High-Power Bushing With Elastic Conductor Decoupling
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Solution Overview
Problem
Conventional high-power bushings fail due to mechanical stress and vibrations, especially at extreme temperatures, leading to insulating material degradation and increased device failures over an extended lifetime.
Innovation Solution
The bushing design incorporates an elongated insulating body with an elastically deformable conductor, featuring a tapered clearance between the conductor and the insulating body to decouple mechanical forces, reducing stress on the insulating material and enhancing reliability through elastic deformation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bushing uses a robust and stiff configuration with integral copper bolt and epoxy resin, then mechanical strength and electrical integrity are improved, but the bushing exhibits increased failure events under extreme temperatures and mechanical forces
Solution Approach 1:
The bushing is divided into separate components: a copper bolt portion and an epoxy resin insulating portion, which are assembled together rather than formed as an integral component. This segmentation allows each material to independently handle its optimal load type without being constrained by the other material's properties.
Solution Approach 2:
The invention changes the mechanical parameters of the bushing by introducing a clearance between the copper bolt and epoxy resin, transforming the structure from rigid to compliant. This allows the bushing to accommodate thermal expansion and mechanical forces through elastic deformation rather than maintaining fixed rigid dimensions.
2Object-affected harmful factors
If the bushing uses copper bolt surrounded by epoxy resin, then electrical insulation is improved, but differential thermal expansion causes cracks in the insulating material
Solution Approach 1:
A clearance acts as an intermediary space between the copper bolt and epoxy resin, allowing differential thermal expansion to occur without direct mechanical constraint. This intermediary space prevents stress concentration and crack formation while maintaining electrical insulation through the epoxy resin's positioning function.
Solution Approach 2:
The clearance is designed in advance to accommodate expected thermal expansion differences between copper and epoxy resin. This pre-built cushioning space prevents harmful stresses from developing during temperature cycles, protecting the insulating material from crack formation.
3Strength
If the bushing is formed as an integral component by injection molding, then mechanical robustness is improved, but the bushing cannot accommodate mechanical forces and vibrations over extended lifetime
Solution Approach 1:
The bushing transitions from a static rigid structure to a dynamic compliant structure where the copper bolt can move elastically within the clearance. This dynamic capability allows the bushing to absorb mechanical forces and vibrations during operation, extending its service life under harsh conditions.
Solution Approach 2:
The clearance creates a flexible mechanical arrangement where the copper bolt can deform and move within the epoxy resin housing. This flexibility allows the bushing to accommodate mechanical stresses and vibrations without rigid failure, improving durability over extended periods.
4Power
If heavy external cables are connected to the bushing, then power transmission capability is improved, but bending forces exerted on the copper bolt increase mechanical stress
Solution Approach 1:
The invention converts the harmful bending forces from heavy cable connections into beneficial elastic deformation of the copper bolt. The clearance allows the copper bolt to flex under cable weight and external forces, transforming what would be damaging rigid stresses into manageable elastic deformations that do not compromise the bushing's structural integrity.
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
This design significantly reduces the risk of insulating material damage and enhances the reliability of high-power bushings by allowing elastic deformation of the conductor, thereby mitigating mechanical stress and vibrations, ensuring a longer lifespan and improved performance under harsh conditions.
Implementation Method 1
The first connecting portion is elastically deformable with respect to the first body end portion and/or the second connecting portion is elastically deformable with respect to the second body end portion
Data Source
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AI summary
A bushing (100) for high power applications is provided, in which elastic deformation capability of a connecting portion (121, 122) of the bushing conductor (120) with respect to the insulating body (110) is established. Due to the elastic deformation capability of the connecting portion (121, 122) of the bushing conductor (120) a significant mechanical decoupling of the connecting portion (121, 122) of the bushing conductor (120) and the surrounding body end portion of the insulating body (110) is achieved, thereby significantly reducing the probability of causing damage, which is conventionally induced by radial forces acting on the connecting portion (121, 122) of the bushing conductor (120). In this manner superior integrity of the bushing (100) may be achieved even over a relatively long lifetime in particular in harsh environmental conditions, such as in train applications, and the like.