Compression Connector for Overhead Power Line Conductors
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Solution Overview
Problem
Existing electrical connectors in overhead power line environments face challenges in securely connecting and supporting electrical conductors between support devices, particularly in maintaining a stable connection under various conditions such as windstorms and high electrical demand.
Innovation Solution
A compression connector system that includes a compression device and an outer tube, where the compression device is inserted into the outer tube's central through hole, and a radial compression force is applied to form a unified assembly with the electrical conductor's core and base row of wires, creating a secure lock that prevents the conductor from being removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a compression device is used to connect electrical conductors, then the connection strength is improved, but the device complexity increases due to multiple components (compression device, outer tube, core, base row of wires)
Solution Approach 1:
The electrical conductor is segmented into distinct functional components: a core for structural support, a base row of wires for electrical conduction, and an outer tube for insulation and protection. The compression device is segmented into a body and a separate outer tube that are compressed together to form a unified assembly. This segmentation allows each component to perform its specific function optimally while contributing to overall connection strength.
Solution Approach 2:
The patent implements a nested structure where the core is positioned within the base row of wires, which is in turn positioned within the outer tube. The compression device body and outer tube are nested together during compression to form an integrated assembly. This nesting arrangement maximizes space utilization and ensures that all components work together synergistically to achieve strong, reliable connections.
2Reliability
If the compression device secures the conductor tightly, then the reliability under windstorms and high electrical demand is improved, but the ease of operation decreases due to the complex compression process
Solution Approach 1:
The core, base row of wires, and outer tube are pre-positioned and aligned within the compression device body before the actual compression operation. This preliminary arrangement ensures that all components are in their correct positions and orientations, reducing the complexity and time required during the final compression step and making the installation process more straightforward.
Solution Approach 2:
The compression device body and outer tube are designed to be compressed together as a unified operation, forming an integrated assembly that secures the electrical conductor. This merging of components into a single compression action simplifies the installation process compared to multi-step compression methods, while still achieving the required connection stability for withstanding windstorms and high electrical demand.
3Manufacturing precision
If the outer tube is compressed around the core and base row of wires, then the manufacturing precision of the compressed assembly is improved, but the loss of time increases due to the compression process
Solution Approach 1:
The compression device is designed to apply compression force that slightly exceeds the minimum required to secure the electrical conductor components. This excessive action ensures that the core, base row of wires, and outer tube are compressed together with sufficient precision and tightness, creating a highly reliable connection. The additional compression force compensates for variations in material properties and ensures consistent precision across all installations.
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 compression connector system effectively secures the electrical conductor between support devices, ensuring a stable and reliable connection under various conditions by forming a unified, monolithic assembly that withstands physical and electrical stresses.
Implementation Method 1
applying a radial compression force to a length of the first end of the outer tube in order to radially compress the outer tube, the compression device, first portion of the core, and the first portion of the base row of wires
Data Source
AI summary
An electrical connector includes a compression device defining an aperture and is configured to receive a first portion of a base row of wires and a first portion of a core of an electrical conductor within the aperture. An outer tube defines a central through hole and is configured to receive the compression device within the central through hole. A first end of the outer tube is configured to be compressed around the first end of the compression device, and a first portion of the core of the associated electrical conductor to create a compressed assembly. The compressed assembly is contiguous with a second portion of the base row of wires and a second portion of the core of the associated electrical conductor.