High Voltage Connector Parallel Guide Grooves
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-voltage connectors in satellite systems face challenges with short cable lengths and the risk of flashover, especially in weightless environments, where extending or repairing high-voltage cables is difficult due to the need for high-quality, insensitive electrical connections that are resistant to external electromagnetic influences.
Innovation Solution
A high-voltage connector with parallel guide grooves on a carrier element made of insulating material, allowing for the splicing of high-voltage lines while maintaining mechanical and electromagnetic stability, and featuring a housing with electromagnetic shielding to prevent flashover and mechanical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous high-voltage cable is used to connect TWT and EPC, then the electrical connection quality and insulation performance are improved, but the adaptability and ease of repair are worsened when cable length adjustments or repairs are needed
Solution Approach 1:
The high-voltage cable connection is segmented into modular components: a male connector integrated with the TWT, a female connector integrated with the EPC, and an intermediate cable section. This segmentation allows the cable to be disconnected and reconnected, enabling length adjustments and repairs while maintaining high-voltage connection quality through controlled connection points with proper insulation and contact geometry.
Solution Approach 2:
The connector assembly acts as an intermediary between the TWT and EPC, providing a controlled interface for high-voltage connections. The connector includes insulating carriers, guide grooves for precise wire alignment, and structured contact points that mediate the electrical connection, allowing cable replacement and length adjustment without compromising the overall connection quality.
2Adaptability or versatility
If a high-voltage cable is extended or repaired by splicing, then the cable length adaptability is improved, but the risk of flashover and electromagnetic interference increases at the connection point
Solution Approach 1:
The connector design applies local quality by providing enhanced insulation and structured geometry specifically at the connection point where flashover risk is highest. The insulating carrier material surrounds the wire splices, and the guide grooves maintain precise spacing between conductors, creating localized protection against flashover and electromagnetic interference at the vulnerable splice areas while allowing cable extendability.
Solution Approach 2:
The connector design incorporates beforehand cushioning by pre-arranging insulating structures, guide grooves, and contact geometries that protect against flashover before the connection is made. The insulating carrier is positioned to surround and protect splice points, and the guide grooves are designed to maintain safe spacing between high-voltage conductors, preventing flashover conditions before they can occur during operation.
3Reliability
If a connector with guide grooves and insulating material is used, then the protection against flashover and mechanical stability are improved, but the device complexity increases
Solution Approach 1:
The connector design merges multiple functions into a single integrated assembly: the insulating carrier combines mechanical support, electrical insulation, and structural housing functions; the guide grooves integrate wire alignment, spacing maintenance, and mechanical guidance; and the overall connector unifies the interface between male and female portions. This merging reduces the number of separate components and simplifies assembly while maintaining flashover protection and mechanical stability.
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
The connector enables the extension or repair of high-voltage cables without removing them from the TWT or EPC, providing a stable and interference-resistant connection, reducing the risk of flashover and mechanical damage, and meeting EMC regulations with a lightweight design.
Implementation Method 1
The high-voltage connector has a carrier element with a first guide groove and a second guide groove, the carrier element comprising a high-voltage insulating material
Implementation Method 2
A high-voltage connector with parallel guide grooves on a carrier element made of insulating material, allowing for the splicing of high-voltage lines while maintaining mechanical and electromagnetic stability, and featuring a housing with electromagnetic shielding to prevent flashover and mechanical damage
Data Source
Figure 1~2
Figure 3~5
AI summary
A high-voltage connector (100) for establishing a high-voltage connection between two high-voltage lines (310, 320) is described, comprising a support element (150) with a first guide groove (161A) and a second guide groove (161B), wherein the support element (150) comprises a high-voltage insulating material, wherein the first guide groove (161A) and the second guide groove (161B) are arranged parallel to each other and extend in the longitudinal direction (180) of the support element (150), and wherein the first guide groove (161A) and the second guide groove (161B) are each designed to accommodate a conductor (312, 322) of a first high-voltage line (310) and a second high-voltage line (320), respectively. This enables the establishment of a high-voltage connection that is insensitive to electrical disturbances, mechanically stable and resistant, and pressure-resistant.