High Voltage Connector Shroud for Partial Discharge Mitigation
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Solution Overview
Problem
High voltage potentials lead to partial discharge in air voids between a contact and an adjacent shell due to sharp edges formed during crimping, causing insulation damage from ozone creation.
Innovation Solution
A conductive shroud with a curved outer surface, including a cylindrical tubular rear portion and a hemispherical front portion, is placed around the crimped contact area to prevent electrical discharge, with a screw mechanism to secure the parts in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a contact is crimped to a cable conductor, then the contact is securely attached to the conductor, but sharp edges are formed that cause partial discharge and insulation damage
Solution Approach 1:
A shroud with a curved outer surface is placed around the crimped contact area. The curved surface eliminates sharp edges and corners that would otherwise concentrate electric field and initiate partial discharge, while maintaining the secure mechanical attachment provided by the crimp connection.
Solution Approach 2:
The shroud acts as an intermediary component between the crimped contact and the surrounding environment. It shields the sharp edges formed during crimping from direct exposure to the electric field, preventing partial discharge while preserving the mechanical integrity of the connection.
2Object-affected harmful factors
If a shroud is added around the crimped contact area, then partial discharge is prevented, but the device complexity increases
Solution Approach 1:
The shroud is implemented as a thin-walled cylindrical structure that provides effective shielding against partial discharge. The thin-wall design minimizes the added complexity and material usage while maintaining the protective function of eliminating sharp edge effects.
3Object-affected harmful factors
If the shroud has a curved outer surface, then partial discharge is avoided, but the manufacturing precision requirements increase
Solution Approach 1:
The shroud employs a simple cylindrical geometry with a curved outer surface, which can be manufactured using standard forming processes. The curvature is achieved through conventional metal forming techniques that do not require ultra-precise manufacturing, making the design practical for production.
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 shroud effectively reduces current leakage and minimizes partial discharge, protecting insulation from damage by smoothing the edges and ensuring a secure fit, thereby enhancing the reliability of high voltage connectors.
Implementation Method 1
High voltage (at least one kilovolt) potentials tend to result in partial discharge in air voids between a contact and an adjacent shell or other part that is at a different voltage. The partial discharge occurs at locations on the contact or cable that have sharp edges
Data Source
AI summary
A high voltage connector, such as one that carries current at a voltage of at least one kilovolts, is constructed to minimize partial discharge (a small amount of current flow) out of locations where a cable conductor has been crimped to the rear of a contact, which resulted in sharp points or edges. A shroud is mounted around the connector, which includes a cylindrical shroud sleeve lying around the crimped region of the contact, with the rear end of the shroud sleeve having rounded edges or abutting a rear shroud element, and with the front end of the shroud preferably being of hemispheric shape.