Cross-Bonding Cable Junctions With Standardized Main Structure
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Solution Overview
Problem
Developing and manufacturing three-phase buried high-voltage electric lines with screen stops is complex and costly due to the need for various structural, functional, and dimensional specificities in junctions, which complicates the evacuation of residual currents.
Innovation Solution
A standardized main structure with a standard connection interface for all junctions, combined with a variable removable module that adapts to specific needs, allows for quick and flexible assembly of the electric line by using different types of modules to evacuate residual currents through monopolar or coaxial connecting cables, facilitating efficient and repetitive installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of junctions with screen stops are developed to meet specific functional needs for residual current evacuation, then the adaptability and functionality of the electric line is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The junction is divided into a common base structure and a variable module. The base structure contains standardized elements (connection interface, screen stops, mechanical coupling components) that remain constant across all junction types. The variable module contains only the specific functional elements needed for different residual current evacuation configurations (different cable arrangements, grounding options). This segmentation allows multiple junction types to be created without redesigning the entire junction, reducing manufacturing complexity while maintaining adaptability.
Solution Approach 2:
A universal connection interface is designed that can accommodate different module types. The standardized interface includes common connection points for screens and conductors that work with any module configuration. This allows a single base structure to support multiple junction types (different cable arrangements, grounding configurations) through interchangeable modules, eliminating the need for completely different junction designs for each application.
2Reliability
If custom-designed junctions with specific structural and functional characteristics are manufactured for each application, then the functional performance for residual current evacuation is optimized, but the manufacturing time and cost increase
Solution Approach 1:
The base structure is pre-manufactured with all standardized components (connection interface, screen stops, mechanical coupling elements) in a standardized configuration. This preliminary preparation allows the base structures to be produced in bulk with high efficiency. During assembly, only the specific module needs to be attached, which is a simple operation. This separates the complex manufacturing task (base structure) from the simple assembly task (module attachment), significantly improving manufacturing productivity while maintaining functional performance.
Solution Approach 2:
By segmenting the junction into a standardized base structure and a specific module, the manufacturing process is divided into two stages: mass production of base structures (high productivity) and rapid assembly of modules (simple operation). This segmentation allows the complex parts to be manufactured once and reused, while only the variable parts need to be customized for each application, thereby improving overall manufacturing efficiency without sacrificing functional optimization.
3Adaptability or versatility
If multiple specialized junction designs are developed and maintained, then the specific functional needs for different cable configurations are met, but the ease of manufacture and assembly decreases
Solution Approach 1:
A universal connection interface is designed with standardized connection points for screens and conductors that can accommodate any module type. This single interface design eliminates the need to create different connection interfaces for different junction types. The interface includes standardized coupling mechanisms, contact points, and mounting features that work with all modules, greatly simplifying the manufacturing process while maintaining the ability to meet specific functional requirements through module selection.
Solution Approach 2:
The junction design separates the standardized base structure (manufactured once with all common features) from the variable module (containing only application-specific features). This segmentation means that the complex aspects of junction design are consolidated into a single standardized component that is easy to manufacture. The modules are simple additions that attach to this standardized base, making the overall manufacturing process simpler compared to creating completely customized junctions for each application.
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 rapid, efficient, and flexible assembly of high-voltage electric lines with optimized residual current evacuation, reducing production complexity and costs while maintaining mechanical and electrical integrity.
Implementation Method 1
each of which comprises a central conductor surrounded over its entire length by a metal screen, and the screens of two successive cable portions are separated within this type of junction, in particular to allow the residual currents circulating in the said screens, due to the passage of electric current in the phase conductor cables
Data Source
Figure 1
Figure 2~3c
Figure 4a~4c
AI summary
The line has three-phase conducting cables (2), where each cable is made of successive cable portions (3a, 3b) that are connected together by different types of screen-break junctions (4). Each junction includes a main structure (5), where main structures of all the junctions are identical and include a standard connection socket (7). A variable module (6) is arranged with a complementary connection socket (8) through a linking cable, where the variable module is plugged into the connection socket of the main structure of each junction.