Double-Acting Compression Joint for High-Tension Cable Splicing
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Solution Overview
Problem
Existing conductor joints for high voltage cables compromise bending properties and tensile strength, increase cross-sectional diameter, and are inefficient to install.
Innovation Solution
A double-acting conductor joint using a tubular sleeve and an elongated element that compresses stranded wire layers without increasing the joint's diameter, maintaining the same mechanical and tensile strength as the connected cables, achieved through a combination of external and internal compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional conductor joint with enlarged terminal portions is used to anchor conductors, then the conductors are securely anchored and cannot slip or be displaced, but the cable joint has a larger diameter than the remaining cable which impairs bending properties and reduces tensile strength
Solution Approach 1:
The invention places an inner compression sleeve inside an outer compression sleeve, with both sleeves nested around the conductor strands. This nested structure allows dual-directional compression (internal and external) to be applied simultaneously, achieving secure conductor anchoring while maintaining a compact joint diameter that matches the original cable diameter, thus preserving both reliability and tensile strength
Solution Approach 2:
The invention transitions from single-directional compression (external only) to dual-directional compression by adding internal compression via the inner sleeve. This dimensional change in compression direction enables the joint to achieve equivalent or superior mechanical strength while maintaining a compact cross-sectional diameter, resolving the contradiction between anchoring stability and tensile strength
2Reliability
If a conventional conductor joint with enlarged terminal portions is used to anchor conductors, then the conductors are securely anchored, but the cable joint has a larger diameter than the remaining cable which impairs bending properties
Solution Approach 1:
The nested arrangement of inner and outer compression sleeves allows both sleeves to compress the conductor strands in opposite directions simultaneously. This configuration achieves secure conductor anchoring while keeping the overall joint diameter compact and equivalent to the original cable diameter, thereby maintaining good bending properties without compromising anchoring reliability
3Productivity
If explosive compression is used to compress the connecting tube around conductor strands, then the conductors are quickly anchored, but the process is complex and requires special safety measures
Solution Approach 1:
The invention replaces the explosive compression system with a mechanical compression system using two hydraulic presses. Each press applies compression in opposite directions through inner and outer sleeves, achieving rapid and secure conductor anchoring without the complexity and safety concerns of explosive materials, while maintaining high installation productivity
Solution Approach 2:
The compression process is segmented into two independent directional compressions (internal and external) applied simultaneously by separate hydraulic presses. This segmentation allows each press to operate independently and efficiently, achieving rapid conductor anchoring while simplifying the overall process control and eliminating the need for complex explosive sequencing
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 joint maintains the same bending diameter and tensile strength as the connected cables, with a simple and efficient installation process that does not compromise the electrical properties, and the joint is compact with the same or similar cross-sectional diameter.
Implementation Method 1
compressing the sleeve by means of a hydraulic press
Implementation Method 2
compression of the sleeve causes the layers of stranded wires to be squeezed between the outer sleeve and the inner elongated element
Data Source
AI summary
The invention discloses a conductor joint ant a method for connecting a conductor end of a first cable with a conductor end of a second cable with the conductor joint. The conductor joint comprises a tubular longitudinal sleeve (1) and an elongated element (10). The sleeve has a sleeve length Ls and sleeve openings at each longitudinal end with an inner diameter allowing insertion of the conductor ends to be connected, the sleeve (1) comprising an inner surface shaped as two tubular stairs mirrored around a radial cross-sectional area at a longitudinal center of the sleeve (1), wherein each stair comprises a lower step surface at the nearest sleeve opening oriented along a longitudinal axis of the sleeve (1), a higher step surface at the longitudinal center and a step wall (3a, 3b, 3a′, 3b′) arranged between the lower step surface and the higher step surface oriented along the radial cross-sectional direction of the sleeve (1). The elongated element (10) arranged concentrically within said sleeve (1), wherein the elongated element (10) comprises a core rod (12) having a core rod length Lr and a terminal rod wall (13, 13′) at each longitudinal end.