Medium-Voltage Cable Connector With Self-Centering Tapered Sleeve
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Solution Overview
Problem
Existing connectors for medium voltage cables require multiple components, are tedious to assemble, and suffer from issues such as screw protrusions and inconsistent electrical contact due to the need for centering rings and metal inserts, which complicates the connection process.
Innovation Solution
A connector system comprising a sleeve with a self-tapping conical bore and a shear-off contact bolt that centers conductors of varying diameters, eliminating the need for centering rings, and ensures secure electrical contact by penetrating the conductor in a longitudinal direction, using a self-tapping thread to cut into the insulation and a shear-off mechanism for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If centering rings or metal inserts are used to center different medium voltage conductors in the screw connector, then a single screw connector can cover a range of different diameters, but the device complexity increases due to the number of centering rings or metal inserts required
Solution Approach 1:
The patent removes the centering rings or metal inserts from the connector assembly entirely. Instead, the connector body itself is designed with an integrated conical centering surface that directly centers the conductor, eliminating the need for separate centering components and reducing device complexity while maintaining adaptability to different conductor diameters
Solution Approach 2:
The centering function is merged into the connector body structure itself through the conical centering surface. The centering surface is integrated as part of the connector housing rather than being a separate component, combining the centering and connection functions into a single unified structure
2Reliability
If pressing screws are inserted in radial direction into the connector, then electrical contact is established, but screw protrusions occur occasionally leading to negative impact on quality and reproducibility
Solution Approach 1:
The conductor itself serves as the centering element by being pressed against the conical centering surface. This self-centering mechanism eliminates the need for separate centering components and ensures consistent positioning without relying on additional parts that could vary in quality or reproducibility
Solution Approach 2:
The patent changes the geometric parameters of the connector interior by introducing a conical centering surface with specific angle and dimensions. This geometric parameter change enables the conductor to be automatically centered and positioned consistently, improving manufacturing precision and eliminating screw protrusion issues
3Adaptability or versatility
If multiple pressing screws are used to increase size scaling, then larger conductors can be connected, but the device complexity and assembly tediousness increase
Solution Approach 1:
The conical centering surface serves multiple functions: it centers conductors of different diameters, provides a bearing surface for the conductor, and guides the pressing screws into proper position. This multi-functional design allows the connector to handle various conductor sizes without requiring additional centering components or increasing the number of pressing screws
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 reliable, efficient, and scalable connection method that centers conductors of different diameters without additional components, ensuring consistent electrical contact and reducing assembly complexity by utilizing a multi-range capability and friction locking mechanisms.
Implementation Method 1
a bore having at least one tapered section provided with a self-tapping internal thread
Implementation Method 2
The contact bolt is a shear-off bolt and is screwed into the central bore of the sleeve to reduce the space within the bore and to penetrate into the conductor in longitudinal direction of the conductor
Implementation Method 3
The tapered section of the is configured to be screwed onto the insulation of the conductor
Data Source
Figure 1~2C
Figure 3A~3C
Figure 4~6
AI summary
A connector for contacting a conductor, which is isolated by an insulation is suggested. The connector comprises a sleeve and a contact bolt. The sleeve is provided on a first end with a threaded central bore for accepting the contact bolt and on a second end with a tapered bore having a self-tapping internal thread. The threaded tapered bore is configured to be screwed onto the insulation of the conductor. The contact bolt is screwed into the central bore of the sleeve to reduce the space within the tapered bore. When the connector is mounted on a cable with a stranded conductor, the wires of the conductor are pressed against an internal wall of the tapered bore and a good electrical contact is achieved. The tapered bore centers conductors of different diameters in the sleeve.