Electrical Coupling Assembly With Insulating Cone for Flexible HV Connection
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Solution Overview
Problem
Existing power line devices for high voltage ranges face challenges in connecting to electrical systems like gas-insulated switchgear due to the inflexibility of insulation tubes, which prevents reversible deformation and assembly, requiring complex and time-consuming manual processes for electrical and mechanical coupling.
Innovation Solution
An electrical coupling device with an electrical conductor device and a mechanical connection device that includes a connecting conductor for electrical coupling and an insulating cone with a central feedthrough for mechanical sealing, allowing for easy and cost-effective assembly and disassembly of power line devices to electrical systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulation tube is made rigid to provide electrical insulation, then insulation performance is improved, but mechanical flexibility and reversibility are worsened
Solution Approach 1:
The insulation tube is divided into two separate components: a rigid insulating tube providing electrical insulation and a flexible sealing element (grommet or elastomeric seal) providing mechanical flexibility. This segmentation allows each component to fulfill its specific function without compromising the other.
Solution Approach 2:
The coupling device uses composite construction combining rigid insulating material (such as ceramic or solid plastic) with flexible sealing material (elastomeric or rubber-like material). This composite approach enables both electrical insulation and mechanical reversibility to coexist in the same assembly.
2Strength
If the insulation tube is made rigid to maintain structural stability, then mechanical strength is improved, but ease of assembly and disassembly is worsened
Solution Approach 1:
The assembly is segmented into a rigid insulating tube for structural stability and a separate flexible sealing element for ease of assembly. The flexible element can be easily inserted and removed from the rigid tube, enabling simple assembly and disassembly while maintaining structural integrity.
Solution Approach 2:
A flexible sealing element acts as an intermediary between the rigid insulating tube and the power conductor. This intermediary component facilitates easy assembly by being flexible enough to accommodate insertion while providing the necessary seal, and enables easy disassembly by allowing removal without damaging the rigid structure.
3Reliability
If manual connection processes are used to ensure precise electrical and mechanical coupling, then connection reliability is improved, but assembly time and complexity are worsened
Solution Approach 1:
The electrical connection and mechanical sealing functions are merged into a single integrated coupling device. The rigid insulating tube provides both electrical insulation and structural support, while the flexible sealing element simultaneously provides mechanical seal and facilitates easy insertion. This merging eliminates the need for separate manual connection steps.
Solution Approach 2:
The coupling device is designed to self-align and self-seal during insertion. The flexible sealing element automatically conforms to the power conductor and creates a reliable seal without requiring precise manual positioning or additional fastening operations, thereby reducing assembly time while maintaining connection reliability.
Data Source
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AI summary
The invention relates to an electrical coupling device (1) for electrically and mechanically coupling a power conducting device (2) of an electrical system (3) to an electrical unit (4) of the electrical system (3), comprising an electrical conductor device (5) having a first electrical conductor section (6) and a second electrical conductor section (9), the electrical conductor device (5) having a connecting conductor (11) for electrically coupling the first electrical conductor section (6) to the second electrical conductor section (9), further comprising an insulating cone (12) with a central leadthrough (13), a portion of the electrical conductor device (5) being located in the central leadthrough (13), and finally comprising a mechanical terminal unit (14) having a first mechanical connecting section (15) and a second mechanical connection section (18). The invention further relates to an electrical system (3) and to a method for electrically and mechanically coupling a power conducting device (2) of an electrical system (3) to an electrical unit (4) of the electrical system (3).