Conductive Cable Repair Packing for Severe Strand Damage
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Solution Overview
Problem
Current repair methods for high or very high voltage electrically conductive cables are limited in their applicability, especially when a large number of strands are severed, leading to increased costs and intervention times, particularly when optical fiber cables are involved, as they often require complete cable replacement or complex junction sleeve installations.
Innovation Solution
A method involving the winding of two layers of preformed conductive strand repair trim around the damaged section of the cable, with the first layer made of conductive strands and the second layer of aluminized steel, allowing for effective repair of cables with up to 80% of strands cut, reducing the need for costly replacements and lengthy interventions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the first family of repair methods (pre-formed repair packing) is used, then the repair process is simple and cost-effective, but it can only be applied when the number of severed strands is less than 33% of the conductor cable's breaking load
Solution Approach 1:
The repair packing is divided into multiple layers (first layer, second layer, and optional third layer) with each layer serving a specific function. The first layer provides immediate electrical contact, the second layer reinforces the repair, and the third layer (if used) provides additional protection. This segmentation allows the repair method to handle severe damage while maintaining simplicity.
Solution Approach 2:
The repair packing uses composite structures combining different materials - conductive strands for electrical conductivity, non-conductive packing material for mechanical support, and optionally aluminized steel strands for enhanced strength. This composite approach enables the repair to withstand higher strand loss percentages while remaining cost-effective.
2Adaptability or versatility
If the second family of repair methods (splicing sleeves with hydraulic press) is used, then cables with more than 33% severed strands can be repaired, but the intervention time and implementation resources increase significantly
Solution Approach 1:
The repair packing strands are pre-formed and pre-assembled into layers before being applied to the damaged cable. This preliminary preparation eliminates the need for complex on-site assembly operations like hydraulic pressing, significantly reducing intervention time while maintaining the ability to repair cables with more than 33% severed strands.
Solution Approach 2:
The complex hydraulic pressing operation and splicing sleeve installation process is extracted and replaced by the simpler pre-formed repair packing method. The essential function of restoring electrical continuity is achieved through the pre-formed packing layers without requiring the time-consuming hydraulic press operation.
3Reliability
If complete cable replacement is performed, then optical fiber cables with severe strand damage can be repaired, but the costs and intervention times are very lengthy and expensive
Solution Approach 1:
Instead of replacing the entire cable, the repair packing is applied locally only to the damaged section. The packing layers are wound around the specific longitudinal portion containing the severed ends, providing targeted repair that restores electrical and optical continuity without the need for complete cable replacement, thus significantly reducing intervention time and cost.
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 method enables satisfactory repair of conductive cables with a high percentage of severed strands, maintaining electrical conductivity and mechanical strength, while significantly reducing repair costs and time compared to existing methods, and ensuring minimal disruption to optical signals in fiber-optic cables.
Implementation Method 1
winding of a first layer of preformed repair packing with conductive strands around and in electromechanical contact with the limited longitudinal portion of the conductive cable comprising said sectioned ends
Implementation Method 2
winding of a second layer of preformed repair packing with conductive strands around and in electromechanical contact with the first layer of preformed packing
Data Source
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AI summary
This method for repairing an electrically conductive cable (30), the conductive cable (30) having a plurality of conductive strands wound in at least one strand and a portion of these conductive strands being sectioned at least on the external surface of the conductive cable (30) over a limited longitudinal portion (36) of the conductive cable (30) such that this limited longitudinal portion (36) includes the two sectioned ends of each sectioned conductive strand, comprises winding (112, 114) a first layer (38) of preformed repair packing with conductive strands around and in electromechanical contact with the limited longitudinal portion (36) of the conductive cable (30) having said sectioned ends of each sectioned conductive strand. It further comprises winding (118, 120) a second layer (40) of preformed repair packing with conductive strands around and in electromechanical contact with the first layer (38) of preformed packing.