Extender for Separable Insulated Connector
Find Innovative SolutionsGenerate Solutions
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
1Ease of operation
If a conventional separable insulated connector is used, then the connector can be installed and function properly, but replacing it becomes difficult and labor-intensive when failure or upgrade occurs
Solution Approach 1:
The connector is divided into separable components: a reusable body portion and a replaceable cable adapter portion. This segmentation allows the cable adapter to be quickly removed and replaced without affecting the main connector body, enabling rapid replacement operations.
Solution Approach 2:
A transition piece or adapter mechanism serves as an intermediary between the cable and the connector body. This intermediary component can be easily detached and replaced, facilitating quick connector replacement while maintaining the permanent connection to the cable.
2Ease of repair
If the cable is cut to remove a failed connector, then the connector can be replaced, but the remaining cable becomes too short to reach the compression connector in the replacement
Solution Approach 1:
An extender acts as an intermediary component that bridges the gap between the shortened cable and the replacement connector. This extender includes a compression connector at one end to attach to the cable and a cable adapter at the other end to interface with the connector body, effectively extending the reach without requiring cable replacement.
Solution Approach 2:
The connection system is segmented into multiple functional components: the cable, an extender with compression connector, and the main connector body. This segmentation allows the extender to be inserted between the cable and connector to provide the necessary additional length.
3Length of moving object
If splicing is used to extend the cable, then the cable length can be sufficient, but the process becomes labor-intensive and error-prone
Solution Approach 1:
The extender is designed as a simple, inexpensive, single-use component that eliminates the need for complex splicing operations. Rather than permanently modifying the cable through splicing, a disposable extender provides the necessary length extension and can be easily installed and removed.
Solution Approach 2:
The extender serves as a simple intermediary component that provides length extension without requiring the complex splicing process. It offers a straightforward mechanical connection alternative that avoids the labor-intensive and error-prone steps of stripping, twisting, and securing cable splices.
4Length of stationary object
If a connector with a longer body is manufactured, then it can reach shorter cables, but significant investment in new molds and processes is required
Solution Approach 1:
Rather than manufacturing entirely new longer connectors requiring new molds, the system segments the length extension function into a separate extender component. This allows the main connector body to remain standard size while the extender provides the additional length, avoiding the need for expensive new tooling.
Solution Approach 2:
The extender component serves multiple functions: it provides length extension, maintains electrical connection, and interfaces with both the cable and the standard connector body. This multi-functionality allows a single component to solve the length problem without requiring different connector bodies for different cable lengths.
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
Implementation Method 3
ensuring reliable electrical connections and preventing corona discharge through proper shielding
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.