High Voltage Connection Kit for Traveling Wave Tubes

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Solution Overview

Problem

Existing high voltage connections between traveling wave tubes and voltage supply units are time-consuming to establish and disconnect, prone to high costs due to soldering or casting, and limited to lower voltage ratings, making them unsuitable for modern miniaturized and high-voltage applications in satellite and space flight technology.

Innovation Solution

A high voltage connection kit using crimp connections with space flight qualified plugs and sockets, combined with high voltage resistant shrinking hoses and adhesives, allowing for easy disconnection and repair, suitable for DC voltages up to 10 kV, and adaptable to varying wire thicknesses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If splice connection (eyelet) is used to connect end sections of lines, then connection can be established, but it is very time-consuming to establish, disconnect, and maintain the connection

Engineering Contradiction:

Improveease of connection and disconnectionVSAvoidtime to establish and maintain connection

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The connection system is divided into separate plug and socket components that can be independently assembled and disconnected. The plug connects to one line end and the socket to the other line end, allowing rapid connection/disconnection without time-consuming splice operations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical splice connection (eyelet) is replaced with a crimp connection system that uses a crimping tool to permanently attach the plug to the line end. This substitution enables faster connection establishment compared to traditional splicing methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If splice connection is used, then connection can be made, but such connections are tested only up to about 7 kV, which is insufficient for high voltage applications

Engineering Contradiction:

Improvevoltage rating capabilityVSAvoidapplicability to high voltage applications

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The connection assembly uses composite insulation structures combining shrink tubing material with adhesive bonding. This composite approach creates a sealed, high-voltage-resistant connection that exceeds the 7 kV limitation of traditional splice connections and achieves ratings suitable for 10 kV and above applications.

Inventive Principle:

Principle #40Composite materials

3Reliability

If lines are soldered or cast together, then connection is established, but in case of repair the entire assembly of the traveling wave tube and the voltage supply unit must be possibly scrapped

Engineering Contradiction:

Improveconnection strengthVSAvoidrepairability and component replacement

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The connection system is segmented into modular plug and socket components that can be independently replaced. If a connection fails, only the defective plug or socket needs to be replaced rather than scrapping the entire assembly, enabling easy repair while maintaining strong electrical connections.

Inventive Principle:

Principle #1Segmentation

4Weight of moving object

If traditional connection methods are used, then connection can be established, but the connection is not lightweight and compact as required for modern satellite and space flight applications

Engineering Contradiction:

Improveconnection weightVSAvoidconnection structure simplicity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The shrink tubing is nested over the crimped plug and socket assembly, creating a compact integrated structure. This nesting approach reduces the overall size and weight of the connection while maintaining structural integrity and high voltage insulation, suitable for space flight applications.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 solution provides a lightweight, compact, and cost-effective high voltage connection that is simple to maintain and repair, capable of handling higher voltage ratings, and suitable for space flight applications, while minimizing the risk of blistering and outgasing.

Implementation Method 1

heating the heat-shrinking insulating hose so that both the free cable leads together with the plug connection as well as not crimped cable casing ends of the cables connected with one another are completely shrunk around

Methodology Applied

Scientific EffectThermal contraction: Thermal Contraction

Data Source

PatentEP3200284B1High voltage connection kit

Publication Date: 2019.08.28 TESAT SPACECOM GMBH & CO KG

Figure 1~3

AI summary

The invention relates to a high voltage connection (1) between a first line (2) of a traveling wave tube (3) and a second line (4) of a voltage supply unit (5) for the traveling wave tube (3). The high voltage connection (1) comprises a plug (6) which is connected to an end section (7) of the first line (2) or of the second line (4) by a crimp connection (8), and a socket (9) which is connected to an end section (10) of the other line (4) by a crimp connection (11). Furthermore, the invention relates to a method for manufacturing a high voltage connection (1).