Parallelogram Coupling Joint for High-Voltage MI Cable Splices
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Solution Overview
Problem
Conventional mineral insulated (MI) cable splice designs are not suitable for high voltages above 1000 volts, 1500 volts, or 2000 volts and fail at elevated temperatures, requiring improved compaction of mineral insulation to match the level in MI cables, and existing splicing methods do not provide sufficient compaction or allow compaction for high-voltage, high-temperature subsurface applications.
Innovation Solution
A fitting system that couples insulated conductors with a sleeve having a longitudinal opening for filling and compacting electrically insulating material, featuring angled ends and tapered interior volumes to reduce electric field intensities and enhance compaction, allowing for robust connections at high voltages and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional MI cable splice designs are used, then the splicing process is simple, but the splices fail at high voltages above 1000 volts and elevated temperatures
Solution Approach 1:
The splice assembly is divided into distinct functional segments: a body portion containing the electrical connection, a sleeve portion for insulation, and a compaction mechanism. This segmentation allows each component to be optimized independently for its specific function while maintaining overall reliability at high voltages and temperatures.
Solution Approach 2:
The patent implements preliminary compaction of mineral insulation material into the splice assembly before final assembly. This preliminary action ensures that the insulation is densely packed to withstand high voltages above 1000 volts and elevated temperatures, preventing failure before the splice is put into service.
2Manufacturing precision
If existing splicing methods are used, then the splicing process is quick, but sufficient compaction of mineral insulation is not achieved
Solution Approach 1:
The patent employs a compaction mechanism that uses pneumatic or hydraulic pressure to densely pack mineral insulation material into the splice assembly. This method achieves the required compaction density much faster than manual methods, maintaining manufacturing precision while reducing the time loss during splicing operations.
3Reliability
If high compaction of mineral insulation is implemented, then high voltage and temperature performance improves, but the splicing process becomes more complex
Solution Approach 1:
The splice assembly includes integrated compaction features that allow the insulation material to self-compact during the assembly process. The body and sleeve portions are designed with tapered interiors and engagement mechanisms that automatically compress the mineral insulation to the required density when components are assembled, eliminating the need for separate complex compaction equipment.
4Reliability
If conventional splice designs are used, then installation is simple, but electric field intensities and leakage currents are excessive at high voltages
Solution Approach 1:
The patent modifies the geometric parameters of the splice assembly, including tapered interiors of the body and sleeve portions, and strategic placement of mineral insulation material. These parameter changes reduce electric field intensities and leakage currents at high voltages above 1000 volts, improving reliability without significantly complicating the installation process.
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 enables MI cable splices to operate reliably at high voltages and temperatures, with increased bending and tensile strengths, reducing electric field intensities and leakage currents, thus extending the operating range and ensuring durability in subsurface environments.
Implementation Method 1
tapered interior volumes to reduce electric field intensities
Implementation Method 2
angled ends and tapered interior volumes to reduce electric field intensities and leakage currents
Data Source
AI summary
A fitting for coupling ends of insulated conductors includes a sleeve to couple an end of a jacket of a first insulated conductor to an end of a jacket of a second insulated conductor. The sleeve is located between end portions of the insulated conductors. At least one of the ends of the sleeve is angled relative to the longitudinal axis of the sleeve. The sleeve has a longitudinal opening that extends along the length of the sleeve substantially the distance between end portions of the jackets of the insulated conductors. The longitudinal opening allows electrically insulating material to be filled into the sleeve.