Reconfigurable Jig for Flexible Jumper Positioning
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Solution Overview
Problem
The installation of prefabricated flexible jumpers in electrical substations is hindered by delays and increased costs due to the inability to accurately position and train cables in a controlled environment, leading to misalignment and excessive material/labor requirements when built on-site or on a workbench.
Innovation Solution
A reconfigurable flexible jumper jig system with orthogonal axes and repositionable tooling mounts, including x, y, and z-axis rails, and various adapters for precise positioning and orientation of end fittings, allowing for complete off-site fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flexible jumpers are built on a work bench or one-ended off-site, then fabrication can begin before substation installation, but the jumpers cannot be accurately positioned and trained, resulting in misalignment and excessive material/labor requirements
Solution Approach 1:
The patent applies preliminary action by enabling jumper fabrication to begin before substation installation is complete. The adjustable fixture system allows jumpers to be pre-positioned and trained on a work bench using simulated terminal mount positions, which can then be transferred to the actual substation. This resolves the contradiction by allowing early fabrication (improving productivity) while maintaining positioning accuracy through the adjustable fixture system (preventing precision loss).
Solution Approach 2:
The patent applies dynamics through the adjustable fixture system with movable components that can be repositioned along the jumper length. The fixture includes adjustable clamps and positioning mechanisms that can accommodate different jumper configurations and terminal mount locations. This dynamic adjustability allows the system to maintain manufacturing precision while enabling flexible fabrication timing (improving productivity).
2Manufacturing precision
If flexible jumpers are built on an erected substation, then positioning accuracy is improved, but installation delays and increased costs occur due to lack of controlled environment fabrication
Solution Approach 1:
The patent applies preliminary action by enabling jumper fabrication to begin before substation installation is complete. The adjustable fixture system allows jumpers to be pre-positioned and trained on a work bench using simulated terminal mount positions, which can then be transferred to the actual substation. This resolves the contradiction by allowing early fabrication (improving productivity) while maintaining positioning accuracy through the adjustable fixture system (preventing precision loss).
Solution Approach 2:
The patent applies copying by creating a replica of the substation terminal mount configuration on the work bench fixture. The adjustable fixture system reproduces the spatial relationships and positioning requirements of the actual substation installation, allowing jumpers to be fabricated with correct positioning in a controlled environment. This copying approach enables accurate pre-fabrication without requiring the actual substation to be erected, thereby reducing installation delays.
3Productivity
If jumpers are built out of position on a work bench, then fabrication can proceed without erected substation, but cable training and positioning cannot be achieved
Solution Approach 1:
The patent applies dynamics through the adjustable fixture system with movable components that can be repositioned along the jumper length. The fixture includes adjustable clamps and positioning mechanisms that can accommodate different jumper configurations and terminal mount locations. This dynamic adjustability allows the system to maintain manufacturing precision while enabling flexible fabrication timing (improving productivity).
Solution Approach 2:
The patent applies universality through the multi-functional adjustable fixture system that combines positioning, training, and fabrication capabilities in a single work bench setup. The fixture can simulate various substation configurations and accommodate different jumper types, making it a universal solution for off-site jumper fabrication. This multi-functionality enables cable training and positioning capabilities to be achieved in a controlled environment without requiring the actual substation to be erected.
Data Source
AI summary
The present invention includes a flexible jumper jig which is reconfigurable to replicate the end positions of a flexible jumper as it would be on an installed substation. According to a further preferred embodiment, an exemplary system of the present invention may include a framework forming three orthogonal axes and repositionable tooling mounts for end fittings. According to another aspect of the present invention, an x-axis oriented rail may preferably hold a tooling mount which is configurable to be rotated about its axis to allow for alternate tooling mount orientations. Further, a y-axis oriented rail may be perpendicular to the x-axis rail and may be fixed. Still further, a z-axis oriented rail may be perpendicular to and slide along the y-axis rail. Additionally, a second tooling mount may be attached to the z-axis rail.