Extender for Separable Insulated Connector
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Solution Overview
Problem
Conventional separable insulated connectors in electric power systems are difficult to replace due to the labor-intensive and error-prone process of splicing extension cables, and manufacturing connectors with longer bodies requires significant investment in new molds and processes.
Innovation Solution
An extender for separable insulated connectors that extends the effective length of a standard connector, allowing connection to a shortened cable without the need for splicing or manufacturing longer connectors, using a compression connector and semi-conductive materials to prevent damage and ensure proper electrical shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional separable insulated connector is replaced after cable installation, then the connector can be changed to fix failures or adapt to new equipment, but the replacement process becomes labor-intensive and error-prone requiring cable cutting and splicing
Solution Approach 1:
The connector is divided into two separable parts: a female connector that remains on the cable and a male connector that attaches to the replacement unit. This segmentation allows the cable end to be reused with different connector types, enabling easy replacement without cutting or splicing the cable.
Solution Approach 2:
The male connector is designed to insert into and nest within the female connector, creating a compact assembly that attaches to the cable. This nesting mechanism allows the replacement connector to integrate with the existing cable connection without requiring cable modification.
2Length of moving object
If the connector body is made longer to reach the cable after installation, then the connector can connect to shortened cables, but manufacturing requires significant investment in new molds and processes
Solution Approach 1:
Instead of manufacturing a single long connector body, the solution segments the length requirement into two components: the standard-length female connector on the cable and the male connector with attachment features. This avoids the need for expensive long-body mold development while achieving the same functional reach.
Solution Approach 2:
The female connector acts as an intermediary component that bridges the gap between the cable and the replacement connector. By keeping this intermediary on the cable, the system extends the effective connection length without requiring the main connector body to be manufactured longer.
3Reliability
If the connector is designed for single-use compression connection, then the cable connection is secure and reliable, but the connector cannot be removed and replaced
Solution Approach 1:
The connection system is segmented into a compression-secured female connector on the cable and a separable male connector. The compression mechanism provides reliable electrical and mechanical connection at the cable interface, while the male-female separation enables replacement of the distal connector without affecting the secure cable connection.
Solution Approach 2:
The connector design transitions from a static single-use compression connection to a dynamic system where the male connector can be detached and reattached. The compression connection remains fixed on the cable end, while the male connector provides the necessary mobility for replacement while maintaining connection integrity during 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
Enables efficient and cost-effective replacement of connectors by eliminating the need for splicing and reducing manufacturing costs, while ensuring reliable electrical connections and preventing corona discharge through proper shielding.
Implementation Method 1
the cable 102 connects to the T-body 100 at a compression connector 106, which crimps the cable 102, holding it in place
Implementation Method 2
Conventional cable adapters 104 can include an insulating material 104a and a semi-conductive material 104b
Data Source
AI summary
Removal of a conventional separable insulated connector from an electric power system often results in a shortened electric cable. An extender for a separable insulated connector enables the separable insulated connector to connect to a shortened cable. A conventional cable adapter is inserted into the extender, which includes a conductive connector for accepting the shortened cable and a conductive rod for carrying electric power from the shortened cable to the separable insulated connector. The extender also includes an inner semi-conductive layer that borders the conductive rod and compression connector, an outer semi-conductive layer, and a insulating layer between the two semi-conductive layers. The extender is inserted into a separable insulated connector, which is then connected to the electric power system.