Power Cable Core Connection Sleeve for Compact Crack-Resistant Joints
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Solution Overview
Problem
Existing power cable connection devices for connecting different types of power cables, such as paper-insulated and XLPE insulated cables, are bulky, heavy, and prone to cracking due to thermal expansion differences, making installation in narrow spaces like manholes difficult and compromising durability.
Innovation Solution
A power cable core connection device with an insulated connection sleeve featuring a connection conductor and insulation molding part with controlled slopes and materials matching thermal expansion coefficients, along with a reinforcing insulating layer and stress relief cone, to minimize volume and prevent cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a housing with larger diameter and high-pressure insulating oil is used for paper-insulated power cable connection, then insulation performance is improved, but device volume and weight increase making installation difficult
Solution Approach 1:
The connection device is divided into two separate connection structures: a first connection structure for paper-insulated power cables and a second connection structure for XLPE insulated power cables. This segmentation allows each structure to be optimized independently, eliminating the need for a large housing that accommodates both cable types together, thus reducing overall device volume while maintaining proper insulation for each cable type.
Solution Approach 2:
The high-pressure insulating oil filling requirement is extracted and applied only to the first connection structure for paper-insulated cables, while the second connection structure for XLPE cables uses alternative insulation methods. This extraction allows the overall device to avoid the volume constraints imposed by high-pressure oil filling, enabling more compact design.
2Volume of moving object
If insulation molding part is used to insulate XLPE power cable connecting part, then installation space is reduced, but cracking occurs due to thermal expansion difference
Solution Approach 1:
Different insulation methods are applied to different connection structures based on local requirements: the first connection structure for paper-insulated cables uses high-pressure insulating oil filling, while the second connection structure for XLPE cables uses an insulation molding part. This local quality approach allows compact design where appropriate while maintaining reliability for each specific cable type.
Solution Approach 2:
The material composition and thermal expansion characteristics of the insulation molding part are specifically adjusted to match those of the XLPE cable insulation. By changing the material parameters to have similar thermal expansion coefficients, the molding part expands and contracts at the same rate as the XLPE insulation during temperature changes, preventing cracking and improving durability.
3Volume of moving object
If connection device is divided into each phase of cores, then device volume is reduced, but PMJ size increases making installation difficult
Solution Approach 1:
The connection device is segmented into separate connection structures for different cable types rather than dividing by phase. Each connection structure is designed to accommodate specific cable types with appropriate insulation methods, allowing compact overall volume while maintaining installation ease through standardized connection procedures for each cable type.
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
Enables installation in narrow spaces and prevents insulation cracking, reducing the device's volume and improving workability while maintaining electrical integrity.
Implementation Method 1
the insulating molding part is likely to crack due to thermal contraction/expansion of the insulating molding part or the difference in coefficient of thermal expansion between the connection conductor and the insulating molding part
Data Source
AI summary
The present disclosure relates to a different type power cable core connection device for minimizing the volume of a connection device for connection of different type power cables and minimizing cracking of an insulation molding part having a connection conductor embedded therein when current is conducted to conductors of cores of the different type power cables, and a different type power cable connection system including the same.