Compression Joint Member for Carbon Fiber Cored Aluminum Cable
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Solution Overview
Problem
Carbon fiber-cored aluminum cables face challenges in compression and connection due to low compression resistance, leading to reduced holding force and tensile strength when anchored to steel towers, as traditional steel sleeves collapse the CFRP strand at the open end, resulting in insufficient tensile strength.
Innovation Solution
An assembly component for a compression joint member with a core portion compression member featuring an inclined portion at the housing hole opening, whose outer diameter decreases towards the opening, and a conductive portion compression member that includes a fitting portion to prevent positional shift, ensuring the core portion is connected without collapsing, thereby achieving high tensile strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional steel sleeve is used to compress and connect the carbon fiber core portion, then the connection structure is simple, but the core portion collapses at the open end resulting in insufficient tensile strength
Solution Approach 1:
The compression joint member is divided into multiple functional segments: a core portion compression member for compressing the carbon fiber core, and a conductive portion compression member for compressing the aluminum conductive portion. This segmentation allows each component to be optimized for its specific function, preventing core collapse while maintaining connection simplicity.
Solution Approach 2:
The core portion compression member acts as an intermediary component between the conductive portion compression member and the carbon fiber core. It transfers and distributes the compressive force evenly, preventing localized stress concentration that would cause core collapse, while enabling effective tensile strength transmission.
2Strength
If uniform compression is applied to the core portion, then the compression process is simple, but the open end of the core portion collapses resulting in reduced holding force
Solution Approach 1:
The compression joint member incorporates local quality variations through its tapered internal structure and segmented design. The compression force is distributed non-uniformly, with increased support at the open end where the core is most vulnerable, while maintaining adequate compression throughout. This localized quality enhancement prevents collapse without complicating the manufacturing process.
3Stability of the object's composition
If the compression portion has constant outer diameter, then the manufacturing is simple, but the core portion deforms excessively during compression
Solution Approach 1:
The compression portion features an asymmetric tapered design where the outer diameter varies along its length, being larger at the open end and gradually decreasing toward the closed end. This asymmetric geometry provides enhanced support where the core is most vulnerable to collapse, while maintaining manufacturing simplicity through a single continuous form without complex features.
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 allows for high tensile strength and bonding strength between the power-transmission line and the compression joint member, preventing core portion collapse during compression and maintaining a strong connection without excessive deformation.
Implementation Method 1
the compression portion includes an inclined portion provided at an opening side of the housing hole and whose outer diameter becomes smaller toward the opening side of the housing hole
Implementation Method 2
a compression portion that is compressed for compressing and connecting the end portion of the core portion housed in the housing hole
Data Source
AI summary
An assembly component of a compression joint member that connects a power-transmission line to a connection target, includes a core portion compression member including a housing hole that houses an end portion of the core portion, and a compression portion that is compressed for compressing and connecting the end portion of the core portion housed in the housing hole; and a conductive portion compression member that houses an end portion of the conductive portion and the core portion compression member, and is to be compressed with the end portion of the conductive portion and the core portion compression member, wherein the compression portion includes an inclined portion provided at an opening side of the housing hole and whose outer diameter becomes smaller toward the opening side of the housing hole.