Conical HV Cable Connector for Narrow-Space Installation
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Solution Overview
Problem
Existing high-voltage cable connectors require significant space and auxiliary tools for installation due to the large diameter and weight of HV cables, leading to installation challenges in narrow spaces.
Innovation Solution
A high-voltage plug-connector and socket-connector system with conical surfaces and a mounting part that allows for an angled connection, reducing the need for bending and enabling installation without auxiliary tools, and allowing for a compact connection system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the HV cable is pushed into the inner-cone bushing using straight plug-in connectors, then the electrical connection is established, but the large diameter of the HV cable leads to an increased bending radius requiring additional space
Solution Approach 1:
The connector transitions from a straight linear configuration to an angled configuration, changing the spatial dimension of connection. The angled connector allows the cable to connect at an angle rather than requiring a 90-degree bend, effectively utilizing three-dimensional space more efficiently and reducing the area needed for cable routing.
Solution Approach 2:
The conical surface with matching taper angle provides a curved transition path for the cable insertion, replacing sharp angular bends with gradual conical transitions. This reduces stress concentration and allows for smoother cable routing with smaller bending radii.
2Reliability
If the HV cable is pushed into the inner-cone bushing, then the electrical connection is established, but the weight of the HV cable requires auxiliary installation tools such as pulleys or cranes
Solution Approach 1:
The angled connector design with conical surfaces enables the heavy HV cable to be installed using its own weight and gravity-assisted insertion, eliminating the need for external auxiliary tools like pulleys or cranes. The self-aligning conical geometry guides the cable into place without requiring additional installation equipment.
Solution Approach 2:
The conical surfaces with matching taper angles are pre-configured on both the connector and cable interface, creating a self-guiding insertion path before installation begins. This preliminary geometric configuration ensures that the heavy cable naturally follows the correct insertion path and aligns itself during installation.
3Reliability
If the HV cable is bent to reach the electrical connection spot, then the connection is achieved, but significant problems occur in areas with limited space
Solution Approach 1:
The angled connector utilizes three-dimensional spatial arrangement to achieve electrical connection without requiring the cable to bend within a confined two-dimensional plane. By introducing an angular dimension, the connector allows cable routing that respects the constraints of narrow spaces while maintaining reliable electrical connection.
4Quantity of substance
If the HV cable has a large diameter, then the current carrying capacity is increased, but the bending radius is increased requiring additional space
Solution Approach 1:
The conical surfaces provide a gradual curved transition that accommodates the large diameter of the HV cable without requiring excessive bending radius. The tapered geometry distributes the bending stress along a longer, gentler curve, allowing large-diameter cables to be installed in spaces with limited clearance.
Data Source
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AI summary
A high-voltage (HV) connection system is described. The HV connection system includes a HV plug-connector and a HV socket-connector. The HV plug-connector is installed in an electrical HV unit to form an electrical connection between a second portion of a conductive core of the HV plug-connector and the electrical HV unit in a way that a plug extends outwards of the electrical HV unit. A HV cable with a cable lug is inserted in the HV socket-connector. One opening of the HV socket-connector is plugged on the plug of the HV plug-connector to align the conductive core with a center line of a second channel. An electric connection is created between the cable lug and the conductive core.