Lightweight HV Cable Layer Contrast for Precise Stripping
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Solution Overview
Problem
Existing multi-layered lightweight high-voltage electrical cables face challenges in ensuring precise stripping of the outer semi-conductive layer without damaging the insulating layer, particularly for thin insulating layers, due to the difficulty in visually inspecting the completeness of layer removal and ensuring adequate insulating layer thickness post-stripping.
Innovation Solution
The cable features a void-free and delamination-resistant bond between the outer semi-conductive and insulating layers, utilizing contrasting colors and translucency in the insulating layer to facilitate precise visual inspection and removal, with a method involving material subtraction techniques like cutting or laser removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional stripping tool is used to remove the outer semi-conductive layer, then the outer semi-conductive layer can be stripped away, but it is difficult to ensure by inspection whether the outer semi-conductive layer has been completely removed and whether enough insulating layer remains
Solution Approach 1:
The patent applies color changes by making the insulating layer translucent or transparent while the outer semi-conductive layer is opaque. This color/opacity contrast enables visual inspection to determine whether the outer semi-conductive layer has been completely removed and whether sufficient insulating layer thickness remains, directly resolving the inspection precision problem.
2Weight of moving object
If the insulating layer thickness is reduced to save radial thickness, then the cable becomes more lightweight, but higher precision is needed in stripping as there is less tolerance for errors
Solution Approach 1:
The translucent/transparent insulating layer with opaque outer semi-conductive layer provides real-time visual feedback during stripping, enabling operators to achieve high precision even when the insulating layer is thin. The visual contrast allows detection of the exact stripping point without requiring post-stripping measurement equipment.
Solution Approach 2:
The visual feedback mechanism provided by the translucent insulating layer allows operators to see the stripping progress in real-time and adjust accordingly. This immediate feedback loop enables precise control of the stripping depth, ensuring that the correct amount of insulating layer is removed even when tolerance is minimal.
3Reliability
If the outer semi-conductive layer is stripped further from the cable end to ensure complete removal, then discharge risk is reduced, but more insulating layer thickness is removed
Solution Approach 1:
The opacity contrast between the outer semi-conductive layer and translucent insulating layer enables precise determination of where the outer layer ends and the insulating layer begins. This visual distinction allows operators to strip exactly to the required depth without removing excessive insulating material, balancing discharge prevention with material conservation.
Data Source
AI summary
The disclosure relates to a multi-layered lightweight high-voltage electrical cable 1, comprising: a bundle 2 of metallic wires 3; an inner semi-conductive layer 4, made of a first broad range temperature rated polymeric material of a first color, surrounding said bundle 2 of metallic wires 3; at least one of the metallic wires 3 being in electric contact with the inner semi-conductive layer 4; an insulating layer 5, made of a second broad range temperature rated polymeric material of a second color, surrounding the inner semi-conductive layer 4; an outer semi-conductive layer 6, made of a third broad range temperature rated polymeric material of a third color, surrounding and having a void-free and delamination-resistant bond to the insulating layer 5; the second color and the third color contrasting with each other. The disclosure further relates to a method of stripping an electrical cable 1 and a kit for correct stripping.