Conductor Clamp with Sliding Assemblies for Transmission Line Repair
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Solution Overview
Problem
Existing electrical transmission line repair systems face challenges in ease of preparation and installation on rugged, high-altitude job sites, requiring lighter and more robust components to minimize weight and improve mechanical and electrical integrity, especially in clamps and connectors.
Innovation Solution
The electrical transmission line repair device features a design with symmetrical conductor clamps and tie rails, utilizing a tongue-and-groove configuration between upper and lower assemblies for slidable engagement, and clamping fasteners that sandwich the conductor, providing enhanced structural support and minimizing corona effects through convex surface designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional repair systems are used, then mechanical and electrical integrity can be restored, but the device weight becomes excessive and assembly becomes difficult in rugged environments
Solution Approach 1:
The clamp assembly is divided into multiple modular components including upper and lower clamp assemblies, conductor clamps, tie rails, and fasteners. This segmentation allows each component to be optimized independently for strength-to-weight ratio and enables easier handling and assembly in rugged environments while maintaining overall structural integrity
Solution Approach 2:
The device utilizes composite construction combining different materials with complementary properties - aluminum or aluminum alloy for conductor contact regions to minimize weight and corona effects, and high-strength steel for structural components requiring maximum strength. This composite approach achieves the required mechanical integrity while minimizing overall device weight
2Reliability
If traditional clamp designs are used, then conductor attachment can be achieved, but the structure lacks robustness and requires complex componentry
Solution Approach 1:
Multiple functional elements are merged into integrated assemblies - the upper and lower clamp assemblies are combined with conductor clamps, tie rails, and fasteners to form unified clamp units. This merging reduces the number of separate components while enhancing overall clamp robustness through synergistic structural integration
Solution Approach 2:
The conductor contact regions feature convex curved surfaces that naturally distribute clamping forces evenly around the conductor. This curvature design enhances contact robustness and electrical performance while simplifying the clamp structure by eliminating the need for additional adjustment mechanisms
3Productivity
If conventional assembly methods are used, then installation can be completed, but preparation and assembly become excessively difficult on high-altitude job sites
Solution Approach 1:
Clamp components are pre-assembled into upper and lower clamp assemblies with integrated fasteners and tie rails during manufacturing. This preliminary assembly reduces the complexity of field preparation and assembly operations, allowing technicians to complete installation more efficiently in rugged high-altitude environments
Solution Approach 2:
The clamp assemblies incorporate movable and adjustable elements that allow for flexible adaptation to different conductor sizes and installation conditions. This dynamic design simplifies field assembly by eliminating the need for precise pre-measurement and complex adjustment procedures
4Reliability
If traditional conductor contact designs are used, then electrical connection can be established, but corona effects increase and mechanical integrity decreases
Solution Approach 1:
The conductor contact regions utilize convex curved surfaces instead of flat or sharp edges. This curvature design distributes the electric field more uniformly, preventing field concentration that causes corona discharge. The rounded surfaces maintain excellent electrical contact while minimizing corona effects and associated energy losses
Solution Approach 2:
The contact surface geometry is optimized with specific curvature radii and surface profiles that balance electrical performance and mechanical strength. By carefully selecting and controlling these geometric parameters, the design achieves low corona effects while maintaining the mechanical integrity required for high-strength conductor attachment
Data Source
AI summary
An electrical transmission line repair device including a first conductor clamp, a second conductor clamp and at least one tie rail extending between the first and second conductor clamps in a spaced apart orientation. The first conductor clamp including a lower assembly and an upper assembly. The lower assembly and the upper assembly are slidably engageable with each other so as to define a conductor cavity extending therealong. Clamping fasteners are configured to extend through openings in the upper assembly so as to be threadable toward and away from the conductor contact region of the lower assembly within the conductor cavity.