Jointed Power Cable with Variable Ampacity Sections
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Solution Overview
Problem
The existing methods for designing high voltage power cables require over-dimensioning due to hot spots along the cable route, leading to increased costs and time-consuming on-site jointing of different conductor sections, which is inefficient and expensive.
Innovation Solution
A power cable with a conductive core comprising sections of different cross-sectional layouts, where one section has a higher ampacity than the other, thermally joined during manufacturing, allowing for a single-piece transportation and installation, thereby avoiding on-site jointing and reducing installation time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different conductor sections are jointed using bolt connection and external sleeve, then the cable can accommodate different ampacity requirements along the route, but the installation time and cost increase significantly
Solution Approach 1:
The conductor sections are thermally joined during the manufacturing process before the cable is installed. This preliminary action eliminates the need for time-consuming on-site bolt connections and external sleeve installations, while still allowing different ampacity requirements to be accommodated along the cable route.
Solution Approach 2:
The mechanical bolt connection system with external sleeves is replaced by a thermal joining process. This substitution eliminates complex mechanical assembly operations at the installation site, reducing installation time and complexity while maintaining the ability to join conductor sections with different ampacities.
2Adaptability or versatility
If different conductor sections are jointed using bolt connection and external sleeve, then the cable can accommodate different ampacity requirements along the route, but the installation cost increases significantly
Solution Approach 1:
The conductor sections are thermally joined during the manufacturing process before the cable is installed. This preliminary action eliminates the need for expensive on-site jointing operations requiring specialized equipment, vessels, and crews, significantly reducing installation costs while maintaining ampacity adaptation capability.
Solution Approach 2:
The complex mechanical jointing system requiring external sleeves, bolts, and clamping operations is replaced by a thermal joining process performed in the factory. This substitution eliminates the need for expensive on-site installation equipment and operations, reducing overall installation costs.
3Reliability
If the entire cable is designed according to the worst conditions, then the cable can handle hot spots, but the cable diameter is over-dimensioned and costs increase
Solution Approach 1:
Different conductor sections along the cable route are designed with different cross-sectional layouts optimized for local conditions. Sections in hot spot areas have higher ampacity designs, while sections in cooler areas use more economical designs, eliminating the need to over-dimension the entire cable while maintaining reliability in critical areas.
Solution Approach 2:
The conductor is divided into multiple sections with different cross-sectional layouts. This segmentation allows each section to be optimized for its specific environmental conditions along the route, reducing the total amount of cable material needed compared to designing the entire cable for the worst-case scenario.
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 enables efficient manufacturing and installation of high voltage power cables by thermally joining sections with different ampacities during production, reducing on-site installation time and costs, and preventing hot spots by optimizing cable design.
Implementation Method 1
an electrical insulation system enclosing the conductor
Implementation Method 2
a sheath enclosing the conductive core
Implementation Method 3
the plurality of sections are thermally joined
Data Source
AI summary
A power cable including a conductive core including a conductor including a plurality of sections, and an electrical insulation system enclosing the conductor, and a sheath enclosing the conductive core, wherein one of the plurality of sections of the conductor is a first conductor section and another of the plurality of sections of the conductor is a second conductor section, which first conductor section has a first cross-sectional layout that provides a first ampacity for the first conductor section, and which second conductor section has a second cross-sectional layout that provides a second ampacity for the second conductor section, wherein the first ampacity is higher than the second ampacity, wherein the plurality of sections are thermally joined, and wherein the electrical insulation system extends continually from the first conductor section to the second conductor section of the conductor. A method of manufacturing a power cable is also presented.