency.
Solution Approach 2:
The adapter merges several functional elements into one integrated component. The receiving space, mounting features, and structural body are combined in a single piece rather than being separate components. This merging simplifies the overall assembly process and reduces the number of parts that need to be managed, offsetting the added complexity of introducing conductive particles.
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
This solution reduces the time and risk associated with the connection process while minimizing electrical resistance by using conductive particles to ensure a stable and efficient electrical connection between the power cable and the conductor lead-out rod.
Implementation Method 1
at least one conducting bolt configured to be fastened into the fastening hole to apply pressure to the conductive particles injected into the accommodation space so as to electrically connect the conductor part and the conductor lead-out rod
Data Source
AI summary
A connection structure for connecting a power cable and a conductor lead-out rod to minimize electrical resistance of a contact surface, and conductor connection device of a power cable may be provided with at least one conducting bolt configured to be fastened into a fastening hole to apply pressure to conductive particles injected into an accommodation space so as to electrically connect a conductor part and a conductor lead-out rod; and a fixing bolt configured to be fastened into the fastening hole to fix the conductor part inserted into an accommodation groove of the conductor lead-out rod.