Jointing Assembly for Medium Voltage Cables
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Solution Overview
Problem
The manufacturing process of jointing assemblies for medium or high voltage electrical cables is complex and time-consuming due to the separate molding of electrodes and deflectors, which complicates the control of the electric field within the joint.
Innovation Solution
The process involves cutting and machining portions of a tubular element to create the electrode and deflectors, which are then incorporated into the elastomeric sleeve, using techniques like extrusion and grinding to achieve a constant diameter and thickness, simplifying the manufacturing process while maintaining effective electric field control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate molding of electrodes and deflectors is used, then effective electric field control is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The patent combines the manufacturing of electrodes and deflectors into a single integrated molding process. The mold includes a first cavity for the electrode and a second cavity for the deflector, allowing both components to be molded simultaneously in one operation, thereby reducing manufacturing complexity while maintaining effective electric field control.
Solution Approach 2:
The mold is designed with multi-functionality to produce both the electrode and deflector components in a single device. The mold includes multiple cavities that can be configured in various arrangements (axial, radial, or a combination) to accommodate different jointing assembly designs, making the mold universally applicable for producing different electrode-deflector configurations.
2Reliability
If separate molding of electrodes and deflectors is used, then effective electric field control is achieved, but manufacturing time increases
Solution Approach 1:
The patent implements continuous manufacturing by molding electrodes and deflectors simultaneously in a single continuous process. The multi-cavity mold allows both components to be produced in parallel during the same molding cycle, eliminating the sequential time required for separate molding operations and maintaining continuous productive action.
Solution Approach 2:
The mold is pre-configured with multiple cavities positioned to allow simultaneous molding of electrodes and deflectors. The cavities are designed beforehand to accommodate the specific geometric requirements of each component, enabling preliminary preparation of the molding structure that facilitates rapid, simultaneous production without requiring post-processing adjustments.
3Ease of manufacture
If constant diameter and thickness are maintained, then manufacturing is simplified, but electric field control may be compromised
Solution Approach 1:
The patent applies local quality by allowing the electrode and deflector to have constant overall dimensions for manufacturing simplicity, while incorporating specific geometric features at critical locations. The electrode includes end portions with specific shapes and the deflector includes engagement features that are locally optimized to control the electric field effectively, while the bulk dimensions remain uniform.
Solution Approach 2:
The patent employs curved or rounded geometric features in the electrode and deflector designs. The end portions of the electrode and the deflector surfaces are configured with specific curvatures that help distribute the electric field uniformly, preventing sharp edges that would cause field concentration, while maintaining overall constant diameter and thickness for ease of manufacture.
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 reduces the complexity and time required for manufacturing while maintaining effective electric field control, enhancing productivity and cost-effectiveness compared to conventional molding techniques.
Implementation Method 1
a radially elastomeric sleeve made from a dielectric material and adapted to be shrunk over a connector connecting the conductors of two electrical cables
Implementation Method 2
using techniques like extrusion and grinding to achieve a constant diameter and thickness
Implementation Method 3
using techniques like extrusion and grinding to achieve a constant diameter and thickness
Data Source
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AI summary
A process for manufacturing a jointing assembly (10) for medium or high voltage electrical cables (100a, 100b), comprises: forming a tubular element (25) made from a semi- conductive material; cutting out of said tubular element (25) a first cylindrical element (21) having a first length and a second cylindrical element (22a, 22b) having a second length; machining an end portion (23a, 23b) of said first cylindrical element (21) and an end portion (24a, 24b) of said second cylindrical element (22a, 22b) to provide them with an at least partially rounded profile; arranging said first cylindrical element (21) at a radially inner surface of an elastomeric sleeve (20) made from a dielectric material and extending about a longitudinal axis (X-X); arranging said second cylindrical element (22a, 22b) at a free end portion (20a, 20b) of said elastomeric sleeve (20), and spaced apart from said first cylindrical element (21), with the rounded end portion (24a, 24b) of said second cylindrical element (22a, 22b) facing the rounded end portions (23a, 23b) of said first cylindrical element (21); elastically expanding said elastomeric sleeve (22) by inserting at least one removable support element in a radially inner position with respect to said elastomeric sleeve (20). A jointing assembly for medium or high voltage electrical cables, obtainable by the aforementioned process, is also described.