Cable Lug Protrusion for Blind Connector Assembly Sealing
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Solution Overview
Problem
The installation of cable lugs into connectors for high voltage systems, such as those used in offshore wind energy applications up to 72.5 kV, becomes increasingly difficult due to the high pressure required, making it challenging to ensure a tight and air/water-resistant assembly.
Innovation Solution
A cable lug design featuring a protrusion on one or both surfaces of the second portion, which includes a through hole for a stud, facilitates easier assembly by providing a stop element and improving positioning within the connector, reducing the need for excessive force and ensuring concentric alignment with the threaded pin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure is applied to install the cable lug into the connector, then the assembly achieves tightness and air/water resistance, but the installation becomes more difficult and requires greater operator force
Solution Approach 1:
The protrusion is pre-formed on the cable lug before installation, creating a built-in positioning and force-distribution mechanism that prepares the component for easier assembly while ensuring proper alignment and force distribution during installation
Solution Approach 2:
The protrusion creates a localized interaction point between the cable lug and connector that concentrates the installation force at a specific location, improving force distribution and reducing the overall force required from the operator while maintaining the necessary tightness
2Ease of operation
If the cable lug is designed without a protrusion, then the structure is simpler, but the assembly process becomes more difficult and positioning is less precise
Solution Approach 1:
The protrusion is pre-formed on the cable lug before installation, creating a built-in positioning and force-distribution mechanism that prepares the component for easier assembly while ensuring proper alignment and force distribution during installation
Solution Approach 2:
The protrusion acts as an intermediary element between the cable lug and the connector, facilitating the assembly process by providing a mechanical interface that guides alignment and distributes installation forces, thereby simplifying the overall assembly operation
Data Source
AI summary
A cable lug for a connector includes a first portion having a receiving end receiving a cable and a second portion extending from the first portion and having a through hole through which a stud can be passed. The through hole extends transversally through a first surface and a second surface of the second portion opposite one another. At least one of the first surface and the second surface has a protrusion projecting away from the at least one of the first surface and the second surface. The protrusion is positioned between the through hole and the first portion and is spaced apart from the first portion.