Power Line Coupler With Deformable Protector
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Solution Overview
Problem
Existing power line couplers face issues with cable slippage during storms and inconsistent clamping due to varying cable thicknesses, leading to potential breakage of the joint.
Innovation Solution
A power line coupler design featuring a deformable aluminum protector with a friction-enhancing compound and alternately disposed fasteners, including shear bolts with recesses to securely clamp cables of varying diameters, and a pin locator to prevent removal, ensuring stable coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a helical conductor is tightly wound from one cable onto the other, then the cables are coupled together, but the helical conductor can slip from the cable during storms due to wind-induced swinging
Solution Approach 1:
The coupler is divided into distinct functional segments: a clamp body for mechanical clamping, protrusions for cable deformation, and a friction-enhancing compound layer. This segmentation allows each component to address specific failure modes independently, preventing slippage through multiple mechanisms working in conjunction.
Solution Approach 2:
A friction-enhancing compound is introduced as an intermediary substance between the clamp surfaces and the cable. This compound increases the coefficient of friction, providing enhanced grip and preventing slippage during wind-induced swinging without requiring excessive clamping force that could damage the cable.
2Adaptability or versatility
If a compressible conductor tube is used to clamp cables, then cables can be inserted, but thicker cables cannot be inserted while thinner cables are inadequately clamped
Solution Approach 1:
The clamp incorporates a deformation mechanism where protrusions actively bend the cable into a corrugated shape during tightening. This dynamic adaptation allows the clamp to conform to varying cable diameters, maintaining reliable clamping force across different cable thicknesses without requiring multiple clamp sizes.
Solution Approach 2:
The clamp design changes the physical state of the cable from straight to corrugated through the action of protrusions. This parameter change in cable geometry enables the clamp to securely hold cables of varying thicknesses, as the corrugated deformation increases surface area and friction contact between the clamp and cable.
3Reliability
If fasteners are used to clamp the protector and cables, then the cables are secured, but the fastener tips may slip during separation
Solution Approach 1:
The potential harmful effect of tool slippage during fastener separation is converted into a benefit by designing a recess in the fastener tip that positively engages with the tool. This recess feature prevents slippage and provides tactile feedback, ensuring precise tool placement and controlled fastener removal without damaging surrounding components.
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 secure and reliable coupling of cables, resisting extraction and stress, thereby enhancing the durability and safety of the power line joint.
Implementation Method 1
The protection member may be coated with a friction enhancing compound to impede extraction of the cables
Implementation Method 2
The protrusions may bend each cable to be corrugated and resist extraction from the clamp
Data Source
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AI summary
The present invention relates to a power line coupler for coupling a pair of cables together. The coupler includes at least one protector for protecting the cables. A clamp is provided for clamping the protector and cables together.