HVAC Cable Composite Conductor for Magnetic Loss Reduction
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Solution Overview
Problem
High voltage AC power cables used in offshore maritime infrastructure face significant magnetic losses due to ferritic steel armouring, which can account for up to a third of total energy loss, and existing solutions like using austenitic steel do not fully address the mechanical integrity and manufacturing cost concerns.
Innovation Solution
The implementation of a composite electric conductor with a reinforcement member made of low or non-magnetic steel or high-strength alloys like CuNiSi or aluminium, embedded within the conductor to provide mechanical strength without the need for a conventional armouring layer, reducing manufacturing costs and magnetic losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ferritic steel armouring is used to provide mechanical strength, then the cable can withstand stretching and compression forces, but magnetic losses increase significantly (up to 1/3 of total energy loss)
Solution Approach 1:
The patent removes the traditional ferritic steel armouring layer from the cable structure and replaces it with a non-magnetic steel core integrated into the conductor. This extraction of the harmful magnetic armouring layer eliminates the source of hysteresis and eddy current losses while maintaining mechanical strength through the non-magnetic steel core.
Solution Approach 2:
The patent employs composite conductor construction where non-magnetic steel wires are combined with copper or aluminum conductive material. This composite structure provides both the mechanical strength needed for submarine cable applications and the non-magnetic properties required to minimize energy losses from magnetic hysteresis and eddy currents.
2Loss of energy
If austenitic steel wires are used in armouring to reduce magnetic loss, then energy efficiency improves, but mechanical integrity and manufacturing cost concerns remain
Solution Approach 1:
The patent merges the functions of the armouring layer and the conductor core by integrating the non-magnetic steel core directly into the conductor structure. This eliminates the need for a separate armouring layer while providing both mechanical strength and magnetic loss reduction in a single integrated component.
Solution Approach 2:
The non-magnetic steel core serves multiple functions simultaneously: it provides the mechanical strength required for submarine cable applications, acts as the central structural element of the conductor, and eliminates magnetic losses. This multi-functionality replaces the need for separate armouring and conductor components.
3Strength
If conventional armouring layer is included to ensure mechanical integrity, then cable strength is maintained, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the separate armouring layer from the cable structure, reducing the number of manufacturing steps and material layers required. This simplification directly reduces manufacturing complexity and cost while maintaining mechanical integrity through the integrated non-magnetic steel core.
Solution Approach 2:
By merging the armouring function into the conductor core itself, the patent reduces the total number of components and assembly steps required during manufacturing. This integration simplifies the production process and reduces manufacturing costs while maintaining or improving mechanical strength.
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 approach significantly reduces power losses and enhances mechanical integrity, allowing for deeper water applications while maintaining efficient energy transfer, with calculated AC resistivity reductions of up to 0.6% and enabling cable use in deeper waters without additional armouring.
Implementation Method 1
the fluctuating magnetic fields radiated by the three electric conductors causes hysteresis and eddy current losses
Implementation Method 2
the fluctuating magnetic fields radiated by the three electric conductors causes hysteresis and eddy current losses
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The present invention relates to a high voltage alternative current cable having mechanically reinforced electric conductor, by having a reinforcement member at the centre of the conductors of the cable, where the reinforcement member is made of one or more low or non-magnetic steel wires, one or more wires of CuNiSi precipitation alloy, or one or more aluminium wires made of an EN AW-1xxx, EN AW-2xxx, EN AW-5xxx, AW-6xxx, EN AW-7xxx, or EN AW-8xxx alloy, according to the European aluminium standard.