Pre-Molded Cable Joint for Different-Diameter UHV Cable Splices
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Solution Overview
Problem
Existing methods for connecting power cables with different diameters, such as brazing or arc welding, incur high material and labor costs and risk defects due to manual processes, making them inefficient and risky.
Innovation Solution
A pre-molded joint (PMJ) with a rubber unit and conductor sleeve designed to accommodate cables with different diameters, featuring a central electrode with slanted surfaces to ensure secure electrical and mechanical connections, reducing the need for manual labor and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If brazing or arc welding is used to connect conductors with different diameters, then the connection can be achieved, but additional material costs are required and labor involved is increased
Solution Approach 1:
The patent introduces a joint structure as an intermediary component that connects conductors of different diameters without requiring direct welding or brazing between them. The joint includes a first conductor portion, insulator, and second conductor portion that mechanically and electrically connect the different diameter conductors, eliminating the need for additional welding materials and reducing labor costs.
Solution Approach 2:
The connection system is divided into separate functional segments: the first conductor, the insulator layer, and the second conductor portion. This segmentation allows each component to be optimized independently and assembled without complex welding processes, reducing both material costs and labor requirements.
2Ease of manufacture
If brazing or arc welding is used to connect conductors with different diameters, then the connection can be achieved, but labor involved in conductor connecting work is increased due to additional welding process
Solution Approach 1:
The joint structure is pre-assembled with the insulator and conductor portions configured in advance. This preliminary preparation eliminates the need for time-consuming welding operations during field installation, as the components can be directly connected through simple mechanical assembly procedures.
3Ease of manufacture
If manual brazing or arc welding processes are used, then conductor connection can be achieved, but risk of defects occurring at connected portions between conductors is increased
Solution Approach 1:
The patent replaces the thermal welding processes (brazing and arc welding) with a mechanical connection system. The joint structure provides direct mechanical and electrical connection between conductors of different diameters, eliminating the risks associated with manual welding such as poor fusion, cracks, and defects that compromise connection reliability.
Data Source
AI summary
The present invention relates to a PMJ with different diameters for intermediate connection between ultra-high voltage cables with different diameters. The PMJ with different diameters for intermediate connection between ultra-high voltage cables with different diameters, according to the present invention, is an intermediate connection PMJ having a pair of connected power cables with different diameters, comprising: a first cable in which a first conductor, a first insulator and a first semiconductor are sequentially formed; a second cable in which the first conductor, a second conductor having a diameter greater than that of each of the first insulator and the first semiconductor, a second insulator, and a second semiconductor are sequentially formed; and a rubber unit of which the inner circumferential surface of one side has a first inner diameter connected over the first insulator and the first semiconductor of the first cable, the inner circumferential surface of the other side has a second inner diameter connected over the second insulator and the second semiconductor of the second cable, the second inner diameter being greater than the first inner diameter and including a central electrode inside the center thereof, and the inner surface of the central electrode has a shape of slanting from one side toward the other side thereof.