High Power Single-Pole Connector Axial Positioner
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Solution Overview
Problem
High-power, single-pole electrical connectors used in land-based oil and gas operations are limited by size constraints, requiring larger distribution panels or more connectors due to their physical size, which hinders space efficiency and power capacity.
Innovation Solution
A downsized high-power, single-pole electrical connector design utilizing an insulating axial positioner instead of slip rings, allowing for a smaller outer shell size while maintaining high power ratings by eliminating radial spacing for retaining hardware and sealing O-rings, enabling a size 20 shell to accommodate up to 646 mcm cable with a 1000 A current rating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional slip rings and retaining hardware are used in high-power electrical connectors, then the connector can maintain structural integrity and power capacity, but the connector size increases and more radial spacing is required
Solution Approach 1:
The patent extracts and eliminates the slip rings and retaining hardware from the connector assembly. By removing these traditional retaining components, the design achieves significant size reduction while maintaining structural integrity through alternative means (the insulating axial positioner integrated into the core conductor design).
Solution Approach 2:
The patent merges the functions of axial positioning and electrical insulation into a single integrated component - the insulating axial positioner. This component is formed as part of the core conductor assembly, eliminating the need for separate retaining rings and reducing the number of parts while maintaining structural reliability.
2Power
If more panel-mounted receptacles are added to distribution panels to handle increased power demands, then power capacity increases, but the panel size must increase or spacing between receptacles must be reduced
Solution Approach 1:
The patent segments the electrical distribution system into smaller, more compact connector units. By reducing the size of individual connectors, more connectors can be mounted on a distribution panel of the same size, effectively increasing power capacity without increasing panel area.
3Volume of moving object
If smaller connectors are used to fit more on a distribution panel, then space efficiency improves, but power rating of each connector decreases
Solution Approach 1:
The patent changes the design parameters of the connector by eliminating slip rings and retaining hardware, which removes the radial spacing requirements. This allows the connector to maintain high power rating capabilities in a smaller form factor, breaking the traditional trade-off between size and power rating.
4Volume of moving object
If radial spacing is allocated for retaining hardware and sealing O-rings in traditional connectors, then sealing and retention functions are provided, but the outer shell size increases
Solution Approach 1:
The patent merges the sealing function into the integrated insulating axial positioner design. The positioner is formed as part of the core conductor assembly with sealing surfaces that provide waterproof sealing without requiring separate O-rings in radial gaps, thereby reducing outer shell size while maintaining sealing reliability.
Data Source
AI summary
A downsized, high-power, single-pole electrical connector is disclosed. The connector employs an insulating axial positioner between two rigid insulators, such that the insulating axial positioner maintains proper internal axial alignment while allowing for use of a smaller outer shell.