Double-Acting Compression Joint for Compact HVDC Cable Splicing
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Solution Overview
Problem
Existing conductor joints for high voltage direct current (HVDC) cables compromise bending properties and tensile strength, increase cross-sectional diameter, and are cumbersome to install, failing to match the properties of the connected cables.
Innovation Solution
A double-acting conductor joint comprising a tubular sleeve and an elongated element, where the sleeve and elongated element work together under hydraulic pressure to compress the stranded wires, maintaining the same diameter and enhancing mechanical strength and flexibility, with a method involving removal of protective layers and precise insertion of the core rod into the conductor ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional conductor joints are used to connect HVDC cable conductors, then the conductors can be joined together, but the joint has a larger cross-sectional diameter than the original cables, impairing bending properties
Solution Approach 1:
The invention uses a nested structure where an inner compression sleeve is placed inside an outer compression sleeve. The inner sleeve compresses the conductor strands first, then the outer sleeve provides additional compression. This nested arrangement allows the joint to maintain a compact cross-sectional diameter comparable to the original cables while achieving sufficient compression force for strong electrical and mechanical connection.
Solution Approach 2:
The invention transitions from single-direction compression to multi-directional compression by using both inner and outer sleeves that can apply compressive forces from different directions. The inner sleeve provides radial compression, while the outer sleeve adds circumferential compression, creating a three-dimensional compression field that reduces the joint diameter while maintaining connection strength.
2Shape
If conventional conductor joints are used to connect HVDC cable conductors, then the conductors can be joined together, but the joint cannot withstand the same tensile forces as the original cables
Solution Approach 1:
The nested dual-sleeve structure enables progressive compression where the inner sleeve first compresses the conductor strands to a reduced diameter, then the outer sleeve applies additional compression force. This multi-stage compression process ensures that the conductor strands are tightly bound with sufficient compressive stress to withstand tensile forces equal to or greater than the original cables, while maintaining a compact joint diameter.
Solution Approach 2:
The invention combines the functions of multiple compression elements (inner sleeve and outer sleeve) into a single integrated joint structure. By merging these compression functions, the joint achieves both compact dimensions and high tensile strength simultaneously, as the combined compressive action of both sleeves creates a mechanically robust connection that matches the original cable properties.
3Ease of manufacture
If conventional conductor joints are used to connect HVDC cable conductors, then the conductors can be joined together, but the installation process is cumbersome and time-consuming
Solution Approach 1:
The joint is segmented into distinct functional components: an inner compression sleeve, an outer compression sleeve, and optional positioning elements. This segmentation allows each component to be prepared and positioned independently before final assembly, simplifying the installation process. The modular structure enables workers to insert conductors into the inner sleeve first, then add the outer sleeve, making the process more systematic and less cumbersome than conventional single-piece joints.
Solution Approach 2:
The inner compression sleeve can be pre-positioned on the conductor strands before the outer sleeve is added. This preliminary action allows for proper alignment and initial compression to be established before the final assembly step, reducing installation time and complexity. The pre-positioned inner sleeve serves as a guide and initial compression element, making the subsequent addition of the outer sleeve a simpler operation.
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, ensuring efficient and simple installation with improved mechanical properties and conductive performance.
Implementation Method 1
compressing the sleeve radially towards the elongated element 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
Figure 1
Figure 2A~2B
Figure 3A~3B
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.