Cable Shield Connection Using Constant-Force Spring Clamping
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Solution Overview
Problem
Existing devices for reconstructing or restoring the metallic shield of power cables face challenges such as complex installation, inconsistent contact resistance, deformation of polymeric layers, difficulty in uniform contact with the cable circumference, and ergonomic concerns during deployment of constant force springs, particularly due to varying cable designs and ampacity ratings.
Innovation Solution
The use of a clamping device with a constant force spring, optionally combined with an unwinding feature, to securely attach an electrically-conductive member to the metallic shield, ensuring consistent contact and accommodating cable expansion and contraction, while allowing for factory or field installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing devices are used to reconstruct the metallic shield, then the cable shield can be restored, but the installation process becomes complex and time-consuming
Solution Approach 1:
The device is divided into separate functional components: a conductive member for electrical connection and a constant force spring for mechanical attachment. This segmentation allows each component to be optimized independently and simplifies the overall installation process while maintaining reliable shield restoration.
Solution Approach 2:
The constant force spring is pre-assembled with the conductive member before field installation. This preliminary assembly ensures proper alignment and connection integrity, reducing installation complexity and time while guaranteeing reliable electrical connection to the metallic shield.
2Reliability
If existing devices are used to reconstruct the metallic shield, then electrical connection can be established, but contact resistance becomes inconsistent
Solution Approach 1:
The constant force spring maintains a predetermined constant force on the conductive member, ensuring consistent contact pressure and therefore consistent contact resistance. This force parameter control guarantees reliable electrical connection across varying cable conditions and installation scenarios.
Solution Approach 2:
The device incorporates dynamic elements that allow the conductive member to maintain optimal contact with the metallic shield despite cable expansion, contraction, or movement. The constant force spring dynamically adjusts to maintain consistent electrical connection under varying mechanical conditions.
3Reliability
If existing devices are used to reconstruct the metallic shield, then the shield can be restored, but polymeric layers become deformed
Solution Approach 1:
The device uses a flexible constant force spring that can conform to the cable surface without imposing excessive localized stress on the polymeric layers. This flexible design allows the device to adapt to cable geometry while distributing mechanical loads to prevent layer deformation.
Solution Approach 2:
The device design incorporates cushioning elements and distributes contact forces to prevent deformation of the polymeric layers before installation. The constant force spring is engineered to apply only the necessary minimum force for electrical connection, cushioning against excessive stress on the cable structure.
4Reliability
If existing devices are used to reconstruct the metallic shield, then electrical connection can be established, but uniform contact with cable circumference becomes difficult
Solution Approach 1:
The conductive member is designed with specific local properties at the contact point with the metallic shield, ensuring optimal electrical connection. The constant force spring applies force locally at the critical contact interface while maintaining overall structural integrity, achieving reliable connection without complex installation procedures.
5Strength
If constant force springs are deployed during installation, then secure attachment can be achieved, but ergonomic concerns arise during deployment
Solution Approach 1:
The constant force spring is merged with the conductive member in a pre-assembled unit, eliminating the need for separate deployment operations. This combination maintains strong attachment capability while simplifying the installation process and improving ergonomics by reducing the number of manual manipulation steps required.
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 reliable, efficient, and safe method for connecting to the metallic shield, maintaining consistent contact resistance and preventing deformation of cable layers, suitable for various cable designs and ampacity ratings, thereby ensuring long-term performance and user safety.
Implementation Method 1
a holding feature comprising a constant force spring
Implementation Method 2
an electrically-conductive member comprising a metal braid
Data Source
AI summary
The present disclosure describes various devices and methods for the reconstruction or restoration of a metallic shield of a cable, which provide a holding feature for simplifying the installation of an electrically-conductive member on the metallic shield and improving the reliability of the connection. Both factory-supplied and field-installable holding features are described.