Conductive Cable End Interface for Clean Low-Resistance Termination
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Solution Overview
Problem
Current methods for terminating and joining power cables, especially those with reactive compounds, are cumbersome and often require specialized labor, leading to inefficiencies and inaccuracies in electrical connections, particularly in high-voltage and submarine cables, where precise and reliable connections are critical for quality control and rapid installation.
Innovation Solution
A method and device that apply electrically conductive particulates dispersed in a non-adhering carrier fluid to the cable ends, ensuring effective adhesion without excessive heating, which allows for automated and fast interfacing of cables with reactive compounds, ensuring all or substantially all wires are electrically connected with low resistance and uniform transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding or soldering methods are used to terminate cables with reactive compounds, then electrical connection is achieved, but the reactive compounds contaminate the termination or joint requiring extensive cleaning and de-isolation
Solution Approach 1:
The invention extracts and removes the reactive compound from the cable end section before making the electrical connection. This is achieved through a cleaning process that eliminates the contaminating substance, allowing subsequent welding or soldering without contamination issues.
Solution Approach 2:
The invention performs preliminary cleaning and de-isolation of the cable end section before the actual connection process. By removing the reactive compound in advance, the subsequent welding or soldering can proceed without contamination, eliminating the need for extensive cleaning during or after the connection process.
2Reliability
If manual de-isolation and cleaning of cable wires is performed, then electrical connection quality improves, but the process becomes time-consuming and requires specialist labor
Solution Approach 1:
The invention replaces manual mechanical cleaning and de-isolation processes with automated cleaning means. This automation reduces the time required for the process and eliminates the need for specialist labor while maintaining connection quality.
Solution Approach 2:
The invention performs preliminary automated cleaning and preparation of the cable end section before the connection process. This preliminary action eliminates the need for time-consuming manual intervention during the actual connection process.
3Measurement precision
If insulation is removed by hand for cable characterization, then measurement can be performed, but precise effective lengths of individual strands cannot be measured effectively resulting in data bias
Solution Approach 1:
The invention replaces manual insulation removal with automated cutting means that precisely cut the insulation. This automation enables accurate measurement of individual strand lengths while eliminating the imprecision inherent in manual removal methods.
4Strength
If factory joints are made to meet extensive mechanical specifications for submarine cables, then mechanical strength is achieved, but the process becomes complex and time-consuming
Solution Approach 1:
The invention merges the electrical connection process with the mechanical joining process into a single integrated operation. By combining these functions, the joint achieves both electrical connectivity and mechanical strength without requiring separate complex processes.
Solution Approach 2:
The invention creates a universal joining process that simultaneously achieves electrical connection, mechanical strength, and sealing functions. This multi-functional approach simplifies the overall process while meeting all necessary specifications for submarine cable applications.
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 approach enables precise and efficient cable characterization, production, and installation by ensuring effective electrical and mechanical connections, reducing the need for specialized labor and minimizing the risk of contamination or damage to the cable insulation, while maintaining the mechanical strength and flexibility of the cable.
Implementation Method 1
applying said electrically conductive particulates dispersed in a carrier fluid of a different material than said particulates into contact with said end section, successively adding the electrically conductive particulates onto the end section
Data Source
Figure 1A~1B
Figure 2A~2C
Figure 3
AI summary
The present invention relates to an interface-forming device (x60) and a method for providing an electrically conductive power transmission interface (x30) on the end surface of a power cable (x00) having at least two separate wires (x02) being electrically conductive, the cable (x00) further comprising a reactive compound different from the wires (x02) for providing further features to the power cable (x00). The method comprises the steps of providing an end section of said power cable (x00), said end section comprising wires (x02) having wire ends, the end section further having said reactive compound, and successively adding electrically conductive particulates (x67A) onto said end section by bringing the conductive particulates being dispersed in a carrier fluid of a different material than said conductive particulates into contact with said end section. Thereby, cable joining and terminations are achieved of a higher quality.