High Voltage Cable Connector Crimping and Screw Locking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for connecting high-voltage cables with insulating coatings, such as milliken conductors, face issues with insufficient contact between wires due to insulation layers, leading to high contact resistance and premature failure due to heating and material flow, especially in multi-wire conductors.
Innovation Solution
A method involving a conductive metal pipe connector with a crimping process forming a polygonal pressing contour, where radial threaded holes accommodate locking screws that penetrate the conductors without removing insulation, ensuring secure and consistent contact across the conductor cross-section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation coating is removed from individual wires before connection, then electrical conductance is improved, but manufacturing complexity and work amount increase extremely
Solution Approach 1:
The insulation coating is selectively removed only from the connection area of individual wires using a laser, rather than removing it from the entire wire. This extraction approach improves electrical conductance at the critical connection point while minimizing the overall work amount and preserving insulation elsewhere on the conductor.
Solution Approach 2:
The traditional mechanical method of stripping insulation coatings is replaced with a laser-based removal process. This substitution enables precise, localized removal of insulation only where needed for connection, significantly reducing the total work amount while ensuring reliable electrical contact.
2Reliability
If insulation coating is removed from individual wires, then contact resistance decreases, but the process becomes extremely labor-intensive
Solution Approach 1:
The laser-based insulation removal process replaces time-consuming mechanical stripping operations. The laser can quickly and precisely remove insulation coatings from the connection areas of multiple wires in sequence, dramatically reducing the total process time while ensuring low contact resistance through consistent, controlled removal.
Solution Approach 2:
The laser parameters (power, pulse duration, focal point) are optimized to remove insulation coatings efficiently and precisely. By controlling these parameters, the process achieves rapid insulation removal with minimal heat affect and precise control over the removed area, reducing overall process time while ensuring reliable electrical contact.
3Force
If compression force is applied to multi-wire conductors, then contact force between wires increases, but individual wires rub against each other reducing internal pressure
Solution Approach 1:
The insulation coatings on individual wires are removed in advance before the compression connection is made. This preliminary action ensures that when compression force is applied, the wire surfaces are already exposed and ready for direct metal-to-metal contact, maximizing contact force without the wires rubbing against each other to generate heat and reduce internal pressure.
Solution Approach 2:
The insulation coatings are extracted from the wire surfaces before connection. This removal eliminates the barrier between wire surfaces, allowing compression force to directly increase contact force between conductive surfaces without the wires rubbing against each other, thus maintaining stable wire arrangement and internal pressure throughout the connection's service life.
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 method enhances electrical conductivity and mechanical security without removing insulation, reducing heating and material flow issues, thus maintaining a reliable connection throughout the service life.
Implementation Method 1
the conductor connector is pressed slice by slice with a crimping tool in such a way that the circumference of the conductor connector is a pressing contour formed as a regular polygon is formed
Implementation Method 2
the contact screws are screwed in... The contact force created by the screws connects the conductors to the conductor connector and connects the individual wires of the conductors to each other
Implementation Method 3
a piece of pipe made of electrically well-conductive metal designed as a conductor connector... The electric current flows from one conductor via the conductor connector to the other conductor
Implementation Method 4
If the contact between the individual wires inside the conductor is insufficient due to the clamping created, the result is above-average heating
Data Source
Figure 1~3
AI summary
The invention relates to a method for electrically connecting multi-stranded electrical conductors of two high-voltage cables, each surrounded by an insulating sheath, wherein the following method steps are carried out: (A) the conductors (12) of the two high-voltage cables are exposed at their ends (14) by removing the respective sheath, (B) a metallic tube section designed as a conductor connector (30) is provided, (C) the two conductors (12) are inserted into the conductor connector (30) from different sides, so that their end faces are in contact approximately in the middle of the conductor connector (30), (D) the conductor connector (30) is crimped disc by disc using a crimping tool in such a way that regular polygons are formed as crimp contours on the circumference of the conductor connector (30).(E) Perpendicular to the flat surfaces (34) of the press contours (32) created during pressing, threaded holes (36) for receiving contact screws (40) are produced in the conductor connector (30), (F) radially extending bores (20) are produced in the conductors (12) through the threaded holes (36), (G) the contact screws (40) are screwed in.