Power Cable Connector with Embedded Wireless Sensor
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Solution Overview
Problem
Existing temperature measurement methods for power cable connectors in medium/high voltage systems suffer from poor thermal conductivity, leading to inaccuracies in temperature readings due to direct integration of sensors within the connector, resulting in temperature differences between actual and measured values.
Innovation Solution
A power cable connector design incorporating a housing with a conductive plug and multiple layers, where a passive wireless measuring apparatus is embedded in the second layer, coupled to the conductive plug via thermal conductive materials, allowing for accurate and reliable temperature measurement without direct integration, thereby improving thermal conductivity and reducing partial discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed directly in the power cable connector for temperature measurement, then the measurement function is achieved, but the thermal conductivity is poor leading to temperature measurement inaccuracies
Solution Approach 1:
The patent introduces a thermal conductive material as an intermediary between the sensor and the conductive plug. This mediator improves thermal conductivity and ensures accurate temperature measurement by facilitating efficient heat transfer from the plug to the sensor, resolving the thermal conductivity issue while maintaining measurement accuracy.
Solution Approach 2:
The patent segments the temperature measurement system into distinct functional components: the conductive plug, the thermal conductive material, and the sensor. This segmentation allows each component to be optimized independently - the plug for electrical conductivity, the thermal material for heat transfer, and the sensor for measurement - thereby resolving the contradiction between measurement accuracy and thermal conductivity.
2Measurement precision
If sensors are integrated directly into the power cable connector, then the temperature measurement function is achieved, but partial discharge may occur affecting safety
Solution Approach 1:
The semi-conductive material serves as an intermediary layer between the sensor and the high-voltage conductive plug. This mediator provides electrical isolation that prevents partial discharge while maintaining thermal conductivity for accurate temperature measurement, thereby resolving the contradiction between measurement capability and safety.
Solution Approach 2:
The patent applies different material properties at different locations: the semi-conductive material is used specifically at the sensor interface to provide electrical isolation where needed, while other areas maintain their original conductivity characteristics. This localized application of different material qualities enables temperature measurement without partial discharge.
3Measurement precision
If multiple layers and thermal conductive materials are added to improve temperature measurement, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The patent applies the thermal conductive material and semi-conductive material only at specific locations where they are most needed - at the interface between the sensor and the conductive plug. This localized application minimizes the addition of materials and structural complexity while still achieving the goal of improved temperature measurement accuracy.
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 precise and reliable on-line temperature measurement of power cable connectors, enhancing the safety and reliability of electrical devices by minimizing temperature measurement inaccuracies and potential overheating issues.
Implementation Method 1
a surface of the passive wireless measuring apparatus is coupled to the conductive plug
Implementation Method 2
the passive wireless measuring apparatus is coupled to the second layer via a semi-conductive material. In this way, the possibility of partial discharge can be reduced
Data Source
AI summary
Embodiments of present disclosure relate to a power cable connector, an electrical system and a method for assembling a power cable connector. The power cable connector comprises a housing comprising a first portion adapted to contain a conductive plug inserted therethrough. The power cable connector also comprises a first layer arranged on at least a part of an inner wall of the housing. The power cable connector further comprises a second layer arranged on the first layer so that the first layer is at least partially located between the inner wall of the housing and the second layer. The power cable connector further comprises a passive wireless measuring apparatus embedded into the second layer, wherein in the case that the conductive plug is inserted into the first portion, a surface of the passive wireless measuring apparatus is coupled to the conductive plug. According to embodiments of the present disclosure, the on-line monitoring of the temperature of the conductive plug can be obtained and the power failure can be detected in advance.